Honda CRV 97-00 Service Manual

General lnformation
1-2 Codes ....................... Chassis Paint and 1-10 NumberLocations ......... ldentification 1-11 Warning/Caution LabelLocations ....... Under-hood Emissions Control . . . . . . . . . . . . . . 1.-.1.5 . . . . Label ......... . Lift and SupportPoints 1-19 LiftandSafety Stands....................... Floor ....................... 1-20 Jack .........1-21 Towing Service Precautions ..,................. 1-22 PaftsMarkingLocations for 4WD Precautions Real-time (Four-wheel Drivel......... ................. 1-23
Chassis and PaintCodes

U.S. 1997Model
VehicleldentificationNumber
JHLRD184*VC000001
JHL: HONDAMOTOR CO.,LTD HONDA, Multipurpose Passenger Vehicle(MPV) line, Body and Engine Type RDl: CR V/82084 Body Type and TransmissionType 8: 5-door/4-soeed Automatic Vehicle Grade (Series) 4: LX 5: LX (with ABS) CheckDigit Model Year Vt 1997 C: Saitama Factory Japan(Sayama) in
B-84P NH-552M NH-592P R-94
Supermarine Blue Pearl Cypress GreenPearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed
(o
Vehicleldentification Number and FederalMotor Vehicle
COLOR LABEL
INT. COLOR
WPEF B-84P
EXT. COLOR KA S2BA1 C
to
1-2
U.S.1998Model
JHLRD174*WC000001
JHL: HONDAMOTOR CO.,LTD HONDA. Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RD1:CR-V/82084 RD2:CR'V/82084 Body Type and TransmissionType 7: 5-door/s-soeed Manual 8; 5-door/4-soeed Automatic
Multiport B20B4t 2.01 DOHC Sequential Fuel-injected engine
MDLA: 4-speedAutomatic M4TA: 4-speed Automatic S B X M : s - s p e eM a n u a l d MDLA,SBXM:1000001 M4TA: 3000001in C: SaitamaFactory Japan(Sayama)
B-84P G-82P NH-552M NH-592P R-94
Blue Pearl Supermarine CypressGreen Pearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed
VehicleldentificationNumber and CanadianMotor Vehicle
LABEL COLOR
INT. COLOR
TYPE F
8.84P
EXT. COLOR
KA S2BA1 C
1-3

U.S. 1999Model
Vehicle ldentification Number
JHLRDIT4*XC000001
JHL: HONDAMOTOR CO.,LTD HONDA. Multipurpose
B2OZ2:2.0 DOHC | Sequential Multiport Fuel-injected engine
RDlt CR-vlB20Z2 RD2t CR-V1B2OZ2 Body Type and TransmissionType 7: 5-door/5-speed Manual 8: 5-door/4-spsed Automatic 4: LX MDLA: 4-speedAutomatic MDMA:4-speed Automatic SBXM: s-speed Manual
6:Ex
Chock Digit Model Year X: 1999 C: Saitama Factory Japan(Sayama) in
MDLA:2000001MDMA: 1000001SBXM:2000001-
B-84P B-92P G.95P NH-578 NH-552M R,81
Supermarine Blue Pearl Nighthawk BlackPearl CloverGreenPearl TaffetaWhite SebringSilverMetallic MilanoRed
Vehicle ldentification Number and CanadianMotor Vehicle
COLOR LABEL
INT. COLOR
TYPE F B.84P
EXT. COLOR KA S2BA1 C
1-4
Model U.S.2000
Y JHLRD174* C000001
CO.,LTD JHL: HONDAMOTOR HONDA, Multipurpose Vehicle(MPV) Passenger Line. Body and EngineType RDlt CR-V/82022 RD2iCR-v/BzOz2 Body Type and TransmissionType Manual 7: 5-door/s-speed 8: 5 door/4-soeed Automatic
MultiDort 2.0 Seouential B20Z2t I DOHC Fuel-injected engine
Automatic MDLA; 4-speed Automatic MDMA:4-speed SBXM: s-speedManual
MDLA:3000001MDHA: 2000001SBXM:2000001in CrSaitamaFactory Japan(Sayama)
B-92P B-95P G-95P NH-578 NH-552M R-81
Nighthawk BlackPearl BluePearl Electron CloverGreenPearl Taffeta White SebringSilverMetallic Milano ed R
LABEL COLOR
Safety Standard Certification. lrl ..V
INT. COLOR
F TYPE 8.92P
EXT, COLOR KA S2BA1 C
1-5
and PaintCodes Chassis

Canada1997Model
J H L R D 1 8 5 *V C 8 0 0 0 0 1
HONDAMOTOR CO.,LTD HONDA, Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RDl: CR-V/B2084 Body Typ and TransmissionTyp Automatic 8: s-door/4-soeed
2.0 MultiDort B20g4t | DOHC Seouential Fuel-injected engine
MDMA- 1000001
MDMA:4-speed Automatic Automatic SDMA: 4-speed Factory Japan(Sayama) in C: Saitama
B-84P G-82P NH-552M NH-592P R-94
Supermarine BluePearl CypressGreen Pearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed
Vehicle ldentification Number and Canadian Motor Vehicle Safety Standard Certification.
LABEL COLOR
INT. COLOR
F TYPE
B-84P
EXT. COLOR
KCS2BC2 C
1-6
Canada1998Model
J H LR D 1 4 * W C 8 0 0 0 0 1 7
CO.,LTD JHL:HONDAMOTOR HONDA, Multipurpose Vehicle(MPV) Passenger Lino, Body and EngineType RD1:CR-V/82084 Body Type and TransmissionType Manual 7: 5-door/s-speed Automatic 8: 5-door/4-speed
Multiport Sequential | 8208 4:2.0 DOHC engine Fuel-injected
Automatic M4TA: 4-speed Manual SBXM:5-speed SBXM:1000001M4TA: 3000001* in C: SaitamaFactory Japan(Sayama)
B-84P G-82P NH-552M NH-592P R-94
BIuePearl Supermarine CypressGreen Pearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed
LABEL COLOR
INT. COLOR
TYPE F
8.84P
EXT. COLOR
KCS2BC2 C
1-7

Canada1999Model
Vehicle ldentification Number
J H LR D l T 4 * X C 8 0 0 0 0 1
JHL:HONDAMOTOR CO.,LTD HONDA, Multipurpose Passen0er Vehicle{MPV) Line, Body and Engin6Type RD1:CB-Y/B2OZ2 Eody Typ6 and Transmi$ion Type 7: 5-door/5-speed Manual 8: s-door/4-speed Automatic 4: LX 5: EX ChockDigit Model Yeal X: 1999 C: SaitamaFactory Japan{Sayama) in
B20Z2i I DOHC 2.0 Sequential Multiport Fuel-injected engine
MDMA:4-speed Automatic SBXM: s-speed Manual
B-84P a-92P G.95P NH.552M R-81
Supermarine BluePearl Nighthawk BlackPearl CloverGreenPearl SebringSilverMetallic MilanoRed
VehicloldentificationNumber and Canadian Motor Vehicle Safety Standard Certification.
LABEL COLOR
INT. COLOR
TYPE F B-84P
EXT. COLOR KCS2BC2 C
1-8
J H LR D l7 4 * Y C8 0 0 0 0 1 Manulacturer, Make and Type of Vehicle CO.,LTD JHL:HONDAMOTOR Multipurpose HONDA, Passenger Vehicle(MPV) Line, Body and EngineType RDlt CR-VlB2oZ2 Body Type and TransmissionType Manual 7: 5-door/s-soeed Automatic 8: 5-door/4-sDeed Vehicle Grade (Seriesl 4: LX 5: EX Check Digit Model Year Yr 2000 FactoryCode in C: SaitamaFactory Japan(Sayama) Serial Number B-96P B-92P G-95P NH-552M R-81 YR-524M Blue Pearl Eternal BlackPearl Nighthawk CloverGreenPearl SebringSilverMetallic MilanoRed NaplesGold lVetallic
Multiport | Sequential 8 2022:2.0 DOHC engine Fuel-injected
Automatic MDMA:4-speed Manual SBXM: s-speed
Vohicle ldentification Number and Canadian Motor Vohicle
LABEL OOLOR
tNrcoL0R
F TYPE B-92P
COLOR EXT. KCS2BC2 C
1-9
ldentification NumberLocations
VehicleldentificationNumber lVlNl
Vehiclldentific.tion Number tvtNl
TransmissionNumb6r lManudl)
TransmissionNumbor {Aulomaticl
EngineNumbel
1-10
LabelLocations Warning/Caution
A: CABLEREELCAUTION
MODULEWARNING C: DRIVER A WARNING A I T H E A I R E A GI N F L A T O R S E X P L O S I V E N D , I F HURT CAN SERIOUSLY DEPLOYED, ACCIDENTALLY OR KILLYOU. OR TEST EOUIPMENT . DO NOT USE ELECTRICAL DEVICES. PROBING DEPLOYMENT. THEYCAN CAUSEACCIDENTAL . N O S E R V T C E A B LP A R T S l N S l D E . D O N O T E DISASSEMBLE. WHEN REMOVED . PLACE AIRBAGUPRIGHT M . F O L L O WS E R V I C E A N U A L I N S T R U C T I O N S CAREFULLY.
OF TNSTALLATION THE SRSCABLEREELIS CRITICAL OF OPERATION THE SRS SYSTEM. TO THE PBOPER MANUAL FOR DETAILED TO REFER THE SERVICE INSTRUCTIONS. INSTALLATION MODULEDANGER B: DRIVER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVY METALS S U C H A S C O P P E R ,L E A D O R M E R C U R YM A Y GASESOR HARMFULAND IRRITATING PRODUCE STOMGE TEMPERATURES COMPOUNDS. EXPLOSIVE F 2 { M U S T N O T E X C E E D O O " F1 O O ' C } . O R P R O P E R PROCEDURES. AND DISPOSAL HANDUNG,STORAGE, MANUAI- SRSSUPPI.EMENT, REFER SERVICE TO POTSON C O N T A I N S P O I S O N O U SS O D I U M A Z I D E A N D NITRATE. POTASSIUM AID FIRST tF CONTENTS ARE SWALLOWED, INDUCE VOMITING.FOR EYE CONTACT,FLUSH EYESWITH WATERFOR 15 MINUTES.IF GASES IFROMACID OR WATER CONTACTIARE INHALED,SEEK FRESH A I R . I N E V E R YC A S E , G E T P R O M P T M E D I C A L ATTENTION. OF KEEP OUT OF REACH CHILDREN
(cont'd)
1-11
Warning/Caution LabelLocations
(cont'dl
(U.S.A. modelonlyl modolonlyl {U.S.A.
o: SRSWARNING{HOOD} SUPPLEMENTAL RESTRAINT SYSTEM{SRSI THIS VEHICLE EOUIPPED IS WITH DRIVER AND FRONT SEATPASSENGER AIRBAGS, ALL SRS ELECTRICAL WIRINGAND CONNECTORS ARE COLORED YELLOW. T A M P E R I N G W I T H , D I S C O N N E C T I N GO R U S I N G ELECTRICAL TEST EOUIPMENT THE SRS WIRINGCAN ON MAKETHESYSTEMINOPERATIVE CAUSEACCIDENTAL OR FIRING THEINFLATOR. OF A WARNING T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D . I F ACCIDENTALLY DEPLOYED, CAN SEBIOUSLY HURT YOU. FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY.
E: STEERING COLUMNNOTTCE tHOODI NOTICE TO PREVENTSRS DAMAGE, REMOVESTEERING WHEEL BEFORE REMOVING STEERING SHAFTCONNECTING BOLT. F: MONITORNOTICE NOTICE . NO SERVICEABLE PARTStNStoE. . REFER TO SERVICEMANUAL FoR DETAILED
rNsrRucTtoNs.
1-12
AIRBAGMODULEDANGEN SEATPASSENGER G: FRONT A DANGER EXPLOSIVE/FLAMMABLE WITH ACID,WATER.OR I{EAVY METALSSUCH CONTACT HARMFUL MAY PRODUCE T.EAD. MERCURY OR AS COPPER. COMPOUNDS. GASESOR EXPLOSIVE AND IRRITATING MUST NOT EXCEED2OO"F TEMPERATURES STORAGE I l O O ' C ) . F O R P R O P E RH A N D L I N G ,S T O R A G E ,A N D MANUAL, TO REFER THESERVICE PROCEDURES DISPOSAL SRSSUPPLEMENT. POTSON SODIUM AZIDEANO POTASSIUM CONTAINSPOTSONOUS NITRATE. AID FIRST INDUCEVOMITING.FOR ARE SWALLOWED, IF CONTENTS E Y E C O N T A C T ,F L U S H E Y E S W I T H W A T E R F O R 1 5 MINUTES. IF GASES (FROM ACID OR WATEN CONTACT) SEEKFRESHAIR. IN EVERYCASE,GET ARE INHALEO. ATTENTION. PROMPT MEDICAL OF KEEP OUTOF REACH CHILDREN. A WARNING T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D , I F HURT OR CAN SERIOUSLY DEPLOYED, ACCIDENTALLY YOU. KILL O L . D O N O T U S E E L E C T R I C AT E S T E O U I P M E N T R DEVICES, PROBING DEPLOYMENT. THEYCAN CAUSEACCIDENTAL . NO SERVICEABI-E PARTSlNSlDE.DO NOT DISASSEMBII. WHENREMOVEO. . PLACE AIRBAGUPRIGHT CAREFULLY . FOLLOWSERVICMANUAL INSTRUCTIONS INFORMATION S.A. modell lU H: PASSENGER model} {U.S.A.'97 SIDE, AIEBAGSEEOTHER {U.S.A.'98 00 modelsl AIRBAGWARNING FLIPVISOROVER. l: SRSINFORMATION
lU.S.A.'98 00 models) WARNING INJURYCAN OCCUR' DEATHOR SERIOUS 12 . CHILDREN ANO UNDERCAN BE KILLEDBY THE AIRBAG. FORCHILDREN. PLACE . THE BACKSEATlS THESAFEST C . N E V E RP U T A R E A R - F A C I N G H I L DS E A T l N T H E FRONT. FROMTHEAIRBAG o SIT AS FARBACKAS POSSIBLE . ALWAYSUSESEATBELTSAND CHll-DRESTRAINTS. TEN . THE SRSMUST BE TNSPECTED YEAnS AFTERlT lS INSTALLED. l . T H E O A T EO F I N S T A L L A T I O NS S H O W N O N T H E DOORJAMB. DRIVER'S AIRBAGWARNING PASSENGER J: FRONT lU.S.A.'98 00 models) WARNING C H I L D R E NC A N B E K I L L E D O R I N J U R E D 8 Y T H E AIRBAG. PASSENGER 12 PLACEFORCI{ILDREN THE BACKSEAT IS THE SAFEST AND UNDER. USE SEAT BELTSOR CHILD MAKE SURE ALL CHILDREN SEATS. WARNING TENSIONER K: FRONTSEATBELT WABNING INSIDE MATERIAL EXPLOSIVE HURTOR BURNED, YOU CAN BE SERIOUSLY . DO NOT TAMPER DISASSEMBLE OR PARTSINSIDE. NO SERVICEABLE MANUAL FORCOMPLETE . REFER SERVICE TO INSTRUCTIONS.
model lU.s.A.'97i '97 00modls I lcanada

CAUTION INJURY: TO AVOIDSERIOUS lN . FORMAXIMUM SAFEW PROTECTION ALL TYPESOF YOU MUST ALWAYS WEAR YOUR SAFETY CRASHES, 8ELT. CHILOSEATSlN o OO NOT INSTALLREARWARD-FACING SEATPOSITION. ANY FRONTPASSENGER CLOSETO THE . DO NOT SIT OR LEAN UNNECESSARILY AIRBAG. OVERTHE AIRBAGOR . DO NOT PLACE ANY OBJECTS THEAIRBAGAND YOURSELF. BETWEEN . SEE THE OWNER'S MANUAL FOR FURTHER AND EXPLANATIONS INFORMATION TEN YEARSAFTERlT lS . THE SRS MUST BE INSPECTED INSTALLED. l . T H E D A T E O F I N S T A L L A T I O NS S H O W N O N T H E DOORJAMB. DRIVER'S
(cont'd)
1-13
Warning/Caution LabelLocations
(cont'd)
VACUUM HOSEROUTING DIAGRAMlUndor-hood EmissionsControl Lrb6ll ENGINE COOLANT INFORMATION
SERVICE INFORMANON {Under-hood Emission3 Control l.rbell STEERING COLUMNNOTICE (sepage 1-12)
(Canadamodel)
RAOIATORCAP CAUTION
AIR CONDITIONING INFORMATION
1-14
ControlLabel Emissions Under-hood

Groupldentification Emission (1997 modell
Example: DIAGRAM VACUUMHOSEROUTING
Families and Evaporative Engine

F Engine amily: l v H N 2 . oJ G K E
Year Model v:1s97
T_fT
i I
INFORIMATION VEHICLE Ii/PORTANT

VHN2 ENGINE FAMILY OIJCrcK OLITER DISPIACEMENT'2 VNNl0778YMBP VE f EVAPORATAM]LY
NFORMATON. REfERTOSEBVICEMANUALfORAODITIONAL I-]P TUNT CONDITIONS TEMPERATURE, AT OPERATNG ENGINE NORI\,!AL FAN TL]RNED COOLING OIF OFF ES ALLACCESSOR NNEUTRAL TRANSM1SSION ADJUSTMENIS NEEDED NO OTHEB
CATALYST
ap'
| \6( Zror '.
ND\. 61F r L
TO TNISVENICLE CONFORMS U.S EPAREGUI.ATIONS TRACKS NWL GNI DUTY TO YEAR APPICASLE I99] MODET
Manufaqturer H N :H o n d a Displacement Class 1: Light DutyVehicle Fuol Systom ,nd Numbr of valves Multiport Sequential J: Electronic (threeor more valvesper Injection cylinder) Fuel Type G: Gasoline Standard F: 49 or 50 StatesTier 1 K: 49 or 50 StatesTier 1 Tier 1 1: California TLEV 2: California LEV 3: California ULEV 4: California Catalyst E, F, G, H: ThreeWay Catalyst
I I | L
OBD
K - T: OBDEquipped VHNlOTTBYMBP T|
ON OSVE TRACT CONTROL'EOLJIPPED OR fOUB OF LOADED TEST]NG PERMANENT WHEEL IM ZED SYNCHRON ON VEHTCLES MUST BE CONDUCTED A IOUR WHEELDRVE SPEEO ANONLOADEDTESTPBO(EOUBEMUSIBEPERFORMEO
Evaporative Family:
"r0", "*,
50ST (50 Statesl: OF TO CONFOBMS U.S.EPAAND STATE THISVEHICLE E S C A L I F O R N I R E G U L A T I O NA P P L I C A B LT O 1 9 9 7 A DUTYTRUCKS. YEARNEWLIGHT MODEL 49ST{49 Statos/Federall: TO CONFORMS U.S.EPA REGULATIONS THISVEHICLE YEARNEW LIGHTDUTY TO APPLICABLE 1997IVIODEL TRUCKS. CAL (Calitornial: OF TO CONFORMS U.S.EPAAND STATE THISVEHICLE T '1997 A IA REGULATIONS PPLICABLE O CALIFORN M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S IS THAT THISVEHICLE ONLY INTRODUCED PROVIDED F I N T O C O M M E R C E O R S A L E I N T H E S T A T EO F CALIFORNIA.
V: 1997 Manufacturer HN: Honda Storago System 1: Canister CanistorWorking Capacity (gramsl CanisterConfigulation Bottom) Housing(Closed A: Plastic Bottom) Housing(OPen B: Plastic Fusl System Y: FuelInjection FuelTank M: Metal Standard A: CurrentEvap Evap B: Enhanced Wild C.rd
5 1-1
Under-hood Emissions ControlLabel

Emission Groupldentification (1998 modell
Example:
DwlF\AIo|NG cha\Gtftc+ cootr\r -smsoru1or or FoNoA-IEaoTTxD-ibl oB I a\D M oR-l;ir,FEaFEf1'v!Lrff EzEcoo-aN' wATfB. w r or_ut-ir coolqNt, ENGINE BE MAY SEflIOUSLYSIONTENEO. DSEPLACI CoOTANT 85 itNlgsloF@ MILIS AnEs l@0 rnl, wHrcHEvEs coMEs TNEREAFTR, EvEny REPLACE fmAFSlm m M[Esi@ kml, wHcHrvEB coMEs DCHEC(ONADOCOOLqNTATTHE RSSEFVETANX.iAD]ATOR. NOTTHE DFOR FUFTNEfr INFO8MATION COOT]NC NEAD OWNEN'S ON IN SYSIEM THE MANUAL, . CHECK YOUR OEALEF. W|TH NONDA
Engineand Evaporative Families

EngineFamily:
Modl Year W: 1998 ManufacturerSubcods HNX:HONDA W HNX T O2.O UF1
Family Typo V: LDV T: LDT

Displacomsnt SoquncoCharaciors
IMPORTANT VEHICLE INFORMATION

THIS VEHICLE CONFOEMS I], S.EPA TO FEGIJLAIIONSAPPLICASLE MOOEL TO1993 YAF NEW LIGHT DUIYTNUCXS.
Evaporative Fami Family:

Model Yeat W:1998 Manufastu16rSubcode HNX:HONDA Family Type E: EVAP R; EVAP/ORVR CanisterWork Capacity SgquoncoCharaqtsrs
W HNXEOOSOAAB
rwqHozst2l/sFt/osD l cERI|FtEO
vAlvttAsH lrr0.l010.02nm icolo) EX:01310.02mm SPAS( PIUG GAP I.O IINM 686,13G96 lDLlSPTED 750 50rym I PROCEOURESI 2.0 L TlNt UPCoND/ToNS: ATNOiM ENGINE IEMPETAIURT,ALLACCESSORIESTUNNI fANOFf. TRAI1SMISSON INNEUTMI NO OIIIER AOJUSTI\TFIIS IIEEOED.
CATALYST
GD
50ST {50 States}: THISVEHICLE CONFORMS U.S.EPAAND STATEOF TO CALIFORNIA EGULATIONS PPLICABLE O 1998 R A T MODEL YEARNEWLIGHT DUTYTRUCKS, /$ST (itg Statos/Fodsrsll: THISVEHICLE CONFORMS U.S.EPA REGULATIONS TO APPLICABLE 1998MODELYEARNEW LIGHTDUTY TO TRUCKS. CAL {California}: THISVEHICLE CONFORMS U.S.EPAAND STATEOF TO C A L I F O R N I A E G U L A T T O NA P P L I C A B L E O 1 9 9 8 R S T M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S PROVIDED THATTHIS VEHICLE ONLY INTRODUCED IS I N T O C O M M E R C E O R S A L E I N T H E S T A T EO F F CALIFORNIA.
1-16
Groupldentification Emission (1999 model)

Example:
U-ECo-q.NOEDI Of USE THE COOLANT. @SOLU I ON FONOA '.WNEN NG CNANGINC AOO OR 0F LIFE oILLJTE CooLANT,0RTHE TNE mcrtniuvcoourr mo wlttt NEVEF THE
Families Engineand Evaporative

EngineFamily:
Model Year X:1999 Manutao{urerSubcode HNX:HONDA
UA2 X HNXT02,O
wNrcHEVEn coMEs LEs ffi'"R "Eifil:$o""niii?i,THffi @ M lmo rhl,

^,r*a, rurr"* i'lrt^t orrrr, os @ coMEs wNICHEVER MLEs 1@ kmr
IHE TAN( ATTHE }CNECK ADD OR COOLANT RESER!'E NOT NADIATOS MANUAL' READ OWNER'S NC ON COOL SYSTEM THE DFOfi fWTHEF NFORMATION THE ' CHECK YOUS HONOA OEALER. WIIH
Type Family V: LDV T: LDT

Displacoment SaquenceCharactors X HNXEOO8OAAB
INFORMATION VEHICLE IMPORTANT

S EPA VEHICLE CONFOAMSTOU. NLEV THIS TO MODL APPLICCBLI 1999 FEGULANONS ]nUCKSAND DUTY TIEVLIGHT YEA8NEW IO APPLICASLE 19S9 REGULATIONS CALIFORNIA DUTY IFIJCKS, TLEV LIGHT YEAR NEW MOOEL
Family: Evaporative
,|
F
CATALYST
mm IASN lN:010r0.02 VALVE E X0 1 3 1 0 0m m 2 lCoLDj PLUG SPA8K GAP 10- l l nm 130 5{ rPm t IDLE SPEED 201
OBDIICERT]ATD
Ll:.-.-,1 I rFrll \=#_H*

JL
--'-
Model Yoal X:1999 ManutacturarSubcode
HNX:HONDA
Family Typo E: EVAP R: EVAP/ORVR Canbter Work Capacity SquonceChartsters
NOB I]PCONDIIIONS INGINEAT TUNE ES TLJRN ATL ACCESSOS TEI\'PERATUR NNEL]TML FAN IRANSMSSION OFf NEEOEO. ADJUSTMTNTS NO OINER
SPEED MUsTcoMoufitooNArounwNEElDslvE Iooro nr tist rc orn svtncrE BE rEsr ouRE sT Pf D sE iitriunor mo ovuvo uenn orr Enw aNoN.loaDE PRoCE MU 8E Rr-
GD
50 state TLEV + NLEV {Unrestricted} T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V E R E G U L A T I O N A P P L I C A B L T O 1 9 9 9 M O D E LY E A R S A N E W T L E V L I G H TD U T Y T R U C K S N O C A L I F O R N I A A P P L I C A B L T O 1 9 9 9 M O D E LY E A R E REGULATIONS DUTYTRUCKS. NEWLIGHT
1-17
Under-hood Emissions ControlLabel

Emission Groupldentification (2000 model)
Example:
DWFEN r,tc ChA\CtN! cooraN.ust MsoLU- oNor fioNpA aDD 0R q-af6MrNp-ol rlt DREpf coolaNrAFTEBt3tlomistoR@MtLEs cE r@km),wH ctlEvrscoMEs T|E8EAFTER, EVEny BEprAcE ErdFstoB@ MttEs lmr,t, ffitcHEVER coMEs
DCIIICXOF ADDCOOLA\ I'-FE I
Engineand Evaporative Families

EngineFamily:
Model Yar Y: 2000 ManufaqturerSubcodo HNX:HONDA Y HNX TO2.OUA2
\rvEn coo|-d',r os-Fiiiiifi-' lfi ;!,."5:P!$t:1t9ffilf u u'r+-E 1

AISIRVI TAI{I\. NOI THEMDIAIOR
":3lliJ#fl
s,5TEMTrE sMA\u.r. "lj,9lx6L;T&Iji(0or|]\G 8r!D owrEp IMPORTANT VEHICLE INFORMATION
Family Type V: LDV T: LDT Displacement

SaquencoCharasters
IHIS\/IHICLE CONFONMS U.S.EPA TO NLEV SEGULATIONS APPIJCq3LE 2OOO TO IVOOEL YEAF NEW T!!V LIGHT DUTY TBUCKS AND CALIFONNIA SEGULATIONS APPLICASLE 2OOO TO MOOL YIAA NEW TLEV LIGHT.OUTY TFIJCKS.
Evaporative Family:
Modol Yea. Y: 2000 ManufacturerSubcode HNX:HONDA Family Type E: EVAP R: EVAP/ORVR CanisterWork Capacity SoquencaCharactet3
Y HNXEOOSOAAB
CATALYST
vALvt LA5h tN:0,10r0.02 mm {C0t0l E l : 0 . 1 3 ! 0 0 2h m S P A n ( P L U G G A1 . 0 - 1 1 m m O8OCENTFIED P lDlE PEEo S 734150lpm ?.0 t TUNIUP CoNDIToNS: ENGINE NORM AT TTMPERAIURE ATLACCESSORIES fu BNI TAN TiANSMISS INNUTRAL OFF ON NO OTHER AD.ILJSTMENIS NEEDEO.
.l-L
|oAoEDr/MTESTNG oFTHsvtHrctE gt couolorooN,{raua.wxEtt uLrst onuspreo syNoiRoN DvNAMoMETER. ANoN.LoAoEopBocEounr sr pair zEo olrEiwsE. rEsr uust
50 State TLEV + NLEV (Unrestricied, T H I S V E H I C L EC O N F O R M ST O U . S . E P A N L E V R E G U L A T I O N A P P L I C A B L T O 2 O O O O D E LY E A R S E M N E W T L E V L I G H TD U T Y T R U C K S N D C A L I F O R N I A A R E G U L A T I O N A P P L I C A B L T O 2 O O O O D E LY E A R S E M NEWLIGHT DUTYTRUCKS.
1-18
Lift and SupportPoints

Lift and SafetyStands
place ffi When heaw rear components such as suspension,Iuel tank, spare tire and tailgate are to b lemoved, vehicle, the !iiii-'rn"t r""igtrt in the trunk before hoisting. When substantial weight is removed flom the lear ot the center of gravity may change and can causethe vehicle to tip fotward on the hoist' 30 weighsapproximately lbs (14 kg),placingthe front wheelsin the cargoareacan assembly NOTE:Sinceeachtire/wheel with weight distribution. assist 1. Place lift blocksas shown. the and the 2. Raise hoista few inches(centimeters), rockthe vehicleto be sure it is firmly supported. the lift pointsfor solidsupport' the 3. Raise hoistto full height,and inspect NOTE:Usethe samesuppon pointsto supportthe vehicleon safetystands'
POINT FRONT SUPPORT
LIFTBLOCKS
POIMT REARSUPPORT
1-19
Lift and SupportPoints

FloorJack
1 . Blockthe rear wheelswhen raisingthe front of the vehicle; blockthe front wheelswhen raisingthe rear of the vehicle. Place blocksbehindand aheadof the wheels, the Raisethe vehicle high enough to insert the safety stanos. Adjust and place the safety stands so the vehicle will be approximately level,then lower the vehicle onto them. Always usg safety standg when working on or under any vehicle that is supported by only a iack. Nevor attempt to use a bumper jack for tifting or supporting ths vehicl.
Front:
Center the jack
bracketin the middle of the jack lift platform.
JACK LIFTPLATFORM
Rsar:
Centerthe iack in bracket the middle of the iack lift platform.
JACK LIFT PLATFORM
1-20
Towing
l f t h e v e h i c l en e e d st o b e t o w e d , c a l l a p r o f e s s i o n a l towing service.Never tow the vehicle behind another vehjclewith just a rope or chain.lt is very dangerous. EmergencyTowing Thereare three popularmethodsof towing a vehicle. Flat-bedEquipment- The operator loads the vehicle on the Thisis the bestway of transporting the backof a truck. vehicle. Wheel Lift Equipment- The tow truck usestlvo pivoting armsthat go underthe tires lfront or rear)and liftsthem o f f t h e g r o u n d .T h e o t h e r t w o t i r e s r e m a i no n t h e a g r o u n d . T h e v e h i c l e ' ss u s p e n s i o n n d b o d y c a n b e seriously damagedif this methodof towing is attempted. Equipment The tow truck usesmetalcables Sling-type with hookson the ends.Thesehooksgo aroundpartsof and the cableslift that end of the frame or suspension and suspension the vehicleoff the ground.The vehicle's damagedif thjs methodof towing body can be seriously T i s a t t e m p t e d . h i s m e t h e d o f t o w i n g t h e C R - Vi s unaccePtable. way of towing the CR-Vis on a The onlv recommended f l a t - b e dt r u c k . T w o w h e e l d r i v e C R - V ' sm a y a l s o b e towed with all four wheelson the ground.
Front:
lOwlNG HOOKS.nd TIE DOWN BRACKETS
Rear:
Towing the four-wheel dlive CR-v with only two wheels on the ground will damage parts of the 4wD system. It this vehicle is damaged, it should be towed on a flat-bed truck ol trailel. It the 2 wheel drive CR-v is towed wiih all tour wheels on the ground, do the following: Manual Transmission . Release parkingbrake. the . Shiftthe transmission Neutral in Automatic Transmission . Release parkingbrake. the . Start the engine. . Shiftto lD.lposition. then E position. . Turn off the engine. BRACKET TIEDOWN lmproper towing preparation will damage the transmission.Follow the above procedure exactly. lf you cannot shift the transmission or start the engine, the vehicle must be transported on a flat-bed truck. lf the vchicle is towed with four wheels on the ground, il is best to tow the vehicle no larther than 50 miles (80 km), and keep the speed below 35 mph {55 km/h). Trying to lift or tow the vehicle by ihe bumpers will cause serious damage. The bumpers ale not dosigned to support the vehicle's weight.
1-21
ServicePrecautions
PartsMarkingLocations
To deter vehicletheft, cenain major components are markedwith the vehicleidentification number{VlN).Originalparts will have self-adhesive labelsor labelsattachedwith a break-offbolt. Replacement body parts will have self-adhesive labels, and replacement engineand transmission partswill be stampedwith a codetor spareparts. NOTE: . Be carefulnottodamagethe partsmarkinglabelsduringbody repairs. Maskthe labelsbeforerepainting. ' Labellocation letters without parenthesis indicate originalparts.Letters with parenthesis indicate replacement pans. A, (A): Engine B, (B): Transmission C, (C): FrontBumoer D, (D); Hood E, (E): Tailgate F, (F): RearBumper (Lefrand Right) G, (G):FrontFenders H, {H): FrontDoors(Leftand Right} l, (l): RearDoors(Leftand Right) J, (J): OuterSide Panel(Leftand Right)
1-22
Drivel 4WD(Four-wheel for Precautions Real-time

l , U n d e r n o r m a l c o n d i t i o n s t h e v e h i c l ei s i n 2 W D ( f r o n t - w h e ed r i v e ) .H o w e v e r ,t h e s y s t e m w i l l i n s t a n t l yt r a n s m i t on drivingforceto the rearwheels{depending the drivingforceof the front wheelsand the road conditons) appropriate Pump Systemdoes not have a manual switch to disablethe 4WD system.Wheneverservice 4WD-Dual The Real-time the front or rearwheelswith the engine,alwayslift up and supportthe vehicleso all lour wheels spinning work requires are off the ground (seepage1-19).
1-23
Specifications
Limits............... 2-2 Standards Service and .......... Design Specifications .................. 2-12 ..........2-14 BodySpecifications
Standardsand ServiceLimits
EngineElectrical Section4
MEASUREMENT lgnitioncoil
lgnition wire R a t e dv o l t a g e V P r i m a r y w i n d i n g r e s i s t a n c e0 a t 6 8 ' F ( 2 0 ' C )
STANDAFDINEWI 12 0.63 0.77 25 max. 1 3 4-2

See Section 4 1 . 0 - 1 . 1 ( 0 . 0 3 9- 0 . 0 4 3 )
SERVICE LIMIT
Besistance 68"F(20 C) ktl at Firingorder Type Gap At idle
Sparkplug
l g n i t i o nt i m i n g Alternator belt*r
BTDC
D e f l e c t i o nw i t h 9 8 N { 1 0 k g f , 2 2 l b f )
Alternator
Belttension N {kgf,lbt) gauge Measured with bek tension rpm OutputA (at 13.5V, hot and 6,000 alternator Brushlength
AII M/I A/f Mfi
1 6 12 { R e d ) 8 . 5 1 1 . 5 1 0 . 3 3 . 4 5 ) w i t h s e db e l t 0 u 5.5- 8.0 (0.22 0.31) with new belt 340- 490{35- 50,77 110) with usedbelt 690 880(70 90, 150- 200iwith new belt 95 90 ( 10.50.41) 1.5(0.06i 1.1 1.0 0.5- 0.8{0.02 0.03) 0,0.02 (0 0.0008) ( 2 7 . 9 2 8 . 0 1 . 0 9 8 41 . 1 0 2 4 ) 14.0 14.5(0.55 0.57) (1.40 1.80,3.093.97) 13.7 17.7
Staningmotor
Output kW Micadepth Commutator runout Commutator O.D. Brushlength Brushspringtension N (kgf,lbf)
0.2 (0.008) 0.0s(0.002) ( 27.0 1.06) 9.0 (0.35)
' 1 W h e n u s i n g a n e w b e l t , d d i u s t d e f l e c t i o nt o n e w v a l u e . R u n t h e e n g i n e f o r 5 m i n u t e s t h e n t u r n i t o f { . B e a d i u s t d e f l e c t i o nt o u s e d b e l t v a l u e .
CylinderHead/Valve Train - Section6

MEASUREMENT Compression 250rpm and wide openthrottle , kPa(kgflcm' psi) Warpage Height E n dp l a y
Camshaft to hoider oil clearance
STANDARD {NEW}
SERVICE LIMIT
Nominal 1,230i'12 , 11Al .5 Minimum 930(9.s,135) Maximumvariation 20012.0,2al 1 3 1 . 9-5 1 3 2 . 0{ 5 . 1 9 - 5 . 1 9 9 ) 5 5 0.05 0.1s(0.002 0.006) (0.0012 0.0027) 0.030 0.069 0.03 0.001)max. { 33.204\1.30721 33.528 {1.3200) 16 33.1 \1.321 4) 33.528 {'1.3200) 0.08- 0.12(0.003 0.005) 0.16 0.20(0.006 0.008) (0.2591 0.2594) 6.580 6.590 (0.2579 0.2s83) 6.550 6.560 0.02- 0.05{0.00t 0.002) 0.05- 0.08(0.002 0.003) 1.25 1.55(0.049 0.061) ( 9 1 . 2 5 1 . 5 5 0 . 0 4- 0 . 0 6 1 ) 40.765 41.235 {1.6049 1.6234) 42.765 43.235i'1.6837 1.70221 (1.668i 42.36 44.32t1.1451 6.61 6.6310.260 0.261) 6.61 6.63{0.260 0.261i 1 3 . 7 - 1 4 . 2 5 0 . 5 4 10 . 5 6 1 i 5 1 15.75 16.25 {0.620 0.640i 0.05{0.002) 0.5(0.02) 0.15(0.006) 0.04(0.002)
Cylinder head Camshaft
Totalrunout Cam lobe height
'97,'98models '99,'00models
(Cold)* Valveclearance ValvestemO.D. Stem'to-guide clearance width height Steminstalled

Valve spring Valve guide Freelength
lN EX lN EX lN EX lN EX lN EX tN EX lN EX
lN EX
u* to.rutt
6.52lO.257l 0.08{0.003i 0.'1t(0.004) 2.0 (0.08) 2.0 (0.08) 41.485 {1.6333} 43.485 {1.7120i
I,D, Installed height
IN EX tN EX
6.6510.2621 6.65(0.262i
*: Measured between camshaft the and rocker arm,
2-2
EngineBlock- Section7
MEASUREMENT
Cylinder block
Unit of length: mm (in)
(NEWI STANDARD max. 0.07(0.003) (3.307 3.308) 84.00 84.02 (3.306 3.307) 83.98 83.99 0.01- 0.04(0.0004 0.00161 1.240 1.250 {0.0488 0.0492) 1.220 1.230 {0.0480 0.0484) - 0 2.805 2.825 0.1104 .1112) 1 (0.0022 0.0031) 0.055 0.080 (0.0014 0.0024) 0.035 0.060 0.20 0.30(0.008 0.012) 0.40- 0.55(0.016 0.022) 0.20- 0.50(0.008 0.020) (0.8266 0.8268i 20.996 21.000 (0.0004 0.0007) 0.010 0.017 (0.0006 0.0013) 0.015 0.032 -20.98110.8255 -0.8260) 20.968 48.0(1.89) 0.15- 0.30{0.006 0.012i (2.' 54.976 55.000 l644 2.1654) (2.1642 2.1651) 54.970 54.994 44.976 45.000/.1.1707 1.71111 (0.0002)max. 0.005 (0.0002) max. 0.005 0.10- 0.35(0.004 0.0r 4) 0.03(0.001)max.
Piston
Warpageof deck surface Borediameter Boretaper bottomof skart SkirtO.D.*1trom in Clearance cylinder Groove width {Forringi
Piston ring
clearance Ring-to'groove Ringend gap
Top Second oil ToP Second ToP Second oil
SERVICE LIMIT 0.10(0.004) (3.310) 84.07 0.05(0.002) (3.306) 83.97 0.05{0.002) 1.26(0.0s0) 1.25(0.049) 2.44lo.112l 0.13(0.005) 0.13(0.005) 0.60(0.024) 0.70(0.028) 0.70(0.028)
PistonPin rod Connecting
o.D.
Pin-to-piston clearance Pin-to-rodinterference Smallend borediameter Nominal Large end borediameter Endplayinstalled crankshaft on Mainjournaldiameter Crankshaft N o .1 , 2 , 4 a n d5 i o u r n a l s No.3 journal Rodiournaldiameter Taper Out ol round Endplay Bunout Main bearing-to-iournal clearance oil Bearing N o .1 ,2 , 4 a n d 5 i o u r n a l s No.3 journal oil Rodbearing-to-,ournal clearance *1: '97,'98models15 mm (0.6in) '99,'00models20 mm (0.8ini
oroto.oroi
(0.00041 0.010 (0.0004) 0.010 0.45(0.0r8) 0.04(0.002)
0.0017) 0.024 0.042 10.0009 (0.00120.0019) 0.030 0.048 (0.0008 0.0015) 0.020 0.038
(0.002) 0.06 (0.002) 0.06 (0.002) 0.05
o
2-3
Standards andServiceLimits
EngineLubrication
Engine oil
Section8
MEASUREMENT STANDARO {NEWI SERVICE LIMIT 4.6(4.9, 4.0)Iorengineoverhaul 3 . 8{ 4 . 0 , 3 . 3 ) f o ri l c h a n g e n c l u d i nfg l t e r o i, i 3.5 (3.7, 3.1)for oil change, withoutIilter 0.04- 0.16(0.002 0.006) 0.20(0.008) 4 0 . 1 0 0 . 1 9 ( 0 . 0 0- 0 . 0 0 7 ) 0.20(0.008) 0.02-0.07 (0.001 0.003i 0.15(0.006) 70 (0.7,10)min. 3 4 0{ 3 . 5 , 5 0m i n . )
Capacity f (US qt, lmp qt)
Oilpump
R e l i e fv a l v e
Inner-to-outer rotorclearance Pumphousing-to-outer clearance rotor Pumphousing-to rotoraxialclearance Pressure setting engineoil temp. 176'F(80'C) at kPa(kgt/cm,,psi) At ldle At 3,000rpm
Cooling
Radiator
Section 10
MEASUREMENT Coolant capacity , (USq1,lmp qt) engine, heater,I llncluding line Lcooling and reservoirl Reservoir capacity: q 0 . 6 1( 0 . 6 3 S q t , 0 . 5 3 l m p t ) U pressure kPa(kgf/cm?, psi) Opening Startsto open 'F 1"C) Fullyopen 'F ("C) Valvelift at tully open "ON" temperature "F Thermoswitch {'C) "OFF"temperature 'F ('C) Thermoswitch STANDARO INEW} 5.9{6.2, 5.2}toroverhaul 3.9(4.1, 3.4ifor coolant change 6.0(6.3, 5.3ifor overhaul 4.0(4.2, 3.5)for coolant change 9 3 - 1 2 3( 0 . 9 5 1 . 2 5 1 4 1 8 ) , - 176(76- 80) 169 194(90) 8 . 0( 0 . 3 1 i m i n . 196- 203 (91- 95) Subtract - 14 (3 - 8) trom actual"ON" temperature 5
M/T
Radiator cap Thermostat
Cooling fan
Fueland Emissions
Section 11
MEASUREMENT STANDARD INEW} 260- 31012.7 3.2,38- 46) 270-32012.8 3.3,40- 471 , 5 8 ( 1 5 . 31 2 . 8 ) MT AT {E or E position)
Pressure regulator Pressure with regulatorvacuum hose disconnected '97,'98models , kPa(kgflcm' psi) '99, '00 rnodels Fueltank (USgal,lmp gal) Capacity / En g i n e ldle speed with headlights coolingfan off rpm and '97 model '98 model '99,'00 models Fastidle rpm '97 model '98 model '99,'00 models
750 50 r 7301 50
1,5001200 1,600 200 r 0.1max.
750t 50 750r 50 7301 0 5

1,5001 00 2 1,5001 00 2 1,600 200 r
ldle CO %
2-4
Clutch
Clutchpedal
Section 12
MEASUREMENT height Pedal Stroke Freeplay play Pedal Disengagement height runout Clutchsurface
Rivet head depth Thickness
Unitof length:mm lin) STANDARD INEWI 183(7.20) - 5 135-14515.31 .71) 7 - 2210.24 0.41J 1-9 (0.04-0.35) m 7212.83)in. SERVICE LIMIT
to floor
to floor
(0.002) max. 0.05

1 . 2 1 . 7 1 0 . 0 5 -. 0 7 ) 0 8 . 4 9 . 1( 0 . 3 3 , 0 . 3 6 ) ( 0.03 0.001)max. 0.6 (0.02) max.
0.r5(0.006)
0.2(0.01) 6.0i0.24) 0.15(0.006) 0.8 (0.03)
Clutchdisc plate Pressure
Warpage Diaphragm springfingeralignment
ManualTransmission Section 13
Transmission fluid
Mainshaft
MEASUREMNT Capacity f (USqt, lmp qti Endplay contact area(clutch side) Diameter ball bearing of Diameter needle of bearing contact area Diameterof ball bearingcontactarea (transmission housing side) Runout LD. Endplay Thickness LD. Endplay Thickness Diameterol needlebearingcontactarea Diameter ball bearing oI and needle bearing contact Diametero{ 1st gear contactarea Runout
STANDARD INEW}
1 . 71 1 . 8 1 . 4 ) f o ro i l c h a n g e , 2 . 1 ( 2 . 2 ,1 . 8 ) { o r o v e r h a u l
SERVICE I-IMIT
0.'11 0.18(0.004 0.007) (1.1015 1.1020) 27.977 27.990 (1.4954-1.4961) 37.984 38.000 (1.1018 1.1024) 27.987 28.000 0.02(0.0011max. 43.009- 43.02511.6933 1.6939) 0.06- 0.21 (0.002- 0.008) 34.92 34.97 11.375 1.377) , 31.42- 31.4'7 11.237 1.2391
Adjust ( 2 7 . 9 41 . 1 0 0 ) (1.493) 37.93
Mainshatt and 3rd 4th gears
3rd gear 4th gear
Mainshaftsth gear Countershaft
(1.100) 27.94 0.05{0.002) 43.08011.6961) 0.3 (0.01) 34.811.37) 31.311.23) 1.6939) 43.08011.6961) 43.00943.02511.6933 (0.0020.008) 0 . 3( 0 . 0 1 ) 0.06 0.21 ( 30.8 1.21) 30.92 30.97 {1.217 1.219) - 1.4179) 3s.95 - 36.015 (1.415) 36.000 {1.4173 (0.982) 24.94 24.987- 25.000(0.9837 0.9843) -1.4567) 36.984 37.00011.4561 0.02(0.001)max.
(1.4s4) 36.93 (0.002) 0.0s

(1.696) 43.08 0.2310.009) 47.08 {1.854) 0.18(0.007) ( 3 1 . 0 61 . 2 2 3 ) (1.494) 37.94 26.01t1.0241
1st countershatt gear Countershaft 2nd gear collar Spacer (Mainshaft 4th and 5th gears) Reverse idlergear ring Synchro Dualcone
LD. Endplay Thickness t.D. Endplay Thickness
(1.69331.6939) 43.00943.025 (0.0020.007i 0.06 0.18 (1.061 1.063) 26.9s,27.00 (1.85071.8514) 47.00947.025 ,0.006) 0.07 0.14 10.003 l 2As2 2a.971.139-1.1411
A
t.D. o.D.
Length
l le ' s
t.D. gear Gear-to-reverse shaftclearance

R i n g - t o - g e a rc l e a r a n c e ( r i n g p u s h e d a g a i n s l g e a r )
31.002- 31.O12 .2205, 1.2205) 11 (1.4956 1.4961) 37.989 38.000 56.45- 56.55Q.222- 2.2261 26.03,26.08(1.025 1.027) - 20.043 (0.7880,0.7891) 20.01 6 (0.0014 0.0033) 0.036 0.084
(0.7909) 20.09 0.16010.0063)

0.4 (0.02)
0.85 r.10(0.0330.043) 0.5 1.0(0.02 0.04) 0.5- 1.0(0.02 0.04) (0.0370.066) 0.95 1.68 7.4- 7.6(0.29 0.30) 6.2- 6.4(0.240.2s) (0.0't40.026) 0.35 0.65
Shift fork
(ringpushed gear) against Clearance ring to synchro cone Outersynchro Synchrocone-to-gear Outersynchro ring-to-gear Finger thickness 3rdl4th shiftlork Exceptabove Fork-to-synchro sleeveclearance
0.3(0.01) 0 . 3( 0 . 0 1 ) 0.6(0.02)
't, torag)
Standards and ServiceLimits

ManualTransmission {cont'd}- Section 13
MEASUREMENT Raverse shift Iork Pawl groove width Fork-to-reverse idler gear clearance width*l Groove Fork-to-5th/reverse shaft clearance*' shift at B' Shift arm A Shiftarm C Select arm
Selectlever Shift lever Shift fork diameter at contact area Shift arm A-to-shitt tork shaft clearance
at A atB
STANDARO INEW) '13.0 13.3(0.5' - 0.52) j 0.5- 1.1(0.02 0.04) 7.O5 7.25 i.0.21 - 0.2451 4 7.4-7.7 t0.29 0.301 0.05- 0.35(0.002 0.014) 0.4,0.8 (0.02 0.03) 12.9 13.0(0.508 0.512) 0.2- 0.5 (0.008-0.020) 0.05 0.25(0.002 0.01) r2.9- 13.0(0.508 0.512) 0.05- 0.25(0.002 0.01) 1 7 . 9- 8 . 0( 0 . 3 1- 0 . 3 1 s ) (0.6276 0.6287) 15.94r 15.968 (0.0013 0.0034) 0.032 0.086 (0.6276 0.6287) r5.941 15.968 (0.0013 0.0050) 0.032 0.127 (0.7091 0.7098) 18.010 18.028 (0.0011 0.0022) 0.027 0.057 (1.1026,1.1033) 28.005 28.025 (0.0010,0.0026) 0.025 0.066 0.055- 0.09110.0022 0.0036)
SERVICE LIMIT
18 (0.07)
0.5{0.02) (0.04) 1.0

0.6{0.024i
Shiftarm C'to-shift arm B clearance Diameterof shift arm B contactarea Selectarm'to-shift arm A clearance Diameter shiftarm A contact of area
o.D.
Transmission housing clearance
o.D.
Shift arm cover clearance
Differential carner
Pinion shaftcontact areaLD. Carrier-to-pinion clearance shaft Driveshaft,intermediateshatt contact area LD, Carrier-to-driveshaft clearance Carrierto-interrnediate shaft clearance
0.1 (0.004) 0.12 0.005i { ( 0.15 0.006i
Differential piniongear
Backlash t.D. gearto-pinion clearance Pinion shaft
0.05-0.r5 {0.0020.006) (0.71030.7113) 18.04218.066 0.059 0.095 10.00230.0037)

1.4 2.5i'14 26,12-231
oru ro.ooor
Adjust
Ditferential taperedrollrbesringpreloac Staningtorque N.m (kgf.cm, lbl.ini Transter Diameter rollerbearing of contact area Translershaft {driven gear side} Translorshaft {middle of shaft) Transterdrive gear gearside) Translor drivengearshaft{driven Transter drivengearshaft(splined side) Trans{ergear backlash Totalstarting torqueN.m (kgicm,lbiin)
(1.337 1.339) 33.984 34.000 21.977 27.99011.101 1.1021 - 1.576) 40.002 40.01811.575 - 1.379) 35.002 35.01811.378 (1.062 1.063) 26.975,26.988 0.06- 0.16{0.002 0.006) 2.64 3.41 \21.3,35.4,23.1 30.t|
(1.336) 33.93 27.92 (1.O99) (1.573) 39.95 (1.376) 34.95 (1.060) 26.92 Adjust Adjust
11:fuleasuring points
*2: Measuring points
A'
A 'Ay"
_{-P)
-l-...
2-6
Automatic Transmission Section 14

MEASUREMENT Transmission fluid Capacity I {US qt, lmp q0 4WD 2WD Hydraulic pressure kPa (kgflcm', psi) Linepressure 2,000 at rpm in LII or El position 1slclutchpressure 2,000 at rpm in Da position 1st-hold rpm In l position clutchpressure 2,000 at STANDARO INEW} 6.8(7.2, 6.0)for overhaul 2.6)for fluid change 2.9(3.1, 5.2)foroverhaul 5.9{6.2, 2.4}forfluid change 2.7{2.9, 830- 880(8.5- 9.0,120 130)
U n i t o f l e n g t h :m m ( i n )
SERVICE LIMIT
780(8.0,1' t0)
2nd clutchpressure 2,000 at rpm in El position ('97, 3rd clutchpressure 2,000 at rpm in E position '98 models), or E position with O/DOFFindicator light ON ('99,'00models) ('97, 4th clutchpressure 2,000 at rpm in gl position '98 models), with O/DOFFindicator or E position lightoFF ('99,'00models) rpm (Check with vehicle levelground) on Stallspeed 1st Clutchinitialclearance 2nd,3rd,4th 'lst-hold Clutchreturnspringfree length discthickness Clutch Clutchplatethickness Clutchend platethickness (lsti 1st,2nd,3rd,4th '1st-hold 2nd,3rd, 4th 1st,1st-hold Mark1 Mark2 Mark3 Mark4 Mark5 Mark6 Mark7 Mark8 MarkI Mark 10 Mark6 Mark7 Mark8 Mark9 M a r k1 0 M a r k1 1 lvlark 12 M a r k1 3 M a r k1 4 M a r k1 5 M a r k1 6 Mark17 Mark8 MarkI M a r k1 0 M a r k1 1 M a r k1 2 M a r k1 3 M a r k1 4 M a r k1 5 M a r k1 6 M a r k1 7 Mark1 M a r k2 Mark3 No mark Mark6 Mark7
800- 850(8.2 4.7,120 1241
760t7.7,1101
end platethickness Clutch {2nd,4th)
Clutch end platethickness {3rdi
Clutch end platethickness ( 1 s th o l d )
2,550 -0.033) 0.65- 0.85(0.026 0.40- 0.60(0.016 0.024) 0.5- 0.8(0.020 0.031) 31.1 11 .22) ( 34.6 1.36) 1.88 2.00(0.074 0.079) 'r.95 2.05 {0.077 0.081) '1.55-1.65(0.061 0.065) 2.05- 2.r0 (0.081 0.083) 2.15 2.20(0.085 0.0871 2.25 2.30(0.089,0.091) 2.35 2.40{0.093 0.094} 2.45- 2.50{0.096-0.098} 2.55- 2.60(0.100 0.102) 2.65- 2.70(0.104 0.106) 2.75 2.80i0.108 0.110) . 2 . 8 5 2 . 9 0 1 0 1r2 0 . 1 1 4 ) 2.95 3.0010.116 .118) 0 2.55 2.6010.100 0.102) 2.65 2.70(0.104,0.106) 2.75- 2.80(0.108 0.110) ( 2 2 . 8 5 2 . 9 0 0 . 1 1- 0 . r r 4 ) ( 2.95 3.00 0.116-0.118) ( 0 3 . 0 5 3 . 1 0 0 . 1 2- 0 . 1 2 2 ) ( 3.15 3.20 0.124-0.126) 3.25- 3.30(0.128 0.130) 3.35- 3.40(0.r32- 0.134) 3.45- 3.50(0.136 0.138) ( 0 3 . 5 5 3 . 6 0 0 . 1 4- 0 . 1 4 2 ) 3.65- 3.70(0.144 0.146) ( 2 . 7 5 2 . 8 0 0 . 1 0 80 . 1 1 0 ) ( 2 2 . 8 5 -2 . 9 0 0 . 1 1- 0 . 1 1 4 ) ( 6 2 . 9 5 3 . 0 0 0 . 1 1- 0 . 1 ' j 8 ) 3.05 3.10(0.120 0.122) 3 . 1 5 - 3 . 2 00 . 1 2 4 0 . 1 2 6 ) { 3.25- 3.30(0.128 0.r30) 3.35- 3.40(0.132 0.r34i 3.45- 3.50(0.136 0.138) 3.55- 3.60{0.140 0.142) 3.65- 3.70{0.144 0.r46) 2.05 2.10(0.081 0.0831 2.r5 2.20(0.085 0.087) 2.25- 2.30{0.089 0.091} 2.35- 2.4010.093 0.094i 2.45- 2.50(0.096-0.098i 2.55- 2.60(0.r00- 0.102) 2.65- 2.70(0.r04- 0.106)
2,400,2,700
( 29.1 1.15) 32.6(r.28) worn out Untilgrooves Discoloration Discoloration

Discoloration
Discoloration Discoloration
Discoloration
Discoloration
Discoloration
(cont'd)
2-7

Automatic Transmission (cont'd)- Section 14
MEASUBEMENT Transmission Diameter needle of bearing contact area statorshaftbearing On mainshaft 2nd gear On mainshaft 4th On mainshaft gearcollar On mainshaft gearcollar 1st (torque converter housing side) On countershatt On countershaft gear 3rd 4th On countershaft gear gearcollar On countershaft reverse 1st On countershaft gearcollar housing sidei On sub-shaft {transmission On sub shaft4th gearcollar idlergearshaft On reverse Inside diameter needle of bearing contact area 1st On mainshaft gear On mainshaft 2nd gear On mainshaft gear 4th 1st On countershaft gear 3rd On countershaft gear 4th On countershaft gear gear reverse On countershaft 4th On sub-shaft gear On reverse idlergear fleverse idlergearshaftholderl.D. Endplay Mainshaft gear 1st Mainshaft 2nd gear Mainshaft gear 4th Countershaft gear 1st Countershaft gear 3rd Countershaft gear 4th Sub-shaft4th gear Reverse idlergear Countershaftreversegear hub O.D. Selector Mainshaft gearcollarlength 4th Mainshaft gearcollarflange 4th thickness Mainshaft gearcollarlength 1st Countershaft distance collarlength STANDARD {NEW} SERVICE LIMIT (0.9441 0.9446) Wearor damage 23.980-23.993 (1.4163 1.4169) 35.975 35.99'! ( 3 1 . 9 7 5 3 1 . 9 9 11 . 2 5 8 91 . 2 5 9 5 i 30.975 30.99111.2195 1.2201l' (1.4175 1.4180) 36.004 36.017 (1.4165 1.4172) 35.980 35.996 ( 2 7 . 9 8- 2 7 . 9 9 31 . 1 0 1-61 . 1 0 2 1 i 0 ' ( 3 1 . 9 7 5 - 1 . 9 9 11 . 2 5 8-9 j . 2 5 9 5 i 3 ( 3 1 . 9 7 5 3 1 . 9 9 11 . 2 5 8-91 . 2 5 9 5 ) (1.0233 1.0236) 25.991 26.000 (0.9053 0.9058) 22.9935 23.006s 13.990 r4.000(0.5508 0.5512) Wearor damage (1.3780 1.3786) 35.000 35.016 4 1 . 0 0- 4 1 . 0 1 ( 1 . 6 1 4-21 . 6 1 4 8 ) 0 6 -' (1.4961 1.4967) 38.000 38.016 (1.496'1 1.4967) 38.000 38.016 4 1 . 0 0 0 4 1 . 0 1 ( 1 . 6 1 4 21 . 6 1 4 8 ) 6 (1.2992 1.2998) 33.000 33.016 (1.4961 1.4967) 38.000 38.016 (1.2598 1.2605) 32.000 32.016 (0.7089 0.7094) 18.007 18.020 (0.5676 0.5683) 14.416 14.434 0.05- 0.16{0.002 0.006) 0.05- 0.13(0.002 0.005) (0.002 0.006) 0.05,0.'16 0.1 0.5(0.004 0.020) 0.05 0.17{0.002 0.007) 0.10 0.18(0.004 0.007) 0.0s 0.17(0.002 0.007) 0.05- 0.18(0.002 0.007) 0.10,0.25(0.004 .010) 0 (2.042 2.043) 51.87 51.90 (1.9488 |.9508) 49.50 49.55 ( 4 . 4 3 5 4 . 5 2 50 . 1 7 4 6 - 0 . 1 7 8 1 ) 2 7 . 0 0 , 2 7 . 0{5 . 0 6 3 ' 1 . 0 6 5 i 1 (1.534 1.535) 38.97 39.00 (1.536, 1.537) 39.02 39.05 (1.538 1.539) 39.07 39.10 ( 0 3 9 . 1 2 3 9 . 1 5 1 . 5 4- 1 . 5 4 1 ) * (1.542 1.543) 39.17 39.20 39.22 39.25 11.544 1.545) 39.27 39.30 1'1.5461.547i 38.87 38.90 {1.530 1.531) (1.s32 1.533) 38.92 38.95 21.15- 21.20rc.4327 0.4346) , (0.57't 0.575) 14.5, 14.6 2.4- 2.6(0.094 0.102) 14.5 14.6(0.571 0.575) 2.4- 2.6(0.094 0.102) 24.0 24.1(0.945 0.949) ( 6 2 . 9 5 3 . 1 0 0 . 1 1- 0 . 1 2 2 ) Wearor damage
Wearor damage
il*=lo'. d"'.n"n"
Wearor damage
Countershaft gearcollarlength 3rd gearcollarlength reverse Countershaft gearcollarflange Countershaft reverse thickness 1st Countershaft gearcollarlength lst Countershaft gearcollarflangethickness Sub-shaft gearcollarlength 4th Sub shatt4th gearcollarflangethickness
Wearor damage Wearor damage Wearor damage
2-8
Automatic Transmission - Section 14

MEASUREMENT Transmission
Mainshaft 2nd gear thrust washer thickness
Unit of length: mm (in)
(NEWI STANDARD
3.974.024.07 4.12 4.17 4.224.274.32 4.374.422.95 2.434.9s2.93 4.0010.156 0.157) 4.05{0.158 0.159) 4.1010.160 .161) ( 2 4 . 1 5 0 . 1 6- 0 . 1 6 3 ) 4.20(0.164 0.165) 4.2510.166 0.167 ) 4.30(0.168 0.169) ( 4.35 0.170-0.171) 4.40(0.172 0.173) 4.45(0.174 0.r75) ( 3 . 0 5 0 . 1 1 60 . 1 2 0 ) 2.50(0.096 0.098) 5.00(0.195 0.197) ( 5 3 . 0 0 0 . 1 1- 0 . 1 1 8 1
SERVICE LIMIT
I
Wearor damage Wearor damage
I
t
Thrustwasher thickness l'rainshaft bearingleftside ball Mainshaft gear 1st Countershaft gearsplinedwasher 3rd Sub-shaft4th gear thrust washer One-way clutchcontact areaLD. 1st Countershaft gear gear Parking Mainshaft feed pipeA, O.D.(at 15 mm trom end) Mainshaft feed pipe B, O.D.(at 30 mm from end) teed Countershaft pipeO.D.lat 15 mm from end) Sub-shaft feed pipeO.D.(at 15 mm from end) ring thickness Mainshatt sealing (29mm and 35 mm) I.D. Mainshaft bushing Mainshaft bushingl.D. Countershaft bushing l.D. Sub shattbushingLD. Mainshaft sealingring groovewidth ATFpump gearsideclearance ATFpump gear'tobody clearance Drive Driven ATFpump drivengearLD. ATFpump drivengearshaftO.D.
Sealing ring contact area l.D,
I Wear damage or
Wearor damage Wearor damage 8.95(0.352) 5.95(0.234) 7.95(0.313) 7.95{0.313) 1.42$.O72) (0.2380) 5.045 9.03(0.356) 8.03(0.316) 8.03(0.316) (0.082) 2.095 0.0710.003) Wearor damage Wearor damage (1.3799) 35.050
(3.2810 3.2821) 83.339 83.365 (2.6254 2.6259) 66.685 66.698 8.97- 8.98 (0.353- 0.354) 5.97 5.98{0.2350 0.2354) 7.97- 7.98(0.3138 0.3142) 7.97,7.98 (0.3138 0.3142) 1.87 1.97(0.074-0.078) (0.2369 0.2374) 6.018 6.030 (0.3543 0.3549) 9.000 9.015 (0.3150-0.3158) 8.000 8.022 (0.3150 0.3158) 8.000 8.022 (0.0797 0.0811) 2.025 2.075 0.03- 0.05(0.001 0.002) (0.004,0.005) 0.1050 0.1325 0.0350 0.0625 10.001 0.002) (0.5518 0.5525) 14.016*14.034 13.980 13.990 {0.5504 0.5508) 35.000 35.025 {1.3780 1.3782) 2't.o00 27.021I '1 .063, 1.064) 2 9 . 0 0- 2 9 . 0 1 3 1 1 . r 4 11 . 1 4 2 2 ) 0 7
ATFpump
Regulator valve body Stator shaft
deviceand Shifting parking brake con' trol Servo body

Differential carrier
Inside diameter bearing of oI contact area On torqueconvener side On ATFpump side Reverse shittfork fingerthickness Parkingbrakepawl gear Parking Shiftfork shattborel.D. Shiftfork shattvalvebore l.D. Pinionshaftcontact areaLD. Carrierto-pinion shaftclearance Driveshafvintermediate contact l.D. shaft are Carrier driveshalt to clearance Carrier-to-intermediate clearance shaft
5.90 6.00 {0.232,0.236)

(0.55' l2 0.5516) 14.000 14.010 (1.4567 1.4582) 37.000 37.039 '18.010 18.028 - 0.710) 10.709 0.023 0.057 {0.001 0.002} (1.0246 1.0254) 26.025 26.045 (1.103 1.104) 28.025 28.045 0.045 0.08610.002 0.003) 0.075 0.111 0.004) 10.003-
Wearor damage Wearor damage 5.40(0.213) lWear or otherdefect
(1.4585) 37.045 0.r {0.004) 0.12(0.005) 0.15(0.006)
2WD 4WD
Differential prnron gear
Backlash t.D. gear'to-pinion clearance Pinion shaft

Diameter rollerbearing of contact area gearside) Transfer shaft(transfer Transfer shaft(middle shaft) of Transferdrive gear gearside) Transfer drivengearshaft{driven Transfer drivengearshaft{splined side) gearbacklash Transfer Totalstarting lbf.in) torqueN.m (kgf.cm,
(0.0020.006) 0.05 0.15 (0.71030.7113) 18.06218.066 otu to.oout 0.055 0.095 10.00220.0037)
0 0.15(0- 0.006) (1.515 1.516) 38.485 38.500 27.917- 21.990 |.1.101 1.102) (1.575 1.576) 40.002 40.018 (1.378 1.379) 35.002 35.018 -' (1.062 l.063) 26.975 26.988 (0.002 0.006) 0.060 0.160 2.64- 3.41 127.3 35.4,23.1 30.71 Adjust ( 3 8 . 4 31 . 5 1 3 ) (1.099) 27.92 (1.573) 39.95 (1.376) 34.95 (1.060) 26.92 Adiust Adiust
S e t r i n g - t o - b e a r i n go u t e r r a c e c l e a r a n c e
Transfer
(cont'd)
2-9

(cont'dl - Section 14 Automatic Transmission
STANDARO INEWI MEASUREMENT Wire Dia. Springs Regulator valvespringA Regulator valvespringB Statorreaction spring Modulator valvespring Torque convener valvespring check '97 model '98 - 00 models reliefvalvespring Cooler Relief valvespring 2nd orilicecontrolvalvespring 1-2shittvalvespring 2 3 shiftvalvespring 3-4shiftvalvespring 1staccumulator spring 4th accumulator springB 4th accumulator springA 2nd accumulator springA 3rd accumulator springA 2nd accumulator springB 3rd accumulator springI 3rd sub accumulator spring 2nd accumulator springC Lock-up shiftvalvespring Lock-up timing valvespring Lock'up controlvalvespring 3'4 orifice controlvalvespring Servocontrolvalvespring CPBvalvespring 4th exhaust valvespring 1 . 81 0 . 0 7 1 ) 1 . 8i 0 . 0 7 1 ) 4 . 5( 0 . 1 7 7 ) 1.4{0.055) 1.1(0.043) 1.2(0.047) 1.0(0.039) 1 . 1( 0 . 0 4 3 ) 0.7 (0.028) 0.9 (0.035) 0.9 (0.035) 0.9 (0.03s1 2.1 (0.083) 2.3 (0.091) 2.6 (0.102) 2.410.094) 2 . 8( 0 . 1 1 0 ) 1.6(0.063) 2.1(0.083) 2.7{0.r06) 2.2lO.OA7) 0.9 (0.035) 0.9 (0.035) 0.7 (0.028) 0.6 (0.024) 1.0(0.039) 0.9 (0.035) 0.9 (0.035)
o.D.
14.7(0.579) 9.6 (0.378) 35.4{1.394} 9.4 (0.370) 8.4 (0.331) 8.4 (0.331) 8.4 (0.331) 8.6(0.3391 6.6(0.260i 7.6{0.299} 7.6{0.299) 7.6{0.299) 16.0(0.630) 10.2to.402l 17.0(0.669) 29.0\1.1421 'r7.510.689) 9.0 (0.354) ( 31.0 1.220) 17.0(0.669) 14.510.571) 7.610.299i 8 . 1{ 0 . 3 1 9 } 6.6(0.260) 6.6(0.260i 8.1(0.319) 8.1{0.319) 6.t (0.240)
Fiee Length
No. of Coils
87.8(3.457) 44.011.1321 30.31r.193) 35.0{1.378) 36.4{1.433) 32.4tl.216J 33.8 r.331) { ( 37.1 1.461) 34.8(1.370) 41.3(1.626) 57.0 (2.2441 57.0 12.2441 89.1(3.508) ( 51.6 2.031) 88.4(3.480) 39.011.s35) 94.313.713) 20.710.8r5) 38.2(1.504) 39.0(1.535) 68.0(2.677) 73.7 12.902) 8 r . 4( 3 . 2 0 5 ) 38.0fl.496) 37.9(1.492) ( 52.1 2.051) 41.2 t\ .A5Al 36.4(1.4331
r 1.0 1.9 10.9 12.O 12.7 8.2 13.4 22.0 26.4 26.8 13.8 14.2 2.9 15.9 2.6 6.3 32.0 47.A 20.8 '18.3 '19.5
Differential (4WDl * Section 15

MEASUREMENT
Capacity f (US qt, lmp ql)
STANOABD {NEW' , a 1 . 2( 1 . 3 1 . 1 ) t o v e r h a u l , a 1 . 0( 1 . 10 . 9 1 t f l u i dc h a n g e
Steering
Steering wheel
Section 17
MEASUREMENT playat steering Rotational wheelcircumference Staningloadat steering wheelcircumference N {kgf,lbl) Engine running Angleof rack$uide-screw loosened lrom lockedposition '97, '98 models '99, '00 models Pumppressure with shut off valveclosed kPa (kgvcm,,psi) Recommended tluid Fluidcapacity I {USqt, lmp q0 Deflection with 98 N {1O kgl,22lht) pulleys between Belttension N {kgt,lbf} Measured with belttensiongauge 0 - 1 0( 0- 0 . 3 9 ) 29 (3.0,6.6) 10"1 5" 20" MAX. (70 80,995 1,138) 6,900 7,800
STANDARD INEWI
Gearbox
Pump Powersteering fluid Powersteering belt*
Hondapowersteering fluid. For overhaul 0.85(0.90,0.75) For reservoir 0.4{0.42,0.35) 11.0 14.5(0.43 0.57)withusedbelt 7.5- 10.0(0.30 0.40) with new belt 390- 540(40- 55,88 - 121) with usedbelt 740-880 (75 90, 165 198)withnew belt
* When usinga new belt,adjustdeflection tension new values. Runthe enginefor 5 minutes or to then turn it off. Readjust dellection tension usedbeltvalues. or to
2-10
Suspension Section18
MEASUREMENT Wheelalignment Camber Caster Totaltoe Frontwheelturningangle Wheelbearing E n dp l a y Front Rear Front Front near Inwardwheel wheel Outward Front Rear Aluminumwheel Steelwheel Axial Badial Axial Radial 0"00'1 1' - 1"00' 1' 1 2"10'! 1" 0J3(011/8) r N2 r i ( 1 / 1 6 1 / r 6 ) 1 37"00'! 2 31'30'(Referencei 0 - 0.05{0- 0.002} 0 - 0.05(0 0.002i (NEW) STANOARD 0 - 0.7 (0 0 , 0 . 7 ( 00 1.0(0 0 - 1.0{0 0.03) 0.03) 0.04) 0.04)
Unit of length:mm {in) STANDARD {NEW)
Rim runout
LIMIT SERVICE 2.0(0.08) 'r.5 {0.06) 2.0{0.08) 1.s(0.06)
Brakes Sec'tion 19
MEASUREMENT Parking brake lever Footbrakepedal Playin stroke 196N (20kgf,44lbf) at leverforce Pedal height(withtloor mat removed) NT Freeplay Mastercylinder Discbrake Piston-to-pushrod clearance Discthickness Discrunout Discparallelism Padthickness Rearbrakedrum LD. Liningthickness Front '97,'98 models '99,'00 models Front Front Front STANDARD INEWI when Dulled: - 6 notches 2 To be locked 155(6 1/8) 1 6 1( 6 5 / 1 6 ) 1 5 (1/16 3/16) 0 - 0.4(0- 0.02) STANDARD {NEW' 22.9- 23.1(0.902 0.909) 23.6 23.8(0.929 0.937) 10.5 11.5(0.4' t 0.45) (8.657 8.661) 2r9.9 220.0 3 . 9- 4 . 5( 0 . 1 5 0 . 1 8 )
SERVICE LIMIT
t o l
21.0(0.83) 21.0(0.83) 0.10{0.004) (0.0006) 0.015 1.6(0.06) 221.O 8.7011 2.0(0.08)
Air Conditioning
Air conditioning
Section 22
MEASUREMENT
STANDARD {NEWI
Lubricant type: KEIHIN 10 (P/N38897 Pl3 - A01AHor 38899 SP P l 3- A 0 1 ) Condenser Lubricant capacity Evaporator mf {floz, lmp oz) Lineor hose Receiver Lubricant type:SP 10 Lubricant capacity ml ({l 02,lmp oz} at Stator coil resistance 68'F (20"C)O plate clearance Pulley-to-pressuae Deflection with 98 N (10kgl,22lbli pulleys between Belttension N (kgf,lbf) with belttensiongauge Measured
25 (5/6,0.9) 40 {1 1/3,1.4) 1 0{ 1 / 3 , 0 . 4 ) 10(.]/3,0.4) 1fi'3o, 4.6;"} 130'3'{4 3.05- 3.35 1 0.51 0.15(0.02 0.006) with usedbelt 7.5- 10.5{0.30 0.41) with new belt 5.0- 7.0(0.20 0.28) 3 9 0- 5 4 0( 4 0 5 5 , 8 8 - 1 2 0 ) w i t h u s e d b e l t 740- 880 {75 90, 170- 200)with new belt
Compressor (KEIHIN)
Compressor belt*
* When usinga new belt,adjustdeflection tensionto new values. for then turn it off. Runthe engine 5 minutes or to Readjust deflection tension usedbeltvalues. or
o
2-11
DesignSpecifications
ITEM DIMENSIONS Overall length Overallwidth Overall height Wheelbase Track Seating capacity Grossvehicle weightrating(GVWR) Grossvehicle weightrating(GVWR) Type Cylinder arrangement Bore and stroke Displacement Compression ratio Valvetrain Lubricationsystem Oil pump displacement 6,000 at enginerpm Waterpump displacement 7,600 at enginerpm Fuelrequired STARTER Type Normaloutput Nominalvohage Hourrating Direction rotation of Weight CLUTCH Clutchtype Clutch lacingarea Transmission type PrimaryredLrction Type Gearratio 1st 2nd 3rd 4th 5th Reverse Geartype Gearratao MIT MIT MIT METRIC 4,510 m m 1,750 mm 1,608 mm 2,622mrn 1,533 mm 1,534 mm 5lf 4 , 1 6 5b s t | 1,900 kg Water-cooled, 4-strokeDOHC gasoline engine Inline4-cylinder, transverse 84.0x 89.0mm 3.31x 3.50in .1,973 (m{) cm3 120 u-in c 9.2 9.6 Beltdriven, DOHC 4 valvesper cylinder pump Forced wet sump, and trochoid 501 (53 US qt,44 lmp qt)/minute 1401(148US qt, 123lmp qt)/minute gasoljne UNLEADED with 86 PumpOctane Numberor Higher gearreduction Planetary A/T:1.1kW M/T: 1.0kW 12V 30 seconds Clockwise viewedfrom gearend as 3.7kg 8.2 lbs Singleplatedry, diaphragm spring Torqueconverter 203cm, 31.5sq-in Synchronized s-speedtorward, 1 reverse Electronically controlled 4-speedautomatic,1 reverse Direct I : 1 Manualtransmission 3.500 1.956 1.344 1.071 0.812 3.000*,. 3.461*'
Single helicalgear 4.562
ENGLISH 1 7 7 . 6n i 68.9in 63.3in 1 0 3 . 2n i 60.4in 60.4in
NOTES
Front Rear
(USA) WEIGHT (CANADA) WEIGHT ENGINE
'97,'98mooers '99,'00 models
Approx.
TRANSMISSION
*1: '97- 99 models *2: '00 model
Finalreduction Transfer
Reardifferential
0.434 2.533 Automatic transmission 2.722 1.079 0.711 1.955 gear Singlehelical 4.357
Type Gearratio 1st 2nd 3rd 4th Reverse Geartype Gearratio
Finalreduction Transfer
0.393
2-12
ITEM
AIR CONDITIONING Cooling capacity
METRIC Type/manutacturer No. of cylinder CaPacity Max.speed Lubricant capacity Lubricant type Type Type Type Motor input Speedcontrol Max.capacity
ENGLISH
NOTES
Compressor
j Kcal/h 14,000 BTU/h 3,520 Scroll/KElHlN 85.7mf/rev | 5.23cu'in/rev 10,000 rpm algIloz 130mf 1 sP-10 fin Corrugated Corrugated fin
Siroccofan
-Condenser
Evaporator Blower
200w 112 v
4-Speeo 440 m3/h 15,500 cu fvh
Temperature control Compressor clutch Befrigerant STEERING SYSTEM Type ratio Overall Turns, lock to lock Steering wheeldiameter SUSPENSION Type Front Bear Shock absorber WHEEL ALIGNMENT Camber Caster Totaltoe Frontand Rear Front hear Front Front Rear Front Rear Front Rear Tvpe Type Powerconsumption Type Ouantity Dry,singleplate,poly-V-belt drive 40 W max./12 V HFC-134a 1R-134a) 24j anoz zoo o' g rackand pinion Powerassisted, At 68'F (20 C)
Independent doublewishbone, spring coil with stabilizer Independent coil doublewishbone, spring with stabilizer gas tilled hydraulic nitrogen Telescopic,
0' - r"00'
2.10' 0mm 0in l n 1 / 1 6n i ln2mm Power-assisted selt-ad,usting ventilateddisc Power assisted self-adiusting drum 49 cm, x 2 7.6sq-inx 2 7 3 c m ,x 2 11.3 q-in 2 s x rear Mechanical actuating, two wheelbrakes label. Seetire inlormation 12V, 36 AH/sHR 1 2 V 1 . 0 , . 1k W 1 12V 100A 7.5A, 10A, 15A, 20 A 7.5A, 10A, 15A, 20 A, 30 A, 40 A '100 A 7 . 54 , 2 0 A . 4 0A 12V 60/55 W 12V- 21 W ('97model), 1 2V - 2 7W ( ' 9 8 - 0 0m o d e l s ) 12V 5 W {'97model),3 ('98- 00 models) CP 12V-8W 1 2V , 3 C P 12V-21W 12V 2115 W 1 2 V 2 1C P( 1 8 ) W 12V-8W 12V-8W 12V-5W 1 2 V- 2 1 W 1 2V - 1 . 4 W 12V 1.4 W 1 2V 1 . 4 , 3 W , 3 . 4 W W W W 1 2 V - 0 . 8 4 W ,1 . 1 2 , 1 . 4 , 3 W , L E D 12V - 0.84W, 1.4W, LED 1 2V , 1 . 4W
BRAKE SYSTEM
Tvpe
Pad surface area Lining surfacearea P a r k i n gb r a k e
Drum brake
TIRE ELECTRICAL
Sizeand pressure Baftery Starter Alternator In under-dash fuse/relay box In under hood fuse/relaybox In underhoodABSfuse/relay box Headlights Frontturn signallights lights Frontparking Frontsidemarkerlights Rearsidemarkerlights Rear turn signallights Erake/parking lights Back-up lights Ceiling lights{fronvrear) platelight License Spotlights Highmountbrakelight lgnitionkey light Ashtraylight Gaugelights Indicator lights lllLrmination pilotIights and Heater illumination lights
2-13
Body Specifications
U n i t :m m ( i n )
2-14
Maintenance
............3-2 Points Lubrication for Schedule 1997Model Maintenance (NormalConditions) ...".3-4 Model for Schedule 1997 Maintenance (Severe ."...3-6 Conditions) for Schedule 1998 2000Models Maintenance (NormalConditionsl ..'."3-8 for Schedule 1998 2000Models Maintenance (severe '....'3-10 Conditionsl
Lubrication Points
pointsand type of lubricants be applied.referto the illustrated Forthe detailsof lubrication to indexand variouswork pro(suchas Assembly/Reassembly, cedures Replacement, Overhaul, Installation, etc.)contained eachsection. in
NO. Engine LUBRICATION POINTS LUBRICANT gradeoil.The oil APIService Grade: UseSJ "EnergyConserving" container may alsodisplay APICertitication shown the seal "For Gasoline below.Makesure it says Engines." SAEvjscosity: Seechartbelow. Genuine HondaMTF*1 Genuine HondaPremium Formula Automatic Transmission Fluid (ATF)*' Genuine HondaCVTFluid Genuine HondaDOT3 Brake Fluid*3 Brake fluid DOT3 or DOT4*3 with molybdenum Grease disultide LJrea Grease UM264P/N4'1211 PYs- 305 SteeringgreaseP/N 08733- B070E grease Silicone
Transmission 2
Manual
Automatic Reardifferential Brake line(includes ABS line) ClutchLine

Shift lever pivots (Manual transmission)
3
4 5 6
1 I
Release (Manual fork transmission)

Power steeringgearbox T h r o t t l e c a b l e e n d { D a s h b o a r dl o w e r p a n e l h o l e l
10 l1 12 14 16 17 18 19 20 21 22 23 24 25
Throttle link) cableend (Throttle pushrod Brake master cylinder Pedal linkage Battery terminals F u e l f i l ll i d pushrod Clutchmaster cylinder Hoodhinges and hood lock Tailgate hinges glasshinges Hatch Doorhinges, upperand lower Dooropeningdetent Caliper Piston seal,Dustseal, pin, Piston Caliper Shiltcableand select cable{Manual transmission) Brake line ioints(Front and rearwheelhouse) Powersteering system Air conditioning compressor
grease Multi purpose
Honda WhiteLithiumGrease
Silicone grease
Rustpreventives Genuine HondaPowerSteering Fluid-. Compressor SP 10 lP/N38897 P13- A0lAH or oil: 38899-P13-A01) For Refrigerant: 134a(R,134a) HFC
API SERVICE LABEL
SEAL API CERTIFICATION
E \ l l-;-1 5w-30/---l
/.'z-\e\ t / 6 A
/,.*-G\
10 20 30 40'c 0 r1: Always use GenuineHonda Manual Transmission Fluid {MTF).Using motor oil can causestiffer shifting becauseit does not containthe orooeradditives. *2: Always use GenuineHondaPremiumFormulaAutomaticTransmission Fluid(ATF). Usinga non-Honda ATF can affect shift qualitv. +3rAlways use GenuineHondaDOT3 BrakeFluid.Using a non-Honda brakefluid can causecorrosionand decrease the life of the system. *4: Always use GenuineHondaPowerSteeringFluid.Usingany other type of power steeringfluid or automatic transmission fluid can causedincreased wear and poor steeringin cold weather.
ffi
Recomm6ndedEngine Oil Engine viscosity ambient oil for temperature ranges
-20
20
100'F
-30 -20 .10
3-2
and locksoncea year. all NOTE:Lubricate hinges,latches, is In corrosive areas,more frequentlubrication necessary. HondaWhite LithiumGrease. We recommend
3-3
(for Maintenance Schedule 1997Model)

Normal Conditions
>
z o_u b 6<
x:3
+:l
.g 6
P
I I
t * - ?
E ei6l * : : : " i .9
= !38 i intc : d J 9 E
o : : c u ?
3Ei{:
=9tti EE eX g
(9
(9
e : 3 E .s e
3
.9
;
.9
.E
.6
o z
r E :o?
3I:E3
=< qs
99 E
Z o
.9
e6-
i F :
r l !
E ! E E E*
3p ; 3
. j :
=
E J
]
! g
:
; E
N.j
'oq 3c)
H;< Xoa E :3E 6 53 o! a6 !;.=!eg ! ?! ?3 < r <
E 5 8 3 . 3 3
b ; z ! ! 9
tr
! o
Po o al.9
o : l 9 ! q : ; ; 5
;; E:
o o
.iE (,.- 6 c 9 ,t f 9
z0
5
a
9>
a
: t 9 ; o d6; d9
:..::i .;;6 i 9 = 9 ; H:6 g-:
;
.9
E E
a
a
6
a
a a
.9
a a
o
a
E
a a a
a a a a
a a a a o
-9 E
a
I a
a a
a a
a
s
a
;o ll
3l
P I
' - l
a a
a a
a a
> a
a
a a
a
a
-gl nl
3l EI
>l
2 l l Q I
! 9il ; l _9 E
P I
;
p E
!
;
6
=
E
=
:;
'5
.9
'6
: : s a
p
t
;5
'6
z lE:.9
P t
.E
!
.E
o3i
.
3
!
a l
:EE
dr 3
s
i q
,:I
3-4
z ool{
' o e
d
FET
'o.
l a 3: 99.
o z
I
d! v!
: h
oiE
F P
*,':
o d
=;-e
E E
6 E ,i3
;
6 o 6 0 ; o
6 6
. q E
-!i ! tq! 6 G : 9
} E
ci
6 F :
i -
it
+ E do c _
?
I
a a
o
9 6 E #
; I
3 [
'o 9l
5
'3
c
o a a a
3
E r
F
; E 9 =
' d o
5
9 E
F
Q o ! ! . y c : q
F x I
E E
J_tr
E
.E
; 9 n 9
1t J-
9 ;
O
E
6:.!
.9 '5
:9 * e E t
o _ _r 6 3.9 >
ii E x
c g ;
.9
3FF
6 E 3
.s
':
o co
F F E* = o o i:
;T e
3-5
(for Maintenance Schedule 1997Modell

SevereConditions
O
+ 1 P
z o_u
!
I j
r
.!
E E
tll : o
.e;fi
.! ; ! = Y
(,
'
o
E '
;t
9 0 s F 6 i fi--i f
: E:: "i Y 5 Y =l
Ea g X s
i s * 9c
o z
q.,
= o '; c? I
s i !
E 9
:>
o
EE7
.: .'j 6 t l .
Pe !
gIii".^
E d --; - r
-,{
X 5 > = Bl e .E3
;<
k F!'r I !
zo E
E: . ai>
-J.9
E!EEg
Fi FP:
ii d:.s F
tr
H6 b e +
E J I -9
.i3 PQ o, -oE
et
; 3
f
3p
i ;
9--6
F . te i i . :
i,ii a
zo
+B
a E
- r !9._j
ii ti#>
o
a a a a a a a a a a a a
;-:
-p
P;.:a: l;;;i 3= ; e
E
(9-
o r Ec >
E*E s: *d 1 J d 9 b
a
E
a
O
,E
a
.9
E
5
o a a
4 '.
.2 I ,9
E
.i
a a
O
T _9
,9
a
o
a a o
a a
;
f, 6
a a
a
E
3i
a lI g l E '6 1
E E 3
ui &,
l u: - e
.a
E
,9:
p E
: I
=
6 s
:2 E
o l
.9
;,E
c3;
?l
,PI
= i
.E
:
6
.s .E
.E
g
;EP
;
6
; - ;
g
3-6
z 9,o)l
gEr
E 6
ct
.!2 y F ! d 5 .l' o 6 \
o q : o o
9t
o 'd
E 6
i O
i r
pE
> o )
;
:
.9 .E
c 6
= R
P g
;i
ii;
: Y Z
. :
i
. + F
;
F
.2 -.9 .9
- o Z o
: E
o z
!
:
o g o 9
c o q
; F P c.-.
! 3
t l r
E.E
!
E
q
P
:
;
F
15
o I
EJ
ol3 6 o )
.E
; o -
g
t-E
6 6 !
6 F :
o o
: E
; E n O 0 3 P_ E c
E! r E
e c
9
3 E ..
:
z 5
=
oo(J
a a
o
E E
a
a
er FE o
5 6
-E
r:1
n
:
.=a = y ,
E .:
e
I
r
6 3
ea
a a a
o
p.3
7 >
i 3
. E
:6i
;
q
E
:
: =
E
..t
a
a
o
.
ri
!b .Y c
L O
:g
a
t
e E
E=
3;
. = : > >
:7'Y . .r .> . ee
.s
H
x
':r.
=.8 +;
PI 6 : 6 ! F
E
i: i Ec! b * r' i b-"F:{ ; 3 -h 6 3 i l j 3

i *o o * ' v ! 9 1 r 0 6 i . Y : o 9 ; q , n
HiEE ;
E E
.9
; a .:
E
'6 -6
! !
;E f
. : ^
a qE 9
;;1Er 9 '==,;g 9
c , ^ ; L > - . ;
! b a. hE o : 3J ; ( c o r
7 Y 4
.g
E ; E E g i: !
6 g S a l l : : ;t 6
o f . = ? y , a \ z ' o u u r r :
a p
9 : _ . 1> 9 : .
> s ;
6 E 3
6391
cElj o F
.2 o co
! !
E Fq, !!:!!fr:i o
H F I ; " " '
6
c = o - o P o
i ; 9
5o F z
3-7
(for 1998- 2000Models) Maintenance Schedule

NormalConditions
-z o_u
o
{:9
+:N
p !
E
I
!. ii
eESl
: : - G .
.! E .! .! 3 .9
q = Y
.s
' r
(5
o
2
F
h E n aq
?
t i ??
'66
::
.E
=9'ti EE eX e
+ i >= i
5 <
d 9 i
o z
o o E
9 d
. E p
E d E J
E; i: ;6 :: - - lo. * =
r l
s i *;=-. ^ li:
aor:
EE
trtr
o o
p
cj ct 6
î ..i i
;ii5e
: = F ! - \
1 39: !
E''i-;
o P
r ! ! =
* c
.9 ;t
!;!a;
: a 3 9= a a a a a a a a a a a
*F9 B r<x ii
!Li:
;;;iB:
a
F E t r5 S 1 6!;: a3
3=?;
5 A
'Eoo !i33
P !
l _
. j :
a E :i 6 s 5 > ; PO i
6-a
s=;sE
l 9
=;k
E c>
a
,E 6
E
a
a
a
a a
.9
a a a
a a
a a a a
a o a
.9
a a
e
E
,E
.z
= a : E a a
a
a a
a
a a
a a
E E E E
.F_
3
,
!
.9
s
E g
p
.! !
:
E .9
:
,9
I
E
!
!
.s
E z
;
a
'6
.9
rE
9 6
6 E
o q
2 3
E
a
.E
! E.
; . EF
3-8
I o
z o_u b 6< '6
6t
c)
.9
I
a
.9
- x
F
! =
nz
o z
9*
c o *
3 E
o.2
; o
6 6
t E o P
!-9
i E
o
ut
E E
a
E .!t o)
a
a
c q o X : t 7
a a a
a
3
t 5
; E
*r
* c
E E
i
E n 9
r]Jah o -
;
ti
a;
.g
.E
E
I '6 !
E o: a
E' .g > ; : =
: o E
: d
o T
!z
s
; I
3Fp
tr
o
aEt
< i 9
e
r f
3-9
(for 1998- 2000Models) Maintenance Schedule

SevereConditions
O
r l 9
o _ 4
U;<
*:R
;
!
' 3
<
F
E E
t 3=E e E St
E'
}
^5
E : Y
:
'3
ii;t
;
E
F
l
o I z - :
(, '
; E s IE EgeY.:
s I *N I* !r ; ^;
; F ; , ^ ! hEz!:i9
; 6
:+
E !
!,3;
EE3 ig .9 E E ; b F
!: ir:
-E
IE P 5E 9
O T
o l
.F_ Z
.>
o
EE
o o
j=-;H
.9 it
'6
;;;
c, ci 6
o -
EE
{ai ;i3
ci.ii
E E . E S el ;
! o
o E
: 2 6 a n ii 6:.s F
l P
I E o
:
.9)
! I
9.:-6 : 9 !|;>
t *
e = a q : : 6go-.!5.6
E E ;e 1
a - - q eqo? R
i b
-ii d:1 9;.: 6:
IE
:
.l
-:oo
ii q...
J Q A z * 9
;;;iF3
o6 a
= a
o
k s= ;
a
Is33 E
"
I -p
.i:
o -
l;;"3
=ik
F c>
Hi q H r s 3=i ll a c ; a : |
a a a a a a a
:
.a
a
E 6
a a a
.9
a a a a
a
E
a ;
E =
> 9 i
o
;
c i
a o
.9 ?
z
E
a
E
..i
a s
a a o
= I -
;l +l l .:
5l
o 3
o a a o a a
!l E
a
E
->
a a
a o a a a
a a a
E
il
:l
3 l
i\t
-i
.:
-xi
a?.
.ql
&,6 = R 3 !
! c 6 . . : *
FI :
EI =
E
l FI
o l 9 l ; l
.=
!
j !
E
.g
t
.9 .9
3: :t :4 3;:
.9
g:,.! o--
P:-eCF
YeE
: n
j
iF E
6 .
!
!;3_
:l :t 6 ,PI
.E
s >
9 :
3-10
z Qoll
gF i
.i
F E 9)Y F ? o d -:' o 6 :
E
.9 I
t i 9 6 :.9 ; P : g
3=,
o
= E
a
o o) A : o o
a
.9
.s
.9
i c
.=
6 X
3 F e
c
_9
F
- :
3!
ior
I
'E rj
o i
z
!
E
o g
F 9
9;
6
: E : 7 :
&
;
e
; ::*
.9
q d
Y >
E
; i c o); .9
E 3
9 6
a.9 2 P g o
s3
r-9
3 E
5 3
;*
E 9 E 9
io
E P
o
E I
,i
o
a
E
a
E E
..i
; -E E 6
b 3
tlq
o v
t t
9
:o
E :
; t
n
j
A
9
a
a o
: E
r
a a a a a o
F 3 : >
E;
g
: 6
.E
! :
:
.0
F
F 3
! h
t r g
T
d
J
h
a a
o
: E
r-
J: c q :
e E
9 = = = .:i
. : 6
, = : > > x . Y t t 6.=!!
:7 . 7. . =e=, e ' .
Y,
: : E+ c -b . 3 ' o;9 . , o ! 9 i ; o v
* X
i =
:'
a
q
6
o ( J I
i !
-.1
= Y
?: P o
io Y . ;r = ; * p ? q ll
o a e j . Y
sF
(D
E E
!
E
.g
.9
;U
o >
3 C, E 9
- ! E . E ; : 3) ( 6 - i - c o
;ogn,i,
t2
.9
.ts6
*g
69
66
o-r
5 E
n
!
E ; r l E e : tt (5fr9:;;
: _ : x = c F
" .to'6.: .;2g: iI E .

;
o
9J:?, q'r !
;';1E; 9
3 ; E
o 3 i
> sE
6E E
_9 .q F
.E
o
_9
- e a ;9 j _ . : . ; 9 1 ! : ! : ! ! f : !f +
.= Y o
;E 3
3 i . 9 ; . . . . .
c = o - o
o u s q F :
P !
F :
>;
3-11
EngineElectrical
4-2 ChargingSystem ............. Tools Speciaf 4-22 Location Index ............ Component Starting System 4-23 Diagram....................,........... 4-3 Circuit Index ............ Location Component 4-24 .............................. Troubleshooting 4-4 CircuitDiagram................................ 4-30 ..........,....... Replacement Alternator ........... 4-5 StarterTest 4-31 .......,,................ Alternator Overhaul 4'5 Test ...................... StarterSolenoid .........4-32 RectifierTest 4-7 ....................... StarterReplacement 4-32 Inspection ........... Alternator Brush 4-7 FieldWindingTest ........................... 4-33 4-8 RotorSlip RingTest ........................ StarterOverhaul............................,. 4-33 ............. Stator Test 4-9 ...........................,., BrushInspection Alternator Belt Inspectionand OverrunningGlutchInspection ......4-9 ........4-34 Adiustment and Test ........4-10 Armaturelnspection GruiseControl 4-12 BrushHolderTest ............................ 4-36 ComponentLocationIndex .,,,........ 4-1 2 ......................... StarterReassemb|y 4-37 CircuitDiagram................................ 4-13 Test ............................. Perf ormance 4-38 ControlUnit InputTest ................... lgnition System ..... Main Switch Test/Replacement 4-40 4-14 Index ............ Location Component Set/Resume Switch Test/ 4-15 CircuitDiagram................................ 4'40 .......................,........ Replacement lgnition Timing Inspectionand ....,,., 4-41 4-16 Setting .......................................... Actuator Test 4-42 Actuator Replacement...............,.... 4-17 ........,........ Distributor Replacement 4-43 Actuator CableAdiustment ............ 4-18 .............,,......... Distributor Overhaul 4-43 ClutchSwitchTest .......................... lgnition Control Module (lCM)Input .......... 4 .. . T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . .- 1.9 . . . . . . . .BrakeSwitchTest .................. 4-44 .. ...,. Test .............. 4-44 Actuator Solenoid 4-2O fgnitionCoilTest .............................. 4-45 ..................... ActuatorDisassembly lgnition Wire Inspectionand 4-20 Test ............................................... 4-21 SparkPlugInspection.....................
ENGINE
SpecialTools
Ref. No.
Tool Number A973X- 041 XXXXX 07JGG 001010A 07PAZ 0010100
Description
Oty
PageReference 4-41 434 4-16
VacuumPump/Gauge, 30 in.Hg. 0 BeltTensionGauge SCSService Connector * Included the BeltTensionGaugeSet,T/N 07JGG 0010004 in
o -o o
o
4-2
StartingSystem
LocationIndex Component
INTERLOCK CLUTCH
swtTcH {M/T)
BATTERY Test,section23 Test,page 4-43 adiustment, Switchposition section12
SWITCH{A/T} A/T GEARPOSITION Test,section14 Reolacement. section14
Test,page4 5 Test,page4-6 Solenoid page 4-7 Replacement, page4 8 Overhaul, page4-12 Reassembly, Test,Page4-13 Performance
4-3
StartingSystem
CircuitDiagram
UNDER.HOOD FUSE/RELAY 8OX (100A) N0.41 (40A) N0.42 IGNTION SWITCH
-+o
/ BAI
\i7
cf-.|
BLKMHT
I
I
I I
l
ELKMHT
BLK'WHT
-.1
BLKRED
IGNITION CONTROL MOoULECM) (
STARTEF CUl RELAY
GRY
GRN
I
GEAR PosrroN! I A/T (A/T) | i swrTcH l \/ o N E o r N \ | l
!-p . s i t o n/ : -_ --___J
f';--"-l I I TNTERLooK
fYl""yl, I
8LK
STARTEB (Field wndnglype)
Gl0l
4-4
StartingSystem
Starter Test
NOTE: The air temperaturemust be between 59 and '100'F and 38"C) (15 beforetesting. RecommendedProcedure: . . . Usea stanersystemtester. t i Connecand operatehe equipmentn accordance t instructions. with the manufacturer's Testand troubleshoot described. as Checkthe battery, battery positivecable, ground. for stanercut relay,and the wire connections loosenessand corrosion. Testagain. lf the staner still does not crank the engine,go to step 4. 4. Unplug the connector(BLK /VHTwire and solenoid from the starter. terminal) a 5 . Connect jumper wire from the bafterypositive(+) terminal. terminalto the solenoid The startershouldcrankthe engine.
Alte.nate Procedure: . Usethe followingequipment: - Ammeter,0 - 400A - Voltmeter, - 20 V (accurate within 0.1volt) 0 r T a c h o m e t e r ,-01 , 2 0 0 p m Hookup a voltmeterand ammeteras shown.
TERMINAL NEGATIVE
NOTE: After this test, or any subsequentrepair. reset the ECM/PCM clearany codes(seesection11). to Checkthe Starter Engagement: '1. Remove the No. 44 (15A) fuse from the under-hood fuse/relay box. 2. Turn the ignitionswitchto START(lll)with the shift lever in E or E position (A/T) or with the clutch pedaldepressed {M/T).The startershouldcrankthe e n gi n e . . . lf the starter does not crank the engine, go to step3. lf it cranksthe engineerratically too slowly,go or t o " C h e c kf o r W e a r a n d D a m a g e "o n t h e n e x t page.
. .
l f t h e s t a r t e rs t i l l d o e s n o t c r a n k t h e e n g i n e , its removeit, and diagnose internalproblem. the lf the startercranks engine,go to step6.
23). 6 . Check ignitionswitch(seesection the 7 . Check startercut relay{seesection23}. the 8. Checkthe IVT gear position switch (A/T)or the clutch switch (M[). interlock Checkfor an open in the wire betweenthe ignition switchand starter.
(cont'd)
4-5
StartingSystem
StarterTest (cont'dl
Checklor Wear and D8mage T h e s t a r t e rs h o u l dc r a n kt h e e n g i n es m o o t h l ya n d s t e a d i l y l.f t h e s t a n e re n g a g e s b u t c r a n k s h e e n g i n e , t erratically, removeit, and inspectthe starterdrive gear and torque converterring gear or flywheelring gear for oamage. Checkthe drive gear overrunningclutchfor binding or s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e d r i v e gear held.lf damaged, replace gears. the CheckCrankingVoltage and Current Draw Cranking voltageshouldbe no lessthan 8.7 volts on Ay'T models, and 8.0volts on M/T moders. Currentdraw should be no more than 230 ampereson A,/T models, and 200amperes M/T models. on lf cranking voltageis too low, or currentdraw too high, checkfor: . deador low battery. a o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g , ments. . starterarmature dragging. . shortedarmature winding. . excessive drag in engine. CheckCrankingrpm Enginespeedduringcranking shouldbe above 100rpm. lf speedis too low, checkfor: a loosebafteryor starterterminals. . excesslvely worn stanerbrushes . opencircuitin commutatorsegments. . dirty or damagedhelicalsplinesor drivegear. a defective drive gearoverrunning clutch. CheckStarter Disengagement With the shift lever in @ or @ position(A,iT) with the or clutchpedaldepressed {M/T).turn the ignitionswitchto (lll).and release ON (ll). START to The starterdrive gear shoulddisengage from the torque c o n v e r t e rr i n g g e a r o r f l y w h e e l r i n g g e a r w h e n y o u release key. the lf the drive gear hangs up on the torque converterring gearor flywheelring gear,checkfor . solenoid plungerand switchmalfunction. . dirty drive gear assemblyor damaged overrunning clutch.
Starter Solenoid Test

1. Checkthe hold-incoil for continuitybetweenthe S . t e r m i n a la n d l h e a r m a t u r e o u s i n g( g r o u n d )T h e h coil is OK if thereis continuity.
STARTER
B TERMINAL MOUNTINGNUT 9 N.m 10.9 kgtm, 7 tbtftl
TERMINAL
ARMATURE HOUSING (GROUND}
BLK/WHT WIRE 2. Checkthe pull in coil for continuitybetweenthe S and M terminals. The coil is OK if thereis continuity.
4-6
StarterReplacement
1 . Disconnectthe battery negativecable. Disconnect startercablefrom the B terminalon the the solenoid. then disconnectthe BLK/WHTwire from the S terminal.
B TERMINAL MOUNNNG NUT I N.m (0.9kgl.m, STARTER
Field Winding Test

t. Checkfor continuitybetweenthe brushes. there's lf no continuity, replace armaturehousing, the Checkfor continuity between each brush and the a r m a t u r eh o u s i n g{ g r o u n d ) l f t h e r e i s c o n t i n u i t y . . replace armaturehousing. the
ERUSHES
7 rbtftl
RE
l0 x 1.25mm 4,1N.m {4.5 kgf.m, 33 tbt.ftl

5.
R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r .t h e n remove the starter. I n s t a l l i n t h e r e v e r s eo r d e r o f r e m o v a l . W h e n i n s t a l l i n gt h e s t a r t e r c a b l e , m a k e s u r e t h a t t h e crimpedside ofthe ring terminal is facing out,

Crimpedside of ring terminal
4.
TERMINAL
Connectthe batterypositivecableand negativecable to the batterv.
4-7
Starting System
Starter Overhaul
STARTER SOLENOID
STARTER SOLENOID Test,page4 6 OVEBRUNNING CLUTCH
w
ARUSH
-6^l
MOLYBDENUM DISULFIDE
SPRING CLIP Replace. BBUSH HOLDER Test,page4-12 GEAR HOUSING ARMATURE HOUSING
ARMATURE Inspection Test.page4-10 and ENDCOVER ..'...:|@{ MOLYBDENUM DISULFIDE
BAUSH page4-9 InsPeclon,
4-A
BrushInspection
Measurethe brush length.lf it is not within the service limit, replace brush(or brushholderassembly). the Brush Lsngth Standard{Newl:14.0- I'1.5mm (0.55 0.57inl ServicoLimit: 9.0 mm (0.35in)
ClutchInspection Overrunning
1.
2.
clutchalongthe shaft.Doesit Slidethe overrunning it. move freely?lf not, replace Rotatethe overrunningclutch both ways. Does it l o c k i n o n e d i r e c t i o na n d r o t a t e s m o o t h l y i n reverse? it does not lock in either directionor it lf reDlace it. locksin both directions,
BRUSH
NOTE:To seat new brushes afterinstalling them in their with the holders. slip a strip of #500or #600sandpaper, grit side up, over the commutatorand smoothly rotate will be the armature. The contactsurfaceof the brushes sanded the samecontouras the commutator. to
3.
replace lf the starterdrive gear is worn or damaged, c t h e o v e r r u n n i n g l u t c ha s s e m b l yt;h e g e a r i s n o t available separately. ring gear Check condition the torqueconverter the of or the flywheel ring gear if the starter drive gear teethare damaged.
4-9
StartingSystem
and Test ArmatureInspection
1. f I n s p e c t h e a r m a t u r e o r w e a r o r d a m a g ed u e t o contact with the field winding. lf there is wear or damage. replace armature. the 3. C h e c kt h e c o m m u t a t o rd i a m e t e r .l f c o m m u t a t o r d i a m e t e r i s b e l o w t h e s e r v i c el i m i t , r e o l a c et h e armalure. Commutator Diameter Standard(Newl:27.9- 28.0mm (1.09 1.10in) Limilr 27.0mm (1.06inl Service
lnspect damage. for
lf Check commutatorsurface. the surfaceis dirty the or burnt,resurface with emery cloth or a lathewithwith or in the tollowing specifications, recondition #500or #600sandDaoer.
4.
Measure commutatorrunout. the l f t h e c o m m u t a t o r u n o u ti s w i t h i n t h e s e r v i c e limit, checkthe commutatorfor carbon dust or brasschipsbetween the segments. lf the commutator runout is not within the service limit, replace armature. the CommutatorRunout Standard(Newl:0 - 0.02mm (0 - 0.0008 in) Service Limit: 0.05mm {0,002 inl
4-10
5.
undercutthe Checkthe mica depth. lf necessary, properdepth. mica with a hacksaw bladeto achieve l f t h e s e r v i c el i m i t c a n n o tb e m a i n t a i n e dr,e D l a c e the armature.
7.
Placethe armature on an armaturetester. Hold a hacksaw bladeon the armature core.
NOT GOOD
MICA DEPTI{
Commutator Mica Depth Standard (Nsw): 0.5 - 0.8 mm 10.02 0.03 inl mm (0.008in) ServicoLimit: 0.2 6. Checkfor continuitybetweenthe segmentsof the commutator.lf an open circuit exists betweenany segments. replace armature. the
while lf the bladeis attracted the core or vibrates to the core is turned.the armatureis shorted.Replace the armature. 8. With an ohmmeter,checkthat no continuityexists betweenthe commutator and armature coil core, and between the commutatorand armatureshaft.lf there is continuity. replace armature, the
COMMUTATOR
cotLcoRE
4-11
StartingSystem
Brush Holder Test
1. the O and Check that there is no continuitybetween O brush holders.lf there is continuitv,replacethe brushholderassembly.
Starter Reassembly
NOTE:Use the illustration page 4I as reference on for reassemDty. 1. Pry backeachbrushspringwith a screwdriver, then positionthe brush about halfwayout ol its holder, and release springto hold it there. the
O BRUSHHOLDER
@ BRUSHHOLDER
2. Insertthe brushinto the brushholder,and bring the then attach brush into contactwith the commutator, the a springscaleto the spring.Measure springtension at the momentthe spring liftsoff the brush.
Installthe armaturein the housing.Next, pry back each brush spring again,and push the brush down until it seatsagainstthe commutator,then release the springagainst end of the brush. the
al
F*4#-@ 6t ta
t ll l
ft
la
E ^
SCALE SPRING
3.
I n s t a ltlh e e n dcovero n t h e b r u s hh o l d e r .
SpringTension: 13.7- 17.7N (1.40 1.80kgf, 3.09- 4.00lbf)
4-12
,r
Test Performance
1.
Disconnect wire from terminalN4. the M a k ea c o n n e c t i o n s d e s c r i b e d e l o w u s i n ga s a b heavy a wire as possible(preferably equivalentto the wire usedfor the vehicle).
5.
Disconnectthe battery also from the body. lf the pinion retractsimmediately, is working properly, it To avoiddamagingthe starter, not leavethe batdo for terv connected more than 10 seconds.
3.
Connect the batteryas shown. lf the starterpinion pops out. it is working properly. avoid damaging To the starter,do not leavethe batteryconnected for more than 10 seconds.
o
6. 7. Clampthe starterfirmly in a vise. Connectthe starter to the battery as describedin t h e d i a g r a m b e l o w ,a n d c o n f i r mt h a t t h e m o t o r starts and keepsrotating.
12V BATTERY
ie
Disconnect the batteryfrom the M terminal. lf the pinion does not retract, the hold-in coil is working p r o p e r l y . o a v o i d d a m a g i n gt h e s t a r t e r ,d o n o t T leavethe batteryconnected for more than 10 sec onds.
8,
lf the electric current and motor soeed meet the when the batteryvoltageis at 11.5V, specifications the starteris workingproperly.
Specifications: Maker DENSO Electric current 90 A or less Motor speed 3,000rpm or more
4-13
lgnition System
Component LocationIndex
IGNITIONTIMINGCONTROL SYSTEM . ldle speedInspection/Adjustment, section11 . Inspection and Sening.page4-16
SERVICECHECKCONNECTOR(2P) lwi.c colo6: BRNrnd BLKI
TEST TACHOMETER
SPARKPLUGS page4-21 Inspection, DISTRIBUTOR page4-17 Replacement, page4-18 Overhaul, lgnitionCoilTest, page4,20 lgnitionControl Module CM) InputTest,page4,19
WIRES Inspection Test,page4-20 and
4-14
CircuitDiagram
UNDEF.HOOD FUSE/RELAY 8OX
IGNIT ON SWTCH UNDEF,DASH FUSEi RELAY BOX
6\ l;;l i{Hr6-(-\9-'-'*'.--EII
Eci,.pcM
' i Vl
BLK/YEL
l^
IGNITION cotL
TDCTopdead cenler poslion CKP Cran[shan pro s r l o n C Y PC y l n d e TDC/CKP/CYP SENSOR
IGN]TION CONTROL MODULE (CM) buil-if\ / Has I no|se l
l-- r
IGNTION W]BES
i l' i--, l l i f r
BLU
IJltfi
--cMFcr,r I
I l: '99- 00models Gt01
SPARK PLUGS
l l / ' i
| |
I TACHOMETER
BLU BLU
resr
I I
tott"to*
j
LTTCHoMEIEB '97-'98 models
4-15
lgnition System
and Setting lgnition Timing Inspection
1.
(see Checkthe idle speed,and adjustit if necessary section11). Pull out the servicecheckconnector2P (BRN and holderlocatedunder BLKwires)from the connector side,then connect the dash on the front passenger (P/N07PAz- 0010100) to the scs service connector it. Startthe engine.Holdthe engineat 3,000rpm with no load (A/T in N or E, Mff in neutral)until the fan radiator comeson, then let it idle. Connect the timing light to the No. I ignitionwire, then point the light towardthe pointeron the timing belt cover.
6.
2.
lf necessary, adjust the ignition timing as follows. Loosenthe distributormountingbolts,and turn the to distributorignition(Dl)housingcounterclockwise advancethe timing or clockwiseto retardthe timtn o ,
To RETARD
5.
C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s : headlights, blower fan, rear window defogger,and air conditioner not operating. are lgnitionTiming: idling in neutral M/T: 16"12" BTDC(RED) (RED) idling in E or E AlTt'16" !2" BTDC
MOUNTING BOLTS 24 N.m{2.4kgfm, 17lbtft} 7 . Tightenthe distributormountingbolts,and recheck t h e i g n i t i o ni m i n g . t 8. connector from the serDisconnect SCSservice the vicecheckconnector.
CRANKSHAFT PULLEY
4-16
DistributorReplacement
Removal:
e o
I'
5.
Connect ignitionwires to the distributorignition the (Dl)cap as shown,
1. 2.
Disconnect connector the from the distributor. Disconnect the ignition wires from the distributor ( i g n i t i o n D l )c a p . R e m o v e h e m o u n t i n gb o l t s f r o m t h e d i s t r i b u t o r , t then remove distributor the from the cylinder head.
CAMSHAFT END
3.
No. 1 CYLINDER MARK
6. 7. 8.
Connect connector the distributor. the to page). Setthe ignitiontiming (seeprevious After settingthe ignitiontiming, tightenthe mounting bolts.
BOLTS MOUNTING mm 8 x 1.25 17 2,1N.m {2.,1kgrf.m,lbfftl
lnstallation: 1. 2. 3. Bringthe No. 1 pistonto compression strokeTDC. Coata new O-ringwith engineoil, then installit. Align the lug on the end of the distributorand its mating grooves in the camshaftend, then slip the distributor into position. NOTE:The lug on the end of the distributorand its mating groovesin the camshaft end are both offset to eliminate the possibility installing of the distributor 180o of time. out 4. Installthemountingbolts,and tightenthem lightly.
4-17
lgnition System
Distributor Overhaul
LEAK COVEN
CAPSEAL for Check damage.
DISTRIBUTOR IGNITION IDII ROTOR IGNITION{DII CAP OISTRIBUTOR Checkfor cracks,wear, damage, and to!ling. or Clean replace.
O.RING Replace.
IGI{ITION HOUSING OISTBIBUTOR IDO for and Check cracks damage.
IGNITION COIL Test, page 4 20
@_
IGNITION CONTROL MODULE{ICMI InputTest,page4-19
4-18.
lgnitionControlModule(lCMlInputTest
NOTE: . See section11 when the malfunctionindicatorlamp ( M l L ) o m e so n . c . Performan input test for the ignitioncontrol module ( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atl e s t sf o r t h e ignitionsystemand the fuel and emissions systems. . '97 -'98 models:The tachometer shouldoperatenorm a l l yi f t h e I C Mi s O K . L Remove the distributorignition(Dl)cap,the distributor ignition(Dl)rotor,and the leakcover. Disconnect wiresfrom the lCM. the
8LU WIRE '98 models} {'97 -
Turn the ignition switch ON {ll). Checkfor voltage betweenthe BLK,^/EL wire and body ground.There shouldbe batteryvoltage. . . lf there is no batteryvoltage,checkthe BLK/rEL wire betlveen ignitionswitchand the lclvl. the lf there is bafteryvoltage, go to step 4.
T u r n t h e i g n i t i o ns w i t c hO N ( l l ) .C h e c k o r v o l t a g e f between WHT/BLU the wire and body ground.There shouldbe battery voltage. . lf thereis no batteryvoltage, check: - ignitioncoil. - WHT/BLU wire betweenthe ICM and ignition corl. . lf thereis batteryvoltage,go to step5, '97 model: Disconnect the ECM/PCM connectorA ( 3 2 P ) C h e c kf o r c o n t i n u i t yo n t h e Y E L / G R N i r e . w betweenthe ICM and ECM/PCM. There should be continuity. '98 - 00 models: Disconnect ECM,PCM the connector B (25P). Checkfor continuityon the YEUGRNwire betweenthe ICM and ECM/PCM. There should be continuity. Checkfor continuityon the YEUGRNwire to body ground.Thereshouldbe no continuity. 7 . Reconnect ECM/PClvl the connector. '97 -'98 models: Checkfor continuityon the BLU wire between test tachometer the connector and the lCM.Thereshouldbe continuity. 9. '97 -'98 models: heck or continuity n the BLU f C o wire to body ground.Thereshouldbe no continuity. '10. lf all the testsare normal,replace lCM. the
2.
4-19
lgnition System
lgnitionCoilTest
Using an ohmmeter, measureresistancebetweenthe is terminals.lf the resistance not within sDecifications, replace ignitioncoil. the will vary with the coil temperature; NOTE: Resistance specifications at 68"F(20'C). are Plimary Winding Resistance {Betweenthe A and B terminals): 0.6it- 0.77 0 SecondaryWinding Resistance {Betweenthe A and secondarywinding terminals): 12.8- 19.2kO
lgnition Wire Inspectionand Test

1 . C a r e f u l l y e m o v et h e i g n i t i o nw i r e s b y p u l l i n go n r the rubber boots.Do not bendthe wires;you might breakthem inside. Check conditionof the ignitionwire terminals. the lf any terminalis corroded, cleanit, and if it is broken or distorted, replace ignitionwire. the
IGNITION WIRE
e
TERMINAL {+l A
Connectthe ohmmeter probesand measureresistance. lgnition Wire Resistance: 25 kO max. at 68'F 120'Cl
IGNITION WIRE 4. lf the resistance exceeds 25 kO, replace the ignition wire.
4-20
SparkPlugInspection
for: and ceramicinsulator the Inspect electrodes 2. gaP. the Check electrode . gappingtool. Adjustthe gap with a suitable
ElectrodeGap
. . . .
gap lmproper Oil-fouling deposits Carbon Cracked center insulator electrode
Standard
in) 1.1 3 ' mm (0.043Loo.
is the Replace plug if the centerelectrode rounded as shownbelow:

ROUNDEO ELECTRODE
,--, (--/
Burned or worn electrodesmay be causedby: . Advanced ignitiontiming . Loosesparkplug . Plugheat rangetoo hot . Insufficient cooling Fouledplug may be causedby: . Retarded ignitiontiming . O i li n c o m b u s t i oc h a m b e r n . Incorrect sparkplug gap . Plug heatrangetoo cold . Excessive idling/lowspeedrunnang . C l o g g e d i r c l e a n ee l e m e n t r a . Deteriorated ignitionwires
/
r--'--'--r
-.-l-:=---:1 :
Spark Plugs '97 - '98 modsls:
| |
(N ZFR5F-11 GK) (1 K J 1 6 C R - 1 1D E N S O ) '99 - 00 models; (N ZFR6F-11 GK) (DENSO) KJ2OCR-111 compound to Apply a small quantity of anti-seize and screwthe plugs into the cylinthe plug threads, Then torque them to 18 N'm der head finger-tight. (1.8kgf.m.13lbf.ft).
4-21
Charging System
CHARGING SYSTEMLIGHT (ln the gaugeassembly) Test, page 4-24
BATTERY
Test,
ALTERNATOR Troubleshooting, page4-24 Replacement, page4-30 Overhaul, page4-31 RectifjerTest,page 4,32
ALTERNATOR BELT Inspection Adjustment, and page4 34
4-22
CircuitDiagram
BOX FUSUFtAY UNDES.HOOD BATTERY (1Cr0A) N0.41 ,-a\ (40A) N0.42 WHT/8tK
l.
( tot,o, )
IGNITON SWITCH
8LI(YEL
GRN/RED
ECM/PCM
WHT/RED
V I
ALTERNATOR
4-23
Gharging System
Troubleshooting
lf the chargingsystemlight does not come on or does not go off, or the batteryis dead or low, test the followingitems in the order listedbelow: (seesection23) 1. Battery 2. Charging systemlight 3. Voltage 4. Alternator controlsystem(U.S.A. model) 5. Alternator/regulator ChargingSystem Light Test
ChsrgingSystomLight Check: Turn the ignition switch ON {ll), and makesure the chargingsys tem lightcomeson.
Doesthe charging system lightcome on?
Check for a blown No. 15 17.5 Al fuse and a blown charging system light bulb. lf the tusa .nd bulb are OK, repair th open in th WHT/BLUwire.
Charging System Light Check {com'd}: Startthe engine.
I
I
Doesthe charging system light go offf
Perform the Alte.nator/Regulator Test lsee page +281.
ALTERNATOR CONNECTOR 4P modell {U.S,A.
Voltage Check: Measure the voltageat the No. I lNo.2iterminalof the 4P [3Plconnectorwith the ignitionswitch ON
2
(BLK/YEL)
Wiresade of femaleterminals
{ ).
ls there battery voltage?
Ropair the open in the BLK/YEL wiae betwoen the altemator and under-da3h luso/relay box.
ALTERNATOR CONNECTOR 3P lCanedamodel'
Iemale terminals
(To next page)
m [ ]:Canada odel
4-24
in
(Fromprevious page)
Ch6ckthe L circuil: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 4P [3P] connectorfrom the alternator. ON switch (ll). 3. Turnthe ignition
Doesthe charging system lightcomeon?
Repairthe short to ground in the WHT/BLUwire.
model [ ]: Canada
(cont'd)
4-25
Charging System
(cont'dl Troubleshooting
'97 modol: Alternator Control System Test {U.S.A.model) NOTE:Beforetesting, checkproperoperation ofthe ELDby checking a DTC(seesection.11). for
BATTERY Chockfor a short in the circuit IALTCline): 1. Disconnect the 4P connector from the alternator. 2. Startthe engine, and turn the headlights thigh beamiON. 3. Me8surevoltage between the 4 P c o n n e c t o tre r m i n a lN o . 2 and the positiveterminal of the battery. CAUTION: Be sure to use a voltmeter with ils positive terminal connectedto battery positive and hs negative terminalto the 4P connectorterminal No. 2.
{WHT/GRNI Wiresideof female terminals ALTEFNATOR 4P CONNECTOR
ECM/PCMCONNECTOR I32PI A
lstherelVorless?
,/1./
./ l./
t4
8 1 6 1 7 1 8 t9 20 21
10
21 32
26 27 Check for an open in the wire (ALTClinel: 1 . T u r n t h e h e a d l i g ha n d i g n i t tion switchOFF. 2. Disconnectthe 32P connector from the ECN4/PCM. 3. Checktor continuitybetween the EcM/PcM 32P connector terminalNo.30 and alternator 4P connector terminalNo.2-
2A 29 30
Wire side of femaleterminals
] ALTC I tWHT/cRNl
female terminals
tl
1
WHT/GRN)
ALTERNATOR irP CONNECTOR
ls therecontinuity?
Repairopen in the wi.e betwoen the atternatorand ECM/PCM.
Check for a shorl in the wiro IALTCline): 1 . T u r n t h e h e a d l i g ha n d i g n ; , t I|on swrtcnUFF 2. Disconnect 32Pconnector the from the EcM/PcM. 3. Checktor continuitybetween the ECM/PCN4 connector 32P t e r m i n a lN o . 3 0 a n d b o d y ground. Subslitute a known-good ECM/ PCM,and recheck. It prescribedvoha96 b now available, replacethe original ECM/ PCM.
ECM/PCM CONNECTOR {32P} A
,/ ,/
,/1,/
14
6 8 1 6 l 7 t 8 '19 20 21 27 2A 2S 30
10
23 21 :t2
Wire side of female terminals
I ALTC {WHT/GRNI f)
ls therecontinuity?
Rprir short in the wire between the altornator and the ECM/PCM.
4-26
'98 -'9O modols: Alternator Contlol SYstemTe3t (U.S.A'model) for of NOTE:Beforetesting,checkproperoperation the ELDby checking a DTC(seesection11) EATTERY
Chock tor . short in tha circuit IALTClino): the 4P connector 1. Disconnoct Irom the alternator. 2. Startthe engine,and turn the (highbeam)ON. headlights 3. Measurevoltage between the 4P connectorterminal No. 2 and the positive terminal oI the battsry. CAUTION: Be surc to uso a voltmetor with its oo3itive torminel connccted to battery po3hivo tnd its negativo teami' nal to the 4P connectortorminal No 2.
c
IWHT/GRN) Wire sideol terminals female ALTERNATOR 4P CONNECTOR
'oR
lsthere V or less? 1
Check for an opon in the wire IALTCline): 1 . T u r n t h e h e a d l i g ha n d i g n i t tion switchOFF. 2. Disconnect 31Pconnector the from the ECM/PCM. 3. Checktor continuitybetween 31P connector th6 ECM/PCM terminalNo. 2 and alternator terminalNo. 2. 4Pconnector
ECM,/PCM CONNECTOR c {31P) Wire sideol temaleterminals
Ropairopen in the wiro between the ahornrtor and ECM/PCM.
C ECM/PCMCONNECTOR {31P} ALTC IWHT/GBNI Chack lor a rhort in tho wire {ALTClincl: ' ! . T u r n t h e h e a d l i g ha n d i g n i ' t tion switchOFF. the 2. Disconnect 31Pconnector Irom the ECM/PCM. 3. Ch6ckfor continuitybetween 31P connector the ECM/PCM terminalNo. 2 and body ground. Substituto . known-good ECM/ PCM,.nd rochock. lf prdcdbd voltage b now av.ilable, repl.ce the original ECM/
l u
rcM.
Rcpair rhort in thc wire b.twcon th. ahGrn.tol.nd the EcM/PcM.
(cont'd)
4-27
Gharging System
(cont'd) Troubleshooting
Alternator/RegulatorTest NOTE:Makesurethe batteryis sufficiently charged(seesection23).
Alternator/RegulatorTest: 1 . C o n n e c t S u n V A T - 4 0( o r a e q u r v a l e ntte s t e r ) , n d t u r n a the selector switchto position 1{sraning). 2. Shift to neutral(A/T in E or , N ) p o s i t i o n a n d s t a r tt h e e n g a n eH o l d t h e e n g i n ea t . 3,000rpm with no load until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 3 . R a i s et h e e n g i n es p e e dt o 2,000 rpm, and hold it there.
VOLTMEIER POSmVE
(BED)
t
I
l s t h e v o l t a g e o v e r 1 5 . 1V ?
FIELD SELECTOR TEST
swtTcH
Ahernator/Regulator (cont'd)l Test I Release accelerator pedal, the and let the engineidle. 2 Makesure all accessories are turned off. Turn the selector switch posjtion (charging). to 2 3 Remove inductive pickup, the and zerothe ammeter. { P l a c et h e i n d u c t i v ep i c k - u p over the batterygroundcable so that the arrow pointsto the baftery negative terminal. 5 . R a i s et h e e n g i n es p e e dt o 2 000rpm, and hold ir there.
NEGATIVE TESTER CABI.E {BLKI TESTER

CABLEIREDI
INDUCTIVE PICK.UP {GRN)
WHTWIRE
l s t h e v o l t a g e l e s st h a n 1 3 . 5V ?
Altarnator/Regulator Test (cont'd: Apply a load with a VAT-40 until the battery voltage drops to b e t w e e n 1 2 - 1 3 . 5V .
To next page
4-28
page Fromprevious
65 ls the amperage A or more?
The charging sy3tem b OK. CAUTION:The voh.ge will tise quickly whon th. ahornato. is tull-li.lded Do not allow the voltage to exceod18 V; it mry damagothe .loctrictl 3yaiGm. NOTE: Attach a probe to a VAT-40Iull tield test lead,and inseft the probe into the tull field "A to lGround)"posiSwitchthe fieldselector the holeat the backof the altemator' access readrng. the and tion momentarily. check amperage REGULATOR (Locatedinside the ond coverl FULLFIELD ACCESSHOLE
Aharnator/Regulator Tesl (cont'd): W i t h t h e e n g i n e s p e e ds t i l l a t rom,fulllield the alternator. 2.000
4-29
ChargingSystem
AlternatorReplacement
' t . Disconnect the batterynegative terminalfirst, then
the positive terminal. Disconnect 4P (or 3P) connectorand WHT wire the from the alternator. Removethe adjustingbolt and mounting nut, then removethe alternator belt. Pullout the throughbolt,then removethe alternator.
l I l
N ir
T n
THROUGH BOLT
WHT WIRE
MOUNTINGNUT 10x 1.25mm 44 N.m 14.5 kgf.m. 33 tbtftt
LOCKNUT 8 x 1.25 mm 24 N.m (2.4kgt m, 17 lbl.ft,
Install the alternator reverse in orderof removal.

o.
Adjust the alternatorbelt tension after installation (seepage4-34).
4-30
'll
Overhaul Alternator
NOTE:Do not removethe pulley unlessthe front bearing needsreplacement. To loosenthe pulley locknut,use the tools as shown. lf necessary, an impactwrench. use
PULLEY
,T
PULLEY LOCKNUT kgf.m,81.7 lbf.ft) 111N.m (11.3
INSULATOR BEARING
FRONT BEARING
PULLEY
CAUTION: Do not get grease or oil on the slip rings.
"'^.^t%
BRUSHHOLDER INSULATOB THROUGH BOLT RECTIFIER ASSY Test.page4 32 PULLEY LOCKNUT 111N.m {11.3 kgf.m,81.7lbf,ft)
REAR HOUSING
COVER
4-31
ChargingSystem
Rectifier Test
NOTE:The diodesare designed allow currentto pass to in one directionwhile blockingit in the oppositedirec t i o n . S i n c et h e a l t e r n a t o r e c t i f i e rs m a d e u p o f e i g h t i diodes(four pairs),each diode must be testedfor conti nuity in both directions with an ohmmeterthat hasdiode checking capability; total of 16 checks. a 'l. Check continuityin eachdirectionbetween for - t h e B a n dPt e r m i n a l s . - E ( g r o u n da n d P t e r m i n a l s . ) A l l d i o d e s h o u l dh a v ec o n t i n u i t i n o n l y o n e d i r e c s y tion.
AlternatorBrushInspection
1.
Remove end cover, the thentakeout the brushholder by removing its two screws. M e a s u r e h e l e n g t ho f t h e b r u s h e s i t h a v e r n i e r t w calrper. Alternator Brush Length: Standard(Newl:10.5mm 10.41 inl Service Limit: 1.5mm {0.06in)
2.
VERNIER CALIPER
2.
lf any of the diodesfails,replace rectifier the assembly. (Diodes not available are separatelv.)
lf the brushesare lessthan the servicelimit, replace the alternator brushassemblv.
4-32
RotorSlip RingTest
1. between slip rings. the Check resistance the Thereshouldbe 1.8- 3.0ohms. go . lf resistance meetsthe specification, to step2 . lf resistance oes not meetthe specification, d replace alternator. the
Stator Test
1. Checkthat there is continuitybetweeneach pair of leads.
LEADS
ROTOR SHAFT
corLcoRE
SLIPRINGS
that there is no continuitybetweeneach lead Check and the coil core. It the coil fails either continuitycheck,replacethe alternator.
Checkthat there is no continuity betweenthe slip ringsand the rotoror rotor shaft. the lf the rotor fails eithercontinuitycheck,replace alternator.
4-33
ChargingSystem
AlternatorBelt Inspection and Adjustment
NOTE:When usinga new belt,first adjustthe deflection or tensionto the valuesfor the new belt, then readjust the deflection tensionto the valuesfor the used belt or afterrunningenginefor five minutes. Deflection methodi A p p l ya f o r c eo f 9 8 N ( 1 0 k g t , 2 2 l b l l , a n d m e a s u r eh e t deflection between alternator the and crankshaft pulley. Detlection: UsedBelt:8.5 11.5mm (0.33 0.45inl New Beft: 5.5 - 8.0 mm 10.22 0.31 inl NOTErlf the belt is worn or damaged, replace it. Belt tension gauge m6thod: Attachthe belttensiongaugeto the beltand measure the tension. Followthe gaugemanufacturer's instructions. Tension: Used Belt:340 - /0 N (35 - 50 kgf, 77 - 1r0 tbf) New Belt: 690 - 880 N (70 - 90 kgf, 150- 200 tbt) NOTE:lfthe belt is worn or damaged, replace it.
Measure here
4-34
lf adjustment is necessary: 1. 2. Loosen the mountingnut and the locknut. Move the alternatorto obtain the proper belt tenthe sion,then retighten nuts.
LOCKNUT 8 x 1.25 m m 24 N.m (2.4kgtm,'17lbf ft)
NUT MOUNTING mm 10x 1.25 14N.m{4.5 kgl.m.33lbf.ft)
or Recheck deflection tensionof the belt. the NOTE: For the power steeringpump belt and A,/C referto section17 and belt adjustments, compressor section 22.
4-35
Gruise Control
Component Location Index
CRUISE INDICATOR LIGHT (Builtinto gaugeassembly) BulbLocations. section 23 SET/RESUME SWITCH Test,page 4 40 Beplacement, page4-40
BA
CRUISE CONTROL UNIT Input Test,page 4 38
swtTcH
Test, page 4-44
CLUTCH INTERLOCK Test,page 4-43 Switchposkionadjustment, section12
swrTcH {M/T)
Pedal Height Adjustment, section19.
ACTUATOfiASSEMBLY and VACUUMTANK Test,page4 41 Solenoid Test,page4 44
A/T GEAB POSITION swlTcH (A/Tl '14 Test, section
ACTUATOR CAELE Adjustment, page4-43
+36
Diagram Gircuit
FUSEi BOX UNDER.HOOD RELAY
No41(100A) No42(404) IGNIT ON SWITCH FUSARELAY BOX UNDER.OASH COMEINATON L GH'I SWITCH
RED/BLK
f7 I
INDICATOR LIGHT (0.84W)
lP
IOSET
J
BRAK LGHTS
2 1
6 1
7 1 2 C R U I SC O N T R O T L T E UN 1 1
8 4
3 10
CRUISE PNK CONTROL ACTUATOR
4F\ /lr,mcern
I t
I
BLK
L_l l
I I
BLK
G401
BLK
BLK
t'
Y{"^ i?tr'.flffi'JF )l
t rereasedl : /l loNPedar
G101
*: '98 00 modelswith Automatic Transmission.
n :
G202
8LK
I
4-37
Control Cruise
ControlUnit Input Test
precautions, in and procedures the SRS are locatedin this area.Reviewthe SRScomponentlocations. SRScomponents or beforeperformingrepairs seryice. section(241 '1. Remove driver'sdashboard 20). lowercoverand kneebolster{seesection the 2. 3. Disconnect the 'l4P from the controlunit. connector
terminals be surethey are all makinggood contact to the and socket Inspect connector the and repairthem as necessary, recheck system. lf the terminalsare bent,loose,or corroded, lf the terminalslook OK, makethe followinginput testsat the connector. - lf any test indicates problem. the cause, then recheck system. the find and correct a - lf all the input testsproveOK,the controlunit must be faulty;replace it.
*: '98- 00 modelswith Transmission. Automatic
Wire sideol femaleterminals
4-38
Disconnestthe lilP connectorfrom the control unit. Csvity Wire BRNAr'VHT

1 11
Test condition
Under all conditions Under all conditions Under all conditions lgnitionswitch ON (ll), main switch ON and brakepedaldepressed, then released Under all conditions
Test: Desiredresult
Checkfor resistance groundl to There should be 80 - 120 o. Checkfor resistance groundl to There should be 40 - 60 0. Checkfor resistance ground: to There should be 70 - 110 O. Checkfor voltageto ground: There should be 0 V with the pedal depressed and batteryvoltagewith the pedal released. Checkfor continuityto ground: There should be continuity.
Possiblecause it result is not obtained Faulty solenoid actuator Poorground(G202) An openin the wire
BRN BRN/BLK
GRY
. Faulty brake switch . An openin the wire
BLK
. Poor ground (G401) . An open in the wire B l o w nN o . 5 21 ' 1 A l f u s e i n t h e 5 under-hoodfuse/relaybox Faultybrakeswitch An open in the wire
GRNMHT
pedal Brake depressed, Checkfor voltageto ground: thenreleased There should be batteryvoltagewith
the pedal depressed, and 0 V with the pedal released.
LT GRN/ RED
7
Setbuttonpushed
Checkfor voltageto ground: There should be batteryvoltage.
LT GRN/ BLK
Resume buttonpushed
A} BlownNo.52 {'15 fusein the under-hood fuse/relay box Faulty hornrelay Faulty switch sevresume Faulty cablereel An openin the wire
E l o w nb u l b Blown No. 25 (7.5A) tuse in the under-dash fuse/relaybox Faultydimming circuit in the gauge assembly An open in the wire Faultyvehiclespeed sensor(VSS) An open in the wire
lgnitionswitch ON lll)
10
RED/BLU
Attach to ground: Cruiseindicatorlight in the gauge assemblyshould come on.
lgnitjonswitch ON {ll} and main switch ON; raisethe front of the ELU^r'r'HT vehicle,block one wheel and rotatethe other wheel slowly.
Check for voltage between the ELUA/VHT and BLK O terminalsl @ There should be 0 - 5 V or more -0 - 5 V or more repeatedly.
r3
LT GRN
lgnitionswitch ON {ll} and main switch ON
Checkfor voltageto ground: There should be batteryvoltage.
Blown No. 14 (7.5A) fuse in the under-dash fuse/relaybox Faultymain switch An open in the wire Faulty A/f gear position switch 1A,/Tl Faultyor misadjusted clutch switch
l4
PNK
A'/T: Shift leverin E, E otE lvl/T: Clutchpedal releaseo
Checkfor continuityto ground: There should be continuity. NOTE: There should be no continuity when the shift lever is in other positionsor when the clutch pedal is oepresseo.
fi{/r)
P o o rg r o u n d( G 1 0 1 ) An open in the wire
Rconncttho 14PconnGctorto the control unit.

Start tho engine.turn the main switch ON, and drive the vehicleover 25 mph (40 km/h)with the crursecontrol set Checkfor voltageto ground: There should be approx.5 V . Faultycruisecontrol unit . Shod to ground
BLU
*: '98 - 00 modelswith Automatic Transmission.
4-39
CruiseControl
Main Switch Test/Replacement
pry 1 . Carefully the switchout of the instrument panel. Disconnect 6P connector the from the switch, Terminal of male side rermtnats
6P CONNECTOR
Set/ResumeSwitch Test/Replacement
1 . Disconnect bafterynegative the cable,then disconnectthe positivecable,and wait at leastthree minutes. Disconnect driver'sairbagand front passenger's the (seesection airbagconnectors 24). Remove dashboard the lowercoverand kneebolster. 4. Disconnect 6P connectorbetween the the cablereel sub harness and the main wire harness.
BULES {0.84 Wt Checkfor continuitvbetweenthe terminalsin each switchpositionaccording the table. to \ ;;; OFF ON GG Terminal -_\ 5
Wire sideof temaleterminals
@o @
(9 ,{)
-o o- @ -o
Checkfor continuity betweenthe terminalsof the 6P connectorin each switch position accordingto the table. \ Terminal
lf there is no continuity, replace switch. the
;;;
--_l
S E T( O N ) ( R E S U M EO N )
Cf-
o-
-o c
lf there is continuity.and it matchesthe table, the switchis OK. a lf there is no continuityin one or both positions, go to step 6.
4-40
ActuatorTest
then removethe switch. 6. Remove two screws. the
nnSET/RESUME
cabletrom the actuatorrod 1 . Disconnect actuator the and the 4Pconnector. Connect battery power to the No. 4 terminal and groundto the No. 1, No. 2 and No. 3 terminals, Connect vacuumpump to the vacuumhose.Then a applyvacuumto the actuator.
,s
r.
VACUUMPUMPGAUGE 0-30 in.Hg. A973X-041-XXXXX
7 . Checkfor continuitybetweenthe terminalsin each according the table. to switchposition Terminal -__\ SETION) (ON) RESUME .
1e to
t*,r*
---o oo- ---o
Terminalside ot male terminals lf The actuator rod shouldpull in completely. the rod pulls in only part-wayor not at all, checkfor a leaksolenoid. ing vacuumIineor defective
lf there is continuity,and it matchesthe table, replace cablereel. the lf there is no continuityin one or both positions, replacethe switch.
ACTUATOB ROD
the cable reel sublf all tests prove OK, reconnect harness connector. the 9 . Reconnect driver'sairbagand front passenger's panelon airbagconnectors, and reinstall access the the steering wheel.
1 0 . Reconnect batterypositivecable.then the negathe tive cable.

1 1 . A f t e r c o n n e c t i n g h e a i r b a gc o n n e c t o r sc o n f i r m t ,
proper system operation:Turn the ignition switch ON (ll);the SRSindicator light shouldcome on for about six secondsand then go off.
(cont'd)
4-41
CruiseGontrol
ActuatorTest (cont'dl
5. With voltageand vacuumstill applied, to pull the try actuatorrod out by hand.You shouldnot be able to pull it out. lf you can.it is defectrve.
ActuatorReplacement
' t . Pullbackthe boot. and loosenthe locknut. Then disconnect cablefrom the bracket. the Disconnect cableend from the actuatorrod. the
Ar
1.
.J.
groundfrom the No. 3 terminal. Disconnect The actuator rod should return.lf it does not return,but the vent hose and filter are not plugged,the solenoid valve assemblyis defective. 7. Repeatsteps 2 through 5. and disconnectground from the No. l terminal. The actuator rod should return. lf it does not return,but the vent hose and filter are not plugged,the solenoidvalve assembly is defective. lf you replace the solenoidvalveassembly, sure be to use new O-ringson eachsolenoid. powerand groundfrom the 4Pconnector. Disconnect Disconnect vent hose from the actuator.Connect the a vacuumpump to the actuator vent hose port, and applyvacuum.The actuator rod shouldpull in comp l e t e l y .l f n o t , t h e v a c u u m v a l v e i s s t u c k o p e n . Replace actuator, the
3. 4.
Disconnect 4Pconnector the from the actuator. Disconnect vacuumhosefrom the vacuumtank. the Pullout the vent hose. Removethe three mounting bolts and the actuator with the bracket.
I
4.
ACTUATOR CABLE
ACTUATOR
8.
9.
6.
lf necessary, disconnect cableend from the linkthe pedal,then turn the gromage over the accelerator met 90' in the bulkhead. and removethe cable. Installin the reverseorder of removal,and adjust free play at the actuator rod after connectingthe cable(seepage4-43).
7.
4-42
ActuatorCableAdiustment
'1. Checkthat the actuator cable operatessmoothly with no bindingor sticking. Startthe engine.Hold the engineat 3,000rpm with no load (A,/T E or E position, M/T in neutral) in untilthe radiator comeson, then let it idle. fan Measurethe amount of movementof the actuator rod until ths cable pulls on the acceleratorlever (enginespeed startsto increase). Free play should b e 1 1t 1 . 0m m ( 0 . 4 3 0 . 0 4i n ) . i
ClutchSwitch Test
1. Disconngctths 2P connector from the clutch switch.
SWITCH CONNECTOR 2P CLUTCH of Terminalside maleterminals
ACTUATOR ROD
LOCKNUT FREEPLAY:11 t 1.0 mm r 10.43 0.04 in) lf free play is not within specs,loosenthe locknut, nut as requirsd, and turn the adjusting NOTE: lf necessary, check the throttl cable frso play (sesection11),then recheck the actuatorrod free play. Retighten locknut, the and recheck free play. the
2.
5.
Remove clutchswitch, the for Check continuitybetween terminalsaccordthe ing to the table. Terminal
Clutch Switch OEPRESSED
RELEASED
4.
lf necessary, replacethe switch or adjustthe pedal height(seesectiont2).
st te
4-43
CruiseControl
BrakeSwitch Test
1. 2. from the switch, Disconnect 4Pconnector the Remove brakeswitch. the
{P CONNECTOR
ActuatorSolenoidTest
1. from the actuator. the Disconnect 4P connector
ACTUATOR
of Terminalside male terminals betweenthe terminalsaccordCheckfor resistance ing to the table.

sideof male Terminal termtnals
Terminal
il',",""*(t)
_\
I
---o ---o
VENTSOLENOID 40-600
Check for continuity between the terminals according to the table.
o- - o o o-
VACUUM SOLENOID
30-500
SAFEW SOLENOID 40-600
Terminal
;;;;-t
RELEASED PUSHED
O-
---o o- -o
will vary slightly with temperaNOTE: Resistance resistance at 68"F(20"C). is ture;specified
replacethe switch or adjust pedal height lf necessary, (seesection19).

VACUUM VALVE
To VACUUM TANK
4-44
ActuatorDisassembly
ACTUATOR CABLE
ACTUATOR ERACKET
VACUUM TANK
)rd'
!l
l
VALVES
Test, page 4-44
4-45
E ngine
Engine RemovaUlnstallation ................ 5-1 Cylinder Head/Valve Train ................... 6-1 E n g i n e f o c k. . . . . . . . . . B ...........7-1 Engine Lubrication ...........8-1 IntakeManifold/Exhaust System ........ 9-1 Cooling ......... 10-1
Engine RemovaUlnstallation
EngineRemoval/lnstallation 5.2 . . . . . . . . . . . . . . . . . . . .- . . . . Removal .....................5-12 lnstallation
EngineRemovaUlnstallation
Removal @
4. Remove battervand battervbase. the a Make sure iacks and safety stands are placedproperly and hoist brackets are attached to the correct oositions on the engine. . Make sure the vehicle will not roll oft stands and fall while you are working under it.
6.
BATTERY BASE
I x 1.25mm 24 N.m (2.4kgf.m, 17 tbnft) -t'.-e
7.
NOTEI . U s e f e n d e rc o v e r st o a v o i d d a m a g i n gp a i n t e ds u r faces. o To avoid damage.unplugthe wiring connectors careportion. fully while holdingthe connector lvlark wiring and hosesto avoid misconnection. all Also, be surethat they do not contactother wiring or hoses, interfere or with otherparts.
1. 2.
F
F Y
Secure the hood in the open position. Disconnect battery the negative terminal first,thenthe positive terminal. Disconnect batterycablesfrom the under-hood the fuse/relay box and batterypositive terminal.
5.
Remove the intakeair duct and air cleanerhousino.
INTAKE AIB
6.
Disconnect enginecontrolmodule(ECM)/powerthe from the ECM/ connectors traincontrolmodule(PCM) PCM. Disconnect main wire harness the connector.
on Disconnect enginewire harnessconnectors the the left sideof the enginecompartment.

WIRE ENGINE HARNESS CONNECTORS
7.
CONNECTOR
clamps, then Remove grommetand wire harness the pull out the EcM/Pclvl connectors.
6x1.0mm 11 N.m 11.1 kgl.m,8lbf.ftl
GROMMET
(cont'd)
5-3
Removal/lnstallation Engine
(cont'dl Removal
1 0 . Remove cruisecontrolactuator(seesection4). the 1 t . R e m o v et h e m o u n t i n g b o l t a n d l o c k b o l t , t h e n
removethe P/Spump belt and pump.
MOUNNNG BOLT 8 x 1.25mm 2a N.m 12.4kg{.m, 17 lbtftl P/S PUMP BELT
fuel pressure 13. Relieve {seesection11). Do not 3mok6 whil working on th6 @ tugl systsm. Koep open flam or spark away from the work area. Drain fuel only inlo an approved container. 14. Removethe evaporativeemission (EVAP)control hoseand tuel feed hose. canister
33 N.m (3.4kgt.m,
2s tbf.ft)
LOCKBOLT I x 1.25mm 24 N.m {2.4kgtm, '17lbf.ftl
1 2 . Loosenthe idler pulley bracketbolt and adjusting bolt, then remove the air conditioning(A,/C) compressorbelt.
ADJUSTING BOLT LOCKNUT 8 x 1.25mm 24 N.m {2.4kgf.m, 17 lbf.ftl
,%l *ryft 'fltr

\'t,f
EVAPCC CANISTER HOSE
ID1TR PULI.f,Y ARACKETBOLT 10r 1.25mm a{ N.m 14.5lgtm,33 lbf.ft)
5-4
he '.n
!d
'15. Remove the brakeboostervacuumhose,fuel return hoseand vacuumhose. '97 - 98 modals:

BRAKEBOOSTER VACUUM HOSE
'16. Remove the locknut, the throttlecableby loosening linkthen slip the cable end out of the accelerator age.Take care not to bend the cablewhen removing it. Always replaceany kinkedcablewith a new one. 97 - 98 modeb:
'ol
FUELRETURN HOSE
99 - 00 modob:
'99 - 00 modob: BRAKEBOOSTER VACUUM HOSE
LOCKNUT ADJUSTING NUT
THROTTLE CABLE
(cont'd)
5-5
EngineRemoval/lnstallation
(cont'd) Removal
17. Disconnect powersteering the pressure {psp} switch connector, removethe wire harness and clamo. 19. Disconnect transmission groundcable(M/T). the
GROUNDCABI."E
1 8 . Removethe slavecylinderand clutch hose bracket
(Mrr).
NOTE: . Do not disconnect pipe/hose the assembly. . Do not operatethe clutch pedal once the slave cylinderhas beenremoved. . Takecarenot to bendthe pipe/hose assembly.
R e m o v et h e c o t t e r p i n s , t h e n r e m o v e t h e s t e e l plastic washers, washers, shiftcable, and select cable from the levers(M/T).
sElEcr
CABI."E 21. Removethe cable bracketfrom the clutch housing (M/T).
5-6
the 22. Remove radiatorcaP. use care when removing the radiatol !@ cap to avoid scalding by hot coolani or steam. the 23. Raise hoistto full height the 24. Remove front tires/wheels. the 25. Remove guardbar and splashshield.
SPLASH
the 30. Disconnect primary heatedoxygen sensor(prlpipeA then removeexhaust connector. mary HO2S) '97 - 98 U.S. models (Cslifornia):
PRIMARY HO2S CONNECTOR
GASKET Replace. NUT SELF-LOCKING 8 x 1.25 mm NUT 22 N.m 12.2 kgf.m, 8 x 1.25mm 16 lbf.ftl 16 N.m {1.6 kgf.m. Replace. 12 tbt.ftl Replace. 8 x 1.25mm 2,1N.m {2.4 kgf,m, 17 lbl ft)
NUT SELF.LOCKING 10x 1.25mm 54 N.m 15.5kgf.m, .() tbf.frl Replace.
6x1.0mm
kgf.m, GUARD BAR 9.8N.m{1.0 7.2tbf.rr) 26. L o o s e nt h e d r a i n p l u g i n t h e r a d i a t o r .D r a i n t h e enginecoolant(seepage10-51. the oil 2 7 . Drainthe transmission or fluid. Reinstall drain plug using a new washer lsee section 13 (M/T)or section 14 (ly'T)]. the 28. Drainthe engineoil. Reinstall drain bolt using a new washer{seepage8-4). the Do compressor. not disconnect 29. Bemovethe A,/C !y'C hoses.
ER lC EB
'97 - 98 U.S. modls {ExceptCalifornia): '99 - 00 models:

PRIMARY HO2S CONNECTOR GASKETS Replace.
GASKET Replace. SELF.LOCKING 8 x 'l.25mm 22 N.m (2.2kgf m, 16 rbf.ftl Replace.
NUT SELF.LOCKING 8 x 1.25mm kgf.m, 16 N.m 11.6 12 tbt fr) Replace.
mm 10 x 1.25 54 N.m 15.5kgt.m, 40 rbt.ftl Replace.
{cont'd)
5-7
(cont'dl Removal
31. Removethe shift cable.Take care not to bend the cablewhen removingit. Always replaceany kinked cablewith new one (Afl-).
OOI{TROLPI SNAPPIN
Make marks on the transfercompanionflange and propeller shaftas shown.Usethesemarksto set the propeller shaft in the proper position when reinstalling(4WD). Removethe four bolts securingthe propellershaft, then separate the propellershaft from the transfer companion flange(4WD).
sHtFTCABtt OOVEB
8 x 1.25 mm t2 N.m 12.2 lgtr'l'',, 16tbf.ftl
Remove right damperfork (seesection18). the Disconnect suspension the lowerarm balljoints(see section18),
34. Removethe driveshafts(see section t6). Coat all

precision-finished surfacewith cleanengineoil. Tie plasticbagsover the driveshaft ends.
E x 1.25mm
32 N.m 13.3 lgt.m, 24 lbt'ftl Replce. 37. Lowerthe hoist,
5-8
rd te n-
t 3 8 . R e m o v e h e u p p e r a n d l o w e r r a d i a t o rh o s e sa n d heaterhoses.
the 4 1 . Remove radiator(seepage10"4). the 42. Remove IVC hoseclamp.
rt,
BT
A/C HOSE
g t 3 9 . R e m o v e h e t r a n s m i s s i o n r o u n dc a b l e a n d h o s e clamp(A,/T). 9.8 'm lt.o klt m, l.2tutal
GBOUI{DCABLE
6x ,0mm 6x l1,0mm lof'm, 11 N.m 11.1 I tbf.ftl
40. Remove the ATF cooler hoses, then plug the ATF cooler hoses and, n"" lAfI).
(cont'd)
5-9
(cont'dl Removal
43. Attachthe chainhoistto the engine.
5-10
44. Removethe left and right front mounts and brackets
bracket. the uDper 46. Remove
UPPER
Replace.
M/T:
then remove mount bracket, 47. Removethe transmission mount. the transmission
MOUNT/BRACKET Alf I TRANSMISSION
mountingbolt. 45. Remove rearmount bracket the

REABMOUNT
MOUNTBMCKET
is free Check that the engine^ransmissioncompletely hoses,fuel and coolant hoses,and electriof vacuum calwiring. 150 the 49. Slowlyraise engineapproximately mm (6 in)' Checkonce again that all hosesand wires are disconfrom the enginenransmission. nected the 50. Raise engineall the way, and removeit from the vehicle.
5 - 11
Engine Removal/lnstallation
Installation
Bracket Bolts Torque Specifications:
P/S PUMP BRACKET
t t 1.25m.D 2a 'tn (2,4 kgt ft, 17 tbtftl
SIDEEIIGII{E i'OUT{T BRACKET
10 x 1.25mm 54 t$m 15.5tgfm, iO lbflrl
10 x 125 mm il,a t*m {4.5 tgt'm, d, tbtft)
ALTERI{ATOR BNACKET
A/C @MPRESSOR BRACIGT
t0 r 125 ]nm a,l t+Jnll.5 lgf-rn, 3 tbf{tl

8 r 1.25mm 24 N.m 12.4 kg{.m;
17tbtfrl
10 x 1.25mrn ,L il.tn {1.5 tgt m, :|:l lbf'ft}
5- 12
EngineInstallation: orderof removal. lnstallthe enginein the reverse in Reinstall mount bolts/nuts the followingsequence the may causeexcessrve Failure follow these procedures to and reducebushinglife. noiseand vibration. m 1 . I n s t a l lt h e t r a n s m i s s i o n o u n t a n d b r a c k e t t. h e n tighten the bolts on the frame side. Do not tighten side. on the bolts/nuts the transmission A/T:
TM'{SMISSION MOUNT
2.
then tightenthe nuts in the Install the upper bracket, numbered seauence.
O 12 x 1.25mm 7a N.m {7.5kgf'm, 54 tbf.trl
A 12r1.25mm 7il N.m 17.5kgl'm, 5,r lbt.ft)
mm 12x 1.25 kgtr.m, 6,aN.m16.5 47 tbt f0
R R
3.
mountingbolt. Do not Install the rear mount bracket tightenthe bolt.
TRANSMISSION MOUNT BRACKEY
M/T:
TRANSMISSION MOUNT
12x 1.25mm 64 N.m {6.5kgt.m, 47 tbl.ft) !, m, MOUNN G BOLT Replace.
(cont'd)
5-13
(cont'd) Installation
4. T i g h t e nt h e b o l t / n u t s n t h e t r a n s m i s s i o n o u n t o m bracketin the numberedsequence. AIT: 5. Tightenthe rear mount bracket mountingbolt.
@ 12 x 1.25mm ?4 N.m {t.5 kgt.h, 5,4lbf.ftl
mm O 12x 1.25 6l .m (6.5 m, kgt 47 tbt{r}
12 x 1.25mm 59 N.m {6.0 lgl'm, ait lbf.ftl Replace.
M/T: i?. 12 x 1.25mm 74 N.m {7.5kgf'm.
s/rtbr.ftl
,,.....\.L}
@'...,'..4:
a1l12 x 1.25mm 64 N.m {6.5kgf.m, 47 lbf.ft)
5 - 14
6.
then tightenthe Install the rightfront mounvbracket, sequence. boltsin the numbered A/T:
Loosen th is nut,
7.
Install the leftfront mount,then tightenthe bolts/nut in the numbered seouence. mm O t2 r 1.25 kgt.m, |bfftl 8il N.m18.5 el
i! 12x 1.25mm g N.m {6.5 kgf.m, 47 lbf.ftl Replace.
O 12 x 1.25mm 59 N.m 16.0kgt ln, , lbfttl Replace.
(D to x t.zs mm 44 N.m{4.5kgfm, 33 lbf.ft)
mm @ lo x 1.25 a,a N.m14.5 kgf.m, 33 tbf.trl
M/T:
Loosen this nut.
O 10x r.25mm 4/tN.m14.5 kgt.m, lbf.ft) 33

O 12 x 1.25mm 64 N.m 16.5kgf.m.47 lbf.ft) Replace.
{cont'd)
5-15
EngineRemoval/lnstallo cton
8. Tightenthe nut on the right front mount. AlTi 9. Perform followingchecks the and adjustments: . Check that the springclip on the endsof the driveshaftand intermediate shaftclicksinto place.Use new springclips. . Adjustthe shiftcable(seesectionl4). . Adjustthe throttlecable(seesection11). . Refillthe enginewith engineoil (seepageg-4). . Refillthe transmission with oil or fluid (seesect i o n 1 3o r 1 4 ) . . Refillthe radiatorwith enginecoolant(seepage 10_5). . B l e e da i r f r o m t h e c o o l i n g s y s t e mw i t h t h e heatervalveopen (seepage l0-5). . Cleanthe batterypostsand cableterminalswith sandpaper, assemble them, then apply grease to Drevent corrosron. . Inspect fuel leakage (seesection1l). for After assembling fuel line pans,turn on the ignition switch (do not operatethe starter)so that the fuel pump operatesfor approximatelytwo seconds and the fuel Iine pressurizes. R e p e a t h i s o p e r a t i o n w o o r t h r e e t i m e s ,a n d t check fuel leakage any point in the fuel line. for at
59 .m 16.0tgt m, (l lbfftl Replace.
MlTi
12 x'1.25 mm 59 N.m 16,0 m, /(} lbt ttl kgt Reolace.
5-16
Mount and Brackst Bolts/Nuts Torqus Value Specitications:

x A: '10 1.25mm 64 N.m 16.5kgI.m, 47 lb{.ftl B: 12 x 1.25mm 59 N.m 16.0kgf.m, 43 lblft) Replace. C : 1 4x 1 . 5m m 8:l N.m (8.5kgt.m, 6r lbl'ft) Replace. D: 10x 1,25mm ,t4 N.m (4.5 kgf'm,33 lbIft) Er 12x 1.25mm 83 N.m 18.5kgf.m, 61 lbl.ftl
5-17
Train CylinderHead/Valve
.............6-2 Camshafts Tools Speciaf ..............6-22 lnspection ValveClearance Valves,Valve Springsand Valve Seals ............6-3 Adiustment ................, 6-23 Removal ValveSeals (cylinderhead ............. 6-29 lnstallation Replacement 6-5 removalnot requiredl................. Valve Guides Pulleyand PulleyBolt Crankshaft 6-25 ValveMovement............,,,,.,............ .........6-7 Replacement .........6-25 Replacement Timing Belt .................6-27 Reaming 6-8 Illustrated lndex ............................... Valve Seats ............., 6-9 Inspection ......6-28 Reconditioning 6-9 Tension Adjustment........................ ...........,..... 6-10 Removal .............6-11 lnstallation SpeedFluctuation(CKFI Crankshaft Sensor .........6-13 Replacement CylinderHead 6-14 lllustrated lndex ............................... .................6-16 Removal ................6-27 Warpage ............. 6-30 lnstallation
SpecialTools
Ref. No.
Tool Number 07JAA- 001020A 07JAB- 00'10204 _ OTMAB PY3O1OA 07757 PJ1010A 07942 6570100 07984 657010D
Description Socket, mm 19 Holder andle H PulleyHolderAttachment,50 mm, Offset ValveSpringCompressor Anachment ValveGuideDriver,6.6 mm ValveGuideReamer, mm 6.6
(Xy 1 1
o
,61
PageRefereflce 6-1 6-7
A)
r
1 1
'l
I 6-7
I
| 6-27
6-23,29 6-25,26
a!)
a!)
c--E-rr------------
6-2
ValveClearance
Adiustment
Adjustthe valvesonly when the cylinderheadtempera(38"C). ture is lessthan 100"F 1. the Remove cylinderheadcover. the middlecover(seepage6-11). Remove "UP" mark on the Set the No. 1 pistonat TDC.The pulleysshouldbe at the top, and the TDC markson on shouldalignwith the pointers the back the pulleys Adjustthe valveson No. 1 cylinder. Intake: 0.08- 0.12mm (0.003 0.005inl - 0.20 mm (0.006- 0.008in) Exhaust:0.16 screw Loosenthe locknut,and turn the adiustment until the feeler gauge slides back and forth with a slightamountof drag.
LOCI(NUT 9 x 0.75m.n
25 N.m 12.5 kgf.m, 18lbf.ft)
POINTER
POINTER
Adiusting Screw Locations: INTAKE
No.4
No.3
No.2
No. 1
EXHAUST
(cont'd)
6-3
ValveClearance
Adjustment(cont'dl
6. agajn. Tightenthe locknut, and checkthe clearance Repeat adjustment necessary. the if 180"counterclockwise brinq to 8. Rotate crankshaft the No. 4 pistonto TDC. The "UP" marksshould be pointingstraightdown. Adjustthe valveson No. 4 cylinder.
"UP" MARKS
GAUGE
7.
(camshaft Rotatethe crankshaft 180"counterclockwise pulley turns90'). The "UP" marks shouldbe on the exhaust side.Adjust the valves No.3 cylinder. on
180'counterclockwise brino to Rotate crankshaft the No.2 pistonto TDC. The "UP" marksshouldbe on the intakeside.Adiust the valveson No. 2 cylinder.
.UP" MARKS
"UP" MARKS
1 0 . Install cylinderheadcover(seepage6-32). the pulleybolt (seepage6-7). 1 1 . Retorque crankshaft the
ValveSeals
Replacement(cylinderhead removal not required)
The procedure shown below applieswhen usingthe inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h YA8845-2A7/8" auachment). Use approved eye protection. 1. Turn the crankshaft that the No. 1 and the No. 4 so pistonsare at top deadcenter(TDC). 2. 3. 4. Remove cylinderheadcover. the Remove distributor. the L o o s e na n d d i s c o n n e c t h e t i m i n g b e l t f r o m t h e pulleys. camshaft Remove camshaftholderbolts.then removethe the camshaft holders, camshafts the and rockerarms. 10. Put shop towels over the oil passages prevent to t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r head.
OIL PASSAGE
at.
Selectthe 7/8 in. diameterlong compressor attachment,and fastenthe attachment the front hole of to the leverarm with the speedpin supplied.
9 . Position the pistonat TDC,and insen an air adaptor into the spark plug hole. Pump air into the cylinder t o k e e p t h e v a l v e c l o s e dw h i l e c o m p r e s s i n g h e t springsand removingthe valvekeepers.
5.
lntake Valve Seals 6. Usingthe 6 mm boltssuppliedwith the tool, mount t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d holders. The uprightsfit as shown. camshaft 7. Insertthe cross shaft through the top hole of the two uprights,
OIL PASSAGES
't1. Position the lever arm under the crossshaft so the lever is perpendicular the shaft and the compresto sor attachmentrests on top of the retainerfor the spring being compressed. Usethe rear positionslot on the leveras shown,
(cont'd)
6-5
ValveSeals
(cylinder headremovalnot requiredl(cont'dl Replacement
12. Usingan upwardmotionon the leverarm,compress the valve spring and removethe keepersfrom the pressure the spring. on valvestem.Slowlyrelease step 11 for the othervalvein that cylinder. 1 3 . Repeat 1 4 . Remove valveseals(seepage6-24). the 1 5 . Installthevalveseals(seepage6-29). and the keepersin 1 6 . lnstallthe springs,the retainers reverse orderof removal. '17. Repeat steps9 to 16 for the otherthreecylinders. Exhaustvalve Seals with the tool, mount 18. Usingthe 5 mm bolts supplied t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d camshaft holders. The uprightsfit as shown. 19. Insert the cross shaft through the bottom hole of the two uprights. to 22. Put shop towels over the oil passages prevent t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r neao.
23. Position the lever arm underthe crossshaft so the leveris perpendicular the shaftand the compresto sor attachmentrests on top of the retainerfor the Use spring being compressed. the rear positionslot on the leveras shown.
attach 20. Selectthe 7/8 in. diametershort compressor to ment,and fastenthe attachment the No. 4 hole of the leverarm with the speedpin supplied.
t1
24. Using a downward motion on the lever arm, compressthe valvespringand removethe keepers from t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e spring. Repeat step24 for the othervalvein that cylinder. Remove valveseals(seepage6-24). the 2 1 . Install valveseals(seepage6-29). the and the keepersin 28. Installthe springs,the retainers reverse orderof removal. 29. Repeat steps21 to 28 on the otherthreecylinders.
Position pistonat TDC,and insertan air adaptor the into the spark plug hole. Pump air into the cylinder t t o k e e p t h e v a l v e c l o s e dw h i l e c o m p r e s s i n g h e springsand removingthe valvekeepers.
o-o
Pulleyand PulleyBolt Crankshaft

Replacement
When installing and tightening the pulley,follow the procedure below. pointsshown below. removeany oil, and lubricate Clean, C: Clean x I Remove any oil a: Lubricate CRANKSHAFT PULLEY
WASHER
CRANKSHAFT
X X
o oooo o o o - oooo o ^ oooo o o o o
6r. R o".
X X
Crankshaftpulley bolt size and torque value: 14 x 1.25mm 177N'm (18.0kgf.m,130lbt.ftl NOTE:Do not use an impactwrenchwhen installing.
HOLDER ATTACHMENT. 50 mm, OFFSET OTMAB PY3OlOA SOCKET, mm 19 07JAA- 001020A available} {or Commercially
6-7
TimingBelt
Index lllustrated
HEAD CYLINDER COVER Refer page6-32 to when installing. HEADCOVER GASKET Replace when leaking, or damaged deteriorated. at Apply liquidgasket of the eightcorners the TIMING BELT page6-9 Inspection, page6-9 Adjustment, page6-10 Removal, page6-1 1 Installation, SEAL RUEBER Replace damaged il ot detetiorated. 8 x 1.25mm 37 N.m (3.8kst.m,27lbf ftl
kgf.m, 7.2 tbtft)
\ @
WASHER Replace damaged if or deteriorated,
Cl
k 6
COVER MIDOLE 6x1.0mm 9.8N.m {1.0kgf.m, 1.2lbt.ftl
SEALS RUBBER when damaged Replace or deteriorated, COVER LOWER ADJUSTINGBOLT 10 x 1.25mm 54 N.m (5.5kgl.m, 40 lbf.ft) PULLEY CNANKSHAFT page6-7 neplacement,
TIMINGBELT PULLEY ORIVE

R e p l a c e m e n t ,p a g e 6 ' 7
with concave lnstall facingout, surface Remove any oaland clean, SPEEO CRANKSHAFT FLUCTUATION ICKF} SENSOR 6x1.0mm 9.8Nm(1.0kgl.m, 7.2 tbl.ft)
6x1.0mfi k 1 1N . m{ 1 . 1 g t m , 8.0 rbtft)
BOLT 14 x 1.25mm kgf'm, 177N.m (18.0 130 tbf.fr) Replacement, Page6-7 Do not usean impact wrenchwhen installing.
Inspection
1 . Remove cylinderheadcover. the 2. lnspectthe timing belt for c.acksand oil or coolant s o a k i n g . e p l a c eh e b e l t i f i t i s o i l o r c o o l a n t R t soaked.Removeany oil or solventthat gets on the belt.
TensionAdjustment
NOTE: . Alwaysadjustthe timing belt tensionwith the engine coto. . Always rotatethe crankshaft counterclockwise when i v i e w e df r o m t h e p u l l e y s i d e . R o t a t i n g t c l o c k w i s e m a y r e s u l ti n i m p r o p e ra d i u s t m e no f t h e b e l t t e n t sion. '1. Remove cylinderheadcover the 2. 3. Set the No. 1 pistonat TDC(seepage.6-12). Rotatethe crankshaft five or six revolutions set to the belt. Set the No. 1 pistonat TDC. Loosen adjusting the bolt 1/2turn (180')only.
4. lnspect this areafor wear. 5.
ADJUSTINGBOLT 5,4N.m (5.5 kgf.m, 40 tbtftl For adiustment only,
rotation,
Rotatethe crankshaft three teeth counterclockwise pulley. on the camshaft 3. pulleybolt After inspecting, retorque the crankshaft to 177N.m (18.0kgnm,130lbf.ft). Install the cylinderheadcover(seepage6-32).
9. 7. 8.
Tightenthe adjusting bolt to the specified torque. pulleybolt to After adjusting, retorque crankshaft the 177N.m (18.0 kgf.m, 130lbf.ft). Installthecylinderheadcover(seepage6-32).
6-9
Timing Belt
Removal
Replacethe timing belt at 105,000 miles (168,000 km) accordingto the maintenance schedule{normalcondilf tions/severe conditions). the vehicleis regularly driven in eitherof the following conditions, replacethe timing miles(U.S.A.l 100.000 (Canada). km belt at 60,000 - ln very high temperatures (over 110'F,43"C). - In very low temperatures (under-20"F.-29"C). 1 . Turn the crankshaftpu\ley so the No. 1 piston is at top deadcenter(TDC). 2. Removethe guard bar and splashshield (seepage 5-7). Loosen mountingbolt and lockbolt.then remove the the power steering(P/S)pump belt. MOUNNNG BOLT 8 x 1.25 rnm
24 N.m {2.4 kgt.m, 17 lbf.ftl 10 x 1,25mm 4,1N.m (,1.5 m, 33 lbtftl kgt AELT
5.
Loosen the mountingnut and locknut, then remove the altefnator belt.
LOCKNUT I x 1.25mm 2a N.m 12.4 m, 17 lblftl kgt
,l
6. 7.
(seesection4). Remove cruisecontrolactuator the S u p p o r tt h e e n g i n ew i t h a j a c k ,t h e n r e m o v et h e u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n between the oil Danand the iack.
12 x 1.25mm 74 N.m (7.5kgf m, 54 lbtftl 24 N.m 12.4kgf.m, lt lbf.ftl BRACKET
4.
Loosenthe idler pulley bracketbolt and adjusting (lVC) bolt,then remove the air conditioning compres sor belt(seepage5-4).
6-10
Installation
8. Remove cylinderheadcover. the NOTE:Referto page6-32when installing the cylinder headcover. pulley(seepage6-7). 9 . Remove crankshaft the 1 0 . Removethe middle cover and lower cover. Do not usethesecoversto storeremoveditems.
MTDDLE COVER 6x1.0mm 9.8N.m {1.0kgt m,
Install timing belt in the reverse the orderof removal; Only key pointsare described here, 1. so Setthetiming beltdrivepulley thatthe No. 1 piston is at top dead center (TDC).Align the groove on the timingbeltdrivepulley the pointer the oil pump. to on
POINTER GROOVE
DRIVE PULLEY Clean.

LOWER COVER
2. 9.8N.m(1.0 kgt.m, lbf.ftl 7.2
Set the camshaftpulleysso that the No. I piston is at pulleys TDC.Alignthe TDCmarkson the camshaft to the pointerson the backcover. CAMSHAFT PULLEY Clean.
1 1 . Markthe direction rotationon the timing belt. of 12. Loosen adjusting the bolt 180'.Pushthe tensioner to removetensionfrom the timing belt, then retighten the adiusting bolt.
r-t
AINUSTING BOLT 54 N.m (5,5 kgt m, .(} tbf.rrl
POINTER
1 3 . R e m o v eh e t i m i n gb e l t . t
(cont'd)
6-11
Timing Belt
3. Install timing belttightlyin the sequence the shown. J O Timing belt drive pulley(crankshaft) @ Adjusting pulley =r @ Water pump pulley r @ Exhaust pulley--)@ Intake pulley. camshaft camshaft NOTE: Make sure the timing belt drive pulley and pulleysare at TDC. camshaft pulley and camshaftpulleys 9. Checkthat the crankshaft are both at TDC.
POINTER ON
4.
Loosenand retightenthe adjustingbolt to tension the timing belt. C l e a n .t h e n i n s t a l l t h e l o w e r c o v e r a n d m i d d l e cover. pulley,then tightenthe pulley Installthe crankshaft bolt (seepage6-7).
POINTER
5.
1.
pulleyabout five or six turns Rotatethe crankshaft counterclockwise that the timing belt positions so on the pulleys. Adjustthe timing belttension{seepage6-9).
1 0 . lf the camshaftpulleys are not positionedat TDC, removethe timing belt.adjustthe position following the procedure page6-11. on then reinstall timing the belt. 1 1 . Installthecylinderheadcover(seepage6-32). 1 2 . After installation, adjustthe tensionon eachbelt. . See section4 for alternatorbelt tension adjustmenr. . See section22 for NC compressorbelt tension adjustment. . See section17 for P/Spump belt tensionadjustment.
6-12
CKFSensor
Replacement
1.
Removethe guard bar and splashshield (seepage 5-7t. L o o s e nt h e l o c k b o l t a n d m o u n t i n g b o l t , t h e n removethe P/Spump belt.
4.
Loosenthe locknutand mountingnut, then remove the alternator belt.

LOCKNUT 8 x 1.25mm 24 N.m (2.4 kgl.m, 17 lbtftl
MOUNTING BOLT 8 x 1.25 mm

24 N.m (2.{ kgf.m, 17 lbf.ttl
PUMP
BELT BELT
E
10 x 1.25 mm a4 N.m (4.5kgt m, 33 lbtft)
Remove cylinderheadcover. the pulley(seepage6-7). Remove crankshaft the Remove the middlecoverand the lowercover. Disconnect CKFsensorconnector, the then remove the CKFsensor.
CKFSENSOR
24 N.m 12.4lgf.m, 17 lbl.ftl
6. 7. Loosenthe adjustingbolt and idler pulley bracket bolt,then removethe Ay'C comDressor belt.
ADJUSTINGBOLT LOCKNUT 8 x 1.25mm 24 N.m {2.4 kgf.m, 17 lbf.ft)
aJ.
6x1.0mm 11 N.m {1.r kgnm,8.0lbfft)
|o|'ln PUUCYBMCKETSOLI l0 r 1.25 mm kgl.m,3:'lbtftl 14 .m 14.5
9.
Install the CKF sensor in reverse order of removal.
6-13
GylinderHead
lllustratedIndex
To avoiddamage, wait until the enginecoolanttemperature dropsbelow 100'F(38'C)beforeremovingthe cylinderhead.
6x1.0mm 9.8 N.m (1.0kgI.m, 7.2 lbf.ft) WASHER Replace when damaged or deteriorated, CYLINDER HEAD COVEB Reter page6 32 when to headcover. installing cylinder HEAOCOVER GASKET Beplace when leaking, damaged deteriorated. or at Apply liquidgasket the eightcorners the of
RUBEER SEAL
R e p l a c ei f or deteriorated,
8 x 1.25mm 24 N.m (2.4 17 tbtft) 6x1.0mm 9.8N.m (1.0kgf.m. 7.2 tbf.fo Applyengineoil to the threads. Seesection 4. CYLINDEB HEAD PLUG ReplaceCAMSHAFT HOLDER
---..-@
0+---.."...s<-KEY
DOWEL PIN OIL SEAL Replace. CAMSHAFT PULLEY 8 x 1.25mm 37 N.m {3.8kgf.m, 27 tbtft)
OILSEAL Replace.
6x1.0mm 9.8 N.m (1.0kgl.m,7.2lbtftl
6-1 4
contactsurface. handlinga metal care -?E to reassembling, takeall thenot to fold it or damagetheand applylubricantto any contactparts. partsin solvent, them dry Prior clean
CYLINDER HEADBOLT 1 1x 1 . 5m m 85 N.m {8.7kgf.m,6:} lbf.ft) page6'30. Tightening, Applyengineoilto the threads. END PIVOTBOLT kgl 63 N.m 16.4 m, 46 lbf.ft) SPRING BETAINER INTAKEVALVE SPRING INTAKEVALVESEAL Replace.
gasket.
VALVEKEEPERS
\
EXHAUST VALVE SPRING
EXHAUSY VALVE SEAL Replace.

EXHAUST VALVE GUIDE page6-25 Inspection, page6-25 Replacem6nt, page6-27 Reaming,
VALVESPRING SEAT INTAKEVALVE GUIDE
HEAD
page6-16 Removal, page6 27 Warpage, Valveseatreconditioning, page6 28 page6-30 Installation, EXHAUST VALVE INTAKEVALVE page6-23 Removal, page6-29 Installation, CYLINDER HEAO GASKET Replace.
10x 1.25mm 4,0N.m {i1.5 kgf.m. 33 rbf.ft)
OIL CONTROL ORIFICE Clean. O.RING Replace.
DOWELPIN
8 x 1.25mm 24 N.m (2.4kgf.m, 17 tbf.ft)
6-15
GylinderHead
Removal
Engine removal not required thisprocedure. is for l!@ Make sure iacks and safety stands are
placed properly, and hoist blackels ale attachgd to the correctposition on the engine. NOTE: o U s e f e n d e rc o v e r st o a v o i d d a m a g i n gp a i n t e ds u r faces. o To avoid damage,unplugthe wiring connectors careportion. fully while holdingthe connector . To avoid damagingthe cylinderhead,wait until the (38'C) enginecoolanttemperature drops below 100"F beforeloosening retainingbolts. the . Markall wiring and hosesto avoid misconnection. Also, be surethat they do not contactother wiring or hoses, interfere or with other parts. 1 . Disconnect negative the terminalfrom the battery. 2. Drain the engine coolant (see page 10-5).Remove the radiatorcapto speeddraining. BELT Removethe intakeair duct and air cleanerhousing (seepage5-2).
4. 10x 1.25mm 44 N.m (4.5kgt.m. 33 lbf.ft)
6.
Loosen the locknutand mountingnut, then remove the alternator belt.

LOCKNUT 8 x 1.25mm 24 N.m (2.4 kgf.m, 17 lbt.ftl
R e m o v e h e m o u n t i n gb o l t a n d l o c k b o l t , t h e n t r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d pump (seepage5-4). Loosenthe idler pulley bracketbolt and adjusting bolt, then remove the air conditioning(A,/C) com, pressorbelt.
ADJUSTING BOLT ADJUSTING BOLT LOCKNUT 8 x 1.25 m m 24 N m {2.4ksf.m, 17 lbttt}
7.
Remove P/SOUmo the bracket.
5.
l0 x 1.25mm 44 N.m (4.5kgf.m, 33 rbf.ft)
IOLER PULLEY BBACKET BOLT 10 x 1.25mm 44 N.m {4.5 kgtm, 33 lbf ft)
o-Io
tt\
aA
8.
the locknut, Remove the throttlecableby loosening then slip the cable end out of the throttle linkage. Take care not to bend the cablewhen removingit. Always replaceany kinkedcablewith a new one. '97 - 98 modols:
(seesection11). 9. Relieve fuel pressure Do not smoke while working on the @ fuel systom. Kop opon flame or sparks away from ths work area. Drain fuol only into an approved containgr. '10, Removethe evaporativeemission (EVAP)control hoseand fuel feed hose. canister
'!X, - 00 modob:
CANISTER HOSE
{cont'd)
6-17
GylinderHead
(cont'dl Removal
'11. Remove the brakeboostervacuumhose.fuel return hose,and vacuumhose. '97 - 98 modsls:
BRAKEBOOSTER
12. Removethe breatherhose and oositivecrankcase (PCV) ventilation hose,

'97 98 models: PCVHOSE BREATHEB HOSE
VACUUM HOSE
'99 - 00 models:
BREATHER HOSE BRAKEBOOSTEB VACUUM HOSE
PCVHOSE
6-18
13. Removethe upper radiatorhose, heaterhose and water bypasshose. BYPASS WATER
the 18. Remove cylinderheadcover.

CYLINDER
UPPEB RADIATOR HOSE
HEATER HOSE a c t R e m o v e h e e n g i n ew i r e h a r n e s s o n n e c t o r s n d clampsfrom the cylinderheadand the wire harness intakemanifold. o Fourfuel injectorconnectors ( s . E n g i n ec o o l a n tt e m p e r a t u r eE C T ) e n s o rc o n neclor . Radiator switchconnector fan gaugesendlngunlt connec. Coolant temperature tor . Throttlepositionsensorconnector . Manifold absolute pressure{MAP) sensor connector Primary heatedoxygen sensor (primary HO2S) connector a ldle air control(lAC) valveconnector Distributor connector from the the Remove sparkplug capsand distributor head. cylinder (seesection4). Remove cruisecontrolactuator the
1 7 S u p p o r tt h e e n g i n ew i t h a j a c k ,t h e n r e m o v et h e
the 19. Inspect timing belt (seepage6-9).
u p p e r b r a c k e t .M a k e s u r e t o p l a c e a c u s h i o n between the oil pan and the iack(seepage6-10).
(cont'd)
6-19
CylinderHead
(cont'dl Removal
Remove timing belt (seepage6-10). the 22. Bemove the exhaust manifold bracket and self-locking nuts. '97 - 98 U.S. modsls (Californial: GASKET Replace.
EXHAUSTMANIFOLD BRACKET
2' t. Remove camshaftpulleysand backcover. the
'r
10 x 1.25mm 44 N.m 14.5 kgf,m, 33 rbf.ft) SELF.LOCKING NUT 54 N.m {5.5kgf.m, .{) lbf.ftl Replace. '97 98 U.S. models {Excepi Calitornia}: '99 0O modeb: BACKCOVER GASKETS Replace.
SELF.LOCKING NUT 10 x 1.25mm 54 N.m {5.5kgt.m, 40 lbtft} Replace.
10 x 1.25mm 4il N.m (4.5kgf.m, 33 tbf.ftl
6-20
2 3 . R e m o v et h e i n t a k em a n i f o l dm o u n t i n gb o l t s a n d water bvDasshose.
holderbolts,then removethe 25. Remove camshaft the and rockerarms.Makenote of the camshaft holders rockerarm Dositions.
ARM ROCKER
8 x 1.25mm kgt.m, 2,1N.m 12.4 17 tbf.ft)
26. Remove the cylinder head bolts. To prevent warpage,unscrewthe bolts in sequence1/3turn at a until all bolts are loosened. time; repeatthe sequence SEOUENCE: CYLINDER HEADBOLTSLOOSENING
24. Loosen the locknuts and adjusting screws,
INTAKE No.3 No.2 N o .1
No. 4
No.3
No.2
N o .1
EXHAUST
27. Remove cylinderhead. the
6-21
Camshafts
Inspection
1 . Loosen adjusting the screws. Remove camshaft the holders. Markthe rockerarms,then removethem.
4. R e i n s t a l t h e c a m s h a f ta n d h o l d e r s .T i g h t e nt h e l
11. Removethe camshaftholders.Measurethe widest portionof plastigage eachjournal. on Camshatt-toHoldGrOil Clearance: Standard {Newl: 0.030- 0.069mm {0.0012 0.0027in} ServicoLimit: 0.15 mm (0.006in)
camshaftholderbolts in a crisscross pattern,beginning with the innerbolts. 9.8 N.m (1.0kgf.m.7.2lbf.ft) Seatthe camshafts pushingthem toward the disby tributorend of the headwith a screwdriver. Z e r o t h e d i a l i n d i c a t o ra g a i n s tt h e e n d o f t h e camshaft, push the camshaft back and forth and readthe end play. CamshaftEnd Play: StandardlNewl: 0.05- 0.15mm 10.002 0.005in) ServiceLimit: 0.5 mm (0.02in) 12. lf camshaft-to-holder clearanceis out of toleroil ance: . A n d t h e c a m s h a f th a s a l r e a d yb e e n r e p l a c e d , you must replace cylinderhead. the . lf the camshafthas not beenreplaced, first check total runout with the camshaftsuoDorted Von blocks. CamshaftTotal Runout: Standard (N6w): 0.03 mm (0.001in) max. ServiceLimit 0.04 mm (0.(X)2 in)
7 . Unscrewthe camshaftholder bolts two turns at a t i m e , i n a c r i s s c r o s sp a t t e r n ,T h e n r e m o v e t h e camshaftholderboltsfrom the cvlinderhead. 8. L i f t t h e c a m s h a f t s u t o f t h e c y l i n d e rh e a d .w i p e o them clean,then inspectthe lift ramps,Replace the camshaftif any lobes are pitted, scored,or excessivelyworn. Cleanthe camshaftjournal surfaces the cylinder in head,then set the camshaftback in Dlace.Placea plastigage strip acrosseachjournal.
Rotat6camshatt while measuring.
1 0 . Installthe camshaftholders.and torquethe boltsto

the valuesand in the sequence shownon page6-31. NOTE: Do not rotatethe camshaftsduring inspection. lf the total runout is out of tolerance, replace the camshafts and recheck. the oil clearance still lf is out of tolerance, replace cylinderhead. the lf the total runout of the camshafts within tolis erance, replace cylinderhead the
6-22
Valves,Valve Springs
and ValveSeals
Removal
the 13. Measure cam lobe height. Cam Lobe Height Standard (Newl '97 - 98 models: (1.3072 in) INTAKE: 33.20,1mm inl mm (1.3200 EXHAUST: 33.528 '99 - 00 models: mm 11.327t1in) INTAKE: 33.716 in) mm EXHAUST:33.528 (1.3200 l d e n t i f yt h e v a l v e s a n d v a l v e s p r i n g sa s t h e y a r e in removedso that eachitem can be reinstalled its original Dosition. 1. socketand plasticmallet. Usingan appropriate-sized the retainer loosen valvekeeP to lightlytap the valve the ers beforeinstalling valvespringcompressor'
Inspectthis arealor wear.
2.
Compress the spring Installthe spring compressor. and removethe valvekeeper.
COMPRESSOR VALVESPRING KD No. 3&!. whh *'5 JAW o.
VALVESPRING COMPRESSOR ATTACHMEUT 07757 PJ1010A (cont'd)
6-23
Valves,Valve Springs and Valve Seals

(cont'dl Removal
3. Install the valveguide sealremover.
VALVEGUIDESEALREMOVER LISLEP/N 57900or KD3350 equivalent or (Commerciallv available)
Intake Valve Dimensions A Standard{New}: 30.85- 31.15mm B Standard (New): G Standard {Newl: C ServiceLimiti D StandardlNewl: D Service Limit: 4. Remove valveseal. the
inl 11.21s 1.226 103.80 10/t.10 mm
{i[.087- 4.098in) 6.580- 6.590mm (0.2591 0.2594 in) 6.55 mm (0.258inl 1.35- 1.65mm (0.053- 0.05s in) 1.15mm (0.045 in)
Exhausi Valv Dimensions A Standard(Newl: 27.85 28.15mm 1 1 . 0 9-61 . 1 0 8n ) i B Standard (Newl: 10,1.00 10,1.30 mm (il.09i[- it.l06 in) C Standard {New): 6.550- 6.560mm 10.2579 0.2583inl C ServiceLimit: 6.52mm (0.257 inl D StandardlNewl: 1.65- 1.95mm 10.065 0.077in) D Service Limit: 1.45mm (0.057 inl
6-24
ValveGuides
ValveMovement
w c t 1 . M e a s u r e h e g u i d e - t o - s t e ml e a r a n c e i t h a d i a l indicatorwhile rockingthe stem in the directionof normalthrust(wobblemethod), lntake Valve Stem-to-GuideClearance: Standard(Newl:0.04- 0.10mm (0.002 0.004in) in) 0.16mm (0.006 Limit Service ExhaustValve Stem-to-GuideClearance: Standard {Newl:0.10- 0.16mm (0.004- 0.006inl inl Limit: 0,22mm (0.009 Service
Replacement
1. As illustratedbelow, use a commerciallyavailable air-impactvalve guide driver attachmentmodified t o f i t t h e d i a m e t e ro f t h e v a l v e g u i d e s . I n m o s t cases,the same procedurecan be done using the hammer. sDecial tool and a conventional
VALVEGUIDEDRIVER (Commerciallv available) 6.4 mm
(0.25 inl
_,1-r
*]-'
sz mm
l2.21inl
l r l
'11.3 mm (0.{,r in}
,_T-_
or VALVE GUIDE DRIVER, mm 6.6 0t9a:I- G5t01q) 2. t S e l e c tt h e p r o p e r r e p l a c e m e n g u i d e s .a n d c h i l l f t h e m i n t h e f r e e z e rs e c t i o n o f a r e f r i g e r a t o r o r aboutan hour. Use a hot plate or oven to evenlyheat the cylinder with Monitorthe temperature headto 300"F(150"C). Do a cookingthermometer. not get the head hofter heat may loosenthe excessive than 300'F (150"C); valveseaIs.
3.
t l f t h e m e a s u r e m e ne x c e e d s h e s e r v i c el i m i t , t recheck usinga new valve. 2. is lf the measurement now within the servicelimit, usinga new valve. reassemble the still the lf the measurement exceeds limit,subtract with a micrometer, O.D.of the valvestem,measured with an from the l.D. of the valve guide, measured or insidemicrometer ballgauge. a n T a k et h e m e a s u r e m e n tis t h r e e p l a c e s l o n g t h e valvestem and three placesinsidethe valveguide The difference betweenthe largestguide measures m e n t a n d t h e s m a l l e s s t e m m e a s u r e m e n th o u l d t not exceed servicelimit. the lntake Valve Stem-to-GuideClearance: Standard (New): 0.02- 0.05 mm {0.001 0.002in) mm (0.003in) ServiceLimit: 0.08 ExhaustValve Stem-to-GuideClearance: Standard(New):0.05- 0.08mm (0.002 0.003in) in) Limit: 0.11mm (0.004 Service
3.
CAUTION: To avoid burns, uss heavy gloves when handling the heated cylinder head.
(cont'd)
6-25
ValveGuides
(cont'dl Replacement
Workingfrom the camshaft side,use the driver and a n a i r h a m m e rt o d r i v et h e g u i d ea b o u t2 m m ( O . l i n ) t o w a r d s t h e c o m b u s t i o nc h a m b e r .T h i s w i l l k n o c ko f f s o m e o f t h e c a r b o na n d m a k e r e m o v a l easier. Hold the air hammerdirectlyin line with the valveguideto preventdamaging driver. the CAUTION: Always wear satety goggles or a face shield when driving valve guidss. 5. Turn the head over and drive the guide out toward the camshaft side of the head. 8. Apply a thin coat of cleanengineoil to the outside of the new valve guide. Installthe guide from the camshaftside of the head; use the specialtool to drive the guide in to the specified installed height.lf you have all 16 guidesto do, you mav have to reheat the head.
ATTACHMENT
Valve Guide Installed Height: Intake: 13.75 1i1.25 mm {0.5,[1- 0.561in) Exhaust: 15.75 16.25mm (0.620- 0.640inl
'o C' 6. li a valve guide won't move, drill it out with a 8.0 mm (5/16in) bit, then try again.Drittguidesonty in extremecases; you could damagethe cylinderhead if the guide breaks. Removethe new guide(s) from the freezer, one at a tlme, as you needthem.
7.
6-26
Head Cylinder
Reaming
NOTE:For new valveguidesonly. 1. Coatthe reamerand the valveguidewith cuttingoil. 2. Rotatethe reamer clockwisethe full length of the valveguide bore. C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e removingit from the bore. Thoroughlywash the guide in detergentand water to removeanYcuttingresidue. with a valve(seepage6-25). clearance Check
Warpage
(seepageG22) oil NOTE: lf camshaft-to-holder clearances head cannot be resurthe are not within specification, faced. are oil lf camshaft-to-holder clearances within specifications, checkthe head for warpage.Measurealong the the and threeways across center. edges, . if warpage is less than 0.05 mm (0.002in) cylinder is headresurfacing not required in) lf warpageis between0.05mm (0.002 and 0.2 mm (0.008 resurface cylinderhead. in), limit is 0.2 mm (0.008in) based Maximum resurface mm (5.20in). on a heightof 132.0
EDGE PRECISION STRAIGHT
3.
4.
5.
6 . Verifythat the valvesslidein the intakeand exhaust valveguideswithout exertingpressure.
REAMER HANDLE
mm REAMER,6.6 vALvE GUIDE 0798i1 657010O
Cylindr Hesd Height: mm Standard{New}:131.95 132.05 15.195 5.199inl
6-27
Valve Seats
Reconditioning
lf the guidesare worn (seepage6-25), replace them (see pagee25) beforereconditioning valveseats. the 1. Renewthe valve seatsin the cylinderhead using a valve seat cutter. 5. After resurfacingthe seat, inspect for even valve seating: Apply Prussian Bluecompoundto the valve face, and insertthe valve in its original locationin the head,then lift it and snap it closedagainstthe seatseveral times.
ACTUAL SEATING SURFACE
VALVE SEAT o
PRUSSIAN
C a r e f u l l yc u t a 4 5 os e a t , r e m o v i n g o n l y e n o u g h materialtoensurea smoothand concentric seat. Bevelthe upperedge of the seatwith the 30. cutter and the lower edge of the seatwith the 60" cutter. Check width of seatand adjustacco.dingly.
7.
The actualvalve seatingsurface,as shown by the bluecompound, shouldbe centered the seat. on . lf it is too high (closerto the valve stem), you must make a second cut with the 60" cutter to move it down, then one more cut with the 45" cutter to restore seat width. . lf it is too low (closer to the valve edge), you must make a second cut with the 30. cutter to move it up, then one more cut with the 45. cutter to restoreseat width. NOTE:The final cut shouldalwavsbe madewith the 45" cutter, Insert the intake and exhaust valves in the head, and measure valvestem installed heioht. Intake Vslve Siem Instslted Height: Standard {Newl: it0.765- 41.235mm inl 11.6049 1.6234 SarvicoLimit: itl.il85 mm (1.6333in) ExhaustValve Stem Installed H6ight: Standard {New}: 42.755- .235 mm .61137 1.7022 inl 11 /(|.,185mm (1.7120in) ServicoLimit:
Makeone more very light passwith the 45ocutterto removeany possibleburrs causedbv the other cutters. Valve Seat Width (lntake and Exhaust): Standard {N.w}: 1.25- 1.55mm (0.049- 0.051in) ServicaLimit: 2.0 mm (0.08in)
f-]
VALVESTEM INSTALLED HEIGHT
8.
lf valve stem installed height is over the service limit. replace the valve and recheck. it is still over lf t h e s e r v i c el i m i t . r e p l a c et h e c y l i n d e r h e a d ;t h e valveseatin the headis too deeo.
6-28
Valves,Valve Springsand Valve Seals

lnstallation
1.
Coatthe valve stemswith oil. Insertthe valvesinto the valveguides. Check that the valvesmove up and down smoothly. Install the springseatson the cylinderhead. tool. Install valvesealsusingthe special the NOTE:Exhaust and intakevalvesealsare not interchangeable. WHITE SPRING BLACK SPRING
Place the Installthe valvespring and valve retainer. end of the valve spring with closely wound coils towardthe cylinderhead, Compress the Installthe valve spring compressor. spring,and installthe valvekeepers.
VALVESPRING COMPRESSOR lComm6rciallyavailable) KD No. 383,with *35 JAw or
INTAKE VALVE SEAL
VALVESEAL EXHAUST
VALVEGUIDE SEALINSTALLER lCommerciallyavailable) KO3372 equivalnt or ot 07GAD- PH70100
VALVE SPRIT{G OOMPfi ESSOR ATTACHMENT 0775'- PJ1010A 7. Lightlytap the end of eachvalve stem two or three times with a plasticmalletto ensureproperseating of the valve and valve keepers,Tap the valve stem only along its axisso you do not bendthe stem.
PLASTE
6-29
CylinderHead
Installation
Installthecylinderheadin the reverse orderof removal: 1. 2. Clean the cylinderheadand blocksurfaces. Cleanthe oil controlorifice.Install cylinderhead the gasket, dowel pins and the oil controlorificeon the cylinderblock.Always use a new cylinderheadgasket. 4. Tightenthe cylinderhead bolts in two steps.In the first step tighten all bolts, in sequence, about 29 to N.m {3.0kgf.m,22 lbf.ft);in the finat step,tighten in the samesequence 85 N.m(8.7kgf.m,63 to lbf.ft). Usea beam-type torque wrench.When usinga preset-typetorque wrench, be sure to tighten slowly and do not overtighten. lf a bolt makesany noisewhile you are torquing it, loosenthe bolt, and retighten from the 1ststep. it CYLINDER HEADBOLTS TOROUE SEOUENCE:
CYLII{DER HEAD GASKET Rplace.
DOWELPIN
O.RING Roplace. DOWEL PIN
T i g h t e nt h e i n t a k em a n i f o l dm o u n t i n gb o l t s ( s e e page6-21).
OIL CONTBOL ORIFICE Clean.
Install the exhaustmanifoldbracket. and tightenthe new self-locking nuts (seepage6-20).
Apply clean engine oil to the bolt threads and under the bolt heads.
6 -30
7.
Placethe rockerarms on the pivots and the valve s t e m s .P u t t h e r o c k e ra r m s i n t h e i r o r i g i n a lp o s i lrons. then installthe oil sealswith lnstallthe camshafts, (spring) facing in. Make sure that the the open side are keyways the camshafts facingup and the No. on 1 pistonis at TDC.
'10. lnstallthe camshaft holders. NOTE: o " 1 " o r " E ' m a r k sa r e s t a m p e do n t h e c a m s h a f t holders. . T h e a r r o w s m a r k e d o n t h e c a m s h a f th o l d e r s shouldpoint at the timing belt.
't't, Tighten each bolt in two steps to ensure that the

rockers not bind on the valves. do Wipe off the excessliquid gasketfrom the No. 1 and No. 6 camshaftholderswith a shop towel, Specifiedtorque: 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft) Apply engine oil to the bolt ihreads.
Clean and dry the cylinder head mating surfaces. Apply liquid gasket (P/N 08718- 0001 or 08718of 0OO3) the head mating surfaces the No. 1 and to N o . 6 c a m s h a f th o l d e r s o n b o t h t h e i n t a k e a n d exhaust side.
I?,ITAKE
No. I
EXHAUST EXHAUST
II{TAKE
to Apply liquidgasket th shadedareas.
(cont'd)
6-31
Cylinder Head
(cont'dl Installation
' 1 3 .A l i g n t h e m a r k so n t h e c y l i n d e rh e a d p l u g t o t h e cylinder head upper surface,then installthe cylin d e r h e a dp l u gi n t h e e n d o f t h e c y l i n d e h e a d . r CYLINOER HEAD
PLUG Replace.
1 7 . Install timing belt (seepage6-11). the '18. Adjust (seepage6-3). the valveclearance 1 9 . T h o r o u g h l y l e a nt h e h e a d c o v e r g a s k e ta n d t h e c groove. lnstall the head cover gasket in the groove of the cylinderhead cover. Seatthe head cover gasketin the recesses the camshaft for first, then work it into the groovearoundthe outsideedges.Makesurethe head cover gasket is seated securely in the corners of the recesses with no gap.
1 4 . lnstallthebackcover.
To set the camshafts TDC positionfor the No. l at p i s t o n ,a l i g n t h e h o l e s i n t h e c a m s h a f t s i t h t h e w holes in the No. l camshaftholdersand insert 5.0 mm pin punchesin the holes.Installthe keys into grooves. the camshaft
KEYS
I x 1.25mm 37 N m (3.8*gl.m, 27 lbt.tr) 6x1.0mm
9.8N.m(1.0 kgtm, 7.2|hrftl Pushthe camshaft pulleysonto the camshafts. then tightenthe retaining boltsto the torquespecified.
6-32
are 2 1 . Check that the matingsurfaces cleanand dry. part No. 08718- 0001or 08718 2 2 . Apply liquid gasket, - 0003,to the headcovergasketat the eight corners of the recesses. NOTE: . Do not installthe parts if five minutesor more h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t . Instead, reapplyliquid gasketafter removingold residue. . After assembly. wait at least 30 minutes before filling the enginewith oil.
25. Tightenthe nuts in tvvo or three steps.In the final to step, tighten all nuts, in sequence. 9.8 N.m (1.0 kgf.m,7.2 lbf.ft).
gasket liquid to Apply areas. theshaded
26. C h e c kt h a t a l l t u b e s , h o s e s a n d c o n n e c t o r sa r e
installedcorrectly.
23. Holdthe headcovergasketin the grooveby placing

your fingerson the camshaftholdercontacting surfaces(top of the semicirclesl. O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r head, slide the cover slightly back and forth to seat the headcovergasket. Replace any washerthat 24. Inspect coverwashers. the is damaged or dete(iorated.
6-33
En g i n eB loc k
Tools .............7-2 CylinderBlock Speciaf lllustrated lndex ................................... 7-3 Inspection ..............7-13 Flywheeland Drive Plate PistonPins Replacement ..,.,....7-5 Removal ..,.......,,..... 7-14 Connecting Rod and Grankshaft Installation ............. 7-15 E n dP l a y . . . . . . . . . . . . . . . . . 7 - 6 Inspection .............. 7-16 MainBearings ConnectingRods -7 -14 Cfearance ...............7 Selection ................7 ................7-8 PistonRings Selection -17 Rod Bearings Connecting End Gap .................7 Clearance ...............7-8 Ring-to-Groove Clearance ............... 7 -17 ................7-9 Replacement .........7-18 Selection Pistons and Crankshaft Alignment .............. 7-18 Removal .................7-9 Crankshaft Seal Oil Crankshaft lnstallation ............. 7-19 Inspection .............. 7-11 Crankshaft Pistons lnstalfation .............7-20 fnspection ..............7-12 Oil Seals fnstaflation .............7-20 fnstalfation ....,..,.....7-23
Tools Special
tl
Ref, No.
Tool Numbor 07GAF PH60300 07HAF P120102 07LAB PV00100 07LAD- PT30101 07LAF PR30100 - S800101 07948 07749 0010000 07973 PE00310 07973 PE00320 07973- 6570500 07973- 6570600
Description PistonPin Baselnsert PistonBaseHead RingGearHolder SealDriver PilotCollar SealDriverAttachment. x 80 mm 76 Driver PistonPin DriverShaft PistonPin DriverHead Piston Base PistonBaseSpring
Oty
,l 1 I I 1 1 1 1 1 1 1
PageReterence 7-14,15 1-'t4,15 1-5 1-23 7-14,15 7-'t9,24 7 -'t9, 24 1-14,15 7-14,15 7-'t4,15 7-14,15
o
@ @
/6
@ @ @ @
e E
E g
0
o
@
7-2
lllustratedlndex
Luori""t" "tl internalpartswith engineoil during reassembly.
Applyliquidgasket the matingsurfaces the right side coverand oil pump casebeforeinstalling to of them. Jse liquidgasket, PartNo. 08718 0001or 08718 0003. :lean the oil pan gasketmatingsurfaces beforeinstalling oil pan. the
WASHER Replace.
76 x 1.0 mm
y'
9
t:n-
l.zxstm, 8.7lblftl
oIL PAN
to page1-22 when installing OIL PAN GASKET Replace. 1 1 x1 . 5 m m 76 N.m {7.8kgl.m, 56 lbf.ft} Appiyengineoilto the bolt threaos. NOTE:Afterlorquing eachcap,turn the crankshaft for to check binding. BEARING CAP OOWEL PIN
6x1.0mm 9,8N.m (1,0kgf.m, 7.2 tbt.lrl BAFFI.f PLATE MAIN BEARINGS page7 8 Selection, NOTE:New main bearings must be selected matching crank by the and blockidentification markings.
n
ln
otL m 6 x'1.0 m
9.8 N.m {1.0kgtm, 7.2 tbf.ftl GASKET Replace. OIL PUMP page8-8 Overhaul, Removal/lnspection, page8-9 Applyliquidgasket to mating surface. 8 x 1.25mm 6x1.0mm 9.8N.m 11.0 m, kgt
CRANKSHAFT SEAL OIL Installation, page7-19 1 2x 1 . 0m m Replace. . / , 7 1 N n 1 75 ks{ m 5a lbtft) {a/Tl &it
7.2tbt+tl
6
RIGHTSIDECOVER Apply liquidgasket to matingsurface, O.RING Replace. THRUST WASHERS Groovedsides face outlvard, NOTE:Thrustwasherthickness is lixed and must not be changed by grindingor shimming.
WASHERIA/T}
2a N.m(2.akgt.m,---\6/
ORIVE PLATEIA/T) Check cracks. for 6x1.0mm 9.8 N.m 11.0 kgt.m,7.2lbtft)
CRANIGHAFT SEAL page8-10 Installation, Replace-
6x1.0mm 9.8 N.m l'1.0kgf.m,7.2 lbf.ft)
(cont'd)
7-3
lllustratedIndex(cont'd)
markings identification and crankshaft rod assembly by NOTE:New rod bearingsmust be selected matchingconnecting (seepages7-91. DIRECTION: INSTALLANON PISTON partswith engineoil all Lubricate internal EXHAUST during reassembly.
\9q9Q9e/
INTAKE PISTON PIN page7-14 Removal, page7-15 Installation, Inspection.page7-16 PISTONRINGS page 7-18 Replacement. page7-17 Measurdment, page7-18 Alignmnt,
l1\AAtr\
PISTON page7-12 Inspection,
ENGINCBLOCK Cylinderbore inspection.pago 7-13 Warpage inspoction,Page7-'13 CONNECTING End play, page 7-6 page7-14 Selection,
COiINECI'ING ROD BEARINGS page 7-8 Clearance, Solection.page7-9
RODBEARING CAP CONNECTING page7-20 lnstallation, the NOTE:Install capsso the is bearingrecess on the samesideasthe recess in the rod. RODCAPNUT CONNECTING 8 x 0.75mm 31 N.m {3.2kgl.m. 23 tbf.ftl
Apply engine oil to the bolt threads.
Inspectthe top ot each cylinder bore for carbonbuild up or a ridge the beloreremoving piston. page7-10 Remove ridgeif necessary, the
NOTE:Aftertorquingeachbearing for the to cap,rotate crankshaft check binding.
7-4
Flywheeland Drive Plate

Replacement
ManualTransmission:
the flyRemovethe eight flywheelbolts,then separate flange. After installation, tightwheelfrom the crankshaft shown. en the bolts in the sequence
ENGINE BLOCK 12 x 1.0mm 103 N.m 110.5 kgf.m, 76 lbf.ft)
RINGGEAR Inspect ring gear teethfor wear or damage,
RI G GEARHOTDER 07LAB - PV001|X)
Automatic Transmission:
Removethe eight drive plate bolts, then separatethe flange.After installation, drive platefrom the crankshaft shown. tightenthe bolts in the sequence
/ AzXi{'jA\Ao
12 x 1.0mm 7a N.m (7.5 kgt.m,5a lbf.ftl
7-5,
Rod and Crankshaft Connecting

EndPlay
1. Measurethe connectingrod end play with a feeler gauge. ConnectingRod End Play: Stsndard(Nsw):0.15- 0.30mm {0.006 0.012in) in) Limit: 0./t0mm 10.016 Service 3. firmly away from the dial indiPushthe crankshaft c a t o r ,a n d z e r o t h e d i a l a g a i n s t h e e n d o f t h e t c r a n k s h a f tT h e n p u l l t h e c r a n k s h a f f i r m l y b a c k . t o w a r d t h e i n d i c a t o rt;h e d i a l r e a d i n gs h o u l d n o t limit. exceed service the
SCREWORIVER
2.
lf the connectingrod end play is out-of-tolerance, installa new connecting rod. lf it is still out-of-tolerance, replacethe crankshaft {seepages7-9 and 7-20).
CrankshaftEnd Play: Stand.rd (New):0.10- 0,35mm (0.004 0.014inl 0.45mm (0.018 inl Service Limit: 4. inspectthe thrust washers lf end play is excessive, Reolace and thrustsurface the crankshaft. on oans as n e c e s s a r yT h r u s t w a s h e r t h i c k n e s si s f i x e d a n d . m u s t n o t b e c h a n g e de i t h e rb y g r i n d i n go r s h i m mrng.
7-6
MainBearings
Clearance
1 . T o c h e c k m a i n b e a r i n g - t o - j o u r n a li l c l e a r a n c e , o
removethe main capsand bearinghalves. 2. C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l f w i t h a cleanshoptowel. Place strip of plastigage a acrosseachmain journal. NOTE:lf the engineis still in the vehiclewhen you b o l t t h e m a i n c a p d o w n t o c h e c kc l e a r a n c et,h e weight of the crankshaftand flywheel will flatten the plastigagefurther than just the torque on the cap bolt, and give you an incorrectreading.For an a c c u r a l er e a d i n g ,s u p p o r t t h e c r a n k w i t h a j a c k underthe counterweights checkonly one bearand I n ga I a I r m e .
4.
3.
lf the plastigage measures too wide or too narrow, ( r e m o v et h e e n g i n e i f i t ' s s t i l l i n t h e v e h i c l e ) , removethe crankshaft, and removethe upper half of the bearing.Installa new, completebearingwith the same color code (select the color as shown on the next page).and recheckthe clearance, not Do f i l e , s h i m , o r s c r a p et h e b e a r i n g so r t h e c a p s t o adjustthe clearance. 7. lf the plastjgage shows the clearance still incoris rect,try the ne)dlargeror smallerbearing{the color listedabove or below that one),and checkagain.lf the proper clearance cannot be obtained by using the appropriate larger or smaller bearings,replace the crankshaft and startover.
R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e bolts, 1st step:25 N'm (2.5kgf.m,18lbf.ft) Final siep: 76 N'm 17.8 kgl.m, 56 lbf.ftl NOTE:Do not rotatethe crankshaft during inspectron. R e m o v e h e b e a r i n gc a p a g a i n ,a n d m e a s u r e h e t t widestpart of the plastigage. Main Bearing.to.JournalOil Clearance: Stand8.d {New): N o .1 , 2 , 4 , 5 J o u r n s l s : 0.02i1- 0.0i12 mm (0.0009 0.0017inl No. 3 Journal: 0.030 0.0i18 mm (0.0012 0.0019 inl ServiceLimit: 0.06 mm 10.002 in)
7-7
Main Bearings
Selection
Crankshaft Bore Code Location
Lettershave been stamDed the end of the blockas a on codeJorthe sizeof eachof the 5 main journalbores. U s e t h e m , a n d t h e n u m b e r so r b a r s s t a m p e do n t h e for crank(codes main journalsize), choosethe correct to beanngs. lf the codesare indecipherable because an accumulaof t i o n o f d i r t a n d d u s t . d o n o t s c r u bt h e m w i t h a w i r e brush or sc.aper. Cleanthem only with solventor detergent.
Rod Bearings Connecting

Clearance
1.
Remove connecting cap and bearinghalf. the rod Cleanthe crankshaftrod journal and bearing half with a cleanshop towel. Place plastigage the across the rod journal. Reinstall the bearing half and cap, and torque the nuts. Torqus: 31 N.m (3.2 kgf.m. 23 lbf.ft) NOTE:Do not rotatethe crankshaft during inspection. Remove the rod cap and bearinghalf,and measure the widestpart of the plastigage. ConnestingRod Bearing-to-JournalOil Clearancc: Standard {Newl: 0.020- 0.038mm {0.0008 0.0015in) ServiceLimit: 0.05 mm {0.002inl
PLASTIGAGE
Main Journ.l Cod. Locrtions lNumbcB oi Bar3l
Bearing ld.ntif icrtion Color code is on the edge of the bearing. I
lf the plastigage measures too wide or too narrow, removethe upper half of the bearing,installa new. completebearingwith the same color code {select the color as shown on the next page),and recheck Do the clearance. not file, shim, or sc.apethe bearings or the capsto adjustthe clearance. 7. is lf the plastigage shows the clearance still incor rect,try the next largeror smallerbearing{thecolor listed above or below that one). and check clearc a n c e a g a i n .l f t h e p r o p e rc l e a r a n c e a n n o t b e obtainedby usingthe appropriate largeror smaller bearings. replace crankshaft startover. the and
""""""""
Smallerbearing(rhicker)
Green Green
Elacl
Alue
7- 8
Pistonsand Crankshaft
Selection
Connecting Rod Code Location
Numbershave been stampedon the side of each connectingrod as a code for the size of the big end. Use (codes lhem, and the lettersstampedon the crankshaft for rod journalsize), choosethe correctbearings. to lf the codesare indeciDherable because an accumulaof t i o n o f d i r t a n d d u s t ,d o n o t s c r u bt h e m w i t h a w i r e brushor scraper. Cleanthem only with solventor detergent.
Half of numberis stampedon beanng cap and the othel half is stampedon rod.
Removal
1.
Remove oil pan assembly. the Remove right sidecover. the
Remove oil screen. the Remove oil pump. the Connecting Rod Journal Code Locations {Lettersl
OIL SCREEN
8aring ldentif ication

aolor code is on the edge ol tne Deanng. ---------------r. Larger big end bore
OIL PUMP
sma er bearino {thicker)
l l A o r tl l l l B o ' l l l l l c o t r l ll l
Red Pink
Pink Green Green Brown

Brown Elack
Green Brown Black Blue
5.
Remove baffleplate. the
t - l
I l-.. ilril I
Smaller beanng (thicker)
Green
Smaller 'od
(cont'd)
7-9
Pistonsand Crankshaft
(cont'dl Removal
6. unscrew the the bolts.To preventwarpage, Remove b o l t s i n s e q u e n c e1 / 3 t u r n a t a t i m e ; r e p e a tt h e sequence until all boltsare loosened. 9 . Remove upper bearinghalvesfrom the connecting the caps. rods,and set them asidewith their respective the 1 0 . Reinstall main caps and bearingson the engine in properorder.
1 1 . lf you can feel a ridge of metalor hard carbon
around the top of each cvlinder,remove it with a r i d g e r e a m e r .F o l l o w t h e r e a m e rm a n u f a c t u r e r ' s i n s t r u c t i o n sl.f t h e r i d g e i s n o t r e m o v e d ,i t m a y damagethe pistonsas they 8re pushedout.
7.
and Removethe rod caps/bearings main caps/bearin ings,Keepall caps/bearings order Lift the crankshaft out of the engine.being careful not to damagethe journals.
12. Use the wooden handle of a hammer to drive the

pistonsout.
rod and capsafter 1 3 . Reinstall connecting bearings the rod removingeachpiston/connecting assembly. mark each piston/ 1 4 . To avoid mixup on reassembly, with its cylindernumber. rod connecting assembly rod NOTE:The existingnumber on the connecting does not indicateits positionin the engine,it indicatesthe rod bore size.
7-10
Crankshaft
Inspection
1. Clean the crankshaft passages oil with pipe cleaners or a suitablebrush. Check keywayand threads. the Out-of-Roundand TaDer 4. 2. Measure out-of-round the middleof each rod and at main journal in two places. The difference between m e a s u r e m e n to n e a c hl o u r n a lm u s t n o t b e m o r e s than the servicelimit. JournalOut-of-Round: Standard(Newl:0.005 mm 10.0002 max. inl Service Limit: 0.010mm (0.000i1in)
Alignment 3. M e a s u r e h e r u n o u to n a l l m a i n j o u r n a l st o m a k e t sure the crank is not bent. The difference between m e a s u r e m e n to n e a c hj o u r n a lm u s t n o t b e m o r e s thanthe servicelimit. CrankshaftTotal IndicatedRunout: StandardlNew):0.03mm (0.001 max. in) ServiceLimit: 0.04 mm {0.002in)
Measureout-ol' roundat middle. DIAL INDICATOR Rotate two complete revolut|ons.
Measuretaper at edges.
Suppon with lathelype tool or V-blocks.
5.
Measuretaper at the edges of each rod and main journal.The differencebetweenmeasurements on e a c h i o u r n a lm u s t n o t b e m o r e t h a n t h e s e r v i c e limit. JournalTaperi Standard{Newl:0.005mm 10.0002 max. inl Service Limit: 0.010mm (0.0004 inl
7-11
Pistons
Inspection
L
Check eachpistonfor distortion cracks. or A Measure the pistondiameterat distance from the bottom of the skirt. A: '97 - 98 models15 mm 10.5 inl '99 - 00 models 20 mm 10.8inl Piston Diameter: Standard (New): 8:1.980 txl.990mm (3.3063 3.3067inl Limit: 83.970mm {3.3059inl Service
3.
the differencebetweenthe cylinder bore Calculate (seepage7-13)and the pistondiameter. diameter Clearance: Piston-to-Cylinder Standard{New):0.010- 0.040mm inl {0.0004 0.0016 Limit: 0.05 mm {0.002in} Service
SKIRTDIAMETER
lf the clearance near or exceeds is the servicelimit, inspectthe piston and cylinderblock for excessive wear.
7-12
CylinderBlock
Inspection
Measure earand taperin directions and Y at w X three levelsin eachcylinder. the measurements lf in any cylinderare beyond the ServiceLimjt, replace the block. 2. the Check top of the blockfor warpage. Measurealong the edgesand acrossthe centeras shown.
SURFACES BE MEASURED TO
Engine Block Warpage: Standard(New):0.07 mm (0.003 max. in) Service Limit: 0.10mm {0.004 inl
PRECISION STRAIGHT EDGE
Cvlinder Bole Size: Standard {Newl:84.00 84.02mm {3.307 3.308inl Limit: 84,07mm (3.310 Service inl Bore TaDer: Limit: {Difterencebetween first and third measurement) 0.05mm {0.002 in)
7-13
PistonPins
Removal
1 . Assemble the Piston Pin Tools as shown.
PISTONBASEHEAO 07HAF -PL20102 PISTON PIN BASEINSERT 07GAF- PH60300
ConnectingRods
Selection
Eachrod falls into one of four toleranceranges(from 0 to + 0.024mm {0 to + 0.0009 in 0.006mm (0.0002 in). in) increments) dependingon the size of its big end bore. lt's then stampedwith a number 1.1.2,3, 4) indicating or the range. You may find any combination t 1,2,3, or 4 in any o engrne. Normal Bore Size:,18.0 mm (1.89in) Inspect connecting for cracks the rod and heatdamage.
PISTONBASE 07973- 6570500
CONNECTING ROD BORE REFENENCE NUMBER Half of numberis stampedon bearingcap, the other half on connectno roo.
Adjustthe lengthA of the pistonpin dflver. A: 49.70mm 11.957 in)

PISTON PINDRIVER HEAI 07973- PE00320
R Ir1
nT--u ffi-"""u_ll
PISTON PIN DRIVER SHAFT 07973- PEt0310
PILOTCOLLAR 07LAF- PR30100 Embossod markfacingup.
3.
Placethe piston on the piston base,and pressthe pin out with a hydraulicpress.Make sure that the portion of the piston aligns with the lips recessed o n t h ec o l l a r .
7-14
PistonPins
lnstallation
The arrow must face the timing belt sideot the engineandthe connecting rod oil hole must face the rearof the engine. ROO CONNECTING
otL Hor.E Adjust the length B of the piston pin driver and shaft. B: 49.70mm (1.957 in)
1.
PISTONPIN DRIVERSHAFT 0t973 - Pqxtlo
ffi*r,"ron'nl
PILOT COLLAR OTLAF PF3O1(x' PISTONPIN BASEINSERT 07GAF- PH6o3ttO PISTONBASE HEAD OTHAF PL2O102 PISTON BASE 07973 - 6670500
Placethe piston on the piston base and pressthe pin in with a hydraulic press. Make sure that the recessedportion of the piston alignswith the lugs on the pistonbasehead.
7-15
PistonPins
Inspection
1.
lMeasurethe diameter of the piston pin. Piston Pin Diameter: Standard lNewl: 20.996- 21.000 mm
3.
lf M e a s u r e h e p i s t o np i n t o p i s t o nc l e a r a n c e . t h e t p i s t o n p i n c l e a r a n c es g r e a t e rt h a n 0 . 0 2 4m m i (0.0009 remeasure pistonpin. usingan oversized inL pistonpins are oversize. NOIE: All replacement Piston Pin-to-PistonClearance: StandardlNewl: 0.010 0.017mm in) 10.0004 0.0007
Oversize:
{0.8266 0.8268in} - 21.002 20.998 mm (0.8267 0.8268in)
4.
2.
Zeto the dial indicator the pistonpin diameter. to
the pistonpin diamebetlveen Checkthe difference rod ter and the connecting smallend diameter. Rod Interference: Piston Pin-to-Connecting Standard(New):0.015 0.032mm (0.0006 0.0013 inl
7-16
PistonRings
EndGap
1.
Glearance Ring-to-Groove
After installinga new set of rings, measurethe ring-togrooveclearances: Top Ring Clearance: Standard {New}: 0.055- 0.080mm inl 10.0022 0.0031 inl Service Limit: 0.13 mm 10,005 Second Ring Clearance: Standard{Newl:0.035 0.060mm inl {0.001'l 0.0024 inl Service Limit: 0,13 mm 10.005
U s i n ga p i s t o n ,p u s h a n e w r i n g i n t o t h e c y l i n d e r bore 15 - 20 mm (0.6 0.8 in) from the bottom t M e a s u r e h e p i s t o nr i n g e n d - g a pw i t h a f e e l e r g au g e : . lf the gap is too small,checkto see if you have the properringsfor your engine. the . lf the gap is too large,recheck cylinderbore '13. the diameter against wear limits on page7 PistonRingEnd-Gap: Top Ring Standard(Newl:0.20 0.30mm 10.008 0.012inl ServiceLimit: 0.60 mm {0.024inl SecondRing Standard lNew): 0.i10 0.55 mm {0.016 0.022inl in) Limit: 0.70mm (0.028 Service Oil Ring Standard(Newl:0.20- 0.50mm 10.008 0.020in) ServiceLimit: 0.70 mm (0.028in)
2.
PISTONRING
--:4
ll ENDGAP-1f-
7-17
PistonRings
Replacement
1 . Usinga ring expander, removethe old pistonrings. 2. C l e a n a l l t h e r i n g g r o o v e st h o r o u g h l yw i t h a squared-offbroken ring or a ring gtoove cleaner with a bladeto fit the pistongrooves. The top ring groove is 1.2 mm (0.042in) wide, rhe secondring groove is 1.2 mm (0.042in) wide, and t h e o i l r i n g g r o o v e i s 2 . 8 m m ( 0 . 1 1i n ) w i d e . F i l e down a bladeif necessary. Do not use a wire brush to clean ring lands,or cut ring landsdeeperwith cleaning tool. 3. I n s t a l lt h e n e w r i n g s i n t h e p r o p e rs e q u e n c e n d a position(shownin the right column). NOTE: lfthe pistonis to be separated from the connectingrod, do not installnew ringsyet.
'99 - O0modls:
Alignment
l. Installtheringsas shown.
TOP RING
'97 - 98 models:
l-;
Piston Ring Dimensions:
RING EXPANDER
|k
T f
' 1 A Top Ring {standard}: A: 3.1 mm (0.12in) B: 1.2mm 10.05 inl SecondRing (standard): A: 3.'1 mm (0.f 3 in) B: 1.2mm (0.05in) N O T E :T h e m a n u f a c t u r i n g a r k s m u s t b e t a c i n g m upward.
+-
MARK
ropnrNG+S
SECOND RING+
z:-\
,A-\
o**ô(
ffi+-sPAcER \zu-\
7-18
Oil Crankshaft Seal

lnstallation
Rotatethe rings in their groovesto make sure they do not bind. the Position ring end gaps as shownl
1.
on The sealmatingsurface the blockshouldbe dry and to the Apply a light coat of oil to the crankshaft l i p o f t h es e a l . oil Drivethe crankshaft seal squarelyinto the right sroecover.
DRIVER
RINGGAP SECOND
any ring gap DO NOTposition at piston thrust surfaces,
Appror.90"
Appror. 90' TOP RI.IIG GAP DO NOT position any ring gap in linewith the pistonpin hole.
OIL RING GAP SPACER GAP OIL RINGGAP sealwith the lnstall part numberside facingout.
is Confirm thatthe clearance equalall the way around with a feelergauge. Clearance:0.5 0.8 mm {0.02 0.03inl
0.5-0.8 mm
{O.02 0.03 in)
NOTE| Referto pages7 23 and 8-10for installation oil of the oil oumDsidecrankshait seal.
7-19
Pistons
Installation
1. Apply a coat of engine oil to the ring groovesand cylinderbores.
Crankshaft
Installation
1.
Apply a coat of engineoil to the main bearingsand rod bearings. I n s e r t h e b e a r i n g a l v e s n t h e c y l i n d e r l o c ka n d h i b connect|ng rods.
It the crankshaft alreadyinstalled. is 2. Setthe crankshatt BDCfor eachcylinder. to 3. Remove connecting caps,and slip shortsec the rod tions of rubber hose over the threadedends of the connecting bolts. rod 4. lnstallthe ring compressor, checkthat the bearand angis securely place. in 5. Position pistonin the cylinder, the and tap it in using t h e w o o d e nh a n d l eo f a h a m m e r .M a i n t a i nd o w n ward force on the ring compressor preventrings to trom expanding beforeentering the cylinderbore. 6. Stop afterthe ring compressor pops free,and check t h e c o n n e c t i n g o d - t o - c r a n jk u r n a la l i g n m e n t o r beforepushingpistoninto place. 7. Installthe rod caps with bearings,and torque the
NUISIO:
3.
Holdthe crankshaft the rod journalsfor cylinders so N o . 2 a n d N o .3 a r es t r a i g hd o w n . t Lowerthe crankshaft into the block,seatingthe rod j o u r n a l si n t o c o n n e c t i n g o d s N o . 2 a n d N o . 3 . r Install the rod capsand nutsfinger tight.
4.
31 N.m (3.2kgf.m,23tbf.ft) Apply engineoil to the bolt threads. lf the crankshaft is not installed: 2. Removethe rod caps and bearings, and installthe flng compressor. 3 . P o s i t i o nt h e p i s t o n i n t h e c y l i n d e r ,a n d t a p i t i n u s i n gt h e w o o d e n h a n d l eo f a h a m m e r .M a i n t a i n downwardforce on the ring compressor prevent to rings from expandingbefore enteringthe cylinder oore, 4. Position the pistonsat top deadcenter. all
The arrow must face the timing belt side of the engine.
5.
outward. Rotatethe crankshaft clockwise, and seat the jour n a l s i n t o c o n n e c t i n go d s N o . 1 a n d N o . 4 , I n s t a l l r the rod caps and nuts finger-tight. Installthe caps s o t h e b e a r i n gr e c e s s s o n t h e s a m e s i d e a s t h e i recess the rod. an C h e c kt h e r o d b e a r i n gc l e a r a n c e i t h p l a s t i g a g e w (seepage7 8). then lorque the capnuts. Torque: 3l N.m 13.2kgf.m, 23 lbt.ftl Apply engine oil to the bolt thleads.
6.
CONNECTING ROO OIL HOLE
7.
I n s t a ltl h e t h r u s tw a s h e r s n t h e N o . 4 j o u r n a l . o
RUBBERHOSES
Line up the mark when

installing connecting rod cap.
\\
7 -20
Coat the thrust washer surtacesand bolt threads with oil. Installthemain bearingcaps. (seepage7-7),then with plastigage clearance Check in 2 steps. tightenthe bearingcap bolts 25 N.m {2.5 kgf'm, 18 lbf'ft} First slsp: Sscond step: 76 N'm (7.8 kgf'm. 56 lbf'ft) SEOUENCE TIGHTENING CAPBOLTS MAIN BEARING
1 0 . Cleanand dry the right sidecover matingsurfaces. 1 1 , Apply liquid gasket,part No. 08718- 0001or 08718 - 0003,evenly to the block mating surfaceof the right side cover and to the innerthreadsof the bolt holes.Installit on the cylindrblock
RIGHTSIDE
rod or NOTE:Wheneverany crankshaft connecting after reassembly it bearingis replaced, is necessary t o r u n t h e e n g i n ea t i d l i n g s p e e du n t i l i t r e a c h e s then continueto run temperature, normaloperating 15 minutes. it for approximatelY
6x1.0mm 9.EN.m {1.0 kgt m, 7.2 tbf.ft) PINS OOWEL
NOTE: . Do not install the parts if five minutes or more h a v e e l a p s e ds i n c ea p p l y i n gt h e l i q u i d g a s k e t . Instead, reapplyliquid gasketafter removingthe old residue. . After assembly, wait at least 30 minutes before w f i l l i n g h ee n g i n e i t ho i l . t
(cont'dl
7-21
Crankshaft
1 2 . Apply liquid gasketto the oil pump mating surface of the block. 1 3 . Apply a light coat of oil to the crankshaft, lip of the the seal,and the O-rings.
1 4 . Apply grease the lips of the oil seals. to
1 6 . Apply liquid gasketon the oil pump and right side covermatrngareas. CYLINDER BLOCK
Apply liquid gasket to these pornts,
Align the innerrotor with the crankshaft, then install the oil pump.When the pump is in place,cleanany grease the crankshaft, excess off then checkthat the oil seallips are not distoned.
gsket Applyliquid to thesepornts. 17. Installthe oil pan gasketand oil pan. Wait no than five minutesafterapplyingliquidgasket.
6x1,0mm 9.8 N.m {1.0 kg{.m, ,.2 tbf.ftl
OILPAN
{ ^
I
/
(..6
"[z
I
7.2lbt.trl
GASKET
Replace.
6x1.0mm 9,8 N.m 11.0 kg{.m,
DowEL PtN //
,'t
./o,
|
8 x 1.25mm 24 N.m {2.4 kgf.m, 17 tbt.ftl
OIL PAN
O-RING Replace.
GASKET Replace.
OIL PUMP
7 -22
Oil Seals
lnstallation
18. Tightenthe boltsand nutsfingertight at six points.
1.
oil Dry the crankshaft sealhousing. and to to Apply a light coat of grease the crankshsft the lips of the seals. tool, drive in the timing pulley-end Usingthe special the sealuntilthe driverbottomsagainst oil pump. When the seal is in place,clean any excessgrease and checkthat the oil seal lip is off the crankshaft not distorted,
SEALDRIVER OTLAD PT3O1OA lnstallsealwiththe partsnumberside facingout.
1 9 . Tighten all bolts and nuts, startingfrom nut O. clocktighteningcan cause wise in three steps.Excessive and oil leakage. distortion the oil pangasket ot Torque: 12 N.m (1.2 kgt.m,8.7 lbtft)
(cont'd)
7-23
Oil Seals
4. l/easurethe flywheel-end sealthickness and the oil seal housingdepth.Usingthe special tool, drive the flywheel end seal into the rear cover to the point where the clearance betweenthe bottom of the oil seal and the right side cover is 0.5 - 0.8 mm (0.020.03in) (seepage 7-19). Align the hole in the driver attachment with the pin on the crankshaft.
<:
DRIVER ATTACHMENT 76x80mm 07948- 5800101 I n s t a ls e a l w i t h h e l t n u m b e r i d ef a c i n g s out,
7 -24
EngineLubrication
...".""'8-2 S p e c i aT o o l s . . . . . . . . . . f .'...8-3 I l l l u s t r a t e dn d e x. . . . . . . . . . . O Engine il . . . . . . . . . . . . ' . . ' . .8 -.4 ' .' . Inspection . . .. R e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . ' 8.- 4. . . . . . . OilFilter R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . .8.-.5 . . . . . . . . . . . . Oil PressureSwitch ".....8-7 Testing Oil Pressure ....'.'8-7 Testing OilPump . . . . . . . . . . . , . . . .8 . . . . .-8 Overhaul..... ....'.' Removal/lnspection/lnstallation 8-9
Special Tools
Ret. No.
I
I
Tool Number OTLAD_ PT3O1OA 0 7 9 ' 1-2 6 1 1 0 0 0 1
Description SealDriver Oil FilterWrench
Oty 1 1
Pagc Roforance 8-10 8-6
8-2
lllustratedIndex
OIL CONTROL ORIFICE
'--
\
\ ,/
/o-RrNG
Reptace.
\^
OILPUMP page8-8 Overhaul, page Removal/lnspection, 8 I to Apply liquidgasket matingsurface engineblock. of O-RING
v,/
./
'99 - 00 models: KNOCKSENSOR 31 N.m {3.2 kgf.m.23 lbl.ft)
ENGINEOIL PRESSURE SWITCH 18 N.m {1.8kgtm, 13lbl.ft) (British Standard 1/8in. BSPT PipeTaper) Threads/inch. 28 Useproperliquidsealant.
DOWELPIN 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbl.ft)
8 x 1.25mm 24 N.m 12.4kgf.m, 17 tbf.ft)
PLATE BAFFLE
6x1.0mm 9.8 N.rn{1.0kgtm,7.2 lbtftl
Replace.
OIL PAN GASKET Replace.
6x1.0mm kgf 9.8 N.m 11.0 m, 7.2 tbf.ftl SCREEN
OILPAN Befertopage7 22 w h e ni n s t a l l i n g .
WASHEB Replace.
6x1.0mm kglm,8.7 lblftl 12 N.m 11.2
DRAINBOLT kgf'm,33lbf ft) 4,1N.m {,1.5 Do not overtighten.
8-3
Engine Oil
Inspection
1 . Parkthe vehicle on level ground, and turn off the e n g i n e . l l o w t h e o i l a f e w m i n u t e st o d r a i n b a c k A into the oil pan so the dipstickwill show the actual levet, 2. Make certainthat the oil level indicated the dipon stick is betweenthe upper and lower marks.Insert the dipstick carefully avoid bendingit. to l f t h e l e v e l h a s d r o p p e dc l o s et o t h e l o w e r m a r k , add oil until it reaches uppermark. the
Replacement
CAUTION:Removethe drain plug caretuly white the engino is hot; the hot oil may causescalding. 1 . W a r mu p t h e e n g i n e . 2. D r a i n h ee n g i n e i l . t o
ORAINBOL 4il N.m {4.5kgtm,33 lbf.ft) Do not overtighten.
WASHER Rplace.
3.
Reinstall drain bolt with a new washer,and refill the with the recommended oil. Requirement API Service Grade:Use "Energy " Conserving SJ or "Energy Conserving SH gradeoil. SAE ll" 5W - 30 preferred: You can also usean oil that bearsthe API CERTIFICATION mark. Capacity 3 . 5{ ( 3 . 7U S q t , 3 . 1l m p q t ) at oil change. 3 . 8/ ( 4 . 0U S q t , 3 . 3l m p q r ) at oil changeincluding filter. 4.6{ (4.9US qt, 4.0 lmp qt) afterengineoverhaul. Every7,500miles(12,000 or km) 12 months(Normalconditions) Every3,750miles(6,000 km) or 6 months(Severe conditions).
Change Inlerval
N O T E : U n d e r n o r m a l c o n d i t i o n s t, h e o i l f i l t e r shouldbe replaced everyother oil change.Under at severeconditions, the oil filter should be replaced a t e a c ho i l c h a n g e .
8-4
Oil Filter
Replacement
The numbersin the middle of the API Servicelabeltell you the oil's SAE viscosityor weighl. Selectthe oil for your vehicleaccording this chart: to
AmbientTemperature
CAUTION: After the engine has been tun, ths exhaust pipes will be hot; be carelul when working around the exhaust manitold. 1 . R e m o v et h e o i l f i l t e r w i t h t h e s p e c i a lo i l f i l t e r wrench. lnsoect threadsand rubbersealon the new filter. the Wipe off the seaton the engine block,then apply a light coatof oil to the filter rubberseal.
1 0 0F -30 -20 -10
40c
system. NOTE:Useonly filterswith a built-inbypass
Inspect threads and
A n o i l w i t h a v i s c o s i t yo f 5 W - 3 0 i s p r e f e r r e df o r p i i m p r o v e df u e l e c o n o m ya n d y e a r - r o u n d r o t e c t i o nn You may usea 10 W - 30 oil if the climatein the vehicle. rangeshown on your area is limited to the temperature the chart.
-G
oil to rubberseal Deroreinstalling.
LABEL API SERVICE
4.
R u n t h e e n g i n et o r m o r e t h a n three minutes,then checkfor oil leakage.
(cont'd)
8-5
Oil Filter
(cont'd) Replacement
Installtheoil filter by hand. A f t e r t h e r u b b e r s e a l s e a t s ,t i g h t e n r h e o i l f i l t e r clockwise with the special tool. Tighten: 7/8 turn clockwise Tightening torque:22N.m (2.2kgt'm 16lbt.ft) Some filtershave eight numbers(1 to 8) printedon the surface the filter. of The followingexplainsthe procedure tightening for filtersusingthesenumbers. l) Makea markon the cylinder blockunderthe number that showsat the bottomof the filterwhenthe rubbersealis seated. 2) Tighten the filter by turning it clockwiseseven numbersfrom the makespoint.For example, a if mark is made underthe number2 when the rubber seal is seated, the filter should be tightened untilthe number1 comesup to the markedpoint.
OIL FILTERWRENCH 07912-61 10001
MARK Numberwhen rubber seal is seated. Numberafter tightening.
N u m b e r h e nr u b w ber sealis seated Numberaftertightening 5. 8

1
5 2 3
4
6 7
IJ
6 7
After installation. the engine with oil up to the fill specifiedlevel,run the enginefor more than three minutes, then checkfor oil leakage and oil level. GAUTION: Installation using other than the above procedurecould result in serious engine damage due to oil leakage.
8-6
Oil PressureSwitch
Testing
L
Oil Pressure
Testing
warning light stayson with the engine lf the oil pressure checkthe engineoil level.lf the oil levelis corrunning, rect: L
2.
wire from the engineoil presRemove the YEL/RED sureswrtcn. Checkfor continuitybetweenthe positiveterminal Thereshouldbe continuity and the engine{ground). Thereshould be no contiwith the enginestopped. nuity with the enginerunning.
a Connect tachometer.
Remove the engine oil pressure switch. and install an oil pressure gauge. GAUGE OILPRESSURE ADAPTER (1/8" - 28, BSTP) available) {Commercially (Commercially available)
ENGINE PRESSURE OIL SWTTCH MOUNNNG HOt-E if Startthe engine.Shut it off immedjately the gauge Repair the problembefore no registers oil pressure. continuing. 4. (fan temperature to Allow the engine reachoperating The pressure shouldbe: comeson at leasttwice). Engino Oil Temperature:176'F (80'C) Engine Oil Pressure: At ldle: 70 kPa (0.7 kgt/cm', 10 psil minimum Ai 3,000rpm: 3/r0 kPa {3.5 kgt/cm', 50 psi) minimum inspectthe lf oil pressurein not within specifications, oil pump (seepage8-9).
PRESSURE SWTCH 18 N.m {1.8kgf.m, 13 tbr.ftl Apply liquidsealant to the threads,
lf the switch fails to operate,checkthe engine oil level.lf the engineoil level is OK, checkthe engine orl pressure.
8-7
Oil Pu mp
Overhaul
OUTERROTOR pages Inspection, 8-9,1O
6x1.0mm 5 N.m {0.5kgt m. 4lbtft}
DOWEL PIN 6xl.0mm 9.8 N m (1.0kg,tm, 7.2 lbf ftl
PUMPCOVER
pages lnspection, 8-9,10 Apply liquidgasket to the matingsurface of the cylinder block when anstalling.
REI-IEF VALVE Valvemust slidefreely in the housingbore. Replace valveif it is scored. the 8 x 1.25mm 2{ N.m (2.4 kgf m, 17 tbf.fi)
8 -8
RemovaUlnspection/lnstallation
1.
D r a i n h ee n g i n e i l . t o
1 0 . Removethe screwsfrom the pump housing,then the separate housingand cover. rotor radial clearanceon l l . Checkthe inner-to-outer rotor clearance the pump rotor. lf the inner-to-outer e x c e e d s h e s e r v i c el i m i t . r e p l a c et h e i n n e r a n d t outer rotors. lnner Rotor-to Outar Rotor RadialClearance Standard{Newl:0.04- 0.16mm {0.002- 0.006inl ServiceLimit: 0.20 mm (0.008in)
and 2. Turn the crankshaft, align the white groove on pulleywith the pointeron the lower the crankshaft cover. the 3. Remove cylinderheadcoverand middlecover. Removethe power steering pump belt, air condibelt. tioner belt and the alternator 5. R e m o v et h e c r a n k s h a f tp u l l e y , a n d r e m o v e t h e lowercover. Remove timing belt. the Remove drive pulley. the Remove oil pan and oil screen. the Remove oil pump. the
6. 7. 8. 9.
orL
PUMP
OLRING Replace.
axial clearanceon the Checkthe housing-to-rotor pump rotor. lf the housing-to-rotor axial clearance exceedsthe service limit. replacethe set of inner and outer rotorsand/orthe pump housing. Housing-to-RotorAxial Clearance Standard {New): 0.02- 0.07 mm {0.001 0.003in) inl mm (0.006 So|' ice Limit: 0.15
OIL SCREEN
HOUSING
(cont'd)
8-9
Oil Pump
Removal/lnspection/lnstallation(cont'd)
1 3 . Checkthe housing-to-outer rotor radialclearance. lf the housing-to-outer rotor radialclearance exceeds the servicelimit, reDlace set of inner and outer the rotorsand/orthe pump housing, Housing-to-OuterRotor RadialClearance StandardlNewl: 0.10- 0.19mm {0.004- 0.007in} ServiceLimit: 0.20 mm {0.008inl 1 7 . R e a s s e m b lte e o i l p u m p , a p p l y i n gl i q u i dt h r e a d h lockto the pump housingscrews. 1 8 . Check that the oil pump turnsfreely. 1 9 . Apply a light coatot oil to the seallip.
20. Cleanand dry the oil pump matingsurfaces.

2 1 . Installthe two dowel pins and a new O-ringon the cylinderblock. Apply liquid gasket,part No. 08718-0001 08718or 0003,to the cylinderblockmating surfaceof the oil pump. Apply the liquid gasketevenly,in a narrow beadcenteredon the mating surface.Do not apply liquidgasketto the O-ringgrooves. Apply liquid gasketto the inner threadsof the bolt noles.
Apply liquid gasket alongthe brokenline.
1 4 . Inspectboth rotorsand the pump housingfor scorpans if necessary. ing or otherdamage.Replace 1 5 . Remove old oil sealfrom the oil pump. the
PUMPHOUSING
1 6 . Gentlytap in the new crankshaft seal until the oil special tool bottomson the pump.
NOTE:
. Do not installthe pans if five minutesor more have elapsed sinceapplyingliquid gasket. Instead, reapply liquidgasketafter removingold residue. . After assembly, wait at least30 minutesbetorefilling the enginewith oil.
8-10
24. Apply grease the lip of the oil pump seal. to When the Installthe oil pump onto the crankshaft. pump is in place,clean any excessgreaseoff the crankshaft and checkthat the oil seal lip is not distorted. lnstallthe oil screen.
2't. Install oil pan {seepage7-22). the
8 x 1.25mm 24 N.m 12.4 kgf.m, '17tbf.ft)
O-RING Applyengineoil Replace. DOWEL PIN
6x1.0mm 9.8 N.m {1.0kgf.m, 1.2lbfitl
OIL PUMP
6x1.0mm 9.8Nm(1.0kgf.m, 7.2 tbt ft)
6x1.0mm 9.8N.m (1.0kgf.m. 7.2 tbtftl
OIL SCBEEN
8-11
IntakeManifold/Exhaust System
IntakeManifold Rep1acement ....................................... 9-2 Exhaust Manifold Replacement ....................................... 9-4 Exhaust Pipeand Muffler Replacement ....................................... 9-6
IntakeManifold
Replacement
NOTE: . Use new O-ringsand gaskets when reassembling. . Check folds or scratches the surface the gasket. for on of . Replace with a new gasketif damaged. '97 - 98 models:
INTAK MANIFOLD R e p l a c ei f c r a c k e d o r i f m a t i n g s u r f a c e sa r e oamageo,
INTAKEAIR TEMPERATURE {IATISENSOR 22 N.n 12.2kgl.m, 16 rbf.ftl
8 x 1.25mm 22 N.m 12.2kgtm. 't6 tbf ft)
8 x 1.25mm 22 N.m |.2.2 kgl.rn, '16tbt ftl
I x 1.25 m m 24 N m 12.4 m. kgf 17 tbf.ft) INTAK BRAC} INTAKEMANIFOLO BRACKET ('98 modell B I x 1.25mm 24 N.m 12.4 kgf.m, 17 tbf.ft)
8 x 1.25mm 23 N m (2.3kgt m, 17 tbf.ftl
8 x 1.25mm 24 N.m (2.4kgf.m, 17 tbf.ft)
9-2
'99 - O0modol3:
6x1.0mm 9.8 N.m 11.0 kg{.m, 7.2 tbtltl NESONATOR
O-RING Replace. Applyoil to O-RING betoreinstalling.
6x1.0mm 9.8 N.m {1.0 kgf.m, 7.2 rbr.ftt RESONATOR CHAMBER BRACKET
GASKET Replace.
IATSENSOR 2:2N.m l2.2kgl.n, 16tbtftl
W\qu N,1\J
O.RING Replace.
("\"-\
K\*}Gt
u
INTAKEMANIFOLD Replace cracked it or if matingsurfaces are oamageo.
'n\ .a,,-\\J "

\ G)s
O.RING Replace. 8 x 1.25mm 22 N.m 12.2kgl.m, 16 rbf.ftt
IAC VALVE 8 x 1.25mm 23 N.m (2.3 kgf.m, 17 tbf.ft, 8 x 1.25mm 24 N.m 12.4kgt m, 17 tbt frl INTAKEMANIFOLD 22 N.m 12,2kgl.m, 16 rbfftl
BRACKET
9-3
ExhaustManifold
Replacement
NOTE: . Use new gaskets nutswhen reassembling. and self-locking . Check folds or scratches the surface the gasket. on of for . Replace with a new gasketif damaged. '97 - 98 U.S. models (Calilornia):
8 x 1.25mm 31 N.m (3.2kgf.m, 23 lbtft) Replace. I x 1.25mm 24 N.m (2.4kgl.m, 1? tbf.ft) 8 x 1.25mm 24 N.m (2.i1kgt.m, 17 lbf.ftl
NN
EXHAUST MANIFOLO 10 x 1.25mm 44 N.m 14.5kgf.m, 33 lbf.ft) NUT SELF.LOCKING 8 x 1.25mm kgt.m, 23 lbt'ft) 31 N m 13.2 Replace. EXHAUST MANIFOLD BRACKET 10 x 1.25mm 44Nm{4.5kg{.m. 33 lbf.ftl
9-4
'97 - 98 U.S. models {ExceptCalifornia): '99 - 00 models:
mm 8 x '1.25 31 N.m {3.2kgl.m,23lbl.ft) Beplace. COVER
(v/\
\\'
NL-] ' r \\ r-------.
\F= ,l \\/
8 x 1.25mm 31 N.m {3.2 kgf.m.23 lbf.ft) Replace.
MANIFOLD BRACKET 6x1.0mm 9.8 N m 11.0 kgf.m, 7.2 lbf.ft) 44 N.m {4.5kgf.m, 33 lbtftl
9-5
ExhaustPipeand Muffler
Replacement
nutswhen reassembling. and self-locking NOTE:Use new gaskets 7 - 98 U.S. models (Calitornial:
MUFFLER
GASKET Replace.
NUT SELF.LOCKING 10 x 1.25mm 33 N.m {3.4kgt m, 24 lbl.ft) Replace.
NUT SELF.LOCKING I x 1.25mm 22 N.m (2.2 kg{.m, 16lbt'ftl Replace. the nuts in stePs, Tighten alternating side-to-side.
SECONDARY HO2S 4il N.m lil.5 kgtm, 33 tbf.ft)
PRIMARY HO2S 44 N.m {{.5 kgl.m, 33 tbt.ft)
GASKET Replace.
S*S:--t-..-_
TWC 1 Inspection, section l see GASKET
EXHAUST PIPE A NUT SELF.LOCKING 8 x 1.25mm 22 N.m (2.2 kgf.m, r 6 tbt.ft) Replace. Tighten nuts in the steps, a'ternating side-to-side.
Replace.
6x1.0mm 9.8N.m (1.0kgf.m, 7.2 tbt.ltl
NUT 10 x 1.25mm kgi.m,40lbf'tt) 54 N.m 15.5 Replace.
NUT SELF.LOCKING 8 x 1.25mm 16 N.m {1.6kgt.m, 12 tbt fr) Replace.
'97 - 98 U.S. models (ExceptCalifornial: '99 - 00 models:
GASKET Replace.
MUFFLER
NUT SELF.LOCXING l0 x 1.25mm 33 N.m 13.4 kgl.m, 24 lbtft) Replace.
SELF.LOCKING NUT 8 x 1.25mm 22 N.m (2.2kgf.m, 16 lbl.ft) Replace. Tighten nuts in steps, the alternating sideto side.
SECONDARY HEATED OXYGENSENSOR HO2SI {SECONDARY 4il N.m 14.5 kgl.m, 33 tbf.ftl
PRIMABY HEATED OXYGENSENSOR (PRTMARY HO2S) 44 N.m (4.5 kgf.m, 33 tbf.ftl
GASKETS Replace.
WAYCATALYTIC THREE (TWCI CONVERTER

l n s p e c t i o n ,s e e s e c t i o n 1 1
NUT 10x 1.25mm 5a N.m (5.5kgl.m,40 lbf ftl Replace.
SELF-LOCKING NUT 8 x 1.25mm 16 N.m 11.6 kgf.m, 12 tbf.ftt Replace.
NUT SELF.LOCKING 8 x 1.25mm 22 N,m 12,2kgi'm, 16 tbf.ftl Replace. Tightenthe nuts in alternating steps, side-to-sade.
x 1.0mm 9.8 N.m {1.0kgf.m, 7.2 rbf.ft)
Cooling
ff f u s t r a t e dn d e x. . . . . . . . . . . I . . . . .1 O - 2 Radiator R e p | a c e m e n.t. . . . . . . . . . , . . . . , . . . . . . . . . . . .1 0.- 4. . . . . .. .. EngineCoolantRefillingand Bleeding . . , . , . . . . . . . . . . . .1 . .- 5 .0 .. C a pT e s t i n g . . . . . . . . . . . . . . .1.0.-.7 . . Testing ......10-7 Thermostat R e p | a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . .1 0.- 8. . . . . .. .. Testing ......10-9 Water Pump l l l u s t r a t e dn d e x . . . . , . . . . . l .. 10-10 Inspection . 10-1 1 R e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . .1 0.- 1. . , . . . . . .1 FanGontrol ComponentLocationIndex ............... 10-12 C i r c u i tD i a g r a m . . . . . . . . . . 1.0 - 1 3 . . FanMotor Testing ......... 10-14 RadiatorFanSwitch Testing ............. 10-14 CoolantTemperature Gauge G a u g eT e s t i n g . . . . . . . . . . . .1 . .- 1 5 .0 CoolanttemperatureSending UnitTesting . . . . . . . . , . . . . .0.- 1 5 1.
lllustratedIndex
CAUTION:The system is under high pressurewhen the engineis hot. To avoid dangerol releasing scaldingengine coolant,removethe cap only when the engineis cool. Total Cooling System Capacityfincluding 0.6 I (0.63 US qt, 0.53 lmp qt) for heater and reservoirl: A/T: 5.9{ {6.2US qt, 5.2 lmp qt) M/T: 6.0f (6.3US $, 5.3 lmp qt)
6x1.0mm kgf.m. 9.8 N.m 11.0 1.2 tbl.ftl
l f a n y e n g i n ec o o l a n ts p i l l so n t h e paintedportions the of body, rinse it off immediately. C h e c k a l l c o o l i n g s y s t e m h o s e s f o r d a m a g e ,l e a k so r deterioration and replace if necessar,. Check all hose clamps and retighten if necessary.
RADIATOR Engine coolantrefilling and bleeding, page10-5 Leak test,page10 7 jointsand Inspect soldered for seams leaks. Blow out din from between corefins with compressed air. lf insects, etc.,are clogging radiator,wash them off with RADIATOR CAP low pressurewater. Pressure test, page 10-7
ATF COOLER HOSE Relerto section14 when installing. LOWER
cusHroN
FAN MOTOR 6x1.0mm 7 N.m (0.7kgf.m, 5 lbf ftl
10-2
EngineHoseConnections:
FASTIDLETHERMO VALVE(A/T onlyl IDLEAIR CONTROL IIAC}VALVE
TEF BYPASS HOSE
THERMOSTAT HOUSING
CONNECTING PIPE
VALVE
HOSES
10-3
Radiator
Replacement
1. 2.
D r a i n h ee n g i n e o o l a n t . t c R e m o v e h e u p p e r a n d l o w e r r a d i a t o rh o s e s ,a n d t ATFcoolerhoses. Disconnect fan motor connector. the Remove the radiatorupper bracket, then pull up the raotalor,
5.
s R e m o v e h e f a n s h r o u da s s e m b l i ea n d o t h e rp a r t s t from the radiator. orderof removal. lnstallthe radiatorin the reverse
6.
3.
4.
NOTE: . Setthe upperand lower cushions securely. . Fillthe radiator with enginecooiantand bleedthe air.
6x1.0mm 9.8 N.m 11.0 kgf.m, 7.2 tbl.trl
RADIATOR CAP RADIATOR
6x1.0mm 5 7 N.m (0.?kgd.m, lbl.ftl UPPER MDIATOR HOSE
rriItriiii
Relerto section14 when installing. LOWER CUSHION CONDENSER FAN,/SHROUD ASSEMBLY DRAINPLUG LOWER TOR HOSE
RADIATOR ASSEMBLY
6x1.0mm 7 N.|n 10.7 kgt.m, 5 tbt.ftl
10-4
EngineCoolantRefillingand Bleeding
1. control lever to maxi Slidethe heaterlemperature mum heat. Make sure the engine and radiatorare cooi to the touch. 6. 2. 3. caP. Remove the radiator 7. t L o o s e nh e d r a i np l u g ,a n dd r a i nt h e c o o l a n t .
DRAINPLUG
Apply liquid gasketto the drain bolt threads,then reinstallthe bolt with a new washer and tighten it securely. Tightenthe radiatordrain plug securely. Remove,drain and reinstallthe reservoir'Fill the tank halfwayto the MAX mark with water,then up to the MAX markwith antitreeze.
4.
Remove drainbolt from the cylinderblock. the
DRAINBOLT 78 N.m {8.0ksl.m, 58 lbtft}
(cont'd)
10-5
Radiator
EngineCoolantRefillingand Bleeding(cont'dl
Mix the recommended ntifreeze ith an equal a w amountof water in a cleancontainer. NOTE: . Always use GenuineHonda Antifreeze/Coolant. Using a non-Hondacoolantcan result in corros\on, ca\rsng t\e coo\\ng sys\em \o ma\lunct\on o. fail. For best corrosion protection,the coolant conc e n t r a t i o nm u s t b e m a i n t a i n e d e a r - r o u n da t y 50% minimum.Coolantconcentrations than less 50%may not providesufficient protection against c o r r o s i o no r f r e e z i n g . o o l a n tc o n c e n t r a t i o n s C greaterthan 60% will impair cooling efficiency and are not recommended. Do not use additionalrust inhibitorsor anti-rust products;they may not be compatiblewith the coolant. Engine Coolant Refill CapacityIincluding 0.6 / 10.63 US $, 0.53 lmp qtl for hoater and ressrvoirl: A/T: 3.9 f {4.1 US $, 3.4 lmp qtl M/T: 1.Ot 14.2US $, 3.5 lmp qrl 9. Pour coolantinto the radiatoruD to the baseof the filler neck.When pouringenginecoolant.do not let pans or the paint. lf coolantspill on any electrical any coolantspills,rinseit oft immediately.
1 0 . Startthe engine,and let it run until it warms up (the radiator fan comes on at leasttwice). 1 1 .Turn off the engine.Checkthe level in the radiator, add coolantif needed. 1 2 . Put the radiatorcap on tightly.then run the engine againand checkfor leaks.
10-6
CapTesting
1.
Testing
1.
Removethe radiatorcap, wet its seal with engine tester. coolant, then installit on the pressure of Applya pressure 93 - 123kPa(0.95 1.25kgflcm' , 1 4- 1 8p s i ) . for Check a drop in pressure. the drops,repiace cap. lf the pressure
Wait until the engineis cool, then carefullyremove t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e c o o l a ntto t h e t o p o I t h e f i l l e rn e c k . and apply testerto the radiator, Attachthe pressure a pressure 93 - 123kPa (0.95- 1,25kgf/cm' ,14 of 1 8p s i ) . for Inspect enginecoolantleaksand a drop in pressure. cap. the Remove tester,and reinstall radiator the c t f o C h e c ko r e n g i n e i l i n t h e c o o l a n a n d / o r o o l a n it n o t h ee n g i n e i l . RAOIATOR PRESSURE TESTER (Commercially available)
ADAPTOR (for 32 mm neck, low profile)
2.
2.
3.
3.
4.
TESTER PNESSURE RADIATOR available) lCommercially RADIATOR
5.
ADAPTOR (for 32 mm neck,low Profile)
10-7
Thermostat
Replacement
THERMOSTAT HOUSING
RUBBER SEAL Replace. THERMOSTAT COVER
THERMOSTA Install with pin up.
RADIATOB FAN
swtTcH
24 N.m {2.4kgtm, l7 lbt.ftl
6 x '1.0 mm 12 N.m (1.2kgl.m, 8.7 tbtftl
10-8
Testing
if the Replace thermostat it is open at room temperature. To test a closedthermostat: 1. of Suspendthe thermostatin a container water. Do touch the bottom of the hot not let the thermometer container.
THERMOMETER
THERMOSTAT
Heat the water, and checkthe temperaturewith a thermometer.Checkthe temperatureat which the first opens,and at which it is fully open. thermostat when fully Measure the lift heightof the thermostat open. THERMOSTAT STANDARD above8.0 mm (0.31in) Lift height: opening:169- 176'F(76- 80'C) Starts 194'F(90'C) Fullyopen:
10-9
Water Pump
lllustrated Index
ENGINECOOLANT TEMPERATURE IECTI SENSOR 18 N.m 11,8 kgt.m,
13tbt.ftl
COOLANT TEMPERATURE GAUGE UNIT 9 N.m {0.3kgf.m, 7 tbf.ftt Applyliquidgasket to the threads. 6x1.0mm 9.8 N'm (1.0 kgf.m, 7.2 tbt frl
WATEROUTLET COVER part No. Apply liquidgasker 087'18 0001or 08718 0003 to the mating surface.
RADIATOR FAN SWITCH 2il N.m (2.i1 kgl.m, 17 tbfft)
WATER PUMP page lnspection, 10-11
O-RING Replac.
6xl,0mm 12N.tnn.2 lgl.rn, 8.7 tbf'ft)
CONNECTING PIPE
6x1.0mm 12 N.m 11.2 kgf.m, 8.7 tbtftl
10-10
Inspection
1.
Replacement
1. 2. 3, Remove timing belt (seesection6). the the Remove water pump by removingfive bolts repairand cleanthe O-ringgroove and the Inspect, with the cylinderblock. matingsurface
the Remove timing belt (seesection6) Turn the water pump pulley counterclockwise. that it turnsfreely. Check for Check signsof sealleakage. NOTE:A smallamountol holeis normal. "weeping"from the bleed
2.
6x1.0mm 't2 N.m 112 kgf m. 8.7 tbf.ftl 4. lnstall the water pump in the reverse order of removal.
I I
@-
-<o
Replace.
BIIED HOLE
1 10-1
FanControl
ComponentLocationIndex
ftflEffltrl
UNDEB.HOOD FUSE/RELAY BOX
t lrt
@u!lfl]l
r-1 a-l
RADIATOR FAN RELAY Test,seesection 23
BADIATOR FAN
Removal,page 10-10 Test, page 10-14
BADIATOR FAN MOTOR

Removal, page 10-2
CONDENSER FAN MOTOR
10-1 2
CircuitDiagram
UNDER OASH FUSEiRELAY BOX
SWITCH IGNITION No.41{100A) N0.42140A)
6;\ E;';l wHTsLka rtF',*",El-l

I
BLK/RED
I L^,^,.,
RAOIATOR FAN SWITCH : fClosedAbove) { L 1 9 9 o F9 3 0 CJ)
T*' I
B LK
oro,
FanControl
FanMotor Testing
1 . D i s c o n n e ch e 2 Pc o n n e c t o r . tt
Radiator Fan Switch Testing

Removingthe radiator fan switch while E@ the engine is hot can causethe coolant to spray out, seriously scalding you. Always let the enginc and radiator cool down before removing the radiator fan switch. 1. Remove the radiator switchfrom the thermostat fan housing(seepage10 '10). S u s p e n d h e r a d i a t o r a n s w i t c hi n a c o n t a i n e r f t f o water as shown.
RADIATOR FAN MOTOR
2.
Terminalside of male terminals Test the motor by connectingbatterypower to the N o .2 t e r m i n aa n d g r o u n d o t h e N o . 1 t e r m i n a l . l t lf the motor fails to run or does not run smoothly, reptace rt.
Heat the water, and checkthe temperaturewith a thermometer. not let the thermometer Do touch the bottomof the hot container. Measure the continuitybetweenthe A and B terminalsaccording the table. to \ Terminal
op".*iON
Tr"ip".a*" \.
B o- --o
196- 203"F {91- 95.C) (3 5 - 14"F - 8.C) SWITCH lower than the temOFF p e r a t ur e w h e n i t goeson
Bleedthe air from the coolingsystemafterinstalling the radiator switch(seepage10-5). fan
10-1 4
Gauge Temperature Goolant

Testing Gauge
1 . C h e c kt h e N o . 2 5 ( 7 . 5A ) f u s e i n t h e u n d e r - d a s h box beforetestin9. fuse/relay 2. Make sure the ignition switch is OFF,then disconwire from the coolant temperanect the YEL/GRN u t u r es e n d i n g n i t .a n dg r o u n di t w i t h a j u m p e rw i r e .
SendingUnit CoolantTemperature
Testing
1. wire from the coolanttem the Disconnect YEUGRN perature sendingunit.
TEMPERATURE COOLANT
TEMPERATURE COOLANT
POSITIVE TERMINAL
WIRE YEL/GRN (Covered with insulation) YEL/GRN WIRE 2. t s T u r n t h e i g n i t i o n w i t c hO N { l l ) .C h e c k h a t t h e g temperature augestarts p o i n t e ro f t h e c o o l a n t " H " m a r k .T u r n t h e i g n i t i o n movingtoward the "H" on the switch OFF beforethe pointer reaches t g a u g e i a l .F a i l u r eo d o s o m a y d a m a g eh e g a u g e . t d l f t h e p o i n t e ro f t h e g a u g e d o e s n o t m o v e a t a l l , wire. for check an open in the YEL/GRN 5. the lf the wires are OK, replace coolanttemperature gauge. g l f t h e c o o l a n tt e m p e r a t u r e a u g ew o r k s ,t e s t t h e sendingunit. coolanttemperature 3. Using an ohmmeter,measurethe change in resistance betweenthe positiveterminaland the engine ( g r o u n dw i t h t h e e n g i n e o l d a n d w i t h t h e e n g i n e ) c temPerature. at operating Temperature Resistance (0) 133.F(56'C) 137
(8s 100'c)
46-30
1A5- 212F
differentfrom the lf the readingsare substantially above, inspectthe coolant level and specitications t h e c o o l i n gs y s t e m .l f t h e c o o l i n g s y s t e m i s O K , the replace sendingunit.
10-15
Fueland Emissions
...................... 11-2 Tools Special Component Locations . . . . , . .1.1 - 3 . l n d e x. . . . . . . . . . . . . . . . . . . . . . Svstem Description .. . V a c u u m o n n e c t i o n . . . . . . . . . . . , . . . . , . , . . . . . .11.-.9. . . . . . C s . . 1 .. . E l e c t r i c a lo n n e c t i o n.s . . . . . . . . . . . . . . . . . . . . . . 1. . - 1.5. . . . C .. . . S y s t e m o n n e c t o r . , . , , . , . . . . . . . . . . . . . . . . . . . .11.-.3.6 . , . , . C s Troubleshooting Pr . .. 6 . T r o u b l e s h o o t i n g o c e d u r e s , . , . . . . . . . . . . . .1.1 - . . 0. . Conttol EngineControlModule/Powertrain 11-67 ModuleTerminalArrangement.............., 1t-75 Diagnostic TroubleCodeChart .................... I 1-79 .......,.....,.,............... How to ReadFlowcharts
ldle Control System

............ 11-149 SystemDescription TroubleshootingFlowcharts 11-150 ...... ldle ControlSystem 11-152 fdleAir ControlValve ......................,............. . . .5 A i r C o n d i t i o n i nS i g n a l. . . . . . . . . . . . . . . . . . . . . . .I. 1.-.1.5 . . . g . 1 .. . . A l t e r n a t oF RS i g n a l. . . . . . . . . . . . . . . . . . . . . . . . . . 1. . - 1.5.9 . . . r t l-161 StarterSwitch Si9na1.................................... Switch Signal......11-162 PowerSteeringPressure . . . - .. . S B r a k e w i t c hS i 9 n a 1 . . . . . . . . . . . . . . . . . . . . . . . . .1.1 . .1 6.6. . . V . 1 .. , , F a s tl d l eT h e r m o a l v e. , . , . . . . . . . . . . . . . . . . . . . . . . .1 . . - 1.6.8 . , . .............. 11-169 ldle speed setting
System PGM-Fl
11-80 SystemDescription.................,.,.,,,............... Flowcharts Troubleshooting EngineControlModule/Powertrain ........11-52 ControlModule 11-90 Sensor............. ManifoldAbsolutePressure 11-95 Sensor .................... IntakeAir Temperature 1 Sensor.,..,.,....1-99 EngineCoolantTemperature I 1'103 Sensor ...........,.....,.,.,..,...... ThrottlePosition (Sensor ... 11-110 1) Heated OrygenSensor Primary SecondaryHeatedOxygen Sensor . . . . . . . . . . . . .11.-.1 1 7 .. . { S e n s o2 l r 11-121 HeatedOxygenSensorHeater ..................... ......11-124 FuefSupplySystem 11-126 ,....,.,..... RandomMisfire 11-128 in MistireDetected One Cylinder .....-........... . . . . . . . . . . . .1 1.-. 1 3 0 .. Knock ensor S Se . .. . .1 C K P / T D C / C Y P n s o r . . . . . . . . . . . . . . . . . . . . . . . .11.-.1.3 . . . . . .. . ,. V e h i c l e p e e d e n s o r . . . . . . . . . . . . . . . . . . . . . . . .11.-.1.3 5. . . S S 11-137 Barometric Pressure Sensor .....,...,...,.,,........ 11-138 Electrical LoadDetector...,.,.......................... '11-112 ................,.,, CKFSensor 11'117 lnternaf ECM/PCM Circuit ............................. .,.,.,. 11-148 HO2SReplacement
FuelSupply System
1 . . .1 . . . . . . . . . . . . . . . . . . . . . 1.-.1.7 . F u e lL i n e s 11-175 Fittings..................... FuefTube/Ouick-Conneci ............ 11-178 SystemDescription 1. . . . . . . . . . . . . . . . . . . 1.-.1.7 8 F u e lP r e s s u r g ................,..... 11-179 FuelIniectors .. f .-1 , . e F u e lP r e s s u rR e 9 u 1 a t o r . . . . . . . . . . . . . . . . . . . . . . . . .1 . , . 8.1. . , ....,.,.,.,,,,.,............11-142 FuefFifter . . . . . . . . . . . . . . . . . . .1 . . - . .8.3 . 1.1 . F u e lP u m p . . . . . . . . . . . . . . . . . . 1.1 . .1 . .4 . . - .8 F u e lG a u g e 1 .. . . U F u e lG a u g e e n d i n g n i t . . . . . . . . . . . . . . . . . . . . . . . .I. . . - 1.8.5 . . S 11-185 Low FuelIndicator System ...........,.,..,............... . . . . . . . . . .1 . .- 1 8 7 .1 P G M - FM a i nR e l a y I . . . . . . . . . .1 . .- 1 9 1 .1 Fue|Tank................
IntakeAir System
SystemDescription AirCleanel ThrottleCable B Throttle ody........ ............ 11-193 , . , . , . . . . . . . . . . . . . 1.1 . .1 . .4 . . - .9 ..................... 11-194 . . . . . . . . . . 1.1.- 1 9 6 . .
EmissionControl System
...,....,.,. 11-199 SystemD$cription 11-199 ............... TailpipeEmission 11-199 Converter..................,.,...,, ThreeWay Catalytic 11-2O1 System .,.,,,,.,.., Crankcase Ventilation Positive 11-203 Emission Controls.........,.,.,............ Evaporative
SpecialTools
SpecialTools
Ref.No. Tool Number _ A973X_041 XXXXX Description V a c u u m u m p / G a u g e -0 0 i n . H g P , 3 Oty PageReference '11-201 . 208,214, 2 1 5 , 2 ' t 6 , 2 12 2 0 , ,7 221 222,223,224 , 11 207 224 , 11-60, 88, 1 16, 83, 128,200,205 11-62 1 1 - 1 7 8 ,8 1 1
q
t3' , 3 ) l
07JAZ 0010008 , 07PAZ 0010100 07sAz - 001000A 07405 0040001
Vacuum/Pressure Gauge,0 4 in.Hg SCSService Connector Backprobe Set FuelPressure Gauge
1 1 2 1
11-2
ComponentLocations
lndex
'97 - 98 models:
ABSOLUTE MANIFOLD PRESSURE IMAP} SENSOR Troubleshooting, Page11-90 (TP} THROTTLE POSITION SENSOR page11-103 Troubleshooting, (EVAP) EMISSION EVAPORATIVE VENT SHUT CANISTER CONTROL VALVE t'98 modll page11'213 Troubleshooting, ELECTRICAL LOAD DETECTOR IELD)(USA modol) page11-138 Troubleshooting,
toLEAtRCONTROL llAcl VAI-VE page Troubleshooting, 11-152
AIR INTAKE TEMPERATURE IIATISENSOR page 'l Troubleshooting. 1 -95
STEERING PRESSURE POWER
lPsPl swtrcH
page11-162 Troubloshooting,
SPEED VEHICLE (VSS) SENSOR Troubleshooting, p a g e1 1 ' 1 3 5
CRANKSHAFT POSTTtON/ TOP OEADCENTER/ CYLINDER POStTtON SENSOR {CKP/TDC/CYP} (Builtinto the distributor) page1l-131 Troubleshooting, ENGINE COOLANT TEMPERATURE IECTISENSOR page11 99 Troubleshooting,
CMNKSHAFT SPEED FLUCTUATION ICKF}SENSOR page1'!-142 Troubleshooting.
EVAPORATIVE
CONTROL IVAP)PURGE VALVE SOLENOID Troubfeshooting,page 11'2o5,213
(cont'd)
11-3
ComponentLocations
Index (cont'dl
39 - 00 models:
MANIFOLD ABSOLUTE PRESSURE IMAPISENSOR page11-90 Troubleshooting, THROTTLE POSITION {TP) SENSOR page11-103 Troubleshooting, EVAPOBATIVE EMISSION {EVAPI CONTROL CANISTER VENTSHUT VALVE page11-213 Troubleshooting, ELECTRICAL LOAO OETECTOR {ELD)IUSA modet) Troubleshooting, page I 1-138 IDLEAIR CONTROL OACIVALVE page11-152 Troubleshooting, EVAPORATIVE EMISSION (EVAPIPURGE CONTROISOLENOID VALVE page Troubleshootang, 11-2'13 INTAKEAIR TEMPERATURE (IAT)SENSOR page11 95 Troubleshooting,
VEHICLE SPEED SENSOR IVSSI Troubleshooting, p a g e1 1 ' 1 3 5
POWEB STEERING PRESSURE tPsPtswtTcH page Troubleshooting, 11162
CRANKSHAFT POSTTTON/ TOP OEADCENTER/ CYLINDER POStTtON SENSOR {CKP/TDC/CYP) (Builtinto the distributor) page11 131 Troubleshooting, ENGINE COOLANT TEMPERATURE {ECT)SENSOR Troubleshooting, page11 99
CRANKSHAFT SPEED FLUCTUATION ICKN SENSOR page11-142 Troubleshooting, SENSOR page'11130 Troubleshooting,
11-4
DATA LINKCONNECTOR {DLC)I16P} page11'60 Troubleshooting Procedures, HEATED PRIMARY OXYGENSENSOR 1) HO2SI {PRIMARY {SENSOR page11 110 Troubleshooling, PGM-FI MAIN RELAY page11-l87 Relay Testing, Troubleshooting. page1'1188
,a'=_-_
WAY CATALYTIC HEATED OXYGEN SECONDARY SENSOR 2) HO2S){SENSOR {SECONDARY page11-1 17 Troubleshooting, '97 - 98 models: AIR CLEANER page11'194 Replacement, page1'l-200 Troubleshooting,
SERVICE CHECK CONNECTOR {2PI page11-60 Troubleshooting Procedures,
MODULE POWERTRAIN CONTROL (PCM)(A/TI page11-60 Troubleshooting Procedures, page11'82 Troubleshooting. THROTTLE CABLE page Inspection/Adjustment, 11-1 94 page11-195 Installation,
THROTTLE BODY(TB) page11 196 Inspection, page11-197 Removal, page11-'198 Disassembly,
(PCV) VALVE VENTILATION page11-201 Inspection, FASTIDLE VALVE (A/T}

I n s p e c t i o n ,p a g e 11 - 1 6 8
(cont'd)
11 - 5
ComponentLocations
Index{cont'd)
39 - q, models:
THROTTLE BODYITB) page11-196 Inspection, page11-197 Removal, page11 198 Disassembly,
THROTTLE CABLE page Inspectaon/Adjustment, 11 194 page I l'195 Installation,
AIR CLEANER page11-194 Rplacomenl,
CRANKCASE VENTILATION IFCVIVALVE page11 201 lnspection, FASTIDLETHERMOVALVEIA/T) page11'168 Inspection,
11 - 6
'97 model:
FUELPRESSURE REGULATOR p T e s t i n g , a g e1 1 - 1 8 1 page11 181 Replacement,
FUEL FEED PIPE

FUELFILTER page11 182 Replacement,
FUEL PUMP page11 183 Testing, page11 183 Replacement, FUELGAUGESENDINGUNIT page11 185 FUELVAPORPIPE Testing,
DAMPER FUELPULSATION
FUEL FILL CAP
EVAPORATIVE EMISSION CANISTER IEVAP)CONTROL page1'l-205 Troubleshooting.
EVAPORATIVE EMISSION IEVAPITWO WAY VALVE page11 224 Testing, TANK

R e p l a c e m e n t ,p a g e 1 1 1 9 1
-CONNECT FUEL FITTINGS page11-175 Precautions, page11 175 Disconnection, page11-176 Connection, FUELINJECTORS page11-179 Replacement,
'98 model:
FUEL FEED PIPE FUELFILTER page11 182 Replacement, DAMPER FUELPULSATION FUELVAPORPIPE
FUEITANK FUEL PUMP Replacement, page11 183 Testing, p a g e1 l 1 9 1 page11 183 Replacement, SENDING UNIT FUEL GAUGE page1l'185 Testing,
FUELFILLCAP
EVAPORATIVE EMTSSTON IEVAPI CONTROL CANISTER VENT SHUTVALVE Troubleshooting, p a g e1 1 ' 2 1 3 EVAPORATIVE EMISSION IEVAPICONTROL CANISTER page11-213 Troubieshooting, FUEL RAIL
FUELTANK PRESSURE SENSOR page1l-209 Troubleshooting,
FUEL
page11-179 Feplacement, FUELPRESSURE NEGULATOR page11-181 Testing, Replacement, Page11 181
FUELTUBE/OUICK.CONNECT FITTINGS page11 '175 Precautions, page11 175 Disconnection, page11 176 Connection, EVAPORATIVE EMISSION {EVAP)EYPASS SOLENOID VALVE page11'213 Troubleshooting, VAPORATIVE EMISSION TWO WAY VALVE {EVAP) page11 224 Testing, (cont'd)
Locations Gomponent
Indexlcont'd)
'99 - (X)modols:
FUEL TANK Replacement, p a g e1 1 - 1 9 1 FUELVAPORPIPE FUEL FEEDPIPE FUELPUMP page'11183 Testing, page11_183 Replacement, UNIT FUELGAUGESENDING page11-185 Testing,
FUELFILTER page11 182 Replacement,
EVAPORATIVE EMtSStON IEVAP) CONTROL CANISTER VENT
FUELFILL CAP
VALVE SHUT Troubleshooting, page 1-213 1

EMISSION EVAPORATIVE IEVAP)CONTROL page11-213 Troubleshooting,
FUELTANK PRESSURE SENSOR page1'l'208 Troubleshooting,
DAMPER FUELPULSATION
FUELRAIL FUEL page11-179 Replacement, FUEL PRESSURE REGULATOR page11-181 Testing, page11 181 Replacement, EVAPORATIVE EMISSION TWO WAY VALVE {EVAP) page11-224 Testing,
,CONNECT FITTINGS page PrecaLrtions, 11-175 page11-175 Disconnection, page176 Connection, EVAPORATIVE EMISSION {EVAPIBYPASS VALVE SOLENOID page11 213 Troubleshooting,
FUEL
Vacuum Gonnections
'97 model:
To EVAPORATIVE EMISSION IEVAPI TWO WAY VALVE
EVAPOBAIIVE EMtSStON IEVAPI CONTROL CANISTER
EVAPORATIVE EMtSStON tvaP) PURGE CONTROL VALVE SOLENOID
FRONT OF VEHICLE
PBESSURE REGULATOR
{cont'd)
11-9
System Description
(cont'dl Vacuum Connections
'97 model:
ENGINE COOLANT
r|ll
IT
HEATED oxYGEN sENsoR Ho2s, O PRIMARY {PRIMARY SENSOR lt HEATED oxYGEN sENsoR{SECoNDARY O SECONDARY HO2S. SENSOR 2l (MAPI ABSOLUTE PRESSURE SENSOR ) MANIFOLD cooLANTTEMPERATURE sENsoR @ ENGINE {EcT} (IAI} AIR O INTAKE TEMPERATURE sENsoR SPEED FLUCTUATION SENSOR @ CRANKSHAFT ICKFI ArR O |DLE coNTRoL {tAc)vALvE IDLE THERMo vALvE @ FAST EoDYITB) O THRoTTLE INJEcTon @ FUEL PULSATIoN oAMPER O FUEL FILTEn @ FUEL (} FUEL PRESSURE REGULATOR
@ FUELPUMP
(D FUELTANK (D FUELTANK EVAPORATIVE (EVAPIVALVE EMISSION
o AIRCLEANER
@ RESONATOR (} POSITIVE CRANKCASE VENTILATION {PCVIVALVE EMISSION PURGE CONTROL @ EVAPORATIVE {EVAP}
SOI.'ENOID VALVE EMISSION @ EVAPORATIVE {EVAP)CONTROL CANISTER EMISSION @ EVAPORATIVE {EVAPITWO WAY VALVE (TWC) WAY CATALYTIC CONVERTER @ THREE
11 - 1 0
'98 model:
To EVAP THREE WAY VALVE
To EVAP TWO WAY VALVE
EVAP
PURGE CONTROL SOLENOID VALVE
FRONT OF VEHICLE
(cont'd)
11-11
System Description
(cont'dl VacuumConnections
'98 model:
G/T only)
f \
-i*'";-t
COOLANTJ
(PRIMARY HO2S, SENSOR OXYGEN HEATEO C PRIMARY 1) SENSOR ISECONDARY (, SECONDARY OXYGENSENSOR HEATEO 2) HO2S,SENSOR (!)\\\\ss\SNBSS\\\ETRESS\RE\\NQ\SE\SSR (ECT) SENSOR TEMPERATUBE COOLANT G) ENGINE {IAT}SENSOR O INTAKEAIRTEMPERATURE (CKFISENSOR FLUCTUATION SPEED @ CRANKSHAFT (IAC)VALVE O IDLEAIR CONTROL @ FASTIDLETHERMOVALVE(A/T) BODY(TBI O THROTTLE (0) FUELINJECTOR DAMPER .1' FUELPULSATION .14 FUELFILTER (i FUELPRESSURE REGULATOR PUMP 14 FUEL (D FUELTANK EMISSION {EVAPIVALVE @ FUELTANK EVAPORATIVE
C] AIR CLEANER (O RESONATOR 1iC POSITIVECRANKCASEVENTILATION (PCV)VALVE 6 \$REE$IN\ gN\ NL$\C CON\ER\ER (TNC\ ti\ q\ rpos,xr\tE qN\rssros \E\ aP\ cqN\RoLcaNtsrR CONTROL EMISSION IEVAP)PURGE @ EVAPORATIVE VALVE SOLENOID CANISTER q3 EVAPORATIVE EMISSTON IEVAP}CONTROL VENT SHUTVALVE (EVAP) TWO WAY VALVE EMISSION @ EVAPORATIVE SOLENOID BYPASS EMISSION {EVAP) i EVAPORATIVE VALVE SENSOR 9 FUELTANK PRESSURE WAY VALVE THREE EMISSION {EVAP) Oi EVAPORATIVE JOINT Qd PURGE
11-12
'99 - 00 models:
To EVAPTHREE WAY VALVE
To EVAP TWO WAY VALVE EVAP PURGE CONTROL SOLENOID VALVE
FUEL PRESSURE REGULATOR FRONTOF VEHICLE
(cont'd)
11 - 1 3
System Description
(cont'dl VacuumConnections
'99 - q) models:
ENGINE COOLANT
HO2S, o PRIMARYHEATEDOXYGENSENSORIPRIMARY 1l SENSOR HEATED OXYGENSENSOR {SECONDARY o SECONDARY HO2S.SENSOR 2l (MAPI o MANIFOLDABSOLUTEPRESSURE SENSOR TEMPERATURE IECN SENSOR @ ENGINECOOLANT INTAKEAIR TEMPERATURE IIATI SENSOR SPEED FLUCTUATION SENSOR CRANKSHAFT {CKF) (KS} KNOCKSENSOR IDLEAIR CONTROL IIACIVALVE FASTIDLETHERMO VALVE{A/T} BODY(TB} THROTTLE FUELINJECTOR DAMPER FUELPULSATION FUELFILTER FUELPRESSURE REGULATOR FUELPUMP FUELTANK (EVAPIVALVE FUELTANK EVAPORATIVE EMISSION
@ @ @ @ @ @ @ @ @ @ @ @
@ @ @ @ @ @ @ @ @
AIR CLEANER RESONATOR (PCV} POSITIVE CRANKCASE VENTILATION VALVE THREEWAY CATALYTICCONVERTER ITWCI CANISTER EVAPORATIVE EMISSION {EVAPICONTROL EVAPORATIVE EMISSION IEVAPIPURGE CONTROL VALVE SOLENOID EVAPORATIVE EMISSION {EVAPICONTROL CANISTEF VENTSHUTVALVE EVAPORATIVE EMISSION IEVAPITWO WAY VALVE EVAPONANVE EMISSION SOLENOID {EVAPIAYPASS VALVE FUELTANK PRESSURE SENSOB EVAPORATIVE EMISSION WAY VALVE IEVAPITHREE PURGE JOINT
(t
11-14
-'97 Model Electrical Connections

l-1r
f_
--- --- -t
-lla^^^
tirr
n l no 3wrcx (.J
-'o.:\
T:
I 4
H tl
aEt30F TDC 3ErcON ctP SErAOi CKF 3EN30F TOEIIF-
l-
-'tl
-]lrL
Dl"ii
I-6,
' ^li lGPl
I
f----;;l
t l
oa 9I3
ctovEu
A' lGI
t l
aztL@, FUEL ll'tlEcToes Xo.2
|NJ2 3
catDcP
cra Tltcl Gt ct(iP?
[{J3 A2
er2cxP{
cfl ct(Ftr
Dta ELtr
||tL c|| v!]3

TL T'
uNx coi||lEctoh
f1
b __-l d
t
c. K.uirE
^cc^r?
^ca 6
to l/C CLUTCfl BELAY to iÔl^toh F tl REI Y, @III'C|{AEi FA'I iEL Y
rtT
qr 3c3
ALTF CI'
SERVICE Cl|ECK @ NEqroi
EII ATPI{P
rt: usA
ila
E
t'-
bI. ATPfi
6u I
r
B2aAtPtX
E' TPDI gi7 alP:l Ei. ATPI
)r^ l
t *l f
GAIXIE ASSEIBLY
D{NDtir
I I
Att lE FOgn ON 3wltc
: FUSES (DBACKuP (RADro) (7.sr0. @ "o^n ttot (tuo)' * (DBATfERY(IOOA) rcl (4oA)* o
(DFt E/ flsA). @ No.13 FUELPU P ('l5A) O No. 2s METER(7.5A) (D NO.'I5 ALTERNATORSP SENSOB(7.5A)* O No. 3i STABTERSIGNAL (7.5A) *: In lhc und?r.lrood tu$/rclay bor (cont'd)
11 - 1 5
SystemDescription
-'97 Model(cont'dl Electrical Connections
CONIROI SOLENOIO VALVE EVAPPUFGE
SPEOSENSOR COUNERSHAFI SPEEDSENSOF
CONTNOL SOIENOID VALVE A
PFESSUhE COI{TFOL
sotENotD vALvE
Tor lEiLocK coNtFol UNlt
IERi'INAL LOCATIONS
11 - 1 6
YEL/BLU FED/BI(
(SErOR r) HO2S
l-
(cont'd)
11-17
System Description
No.2 FUEL IIUECIOF cl09
11-18
BLK,TEL JflI
BLU rdHT , -----L+ alx
Frrt\rFEl L-fJl ||
l-
CONDENSERFANFELAY
*1 : USA
(cont'd)
11 - 1 9
SystemDescription
c -F
E h- -F rF
ARN
B R N :BLK eLKr
BLKj
BLxj
8Rt,l,'BLxj ARN,'BI.K.
c113
11-20
cat.,auxt
LT GAN
BLVBLU
RED
GRN BLU,
an12
GAUGE ASSEI'BLY
I
enr2-{
I
I
GEABPOSINON SWITCH A,ry
*".r".o'-
) Inor.".o"*
CONTROL UNIT
(cont'd)
11-21
SystemDescription
-'97 Model lcont'd) Electrical Gonnections
t,l
T
IVTII/BLU -
/8LU l
|l
U
WHT/LU
. l wltT/BLr( ( c352 WHT/BLK
,J I
rcl ({0A} HOiXsIOf 05A)
wltT/GRt{
CRN/FEO
GRI{/FO
BLU/ORN
ALU/'IVHT
T"*,,*.
_f ".*
BLU/W8T
UNOER]IOOD fUSE,/FEIAY 8OX
Btur,tvrr I -.'|
r'tc3r srAaIES
SG|I|^L 05 )
;rfi
BLK/FED
,ato"nL
""r _g!:f
'I_
FUSE/BELAY BOX
11-22
*2: USA
(Fromp!9.1r-221
ca32
**r2",-*J-1
YEVGRN YEvErK -___-I BLU?'I'HT -GRN,/YEL I -YEVGnN
I
PGII.FI UAIN RELAY
"*
--1
C56-2
trru^n -_BLK -
-]
i\
//--\
I
dL
- \_-,/ , /
FUELPUMP
11-23
SystemDescription
-'98 - 00 Models Electrical Connections
lg il T t ( 1 1 BATTERY \ ffi \ t. ro3Ecl,|{r / STAFIEF F q,t

I REL Y
FUEL IUECIONA
lo ^/c clwclr hEL Y lo iADIAIORFAl{iEt Y, coittct{3F F l{ FCLAY Yo|/C all'lc8
att
OAT'OE alsErELY"
tr
POSll|O|l S TClt
ovEi-odYE
*1: A/T '2: USA *3: '98 modol *il: '!X) - 00 model!
(DEAGK (RADlo) (75A). uP @ HoB sroP (rsAr (tood' O BATTERY (Drci (4oa)' O Fl E/trl(lsA)r (ONo.13FUEL (l5A) PUmP O No.2s HETER O.5a) (DNo.15AITERNATOB SENSoR (7.5A)' SP 3l stcNAL (7.5A) @r.ro. STAnTER t: in tha und!..hoodfule/irl.y box
TESTTACHOiIETER coNr{EctoB CoNTEOLUNIT+r lo CRUISE TANK PRESSUFE SENSOF VAIVE CONTROL SOIENOID EVAPPURGE
VETIT SHUTVALVE EVAPCONIFOLCANISTEF
sp:rosENsoF*1 COUNIERSHAFT SPEEDSENSOR'T A*1 coNlRo! solENotD vALvE
H02S (SENSOF 1)
COI'TIFOL UNIT*! TOINTEFLOCK
rcrocrsgrson*'
TERI/lINAL LOCATIONS
(cont'd)
11-25
SystemDescription
Electrical Connections '98 - 00 Models (cont'dl
G] - l
ct sEt{goh
' c14t I J/C
llo23 (SEltgOi O
l!to2srfic
SECOiD hY HO2a (aE toh 2)
11-26
Iil
t t r: r E 1 tl ll
I I
Y sExsoF I
I ll Y s.nsoR I l | IL|
I f-=-r '""
ILfr l-
. - ac x P I Y sErsonl
I
I |
FI
t q l r-__:__-)
{o.l
FUEL IIUECIOF
No. 3 FUE! IiUECIOn
r - l l _ , I
(cont'd)
11-27
SystemDescription
-'98 - 00 Modelslcont,dl Electrical Connections
l M
l--
+
_
sL( yEL JJ{FiE-l sLU wnf li,"+l

8rk _{lr]]]]]]] |
F >rt
-4.
" l---r
i w;i-nu
' a
r q - v--J K
t_.1
CONOEflSERFANRELAY
rlrA/T .2: USA *4: '99 - 00 models
11-28
".o"*'-{l -- 3 |
CONTROI soLENOroVALV
elrcvrlJ-l
tT GFtt/wxt
,o""r"*Jffil "."** {H I
ca6l
sotEtrolo vALvE
'.,r".u-fffil
GR/8LX'-11-
,.YGRN'-I f+<-l
FUEI TAIIX PRESSUBE SENSOF
To CRt ISE coNtFol u|{lt
*1 : A/T (cont'd)
11-29
SystemDescription
-'98 - 00 Models(cont'dl Electrical Conneetions
fJ-
fJ
fJ
f:t
9RN/
F l
!l T
BRN/
F]
atx'
T l
BRN/ gLxl aLKl BRN/ aLKl c121
BLKt
r=r
BRN/
eLxr
STNFT @NTFOL SOICNOIDVALVE
c115
IIAINSIIAFI SPEED SENSOF c119
clll --l
A/t cLulctl PFESSURE COIiTTHOL SOIENOID VALVE
11-30
n"t,lonrJ 1"r.]
L : ]
-*"{
r-YEL.- --_l cRN

l-- GRN/BLK ILTGRN1 -BIK/BLU
] -.,]
REO BtuT
r.I=
-*i] -::'",1
*I : A/T +3: '98 model
(cont'd)
11 - 3 1
SystemDescription
-'98 - 00 Models(cont,dl Electrical Connections
OVE&ORVE OFF [{DtcatoR LlfP
C UqEAASEr|ELY
A/I GEAA PO3MON SWITCH
*tnzaeo'
) ,r*ear_oo,
@lillFo|. ur{tT
* 1 :N f *4: '99 - 00 modets
11 -3 2
L*_"."{h
c$3 c.r'
-*^;1n-;"*, u
-
cl/I
crxl
I *,,,,".u:][
wF /BLx__1
c35lI
,-wnrzEr-x{
8uc{rHr --l
-!"'*
clfz
u|,|oEF-ftooD BOI FUAE/NEIAY
=-
B ITEFY
r-t
Lh-v
BMIG STITCH
E|.UflTT' YEVORN cal7 9q/wHr Et&{lll BLX/WFI
YEL
{cont'd)
11-33
SystemDescription
-'98 - 00 Models(cont'dl Electrical Connections
PGU.FI MAII{BEIAY
-YEL/GBN-BLx-_L
cs6-2 ,z-_\ p \ -f l- \ ./
"---.,
FUELPUI{P
cssr
11-3 4
SystemDescription
-'97 Model SystemGonnectors [EngineCompartmentl
MAIN WIRE HARNESS
UNOER.HOOD FUSE/RELAY
..'.'.'
80x
ct21 cl11
cl16
11 - 3 6
cl11
cl15
c 6 eFr 1 1 2 l
cl.t7 r-r=l r 2 l
t l
2 l
I 3 l . l
w
--l Ft RE!'wr lll ft'-cRN/sLK,
l r , r l
f,_rr'Hr-lwHr'------T!-Isrf,-*--/r*".er* I]]ll -;-BLi'uF
c129 .__1-..']..-r 1 1 2 3 l
ffl.E*-------lO stx,YEL I
TtlBru/"Nr----
c35l
c354.'
l4;i;1_s;:a
'-{-l-r
riiiltTf,n
fd,sLK rHr-----l
t-rlBL(
19
cFNnEo
*2: USA
YEUBLKl NOTE:o Different wireswith the samecolor havebeengivena numbersuffixto distinguish them {for example, and YEUBLK, not the same). are O: Related Fueland Emissions to System. - Connector with maleterminals(doubleoutline): View from terminalside - Connector with femaleterminals(singleoutline): View from wire side
(cont'd)
11-37
SystemDescription
-'97 Model {cont'd) SystemGonnectors [EngineCompartment]
MAIN WIRE HARNESS
ENGINE WIBE HARNESS
cr03
c105 tusAl l
c105
cr07 rfjl
l l . 2 l
cr08 1 1 2 l
r__F 2
1 1
-+ 2 l l l
l 3 l . l
r#-r
l r , 2 3 l
I T'*--film----t
[--1;N,/ruo; l]]l ] t,Id&Yr
titna.
tl
|.-T;s,,. -
t F l
tildK"ri t ltlB$jrma -
cltxt
t0
r--q ll 2 l
r--= lr 2l
A
li
u)
e@;----
{ ' ) \:)
t.;ERN,f Ttl;Eor-L -_-]l -
l';FELM
----l
lEl;.
lEl*",]!
o
I
N O T E :. . .
t D i f f e r e n t i r e s w i t h t h e s a m e c o l o r h a v e b e e ng i v e n a n u m b e rs u f f i x t o d i s t i n g u i s h h e m ( f o r e x a m p l e , w YEUBLK1 YEUBLK' not the same). and are O: Related Fueland Emissions to Svstem. - Connector View from terminalside with maleterminals(doubleoutline): - Connector with femaleterminals{singleoutline): View from wire side
11 - 3 9
System Description
SystemGonnectors lDashand Floor]-'97 Model
DASHBOARD WIRE HANNESS MAIN WIRE HARNESS
REAR HEATED OXYGEN SENSOR HARNESS SUA
WIREHARNESS
cat2
titT T)l
t]l filsl].Mr
FT-I l5l'ri":'*l]]l
lwittost crui.! comrol)

1 I
3
9 t0 1'l
2
/ 9
,t\./
r\.2
18 t,/
20
1ol,/ /
1 3 1 a 1 1 5 16 ./
ta
r$r
l t 4 . l' l
riTLiGN --]]l I111
lolZmlvv{-l -l l@is',t'A' t-l

I
f.Tt.-f f
rtTa*
lo-6dN'!Hnl .]l
[tltu/cs
c426 rrFr-r | 1 1 23 l . l
t';l;Kvi-l
fol**"---
NOTE: o Different wires with the same color have been given a number suffix to distinguish them (for example.
YEUBLKl and YEUBLK' not the same). are

a O: Related Fueland Emissions Svstem. to
View from terminalside Connector with maleterminals(doubleoutline): View from wire side with femaleterminals(single outline): Connector
(cont'd)
11-41
SystemDescription
SystemGonnectors [Dashand Floor]-'97 Model (cont'dl
DASHEOARD WIRE HARNESS
MAIN WIRE HARNESS
11-42
5 l6 '11
9 to l 8 l9
1 t 12 13
-t
i
(}
NOTE: o Differentwires with the same color have been given a number suffix to distinguish them (for example,
YEUBLKI and YEUBLK' are not the same).

a O: Related Fueland Emissions to Svstem. a - Connector View from terminalside with maleterminals(doubleoutline):
Connector with femaleterminals(single outline); View from wire side
(cont'd)
11-43
S)stern Dessr\ptron
SystemConnectors lDashand Floor]-'97 Model {cont'd)
MAIN WIRE HARNESS ENGINE WIRE HARNESS
//l
tao,
c1z2
(PCM.AI
{PCM.D}
11-44
ct23 {PCM-Al
c124 (PCM,B)
1 2 \ 3 1 5 6 1 8 1 1 1 2 1 3 r a 1 5 1 6 '11 l 8
iJq
.t
,,
cr25 tPCM-Cl
cr26 tPicM-ol
1 2 3 a 5 X r r l 1 2 13 l a t 5 t 6
9 1 0
1 1 t 8 19 20
ii) !t D
o
lit
o o n n a
1 1 1 1 2 t 3 !il
6 '16 I t
9 1 0
't8 t9 20
t NOTE:o D i f f e r e n w i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e rs u f f i x t o d i s t i n g u i s h h e m ( f o r e x a m p i e , t YEUBLKT YEUBLK2 not the same). and are Svstem. O: Related Fueland Emissions to - Connector View from terminalside with maleterminals(doubleoutline): - Connector View from wire side with femaleterminals(singleoutline):
11-45
System Description
-'98 Model SystemConnectors lEngineGompartment]
MAIN WIRE HARNESS
UNDER.HOOD FUSE/RELAY BOX
ENGINE w|RE HARNESS
*2: USA
11-46
ctt5
ct10
t'ltl [.1.1
lSlwHr ------lo GnNAUC I TdTBLx/YEL-----1 fdBtx vNP
\,v
tdTiaotfi-----l ---l
IETcRll,aLX'
fr
ffi
fr
I6rc;iEiF--l ll IltIYEr,
fr
fr
ct19
fr
l6lcnN' lo eLU' -'l
SLKI
f'Ttfrl
L4.lrl
I ldTcRN/BrF----lO iEo/BL(
LrsLU
cRY
tdFLxr-----l
T
T
I O BL|ÊL l6l6tu/rJHr'
tsTYE'Jrr
-1|
c354*'
G361
r'ft]
16T816rr-----l lol "." I
lO GF&aEp I
fr
lSTLr GRr/wHr--F ]ilwH-----
NOTE;. . .
Different wireswith the samecolor havebeengivena numbersuffixto distinguish them (for example, YEUBLK1 and YEUBLK, not the s8me). are O: Related Fueland Emissions to System. - Connector with maleterminals(doubleoutline); View from terminalside - Connector with femaleterminals(singleoutlinel:View from wire side (cont'dl
11-47
System Description
-'98 Model (cont'd) SystemConnectors lEngineCompartmentl
MAIN WIRE
ENGINE WIRE HARNESS
c t5
{usa)
t'ltl I'l.l
Ttlrsrtsu
ftT,,tHr/FEpi
r'ftr
.
IET$'rmc' -- I ftlarxrEl-l ftlwn/srt l
NOTE: o Differentwires with the same color have been given a number suffix to distinguish them (for example,
YEUBLKl and YEUBLK, not the same). are o: Related Fueland Emissions to Svstem, a - Connector Viow from terminalside with maleterminals(doubleoutline): - Connector with femaleterminals{singleoutline): View from wire side (cont'd)
11 - 4 9
SystemDescription
-'99 - 00 Models SystemGonnectors lEngineCompartment]
MAIN WIRE HAENESS
UNDER.HOOO FUSE/RELAY BOX
ENGINE WIRE HARNESS
cl11
c114
15
c116
cl17
c118
ffirl lilr
t-lwHn-----t
I ' IGRNtsLI'
,g
1lI
ffi
ft
ffi
ffi
ffi
f"l".*,.
rdTnEDlllHr-----l6lcRN/Buc -
----
Effi-ffiffi
trhlx,l/vH?
c121
c129
ffi
'1)
f'ftf
t6-tBrK -----_l
l]l I l lBrxrEr lShLU^,/Nrr
c135
Gt51
Gt52
ElzTt)
IiTYvnED-----l TdTcFN/rHr, FfREp/cFr l
Gt54.'
-Ell 1 l 23 l
ldTBLxr'rtvii-----l TitlBL. I o cFN/Frp l
*2:USA YEUBLK1 them (for example, NOTE:o Different wireswith the samecolor havebeengivena numbersuffixto distinguish YEUBLK, not the same). and are a O: Relatsd Fueland Emissions to System, a - Connector with maleterminals{doubleoutline): View from terminalside - Connector View from wire side with femaleterminals(singleoutline): (cont'd)
11-51
System Description
-'99 - 00 Models{cont'dl SystemGonnectors [EngineCompartment]
MAIN WIRE HARNESS
11-52
c103
c104 l1 2l
f -T;iE;;n I ' WNT]FEDI ---L
c105 (usA)
c105 {Canadal
c107
c108
Ir zl
lrlBR,r tll
FIrt
lslrl
filBLKry.L ll]I fu-,wHrcn[ l]l ftl-wNr/sr't ---l TaTtNanEc!
r'fifl
-'-l fi'Iw|r/nE D. -_-l T'TBt(ryEL t]l
ffi
|iTYEULX' -I
ffi
FfBLK//EL---l -l l -IREor/Ar
t lnrtsrr
-rfnri-r
c134 c109
10
c133
ffi
---l l-!. IYEUBLK.
ffi
1 " 1 " " '-
riaF.\rjrr. - l]l I ttInEoYEr,
c137
c303
fil
----l FEp/Bru
N O T E :. . .
t D i f f e r e n w i r e s w i t h t h e s a m e c o l o r h a v e b e e n g i v e n a n u m b e rs u f f i x t o d i s t i n g u i s h h e m ( f o r e x a m p l e . t are not the same). YEUBLK' and YEUBLK' Svstem. to O: Related Fueland Emissions - Connector View from terminalside with maleterminals(doubleoutline): - Connector View from wire side with femaleterminals{singleoutline):
11 - 5 3
System Description
SystemConnectors [Dashand Floorl-'98 - 00 Models
\
DASHBOARD WIRE HART{ESS
Ita|l{ wtRE HARIIIESS
REAR HEATED OXYGEN SENSOR SUBHAR ESS LEFT SIDE WIRE HAR ESS
1 1 -5 4
c4r2
ll,Vt'll
6fswYv-ii----
E-rn
--
F lwir,L(
-l
!E!E!t
LT GRN
3
I
rolrr
/l/lt
l/
r . l , / za
/te
tol./ /llEl1.lt6
r . l/
tl
tHrBLt
lwlrhot|t crub. 6.trroll
-ftr
I'X.l l ' l . l
l-i'f iifiN ftTGRY fdlGiffil fdlw{rcftr -----l ---1
r'TfifiI
TdliL,,rw{r----I l @ c R M/ H r ' lO wt{r D' ---l I TofuLr/,txl-
rdT6iffi---l ET----- ---l l.T--
NOTE:o Differentwires with the same color have been given a number suffix to distinguish them (for example, not YEVBLK1 YEUBLK' are the same). and a O: Related Fueland Emissions System. to View from terminalside a - Connector with maleterminals(doubleoutline): (cont'd) - Connector View from wire side with femaleterminals(singleoutline):
11 - 5 5
SystemDescription
SystemConnectors lDashand Floorl-'98 - 00 Models(cont'd]
c510
DASHBOARD WIRE HARNESS
MAINWIEE HARNESS
'4: '99 - 00 models
11 - 5 6
rE0
c508 2 3 a
1 l 12 13 6 E 9 10 1 5 1 6 1 1 1 8 1 9 20
.,
|l!
c552
c580
c546
trLtzl |.-l.T'|
r,'ffijt
vl5l6l 1-t""' -----l
I I l]l I lo lLrcRN, I O IsLKM/Hr l r l I t lYErrLU T-ilcirrlLrr
\:9
a.a
YEL
ffi rcrBr.
l--l
I t
rdTYEcii-----lll
ETGRN/Brxi - lll fSliaGFNr-
I a l Y E U c n NftTYEL'BrK
c760
c76t*.
mJv
F6EFN----t 2 l
, - + , ,
ftTcll-l
I IO IBLK
l.f.T'-]
''l
lrl2l3l1l
ftTYEUsr. t TstYEr *4:'99 -00 models NOTE: .
ftTwHr/BL(---'1 f.ft1.
(for example, Different wires with the same color have been given a number suffix to distinguish them
are not the samol. and YEUBLKT YEUBLK' System to O: Related Fueland Emissions View from terminalside a - Connector with maleterminals{doubleoutline): - Connector View from wire side outline); with femaleterminals{single
(cont'd)
11-57
System Description
SystemConneetors lDashand Floorl-'98 - 00 Models(cont'dl
DASHBOARD WIREHARNESS
MAIN WIB HARNESS
ENGINE WIRE HARNESS
n lno,
c,47 (ECM/PCM.A} c121 (ECM/PCM-8)
(PCM.D}
c't22
c124 {ECM/PCM.B}
cl25 tECM/PCM-C)
1 I 2 3 a 12 t 3 l t a 't5 t 0 1 1 t 8 t 9
tt
c126 (PCM-O)*,
c121*3
c127'.
c132
ot33
3 1 t 12 l 3
6
C,r47(ECM/PCM-Al
10
l 6 17 la t9
*1:4,/T *3: '98model '4:'99- 00models NOTE:. . .
'1all
Differentwires with the same color have been given a number suffix to distinguish them {for example, not and YEUBLK1 YEUBLK' are the same). Svstem. O: Related Fueland Emissions to - Connector View from terminalside with maleterminals(doubleoutline): - Connector View from wire side outline): with femaleterminals(single
11-59
Troubleshooting
Troubleshooting Procedures
How To BeginTroubleshooting When the Malfunction indicator Lamp(MlLl has beenreported or there is a driveability problem,usethe approprion, procedure ate belowto diagnose and repairthe problem. A. Whenthe MIL hascome on: 1. Connect (DLC)locatedbehindthe the Honda PGM Testeror an OBD Il scantool to the 16PData Link Connector right sideof the centerconsole. Turn the ignitionswitchON (ll). Checkthe DTCand note it. Also checkand note the freeze frame data. Referto the Diagnostic TroubleCode Chart and begintroubleshooting.
NOTE: . SeetheOBDll scantool or HondaPGMTesteruser'smanuals specific for operating instructions. . The scantool or testercan read the Diagnostic TroubleCodes(DTC), freezeframe data,currentdata,and other EngineControlModule(ECM}/Powertrain ControlModule(PCM) data. . Freeze frame data indicates engineconditions the when the first malfunction, misfireor fuel trim malfunction was detected. can be usefulinformation lt when troubleshootino. B. Whenthe MIL has not come on, but there is a driveability problem,referto the SymptomCharton page 11-64. C. DTCswill be indicated the blinkingof the Malfunction by Indicator Lamp{MlL)with the SCSservice connector connected. Connectthe SCS serviceconnectorto ServiceCheckConnector shown. {The 2P ServiceCheckConnecror as rs locatedbehindthe right side of the centerconsole.) Turn the ignitionswitchON 0l).
DATA LINKCONNECTOR I16PI
11 - 6 0
ll.
ResetProcedure ControlModule{PCM) EngineControtModule(EcM)/Powertrain will resetthe ECM/PCM. Eitherof the followingactions . (see the oBD ll scan tool or s use the oBD ll scantool or Honda PGM Testerto clear the ECM' s/PCM'memory. instructions ) operating for Testeruser'smanuals specific HondaPGM 10
box for fuse/relay (7.5 the BACKUP (RADIO) A) fuse from the under-hood . Turn the ignitionswitchoFF. Remove seconos.
BACKUP {RADIOII7,5 AI FUSE
BOX FUSE/RELAY
must be done afterany troubleshooting) {this procedure lll. FinalProcedure and there are no is connector connected. lf if 1. Removethe SCSServiceConnector it is connected. the SCSservice will stayon when the ignitionswitchis turnsd oN (ll). the storedin the ECM/PCM, MIL DTCS Procedure. Reset 2. Do the ECM/PCM 3. Turn the ignitionswitchOFF ( the 4. Disconnect OBD ll scantool orHonda PGMTesterfrom the DataLinkConnector16P)'
(cont'd)
11 - 6 1
Troubleshooting
Troubleshooting (cont'd) Procedures
lf the inspection a particular for code requires voltageor resistance checksat the EcM/pcM connectors, removethe right kick panel.Unboltthe EcM/PcM.and connectthe backprobe setsand a digitalmultimeteras described below,checkthe systemaccording the procedure to described the appropriate for code(s) listedon the followingpages.
@@)@)c,
How to Us6 tho BackprobeS6ts connectthe backprobe adapters the stacking to patchcords.and connectthe cordsto a multimeter. Usingthe wire insulation as a guide for the contoured of the backprobe tip adapter,gently slidethe tip into the connector from the wire side until it comesin contact with the terminalend of the wire.
Backp.oboAdapto.
BACKPROBE SET o'SAZ - (xtlqDA lTwo requir.dl
DIGITAI. MULTIMETER (Commarci.llyrvrilabl.l or KS-AHM-32-@3
11-6 2
CAUTION: . Puncturingthe insulation on a wile can causepoor ot intelmittent electricalconneciions. in . Bring the tester probe into contact with th terminal from the terminal side of wire htrness Gonnectors the engine probe and do not insgrt lhe probe. comoartment. Fol temale connectols,iust touch lightly whh the tester
(cont'd)
11 - 6 3
Troubleshooting
Troubleshooting Procedures(cont'dl
Symptom Chart Listedbeloware symptomsand probable causes problems for that DO NOTcausethe Malfunction Indicator Lamp(MlL)to come on. lf the MIL was reported go to page 11-60. on, Troubleshoot eachprobable causein the order listed(from leftto right)until the symptomis eliminated, The probable causeand troubleshooting pagereference be found below. can SYMPTOM Enginewill not start Hardstarting Coldfast idletoo low Coldfast idle too high ldle speedfluctuates Misfireor rough running
LOl/\/power
PROBABLE CAUSE 4 , 2 , 3 , 5 , 2 0 ,' t 5 ,1 2, 4, 12,17,14, 't9 7 ,a , 9 ,6 , 1 7 7,8,9,11,10 9 , 7 , 8 ,' t 1 ,1 0 Troubleshootfor misfire on pages '11-126, 1|21 2, 10,11,13,'17,18,20 2 , 4 , 1 2 , 1 , 2 0 , 9 , 5 ',t 6
Engine talls s OtherProbable Causes an enginethat will not start: for - Compression - Intake leakage air - Enginelockedup - Timing belt - Startingsystem - Overheating - Battery ProbableCauseList (Forthe DTCCh8rt, see page ll-75.) ProbableCause
'I
Page 11-42 I 1-178 11-187 Section4 't1-'t31,146 I 't-95 11-152 1'l-168 11-169 11-196 11-'194 '1 -90 'l 11- 103 11-137 Section14 11- 166 r1-194 11 , 1 9 9 11-203
System
Engine (ecvtffi controt ruoaute

Fueloressure PGM-Fl main relav lgnitionsystem positionsensorcircuit Crankshatt Position/Top DeadCenter/Cylinder Intake Temperature (lAT)sensorctrculr Air ldleAir Control(lAC)Vatve Fastidle thermo valve ldle speedadjustment Throttle body Throftlecable ManifoldAbsoluteP."""rr"ffi (TP)sensor ThroftlePosition pressur"(gnnoBarometric gear positionsignal Ay'T Brakeswitchsignal Air Cleaner Three Way CatalyticConverter(TWC) Evaporative emission(EVAP) control Contaminated fuel
5 6 7 8 10
'11
12 14 15 16 17 18 '19
20
11 -6 4
ECM/PCMData variousdata can be the OBD ll scan tool or the Honda PGM Testerto the 16Pdata link connector(OLC), By connecting practice The retrieved from the ECM/PCM. itemslistedin the table belowconformto the SAErecommended by The HondaPGMTesteralso readsdata beyondthat recommended SAE. failuresor engineproblems. of this understanding datawill help to find the causes intermittent NOTE: and on valuesand may be differentdepending the environment values" given below are approximate The ',operating vehicle. the individual "at in warmed up, transmission position Unlessnotedotherwise. idle speed" meansidlingwith the enginecompletely turnedotf. the A,./C all accessories and Parkor neutraland Data Diagnostic TroubleCode (DTC) Desc.iption Oprating Valuo FreezeData
EngineSpeed
lf no problemis detected, a detects problem,it will storeit as a lf the ECM/PCM there is no output. of codeconsisting one letterand tour numbers code (Poxxx) on Depending the problem,an SAE-defined (P'lxxx) will be outputto the code or a Honda-defined tester. Nearlythe sameas computesenginespeedfrom the signals The ECN4/PCN4 indication tachometer Position sensor. sentfrom the Crankshaft the This data is usedfor determining time and amountof At idle speed: '97 - 98 models: fuel iniection. 750t 50 rpm '99 - 00 models: 730f 50 rpm pulsesignalsfrom the Vehicle converts The ECM/PCM SpeedSensor(VSSIinto speeddata. Nearlythe sameas indication speedometer With engin6stopped: Nearlythe sameas atmosphericpressure At idle speed: 2a - 41 kPa{210- 310 i m m H g ,8 . 3- 1 2 . 2 n H g )
YES
YES
Vehicle Speed
YES
pressure causedin the intakemanifoldby The absolute Manifold engineload and speed. Absolute (MAP) Pressure
YES
into voltcoolanttemperature EngineCoolant The ECTsensorconverts The the ECM/PCM. sensoris a thermistor age and signals Temperature with coolanttemperachanges whose internalresistance {ECT) from the usesthe voltagesignals ture.The ECM/PCM fuel the to ECTsensor determine amountof injected Heated Oxygen Sensor(HO25) (Primary, Sensor1) (Secondary Sensor2)
With cold engine: Sameas ambienttemPeratureand IAT With enginewarmed uP: approx.163- 2'12'F (73- 100"c) V 0 . 0- 1 . 2 5 the detects oxygencontentin OxygenSensor The Heated At idle speed: to gas and sendsvoltagesignals the exhaust the controls about0.1- 0.9 the Based thesesignals, ECM/PCM on ECMiPCM. the airlfuelratio.Whenthe oxygencontentis high (thatis. the ratio), than the stoichiometric when the ratiois leaner is lower. voltagesignal Whenthe orygen contentis low (thatis, when the ratio ratio),the voltagesignal is richerthan the stoichiometric is higher.
YES
NO
(cont'd)
11 - 6 5
Troubleshooting
Troubleshooting (cont'd) Procedures
Data HO2S Feedback Loop Status Descliption Loop statusis indicated "open" or "closed". as Closed: Basedon the HO2Soutput,the ECM/pCM determinesthe airlfuelratioand controls amountof the injected fuel. Open:ignoringHO2Soutput,the ECM/pCiM refersto sig, nalsfrom the TP, MAP,and ECTsensors controlthe to amountof injected fuel. Operating Value At idle speed: closed Freezo Data
YES
ShortTerm F u e lT r i m
The airlfuelratiocorrection coefficient correcting for the t:20y" amountof injected fuel when HO2S feedback in the is closedloop status. Whenthe signalfrom the HO2Sis weak,shortterm fuel trim gets higher,and the ECM/PCM increases amountof injected the fuel.The airlfuelratio gradually gets richer, causinga higherHO2Soutput. Consequently. shortterm fuel trim is lowered. the and the ECM/PCM reduces amountof injected the fuel. This cyclekeeps the airfuel ratiocloseto the stoichiometricratiowhen in closedlooDstatus. Longterm fuel trim is computedfrom shon term fuel trim and indicates changes occuringin the fuel supply systemover a long period. lf long term fuel trim is higherthan 1,00. amountof the injected fuel must be increased. it is lowerthan L00. lf the amountof injected fuel must be reduced. The IAT sensorconverts intakeair temperature into voltage and signalsthe ECrU/PCM. When intakeair temperature is low, the internalresistance the sensor of increases, the voltagesignalis higher. and Basedon the accelerator pedalposition, opening the angleof the throttlevalveis indicateo. lgnitiontiming is the ignitionadvance angleset by the ECM/PCM. ECM/PCM The matches ignitiontiming to the drivingconditions. CLVis the engineload calculated from the MAp data. ! 20%
YES
LongTerm F u e lT r i m
Intake ir A Temperature (IAT) Throttle Position

lgnition Timing
With cold engine: Sameas ambienttemperatureand ECT At idle speed: approx.10% A t i d l es p e e d 1 6 ' 1 4 . : BTDC with the SCSservtceconnector connected. At idle speed: 2A- 410/o At 2,500rpm with no load: 13 - 260/o
YES
NO
Calculated LoadValue (cLV)
YES
11 _ 6 6
-'97 Model ControlModuleTerminalArrangement Powertrain
A FCM CONNECTOR (32P)

frminal numlreJ Wire color YEL 2
Telminal nama lNJ4(No.4 FUEL INJECTOR)
Wire sideof lemaleterminals
voltageis 12V. battery NOTE:Standard

Description Drives No. 4 {uel injector. DrivesNo. 3luel injector. Drives No.2 tuel injector. Drives No. 1 fuel injector. D ves secondaryheatedoxygen sensorheater. Drivesprimary heatedoxygen sensor heater, With ignition switch ON {ll): batteryvoltage duty Withfully warmedup enginorunning: controlled With ignition switch ON lll): batteryvoltage with fully warmed up enginerunning:duty controll6d Less than 1.0V at all times With ignition switch ON (ll): batteryvoltage With ignition switch OFF:0 V duty controlled With nginerunning: engine coolant With enginerunning, battery voltage below 154'F(68"C): enginecoolant With enginerunning, duty controlled above 154"F(68"C): 0 V for two secondsafter turning ignition switch ON lll), then batteryvoltage With comoressorON: 0 V With compressorOFF:bafteryvoltage With MIL turned ON: 0 V With MIL turned OFF:bafteryvoltage enginerunning: With tully warmed-up battery voltage load:0' with smallelectrical During driving With ignition switch ON (ll): bafteryvoltage pulses With enginerunning: Lessthan 1.0V at alltimes With ignition switch ON (ll): batteryvoltage 0 With engineswitchOFF: V fan 0 With radiator running: V With radiatorfan stopped:bafteryvoltage Signal duty controlled With enginerunning:
6
I
10 l1
l N J 3( N o . 3F U E L INJECTOR) l N J 2{ N o . 2F U E L RED INJECTOR) l N J l ( N o .l F U E L BRN INJECTOR) (SECONDARY SO2SHIC OXYGEN SEN BLK WHT HEATED CONTROL) SORHEATER (PRIMARY PO2SHTC HEATED OXYGEN BLKAr'YHT HEATER SENSOR CONTROL} GROUND} 8RN/BLK LGl (LOGIC PG1lPOWER GROUND} BLK
BLU
YEUELK
BLI(BLU
IGPl lPOWER SOURCE} AIR IACV{IDLE VALVE} CONTROL PCS(EVAPPURGE CONTFOL SOLENOID VALVE) PUMPRELAY) FLR(FUEL
12
Groundforthe PCMcontrol circuit. Ground for the PCMpower circuit. Power sourcefor the PCMcontrol circuit. Drives IACV. Drives EVAPpurge control valve. solenoid
REDryEL
16 11 18 19* 20
GRN/VEL 8LI(RED
Iuel pump relay. Drives clutch relay. DrivesAy'C DrivesMlL. controlsignal. Sendsalternator
CLUTCH ACC (A,/C RELAY} MIL (MALFUNCTION GRN/ORN INDICATOR LAMP} ALTC(ALTERNATOR WHT/GRN CONTROL} YEUGRN BRN/BLK BLK YEUBLK GRN
22
23 24 27
ICM(IGNITION CONTROL Sendsignitionpulse. MODULE) GROUND} Groundtor the PCMcontrolcircuit. LG2(LOGIC GROUND} Groundlor the PCMpowercircuit. PG2{POWER Power sourcefor the PCMcontrol IGP2 SOURCE} {POWER circuit. (RADIATOR FAN Drives radiator{an relay. FANC CONTROL)
*: USA
{cont'd)
11-67
Troubleshooting
-'97 Model (cont'dl Powertrain ControlModuleTerminalArrangement
PCMCONNECTOR I25PI B
B PCM CONNECTOR I25P}

Terminel number 1
color
terminals Wire sideof female
NOTE:Standard batteryvoltageis l2 V.
Terminal name Oescription DrivesA,/T clutch pressure control valve solenoid DrivesA,/T clutch pressure control solenoid valve
D r i v e ss h i f t c o n t r o l s o l e n o i dv a l v e A .
Signal With ignitionswitchON (ll):duty controlled With ignitionswitchON (ll)rduty con trolled
LS 1A/TCLUTCH PRESSURE CONTROL -) SOLENOID VALVE RED LS + (A"/T CLUTCH PRESSURE CONTROL VALVE +) SOLENOID CONTROL SHA(SHIFT A) SOLENOID VALVE
8LU//EL
4 5
I
GRN/BLK YEL PNK
LCB (LOCK-UP CONTFOL VALVEB) SOLENOID LCA (LOCK.UP CONTROL VALVE A) SOLENOID
(Ay'T ATPD3 GEAR POSITION SWITCH}

SHB(SHIFT CONTROL VALVE 8} SOLENOID
11
GRN/VVHT
12
WHT/BED GRN/BLK
ILU(INTERLOCK CONTROL UNITi D4IND(04 INDICATOR LIGHT}
In 2nd,R position. 2nd and 3rd gearin in D4, D3 position: Batteryvoltage In lst gearin D4,D3 position, 4th gear in in D4 position: V 0 voltage Drives lock-up controlsolenoid With full lock-up; Baftery valveB, With half lock-up: duty controlled With lock'upON:battery voltage Drives lock-up controlsolenoid With lock-up OFF:0V V DetectsA/T gear position switch In D3 position:0 ln any otherposition: battery voltage signal. _ valveB. In 1st,2nd position, 1st and 2nd gearin in Drives shiftcontrol solenoid D4,D3 position: Battery voltage In R position, 3rd gearin 04, D3,in 4th ;n gearin D4 position: V 0 Detects interlock controlunh signal. With ignitionswitchON (ll)and brake pedaldepressed: battery voltage light. With D4 indicator lightturnedON:battery DrivesDl indicator voltage With D4 indicator lightturnedOFF: V 0
14
NMSG (MAINSHAFT Groundtor mainshaftspeedsensor. SPEED ENSOR ROUND} S G
RED 16
1'l
BLU BRN GBN
18 22 23 24 25
BLU YEL
LT GRN
NM (MAINSHAFT SPEED SENSOR) ATPR(A"/T GEAR POSITION SWITCH) ATP2(A./T GEAR POSITION SWITCH) ATP1(4,,/T GEAR POSTTTON SWTTCH) (COUNTERSHAFT NCSG SPEED SENSOR GROUND) NC (COUNTERSHAFT SPEED SENSOR) (M GEAR ATPD4 POSITION SWITCH) ATPNP {A/TGEAR POSITION SWITCH)
Detectsmainshaftspeedsensor srgnal,
Detects A/T gear position switch srgnal.
pulses With enginerunning: InRposition:0V In any otherposition: battery voltage In 2nd position: V 0 In any otherposition: voltage battery ln lst position: V 0 In any otherposition: voltage battery
DetectsA/T gear position switch srg al, n DetectsA/T gear position switch srg al, n Groundtor countershaft speed sensor, Detectscountershaftspeedsensor srgnal. DetectsA,/Tgear positionswitch srgnal. DetectsA/T gear positionswitch signal.
With agnition switchON (ll),and lront pulses wheelsrotating: In D4 positionr V 0 In any otherposition: battery voltage In parkor neutral:0 V In any otherposition: about5 V
11 - 6 8
C PCMCONNECTOR (31PI
C PCMCONNECTOR {31PI
ferminal number
terminals Wire sideof femaie
batteryvoltageis 12 V. NOTE:Standard
Terminal name
Wire color BLUiRED
Doscription Detects CKFsensor. Detects sensor. CKP Detects TDCsensor. cYP sensor. Detects Detects switchsignal. A,/C Detects starterswitchsignal. checkconnector Detects service (the causing DTC a signal signal indication) scantool Sendsand receives srgnal. Powersourcetor the PCM for Power source control circuit. the DTCmemory
Ground for CKFsensorsignal.
Signal : W i t h e n g i n er u n n i n g p u l s e s With engine running: pulses With engine running: pulses With engine running: pulses
't 2 3
4 5
(CKF P SENSOR CKFP SIDE) (CKP P SENSOR CKPP BLU SIDE) (TDC P TDCP SENSOR GRN SIDE) (CYP P CYPP SENSOR YEL SIDE) ACS(A/CSWTTCH BLU,frED SIGNAL) SWITCH STS(STARTER BLU/ORN SIGNAL) BRN LT BLU CHECK SCS(SERVICE SIGNAL) K-LINE
With AJC switchON:0 V batteryvoltage switchOFF: With A,/C With starterswitchON (lll): baftery voltage 0 With stanerswitchOFF: V
0 With the connectorconnected: V about With the connectordisconnected: 5 V or battery voltage
7 8
ON With ignition switch (ll):pulses

Batteryvoltage at all times
10
11
BACK VBU(VOLTAGE WHT/BLU U P )

(CKFSENSOR M WHT/RED CKFM SIDE)
12 13
14
WHT RED BLK
(CKP signal. I\4 Ground CKP lor sensor SENSOR CKPM SIDE) (TDC signal. SENSOR M for TDCM Ground TDCsensor SIDE} (CKP signal. M for sensor SENSOR Ground CYP CYPM SIDE} (P/S PSPSW PRESSURE DetectsPSPswitch signal.
16
GRN
swtTcH)
17
WHT/RED
FR ALTF(ALTERNATOR SIGNAL)
FR Detects alternator signal. VSS Detects signal.
18
SPEED VSS(VEHICLE BLUA/VHT SENSOR)
At idle with steeringwheel in straight ahead position:0 V At idle with steeringwheel at full lock: battery voltage With fully warmed up engine running: 0 V-batteryvoltage {dependingon load) electrical Wirh ignitionswitch ON (ll) and front wheels rotating:cycles0 V - 5 V or battery voltage
(cont'd)
Troubleshooting
-'97 Model (cont'd) Powertrain GontrolModuleTerminalArrangement
O PCMCONNECTOR {16PI
PCM CONNECTOR (I6P) D f.rminal Wir! color numbcr 1 Trminal nam6 TPS ffHROTTLE POSITION SENSOR}
Wiresideof f6male terminals
NOTE: Standard battery voltage is 12 V. Description DetectsTP sensor signal. Signal With throttlefullv oDen:about4.8V With throttlefullv closed: about0.5V With ignitionswitchON {ll):about 0.1- 4.8V (depending engine on coolanttemperature) With ignitionswitchON (ll):about3 V At idle;about 1.0V (depending enginespeed) on With ignitionswitchON (ll):about 5 V With ignitionswitchOFF:0 V With brakepedalreleased:0 V With brake pedal depressed:battery voltage With throttlefully openedfrom idlewith fully warmed up engine:above0.6V With throttlequicklyclosed:below 0.4v With ignitionswitchON lll): about 0.1- 4.8V (depending intakeair on temperaturel With ignitionswitchON (ll):about5 V With ignitionswitchOFF:0 V Lessthan 1.0V at all times Lessthan 1.0V at all times
RED/BLK
ECT(ENGINE COOLANT DetectsECTsensor signal.
RE D,4/VHT TEMPERATURE
SENSOR
MAP(MANIFOLD Detects MAP sensorsignal. RED/GRN ABSOLUTE PRESSURE SENSOR)

VCCl (SENSOR YEURED VOLTAGE)
E
Powrsourcefor MAP sensor. Detectsbrakeswitch signal.
GRN/WHT
BKSW(BRAKE SWITCH)
WHT
(PRIMARY PHO2S HEATED OXYGEN SENSOR 1) SENSOR

IAT (INTAKE TEM. AIR PERATURE SENSOR)
Detectsheatedprimary oxygen sensor(sensor1) signal.
DetectsIAT sensor signal.
RED//E L YEUBLU
GRN/BLK GRN/WHT
10
11 12
(SENSOR VCC2 VOLTAGEI

SG2(SENSOR GROUND) SGl (SENSOR GROUND)
Providessensor voltage. Sensorground. Groundfor MAP sensor. Groundfor secondary heated orygen sensor(sensor 2).
13
14
SHO2S SG (SECONDARY HEATED RED/YE L OXYGEN SENSOR, SENSOR GROUND) 2 (SECONDARY SHO2S HEATED OXYGEN WHT/RED SENSOR, SENSOR 2)
Detectssecondaryheated orygen sensor(sensor 2) signal, Detects ELDsignal.
With throttlefully openedfrom idlewith fully warmed up engine; above0.6V With throttlequicklyclosed: below
0.4 v
EL (ELD)
16* GRN/RED With parkinglightsturnedon at idle about2.5- 3.5V With low beamheadlights turnedon a t i d l e :a b o u t1 . 5- 2 . 5 V
1 -7 0
ControlModuleTerminalArrangement 38 - 00 Models Engine/Powertrain

A ECM/PCMCONNECTOR (32P}
5 a
It 2l s!u
I
,/./
t5
sca
,/
l,/
n
CI
sTs
Wire sideot femaleterminals
A ECM/FCMCONNECTOR {32P)
D93cription
bafteryvoltageis NOTE:Standard
Signal W i t h i g n i r i o n s w i t c h O N { l l ) rb a t t e r y v o l t a g e With igîtion switch ON (ll): battery voltage
'12 V.
BLU LT GRNMHT
2WBS{EVAPBYPASS S O L E N O IV A L V E ) D VSV {EVAP CONTROL CANIS TEBVENTSHUTVALVE) E C R S( C R U I SC O N T R OS I G ' L NAL) PCS(EVAP PURGE CONTROL VALVE) SOLENOID
Drives EVAP bvoass solonoid valve.
D.ivesEVAPcontrolcanislervent shut ShiftOownsignalinputfrcmcruisecon

Drives EVAP purge controlsolonoid valve.
5',
BLU
p W h e nc r u i s e o n t r o i s u s e d : u l s e s c l , c , W i t h e n g i n sr u n n i n ge n g i n e o o l a n tb e l o w1 5 4 ' F (68'C)rbatteryvoltage r , c , W i t h e n g i n e u n n i n ge n g i n e o o l a n ta b o v e1 5 4 " F {6a'C}rduty conl.olled With ignitionswitch ON (ll): baneryvoltage r : W i t h f u l l yw a r m e du p e n g i n e u n n i n gd u t y w i t h r h el e r m i n a c o n n e c t e d :v l 0 W i t ht h e r e r m i n a l d i s c o n n e c t e d r a b5 v to r ou i W , r h0 4 ' , O " i n d r c a t ol r g h tt u r n e dO \ b a t t e r , V W i t h D 4 * 3D * . i n d i c a t olri g h tt u r n e dO F F r 0 ,
RED/YEL
ELIOWHT
S O 2 S H T( S E C O N D A R V C HEATED OXYGEN SENSOR HEATER CONTROL) SCS(SERVICE CHECX SIGNAL)
Drivessacondaryheatedoxygen sensor
10
BRN
Detects seNics check conneclor signal (he signalcausinga DTC indicatjon)
l4'r
GRN/8LK GRNI/EL AL|(/RED GRN/ORN BLU GRN 8LU/t/EL WHT/RED
( D4INDD4INDICATOR)+3 D I N D( D I N D I C A T O R T I P R F L R( F U E L U M P E L A Y ) RELAY} ACC(I/C CLUTCH INDICA. MIL (MALFUNCTION TORLIGHT) E N E P( E N G I N S P E E D U L S E ) P FANC{RADIATOR FANCON TROL)
K-LINE
Dr'indicaior light. DrivesD4*3.
16
17
Drivssfusl pump relay. Drivesl,/C clurch rclay. DrivsMlL. Outputsenginespsed pulse. Drivesr6diatorfan rslay. s S e n d s n d r e c e i v s c a nt o o l s i g n a l . a secondaryhatdoxygensensor Detects
0 V f o r i w o s e c o n d sa f t e r r u ' n i n 9 i g n ' l i o n s w i l c h ON lll), then banery voltage
18 19 20 21 23 21 26 2f
W i t hc o m p r e s s o r N r 0 V O OFF:batteryvoltage With compressor With MlLturned N:0V O With MIL turned OFF:batteryvoltage : W i t hs n g i n er u n n i n 9 p u l s e s fr V W i t h r a d a a t oa n r u n n i n g : 0 With radaatorfan stopped:batteryvollage With ignition switch ON (ll): p'rlses With throttlefully openedfrom idle wilh fully 0 w a l m e du p e n g i n ea b o v e . 6V : with rhrottlequicklyclosed:below 0-4V Whh staner switch ON (lll): batlery voltage With srarterswitch OFF:0 V
At idle with steeing whel in stBighl aheadposition:0 V At idls with nee ng wheel al full lockr banory voltage
(SECONDARY SHO2S HEATED SENSOR. SENSOR 2i OXYGEN SWITCH SIG, STS (STARTER NAL} PSPSW {P/SPsESSUFE SIGNAL) SWITCH ACS (Ir'C SWTCH SIGNAL} SLU {INTERLOCK CONTROL UNIT) ( P T A N K F U E L A N KP R E S ' T SURE ENSOR) S E L( E L D }
BLU/WHT
GBN
Dotocts srarterswitch signal. Detecrs PSPswitch signal. Dtects ly'C switch signal.
Orives interlock control unil.
BLU/BEO WHT/NED
LT GRN
With Ay'C switch ON:0 V With l/C swilh OFF:about 5 V

With ignilion switch ON (ll)and brakepedal depressed: battery vohage W i t h a g n i t i o ns w i t c h O N ( l l ) a n d f u e l f i l l c a p opensd; about 2.5 v
2A'\
29
Detocts fueltank pressuresensorsignal. DetectsELDsignal.
GBN/FED GRN/WHT BKSW(BRAKE SWTTCH)

Dstcts brake switch signal.
r 2 W i r hp a a i n g i g h t s t u m e d a t i d l e : a b o u t. 5- 3 . 5V on u W i t h l o w b e a mh e a d l i g h tts m e do n a t i d l e : about .5-2.5V 1

W i r h b r a k e p e d a l r e l e a s e d : 0V With brake pedal depressed: battery vollage
13: '98 modsl 15: USA
(cont'd)
11-71
Troubleshooting
- '98 - 00 Models Engine/Powertrain ControlModuleTerminalArrangement (cont'd)
B ECM/PCMCONNECTOR {25PI
B ECM/PCMCONNECTOR I25PI
Ierminal Wire color numbt 1 Terminsl name
Wiresideof femaleterminals
bafteryvoltageis l2 NOTE:Standard
Description Signal
YEUBLK BLK RED BLU YEL
voltswitchON (ll):battery source the ECM/PClvl with ignition for IGPl(POWER SOURCE) Power age control circuit. V with ignition switchOFF:0 ( R control Lessthan 1.0V at all times P G 1 P O W EG R O U N D } Ground for the ECM/PClvl
circuit.
roR)
( l N J 2 N o . F U E LN J E C - DrivesNo. 2 Iuel injector. 2 I
With engine running:duty controlled
l N J 31 N o . F U E LI N J E C - DrivesNo. 3Iuel jnjector. 3 TOR) l N J 4{ N o . 4 F U E LI N J E C - DrivesNo. 4 fuel injector. TOR)
8*1
WHT YEUBLK BLK BRN
control LS- (A"/T CLUTCH PRES. A,/T clutchpressure valvepowersupply SURE CONTROL SOLE, solenoid _ NOID VALVE SIDE) negative terminal. for IGP2IPOWER SOURCE) Powersource the ECN,I/PCM control circuit. (POWER control PG2 GROUND} Ground for the ECM/PCM
l N J l ( N o . 1 F U E LI N J E C TOR) crrcurt. DrivesNo. l tuel injector. Sendsignition pulse.
With ignition switch ON (ll):duty controlled With ignition switch ON (lll: baftery voltage With ignition switch OFF:0 V '1.0 Lessthan V at all times With engine running:duty controlled With ignition switch ON (ll): battery voltage With engine running: pulses With ignition switch ON (ll):duty controlled With OVER-DRIVE indicatorlight OFF turned ON: 0 V OFF With OVER-DRIVE indicatorlight turned OFF:battery voltage
10
'
YEUGRN TROL MODULE) RED
rcM {rGNrTroN coNLS+(A,,IT CLUTCH PRES SURE CONTROL SOLE+ NOID VALVE SIDE) (OVER-DRIVE ODIND OFF INDICATOR} LG1(LOGIC GROUND)
17*1
19*.
PNK
control A,/T clutchpressure valvepowersupply solenoid positive terminal Drives OVER-DRIVE OFF light. indicator
20
BRN/BLK
VBU (VOLTAGE BACK WHT/BLU U P ) 22 23 BRN/BLK BLVBLU LG2(LOGIC GROUND) IACV{IDLEAIR CON. TROLVALVE)
for control Lessthan 1.0V at all times Ground the ECM/PCM circuit. Powersource the ECM/PCM Batteryvoltage at all times for control circuit. Power fortheDTC memory. source
Ground for the ECN4/PCM control ctrcutt, DrivesIAC valve. Lessthan 1.0V at all times With engine running: duty controlled
*2t MlT *3: '98 model "4: '99 - 00 models
11-72
C ECM/PCMCONNECTOF (31PI
C ECM/PCMCONNECTOR (31P)
Termidal
Wire sideo{ femaleterminal
batteryvoltageis 12V. NOTE:Standard

D.3cription Signal Wilh ignition switch ON (ll): baneryvoltsge duty With ftrllywarmsd up ngine runnang: With fully wafmod up ngine rnningrbanry voltago Du ng driving with small elsctricallo6d:0 v pulses With engine knockang: r V u W t h f u l l y w a r m e d p n g i n eu n n i n g : 0 - b a t t e r y on voltag{dpending slsctricalload) Lssthan 1.0v 6t all times W i t h n g i n u n n i n gp u l s s r r with ihfottls fully openedfrom idle with fully, walm6d up engins:above0.6 V With throttloquicklyclossd:below 0.4 v t W i t h i g n i t i o n w i t c h N ( l l ) : a b o u3 V s O s A t i d l s :a b o u l1 . 0V { d s p s n d i n o n e n g i n e p e e d ) g Lsssthan 1.0V at all tims
Power soufce to MAP snsor.
8LI(WHT
HEATED POzSHTC {PRIII4ABY HEATER OXYGEN SENSOR CONTROL) CON, ALTC(ALTERNATOR TROL) K S( K N O C K E N S O R ) S FR ALTF(ALTERNATOR SIGNAL} R S G 1( S E N S O 6 8 0 U N D } (CKPSENSOF SIDE) P CKPP M CKPI.,I| {CKPSENSOF SIDE) PHO2S HEATED {PRIMARY SENSOR 1) OXYGEN SENSOR, MAP (MANIFOLD ABSOLUTE PRESSURE NSOR) SE B S G 2( S E N S O G N O U N D i VCCl {SENSOR VOLTAGE) TDCP{TDCSENSOR SIDE) P M TDCM ITDCSENSOR SID) ( P CKFPCKF ENSOR SIDE) S SENVSS (VEHICLE SPEED
Drivssprim6ry h$ted oxygsn sensor
Sondsalternalorcontrol signsl.
2"
3'1
WHT/GBN FED/8LU WHT/RED
DstectsKS signal. Detects alternatorFRsignal. Groundfor l/tAP sensor. DatclsCKPs6nsor. Groundfor CKPsnsor. Detoctspfimary he6t6doxygenssnsor {sonso1)signal. r D6tects MAP snsorsign6l.
5 1 8 9 15
GRN,4trHT
BLU
17 18 19 20 2l
RED/GRN GRN/BLK YEUBED GRN RED BLU/RED
With ignition switch ON (ll): about 5 V With ignition switch OFF:0V W i t he n g i n e u n n i n gP u l s e s f : With sngins running: pulsss O W i t h i g n i t i o n w i t c h N ( l l ) a n df r o n tw h e e l s s rotaringrcyclss v- 6bout 5 V or banryvoltage 0 With igniiion switch ON (ll):about 0.1 - 4.8 V (dpnding iniate air tmpraturc) on With ignition switch ON (ll): about 0.1 4.8 V on {doponding 6ngincoolanllemper6tu16) with rhrottls fully opn: aboui 4.8 v with throtrl6fullyclosed: about 0.5 v With ignilion switch ON (ll):about 5 V Whh ignitionswitch OFF:0 V With ngins runningrpulsss
Derecis TDCsensor. Groundfor TDCsensor. DstsctsCKFsnsor.
22
23 25 26 27
BLU/WHT
RED//EL REO/WHT RED/BLK YEUBLU YEL BLK
vss Dstscrs signal.

Detacts IAT sensorsignal. oetsctsECTsensorsignal. TP Dotects sensorsignrl. Provids snsorvoltage. DsrsctsCYPsensor. Groundfor CYPsansor. 6.ound lof CKFssnsorsignal.
soR)
IAT (INTAKE TEMPERA' AIR TURE ENSOB) S ECT{ENCINE COOLANT TEMPERATURE SENSOR) TPS (THROTTLE POSITION SENSOR) VCC2lSENSOR VOLTAG} CYPP ICYPSENSO8P SIDE) CYPM(CYPSENSOR SIDE) M
2A
29 30 31
M WHT/RED CKFM{CKFSENSOR SIDE) 11.AfT 13. '94 model '2:M/T 14:'99- 0omodsls .5: USA
(cont'd)
11-73
Troubleshooting
Powertrain Control Module Terminal Arrangement -'98
ECM/PCMCONNECTOR {16P} D
- 00 Models (cont'dl
PCM CONNECTOR (16P) D
NOTE:Standard batteryvoltageis 12V.

Ds4ription Sign!l With lock-upON: b6tteryvoltags W i t hl o c k - u p F F : 0 O V In 1st,2nd position,in lst and 2nd gear anD4, D3 (D)11 position:batteryvohag In P, R, N position,in 3rd geaf in D1, D3 (D)*. position,in 4th gear in D4 (D)*rpositionr0V With full lock-up:8atteryvoitage With half lock'uprdutycontrolled With ignition switch ON (ll): batteryvoltage With ignition switch OFF|0 V In any other positjon:battsryvoltage Drivesshift conrrolsolenoidvalvp A. In 2nd, R position,an2nd and 3rd ge6r in D4, D3 (D)r' posilion:batleryvoltage In 1st gear in 04, 03 {D)}. position,in 4th gear in D 4 ( D ) * .p o s i t i o ni,n P , N p o s i t i o n : 0 V In D3position:0 V h any other posiiion:banryvoltage With Ovor Drivs OFF(O/DOFFindicatorlight t u r n e dO N ) :0 V Wilh Ovsr Drivs ON (O/DOFFindicrto.lasht turned OFF): about 5 V I n D 4 r 3O * . p o s i t i o n : 0 , V In any other posilion:batteryvoltage With ignition switch ON (ll), and ffonr wheels W i l h e n g i n e u n n i n gp u l s e s r :
YEL
LCA {LOCK,UP CONTBOL SOLENOID VALVEA) S H B( S H I F T O N T R O L C SOLENOIO VALVEB)
Orivslock'up conrrolsolenoidvalve A.
Drivesshift controlsolenoid valve B.
2+1
GBN,M/HT
GRN/BLK BLK/YEL
LC 8 (LOCK,UP CONTROL SOLENOID VALVEB} VBSOL(BATTERY VOLTAGE F O R O L E N O IV A L V E } S D ATPR{AI GEAEPOSITION SWITCH) SHA (SHIFT CONTROL SOLENOID VALVEA)
Driveslock up controlsolenoidvalve B. Powrsourceof solenoidvalvs. DelsclsA/T gear posrtionswirch srgnal.
BLU,ryEL
PNK
ATPD3(AT GEARPOSITION
Detects A,/Tgar poshionswirchsign6l.
swrTcH)
O D S W( O V E R . D B I V E I T C H ) Detects SW OVEF-DRIVE swirch sagnal.
PNK
9'' 10.,
YEL BLU RED
ATPDI}3,O}I {AT GEAR POStTtON SWTTCH) NC (COUNIERSHAFT SPEED SENSOR) NM IIVAINSHAFT EED SP SENSOB)
Dotcts A/T gar positionswirch signal. Detsctscounlrshaft speedsensor Detectsmainshaftspeedsensorsign6ls.
N M S G{ M A I N S H A F T S P E E D Groundfor mainshaftspeedsensorSENSOB BOUND) G

'13*1 LT GRN
ATPNP(AT GEARPOSITION
DelectsA,/Tgear positionswitch signat. DstectsA,/Tgear positionswitch signal.
swtTcH)
ATP2(AT GEARPOSFION
I n p a r ko r n u t r a l : 0 V h any other posilion:about 5 V h any othsr position:batteryvoltsgs
8LU 15.' t6''

i1:A/T '2: M/T
swrTcH)
ATP1{AT GEARPOSITION DetsctsA/T gear positionswitch signal.
BRN GRN
*3:'98 model *4:'99 00 models
swrTcH)
NCSG COUNTERSHAFT { SPEED ENSOR ROUND} S G Grouodfor counterchaft spedsnsor.
In any other position:htteryvoltage
11-74
DiagnosticTrouble Code (DTCIChart

DTC (MlLindication*l
P0107 (3) Detection ltem ManifoldAbsolute Pressu.e Circuit Low Input ManifoldAbsolute Pressure Circuit H i g hI n p u t Intake Air Temperature Circuit Range/Performance Problem lntakeAir Temperature Circuit Low Input lntakeAir Temperature Circuit H i g hl n p u t EngineCoolant Temperature Circuit Range/Performance Problem EngineCoolant Temperature Circuit Low Input EngineCoolant Temperature Circuit H i g hI n p u t ThrottlePosition Circuit Low Input ThroftlePosition Circuit H i g hI n p u t PrimaryHeated OxygenSensor Circuit Low Voltage (Sensor 1) ProbableCause Openor short in MAP sensorcircuit MAP sensor ECMiPCM Open in MAP sensorcircuit MAP sensor ECM/PCM . IATsensor 11-95 Short in IAT sensorcircuit IAT sensor ECM/PCM Open in IATsensorcircuit IAT sensor ECM/PCM Pago 't'l-90
P0108
{3)
11-92
P01 1*3 1
(10)
P0112
(10)
11-96 'I 1-97
P0113
(10)
P0116
(86)
ECT sensor Cooling system Shortin ECT sensor circuit ECT sensor ECM/PCM Open ECT in sensor circujt ECT sensor ECM/PCM
Openor short in TP sensorcircuit TP sensor ECM/PCM
11-99
P0117
(6)
11 - 1 0 0
P0118
(6)
11-101
P0122
\11
11-103
P0123
l7l
Open TPsensor in circuit TPsensor ECM/PCM

1) Short in PrimaryHO2S{Sensor circuit PrimaryHO2S(Sensor1) Fuelsupplysystem ECM/PCM Openin PrimaryHO2S(Sensor circuit 1) PrimaryHO25(Sensor1) ECM/PCM . PrimaryHO2S(Sensor1) . Exhaust system . Openor short in PrimaryHO2S(Sensor 'l) heatercircuit . ECM/PCM
11-107
P0131
(1)
11-110
P0132
(1)
PrimaryHeated Orygen Sensor CircuitHighVoltage (Sensor 1) Primary HeatedOxygen Sensor Slow Response (Sensor 1) PrimaryHeated OxygenSensor Heater CircuitMalfunction {Sensor1)
' 1 11 1 3
P0133
(61)
11 'I16
P0135
(41)
11-12'l
*: TheseDTCS connector Indicator Lamp (MlL)with the SCSservice will be indicated the blinkingof the Malfunction by connected. **: The E (E)*u indicator tightand the Malfunction Indicator Lamp(MlL)may come on simultaneously. *1' AIT *3 '97 model +5;'99 - 00 models *2: MlT *4:'98 model {cont'd)
11-75
Troubleshooting
DiagnosticTrouble Code (DTCIChart (cont'd)
DTC
lMlL indicationl
P0137
Detectionhem
Secondary Heated Oxygen Sensor Circuit Low Voltage { S e n s o r2 ) H S e c o n d a r y e a t e dO x y g e nS e n s o r C i r c u i tH i g h V o l t a g e
Probable Caus. (Sensor circuat Shon in Secondary HO2S 2) (Sensor Secondary HO2S 2) ECM/PCM (Sensor circuit Open Secondary in HO2S 2) (Sensor HO2S Secondary 2) EC|\il/PCM (Sensor HO2S 2) Secondary (Sensor Open orshonin Secondary HO2S 2) heater circuit EC|V/PCtu
Fuel supply system P r i m a r yH O z S( S e n s o r1 ) Contaminated fuel E x h a u s tl e a k a g e
Page
'n-1t7
(63) (63)
P0138 P0139
1 11 1 8
Secondary Heated Oxygen Sensor {63) 2i lSensor

P0141 (65) Second6ry Heated Oxygen Sensor Heater C i r c u i tM a l f u n c t i o n ( S e n s o r2 ) System Too Lean P0r71 (45)
11-120
11
't2l
1 1124
System Too Rich P0112 (45)
Fuelsupplvsystem (Sensor Primary HO2S 1)

11124
Contaminated fuel
Random Mistire and lgnition system Fuel supply system I A Cv a l v e C o n t a m i n a t e du e l f L a c ko f f u e l C y l i n d e r1 C y l i n d e r2 C y l i n d e r3 - C y l i n d e r4 Misfire Detected Knock Sensor {KS) Circuit Malfunction P0325*5 F u e li n j e c t o r Fuel injector circuit lgnition system 11-126
Po3ol P0302 P0303 P0304

P0301 P0302 P0303 P0304
ltr \ 112 | 173 i \74t

/71 \ 112| 173| \74l {23)
{4} (4) {67)
't't 127
Open or shon in Knock Sensor (KS) circuit K n o c kS e n s o r( K S ) ECM/PCt\4 Crankshaft Position Sensor Crankshaft PositaonSensor circuit ECl\,l/PC l\,'! Crankshaft Position Sensor Timing belt skipped teeth Three Way Catalytic convener Secondary HO2S {Sensor 2) EVAP Purge Control Solenoid valve EVAP Purge Control Solenoid valve circuit Throttle gody (purge port) Tubing PCM FuelTank PressureSensor ECM/PCM
11-130
P033s P0336 P0420
Crankshaft Position Sensor Circuit

Crankshaft Position Sensor Range/Performance Catalyst System Efficiency Below Threshold Evaporative Emission ControlSystem Insulficient Purge Flow
11-131 11,131 't1-200
P0441*3
(92)
'It 205
P0451*5 (91i
F u e l T a n kP r e s s u r e e n s o rC i r c u i t S Bange/Performance Fuel Tank PressureSensor Circlit Low Input F u e l T a n kP r e s s u r e e n s o rC i r c u i t S HighInput
t't-208 11-209
P0453*r.5
{91)
OpsnorShortin FuelTank Pressure Sensor circuit FuelTankPressure Sensor ECM/PCt\4 Openin FuelTankPressure Sensor circuit Fuel TankPressure Sensor ECt /PCt\.1
11-211
*: TheseDTCS will be indicated the blinkingo{ the Malfunction by Indicator Lamp (MlL)with the SCSservice connector connected. **: The E (El*s indicator light and the Malfunction Indicator Lamp{MlL)may come on simultaneously, *1; A/T *3: '97 model *5: '99 - 00 models *2: MlT *4: '98 model
11-76
DTC (MlLindicationl P0500 t17)*,
Dotection ltom Vehicle Speed Sensor Circuit Malfunction

VehicleSpeed SensorCircuit Malfunction ldle Control System Malfunction Automatic Transaxle
ProbableCause Vehicle Speed Sensor Vehicle it Speed Sensor circu ECtVI Vehicle Speed Sensor Vehicle Speed Sensor circuit PCM IACvalve ThrottleBody Fastidlethermovalve*1
Page
11 - 1 3 5
P0501
l17J*1
11-135 ' ]1 150
P0505
(14)
P0700 P0715 PO720 P0730 P0740 P0753 P0758 P1106 (13)
Section l4
P1107
(13)
P1108
(13)
Barometric Pressure Circuit Range/Performance Problem Barometric Pressure Circuit LowInPut Barometric Pressure Circuit HighInpur
Throttle Position Lower Than Expected
(Baro ECM/PCM sensor)

11-137
. ECM/PCM sensor) {Baro

11-137
ECM/PCM sensor) {Baro

11,137
. TPsensor
11-109
P1121
(7)
P1122
(7)
P112a
(5)
Throttle Position H i g h eT h a n r Expected Manifold Absolute Pressure LowerThan Expected

ManifoldAbsolute Pressure HiqherThan Expected Electrical Load DetectorCircuit Low Input
' TP sensor
11-'109
. MAPsensor
11-94
P1129
(5)
' MAPsensor
1l-94
P1297 P1298
P1300'3 P0301 P0302 P0303 P0304
(20) (20)
Electrical LoadDetector Electrical LoadDetector circuit ECM/PCM

Load Detector Electrical Electrical Load Detectorcircuit ECM/PCM
11 -1 3 8
Electrical Load Detector Circuit HighInput

Random lvlisfire
11-140
7l 72 13 14
lgnition system Fuelsupply system MAPsensor IACvalve fuel Contaminated Lack offuel
11-126
*: TheseDTCS will be indicated the blinkingof the Malfunction by Indicator Lamp {MlL}with the SCSserviceconnector connected. **:The E (E])+s indicator light and the Malfunction Indicator Lamp(MlL)may come on simultaneously. *1:A,./T "3: '97 model +5:'99 - 00 models *2: M/T *4:'98 model
{cont'd)
11-77
Troubleshooting
Diagnostic TroubleCode(DTCI Ghart(cont'd)
DTC {MlLindication}
P1336 P1337 P1359 154) i54) (8) Detection ltem Crankshaft Speed Fluctuation Sensor Intermittent Interruption
Crankshaft Speed Fluctuation Sensor No Signal
ProbableCause . CKF sensor
Pagc
11-142
P1361
(8)
Crankshaft Position/Too Dead Center Sensorrcylinder Position Connector Disconnection Top DeadCenter Intermittent Sensor Interruption
Top Dead Center SensorNo Signal
CKF sensor CKF sensor circuit ECM,FCM ' CKP/TDC/CYP sensorcircuit
11-142
11-146
11-131
P1362 P1381 P1382
(8) (9) (9)
Cylinder Position Sensor Intermittent Interruption Cylinder Position Sensor No Signal Evaporative Emission ControlSystemLeakDetected (FuelTank System)
TDCsensor TDCsensor circuit ECM/PCM . CYPsensor CYPsensor CYP sensor circuit ECM/PCM F u e l f i lc a p l Vacuum connection Fueltank Fuel tankprossure sensor EVAP valve bypasssolenoid EVAP two way valve EVAP controlcanister vent shut valve EVAP controlcanister purgecontrolsolenoid EVAP valve Vacuum connection EVAP control canister Fuel tankpressure sensor EVAP valve bypasssolenoid EVAP two way valve EVAP control canister ventshutvalve Fueltank purgecontrolsolenoid EVAP valve IACvalve IACvalvecircuit ECM/PCM . ECM,FCM
11-131
11-131
11-131
P1456n.*
{90}
11-213
Evaporative Emission ControlSystemLeakDetected (EVAP Control Canister Svstem)

Pr457n.s {90)
11-219
P1508 Pr607
(14)
ldleAir Control Valve Circuit Failure

EngineControlModule,Powertrain ControlModule InternalCircuit FailureA
11-152
(-)
11-147
P1705 Automatic P1706 Transaxle '14 P1753 Section P1758 P1768 r: TheseDTCS will be indicated the blinkingoJ the Malfunction by IndicatorLamp (MlL)with the SCSservice connector connected. **: The Di (E)*5 indicatorlight and the Malfunction tndicator Lamp (MlL)may come on simultaneously. *1: A[f *3;'97 model *5: '99 - 00 models *21M/f *4: '98 model
11-7 8
How to ReadFlowcharts
A flowchartis designed be usedfrom startto final repair.lt's likea map showingyou the shortest to distance. beware: But lf you go off the "map" anywherebut a "stop" symbol,you can easilyget lost.
brARn
tw"t t.-OotO FcTloNl @ fS-OPl (boldtype)
Describes conditions situation starta troubleshooting the or to flowchart. performa test,set up a conditionetc. Asksyou to do something; Asksyou aboutthe resultof an action, then sendsyou in the appropriate troubleshooting direction. The end of a seriesof actionsand decisions, describes final repairactionand sometimes a directsyou to an earlierpart of the flowchartto confirmyour repair.
NOTE: . The term "lntermittent Failure"is used in thesecharts.lt simply meansa systemmay have had a failure,but it checks out OK at this time. lf the Malfunction Indicator Lamp (MlL)on the dash does not come on, checkfor poor connections (seeillustration or loosewires at all connectors related the circuitthat you are troubleshooting to below). . Most of the troubleshooting flowchartshave you resetthe EngineControlModule (EcM)/Powertrain ControlModule (PCM) and try to duplicate Diagnostic the TroubleCode(DTC). the problemis intermittent lf and you can't duplicate the code,do not continuethoughthe flowchart.To do so will only resultin confusion and, possibly, needlessly a replaced ECM/PCM, o "Open" and "Short" are common electrical terms.An open is a breakin a wire or at a connection. short is an acciA dental connection a wire to ground or to anotherwire. ln simple electronics, of this usuallymeanssomethingwon't (likeECM'S/PCM'S), can sometimesmeansomethingworks,but not the way it's work at all. In complexelectronics this suooosed to.
LOOSE
11-79
PGM-FI System
SystemDescription
INPUTS CKP/TDC/CYP Sensor CKFSensor MAP Sensor ECTSensor IAT Sensor TP Sensor PrimaryHO2S Secondary H02S (ECM)/ ENGINE MODULE CONTROL (PCM) POWERTRAIN MODULE CONTROL OUTPUTS FuelInjectors PGM-Fl Main Relay(FuelPump) MIL IACValve Ay'C Compressor ClutchRelay Radiator FanRelay Condenser Relay Fan ALT
""d |iuel 1"j""- Th,rhg Drrafr";-l Et*-.nt"tdt"cont.orl
vss
tcM
KS*5 BAROSensor ELD*6 StarterSignal ALT FRSignal Air Conditioning Signal Ay'T GearPosition Signal*1 Baftery Voltage(lGN.1) BrakeSwitchSignal PSPSwitchSignal *5 FuelTankPressuae Sensor*4. Countershaft SpeedSensor*1 Mainshaft SpeedSensor*r OVER-DRIVE SwitchSignal*s
to,r*,c;;trffi;]
. l.----.---:. |lmrngLonrrorI Lrgnrnon
EVAPPurgeControlSolenoid Valve PrimaryHO2SHeater Secondary H02S Heater *5 EVAPBypass Solenoid Valve*a EVAPControlCanister Vent Shut DLC Lock-up ControlSolenoid Valve*l Shift ControlSolenoid Valve*1 Ay'T Clutch PressureControl Valve*1 Solenoid *a D4 Indicator Light'1*3, *5 D Indicator Light,l OVER-DRIVE Indicator OFF Lighl*t *: * 1 :A / T '2: M/f { 3 : ' 9 7m o d e l +4:'98 model *5: '99 - 00 models "6: USA
B*k',p Fr""il] Ecir/PcM m;"t-ll-r*'io*l
PGM-FlSystem The PGM-Fl systemon this model is a sequential multiportfuel injection system. Fuel iniecior Timing and Duration The ECM/PCM containsmemoriesfor the basicdischarge durationsat variousenginespeedsand manifoldpressure. The basicdischarge duration,after being read out from the memory,is further modifiedby signalssentfrom varioussensors to obtainthe final discharge duration. ldle Air Control ldle Air ControlValve(lACValve) When the engineis cold,the Ay'C compressor on, the transmission in gear,the brakepedalis depressed, P/Sload is is the is high,or the alternator charging, ECM/PCM is the controlscurrentto the IACValveto maintainthe correctidle speed. lgnition Timing Control o The ECM/PCM contains memoriesfor basic ionition timing at various engine speedsand manifold air flow rates. lgnitiontiming is alsoadjusted enginecoolanttemperature. for . A knockcontrolsystemwas adoptedwhich setsthe idealignitiontiming for the octaneratingof the gasoline used.*s Other Control Funstions 1. StartingControl provides rich mixtureby increasing Whenthe engineis started. ECM/PCM the a fuel injectorduration. 2. FuelPumpControl . When the ignition switch is initiallyturned on (ll). the ECMiPCM supplisground to the PGM-FI main relay that supplies currentto the fuel pump for two seconds pressurize fuel system. to the . When the engineis running,the ECM/PCM suppliesground to the PGM-FI main relaythat suppliescurrentto the fuel oumo. . When the engineis not runningand the ignitionis on, the ECM/PCM cuts groundto the PGM-FI main relaywhich cuts currentto the fuel pump.
11 - 8 0
5.
Fuel Cut-off Control . Duringdeceleration iscutoffto improvefueleconomyat with the throttlevalveclosed, currentto the fuel injectors speedsover 970 rpm ('97- 98 models), 920 rpm ('99- 00 modelsl. . Fuelcut-offactionalso takes placewhen enginespeedexceeds 6,500rpm ('97 - 98 models),6900rpm ('99 - 00 models), regardless the positionof the throttlevalve,to protectthe enginefrom over-rewing. of With Ay'T model.the PCMcutsthe fuel at enginespeeds over 5,000rpm when the vehicleis not moving.*' 4,./C ComoressorClutch Relav from When the ECM/PCM receives demandfor coolingfrom the air conditioning a system,it delaysthe compressor beingenergized, enriches mixtureto assurea smoothtransition the Ay'C and the to mode. (EVAP) Evaporative Emission PurgeControlSolenoid Valve Whenthe enginecoolanttemperature above 154"F(68'C), is the ECM/PCM controlsthe EVAPpurgecontrolsolenoid valvewhich controlsvacuumto the EVAPpurgecontrolcanister, Alternator Control The systemcontrolsthe voltagegenerated the alternator accordance with the electrical load and driving mode. at in which reduces engineloadto improvethe fuel economy. the
PCMFail-saf e/Back-upFunctions 1. Fail-safe Function ignoresthat signal and assumesa pre-pre When an abnormalityoccursin a signalfrom a sensor,the ECM/PCM grammedvaluefor that sensorthat allowsthe engineto continue run. to Function 2. Back-up When an abnormality are by circuitindependent occursin the ECM/PCM itself,the fuel injectors controlled a back-up of the systemin orderto permitminimaldriving. 3. Self-diagnosis Function Indicator Lamp (MlL)l IMalfunction When an abnormality occursin a signalfrom a sensor, suppliesgroundfor the MIL and storesthe DTC the ECM/PCM in erasablememory.When the ignition is initiallyturned on {ll),the ECM/PCM suppliesground for the MIL for two seconds checkthe MIL bulb condition. to 4. Two Trio DetectionMethod To preventfalseindications, Two Trip Detection fuel idle the Methodis usedfor the HO2S*1, metering-related. control system,ECTsensorand EVAPcontrol systemself-diagnostic functions. When an abnormality occurs, the ECM/PCM storesit in its memory.When the same abnormality recursafter the ignitionswitch is turned OFFand ON (ll) again, informs the driver by lighting the MlL. However,to ease troubleshooting, this function is cancelled the ECM/PCM when you jump the service when an abnormality checkconnector, The MIL will then blink immediately occurs. 5. Two (or Three)DrivingCycleDetection Method{'97 model) A "DrivingCycle"consists startingthe engine,beginning of closedloop operation, and stoppingthe engine.lf misfiring that increasesemissions or EVAPcontrol system malfunction is detected during two consecutivedriving cycles. or TWC deterioration detected is duringthreeconsecutive drivingcycles, ECM/PCM the turnsthe MIL on. However, to easetroubleshooting, functionis cancelled this when you jump the servicecheckconnector. The MIL will then blink immediately when an abnormality occurs. *1: '97 - 98 models *2: '99 - 00 models
PGM-FI System
Powertrain Control Module {PCM}-'97
The Malfunction lndicator LamD (MlL) nev6r comes on {evenlor two seconds) after ignition is turned on (lll, or it's on dimly and flickers.
Model
(7.5 NOTE:lf this symptomis intermiftent, check a loosefuse No.25 METER A) in the for underdashf{rse/relay box, a poor connection PCMterminalA18, or an intermittent at openin the GRN/ORN wire between PCM(A18) the and the gaugeassembly.
Turnthe ignitionswitchON {ll}. ls the charging systemlighton? Try to stan the engine. Rep.ir short or opon in tho wire batween No. 25 METER (7.5Alfuso and gauge a$mbty. R6pl.cNo. 25 METER17.5Al fus.
PCM OON ECTORA {32P} PGl IBLKI
Doesthe enginestart?
Chocktor.n open in th6 wire3 PG2linesl: {PG1, 1. Turn the ignitionswitchON (ll). 2. Measurevoltage between body ground and PCM connectorterminals A10 and A23 individually. Check for an opn in the wir6 or bulb (MlL linl: 1. Turn the ignitionswitchOFF. 2. Connectthe PCM connector terminalA18 to body ground with a iumperwire. 3. Turnthe ignitionswitchON {ll).
ls thorelssthan 1.0V?
npeir open in tho wirelsl hwoon PCM and Glol (loc!t.d at thc tha.mo3tat houling thrt htd moro th.n 1.0V.
Substituto . known-good PCM and rcheck.ll symptom/indication goss away, rcplacathe original PCM.
A PCMCONNECTOR {32PI
l s t h e M I Lo n ? -
R6pai. open in th. wilei belwoon rcM lAl8l dnd g.uge a3rombly. Roolac the MIL bulb. Wire sideot temaleterminals
Substitut6 a known-good PCM and rocheck.ll 3ymptom/indication goes away, replacethe o.igin.l PCM.
11-42
The Malfunciion lndicator Lamo {MlL) stavs on o. comes on aftel two seconds,
NOTE: . Whenthereis no Diagnostic TroubleCode(DTC) the stored, MIL will stay on if the SCS service connector connected the ignition is and switchis on. . lf this svmotomis intermittent, for: check - A looseFl E/M(15Aifuse in the underdash tuse/relay box - A looseNo. 13 FUEL fuse/relay PUMP{15A) fuse in the under-dash box - An intermittent the PCM(C7)and the service checkconshort in the wire between An intermittent the shortin the wire between PCM(A18)and the gaugeassembly An intermittent shon in the wire betlveen PCM(D4)and the MAP sensor the the and the TP sensor. An intermiftent shortin the wire between PCM{D10) PGM-Fl main relay. 'See the OBD ll scantool or HondaPGM Testeruser'smanualslor specilicoperating instructions, -
Check the Oiegnosiic Trouble Code(DTC): 1 . C o n n e ca n O B D l l s c a nt o o l t or HondaPGMTester. ON 2. Turnthe ignition switch 1lli. 3. Read the DTC with the scan tool or HondaPGII Tester.
Are any DTCIs) indicated?
Go to troubleshootingprocedures (spage11501. the NOTE:An openor shortin the wire between PCM(C8)and the DLCwill keepthe You shouldioterpret lrom communicating with the PCM. scantool or HondaPGMTester this as no DTCS indicated. are
Ch6cklh6 DTCby MIL indication: 1. Turnthe ignitionswitchOFF. 2. Connect conthe SCSservice n e c t o rt o t h e s e r v i c ec h e c k connector. 3. Turnthe ignition switch (ll). ON
Doesthe MIL indicate any DTc? -
Repair opon or short in wi.6 between the PCM (C8) and Data Link Connector. Go to troubloshooting procedurs {3eepage 11-601. PCMCONNECTOR c l3lPl scs .BRNI
Try to startthe engine.
Doesthe enginestart?
C h e c kt o r a s h o r t i n t h e w i r e line): {SCS 1. Turn the ignition switch OFF a n d t u r n t h e i g n i t i o ns w i t c h oN flt). 2. Measure voltagebetweenthe P C M c o n n e c t o r e r m i n a lC 7 t and body ground.
lTo page11 84)
Wire sid6of fmaleterminalg
ls thereapprox. V? 5
Repairshort to body ground in the wire between PCM lCTl and servicecheck connector.
(To page1'l-84)
(cont'dl
11-83
-'97 PowertrainControlModule (PCM)

( F r o mp a g e 1 1 8 3 )
Model (cont'dl
Checkfor a short in the wire (MlL line): 1. Turnthe ignitionswitchOFF. 2. Disconnect PCMconnector the A {32P). 3. Turnthe ignition switch (ll). ON Repairshort to body ground in the wire between the PCM {418} and MlL.
lsthe MILON?
Substitute a known-good PCM and recheck. lf symptom/indication goes away. replace the original PCM.
InspectFl E/M (15 A) fuse in the fuse/relay box. undeFhood Reoair shod in the wire between Fl E/M {15 A} fuse and PGM-FI main relav. Replace FIE/M 115 A)fuse.
No. 13 FUEL PUMP(15Ai Inspect fuse in the underdashfuse/relay Repair short in lh wire bolween No. 13 FUEL PUMP main 115A) Iuse and PGM-FI ReplaceNo. 13 FUELPUMP A) 115 fuse.
CheckloJ a short in a sensor: 1. Turnthe ignit;on ON switch (ll). 2. Disconnect the 3P connector of eachsensor one at time: . MAPsensor
( T op a g e1 1 - 8 5 )
1 1 -8 4
(Frompage 11-84)
Does the MIL go off.,
Reolacethe Sensor that caused the lighl lo go out.
D PCMCONNECTOR (16PI VCCl NEL/RED}
Check for a short in the wires lvCC linesl: 1. Turnthe ignitionswitchoFF. the PCM connec 2. Disconnect tor D (16P). 3. Checkfor continuitybetween bodygroundand PCMconnec D4 tor terminals and Dl0 indi vidually. Repair shorl lo body ground in the wile between the PCM {D4}and the MAP sensor. Repairshort to body ground in th wire between the PCM lol0l and the TPsensor. Check tor an open in the wires llGPline3l: 1 . D i s c o n n e ctth e f u e l i n j e c t o r and IAC valve con connectors switch (lli. ON 2. Turnthe ignition v 3. [,4easure oltage between b o d y g r o u n d a n d P C Mc o n ' A'11and A24 nectorterminals individually.
terminals Wiresideof female
PCMCONNECTOR (32PI A
Checkfor an open in the wires {LGlinesl: 1. Turnthe ignitionswitchOFF. 2, Reconnect sensorconnecall tors, 3. Reconnect PCMconnector the D (16P). switch (ll). ON 4. Turnthe ignition 5 , M e a s ur e v o l t a g e b e t w e e n b o d y g r o u n d a n d P C Mc o n nectorterminalsAg a^d 422 individually.
R e p a i ro p e n i n t h e w i r e ( s l boiween the PCM 1A11,A24) and the PGM-Flmain relav. Chck lor poor connections or loose wires at ihe PGM-FI main relay. Tesi lhe PGM-FImain relav {seep.g6 1l-1871.
Wire side of lemale terminals
l s t h e r e l e s st h a n 1 . 0 V ?
R6pair open in the wire{sl between the PCM {A9. A22l and G101 {located at the thetmostat housing) that had morethan 1.0V.
Substituto a known-good PCM and rechck.It symptom/indication goos away, replacethe original PCM.
11 - 8 5
PGM-FI System
Engine ControlModule(ECM/PCM) '98 - 00GontrolModule/Powertrain Models
Tho Maltunction Indicator Lamo (MlL) n6Yor como3 on leven lor two laconds) rft6r tho ignhion is turnod ON {lll. NOTE: . lf this symptom is intermittent,checktor: - A looseFl E/M{15A) fuse in the under-hood fuse/relay box - A looseNo. 25 METER A) fusein the under-dash fuse/relay box {7.5 - A looseNo. 13FUELPUMP(15Alfuse in the underdashfuse/rolay box - An intermiftent (A18)and the gaugeassemshort in the wire between ECM/PCM the (C19) An intrmiftent shortin the wire between ECM/PCM the and the MAPsensor (C28), An intermiftent short in the wire betweenrhe ECM/PCM the TP sensor,the EGRvalvelift sensor {ueltank Dressure and/or sensor A laulty PGM-FI main relay
Turnth6 ignitionswitchON (ll).
ls the low oil pressure lighton? -
Repair lhort or opcn in tho wire between the No. 25 METER17.5Al fu3e snd the gaugeassembly. Repl.co the No. 25 METER 17.5 fus. Al ECM/PCMCONNECTOR (32P} A
Try to start the engine. Chockfor an opsn in th wiro or bulb {MlL line,: 1. Turnthe ignitionswitchOFF. 2. Connectthe ECM/PCMconnectorterminal A18 to body groundwith a iumperwire. 3. Turn the ignitionswitch ON (ll).
Wiresideof female terminals Rep.ir open in the wi.os botween the ECM/FCM lA18l and the gaugo rasombly. Roplece the MIL bulb.
ls th6 MIL on?
Turnthe ignitionswitchOFF. Inspect the Fl E/M 115A) tuse in the undeFhoodfuse/relay box.
Substitute a known-good ECM/ PCM and rochock. lf rymptom/ indication goes eway, replace tho o gind ECM/PCM.
Repair short in the wire between lhe Fl E/M (15 Al f u s G a n d t h e P G M - F lm . i n .slay. R o p l s c et h F l E / M ( 1 5 A l fu3.
I n s p e c t h e N o . 1 3 F U E LP U M P (15A) fuse in the under-dash fuse/relaybox. Repair short in th6 wire between tho No. 13 FUEL P U M P 1 1 5A ) l u s e a n d t h e PGM-FImain .elay. R e D l a c et h o N o . 1 3 F U E L PUMP115Al tuse.
(Topage11-871
(Frompage11-86) ECM/FCMCONNECTOR {25PI A IGPl (YEL/BLK)
Chck tor rn opon in tha wiioa (lGPlino.): fuel 1. Disconnectthe injctorand IACvalveconnectors. 2. Turn the ignitionswitchON {ll}. 3. Measurevoltage between body ground and ECM/PCM connctorterminals B'l and 89 individually. Repaii opon in th6 wirc{3l betw.6n tho ECM/PCM (B1. B g l l n d t h o P G M - F Im a i n roby. Chock for poor connactions or loo3 wiJo3 at the PGM-FI main ralry. T.st the PGM-FImtin r.lay (soop.ge 11-1871.
vXv)iiP2 rELlBLK)
2 I 19 10 11 21
't3 23
17
20
ls there batteryvoltage?
Chack for an opon in tho wire3 {PG,LG lino3l: 1 . R e c o n n e ctth e l u e l i n i e c t o r and IACvalveconnectors. 2. Measurevoltage between body ground and ECM/PCM connector terminals82, 810, 820 and 822 individually.
lstherelessthan1.0V?
B.pair open in the wiroltl b.twocn tho ECM/PCM .nd G101 lloc.t6d rt th. thormoiat houingl that had mo.e than 1.0 V. ECM/PCMCONNECTOR {3'IP} C | 2 i 3
7 E
Chock for a shon in the wira3 {VCCI, VCC2lin..l: Measurevoltage betweenbody ground and ECM/PCN4 connector terminalsC19and C28individuallv.
't6 1 7 1 8 1 9 20 21\22 26 27 2el E 30 31
s /
ls thereapprox.5V?
Chock lor a short in r snsor: While measuring voltage betwoen body ground and ECM/ P C M c o n n e c t o rt e r m i n a l s C 1 9 disconnecl and C28 individually, the 3P connector ol each sensor one at time: . TP sensor . Fueltankpressure sensor
vcc2
(YEL/BLUI
kt
vccl
(YEL/RED)
ls there approx. 5 V? Sub3lhuio . known-good ECM/ PCM .nd rcch6ck. lf tymptom/ indic.tion go.3 away, rapl.ce th. original ECM/PCM.
Rooairahort in tho wire btwoen tho MAP sen3or.TP sensor, Fuel tank DreaaureSonsor and the ECM/PCMtC19,C28).
R e p l e c et h e r o n s o r t h t t h a d approx. 5 V.
lcont'd)
11-47
PGM-FI System
'98 - 00 Models (cont'dl
The Malfunction lndicator Lamo lMlll 3lays on or comes on after two 3econds.
Engine ControlModule/Poweftrain ControlModule(ECM/PCM)

NOTE: . When there is no Diagnostic Trouble Code IDTC)stored,the MIL will stay on iI the SCS serviceconnectoris connected and the ignitionswitch is ON (ll). . lf this symptom is intermittent,checkfor: - An intermittentshort in the wire betweenthe ECM/PCM (A10)and the servicecheck connoctor - An intermittentshort in the wire between the ECM/PCM (At8l and the gauge assemDty . See the OgD ll scantool or HondaPGMTesteruser'smanuals specific for operating rnstructions.
Check the Dirgnostic Troublo Cod (DTCI: '1. Connect scantool or Honda a PGMTester. 2. Turnthe ignition switch (ll). ON 3. Readthe DTC with the scan tool or HondaPGMTester.
Go to troublGhooting procadura. (3c prg l lS0l
check tho DTc by MIL indication: 1. Turnthe ignitionswitchOFF. 2. Connectthe SCS serviceconnector to the service check connector, 3. Turnthe ignition switch (ll). ON Ropair op.n ol Bhort in wiro b.twe.n thc ECM/FCtrl (A21) and D.i. Link Connoctor. Go to troublo3hootlng procdur6. lt o pag. 11.6lrl
Doesthe MIL indicate any DTC?
Try to start the engine.
Doesthe enginestan?
Sub3titute r known"good ECM/ PCM .nd roch.ck. lt .ymptom/ indic.tion gooa awsy, repl.co the origin.l ECM/PCM. ECM/FCMCONNECTOF {32P) A
Check tor a 3hort in the wire ISCSlinel: 1. Turn the ignition switch OFF and turn the ignition switch
o N{ ) .
2- Measurevoltage between body groundand the ECM/ PCi, conneclor terminal A10. Wire sideof femslet6rminals
Ropria ahort to body ground in tho wi.c Mwe.n tho ECM/PCM lA10l and aarvic. check connsctor.
lTo page1l-89)
11-88
(Frompage11-88)
Checktor a short in the wire (MlL linel: 1. Turnthe ignitionswitchOFF. con 2. Disconnect ECM/PCM the nectorA (32P). 3. Turnthe ignitionswitchON (lli. Repairshort to body ground in the wire btwe.n the ECM/PCM lA18) and tho MlL. Substituto a known-good ECM/ PCM .nd recheck. lf symptom/ indication goo3 .way, replace th original ECM/PCM.
1-89
PGM-FI System
(MAPISensor ManifoldAbsolutePressure
The scan tool indicatesDiagnosticTrouble Code (DTC)POl07:A low input (high vacuum) problem in the (MAP)sensor, ManifoldAbsolutePressure The MAP sensorconvensmanifoldabsolute pressure into electrical signalsand inputsthe ECM/pCM.
OUTPUI VOLTAGE
tvl3.s 3.0
2.5 2.O 1.5 1.0 0.5
r o - 1 5 ^ 1 o 25 30 lin.H9) GAUGE .5 READIT{G 100 200 300 a00 5oo 6fi, 7d)
lmmHgl
Th6 MIL has ben reoorted on. DTCP0107is 3tored.
Problomverification: 1. Turn the ignitionswitchON lll). 2. Checkthe lvlAPwith the scan root.
ls approx. kPa(760mmHg, 101 30 in.Hg),2.9 indicated? V
lrtormittem tailu.e, lystam b OK at thb timo. Checktor poor connoctions or loosa wird at C131 (MAP rensor) and rt the ECM/ PCM.
Check for an op6n in wi.o IVCC1 linel: 1. Turn the ignitionswitchOFF. 2. Disconnectthe MAP sensor connector, 3. Turn the ignitionswitch ON {ll}. 4. Measurevoltage between the MAP sensorconnectorNo. 1 termanal No. 2 terminal. and
MAP SENSOR CONNECTOR 3P IC131I
vccl
(YEL/RED}
ls thereapprox.5 V?
Roprir opn in the wir6 bstween tho ECM/PCM(D4,C19*l and the MAP sensor.
Wiro side ol temale terminals
(Topage11-91)
11-90
{Frompage11-90)
Chocktor .n open or short in the MAP 3n30r: C h e c kt h e M A P w i t h t h e s c a n tool.
2 ls approx. kPa(15mmHg, V 0.6in.Hg),0.1 or lessindicated?
Chock for a lhort in the wire (MAPlinol: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tt h e E C M / P C M (C D connector (16P), 131P))*. 3. Checkfor continuitybetween No.3 connector the MAP sensor terminaland body ground.
(C131I 3P MAP SENSOR CONNECTOR
Rp.ir 3hort in the wire bstwcen tho ECM/PCM(D3,C17') rnd tho MAP 3rnsoi.
Wire sideof lgmaleterminals
Sub3lilut. . known-good ECM/ PCM and rocheck. lf normal MAP k indic.tcd, r.pl.co thc originrl ECM/PCM.
(cont'd)
11 - 9 1
PGM-FI System
Manifold Absolute Pressure(MAP)Sensor (cont'd)
Trouble Code (DTC)P0108: high voltage (low vacuum) problem in the A [tn,t nn-] The scan tool indicatesDiagnostic |jg (MAP)sensor. ManifoldAbsolutePressure
The MIL has boen reportedon. DTCm108 is slored. Problemveritication: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson, then letit idle. 2. Checkthe MAP with the scan tool. ls 101kPa{760mmHg,30in.Hg), 2.9V or higherindicated? Intermittent tailuro, system i3 OK at this time. Checktor ooor connections or loose wires at C131 snd the ECM/rcM. IMAPs6nsor) MAP SENSOR CONNECTOR 3P IC131I Check Ior an open in the MAP sensor: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e M A P s e n s o r 3P connector. 3. lnstall a jumper wire between the MAP sensor3P connector terminals No.3 and No.2. 4. Turnthe ignition switch {ll). ON 5. Checkthe MAP with the scan tool. ls 10'lkPa(760mmHg,30in.Hg), 2.9V or higherindicated?
tcRN/wHrll
IIRED/GRN|
Check for an open in wire (SGl liDel: 1. Remove jumperwire. the 2. Measure voltagebetween the MAP sensor 3P connectorterminalsNo. 1 and No-2. ls thereapprox.5 V? YES R6p.ir open in the wire betwoen the ECM/PCM(D12,CTrl and the MAP sensor.
vccl IYEL/RED}
Check for an open in the wire (MAPline): 1. Turnthe ignitionswitchOFF. 2. lnstall a iumper wire on the PCMconnectors betweenD3 and D12. 3. Turnthe ignition switch (ll). ON 4. Check the MAP wirh the scan tool. ls 101kPa1760 mmHg,30 in.Hg), 2.9V or higherindicated? Ropair opon in the wire between the PCM {D3, .nd the MAP son3('t.
D PCMCONNECTOR I16PI JUMPER WIRE
sGl IGRN/WHTI
Wire side of lemale termin6ls
(To page11,93) ': '98- 00 models
1 1-92
(Frompage11-92)
I
Check for an open in the wire {MAPlinel: 1. Turnthe ignitionswitchOFF. 2 . I n s t a l la j u m P e rw i r e o n t h e betlveen connectors ECM/PCM C7andC17. ON switch (ll) 3. Turnthe ignition the MAP with the scan 4. Check tool. ls 101kPa(760mmHg,30in.Hg), 2.9V or higherindicated? Bopairopn in the wi.es between the ECM/PCM(c1?l and the MAP 5en30t.
Substitute a known'good ECM/ PCMand recheck.lf normal MAP k indicated, replace the o.iginal ECM/PCM,
(cont'd)
11-93
PGM-FI System
(MAP)Sensor(cont'dl ManifoldAbsolutePressure
The scan tool indicates Diagnostic TroubleCode (DTC)P1128: ManifoldAbsolutepressure (MAp) lower than exoected.
The MIL has be6n rportedon. DTCPl128 is stored.
Problomverification: 1. Turnthe ignition switch 1lli. ON 2. Check the MAP with the scan tool,
ls 54.1 kPa(406 mmHg,16.0 in.Hg), 1.61 or higherindicated? V
I to.mittent failure, 3ydom i! OK al thbtimc,
The scan tool indicates Diagnostic TroubleCode (DTC)P'l129:ManifoldAbsolutePressure (MAP)higherthan expected.

The MIL has boenreportodon. DTCPl129 is stored.
Problemveritication: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load lin Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then Iet it idle. 2. Check the MAP with the scan tool,
ls 43.3 kPa(325 mmHg,12.8 in.Hg), '1.32 or lessindicated? V
Intarmittani fuilure, systom i3 OK at this time.
11 -9 4
(lAT)Sensor IntakeAir Temperature

1P0111 | ('97model)the lntakeAir TemDerature Sensorcircuit. (lAT)
problemin P0111: ranoe/performance A Troublecode (DTC) Diagnostic The scantool indicates
as of The resistance the thermistordecreases the intake resistor(thermistor). dependant The IAT Sensoris a temperature increases shown below as air temDerature
The MIL has beenreportedon. DTCP0111is stored. Or lrom ProbableCauseList.
RESISTANCE IKOI
Problemvetification: OFF. switch 1. Turnthe ignition the 2. Disconnect IAT sensor2P connector, the 3. Remove IATsensor. the 4. Reconnect IAT sensor2P connector, etposed the IATsensor 5. Leave to ambienttemPerature. 6 . T u r n t h e i g n i t i o ns w i t c hO N 7. check the IAT with the scan tool-
. 3' aa ro. r?a arl ,.t r.fl 20 0 to ao ao aa ioo t2otocl
INTAKEAIB TEMPERATURE
flr).
Rplace IAT son3or. the
Checkthe IAT sensor output: 1. Warm the IAT sensor with a hair dryer. 2. Checkthe IAT with the scan tool.
Did the IATrise2.0'F(1.0'C) or morefrom the ambient temperature?
Intermittent f.ilure, aY3temis OK ai this tim6.
the IAT sensor. Replace
(cont'd)
11 - 9 5
PGM-FI System
IntakeAir Temperature (lAT)Sensor(cont'dl
The scantool indicates Diagnostic Troublecode (DTC) P0112: low voltage(hightemperature) A problemin the Intake Temperature Air 0AT)sensorcircuit. The IAT Sensoris a temperature dependant resistor(thermistor). The resistance tho thermistordecreases the intake of as air temperature increases shown below. as
The MIL has been reDonedon. OTCm112 is stored, Or from ProbableCausList. RESISTANCE IKO)
Problemvsrification: 1. Turnthe ignition switch flt). ON 2. Checkthe IAT with the scan tool.
-. 32 aa rorr 1?a 2ra 2aa f.el -m 0 20 rto ao i0 too l2ofcl
ls 302'F (150'C)or higher (or H - L i m i ti n H o n d a m o d e o f PGMTesteri 0 V indicated? or ls the correct ambienttemperatureindicated,,?
INTAKEAIR TEMPERATUR
Beplocetho IAT sensor. It the engineis warm,it will b higher than ambient temperature.
Check for a short in the IAT sensot: 1. Disconnect IAT sensor2p the 2. Checkthe IAT with the scan tool.
Intermittent failure, system i3 OK at this time. Ch6ckfor poor connectiona o. loose wires rt C133 {lAT snsorl and rt th6 ECM/pCtr4.
ls 302"F{150"C) higher{or or H - L i m i ti n H o n d am o d e o f PGMTester) 0 V indicated? or
Raplace the lAT aensor. IAT SENSOR CONNCCTOR 2P (C'33I
Chckfor a short in the wir6 llAt linel: 1. Turn the ignitionswitchOFF. 2. Disconnect ECM/PCM the connector (16P}, (31P)'). {D C 3. Checkfor continuitybetween the IATsensor connector 2P ter minalNo.2 andbodyground.
i
)
'
2
)
/
A 9)
tAr (RED/YEU
-L
Wi16 sideof femsleterminals Repairshort in the wi.o botween th6 ECM/rcM {D8,C25*l and th6 IAT 3ensor. Substitute a known-good ECM/ PCM and recheck. lf normel IAT is indicaled, replace the original ECM/PCM, *: '98- 00 models
11 - 9 6
problemin the P0113: high voltage(low temperature) A TroubleCode(DTC) Diagnostic The scantool indicates (lAT)sensorcircuit. Intake Temperature Air
The MIL has beenreportedon. OTCP0113is stored.
Problemvrification: 1. Turnthe ignition switch (ll). ON 2. Checkthe IAT with the scan tool, Intermiftent failure, syatem is OK at this time. Ch.ck for Door connections or loose wires at c133 llAT s6nsorland at the ECM/ PCM.
ls -4'F (-20"C) less(or L Limit or in Hondamode of PGMTester)or 5 V indicated?
2P ICl33I IAT SENSOR CONNECTOR
Checklor an open in the IAT sensor: 1. Disconnect IAT sensor2P the connector, 2. Connect IATsensor2P con the n e c t o r t e r m i n a l sN o . 1 a n d wire. No.2 with a ,umper 3. Checkthe intakeair tempera' ture with the scantool.
sG2 {GRN/BIIO
WNE JUMPEN IAT IRED/YELI
Wire side ol female terminals
ls -4'F (-20"C) less(or L-Limit or in HondamodeoI PGMTester)or 5 V indicated?
Replace the IAT sensor.
YES
_!!7rqd9ll_____Checklor en opan in the wires llAT, SG2 lines): 1. Turnthe ignitionswitchOFF. 2. ConnectPCM connectorterm i n a l sD 8 a n d D 1 1w i t h a ON 3. Turnthe ignition switch lll). 4. Checkthe IAT with the scan tool. IAT IRED/YEL) ls -4"F {-20"C) Iess(or Llimit or in Hondamodeot PGMTester)or 5 V indicated? Rgpairopen in the wires btween the PcM (D8. D11) and rhe IAT 3en30r, FCM CONNECTOR IT6PI O
sG2
IGRN/BLK}
JUMPER w|BE Wire sideof female terminals
(cont'd)
(Topage11-98)
11-97
PGM-FI System
(lATl Sensor(cont'd) IntakeAir Temperature
(Frompage11,97)
Checkfor an open in the wires {lAT,SG2lines): 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCM connector terminalsC18and C25with a jumperwire. 3. Turnthe ignition switch (ll). ON 4. Checkthe IAT with the scan tool. ls -4'F 1-20"C) less(or L limit or in Hondamodeof PGMTesteri or 5 V indicated?
ECM/PCMCINNECTORC t3lPl
2 ./ 5 7 I I 16 1 7 1 8 19 20 21 22
23
IAT{RED/YELI
4 Wp,
29 c) 31 sG2{GRN/BLK)
JUMPERWIRE Wire sideof fernale terminals Repsir opn in the wirca batween the ECM/PCM1C18, C25l and the IAT snsor.
Substitute a known-good ECM/ PCM rnd recheck, lf normal IAT is indicated, leplaco the originsl ECM/PCM.
'l
11 - 9 8
(ECTI Sensor Temperature Goolant Engine

problem in the Engine A Trouble Code (DTC)P0116: range/performance The scan tool indicatesDiagnostic (ECT) Sensorcircuit. Temperature Coolant as (thermistor). resistance the thermistor decreases the engine of The resistor dependant The ECTSensoris a temperature increases shown below as coolanttemperature
RESISTANCE tk0l
THERMISTON
- 4 3 2 6 8 r 0 a r a 0 1 7 6 1 22 a E ' r ) 2 { -2O O 20 ito tO .o ! t2O I c) ENGINE COOLANT TEMPERATURE
first, then trouthose DTCS troubleshoot are stored at the same time as DTC P0116, NOTE:lf DTC P0117and/or P0118 bleshootDTCP0116. PossibleCause a ECTsensordeterioration and coolingsystem . Malfunction the thermostat in Troubleshooting Flowchart
The MIL has benroportedon. DTCP01'16 stored. is
Probl6mverification: 1 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000 rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 2. With the scan tool, checkthe ECT.
or ls 176- 200'F(80- 93"C) 0.4-0.TVindicated?
Intermittent failure, sYstemb OK at this tim6. Check lhe thermostat and the cooling 5y3tom.
Check the thermostat and the cooling system. It thy are OK, reolacethe ECTseNor.
(cont'd)
11 - 9 9
PGM-FI System
(ECTI EngineCoolantTemperature Sensor{cont'd)
[F011' :
-
The.scan tool indicates problemin the Diagnostic TroubleCode(DTC) P0117: low voltage(hightemperature) A (ECT) EngineCoolant Temperature sensorcircuit.
The MIL has been rooortodon. DTCml17 is sto.od.
Problemverification: 1. Turn the ignitionswitchON {ll). 2. Checkthe ECTwith the scan tool,
(150'C) higher(or ls 302"F or H Limitin Hondamodeot PGMTester) 0 V indicated? or
Intermittont f.ilure, sysiom is OK at thk time. Checkfor poor connections or loo3e wire3 at C1lil (ECT sensorl and et the ECM/ PCM.
Checkfor a Bhort in the ECTsen301:
'1. Disconnect ECT the sensor2P connefior, 2. Checkthe ECTwith the scan tool.
(150"C)or ls 302"F higher(or H-Limit Hondamodeof in PGMTester) 0 V indicated? or
ECTSENSOR CONNECTOR 2P {C114I
C h e c kf o r r s h o r l i n t h e w i r s (EgTlinel: 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the con(C nector (16P), (31P)*1. D 3. Checktor continuitybetween the ECT sensor connectorter 2P minalNo.1 and bodyground. Wire sideof femaleterminals ls therecontinuity? Repairshort in the wir between the ECM/FCM(D2,C26rl ,nd th6 ECTsenaor.
Substitute a known-good ECM/ PCM and recheck.It normal ECT i! indicatod, replaco the oiiginal ECM/PCM. *:'98 - 00 models
1-1
problemin the The scantool indicates Diagnostic TroubleCode{DTC) P0118: high voltage{low temperature) A (ECT) EngineCoolant Temperature sensorcircuit.
The MIL has benreportedon. DTCP01'18 stord. is
Problemverification: 1. Turnthe ignition switch {ll). ON 2. Checkthe EcT with the scan tool-
ls -4"F (-20'C)or less(or L-Limit in Hondamodeot PGMTester) or 5 V indicated?
Intermiftent tailu.,3ystem is OK at this time, Checl foJ poor connction3 or loose wires et C1'14 (ECT ren3or) and at the ECM/ PCM.
(C11ill 2P ECTSENSOR CONNECTOB
Checkfor an open in the ECTsen1. Disconnect ECTsensor2P the connector. 2 . C o n n e c tt h e E C Ts e n s o r2 P connector No. 1 and terminals No.2 with a jumperwire. 3. Checkthe ECTwith the scan tool.
ECT (ncD/wlrT) JUi,IPEB WNE
sG2
(GRN/8LKI
Wirc side of lemale terminals
ls -4'F (-20'C) or less (or L'Limit in Hondamodeof PGMTester)or 5 V indicated?
('97model) D PCMCONNECTOR {T6PI JUMPERWIRE Checkfor an open in the wiies SG2 lines): {ECT, 1. Turnthe ignitionswitchOFF. 2. ConnectPCM connectorter m i n a l sD 2 a n d D 1 1 w i t h a iumperwire. 3. Turnthe ignitionswitchON {ll}. 4. Checkthe ECTwith the scan tool,
ECT IREDAAIHT)
IGRN/BLX}
Wire sideoI femaleterminals
ls -4"F (-20'C)or less(or L-Limit in Hondamodeof PGMTesterior 5 V indicated?
Repairopen in th6 wire! botwen the PCM lD2, D'l1l and the ECT
3n30t.
(To page11-102)
(cont'd)
11 - 1 0 1
PGM-FI System
(ECTI EngineGoolant Temperature Sensor(cont'dl
( F r o m a g e1 1 1 0 1 ) p
Chacklor an open in the wires (ECT, SG2 lines): 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCM connector terminals C18 and C26with a 3. Turnthe ignitionswitchON (ll). 4. Checkthe ECTwith the scan tool.
ECM/PCMOONNECTOR 13lPI C
1 7 I 9 't8 '19 ,/ 16 1 7 20 n
ECTIRED/WHTI
sG2(GRN/BLK)
JUMPERWIRE Wiresideof temaleterminals
ls -4"F (-20"C) less(or L-Limit or in Hondamodeof PGMTesterlor 5 V indicated?
Ralpairopen in tho wir6s b6twen tho ECM/PCM1C18, c26l 6nd tho ECTsensor.
Substitute a known-good ECM/ PCM and rech.ck. lf normal ECT is indicrted, replace ths originsl ECM/PCM.
11-102
ThrottlePosition(TPlSensor
problem in the Throttle A The scan tool indicatesDiagnostic TroubleCode (DTC)P0122: low input (voltage) (TP)sensorcircuit. Position the lt to The TP Sensoris a potentiometer. is connocted the throttlevalve shaft.As the throttle positionchanges, throftle positionsensorvariesthe voltagesignalto the ECM/PCM.
'97 mod6l: The MIL h.3 been reoorted on. OTC m122 b 3tored.
BRUSH HOI,I'ER OUTPUT VOLTAGE IVI 5
Problemvorificalion: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutralluntil t h e r a d i a t o rf a n c o m e s o n , then turn the ignition switch OFF. 2. Turn the ignitionswitchON (ll). 3 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.
4 3 2 1 0 THROITLE OPCNIiIG FUTI IHROTTI"E
TP SENSOR CONNECTOR 3P {Cl3OI ls there approx. 10%when the throttle is fully closedand approx.90%when the throttle is fully opened? Intormittent feilu?e, 3y3tem is OK at thb iime. Checktor poor connodiona or loose wiros at C130 tTPloNorl .nd rt th PCM.
vcc2
IYEL/BLUI
Check tor an open in the wire {vOC2linel: 1. Turnthe ignitionswitchOFF. 2. Disconnect TP sensor3P the connector, 3. Turnthe ignitionswitchON lll). il. Measure voltage between the TP sensor3P connector terminals No.1 andNo.3.
Wi.6 6ide ot fgmaleterminsls
D PCMCONNECTOR I16PI
ls thereapprox.5V?
Checkto. an open in wir6 {VCC2 linel: Measurevoltage between PCM connector terminals 010 and D11. Ch6ckto. an opon or shon in TP sonaol: 1. Turnthe ignitionswitchOFF. 2, At the sensor side, measure r e s i s t a n c e e t w e e nt h e T P b sensor3P connectorterminals No. 1 and No. 2 with the throttle fullyclosed.
(GRN/BLX)
Wiresideof female terminals Repairopen in the wirc between PCM{D10}and TP 3ensor.
Sub3tituto . known-good PCM and rechock. It proscribed voltag. b now availablo.rcplacoth6 originsl PCM, Terminal sideof maleterminals
( T op a g e1 1 - 1 0 4 )
(cont'd)
11 - 1 0 3
PGM-FI System
ThrottlePosition(TP)Sensor(cont'd)
(Frompage11 103) TP SENSOR CONNECTOR 3P ls thereapprox. - 0.9kO? 0.5
Chockfor an open or short in the TP sensor: Measureresistance betweenthe T P s e n s o r P c o n n e c t otre r m i n 3 n a l sN o . 2 a n d N o . 3 w i t h t h e throttlet!lly closed. Terminal sideof maleterminals ls thereapprox.4.5kO? PCMCONNECTOR I16PI D Check to. an open in the PCM (TPS linell 1 . R e c o n n e ct th e T P s e n s o r3 P connector. 2. Turnthe ignition switch (ll). ON 3. Measurevoltage between PCMconnector (16P) D termin a l sD 1a n dD 1 l . TPS IREO/ BLK) SG2 (GRN/BLKI
Wiresideol femaleterminals ls thereapprox.0.5 whenthe V throftle is fully closedand approx.4.5V when the throttle is fullyopened? Substitute a known-good PCM and recheck. It orescribod voltage is now available,roplacothe o.iginal PCM.
Repairshort in the wire bstween the PCMlDl)snd the TP ssnso..
11-104
I
'98 - 00 model3: The MIL has boon reDortod on. DTCm122 b rtorod.
P.oblom veiification: 1. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rt a n c o m e s o n , then turn the ignition switch OFF. 2. Turnthe ignitionswitchON lll). 3 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool. TP SENSOR CONNECTOR 3P {C130} ls thereapprox. 10% whenthe throttle is fully closedand approx.90%when the throttle is fully opened? Intarmittent failure. system is OK at thia time. Checkfor poor connctions or loolo wires rt C130 ITPs.nsorl and.t the ECM/FCM.
sG2 IGRN/BLKI
vcc2
IYEUBLUI
Checkfor an opon or short in tho wire {VCC2linel: 1. Turnthe ignitionswitchOFF. 2. Disconnect TP sensor3P the connedor, 3. Turn the ignitionswitchON (ll). 4 . M e a s !r e v o l t a g e b e t w e e n terthe TP snsor3P connector minals No. 1 andNo.3.
Wire side oI Iemale lerminals
C ECM/PCMCONNECTOR (31P}
sG2IGRN/BLKI
1 3 5 / 1 6 17 25
al ,
ls thereapprox. V? 5 23 Checklor an opon in wiro IVCC2 linel: Measurevoltage betweenECM/ and rcM connectorterminalsC'18
gJ lzgi3o I sr T ^ vccz {YEL/8LUl

27)
zzl lrs]zolzr
18 sl./|
Wire sid6of temaleterminals
c2a.
Chockfor en opn or Bhort in TP 3an30r: 1. Turnthe ignitionswitchOFF. 2. At the sensor side, measure r e s i s t a n c e e t w e e nt h e T P b sensor3P conneclorterminals No. 1 and No. 2 with the throttle fullyclosed. B.psir opon in the wire b{woon tho ECM/PCM {C281and th6 TP 3en!xtt.
ls lherapprox. V? 5
(To page11-106)
Subslitute e known-good ECM/ PCM .nd r.chock. lf pro3cribed voltrge iB now rYrilablo, replaca th. originll ECM/PCM. Terminalsideof maletorminals
(cont'd)
11 - 1 0 5
PGM-FI System
ThrottlePosition(TPlSensor(cont'dl
(Fromp6ge11-105) TP SENSOR CONNECTOR 3P ls there approx. 0.5 - 0.9 kO?
Chockfor rn opn or 3hort in tho TP sonsor Measure resistancebetween the TP sensor 3P connectorterminals No. 2 and No. 3 with the throttle fully closed. Terminalside of mal6 terminals ls thre approx. 4.5 k0?
Check lor an open in the ECM/ PCM ITPSlinel: 1. Reconnect TP sensorcon' the nector. 2. Turn the ignitionswitchON {ll). 3. Measurevoltage between ECM/PCM connectorC (31P) terminals C18and C27.
ECM/PCMCONNECTOR {31P} C
I
3 23
7 l 27 t l
la
1 6 17 t 8 1 9 l m
l 2 e30 31
TPS IRED/BLK)
Lle (GRN/BLKI {9}
Wire sideol temaletorminals ls thgre6pprox.0.5V when the throttle is Iully closedand approx.4.5V when the throttle is lully opened? Subrtituto . known-good ECM/ PCM rnd rocheok. lI pro.cribed voltaga ia now rvailablc, rcpl.ce th. o.igln.l ECM/PCM.
Raoai. ahort in th wira lrltw.an the ECM/PCM (C181lnd th TP

3n3rot.
11 - 1 0 6
A The scantool indicates Diagnostic TroubleCode(DTC)P0123: high voltageproblemin the ThrottlePosition (TP)sensorcircuit.
The MIL hlr brn r.9ort.d on. DTCP0123ir stored.
Pioblom vorificltion: 1 . S t a r t t h e o n g i n 6 .H o l d t h ongine at 3,000rpm with no load {in Parkor neutral)until t h 6 r a d i a t o rf a n c o m e s o n . then turn the ignition switch OFF, 2. Turn the ignitionswitchON (ll). 3 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.
ls therespprox. 1oyo when tho throttle is Iully closedand approx.90%when the throttle is tully opend?
Intarmittant tailuro, ryrtern b OK at this timo. Chocklor poor connections or loo3o wir3 at C130 ITP 3orcorl .nd at tho ECM/FCM.
TP SENSOR @]{NECTOR IC13O} 3P
sG2 (GnN/Br.Xl
Choct toJ an opcn in th6 TP s6n3t']: 1. Turnthe ignitionswitchOFF. 2. Disconnect TP sensor3P the connectol, 3. Turn the ignitionswitchON (ll). 4. At the wir6 harnossside, measuro voltage betweonthg TP sensor 3P connectortrminals No. 1 and No.3.
vocr
tYEt/8LU)
Wiro side of fom.le terminals
ls thereapprox.5V?
('97model) PCMCON'{ECTOF I16PI D Chack for an oDan in tha wira (SG2linel: M6asu16 voltage b6tween PCM connctorterminalsDl0 and D'!1.
{GBIT/BLKI
ls there approx. 5 V? R.pai. opcn in tha wira botwcon tho PcM {o111rnd the TP 3en3('t,
Wire side ot femaleterhinals
(Topage11-108)
(cont'd)
11-107
PGM-FI System
ThrottlePosition(TP)Sensor(cont'dl
(Frompage11-107)
Check lor an open in the wirc (SG2line): Measurevoltage betweenECM/ PCMconnector (31P) C terminals C18and C28.
ECM/PCMCONNECTOR {31PI C
Ropairopen in th wire betweon rhe ECM/PCM(Cl81.nd the TP

56nSOl,
Substitute a known-good ECM/ PCM and rocheck.lf pre3cribed voltago is now avaibble, replace tho origin.l ECM/PCM,
11 - 1 0 8
(TP)lowerthanexpected. TroubleCode{DTC) Pl121;Throttle Position Diagnostic Pl121 lThescantool indicates

The MIL has been reportedon. DTCPl121 is stored,
Problemveritication: 1. Turnthe ignition switch (ll). ON 2 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.
(12.97.)* higher ls 14.1% or indicated when the throttleis fullyopened?
Intormittent failur6, systom is OK at this lime.
(TP)higherthanexpected. Diagnostic TroubleCode(DTC) P1122: ThrottlePosition I Pl122 | The scantool indicates

The MIL has benreoortedon. OTCP1122is dored.
Problemverification: 1. Turnthe ignition switch lll). ON 2 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.
(16.9%)' less ls'17.670 or indicated when the throftle is lully closed?
IntermitteDt tailu.o, system is OK at thb time.
*:'99 - 00 models
1-109
PGM-FI System
(Sensor 1) HO2S) PrimaryHeatedOxygenSensor(Primary
(HO2S) In detectthe oxygencontentin the exhaustgas and signalthe ECM/PCM. operation, The HeatedOxygenSensors To the receives signalsfrom the sensorand variesthe durationduring which fuel is iniected. stabilize the the ECM/PCM in 1) The PrimaryHO2S(Sensor is installed exhaustpipeA. output,the sensorhasan internalheater. sensor's
HO2S: ztRcoNtA
EI.IMENT
sNsoR
TERMINALS
VOLTAGE IVI
HEATER HEATEB TERMINALS
RICH AIR. . LEAN FUEL NATO
A TroubleCode (DTC)P0131: low voltage problem in the PrimaryHeated The scan tool indicatesDiagnostic 1} OxygenSensor(HO2S) {Sensor circuit, 37 - 98 models:
The MIL has been reoorted on. DTC P0131 is stoied.
Problemverification: 1. Do the ECM/PCM ResetProceoure. S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until the radiator comeson. fan Test-drive with the A/T in E position(M/T in 4th gear) Check the Primary HO2S {Sensor1} output voltagewith the scantool during acceleration usingwide openthrottle. Intermittent f.ilure, system is OK at this time. Check fo. poor connections or loose wirer at C111 (Primary HO2S,SeGor 1) and at rh ECM/FCM. Checkthe fuel pressure(seepage 11-178).
Repairthe fuel supply system.
{ T op a g e1 1 ' 1 1 1 }
11 - 1 0 1
p { F r o m a g e1 1 - 1 1 0 }
Checktor a shorl in the HO2S: 1. Turnthe ignitionswitchOFF. the 2. Disconnect PrimaryHO2S (Sensor'1i connector. 4P 3. Startthe engineand let it idle. 4. Check the Primary HO2S (Sensor with 1)outputvoltage the scantool.
Doesit stay at 0.1 V or less?
Replace the HO2S{Sensor1). (Cl111 PRIMARY HO2Sls.n.or 'l I 4P CONNECTOR
Check for a short in the wir (PH02Slinel: 1. Turnthe ignitionswitchOFF. con2. Disconnect ECM/PCM the (D nector (16P), (31P)*). C 3. Checktor continuitybetween the PrimaryHO2S{Sensor1) 4 P c o n n e c t o tre r m i n a lN o . 1 and body ground. Repairshort in tho wire botwesn the ECM/PCMlD7, C16*) .nd th6 Prim.ry HO2S(Snsor11.
PHO2S ---'t rwHTr T-T-l T-1 1 2l
6 t lr___J_J r rl Y
Substituto a known-good ECM/ PCM and recheck. ll 3ympiom/ indicationgoes away. raplaceth. origin.l ECM/PCM.
(cont'd)
11-111
PGM-FI System
PrimaryHeatedOxygenSensor(Primary HO2SI(Sensor (cont'd) 1l
'99 - 00 models:
The MIL has bsen reported on. DTCP0131ir storod.
Problemve fication: 1. Do the ECM/PCM Reset Procedure, 2. Start the engine. Hold the engine at 3,000rpm with no load {in Parkor neutral)until lhe radiator comeson. tan 3. Check the Primary HO2S (Sensor1) oltput voltage with the scantool during acceleration usingwide opnthrottle. Doesthe voltage stay at 0.5 V or less? Inl.rmittant failura, 3yrtam i! OK at thb tim.. Ch.ck tor poor connectiona oa looaa wlraa al C111 {Pri|n.ry HO2S,Son3or 1l .nd .t tho ECM/FCM,
Checktho fuel pressure(seepago 1r,178).
R.p.ir th. ful lupply ry!t.m.
Chocklor a short in tho HO2S: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe Primary HO2S (Sensor 4Pconnector. 1) 3. St6rtthe engineand lot it idle. 4. Check the Primary HO2S (Sensor1) output voltage with the scantool,
Does it stay 6t 0.5 V or less?
Rephc. th6 HO2S(S.n3or 11.
Chock for a short in tho wirc (PHO2S lino): 1. Turnthe ignitionswitchOFF. 2. Disconnect ECM/PCM the connector (31P). C 3. Check tor continlity between the PrimaryHO2S{Sensor'l} 4P connectorterminal No. I and body ground.
PRIMARY HO2S(Son.or 1l aP CONNECTOR |C111)
PHO2S T--1 rwHTr f-T---] --1 1 2l
t6)lslrl v L__r__J
t---
_L
Wire sideol female terminals Ragah rhort in tha wira balwoan t h . E C M / P C M{ C l 6 1 r n d t h c Prirn.ry HO2S(S.n3or 11. Substltut6 a known-good ECM/ PCM and recheck. lf rymptom/ indicrtion 00os away, raplaco thc original ECM/PCM.
11-112
The scan tool indicates Diagnostic TroubleCode (DTC)P0132: high voltage problemin the PrimaryHeated A (Sensor circuit. OxygenSensor{Primary HO2S) 1) '97 - 98 models:
Problemverification: 1. Do the ECM/PCM ResotPro, ceoute, 2. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiator comeson. fan 3. Test-drive with the Ay'Tin E (M/Tin 4th gear). position 4. Check the Primary H02S 1}outputvoltage {Sensor with the scantool duringdeceleration using completelyclosed throttle. Does the voltage stay at 1.0 V Intormittent l.ilure, 3ystem ia OK at thb timo. Chcck fo. poor connections01 looso wi.es at C111 {Prim!ry HO2S, Sensor 1} and ECM/PCM.
Checkfor an open in th6 Primary H()2S: 1. Turnthe ignitionswitchOFF. 2. Disconnect PrimaryHO2S the (Sensor connector1) 3 . C o n n e c tt h e P r i m a r yH O 2 5 lSensor1) 4P connector termin a l sN o . 1 a n d N o . 2 w i t h a jumper wire. 4. Turnthe ignition switch (ll). ON 5. Check the Primary HO2S (Sensor1) output voltagewith the scantool, ls there1.0V or more?
PHO2S IWHTI
sG2
IGRN/ BLK}
Wire sideot female terminals
{'97 model}
Chck for an opon in the wires (PHO2S, SG2linesl: 1. Turnthe ignitionswitchOFF. 2. ConnectPCM connectorterm i n a l sD 7 a n d D l 1 w i t h a 3. Turnthe ignition switch (ll). ON 4. Check the Primary HO2S {Sensor1) output voltagewith the scantool. ls there1.0V or more? Roprir opon in the wire betweon tho PCM {D7 01 D11l and the Primsry HO2S{S6nsor1).
PCMCONNECTOR {16PI D JUMPERWIRE PHO2SIWHTI SG2 IGRN/BLK}
{ T op a g e1 1 - 1 1 4 )
I (cont'dl
11-113
PGM-FI System
1} PrimaryHeatedOxygenSensorlPrimaryHO2S) {Sensor {cont'dl
(From age'11-l13) p
Ch.ck for an open in the wire (PHO2S linel: 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCM connector terminals C16and C18with a 3. Turnthe ignition switch {ll). ON 4. Checkthe Primarly H02S (Sensor outputvoltage 1) with the scantool. ls there1,0V or more? Rp.ir open in the wire bqtwen t h e E C M / P C M ( C 1 6 1a n d t h PrimaryHO2S(Sen.or'l).
Substitute a known-good ECM/ PCM and rachck.lt 3ymptom/ indication goos away, replace the origin.l ECM/PCM.
11-114
'99 - 00 modols:
Th6 Mll has bon reDortodon. DTCml32 is itorod.
Problemvorification: '1. Do the ECi!4/PCM ResetPro cedure, Start the ongine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiator comeson. fan Check the Primary HO2S with lSensor1) outputvoltage the scan tool during decelelation using completelyclosed throftle. Int.rmitt .fi tailuro, syltom b OK at thit tima. Checkfor poor connactiona oi loo3a wirar !t Cltl (Primrry HO2S,S.nror 1) .nd .t th. ECM/FCM.
Doos the voitage stay at 1.5 V or more?
PRIMARY HOzS (S6n!or 1l aP CoNNECTOR lcltl)
Checkfor an opsn in the Prlmary HO2S: 1. Turnthe ignitionswitchOFF. 2. Disconnect PrimaryHO2S the (Sensor 1)connector. 3 . C o n n e c tt h e P r i m a r yH O 2 S (Sensor1) 4P connectort6rmin a l sN o . 1 a n d N o . 2 w i t h a iumperwire. 4. Turn the ignitionswitchON (ll). 5, Check the Primsry H02S (Sensor1) output voltagewith the scantool,
Pt()2s IWHTI
sG2
{GRN/ BTJ(I
Wire side of tem6leterminsls
lsthere 1.5V or more?
Check for an op6n in th6 wiro line): {PHO2S 1. Turntho ignitionswitchOFF. 2. Connect ECM/PCMconnector terminals C16 and C18with a iumperwire. 3. Turnthe ignition switch lll). ON 4. Check the Primary HO2S (Sensor outputvoltage 1) with the scantool. Ropair opon in thc wire bc{w.cn t h e E C M / P C M{ C l 6 } . n d t h e PrimaryHO2S{Snror 1}.
ECM/PCMCONNECTOR (31P} C 2 23
7 8 9 't8 1 9 1 2 A 22 0 / 1 6 17 E 29 g) 31
PHO2S{WHTI ls there1.5V or more?
sG2IGRN/BLKI
JUMPERWIRE Wire sideol temalet6rmin6ls
Substituto a known-good ECM/ PCM snd rochock.lf 3ymptom/ indicetion goa awry, roplaca tho origin.l ECM/PCM.
(cont'd)
1 1 11 5
System PGM-FI
Primary Heated Oxygen Sensor (PrimaryHO2S)lSensor 1) (cont'd)
problemin the PrimaryHeated A P0133: slow response Diagnostic TroubleCode(DTC) scantool indicates tFO133 \ lhe : Oxysen Sensor (Primarv HO2S\ (Sensor 1) circuit. Description By controlling airlfuelratiowith a PrimaryHO2S(Sensor and a Secondary the HO2S(Sensor the deterioration the 1) 2), of period.When the feedback periodof the HO2Sexceeds cer PrimaryHO2S(Sensor1) can be evaluated its feedback by a tain valueduringstabledrivingconditions, sensor the will be judgedas deteriorated. When deterioration beendetected has duringtwo consecutive trips,the MIL comeson and DTCP0133 will be stored. NOTE: lf DTCP0131, P0132 and/or P0135 are storedat the same time as DTCP0133. troubleshoot those DTCS first, then troubleshoot DTCP0133. PossibleCause . PrimaryHO2S(Sensor Deterioration 1) (Sensor Deterioration . PrimaryHO2SHeater 1) . Exhaust systemleakage Troubleshooting Flowchart
The MIL has b6n reoortedon. DTCP0133is stored.
ProblemVerilication: '1. Do the ECM/PCM ResetPro cedure. 2. Connect scantool. the 3. Start the engine.Hold the engine at 3,000rpm with no load lin Parkor neutraliuntil the radiator comeson. fan 4. Connect SCSservice the con nector. 5. Test-drive underthe following condations, 55 mph (89 km/h) steady speed - M in @ position posi (E tion and Over DriveON)*, (M/Tin sth gear) - Until readiness code comes
Intermittent failure, system is OK at this time. Checktor poor connectionsor loose wires at C111 (Primary HO2S,Sensor 1) and al the ECM/PCM. Replacethe Primary HO2S {Sensor 11.
11 - 1 6 1
(Sensor 2) HO2S) HeatedOxygenSensor(Secondary Secondary

A P0137: low voltageproblemin the secondaryHeated Troublecode (DTC) Diagnostic The scantool indicates (Sensor circuit. (Secondary 2) HO2S) OxygenSensor
The MIL hrs been reported on. DTC P0137 is stored.
Problemveritication: ResetPro' 1. Do the ECM/PCM cedure. 2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm wilh no load (in Parkor neutral)untal {an the radiator comeson, H 3 . C h e c kt h e S e c o n d a r y 0 2 S l S e n s o r2 ) o u t p u tv o l t a g ea t 3,000rpm with the scantool. lnlermittent failure, 3ystem i5 OK at this time. Checktor Poor con' noction3 or loose wires at C127 {locatod on ECM/PCM bracket}, C721 (Secondary HO2S, Sensor 2l and at the ECM/PCM.
Doesthe voltage stay at 0.3 V or less?
Checkfor a short in the Secondary HO2S: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tt h e S e c o n d a r y HO2SlSensor2) 4Pconnector. 3. Startthe engine. H 4 . C h e c kt h e S e c o n d a r y O 2 5 (Sensor outputwith the scan 2) tool.
HO2Sls.nlor 2) SECONDARY 4P CONNECTOB lC721l C h e c kl o r a s h o r t i n t h e w i r e (SHO2S linel: 1. Turnthe ignitionswitchOFF. n 2. Disco nect the ECM/PCM A connector (16P}, (32P}'). {D 3. Check for continuity between HO2S(Sensor the Secondary 2i 4Pconnector terminalNo. 1 and bodyground. Reoairshort in the wire btwoen rhe ECM/PCM|D14, 423*l and the SecondaryHO2S{Sensor2).
Substitute a known-good ECM/ PCM and rocheck.lf symptom/ indication goes away, replace the original ECM/PCM.
(cont'd)
*: '98 - 00 modeis
11-117
PGM-FI System
Secondary HeatedOxygenSensor(Secondary HO2SI(Sensor (cont'dl 2l
The scantool indicates Diagnostic TroubleCode(DTC) P0138: high voltageproblemin the Secondary A Heated (Sensor circuit. OxygenSensor(Secondary HO2S) 2)
The MIL hra bon Eported on, OTCm138 b stor.d.
PJoblcmv6dtic.tion: 1. Do the ECM/PCM ResotProcedure, S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)trntil the radiator comeson. lan Check the Secondary HO2S (Sensor2) outpl.rt voltage at 3,000rpm with the scantool. Int.rmitto tailurc, syst.m b OK rt ihi! timo. Chack fo. poo. oonnoctioni or looaa wiiaa at C127 lloc.ted on EcM/PcM br.cket), C721 (Second!ry llO2S, Sonlol 2).nd at th. ECM/PCM. SECONDABYHO2S (Sonror 2) 1P CONNECTORrC721 l
Doesthe voltage stay at 0.6 V or more?
Chockfor an opon in the Socondary HO2S: 1. Turn the ignitionswitchOFF. 2 . D i s c o n n e c tt h e S e c o n d a r y HO2S(Sensor2) 4P connector. 3. Connectthe SocondaryHO2S (Sensor2) 4P connectorterminalsNo. 1 and No. 2 with a 4. Turn the ignitionswitchON {ll}. 5 . C h e c kt h e S e c o n d a r y O 2 S H {Sensor2) output voltagewith the scantool.
sHo2s {WHT/REDI
sH()2sG
IGFN/WHTI
ls there0.6V or more?
('97model) Ch6ck for an open in thg wiro3 (SH()2S, SG2 line3l: 1. Turnthe ignitionswitchOFF. 2. ConnectrcM connectorterminals 014 and D13 with a J!mper wite. 3. Turnthe ignition switch (ll). ON 4 . C h e c kt h e S c o n d a r y O 2 S H ( S n s o r2 ) o u t p u t v o l t a g e with the scantool. PCMCOI{NECTOR {16PI D
sHo2sG (RED/YELI
JUMPERWIRE
lsthere0.6V or more?
Rapair op6n in tho wir. b{woan tho PcM lDla or Dl3l .nd tho S.condlry HO2S{Senlor 21.
Wirc sideol lemaleterminals
{ T op a g e1 1 - 1 1 9 )
11 - 1 8 1
( F r o m a g e1 1 - 1 1 8 ) p
('98- 00 models) ECM/PCMCONNECTORS A l32Pl Check for an open in tha wire ISH()2Slinel: 1. Turnth ignitionswitchOFF. connector 2. ConnectECM/PCM A23 and C18with a terminals iumperware. switch (ll). ON 3. Turnthe ignition 4. Checkthe Secondary HO2S (Sensor2) output voltage with the scantool. Repairopon in tho wire botwaen t h e E C M / P C Ml A 2 3 l a n d t h e Second.ry HO2S(Sonsot21.
SHO2S W}iT/RED) JUMpER | W;RE
ls there 0.6 V or more? L _._._ _ _
Wire sideof fomaleterminals I
Substitute a known.good ECM/ PCM .nd recheck. It symptom/ indication goes rway, replace the origin.l ECM/PCM.
(cont'd)
1 11 - 1 9
PGM-FI System
Secondary HeatedOxygenSensor(secondary HO2SI(sensor2l (cont,d)
lTol3al -
The scantool indicates Diagnostic TroubleCode(DTC) P0139: slow response A probtemin the Secondary Heated (Sensor circuit. UxygenSensor(HO2S) 2l
The MIL has ben reoortedon. DTCP0139is storad.
Problmve.itication: 1. Do the ECM/PCM ResetPro cedure, S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until the radiator comeson. fan C h e c kt h e S e c o n d a r y O 2 S H (Sonsor2) output at 3,000 rpm with the scantool.
Doesthe voltage staywithin 0.3- 0.6V for two minutes?
lntehittont failure, 3ystem is OK at this time. Chock for poor connections o. loose wi.es at C127 (located on ECM/PCM brackt), C721{Secondary HO2S,Sensor2l and at the EcM/PcM.
1 1 -1 2 0
Heater HeatedOxygenSensor(HO2S|
tool indicatos Diagnostic Trouble Fol3slThe scanHO2S)(Sensor1) Heatercircuit. Code {Primarv (DTC) OxygenSensor P0135: problemin the PrimaryHeated A (DTC)P0141: problem in the SecondaryHeatedOxygen Sensor A
F o 1 1 t The scantool indicatesDiagnosticTrouble Code l (Secondary HO2S)(Sensor2) Heatercircuit.

Th6 MIL h.. bocn roponod on. DTC P0135,and/oi mlal are stored.
Probl.m verification: ResotPro1. Do the ECM/PCM cedure, 2. Startthe engine.
Int.rrnittaii frilurc, awtom ir OK at thi3 time. Chocklor poor conn.ctiona or loosa wiro3 !t C111 lPrim.ry HO2S, Sen3o. 11.C12? llocatcd on ECM/PCM br.ck.t), C721 lsocond.ry Ho2s, s.n3or 2r and at tho ECM/PCM.
PBIMARY HO2Sls.n.or ll 4P CONNECTOR(CI 11I, SECONDARY HO2Sls.n.o.2l aP CONNECTOR lc721l.
Ch.ck ior an opon or shoYt in the HO2S: 1. Turnthe ignitionswitchOFF. 2. Disconnoct the Ho2s (Primary or Secondary*)(Sensor1 or Sensor2)4P conneclor. 3 . A t t h e H O 2 Ss i d e , m e a s u r e resistancebetween the HO2S 4P connector terminalsNo. 3 a n dN o . 4 .
Terminal sideof maletrminals
ls there10- 40 0?
C h e c kf o r c o n t i n u i t y b e t w e e n body ground and the HO2S 4P c o n n e c t o r e r m i n a l sN o . 3 a n d t No. 4 individually. PRIMARY HO2Slson.o. 1l aP CONNECTOR 11}, SECONDARY {Cl HO2Sls.nror 214P CONNECTOR
tcr21l.
Checktor an op6n or 3hort in the wires IPO2SHTC, SO2SHTC' linel: 1. Turnthe ignition swhchON {ll). 2. Moasurevoltage between the HO2S4P connector terminals N o . 3a n dN o . 4 .
so2sHTc
tBLK/WHn.
PO2SHTC (BLK/ WHTI tGl IBLKAAIHTI'
Wire sid of lemale terminals
('97model:To page'11-122) ('98- 00 models: page11-'123) To *: P0141
('97model:To page'11-122) To 1'98 00 modelsl page11-123)
(cont'd)
11-121
PGM-FI System
HeatedOxygenSensorIHO2S) Heater(cont'd)
{'97model) PRIMARY HO2S(S.nsor 1) ap CONNECTOR {cl111
Chockfor en open or lhort in the wire (lG1 line): M e a s u r ev o l t a g e b e t w e e nt h e HO2S4P connector terminalNo. : 3 ( s e c o n d a r yN o . 4 ) a n d b o d y ground, Reprir op6n or 3hort in thc wirc betwo.n th No. 15 ALTERNA(7.5 Al fu!. rnd TOR SP SENSOR tho HO2S(Primary.Socond.ry*). Chck for an open in the wire (PO2SHTC, SO2SHTC.lin): 1. Turnthe ignitionswitchOFF. 2. Reconnect HO2S4P conthe 3. Disconnect the PCM connector A (32P). 4. Turnthe ignition switch (ll). ON 5 . M e a s u r ev o l t a g e b e t w e e n PCM connectortrminals46 andA10(A5andA10)*.
| 1 1 2|
'ot X(9
tErK/
YELI -L
|.i-l 1 3. l
Wiresideof female terminals
SECONDARY HO2S 21 ISENSOR 4P CONNECTOR
lcr21l,
IGl IBLK/WHTI
ls thero0.1V or less?
Bepair opon in the wiro botwoon the PcM (A6. A5lr and tho Ho2s {Prim.ry, Socond!ryr}.
Substitute a lnown-good PCM and recheck. lt 3ymptom/indication goes away, .oplacothe original PCM.
( F r o m a g el 1 - 1 2 1 ) p
Wire sideof female terminals Check fo. a ahort in the wire SO2SHTC.lins): IPO2SHTC, 1. Turn the ignirion switchOFF. 2 . D i s c o n n e c tt h e P C M c o n nector A {32P). 3. Checklor continuily between the PCM connectorterminal 46 (A5)*and body ground.
So2HTCIALK/WHTI*PO2SHTCIBLK/WHTI
Bopair short in the wire lrotwsen tho PC{r4 {A6, A5rl and the HO2S lPiimary, Scondary.l. Substitute a known-good PCM and .echgck. lf 3ymptom/indication gos awry. repl.cethe original PCM.
11-1 2 2
('98- 00 models)
HO2S PRIMARY {S.n3or 1l aPCONNECTOR lc111l

Check for an open in the witoa (lGP,lGl'lino): Mgasurevoitage betweenthe primary HO2S4P connector terminal HO2S: No. 4) and No. 3 (secondary body ground. Bepair opan or short in tho wilo bdtween th6 nlo. 15 ALTERNATOR SP SENSOR17.5Al fu$ .nd th6 HO2S{Primrry, Scondtrytl. Chock lor sn opon in the wires SO2SHTC'lincl: IPO2SHTC, 1. Turnthe ignitionswitchOFF. the 2. Reconnect HO2S4P connector. con3. Disconnect ECM/PCM the connector C (31P)(ECM/PCM neaor A (32P))*. 4. Turnthe ignition switch (ll). ON 5. Moasurevoltage between ECM/PCM connectorterminals 82 andCl (82andA8)*. ls there0.1V or less? Repsir opsn in tha wire between tho ECM/PCM(C1, A8.) .nd the HO2SlPrimsry,Socond.ry*}.
1 1 2 l
r--T -
l 3 t . l L-.IJ------J lcl /5' tErK/ g, YELI I

Wiresideof femaleterminals HO2S SECONDARY 2} {SENSOR 4P CONNECTOR (c7211'
IGl IBLK/WHT}
terminals Wire sideof female ECM/FCMCONNECTORS PGl (BLK}
Sub.titute a known-good ECM/ PCM and rocheck. lf iymptom/ indicrtion goes away, repbce the original ECM/PCM.
lFrom page11-12'!)
Chock lor a short in the wi.es (PO2SHTC, SO2SHTC'linol: 1. Turnthe ignitionswitchOFF. 2. Disconnect EcM/PcM conthe connector C {31P)lECM/PCM nectorA (32P))*. 3. Check for continuity between terminal ECM/PCM connector Cl (A8)*and bodyground. ls therecontinuity? Roolir 3hort in th. wiro betwoon the ECM/PCMlC1, A8'l and the HO2S(Primary,S6condary*).
Sub3tituie s known-good ECM/ PCM and rech6ck. It symptom/ indicaiion goes away. lgplaco th6 origin.l ECM/PCM. : P0'14'l Wire sideof lemaleterminals
11-123
PGM-FI System
Fuel Supply System
[POliil p0'171:Thefuet The"""ntool indicates Diagnostic TroubteCode(DTC) systemistoo lean. indicates Diagnostic Troubtecode {DTc)p0172:Thefuel svstemistoorich.
[Fo17ZJ rh""""ntool
Description By monitoring the LongTerm Fuelrrim, long term malfunctions the fuel systemwill be detected. in lf a malfunction has beendetected duringtwo consecutive trips,the MIL will come on and DTc p0171 and/orpol72 will be stored. NOTE: lf someof the DTCS listedbeloware storedatthesametimeas DTCP017'l and/orp0172, troubleshoot those DTcs first,then troubleshoot DTCP0171 and/orPO1i2. P0107, P0108, P1128, P'1129: MAP Sensor P0135: PrimaryHO2S(Sensor1)Heater P0137, P0138: Secondary HO2S{Sensor 2) P0141: Secondary H02S (Sensor Heater 2) P0441*r: EVAPSystemlnsufficient PurgeFtow *?i P1456*,,P'l457 EVAPSystem Insufficientpurge Ftow
* 1 : ' 9 7m o d e l *2: '98 - 00 models
PossibleCause DTCP0171 too lean FuelPumpinsufficient flow/pressure FuelFeedLineclogged.leaking FuelPressure Regulator stuckopen FuelFilterclogged FuelInjector clogged, leakage air Gasoline doesn'tmeet Owner'sManualspec. PrimaryHO2S(Sensor deteriorated 1) ValveClearance Exhaust leak FuelPressure Regulator clogged, stuckclosed FuelReturnPipeclogged FuelInjectorleaking Gasoline doesn'tmeetOwner'sManualspec. PrimaryH02S (Sensor1) deteriorated EVAPPurgeControlSolenoid Valveleaking, stuckopened ValveClearance
DTCP0172
flch
11 -1 2 4
TroubleshootingFlowchart
The MIL has beenrePortedon DTC P0171 andlot P0172 are stored,
pressure high too ls the lLrel Checklhe Primaty HO2S: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkot neutral)until fan the radiator comeson 2 . C h e c kt h e P r i m a r yH O 2 S ( S e n s o r ) o u t P u tw i t h t h e 1 scantool.
Checkthe lu6l pressuroregulator and tusl relum PiPe.
Checklh fuel pumP. fuel faed pipe. fuel fiher, and luel Prossurc .eguhior.
Doesit stayat lessthan0.3V or morethan 0.6V?
Checkfor a sticking or leaking EVAPpurge control solenoid vacu With a vacuumpump,aPPIY u m t o t h e E V A PP u r g ec o n t r o l v s o l e n o i d a l v ef r o m t h e i n t a k e manifold side.
Doesit holdvacuum?
and Checkth6 valve clearancs adjust il necessary. It the valv clearancesare OK, replace the fuel iniectors.
PGM-FI System
Random Misfire
lF()gool", tftod-' and some lpiogol or throughTo3oti P0300*,, P1300*1 some of po30tand
The scantool indicates Diagnostic TroubleCode (DTC) pO3O4; Random misfire.
Descriotion Misfiredetection accomplished monitoringthe crankshaft is by speedwith the crankshaft speedfluctuation(cKF)sensor which is attached the crankshaft. to lfmisfiring strongenoughto damagethe catalyst detected, MIL will blinkduring is the the time of its occurrence, DTc and P0300*' P1300*1 some of DTCsP03olthrough P0304 , and will be stored.Then,after misfirehasceased, MtL will come the on, lf misfiringthat increases emissionsis detectedduring two consecutive driving cycles,the MIL will come on, and DTc p0301 and some of DTCS through p0304 wi be stored. NOTE:lf some of the DTCS listedbeloware storedat the sametime as a misfireDTc, troubleshoot those DTcsfirst. then troubleshoot misfireDTC. the P0106, P]128,P1'129; MAp sensor P0171. P0172; Fuetmetering P0505:ldle Control Svstem P1336, P1337; CKFsensor P1361, P1362: TDCsensor Pl381.Pl382:CYPsensor *1:,97 model P1508: valve IAC *2: '98 - 00 models PossibloCaus . Fuelpump insufficient fuel pressure, amountofflow . Fuelline clogging. blockage, leakage . Fuelfilter clogging a Fuelpressure regulator stuckopen . Distributormalfunction . lgnitioncoil wire open,leakage . lgnitioncontrolmodulemalfunction . Valves carbondeposit a Compression low a Fueldoes not meetOwner'sManualspec.,lackoffuel Troubleshooting By test-driving, determinethe conditionsduring which misfireoccurs.Depending these conditions, on test in the order described the table below. in
\ [
Possible cause -.... ;;;;-
Crankshaft speedfluctuation sensor section 6

,6)
Fuel pressure 11-178
Distributor and lgnitionwires section 23
tcM
section 23
Valve Clearance section 6
Condition Only low rpm and load Only accelerating Only high rpm and load Not specification
o o
o
@ @
o
,a'
o
G\
@ @
NOTE:lf misfiredoesn'trecur,some possible causes fuel that doesn'tmeet owner'smanualspec,lackof fuel, carbon are deposits on spark plu9, etc.
11-1 2 6
in MisfireDetected OneCylinder
Ipffi1] P0301: Cylinder1 misfiredetected. TroubleCode(DTC) Diagnostic Thescantootindicates 2 P0302; Cylinder misfiredetected. TroubleCode(DTC) Diagnostic lF03O2l 16".""n toot indicates P0303: Cylinder3misfiredetected. TroubleCode(DTC) Diagnostic I P0303 | fne scantool indicates Cylinder4 misfiredetected PO3O4: TroubleCode(DTC) Diagnostic lF0il04l 16" ""un tool indicates Description sensor speedfluctuation(CKF) speedwith the crankshaft by Misfiredetectionis accomplished monitoringthe crankshaft to which is attached the crankshaft. and DTC the is lf misiiringstrongenoughto damagethe catalyst detected, MIL will blinkduringthe time of its occurrence. the will be stored.Then,afterthe misfirehasceased, MIL will come on. and/orP0304 P0303 P0301, P0302, driving cycles.the MIL will come on, and DTc emissionsis detectedduring two consecutive lf misfiringthat increases will be stored. P0303 and/orP0304 P0302, P0301, those DTcsfirst,then NOTE:lJ some of the DTcs listedbelow are storedat the sametime as a misfireDTc, troubleshoot the troubleshoot misfireDTC. MAP sensor P0108, P'n2a,P1129t P0107, 'l system Po'17, P0112tFuel suPP|Y P0441: EVAPinsufficient Purgeflow P1337: CKFsensor P1336, TDCsensor Pl361,P1362: P1359, CYPsensor Pl381,P1382: PossibleCause air fuel leakage, leakage . Fuelinjector clogging, . Fuelinjector circuitopen or shorted fouling,malfunction . Sparkplug carbondeposits, . lgnitionwires open,leaking . Distributor malfunction . Compression low . Valveclearance of specification out
(cont'd)
11-127
PGM-FISystem
MisfireDetested OneCylinder(cont'dl in
Troubl93hootingFlowchart Th. MILh!3 b6onr.portod on. DTCm30r, P0302, m303. or P0304 indicated. is
Ch.ck tho fuol inicctor tunction: Startthe engino,and listenfor I clicking soundat the fuol injector in the problmcylinder.
The illustration shows '97 - 98 models,'99 - 00 models are similar. Check an open or short in the for harnessbetweenthe ECM/PCM and the luel injector.
Boprir opan or 3hort in tha wlre.
Roplaco tuel inioctor. th. Substitut. . known-good E C M / P C M. n d r o c h o c k .I t 3ym ptom/ indicati on go.3 a w . y , r e p l a c et h e o l i g i n a l ECM/PCM.
Problom vorification: 1. Atter chackingthe lrezedata, do the ECM/PCM Reset Procedure. 2. Exchange sparkplug from the the problemcylinder with one ol another cylinder. 3. Connectthe SCS service connector. 4. Tost-drive vohicleseveral the times in the rangool the freeze data.
NOTE: .lf there is no freezedata ol misfiring, just clearthe DTC. .lf there is no freezedata ot misfiring, test drives under various conditions are necessary,
(Topage'11-129)
1 1 -1 2 8
( F r o m a g e1 1 - 1 2 8 ) p
P0303, ls DTCP0301,P0302, indicated? or P0304
lntormittent misfire due lo spark plug fouling, etc. (no mislire at this tim).
ooesthe misfireoccurin the othercylinder?
Replace faulty spark Plug. the
Check lor fuel iniector maltunct|on: 1 . E x c h a n g eh e f u e l i n j e c t o r t f r o m t h e p r o b l e mc y l i n d e r with one from anothercylinder. idle 2. Letthe engine for two min utes. the vehicleseveral 3. Test'drive times in the rangeof the freeze data,
NOTE:lf there is no freezedata of mis firing, test drives under variouscondi_ tionsare necessary.
P0303, P0302, ls DTCP0301, or P0304indicated?
lntermittent misfiro due lo bad contrct in the fuel iniector connector {no misfire at this time).
Does the misfireoccurin the othercylinder?
Replace lhe faulty luel inlector.
Checkfollowing items - Valvo clearance - Cvlinderlak-down - Compression - Crsnkshaft Speed Fluctuation ICKF)sensol
11-129
PGM-FI System
KnockSensor{KSl
('99- 00 models)The scantool indicates Diagnostic TroubloCode(DTC)P0325: malfunction the circuitof A in the KnockSensor(KS).
The MIL has been rooortedon. DTCm325 is storod.
Problemverification: 1. Do the ECM/PCir, ResetPro cedure, 2 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rt a n c o m e s o n , then let it idle. 3 . H o l d t h e e n g i n e a t 3 , 0 0 04,000 rpm for at least 60 seconds, Intermittent lailu.e, 3ystom is OK at thi3 tim. (te3t drive m.y be nacalLrYr. Chock to. poor connsctions ol loora wiros rt C137 lknock aon.o. (KS))and ar the ECM/FCM. Chck tor a short in the wir6 {KS linel: 1. Turnthe ignitionswitchOFF. 2, Disconnect the knock sensor lP connector. 3. Checklor continuitybetween E C M / P C M o n n e c t o rt e r m i c nalsC3and body ground. ECM/PCMCONNECTOR 131P} C
Replil rhort in the n irg b6{wocn tho ECM/PCMlc:ll and the knock sngr1. Check fo..n open in the wire {KSline): C h e c kf o r c o n t i n u i t y b e t w e e n ECM/PCM connector terminal C3 and knocksensorconnector ter, m i n a lN o .1 .
KS 1P CONNECTOR IC13?'
KS IRED/BLU)
Wire side ol female termtnals B.pair opon in the wirc lrotween lho ECM/PCMlctl and thc knock acnsor. NOTE: Torquethe knocks6nsorto 31 N.m (3.2kgl.m, 23 lbf.ft). Wire sideot femaleterminals
ls therecont;nuity?
KS c (31P) (BED/BLU)
ECM/PCMCONNECTOR
Substitutea known-goodknock sensor and recheck.
ls DTCP0325indicated?
Bcpl.ce the originalknock 3nsor,
Substituto a known-good ECM/ PCM and .echeck. lf 3ymptom/ indication goes away, replace the original ECM/PCM.
11 - 1 3 0
Sensor Position(CKP/TDC/CYPI DeadGenter/Gylinder Position/Top Crankshaft
tro-rslThe scantool indicatesDiagnosticTroubleCode sensorcircuit,

1Tffi61 Position{CKP) sensor circuit.
(DTC)P0335; malfunctionin the Crankshaft Position(CKP) A
problemin the Crankshaft A P0336: range/performance TroubleCode(DTC) Diagnostic The scantool indicates in interruption the Top DeadCenter P1361: Intermittent TroubleCode {DTC) Diagnostic tool indicates sensor No TroubleCode (DTC)P1362: signalin the Top DeadCenter(TDC) Diagnostic tool indicates
tF136t scan circuit. (TDC) sensor

The fPfa6r-1 scan ci.cuit.
The
The tF138tl scan circuit. (CYP) sensor
in interruption the CylinderPosition Intermittent P1381: TroubleCode(DTC) Diagnostic tool indicates
I-Pi382lcircuit.
sensor No TroubleCode {DTC)P1382: signalin the CylinderPosition(CYP} Diagnostic The scantoot indicates
Description enginespeed.The TDC timing for fuel injectionand ignitionof eachcylinderand also detects The CKPSensordetermines The CYPSensordetectsthe and when crankangle is abnormal. ignitiontiming at start-up{cranking) Sensordetermines Sensoris built into the distribuThe CKP/TDC/CYP to fuel injection eachcylinder. positionof No. 't cylinderfor sequential ror. DTC troubleshoot P1381 and/orP1382, Pl361,P1362, P0336, is NOTE:lf DTCP1359 storedatthesametimeas DTCP0335, those DTCS. first,then troubleshoot P1359
'97 model:
The MIL has ben reportedon. DTC P0335, P0336, P136' 1, are P1362, Pl341 and/oi P1382 stored. lOP DISTRIBUTOR (Cl211 CoNNECTOR TDCPIGRNI
Problemverific.tion: Procedure. 1. Do the PCMReset 2. Startthe engine. P1361, P1362, ls DTCP0335, P0336, indicated? P1381 and/orP1382 Intermittent lailure, 3yd6m i3 OK at thb tims. Chcck tor poor connections ol looso wire3 si C12'l ldistributor) .nd .t the PCM. sideof Terminal maleterminals
S E N S O E DTC CKP P0335 P0336 P1361 P1352
P' I381 P1342
CYPP IYELI
Ch.ck for an open in tho CKP/ TDC/CYP sensor: 1. Turn the ignitionswitchOFF. 10P the 2. Disconnect distributor connector. between 3. Measureresistance the terminalsof the indicated (seetable). sensor ls there 350 - 700 o?
(BLKI CYPM TIrcMIREOI

SENSOB
l
WIRE PCM E R M I N A I COLOR
c2
c12
8LU
2 9 3 't0
GRN
TDC
Replace tho distributor ignition housing {sea3ection41.
CYP
c13 c4 c14
RED YEL BLK
{cont'd)
(To page11-132)
11-131
PGM-FI System
(CKP/TDC/CYPI Grankshaft Position/Top DeadCenter/Cylinder Position (cont'd) Sensor
{ F r o mp a g e 1 ' 1 - 1 3 1 )
DISTRIBUTOR 10PCONNECTOR tCl2l) CKP P IBLUI TDCP {GRNI
Check for a short in the CKP/ TDC/CYP sensor: C h e c kf o r c o n t i n u i t y o b o d y t ground on both terminalsof the (see indicated sensorindividually t a b l e n p a g e1 l 1 3 1 ) . o
ls therecontinuity?
Rplac the distributor ignition housing {seesection4}.
Chckfo. an open in the wires lines): {CKP/TDC/CYP '1. Reconnect distributor the 10P connector. 2. Disconnect PCMconnector C (31P). 3. Measureresistance between the terminalsof the indicated sensoron the PCMconnector o l s e e t a b l e n p a g e1 l 1 3 1 ) . Repairopen in the indicated sensor wires {se6 table on page 11131).
Terminal sideof maleterminals
PCMCONNECTORS I31P) C CKPP TDCP CYPP IBLU) IGRNI IYEL}
ls there350- 7000?
Check tor a short in the wires linesll {CKP/TDC/CYP C h e c kf o r c o n t i n u i t y b e t w e e n body groundand PCMconnector terminals C3and/or individC2, C4
ls therecontinuity?
RDair short in the indicatodsensor wires lsee table on page 1113rI.
{WHT)
IREDI IBLK) Wire side of female terminals
Substitute a known-good PCM, and recheck.lf symptom/indication goes away, rplacelhe original PCM.
CKPP
TDCP
CYPP
'98 model: 1OP DISTRIBUTOR (C121) CoNNECTOR TDCP(GRN) CYPP(YEL}
'98 - 00 models:
The MIL ha3beenreoortedon. DTC P0335. P0336, P1361, P1362. P1381andlor P13V are stord, Problemverification: 1. Do the ECM/PCM ResetPro cedure. 2. Startthe engine. ls DTCP0$5, m$6, Pl361,P1362, P1381 and/orPl382 indicated?
'99 - 00 modelr: 8P DISTRIBUTOR coNNECTOR {C121) TDCP (GNN} CYPP IYEL}
TDCM(REDI
CYPMIBLKI Terminal sideof maleterminals Intermittant tailure, svstom is OK at this time. Check for poor connections or loose wirgs al C121 {distributo.l .nd at the ECM/ PCM.
CYPM IBLKI
TDC (RED} M side terminals Terminal of male

S E N S O R DTC P0335 P0336 P1361 Pl362 P]381 P]382 SENSOR ECM/PCM WIRE ERMINAT I E R M I N A I COLOR mode ):'99 1 t2)
8 (6)
CKP
c8 c9 c20 c21 c29 c30
BLU
2 (3) 9 (7) 3 (4) 1 0{ 8 )
GBN RED YEL BLK
Check for an open in th6 CKP/ TDC/CYP sensor: 1. Turnthe ignitionswitchOFF. 2. Disconnect distributor the 10P (8P)*connector. 3, Measureresistance between the terminalsof the indicated sensor {seetable). ls there350 7000?
'98
TDC
CYP
Rephce the distributor ignition houaing l3e93oction4).

modeli
TDCP {GRNI
Check for a short in the CKP/ TDC/CYP snsor: C h e c kf o r c o n t i n u i t y o b o d y t ground on both terminalsof the (see indicated sensorindividually table).
Replacotho distributor ignition housing lsee soction tll.
Check for an opn in th6 wires linesl: ICKP/TDC/CYP 10P 1. Reconnect distributor the (8P)* connector. 2. Disconnect ECM/PCM connector C (31P). between 3. Measureresistance the terminalsof the indicated con sensoron the ECM/PCM nector(seetable).
C ECM/PCMCONNECTOFS {31P)
CKP P {BLU)
CKPM IWHT)
ls there350 700O?
Repairopen in the indicated sensor wires lsee t.ble). ':'99 - 00 models
TOCP IGRNI CYPP (YEL)
(RED) CYPM (BLKI
(Topage11-134) terminals female
(cont'd)
11 - 1 3 3
System PGM-FI
Position(CKP/TDC/CYPI Position/Top DeadCenter/Cylinder Grankshaft Sensor{cont'd}
(Frompage11 133) C ECM/PCMCONNECTOR {3IPI
Chock lor r 3hon in tho wirer lin6): ICKP/TDC/CYP C h e c kf o r c o n t i n u i t y b e t w e e n body groundand ECM/PCM connectorterminalsC8, C20 and/or C29individually.
Rep.ir lhort in ths indicatedsonaor wiroa 136otable on prge 11133). Substituto r known-good ECM/ PCM, and .6chock. tf 3ymptom/ indication goe3 swey, replrce tho original ECM/PCM.
Wire sideof female terminals
11 -1 3 4
Vehicle Speed Sensor (VSSI |posol lPosoo-]-'. l-'

'97 modol:
The MIL hes boen roported on. DTCm501 is 3tord. Problomverificetion: 1. Test'drive vohicle. the 2. Checkthe vehiclespeedwith the scantool, lntormittent tailure, rystom b OK at thia timo. Chocktor poor connection3 or 10o3owires rt C129 lvss) .nd rr rhe Pcfr4, FCM CONNECTORS A t32Pl
LG1
A P0500*' orP0501*r: range/perforThe scantool indicates Diagnostic TroubleCode{DTC} * I ; A/T mancein the VehicleSpeedSensor(VSS) circuit. *2i Mfi
(BRN/BLK)
ls the correct speedindicated?
Chockfor an open in tho PiCM: 1. Turnthe ignitionswitchOFF. 2. Block the rear wheels and set the parking brake. 3. Jack up the lront of the vehicle and support it with salety stands. 4. Turn the ignitionswitchON (ll). 5. Elockthe right front wheel and slowly rotate the left tront wheel by hand. 6. Measurevoltage between PCMconnector terminals C18 and A9. Doesthevoltagepulse0 V and 5 V or batteryvoltage?
N O T E :D o n o t u s e t h e e n g i n et o t u r n t h o front wheels with th6 rear wheels on the ground. The 4WD system will engage and Iurchforward. the vehicle will suddenlv Wire side ot femaleterminals
Substitulc a known-good PCM and .och6ck. It symptom/indicd. tion go.a away, .cplacotho originel FCM.
LGl
{BRN/BLKI
Checkfor a .hort in the PCM: L Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tt h e P C M c o n ' nector (31P). C 3. Turnthe ignition switchON (ll). 4 . E l o c kt h e r i g h t f r o n t w h e e l and slowly rotate the left front 5. Measure vohagebetweenPCM connector terminalsC18 and A9. pulse0 V Doesthevoltage and 5 V or battery voltage? Substituto e known-good PCM and rochock. f rymptom/indication goos rwry, roplsc. tho originalFCM.
Repair short in the wire between the PCM lC18l, cruise control unit, speodometer, and VSS, Repair opon in the wire between the PCM {C181.nd
rhevss.
f wire is OK. tost lho VSS l3oo soction 231.
(cont'd)
11-135
PGM-FI System
VehicleSpeedSensor(VSSI{cont'd}
'98 - 00 models:
The MIL ha3 beenreDonedon. DTC P0500" or P0501*1i3 3torod. ECM/PCMCONNECTORS B t25Pl
Probl6mverification: 1. Test-drive vehicle. the 2. Checkthe vehiclespeedwith the scantool, Intermittont failu.e, svstem is OK at thk time. Check for poor connection! or loose wiros at C129 lvss) .nd ar the EcM/PcM.
ls the correctspeed indicated?
Checkfor rn open in the ECM/ PCM: l Turnthe ignitionswitchOFF. 2. Elockthe rearwheelsand set the parking brake. 3. Jack up the front oI the vehicle and support it with satety stands. 4. Turn the ignitionswitchON {ll}. 5. Blockthe right front whoel and slowly rotate the lett front 6. Measurevoltage between E C M / P C M o n n e c t o rt e r m i c nals820 and C23. Doesthe voltage pulse between 0 V and 5 V or battery voltage?
NOTE(4WD):Do not use the engineto turn the front wheelswith the rearwheelson the ground. The 4WD system will engage and the vehicle will suddenly lurchforward.
Substitute a known-good ECM/ PCM and rochock. ll symptom/ indicetion 9063 away, .oplace th origin.l ECM/PCM.
Check for a short in the ECM/ PCMI 1. Turn the ignitionswitchOFF. 2. Disconnect CM/PCM on E c nector 131P). C 3. Turn the ignitionswilch ON {ll). 4 . B l o c kt h e r i g h t f r o n t w h e e l and slowly rotatethe left front 5. Moasure voltagebetweenECM/ PCMconnector terminals820 and C23. Sub.titute a known-good ECM/ PCM and rschock. It rymptom/ indication goos .w.y. replece rhe original ECM/PCM.
B (25P)
Doesthe voltage pulse betlveen 0 V and 5 V or battery voltage?
R.pair short in the wiro betwen the ECM/PCMlC23) .nd tho VSS. Roprir open in th6 wire botweon the ECM/PCMlc23l and th6 vss. It wirc is OK, te3t ihe VSS (!e soetion23).
*2:Mft
11 - 1 3 6
(BARO) Pressure Barometric Sensor

problemin the Barometric A The scantool indicates Diagnostic TroubleCode(DTC) P1106: range/performsnce Pressure Sensorcircuit. {BARO)
The MIL has been reDortedon. OTCPl106b slored.
Problemve.ification: 1. Oo the ECM/PCMreset pro' ceoure. 2. Start the engine.Hold the engine at 3,000rpm with no load (;n Parkor neutral)until the radiatorlan comeson, then letit idle. 3. Connect the SCSservice connector, 4. Test'drivewith the A/T in E position,M/T in 4th gear. 5. AccelerateIor five seconds usingwide openthrottle.
ls DTCP1106 indicated?
Intermittent fsilure, sy3tom i5 OK at this time.
Substitute a known-good ECM/ PCM .nd recheck.It symptom/ indication goes away, replacethe origioal ECM/PCM.
P1107: low voltageproblemin the Barosensorcircuit. A TroubleCode(DTC) fTiloz l The scantool indicatesDiagnostic The tP11o8l scan tool indicatesDiagnosticTrouble Code circuit.
The MIL h.3 ben roportdon. OTCPl10?or Pl108i3 stored.
(DTC)Pl108: A high voltage problem in the Baro sensor
Problomveritic.lion: L Do the ECM/PCM ResetProcedure. 2. Turnthe ignition switch (lli. ON
ls DTCP1107 P1108 or indicated?
Intarmittoni failure, lystom b OK at thb time.
Sub3tituto a known-good ECM/ PCM and rcch6ck. ll symptom/ indication 9oo3 away. .oplaco rho o.igin.l ECM/PCM.
PGM-FI System
Elestrical LoadDetector(ELDI(USAModell
A Load The scan tool indictesDiagnostic Trouble Code (DTC)P1297: low voltage problem in the Electrical (ELD) Detector circuit. '97 model:
Problemvsriticltion: 1. Do the PCMFesetProcedure. 2. Startthe engine. 3. Turn on the headlights. Intormittent lailuic, 3vstom k OK at thk time. Ch.ck tor poor connections or loose wiro3 at C127 (loc.ted on PCM b.sckot), C354 {ELO,.nd at tho FCM. ELD3P CONNECTOR {C354I Ch.ck for 3hort in lho ELD: Measurevoltage between body groundand the ELD3P connector t e r m i n aN o . 3 . l
--+- l 3 l l 1 L 2
lerO) tcnrulaeot
ls thereapprox.4.5V?
Checkfor a short in tho wire IEL linel: 1. Turnthe ignitionswitchOFF. 2. DisconnectPCM connector D (16P). 3. Checkfor continuitybetween body ground and PCMconnec tor terminalD16.
PCMCONNECTOR I16P) D
Wire sideof femaleterminals Rcpair 3hort in tho $rire botwon the PcM lDl6l and tho ELD.
Substituto a known-good PCM and rocheck. lf 3ymptom/indic.tion goos !w!y, repl.ce the original PCM.
11 - 1 3 8
98 - 00 mod6l3:
OTCPl17 is 3tored.
Problcm vcrificrtion: 1. Do the ECM/PCM ResetProcedure, 2. Startthe engine. 3. Turn on the headlights.
ls DTCP1297indicated?
Intcrmittent tailuro, ryrtom ir OK !t thi3 timo. Ch.ck tor poor connectiont or looao wire! at CXl54 IELD)rnd at rh6 ECM/PCM,
ELD3PCONNECTOR ICAs4I
Chockfor 3hort in tho ELD: Measurevoltage between body groundand the ELD3P connector terminalNo.3.
-I
f 2 l l 3, l _
r'. l--&)
iGRN/RED)
ls there approx. 4.5 V?
ECM/PCMCONNECTOR I32P) A Chcck lor a 3horl in tho wiio (EL linol: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tE C M / P C M o n c nectorA (32P). 3. Check for continuity between body ground and ECM/PCM connctortrminalA30. Wire sid6of femaleterminals Ropairshon in thc wira botwocn tho PcM (A301 rnd rho ELD.
Sub.tituto a known.good ECM/ PCM .nd rocheck. ll lymptom/ indication gocs .w!y. replsce th6 o.iginal ECM/PCM,
(cont'd)
1 1 139
PGM-FI System
(USAModel)(cont'dl Electrical LoadDetestor(ELDI
Load Trouble Code {DTC)Pl298; A high voltage problem in the Electrical The scan tool indicates Diagnostic (ELD) Detector circuit. 97 modsl:
ELD3P CONNECTOR {C35,'I Problamverification: 1. Do the PCMReset Procedure. 2. Startthe engine. 3. Turn on the headlights. Intermittent tailuro, systcm is OK .t this time. Chack for ooor connoction! or looro wire3 at C127 {locaied on PCM brackot), C35{ {ELDIand .t tho PCM. Chack for an opan in tho wile llGl linol: 1 . T u r n t h g i g n i t i o na n d h e a d lightsOFF. 2. Disconnect ELD3P connector. the 3. Turn the ignitionswitchON {ll). 4. M6asurevoltage btwen body ground and the ELD 3P connoctor terminalNo. 1. Repail opn in th. wire btwsn S tho No. 15 ALTERNATOR P S E N S O R1 7 . 5 A ) t u s e i n t h e under-dlrh fuso/r.lay box and th6 ELD. Chock lol !n open in the wire IGND linel: '1. Turn the ignition switch and headlights OFF. 2. Disconnectthe ELD 3P con neqor, 3. Check for continuity between body ground and the ELD3P connector terminalNo.2. Ropairopon in th6 wi.e betweon th. ELDconnectorrnd GiO2, Wire sideof lemaleterminals PCMCONNECTORS Ch.ck lo. an open in th wiro (EL line): Checkfor continuity between the ELD3P connector terminalNo. 3 and PCMconnector terminal016. ls therecontinuityT
WiresidooI lemaleterminals
rlzl --T_ow r l
/6\ IBLKI
EL {GRN/NEDI
R6pafu op6n in tho wire between the PCM{D161snd ELD. th6 Subltituto . known-good PCM and rachock, f symptom/indic.tion goes awry, ropl.ce the origin.l PCM.
Chock for . malfunction in the ELD: 1 . R e c o n n e ctth e E L D 3 P c o n neclor, 2. Start the engineand allow it to idle. 3. While measuring voltage betweenPCM connectorter m i n a l s0 1 6 a n d A 9 . t u r n t h e headlights (low). on
Does voltage the drop?
1 1 -1 4 0
38 - 00 modeb:
Problemverification: 1. Do the ECM/PCM ResetPro ceoure. 2. Stanthe engine. 3- Turn on the headlights. ls DTCP1298 indicated? Intermittent feilure, sysl.m is OK at this time. Checkfor ooor connections or loose wires at C354 (ELDIand at the ECM/PCM.
ELO CONNECTOR 3P {c35/rl
Check lor an open in the wire (lG1line): ' 1 . T u r n t h e i g n i t i o na n d h e a d lightsOFF. 2. Disconnect ELD3P connector. the 3. Turnthe ignition switch (ll). ON 4, Measu e voltage between r body ground and the ELD3P '1. connector terminalNo.
Wire sideot temaleterminals
ELD3P CONNECTOR {C35,lt
Reprir open or short in th6 wire botweon the No. 15 ALTERNATOR SP SENSOR{7.5 Al fuse in the under-drah fuse/relay box and the ELD.
Check tor an opon in tho wire {GNDline}: 1. Turn the ignition switch and headlights OFF. 2. Disconnectthe ELD 3P con nector. 3. Check for continuity between body ground and the ELD 3P connector terminalNo.2, Repairopon in the wire between the ELDconneclor and GilO2.
Ched(fo. an opn in the wir (ELlinel: Checkfor continuity between the ELD3P connector terminalNo. 3 and ECM/PCM connectorterminalA30. Repairopn in tha wile botwecn the EcM/PCM lA30l .nd rhe ELD.
EL IGRN/RED} Wire sideof female termrnars ECM/PCMCONNECTORS A l32P)
Checkfor s malfunction in lhe ELD: 1 . R e c o n n e ctth e E L D 3 P c o n nector. 2. Start the engine and allow it to idle. 3 . W h i l e m e a s u r i n gv o l t a g e between ECM/PCM connector terminalsA30 and 820, turn the headlights (low). on
Wire sideof femaleterminals Substiiute a known-good ECM/ PCM and recheck. It symptom/ indication goos away, replace the original ECM/PCM.
11-141
PGM-FI System
(CKF) Grankshaft SpeedFluctuation Sensor
Tj":""l.tool indicates Diagnostic TroubleCode(DTCIP1336: Intermittent interruption inthe Crankshaft Speed fF13361l : (CKF) Fluctuation sensorcircuit. The scan tool indicatesDiagnostic Trouble Code (DTC)P1337: signal in the Crankshaft No SpeedFluctuation(CKF) sensorcircuit. Description The diagnostic systemhas a pulserrotor on the crankshaft and a pulsepick-upsensoron the engineblock.The ECM/PCM monitorsthe crankshaft speedfluctuationbasedon the CKFsensorsignal,and judgesthat an enginemisfireoccurredif goes beyonda predetermined the fluctuation limit.
37 mod.l:
Tho MIL ha3been reportedon. DTC P1336and/or P1337are stored.
Problemverificrtion: 1. Do the PCMReset Procedure. 2. Startthe engine.
CKFSENSOR
Intermittent {ailure,systom is OK .l thia timo. Ch6ck tor poor connections or loose wir$ at Clorl ICKFsonsorl .nd at tho PCM. Chocktor an opon in th6 CKF.en' 30r: 1. Turn the ignitionswitchOFF. 2. Disconnect CKFsensor2P the connector, 3, Measure the resistance b e t w e e nt h e C K Fs e n s o r2 P connector terminals No. 'l and No.2.
CKFSENSOR CONNECTOR 2P IClO4I

T:] l-r'r Lll l 1' z L' l ' ' P CKF I lcKFM talu/aeotfdJ twxrneor
ls there1.6-3.2 kO?
\-7
Checkfo. a short in the CKF3ensot: C h e c kf o r c o n t i n u i t y b e t w e e n body groundand the CKFsensor 2P connector terminals No. 1 and No.2 individually.
Terminal side of male terminals
(Topage11-113)
1 1 -1 4 2
p { F r o m a g e1 1 - 1 4 2 ) PCMCONNECTOR 13lPI C Chock to. an open in the wires (CKFlin06l: 1. Reconnect CKFsensor2P the connector, 2. D;sconnect the PCM connect o rC ( 3 1 P ) . 3. Measureresistance between PCM connectorterminalsC1 a n dC l 1 . Wire sideof lemaleterminals ls there1.6- 3.2k0? Ropair open in the wire betwoon tho PCM lcl, Cl1l and th6 CKF !6naor. CKFP IELU/REDI
Chock tor a short in the wires (CKFlino3): C h e c kf o r c o n t i n u i t y b e t w e e n body ground and PCMconnector terminalCl.
Rcoair short in thc wire btween the PCM{Cl I and the CKF.en!o..
Subsiituto r known-good PCM and r6chock. lf symptom/indication goe3away, roplacothe origin.l rcM.
(cont'd)
11-143
PGM-FI System
(CKFI Grankshaft SpeedFluetuation Sensor(cont'dl
.98 - 00 modols:
The MIL has boon reportedon. DTC P1336and/or P1337are stored.
ProblGm verification: 1. Do the ECM/PCM ResetProcedure, 2. Stanthe engine. Inte.mittant failuro, 3y*om b OK at thb tima. Chack lor ooor connections or looso wirea at C10a { C K Fs e n s o r la n d . t t h e E C M / PCM, Chgckforun open in tho CKFsonsori 1. Turnthe ignitionswitchOFF. 2. Disconnect the CKFsensor 2P connector. 3. Measure the resistance between the CKF sensor 2P connector terminals No. 1 and No.2.
2P IClO'I CKFSENSOR CONNECTOR

r-:-i-_l
tr_CKFP I
2 l 1, - l l , '
lsthere1.6- 3.2kO?
tsLuneotTOl wlrrneo) \7
ICKFM
Terminal sideof maleterminals Checkfor a short in the CKFsenC h e c kl o r c o n t i n u i t y b e t w e e n body groundand the CKFsensor 2P connector terminals No. 1 and No.2 individually.
r:l
t !E l
.KFPXA"*." \:f
talu rneor f rwxvneor
Check for an open in the wires ICKFlinca): 1. Feconnect CKFsensor2P the connector. 2. DisconnectECM/PCM connect o rC ( 3 1 P ) . 3. Measureresistance between ECM/PCM onnector ermi' c t nalsC22and C31.
C ECM/PCMCONNECTOR (31P) CKFP IBLU/REDI

1 2 7 8 1 6 1 7 1 6 't9 20 21 22 26 27 28 29 3() 3 l
,/ 2s
M M CKF (WHT/BEOI terminals Wi16 sideof l6male

Repairopon in the wir6 botwoon glll lnd th6 the ECM/PCM1C22, CKFs6n3or.
__l (o -l I T
ls there1.6- 3.2kO?
(Topage11'1451
11-144
( F r o m a g e1 1 - 1 4 4 ) p C ECM/PCMCONNECTOR (31PI CKFP {BLU/RED)
Check for a shorl in the wires (CKFlines): C h e c kl o r c o n t i n u i t y b e t w e e n con body ground and ECM/PCM nector terminalC22.
ls therecontinuity?
Repairshort in tho wire between the ECM/PCM{C221 and rh. CKF
Wire sideof femaleterminals
Substitute a known-good ECM/ PCM and recheck. lf svmptom/ indication goes away. replace the original ECM/PCM.
11-145
System PGM-FI
Sensor Position(CKP/TDC/CYP) Position/Top DeadCenter/Cylinder Crankshaft
Position/Top Dead : Diagnostic TroubleCode (DTC)P 1 3 5 9A problemin the Crankshaft The scantool indicates sensor circuit. Center/Cvlinder Position tCKP/TDC/CYP)
The MIL has been reoortedon. DTCP1359is stored.
Problemverific.tion: 1. Do the ECM/PCM Reset Procedure. 2. Startthe engine.lf the engine won't start, crank it continuouslyforat least15seconds.
Intermitteni lailure, system is OK. Check for ooor connectionsor loos wires al C121 {distributor} and at the ECM/PCM.
o C h e c kf o r p o o r c o n n e c t i o n s r loosewires between the distribu' tor andthe EcM/PcM.
Substitute a known-good ECM/ PCM, and recheck. ll symplom/ indication goes away, replacethe original ECM/PCM.
1 1 -1 4 6
ECM/PCM Internal Circuit

lFi6oil
-
P1607: ECM/PCM An Internal CircuitProblem. Th" """n tool indicates Diagnostic TroubleCode{DTC)
The MIL has been reoortedon. DTCPlmT is slor6d.
Problomveritication: 1. Do the ECM/PCM ResetPro 2. Turnthe ignition switch (ll). ON 3, Waitthreeseconds,
Sub3tiiut a known-good ECM/ PCM and recheck.lf symptom/ indicationgoes away, replacethe originalECM/rcM.
11-147
PGM-FI System
HO2SReplacement
1. Disconnect HO2S4P connector, the and removethe HO2S.
PRIMARY H02S:
PRIMARY HO2S 4P CONNECTOR
02 SENSOR WRENCH
PRIMARY HO2S 44 N.m {4.5kgt m,33lbf.ftl
SECONDARY HO2S:
SECONDARY HO2S 4,0N.m (4.5 kg{.ft, 33 lbtftl
2.
Install the HO2Sin reverse orderof removal.
11-1 4 8
ldle Control System

SystemDescription
by The idle speedof the engjneis controlled the ldle Air Control(lAC)Valve' currentcontrolledby the to into the intakemanifoldin response electric the amount of air bypassing The valvechanges the Whenthe lAc valve is activated, valveopensto maintainthe properidle speed. ECM/PCM.
YEL/ BLK FromPGM'FI TMAIN RELAY
VARIOUS SENSORS
IAC VALVE INTAKEMANIFOLD
to After the enginestarts,the IACvalve opensfor a certaintime. The amountof air is increased raisethe idle speed - 300 rpm. about 150 ts when the cootanttemperature row, the lAc valve is openedto obtain the proper fast idle speed The amount o{ to in air bvoassed is thus controlled relation the enginecoolanttemperature P0505 TroubleCode(DTC) and When the idle speedis out o{ specification the scantool does not indicateDiagnostic items: or P1508, checkthe following . Adjustthe idle speed(seepage11-169, 170) . A i r c o n d i t i o n i ns i g n a ( s e e p a g e l l - 1 5 5 1 l g . A L TF Rs i g n a ( s e ep a g e1 l - 1 5 9 ) l . Starter switchsignal(seepage11-16'1) . A,/T gear positionsignal(seesection14) . P S P w i t c h i g n a( s e e p a g e l l - 1 6 2 ) s l s . Brakeswitchsignal(seepage11-165) . F a s ti d l e t h e r m o v a l v ( s e e a g e ' 1 1 6 8 ) 1 e p . Hosesand connecttons . IACvalveand its mountingO-rings
4.
170) the IAC a lf the aboveitemsare normat,suDslitute known-good valveand readjust idle speed{seepage 11-169, or (and the scantool does not indicateDTC P0505 Pl508) lf the idle speedstill cannot be adjustedto specification and recheck lf symptom goes away' replacethe substitutea known-goodECM/PCM after IAC valve reolacement, originalECM/PCM.
11-149
ldle Control System

ldle ControlSystem
Diagnostic T.oubleCode(DTCIPO5O5: I P0505 | The scantool indicates ldlecontrolsvstemmattunction. NOTE:lf DTCP1508 storedat the sametime as DTCP0505, is troubleshoot DTCP1508 first.then troubleshoot DTCp0505. PossiblsCause . IACvalvemechanical malfunction . Throttlebody cloggedport,improperadlustment . Intakemanifoldgasketleakaging . Intake hoselooseleakaging air . Vacuumhose leakaging a ECTsensorincorrect output . ThrottlePosition sensorincorrect output TroubleshootingFlowchart
The MIL has been reDortedon. DTCP0505is sto.ed.
Problemverificationi 1. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiatorIan comeson, then let it idle. 2. With the scan tool, checkthe lollowingitems. - Throttleposition should be approx. 10%with the throttle {ully closed. - E n g i n ec o o l a n tt e m p e r a ture shorJld 194- 205'F be (90- 96"C). lf they are not within the spec., repair faultysenthe sor circuit. 3 C h e c kt h e e n g i n e s p e e d a t idle with no-loadconditions: headlights,blower fan. rear defogger, radiator lan, and air conditioner not operaling, are
ls it 750{730)* 50 rpm? i
Inte.mittent failure. syltem is OK at this time.
ls il 700(680)'rpm or less?
l:'99 - 00 models
{ T op a g e1 1 - 1 5 1 )
( T op a g e1 ' l - 1 5 1 )
(Frompage11-150)
Checkthe IAC valve: from the Disconnect 2P connector the IACvalve.
Doesthe enginespeeddroP or the enginestall?
Adiust the (basel idl speed lsee page11-169, 1t0).Itihe ba3eidle speed cannot be adiustd, clean the Dorts in the throttle body.
UPPER
p { F r o m a g e1 1 - 1 5 0 }
Checkthe tast idle lhermo valve: 1. Turnthe ignitionswitchOFF. 2 . R e m o v et h e i n t a k ea i r d u c t from the throttle body. 3. Startthe engineand let it idle. 4. Put your finger on the lower pon in the throttlebody.
VALVE THERMO (A/Tonlyl

Doesthe enginespeeddrop? Checkenginecool.nt leveland for air in the cooling sy3lem. lf OK, reolacethe f.st idle thermo valve.
Putyour Iingeron the uPPer Port in the throttlebody. Check for vacuum leaks, make sure the throttle valve is com' pletely clo3ed.and repair as nec-
Doesthe enginespeeddroP?
Adjust the idle spoed lsee Page lf 11-169.1701. the adiustment does not correct lhe problem, r.olace the IAC valve.
ldle Control System

ldle Air ControlllAC)Valve
The scan tool indicatesDiagnostic Trouble Code (DTC)Pl508: A probtem in the ldle Air ControtflAC)varve circuit. The IACValvechanges amountof air bypassing throttlebody in response a currentsignalfrom the ECM/PCM the the to in orderto maintainthe properidle speed.
From AIR To INTAKE CLEANER MANIFOLD
37 model;
The MIL has beon .eportd on. OIC Pl508 is sto.ed.
Problemveiification: 1. Do the PCMReset Procedure. 2. Startthe engine,and warm it up to normal operatingtemperature. Inte.mittent failure, systcm b OK at thi3 time. Checktor poo. connections or loose wircs at C132 (lAC v.lvel and at the PCM. IAC VALVE2P CONNECTOR {C132} Check lor an open in the wir6 {lGPl lins}: 1. Turnthe ignitionswitchOFF. 2. Disconnect the IAC valve 2P connector. 3. Turn the ignitionswitchON {ll). 4. Measure voltagebetweenbody ground and the IAC valve 2P connector terminal No.2. Repairopen in the wire trctwoon tha IAC v!lv6 and the PGM-Fl main relly. PCMCONNECTOR I32PI A Chockfor an opan o. short in tho wi.e (lACv linel: 1. Turn the ignition switch OFF and reconnect the IAC valve 2P connector. 2. Disconnect PCMconneclor the A (32P). 3. Turn the ignitionswitchON {ll). 4 , M e a s u r ev o l t a g e b e t w e e n body ground and PCM connector terminalA12.
ls DTCPl508indicated?
,f\
rcp'
IYEL/BI.(I
I- 2d - 1 f )
Y
Wir side of female terminals
tacv
IBLK/ BLU) Wire sideof female terminals
{ T op a g e1 l - 1 5 3 )
( F r o m a g e1 1 - 1 5 2 ) p Bepair opn or short in the wire betweon th PCM {A121and the IAC vrlve.
voltage? ls therebaftery
Checkthe IAC valve function: Momentarilyconnect PCM con' n e c t o rt e r m i n a l sA 1 2 a n d A 1 0 with a iumoerwire severaltimes, terminals Wire sideof female Doesthe IACvalveclick?
Substitute . known-good PCM and rcheck, lt 3ymptom/indication goes away, replacothe origi_ nalPCM,
1-153
ldle Air Control(lAC)Valve{cont'd}

'98 - 00 models:
The MIL has boen r.ported on. DIC Pl 508 b 3tored.
Problemveritication: L Do the ECM/PCM ResetProcedure. 2. Startthe engine,and warm it up to normal operatingtemperature. Intrmittent failure, systom is OK al lhis timo. Check lor poor connections or looro wirca at C132 (lAc vrlvel and .t rho EcM/PcM. IAC VALVE2P CONNECTOR {C132I
Chock tor an open in the wir6 llGPl linel: 1. Turnthe ignitionswitchOFF. 2. Disconnect the IAC valve 2P connector, 3. Turnthe ignition switch (ll). ON 4. Measure voltagebetweenbody ground and the IAC valve 2P connectortermina No, 2. I Repairopon in the wira botwoon the IAC valve and tho PGM-FI main aalay. Checktor an open or short in the wire (IACVlinel: 1. Turn the ignition switch OFF and reconnect the IAC valve 2P connector. 2. Disconnect CM/PCM onE c nectorB {25P). 3. Turn the ignitionswitchON {ll}. 4. Measurevoltage between body ground and ECM/PCM connector terminal823. Ropair open or short in thg wire between tho ECM/FCMlB23l and the IACvalve.
*l tYELrBLxl I2/'-
F\
rcpt
rf) Y
Wire side ot fem.le terminals
B ECM/PCMCONNECTOR (25PI 2 'to

20 5 1l 13 21 22 t7 8
9 19
23
tAcv (BLK/BLUI
Wiresideof femaletorminals ls there batteryvoltage?
PG1 {BLKI
1
Checkthe IAC valve func,tion: Momentarilyconnect ECM/PCM connector terminals823 and 82 with a jumperwire several times.
2 |
t 3 4 5
17
9 1 0 1 1 13 19 20 | 121)22
tAcv (BLK/
BLU) JUMPER WIRE
Does the IACvalve click?
Subslitute . known-good ECM/ PCM .nd rechock.lf symptom/ indication goes aw.y, replac. th original ECM/PCM.
Air ConditioningSignal
system. the This signals EcM/PcMwhen there is a demandfor coolingfrom the air conditioning '97 modol:
Chock for a shorl in thc wiro (ACSlinol: 1. Turnthe ignitionswitchOFF. the A/C pressure 2. Disconnect switch2Pconneclor. ON switch (ll). 3. Turnthe ignition , 1 . [ I e a s ur e v o l t a g e b e t w e e n PCM connectorterminalsC5 andA9.
Wiresideof lemaleterminals
C PCMCONNECTOR (31PI ACS IBLU/RED) Check for . .hon in the wire IAGS linel: 1. Turnthe ignitionswitchOFF. C PCM connector 2. Disconnect (31P). 3. Check for continuity between body ground and PCM connector torminalC5. Wiresideof female terminals
Reoaii short in tho wire btwoen rh6 PCM (Csl and the A/C pres3urc 3witch.
Check tor an opon in the wite (ACClino): the 1. TLrrn ignitionswitchOFF. the A/C pressure 2. Roconnect switch2Pconnector. 3. Turn the ignitionswitchON (ll). r 4 . M o m e n t a i l y c o n n e c tP C M A connectoterminals 9 and r 417 with a iumper wire sev' eraltimes,
Subcdtrte a known{ood PCM and recheck. lf pr6actibed voltage is now av{ilable, roplace the origind PCM, Soethe eir conditionorin3pclion lsee soction221.
A PCMCONNECTOR (:TIPI JUMPERWIRE
(To page11-156)
Wire sideoI Iemaleterminals
(cont'd)
5 11 - 1 5
ldle GontrolSystem
Air ConditioningSignal(cont'dl
(Frompage11-'155) UNOER.HOOD FUSE/RELAY BOX 9P CONNECTOR tqt52) 1 5 JUMPER WIRE
ls therea cl;cking noisefrom the 4!/C compressor clutch?
Ch6ck for an open in th wire (ACClinel: Momentarilyconnectthe underhood fuse/relaybox 9P connector t e r m i n a lN o . 5 t o b o d y g r o u n d with a jumperwire several times.
2
6
3
I
ACC IBLK/R IBLK/REDI Wire sideof female termrnats
ls therea clicking noisefrom the 4!/C compressor clutch?
See air condiiioner inspection {seesection221.
Repai. op6n in the wire betwoen the PcM (A17) and tho A/C clutch relay.
A t32Pl
Checkthe A/C operation: 1. Startthe engine. 2. Turnthe blowerswitchON. 3. Turn the A"/C switch ON.
PCMCONNECTORS
C t3rp)
Wire sideol lemaleterminals Check for an open in the wire (ACSline): Measurevoltage between PCM connector terminals and C5. Ag
Doesthe A,/C operate?
Air conditioningsignal is OK. ls therelessthan 1.0V? Repair open in the wire between the PCMlCSland the A/C awitch.
Subqtitute a known-good FCM .nd rch6ck.lt 3ymptom/indication goes awav, replece the originalrcM. Soe th eir conditioner in3pection (s6aec.tion 22).
'98 - 00 models:
ECM/PCMCONNECTORS A {32P1
Check for a shott in the wire {ACSlinel: 1. Turnthe ignitionswitchOFF. the A/C Pressure 2. Disconnect switch2Pconnector. switch (ll) ON 3. Turnthe ignition 4. Measurevoltage between t c ECM/PCM onnector erml nalsA27 and 820.
A ECM/PCMCONNECTOR (32PI Checktor . short in the wire IACS linel: 1. Turnthe ignitionswitchOFF. connec2. DisconnectECM/PCM tor A (32P). 3. Checkfor continuitybetween body ground and ECM/PCM A27. terminal connector
Wiresideof femaleterminals R.oak short in the wile between rhe ECM/PCM(A271and the A/C switch. Dressure
ls therecontinuitv?
ECM/PCMCONNECTORS Check for an open in the wire (ACCline): '1. Turnthe ignitionswitchOFF. the A/C Pressure 2. Reconnect switch2Pconneclor. 3. Turn the ignitionswitchON (ll). 4 . M o m e n t a r i l yc o n n e c tE C M / A17 terminals PCMconnector a n d 8 2 0 w i t h a j u m P e rw i r e severalllmes, Sub6titute a known{ood ECM/ rcM and recheck. lf pte6cribed re' voltage i3 now available, pl.ce the origioalECM/rcM. Seeih6 air conditionerinspection (s6esection221. A (32P1
ACC(BLK/REOI
{To page11 158)
(BRN/BLKI JUMPERWIRE LG1
{cont'd)
11-157
ldle ControlSystem
Air Gonditioning Signal(cont'd)
(Frompage'11,157)
ls therea clicking noiselrom the y'y'C compressorclutch?
Check Ior dn opon in the wiro IACClinel: Momentarily connectthe underhood fuse/relaybox 9P connector t e r m i n a lN o . 5 t o b o d y g r o u n d with a jumperwire several times.
UNDER-HOOD FUSE/RELAY BOX9PCONNECTOR {G'52I

2 5 5
3 a
8 9
JUMPER WIRE
(BLK/RED' ACC(BLK/R Wire side ot otfemale terminals
ls therea clicking noisefrom tho A,/C comprossorclutch?
Sae rir conditional in3paction lroa saction 221.
Repai. open in th6 wiro lrtwlan the ECM/PCMlAl7l .nd tho A/C clutch rolay.
ECM/PCM CONNECTORS
Check tho op.ration of tho A/C: 1. Stan the engine. 2. Turnthe blowerswitchON. 3. Turn the Ay'C switch ON.
Doesthe !y'C operate?
ChGGk an open in the wi.e for IACS linel: Measurevoltage betweonECM/ P C M c o n n e c t o rt e r m i n a l sA 2 7 and 820.
Wiresidof female torminals
Air conditioning 3ignal i3 OK. ls voltage lessthan 1.0V?
Rap.ir opon in the wir6 bdtunaan rh. Ecil/FcM lA27l rnd rh. A/c rwitch.
Sub6lftna a known{ood ECM/ PCM and rechock. lf symptom/indicetion goes away. roplace originalECM/rcM. the See the ah conditionor inspoction {3esection 22},
Alternator(ALT)FRSignal
(ALTIis charging. when the Alternator the This signals ECM/PCM ,97 modet:
Inspectionot ALT FRSignal. C h e c kl o r a s h o r t i n t h e w i r e {ALT F line}: the 1. Disconnect 4P 13Pi*con nectorfrom the ALT. ON switch (ll) 2. Turnthe ignition 3, Measurevoltage between C17 terminals PCMconnector and A9.
GONNECTORS PCM
terminals wire sideof female
c (31P|
Check for a short in the wire (ALT F linel: 1. Turnthe ignitionswitchOFF. the negativebat' 2. Disconnect tery cable from the battery. C PCM connector 3. Disconnect (31P). 4. Checkfor continuitybetween b o d y g r o u n da n d P C Mc o n nector terminalC17.
5 ls thereapprox. V?
Checkth ope.ation of the ALT: 1. Turnthe ignitionswitchOFF the ALT 4P {3Pi* 2. Reconnect connector the ALT. to 3. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 4. Measurevoltage between terminalsC17 PCMconnector and A9. when Doesthe voltagedecrease are headlights reardefogger and turnedon?
Ropeirshort in the wir6 betweon the PCM lC17l and the ALT.
Substitut. a known-good PCM and recheck. lf prescribed voltage is now availablo,replacethe originalPCM.
ALT FRsignal b OK. (C1O5I ALT CONNECTOR lP ALT F r-F3Pr
Chd( for an opn in tho wire IALT F linel: 1. Turnthe ignitionswitchOFF. the negativebat2. Disconnect tery cablelrom the battery. PCMconnectorC 3. Disconnect (31P). the 4. Disconnect 4P (3P)*connectorlrom the ALT. 5. Connectthe ALT 4P (3P)* connector terminalNo. 4 (No. 1)* to body groundwith a iumper 6. Check for continuity between con' body ground and PCN4 nector terminalCl7. ls therecontinuity?
lll2llw|{frREDl | -3 . r - ' l
wne lruueen
JUMPER WIRE
wire side ol fmale terminals C PCMCONNECTOR I31P)
ALT F IWHT/REDI Repair open wi.e between the PCMlCl7l and the ALT. Wire sideof femaleterminals
11 - 1 5 9
ldle GontrolSystem
Alternator(ALT)FRSignal(cont'dl
'98 - 00 modols:
Inspctionof ALT FRSignsl. ECM/PCMCONNECTORS
B (25P)
AI.T F IWHT/REDI Check fo. a shon in th. wire {ALT F linel: 1. Disconn6ct 4P (3P)*conthe nectorfrom the ALT. 2. Turnthe ignition switch {ll). ON 3. Measure voltagebetweenECM/ PCM connectorterminalsC5 and 820.
ls thereapprox. V7 5
Checkthe opcration of the ALT: 1. Turnthe ignitiooswitchOFF. 2. Reconnect rhe ALT 4P (3P)* connectorto the ALT. 3. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rl a n c o m e s o n , then let it idle. 4. Measure voltagebetweenECM/ PCM connectorterminalsC5 and 820.
Chck for a sho.t in iho wirc lAlT F lino): 1. Turnthe ignitionswitchOFF. 2. Disconnecl the negativebat, tery cablefrom the battery. 3. DisconnectECM,PCM connect o r C( 3 1 P ) . 4. Checkfor continuitybetwoen body ground and ECM/PCM connector terminalc5.
Wire sideof femaleterminals Roprir lhort in tho wirc bstween tho ECM/PCM{Csl and the ALT.
Substitut. r known-good ECM/ PCM and roch.ck. It Droscrib.d voltage b now lvrilabls, .eplacc th. o.igin!l ECM/PCM.
Doesthe voltage decreasewhen headlights reardefogger and are turnedon?
ALT FR3ignol is OK, (C1I}5I ALT CONNECTOR 4P
Chocklor an opon in tha wire (ALT F linel: 1. Turnthe ignitionswitchOFF. 2. Disconnect the negativebattery cablefrom the battery. 3 . D i s c o n n e c tE C M / P C M o n c nector (31P). C 4. Disconnect 4P 13P)*con, the nector from the ALT. 5. Connect ALT 4P {3P)*conthe nectorterminalNo. 4 1No.1)* to body groundwith a jumper 6. Check for continuity betwen body ground and ECM/PCM connector terminalC5. ls therecontinuity?
l3laF1 WIRE I JUMPER +
rH] Arr F l'l'ltwHr/REo)
JUMPER WIRE
ECM/PCMCONNECTOR {31P} C ALT F {WHT/REDI Rsprir opan wiro batw.en tho ECM/PCMlcsl .nd th. ALT.
Wire sideot Iemaleterminals ": Canada
11 - 1 6 0
Starter Switch Signal

when the engineis cranking. This signalsthe ECM/PCM '97 model:
in Transmission E or E position. PCMCONNECTORS A {32P} Checkfor an opan ot short in the wire (STSlinel: Measurevoltage between PCM C c o n n e c t ot e r m i n a l s 6 a n d A g r w i t h t h e i g n i t i o ns w i t c h i n t h e start(lll)position. LGl (BBN/BLK)
c t31P) STS(BLU/ORNI
Wire sideof femaleterminals SIGlnspectthe No. 31 STARTER NAL (7.5 A)Illse in the under'dash
Starter swiich signal i3 OK. -
Reoair short in the wire between the PCM lc6l and th. SIGNAL175 No. 31 STARTER A) tuse ot the PGM-FImain reray. Reolacethe No. 31 STARTER SIGNAL t7.5Altu.e.
Repairopon in the wire betweon rh6 PCM lc6l and the No 31 A)fuse. SIGNAL17.5 STARTER
'98 - 00 models: NOTE: . M/T: pedal must depressed. be Clutch . A/T:Transmission orE position in E
A (32P) Checktor an open or short in the wir (STSline): Measurevoltage betweenECM/ P C M c o n n e c t o rt e r m i n a l sA 2 4 and 820 with the ignitionswitch (lll). in the startposition ECM/PCMCONI{ECTORS
voltage? ls therebattery
SIG Inspect No. 31 STARTER the NAL(7.5A){usein the under-dash
Wire sideoI femaleterminals Reoair shorl in the wire betwen the ECM/PCMlA2,fl SIGand the No, 31 STARTER NAL t7.5 Al tu3 ot the PGM' Fl main rclay. Repl.c. tho No. 31 STARTER Al SIGNAL17.5 fu3e.
Starter switch 3ignal is OK. -
Repairopon in tho wire between the ECM/PCM{A241and the No 31 STARTER SIGNAL(7.5A) tu3e
11 - 1 6 1
ldle GontrolSystem
(PSP) PowerSteeringPressure Switch Signal
This signalsthe ECM/PCM when the power steering load is high. '97 model:
Inspectionot PSPswitch signal.
Checkfor an open in the wire {PSP SYV line): 1. Turnthe ignition switch (ll). ON 2. Measurevoltage between PCN4 connector terminals C16 and A9. Checktor an open in lhe wire (PSP SW linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe PSPswitch 2P connecror, 3. Turnthe ignitionswitchON (ll). 4. At the harnessside, connect the PSPswitch 2P connector t e r m i n a l sN o . 1 a n d N o . 2 with a jumperwire. 5, Measutevoltage between PCMconnector terminals C16 and A9.
PSPSWTTCH CONNECTOR 2P 1C135) PSPSW (GRN) JUMPERT_7
ls therelessthan 1.0V?
vnRE t--f
r)
GNDIBLK} Wire3id6of female terminals

Ropsir open in the wi.e betwoon the PCM lcl6l and the PSPswitch. Ropdir open in BLK wire between the PSP switch and G101.
Check the operation oI lhe PSP switch: 1. Stanthe engine 2. Turnthe steering wheelto the full lockposition*. 3. Measure voltagebetweenPCM connector terminalsC16 and A9.
PSPswitch signal is OK.

*: Do not hold the steeringwheel at tull lock for more than five seconds,
(To page11-163)
{ F r o mp a g e 1 1 1 6 2 )
PCMCONNECTORS C h e c kf o r a s h o r t i n t h e P S P swilch: 1. Turnthe ignitionswitchOFF. 2. Disconnect the 2P connector from the PSPswitch. switch (ll). ON 3. Turnthe ignition 4 . l l e a s ur e v o l t a g e b e t w e e n C16 PCMconnector terminals and A9.
c t3lPl
Checktor a short in the wire (PSP SW linol: 1. Turnthe ignitionswitchOFF. PCMconnectorC 2. Disconnect (31P). 3. Checkfor continuitybetween body ground and PCMconnector terminal C16.
Reoairshort in the wire betwoon rhe PCM {C16)and the PSP 3witch.
Substitute a known-good PCM and rocheck.lf proscribodvoltage b now available,replacethe original PCM.
(cont'd)
1 1 163
ldle ControlSystem
(PSP) PowerSteeringPressure Switch Signal(cont'dl
'98 - 00 models:
Inspectionof PSPswilch 3ignal. ECM/FCMCONNECTORS
Chcktor rn opon in the wire (PSP SW line): 1. Turnthe ignition switch {ll). ON 2. Measure voltagebetlveen ECM/ PCMconnector terminals 426 and 820. Chockfor an open in the wire IPSP SW lin): 1. Turnthe ignitionswitchOFF. 2. Disconnect PSPswitch2P the connector, 3. Turnthe ignitionswitchON (ll). 4. At the wire side.connectthe PSPswitch 2P connector ter m i n a l s o .1 a n d N o . 2 w i t ha N 5. Measure voltagebetweenECM/ PCM connectorterminals 426 and 820. Wiresideof femaleterminals PSPSwlTCH 2P CONNECTOR ICl35} PSPSW IGRNI JUMpER f-7
wtRE L-5 rl
GND (3LX} Wire sideof lemaleterminals Ropai. open in the wire betweon th6 ECM/PCM (A26) and th6 PSP.witch. R6p.ir open in BLK wire between tho PSP 3witch and G1 0 1 ,
Check the opration of the PSP switch: 1. Stanthe engine 2. Turn steering wheelto the full lockposition*. 3. Measure voltagebtweenECM/ PCMconnector terminals A26 and 820.
lstherelessthan 1.0V?
PSPswitch signal is OK. *: Do not holdthe steering wheelat lull lockfor morethan five seconds.
(Topage 11-165)
11-164
{Frompage11 164i
ECM/PCMCONNECTORS
C h e c kf o r a s h o r t i n t h e P S P switch: 1. Turnthe ignitionswitchOFF. 2, Disconnect the 2P connector from the PSP switch. switch (ll). ON 3. Turnthe ignition voltagebetlveen ECM/ 4. Measure A26 PCMconnector terminals and 820. Wiresideof femaleterminals
A l32Pl
Checklor e 3hort in the wire IPSP SW linell 1. Turnthe ignitionswitchOFF. E c 2. Disconnect CM/PCM onnectorA (32P). 3. Checkfor continuitybetween b o d y g r o u n da n d E C M / P C M connector terminalA26. terminals Wiresideof female
ReDair short in the wir bstween the ECM/PCM(A26)and the PSP switch.
Substitute a known-good ECM/ PCM and rechock. It Drescribod voltago is now available,roplace the origin.l ECM/PCM,
11 - 1 6 5
ldle ControlSystem
BrakeSwitch Signal
This signals ECM/PCM the when the brakepedalis depressed.
Inspction Brak. Switch Signal. of
Are the brakelightson without pressing brakepedal? the
Do the brakelightscome on?
Inspectthe HORN,STOP{15 A) fuse in the undeFhoodluse/ relay box.
Reoair short in the wire between th b.ake switch and th6 HoRN, STOP{15 A)luso, Replacothe HoRN, STOP (15 Al fuse.
'-
('97model) -_-
Il
Repair op6n in the wir between the brake switch and tho HORN,STOP(15 Allus6. Inspect the brrke switch (see aection l9l.
Check tol .n open in the wire {BXSWlinel: 1. Press brakepedal. the 2. Measure voltagebetweenrcM connector terminaisD5 and Ag with the brakepedal pressed.
a t32P)
PCMCONNECTORS
D ll6Pl BKSW (GRN/WHT)
Wire sideof female terminals Reprir open in the wire between the PcM lD5l rnd the brake switch.
(Topage11-167)
11 - 1 6 6
(Frompage11-166)
Chock for en open in the wire (BKSWline): 1. Press brakepedal. the 2. Measure vohagebetweenECM/ PCM connectorterminals A32 and 820 with the brakepedal pressed.
ECM/FCMOONNECTORS
Ropairopon in tha wire bstwson r h e E C M / P C Ml A 3 2 l r n d t h e brako switch. Wiresideof femalo terminals
Brakeswitch signd b OK.
11-167
ldle ControlSystem
Fastldle ThermoValvelA/T)
Description To preventerraticrunningwhen the engine is warming to up, it is necessary raisethe idle speed.The fast idle t h e r m o v a l v e i s c o n t r o l l e db y a t h e r m o w a xp l u n g e r . When the engine is cold, the engine coolantsurroundthe ing the thermowaxcontracts plunger,allowingaddiinto tional air to be bvDassed the intakemanifoldso that operatthe engineidlesfaster.Whenthe enginereaches ing temperature. valve closes,reducingthe amount the into the intakemanifold. of air bypassing IDLE ADJUSTING Inspgction it NOTE:The fast idle thermo valve is factoryadjusted; shouldnot be disassembled. 1. 2. 3. Remove the intakeair ductfrom the throttlebody. Startthe engine, Put your finger over the lower port in throttlebody, and makesurethat there is air flow with the engine cold (enginecoolanttemperaturebelow 86"F,30'C).
lf there is no air flow, replacethe fast idle thermo valveand retest, IDLE THERMO VALVE
O-RINGS Replace.
AIR BYPASS VALVE
kgfl.m, lbl.ftl 7.2 11.0
Startthe engine.Holdthe engineat 3,000rpm with no fan load (in Parkor neutral) until the radiator comes on, then let it idle. Checkthat the valve is completelyclosed.lf the valve is leaking, idle speedwill drop when you coverthe the lowerpon. Check enginecoolantleveland for air the in the enginecoolingsystem{seesection10).lf the cooling system is OK, replacethe fast idle thermo valveand recheck.
11-168
ldle Speed Setting

Inspoction/Adiustmont 37 modsl:
IDLE
Adjust the idle sp6ed,if necessary, turning the by idle adjusting screw.
NOTE: . Before setting the idle speed, check the following items: - The MIL has not beenreportsdon. - l g n i t i o ni m i n g t - Sparkplugs - Air cleaner - PCVsystem . lcanada) Pull the parking brake lever up. Stan the engine, then checkthat the headlights off. are 1. Startthe engine.Hold the engineat 3,000rpm with no load (in Park or neutral) until the radiator fan comeson, then let it idle. Connect tachometer a HondaPGMTester. a or from the ldle Air ConDisconnect 2P connector the trol (lAC)valve. Turn the ignitionswitchOFF.
IAC VALVE
7 . Reconnectthe 2P connector to the IAC valve, then remove the BACK UP (RAD|Ol(7.5 Al fuse in the under-hood fuse/rslav box for 10 seconds to reset the PCM. Restartand let the engine idle with no-loadconditions for one minute,then checkthe idle speed. NOTE: (CanadalPullthe parkingbrakelever up. Stan are the engine,then checkthat the headlights off. ldlo Epedrhould be: 75Ot 50 rpm (in P.rk or noutr.ll Let the engine idl6 for one minute with the headlights(Low)ON, and checkth idl speed. ldle lpcod 3hould bo: 750 t 50 ]pm (in Park or nautlal) Turn the headlights off. Let th engine idle for one minute with the headlights (Low) ON, heater fan switch at Hl and air conditioneron. then checkthe idle sDeeo. ldl. specd should b6: 7d) 1 50 rpm {in Park or nautral} see lf the idle speed is not within specification, the (cont'd) symptomcharton page11-64.
lf the enginestalls,restart enginewith the accelthe erator pedal slightly depr6ss6d,Stabilizethe rpm at 1,000, then slowly release pedaluntil the engine the idles. C h e c k i d l i n g i n n o - l o a d c o n d i t i o n s :h s a d l i g h t s , blowerfan, rear dfogger, radiatorfan, and air conditionerare not operating. ldle spood should b.: {80 t 50 rpm {in Park or noutr.ll
11 - 1 6 9
ldleControlSystem
ldle Speed Setting (cont'd)
38 - 0Omod6l3: NOTE: Beforesettingthe idle speed,checkthe following items: - The MIL has not beenreported on. - lgnitiontiming - Sparkplugs - Air cleaner - PCVsystem 1. Startthe engine.Holdthe engineat 3.000rpm with no load (in Park or neutral) until the radiator fan comeson, then let it idle. Connecta tachometer. Disconnect IACvalve 2P connectorand the EVAP the purge control solenoid valve 2P connector. lf necessary, adjust the idle speed,by turning the idle adjusting screw. After adjustingthe idle speed,recheck the ignition timing (seesection4). lf it is out of spec,go backto steo 4. tDt.E
ADJUSTING
CONTROL VALVE SOLENOID
VALVE SOLENOID lf the enginestalls,restartthe enginewith the accelerato. pedal slightly depressed.Stabilizethe rpm at 1,000, then slowly release pedaluntil the engine the idles. Chek idle in no-loadconditions:headlights, the blower fan, rear defogger,radiatorfan, and air conditioner are not operating, ldle speed should bo: 480 t 50 rpm {in PErkor noutrall
6. Turn the ignitionswitchOFF. 7. Reconnect 2P connectors the IAC valve and the to the EVAPpurgecontrol solenoidvalve,then do the ECM/PCM reset procedure. 8. Restart and idle the enginewith no-loadconditions for one minute,then checkthe idle speed. ldle speod should be: ,98 model: 750 t 50 rpm tin Park or neutral) '9!l - 00 modsls: 730 i 50 lpm lin Psrk or neutral) NOTE:lf the idle speed increases 780 t 50 rpm to (770 1 50 rpml*, this means the EVAPsystem is purgingthe canister. stop the purgingtemporariTo ly, raisethe enginespeedabove 1,000rpm with the pedal, accelerator then slowly release pedal. the *: '99 - 00 models 9. Let the engine idle for one minute with the headlights(Low)ON, and checkthe idle speed. ldle speed should be: 38 mod6l: 750 f 50 rpm (in Palk or neutrall '99 - 00 modols: 730 t 50 rpm (in Palk or neutral) 10. Turn the headlights off. Let the engine idle for one minutewith the heaterfan switchat Hl and air conditioneron, then checkthe idle speed. ldls spqed should be: '98 model: 780 t 50 rpm (in Park or neutrall '99 - 00 modls: 7701 50 rpm lin Park or neutral) lf the idle speed is not within specification. the see SymptomCharton page11-64.
11-170
FuelSupplySystem
FuelLines
Check fuel system lines, hoses, fuel filter, and other components for damage, leaks or det6rioration, and rplace it neces-
sary. '97 model:

33N.m (3.4 kg(.m, lbf.ftl 2s
27 N.m kg{.m,21 lbf.ft) 12.8
'98 model:
27 N.rn (2.8 kgl.m, 21 lbf.ft)
(cont'd)
11-171
Fuel Supply System

FuelLines(cont'dl
'99 - 00 models:
33 N.m (3.4kgl.m.25lbtftl
11-172
'97 model: if Checkall hoseclamps,and retighten necessary.
FUEL FILTER
{"2
/\
___--tJ
,"1 <,,
I
B
FUEL TUBE/ OUICK-CONNECT FITTINGS
' ^ s
,4\-') |
EVAPORATIVE EMISSION {EVAP} CONTBOL CANISTER
ft\ q'l
/'------/ , / B
To FUEL PRESSURE REGULATOR
Clampin the middle
(cont'd)
10-14mm (0.39- 0.55 inl
11-173
Fuel Supply System

Fuel Lines (confd)
'98 - (X)models: if Checkall hoseclamps,and retighten necessary.
SASE GASKET Replace.
FUEL FILTER
To FUEL PRESSURE REGULATOR C l a m p nt h em i d d l e i
10-14mm (0.39 0.ssin)
11-174
Fittings FuelTube/Ouick-Gonnect
Procautions Do not smoke whils working on the fuel @ syst6m, Koop open flames away from your work ar9a. The fuel tube/quick-connect fittings assemblyconnects the in-tank fuel pump with the fuel feed pipe.For removthe ing or installing fuel pump and fuel tank, it is necesor the fittings. saryto disconnect connect quick-connect Payattention following; to . fittings assemblyis not The fuel tube/quick-connect not heat-resistant; careful to damageit duringweldbe procedures. ing or otherheat-generating The fuel tube/quick-connect fittings assemblyis not do acid-proof; not touch it with a shop towel which was used for wiping batteryelectrolyte. Rplace the fittings assemblyif it came fuel tube/quick-connect similar. into contactwith electrolyte somethino or Disconnection Do not smoke while working on the fuel !@ syst6m. Keep open flames away from your work area. 1. 2. Disconnect batterynegative the cable. Removethe fuel fill cap to relievefuel pressurein the tank. (seepage 11-178). Relieve fuel pressure fittings for dirt, and Checkthe fuel quick-connect cleanif necessary. Hold the connector with one hand and pressdown the retainertabs with the other hand.then pull the connector off. NOTE: . Be carefulnot to damagethe pipeor other parts. Do not usetools, . lf the connector does not move,keepthe retainer pull and push tabs pressed down, and alternately the connector until it comesoff easily. . Do not removethe retainerfrom the pipe; once removed,the retainermust be replacedwith a new one.
LOCKII{G PAWL
3. 4.
5.
. Whenconnecting disconnecting fuel tube/quickor the be connectfittings assembly, carefulnot to bend or twist it excessively, Replaceit if damaged, quick-connect fittings can be reconnected, A disconnected but the retaineron the mating pipe cannot be reusedonce it has been removed from the pipe. Replacetha retainer . . . . replacing fuel pump. the replacing fuelfeed pipe, the it has beenremoved from the Dioe, it is damaged.
RETANEN TAB
@NNCCTOR Pressdown.
6.
Checkthe contactareaof the pipe for dirt and damage. . lf the surfaceis dirW,cleanit . lf the surfaceis rusty or damaged,replacethe fuel pump or fuelfeedpipe,
RCTAINER
TUBE FUEL
CONNECTOR CONNECTOR RETAINER
CONTACTANEA
{cont'd}
11-175
FuelSupplySystem
FuelTube/Ouick-Connect Fittings{cont'd)
7. To prevent damage and keep out foreign matter. coverthe disconnected connector and oioe end with plasticbags. Connection Do not smoke white working on the fuel E!@ system. Keepoper flamss away flom your work atea. 1. Checkthe pipe contact area for din and damage, and cleanif necessary.
COiITACT AiEA
PL TSnC EAGS
Insena new retainer intothe connector the retainer if is damaged,or after . replacing fuel pump. the . replacing fuel feed pipe. the . removingthe retainer from the pipe.
AASE GASKET Beplace.
11-176
3.
Beforeconnecting new fuel tube/quick-connect a fitt i n g a s s e m b l y , e m o v et h e o l d r e t a i n e rf r o m t h e r mating pipe.
5.
Makesure the connectionis secureand that the pawls are firmly lockedinto place;checkvisually and by pulling connector. the
with the tabs pulled apart, remove and discard the retarner
6.
Ncw FUELTUBE/ OUICK.CONNECT FI?TING ASSEMBLY
Reconnect batterynegativecable,and turn the the i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l r u n f o r abouttwo seconds, fuel pressure rise.Repeat and will two or threetimes,and check that thereis no leakage in the fuelsupplysystem.
4.
Align the quick-connect fittings with the pipe. and align the retainerlockingpawls with the connector grooves.Then pressthe quick-connect fittingsonto the pipe until both retainerpawls lock with a clickI n gs o u n d . put NOTE:lf it is hardto connect, a smallamountof n e w e n g i n e i l o n t h e p i p ee n d . o
FuelSupplySystem
SystemDescription
The fuel supply system consistsof a fuel tank, in-tank high-pressure fuel pump. PGM-Flmain relay,fuel filter, fuel injectors, and fuel delivery fuel pressureregulator, and return lines.This system deliverspressure-regulated fuel to the fuel injectorsand cuts the fuel delivery when the engineis not running. Inspection 1, 2. fuel pressure. Relieve Remove 12 mm banjobolt on the fuel filterwhile the holding the fuel filter with anotherwrench.Attach the 12 mm fuel pressure adapterbolt and the special tool.
FUEL PRESSURE REGULATON
FuelPressure
Relieving Beforedisconnecting fuel pipes or hoses,releasepressure from the system by looseningthe 12 mm banjo bolt on the too of the fuel filter.
FUEL PRESSURE GAUGE 07406- 0040001
Do not smoke while working on the fuel system. Kep open flames or sparks away from your work area, Be sure to relieve fuel pressurewhile the ignition switch is off.
1.
Write down the frequencies the radio's preset for buttons. Disconnect batterynegative the cablefrom the battery negative terminal. Remove fuel fill cap. the Use a box end wrench on the 12 mm banjo bolt at the fuel filter while holdingthe fuel filter with another wrench. Place rag or shoptoweloverthe '12 a mm banjo bolt. Slowly loosenthe 12 mm banjo bolt one complete rurn 12mm BANJo BOLT
The illustration shows '97 - 98 models, '99 - 00 models are similar.
TOWEL SHOP NOTE: Replacethe washers whenever the 12 mm baniobolt is loosened removed. or
the with the Startthe engine.Measure fuel pressure engineidling and the vacuumhose of the fuel presfrom the fuel pressure sure regulatordisconnected regulatorand pinched.lf the enginewill not start, turn the ignitionswitchon (ll),wait for two seconds, turn it off, then back on again and read the fuel pressure. Pressureshould be: '97 - 98 modls: 260 -31O kPa 12.7 3.2 kgf/cm,, 38 - 46 psil '99 - 0Omodels: 270 - 32OkPa Q.A - 3.2 kgf/cm', ifo - /U psil vacuumhoseto the fuel pressure regulator. Reconnect Prgs3ure should be: '97 - 98 models: 210 - 25OkPa 12.1- 2.6 kgf/cm', 30 - 37 psi) '99 - 00 models: 22O-26iJ kPa 12.2 2.7 kgt/cm', 31 - 38 psi) is first checkthe lf the fuel pressure not as specified, fuel pump (seepage 11-183). the fuel pump is OK, lf checkthe following: . l f t h e f u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d , inspect for: - Pinched cloggedfuel returnhoseor line. or - Faultyfuel pressureregulator(see page 11181). . lf the fuel pressureis lower than specified.inspect for: - Clogged fuel filter. - Faulty fuel pressureregulator(see page 111811. - Fuelline leakage.
11-178
FuelInjectors
R6placomoni (seepage 11-178). 1. Relieve fuel pressure the 2. Remove resonato. the chamber('99- 00 models).
S
O.RING Beplace.
Disconnectthe connectorsfrom the fuel injectors, and disconnectthe IAT sensor 2P connector ('97 - 98 models) and EVAPpurge control solenoid valve 2P connctor ('97 - 98 models), Disconnectthe PCVvalve and the vacuum hose from the fuel pressureregulator. Place shop towel overthe fuel returnhose,then disconnect from the fuel pressure a it regulator. Remove the retainer nuts on the fuel rail. Disconnect fuel rail. the 7, Removethe fuel injectorsfrom the intake manifold. '97 - 98 model3: EVAP PURGE CONTROL SOLENOID VALVE CONNECTOR 2P
FUELPULSATION IAT SENSOR 2P CONNECTOR
12 N.m {1.2 kgt'm, 8.7 tbtft) FUEL PRESSURE REGULATOR O.RING CUSHION Replace. SEAL RING Replace.
FUEL PRESSURE REGULATOR O.RING Replace. CUSHION RING Replace. SEAL RING Replace.
11-179
FuelSupplySystem
FuelInjectors {cont'dl
8. Slidenew cushionringsonto the fuel injectors. o h e 9 , C o a tn e w O - r i n g s w i t c l e a n n g i n e i l , a n dp u t t h e mo n t h e f u e li n i e c t o r s . '10. lnsertthe fuel injectors into the fuel rail first. p m t n 1 1 . C o a t n e w s e arl i n g s w i t h c l e a e n g i n e o i l , a n d r e s s h e m i n t ot h e i n t a k e a n i f o l d in 12. To preventdamageto the O-rings,installthe fuel injectors the fuel rail first, then installthem in the intakemanifold.
FUEL RAIL
The ill!stration shows '97 -98 models,'99 00 models are similar.
nuts. 13. lnstalland tightenthe retainer regulator. 14. Connect vacuumhosesand fuel returnhoseto the fuel pressure the 15. Connect PCVvalve. the to the 16. Connect the connectors the fuel injectors, IAT sensor('97 - 98 models),and the EVAPpurge controlsolenoid valve{'97- 98 models). chamber('99- 00 models). 1 1 . Coata new O-ringwith cleanengineoil, and installthe resonator 1 8 . Turn the ignition switch ON (ll), but do not operatethe starter.After the fuel pump runs for approximatelytwo seconds, whetherthereis any fuel leakage. Repeat two or threetimes,thencheck this the fuef pressure the fuel linerises. in
11 - 1 8 0
Regulator FuelPressure
Tesiing 1. tool and the 12 mm fuel pressure Attachthe special bolt to the fuel filter (seepage 1l-178) adapter Startthe engine. should be: Prasgure '97 - 98 models; 260- 310 kPa (2.7- 3.2 kgl/cm' ,38 -,16 psi) '9!t - 00 models: 27O 32o kPa l2-8- 3.3 kgf/cm', 40 - /l7 psil (with the lugl pressure rsgulator vacuum hose disconnestedand pinched) Replacement '1. Placea shop towel under the fuel pressureregula(seepage 11-1781. fuel pressure tor, then relieve 2. 3. Disconnect vacuumhoseand fuel returnhose. the Removethe two 6 mm retainerbolts and the fuel pressure reguralor.
2.
12 N.m (1.2kgf.m, 8.7 tbf.ft)
FUEL PRESSURE GAUGE 07406 - 0040001

CLAMP
Replace.
FUEL PRESSURE NEGULATOR
shows Theillustration '97- 98models,'99 models -00 aresimilar.
shows Theillustration '99 '97- 98models, 00models similar. are
the vacuum hose to the fuel pressure Reconnect regulalor.

4.
Apply cleanengineoil to a new O-ring.and carefully installit into its properposition. Install the fuel pressure regulator in the reverse orderof removal,
riseswhen the vacuum Checkthat the fuel pressure regulatoris disconnecthosefrom the fuel pressure ed agarn. t l f t h e f u e l p r e s s u r e i d n o t r i s e ,r e p l a c e h e f u e l d pressure regulator.
11 - 1 8 1
FuelSupplySystem
FuelFilter
Replacamont
. .
Do not smoke whilo working on tuol syslom, Keepopen flame away from your work area. While rsplscingths fuolfihor. bo carefulto kop a safe distanca betweon baftsry tarminals and any tools,
The fuel filter should be replacedwheneverthe fuel Dressure drops belowthe specified value*with the fuel pressure regulator vacuum hose disconnected and pinchedl after makingsure that the fuel pump and the fuel pressure regulator OK. are i: '97 - 98 modelsi 260 - 310 kPa 12.7 3.2 kgllcm2,3g 46 psil '99 - 00 mod6fs: 270 - 320 kP8 12.8 3.2 kgilcm2, 40 il7psi) 1, 2. 3. Place shop towel underand aroundthe fuel filter. a (seepage l1-l7B). Relieve fuel pressure Remove enginewire harness the bracket and power steering feed hoseclamp. Remove the banjo bolt and the fuel feed pipe while supportingthe fuel filter with another wrench. as snown. Remove fuelfilter clampand fuel filter, the Install the new fuel filter in the reverse orde. of removal, and notetheseitems: . . Whenassembling, new washersas shown. use C l e a nt h e f l a r e d j o i n t o f h i g h p r e s s u r en o s e s thoroughlybeforereconnecting them.
12 mm SEAUNG BOLT 33 hl.m l3.a kgt m, 25 lbt frl
9.8 N.|n kgf'm, 11.0 t.2 tbt.ftl
4.
11 -1 8 2
FuelPump
Testing lf you suspect a problem with the fuel pump, checkthat the fuel pump actuallyruns;when it is oN (ll),you will hearsome noiseif you hold your ear to the fuel fill port The fuel pump shouldrun with the fuel fill cap removed. when ignition switch is first turned ON (ll). for two seconds lf the fuel pump does not make noise,checkit as follows: 1. Foldthe left rear seat cushionforward,and remove the baseframe cover (seesection 20). panelfrom the floor. Remove access the 6. 3. Make sure the ignition switch is OFF,then disconnectthe fuel pumP5P connector. termrmain relay7P connector Connect the PGM-FI nal No. 4 and No, 5 with a jumperwire.
PGM.FIMAIN (Cit:}2l RELAY7P CONNECTOR
Raplac6mont 1. Foldthe left rear seatcushionforward,and remove the baseframe cover(seesection20). panelfrom the floor. Remove access the (seepage 11-178). Relieve fuel pressure the the Disconnect fuel lines. from the fuel pump. the Disconnect 5Pconnector the Remove fuel pump mountingnuts.
2. 3, 4. 5.
2,
4.
I'TtlJil -r'-r t f
,frTt-
l . l 5 l 5 1 7 l
, a t \. pUMp Lrtcl tyEL/cRNl FUEL rYEL/cRNl I I Wirsideof JUMPER female terminals WIRE
5.
Checkthat battery voltage is available between the fuel pump 5P connectorterminal No. 4 and body groundwhen the ignition switchis turnedON (ll). 5P {C562} PUMP CONNECTOR FUEL
1
2 a
5
FUEL PUMP (YEL/GRNI

wire sideof femaleterminals
c l f b a t t e r yv o l t a g e i s a v a i l a b l e , h e c kt h e f u e l pump ground. lf the ground is OK, replacethe fuel oumo. (see checkthe wire harness lf there is no voltage, p a g e1 1 - 1 8 8 ) .
7. 8.
the Remove fuel pump from the fuel tank. I n s t a l lt h e f u e l p u m p i n t h e r e v e r s eo r d e r o f removal.
11-183
FuelSupplySystem
FuelGauge
Tssting NOTE:Referto section23 for the fuel gaugesystemcircuit diagram. '1. (7.5A) fuse in the underCheckthe No. 25 METER dash fuse/relaybox before testing. Foldthe left rear seatcushionforward,and remove the baseframe cover{seesection20). Remove access panelfrom the floor. the Disconnect 5Pconnector the from the fuel pump. Measurevoltage betweenthe 5P connectorterminalsNo.2 and No. 5 with the ignitionswitchON ( ). Thereshouldbe between5 and 8 V. Turnthe ignitionswitchOFF. 7 . Attach a jumper wire betweenthe No. 2 and No. 5 terminals, then turn the ignitionswitchON fll). Checkthat the pointerof the fuel gaugestartsmoving toward the "F" mark. Turn the ignition switch OFF before the pointer reaches"F" on the gauge dial. Failure do so may damagethe luel gauge. to NOTE:The fuel gaugeis a bobbin (cross-coil) type, hencethe fuel level is continuously indicatedeven w h e n t h e i g n i t i o ns w i t c h i s O F F ,a n d t h e p o i n t e r movesmore slowlythan that of a bimetaltype. . . lf the pointerof the fuel gaugedoes not move at all. replace gauge. the lf the gauge is OK, inspectthe fuel gauge sendingunit.
2.
3. 4. 5.
FUELPUMP 5P CONNECTOR
tc56al
Wire side of female trminals
a lf the voltageis as specified, to step 6. go a lf the voltageis not as specified, checkfor:
an open in the YEUBLK BLKwrre. or poor ground (c552).
1 1 -1 8 4
Unit Sending FuelGauge

Tgsting Do not smoke while working on tho fuel @ systom. Keop open flamo 8waYfrom your work araa. 1. Foldthe left rearseat cushionforward,and remove the baseframe cover(seesection20). panel. Remove access the the With the ignitionswitchOFF.disconnect 5P connectorfrom the fuel pump. (seepage 11-178). fuel pressure Relieve Disconnect fuel lines. the Remove fuel pump, the 7. the No. 2 and No. 5 between Measure resistance the 1/2 terminalsat E (EMPTY), (HALFFULL)and F (FULL) by movingthe float.
2. 3.
4. 5. 6.
lf you do not get the above readings,replacethe fuel pump.
11-185
FuelSupplySystem
Low Fuel Indicator System
Indicator Light Testing NOTE:Refer section to 23forthe lowfuel lndicator circuit clragram. 1. 2. (7.5A) fuse in the underCheckthe No. 25 METER dash fuse/relaybox before testing. Parkthe vehicleon levelground. Do not smoke while working on the @ fuel system. Keep open flame away trom the work aroa. Drain fuel only into an approved container. D r a i nt h e f u e l i n t o a n a o D r o v e d o n t a i n e r T h e n c . installthe drain bolt with a new washer. Add lessthan 8 f (2.1U.S.Gal. 1.8lmp. Gal)of fuel, and turn the ignitionswitchON {ll).The low fuel indicatorlightshouldcome on within four minutes. 8. Add 4 / of fuel (1.1U.S.Gal,0.9 lmp. Gal).The light shouldgo off within four minutes. . lJ the light does not go off, checkfor: - a short in the GRNA/EL wire between the fuel gaugesendingunit and fuel gaugeassembly. - faultygaugeassembly. . lf the light goes off, the low fuel indicatorlight is
oK.
INDICATON LIGHT
. .
lf the light comes on within four minutes,go to step8. lf the lightdoesnot comeon withinfour minutes. go to step 5.
7.
Remove seatcushion(seesection20). the Removethe fuel tank accesspanel from the floor, and disconnectthe 5Pconnectorfrom the fuel pump, Connect No. 1 and No. 2 terminals the with a jumper wire. . . l f t h e l i g h t c o m e s o nc h e c k t h e e n d i n g n i t . , s u lf the light does not come on, checkfor: - a n o p e n i n t h e G R N / y E L i r e b e t w e e nt h e w fuel unit and fuel gaugeassembly. - blown bulb. - poor ground (G552). (C562) FUEIPUMP CONNECTOR 5P WIRE JUMPER
IGRN/YEL}
Wiresidol temleterminals
11 - 1 6 8
Main Relay PGM-FI

Description The PGM-Flmain relav actuallvcontainstwo individual side of the This relay is locatedat the passenger relays. wheneverthe ignitionis on cowl. One relay is energized w h i c h s u p p l i e st h e b a t t e r yv o l t a g et o t h e E C M / P C M , power to the fuel injectors,and power for the second relay. The second relay is energizedfor two seconds when the ignition is switchedon, and when the engine to is running, supplypowerto the fuel pump Belay Testing t N O T E :l f t h e e n g i n es t a r t sa n d c o n t i n u e s o r u n , t h e main relayis OK. PGM-FI 1. 2. 3. s t R e m o v e h e g l o v e b o xa n d t h e p a s s e n g e r 'd a s h 20). boardlowercover (seesection main relay the Remove PGM-FI Aftachthe batterypositiveterminalto the No. 2 terterminalto the No. 1 minal and the batterynegative terminal of the PGM-Flmain relay.Then checkfor continuitybetweenthe No. 5 terminaland No. 4 termain relay minal of the PGM-FI go . lfthere is continuity, on to step3. main . lf there is nocontinuity,replacethePGM-Fl relavand retest.
No.2
PGM.FI MAIN RELAY
No.5 No.5 To lGN.1 To BAT O To FUELPUMP To ECM/PCM CONNECTOR TERMINAL (411and A24, Bl .nd Bgal (IGP)
To GROUND
To ST. SWITCH To ECM/PCM CONNECTOR TERMINAL A16 (FLR)
To FUEL PUMP
98- 00 models terminalto the No. 5 terAttachthe battervDositive terminalto the No. 3 minal and the batterynegative main relay.Then checkthat termjnalof the PGM-Fl there is continuitybetweenthe No. 7 terminal and main relay. No. 6 terminalof the PGM-FI go . lf there is continuity, on to step 4. main . lf there is nocontinuity,replacethePGM-Fl relayand retest. 5 . Attachthe battervoositiveterminalto the No.6 terterminalto the No. 1 minal and the batterynegative main relay.Then checkthat the PGM-Fl terminalof there is continuitvbetweenthe No. 5 terminal and main relay. No. 4 terminalof the PGM-Fl main relayis OK. . lf thereis continuity, PGM-Fl the P I . l f t h e r ei s n o c o n t i n u i t y ,e p l a c e t h e G M - Fm a i n r (cont'd) relayand retest.
11-147
FuelSupplySystem
PGM-FI Main Relay(cont'dl
Troubleshooting
Enginewill not start. InsDection ol PGM-FI main relay and relay harness, PGM.FIMAIN RELAY7P CONNECTOR lc(}21 Check fo. an open in the wire IGNDlinol: 1. Turnthe ignitionswitchOFF. 2. Disconnect the PGM Fl main relay7P connector. 3. Checkfor continuitybetween the PGM'FI main relay7P connector terminal 3 and body No. ground. Repairopcn in th wire between the PGM-FI main relavand G101. GND
trTr]--Flq FI,Til'I A
Checktor an open or short in the wiro (BATline): M e a s u r ev o l t a g e b e t w e e nt h e PGM'FImain relay 7P connector terminal 7 and bodyground. No. ls there bafteryvoltage? Checklor an open or short in the wire (lGl line): L Turn the ignitionswitch ON (ll). 2. Measurethe voltage between the PGM-FI main relay7P con nectorterminalNo. 5 and body ground. Repair open or shorl in the wire between the FGM-FImain relayand the No. 13 FUEL PUMP115 tuse. A) Replaco No. 13RJELPUMP the 115A) luse in the und6.-d$h fuso/ relav box. Repai. open or short in lhe wir6 belween the PGM-FI main relay and the Fl E/M (15 Al fu3e. Replace FIE/M (15Altus6 th6 in th under-hood fuse/.6lay
Checkfor an open or short in the wire {STSline): 1. Turnthe ignitionswitchto the (lll) START position. NOTE: . M/T: Clutch pedal must be depressed. . A/T: Transmission E or in Elposition. 2. Measurethe voltage between t h e P G M - F lm a i n r e t a y7 P connector terminalNo. 2 and body ground.
('97model:To page11-189) ( ' 9 8 0 0 m o d e l s : T p a g e1 l 1 9 0 ) o
Repair open or short in the wire betwen the PIGM-FI m.in rclay and th No. 31 STARTER SlGllAL 17.5A) tuse. Repl.ce the No. 31 STARTER SIGNAL 17.5Al tuse in the under-dash tuse/relaybox.
11 - 1 8 8
lFrompage11 188) ('97model) (C432I 7P PGM.FIMAIN RELAY CONNECTOR FLR IGRN/YELI
-t
Ch6ck lor an open in the wir line): {FLR 1. Turnthe ignitionswitchOFF. the PCM connec2. Disconnect tor A (32P). 3. Checkfor continuitybetween main relay 7P conthe PGM-FI nectorterminal No. 1 and PCM A16. terminal connector Wire sideof lemaleterminals Repairopen in the wire be{weon the PCM lAl6l and the PGM-FI main relay.
Checkfor an open in the wirs lGP2lins): {lGP1, '1. Reconnect PCMconnector the A (32P). 2 . R e c o n n e ct th e P G M ' F lm a i n relayconnector. ON switch (lli. 3. Turnthe ignition voltagebetweenPCM 4. Measure terminalsA11 and connector A 1 0 , a n d b e t w e e nA 2 4 a n d A10. voltage? ls therebattery Repair open in the wir bet' ween th PCM {A11,A2ia}end main relay. the PGM-FI main rolaY. Reolsce PGM-FI the
IGP2 (YEL/BLK)
Checktor an open in the PCM: 1. Turnthe ignitionswitchOFF. r 2, Measu e voltage between A16 terminals PCMconnector a n d A 1 0w h e nt h e i g n i t i o n switch is first turned ON {ll) for
V ls there'1.0 or less?
Substitute a known-good PCM and recheck. lf ptesctibed volttge is now available,roplacotho orig' in.lPCM.
(cont'd)
C h e c k t h e P G M - F lm . i n . e l a V (seepage11-187). _l
8 11 - 1 9
FuelSupplySystem
PGM-FI Main Relay(cont'dl
(Frompage11,188) ('98- 00 models)
-l
(C2) PGM.FIMAIN RELAY CONNECTOF 7P Check lor an open in the wire (FLRline): 1. Turn the ignitionswitchOFF. 2. Disconnect ECM/PCM the con nectorA (32P1. 3. Checkfor continuitybetween the PGM-FI main relay7P connectorterminalNo. '1and ECM/ PCMconnector terminal416. terminals Wiresidof female Repaiaopen in the wire between the EcM/PcM lAl5l .nd the PGM-FIm.in relay.
Check for an open in the wires llcPl,lGP2linos): 1. Reconnect the ECM/PCN4 connector I (25P). 2. Reconnect the PGM Fl main retayconnector. 3. Turn the ignitionswitchON l). 4, Measurevoltage between ECM/PCM connectorterminals B1 and 82, and between 89 and 82.
ECM/PCMCONNECTOR I25PI B
Dde"Jt;;li L-F-T-PGl (BLK} 3 IGP2 (YEL/BLKI 1 9
8 17
s l 1 0
20
11
13 21 22
Ropai. open in tho wire b6twen th. ECM/PCM lBt, Btl .nd the FGM-FImain rd.y. Rplacth6 FGM+| main retay,
ECM/PCMCONNECTORS Chock for an open in the ECM/ PCM: 1. Turnthe ignitionswitchOFF. 2, Measurevoltage between ECM/PCM connectorterminals 416 and 82 when the ignition switch is first turned ON (tl) for a t32Pl
ls there1.0V or less?
Subrtitute e known-good ECM/ PCM and recheck. lf prescribsd voltage b now ovrihble, replaco the originelECM/PCM. Wiresideof fmale terminsls
Check the PGM-FI main.elav (s6epage 11-1871.
11 - 1 9 0
FuelTank
Replacement @ 1. 2. 3. 4. 5. 6. 7. 8. g. Do not smoke while working on fuol systam Keep open flame away from your work area' (seepage11-178). Relieve fuel pressure the 20). Foldthe left rearseatcushionforward,and removethe baseframecover{seesection panelfrom the floor. the access Remove ('98-00 models)' (C580) and the 1C562) 6P connector Disconnect 5Pconnector fittings{seepage 11-175} Disconnect fuel returnhoseand quick-connect the jackstands. and supportit with Jackup the vehicle, Remove the middlefloor beam. contaaner. the Remove drain bolt, and drainthe fuel into an approved 174).slide backthe clamps.then twist hosesas you pull, to avoid damaging the Disconnect hoses(seepage 11-173,
them. a 10. Place jack,or othersuppon,underthe tank the 11. Remove strapnuts,and let the strapsfall free lly appliedto its mount,carefu pry it off the mount, the 12. Remove fuel tank.lf it stickson the u ndercoat '13. lnstallthedrain bolt with a new washer,then coatthe drain bolt with Noxrust1248' Allow the Noxrustto dry for 20 minutes. orderof removal. 14. Installpartsin the reverse '97 modol:
AOCESSPANEL
CONNECTOR
DRAINEOLT 49 N.m 15.0kgf'm, 36 rbt frl
(cont'd)
11 - 1 9 1
FuelSupplySystem
FuelTank (cont'd)
,98 - 00 models:
5P CONNECTOR 6P CONNECTOR
38 N.m (3.9ksf.m,28lbtftl
11-192
Intake Air System

SystemDescription
intakeair duct, ThrottleBody of The systemsuppliesair for all engine needs.lt consists the intakeair pipe,Air Cleaner, in (TB),ldle Air Control(lAC)Valve,fast idle thermo valve,and intakemanifold.A resonator the intakeair pipe provides silencing air is drawn into the system. as additional
YEL| BLK
Fiom PGM'FI MAIN RELAY
vaRtous
SENSORS
INTAKEMANIFOLD
IDLE THERMO
lJ-_iuo'u'j"'
FESONATON
THROTTLE BODY(TB) INTAKE AIR DUCT
11 - 1 9 3
IntakeAir System
Air Cleaner
Air CleanerEloment Rsplacomsnt NOTE:Do not cleanthe air cleanerelementby blowing it off with compressed air,
ThrottleCable
Inrpection/Adiustmcnt 1. Stan the engine.Hold the engineat 3,000rpm with no load (in Parkor neutral) until the radiatorfan comes on, then let it idle. Check that the throttlecableoperates smoothlywith no bindingor sticking. Repair necessary, as Checkcable free play at the throttle linkage.Cabte deflection shouldbe 10- 12 mm (3/8- 1l2in.l.
2.
3.
'97 - 98 modols:
CABLE BRACKET
m
DEFLECTION 10-12mm BIA- 112i^l '99 0O modsls: DEFLECTION l0-12mft Bla - 112inl LOCKNUT
AIR CLEANER ELEMENT No.mal conditions: Replace cleaner air element every 30,000 miles{48,000 or 24 km) monthswhichever comesfirst. Severecondition3: Replace cleaner air element every 15,000 miles124,000 or 12 km) monthswhichever comestirst.
NUT lf deflection not within specs,loosenthe locknut, is turn the adjusting nut untilthe deflection as speciis fied,then retighten locknut. the With the cableproperlyadjusted. checkthe throttle valve to be sure it opens fully when you push the acceleratorpedal to the floor. Also check the throttle valve to be sure it returns to the idle position whenever you releasethe acceleratorpedal.
11-194
lnstellation 1. Openthe throttlevalvefully,then installthe throttle cable in the throttle linkage,and install the cable housingin the cablebracket.
'97 - 98 modals: lhere shouldbe no clearance.
97 - 98 modols: LINKAGE THRoTTLE CABLE
AD.'USTING NUT 9.8 N.m (1.0 kg{.m, 7.2lbllrl
'99 - 00 modeb:
INNERCABLE LOCKNUT
'99 - (Xl modols:

ADJUSTING
CABLE BRACKET
BRACKET 2. Sta.t the engine.Hold the engineat 3.000rpm with no load (in Park or neutral) until the radiator fan comeson, then let it idle. Hold the cable sheath,removingall slackfrom the cable. Set the locknut on the cable bracket. Adiustthe adjusting so that its free play is 0 mm. nut Rimove the cable sheath from the throttle bracket, resetthe adjusting nut and tightenthe locknut.
9.8 N.m l'1.0kgt'm, 7.2 tbr.ft)
IntakeAir System
ThrottleBody
Doscription The throttle body is a single-barrel side-draft type. The lower portion of the throttle valve is heatedby engine coolantfrom the cylinderhead.The idle adjusting screw which regulates the bypassair is locatedon the top of the throttlebodv. lnspection Checkthat the throttlecableoperates smoothlywithout bindingor sticking. lf thereare any abnormalities, checkfor: . Excessive wear or play in the throftlevalveshaft. . Sticky or binding throttle lever at the fully closed positton. . Clearance betweenthrottle stop screw and throttle leverat the fully closedposition. 97 - 98 models: THROTTLE LINKAGE
The illustration shows '97 - 98 models,'99 - 00 rnodels are similar.
THROTTLE LINKAGE
Replacethe throttle body if there is excessiveplay in the throttlevalveshaftor if the shaft is bindingor sticking.
11 - 1 9 6
Removal '97 - 98 models:

GASKET MAP SENSOR
,:4W)
TP SENSOR
R \ t
FASTIDLETHERMO VALVE(A/T onlyl
'99 - O0models:
TP SENSOR
F(
\g-.-'
22 N.m 12.2kgl m, 16 tbtft)
FASTIDLETHERMO VALVElA/T only)
NOTE: . Do not adjustthe throttlestop screw. . After reassembly, adjustthe throftlecable(seepage11-194). . The TP sensoris not removable.
(cont'd)
11-197
IntakeAir System
ThrottleBody (cont'd)
Disassembly
O-RING{A/l only) Replace.
ADJUSTING SCREW
IDLETHERMO VALVE (A/T only)
9.8 N.m (1.0kgl.m,7.2lbf.ftl The illustration shows'97- 98 models,'99 00 modelsare similar.
11 - 1 9 8
Emission ControlSystem
SystemDescription
a T h e e m i s s i o nc o n t r o l s y s t e m i n c l u d e s , T h r e eW a y Ventilation CatalyticConverter{TWC),PositiveCrankcase (PCV) Emission(VAP)Control svstem and Evaporative system.The emissioncontrol system is designedto meet federaland stateemissionstandards.
(TWCI Converter ThreeWayCatalytic

DsscriDtion Three Way Catalytic Convertsr lTwcl: The Three wav CatalvticConverter (TWC) is used to (HC),carbonmonoxide(CO), and converthydrocarbons (NOx) in the exhaustgas to carbon oxides of nitrogen (Nr)and water vapor, dinitrogen dioxide(COr),
Tailpipe Emission
Inspsction Do not smoke during this procsdura. Keep !@ any open tlame away from your work area. 1. Startthe engine.Hold the engineat 3,000rpm with n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n comeson, then let it idle, Connect tachometer. a adjustthe idle speed,(see Checkand, if necessary, p a g e1 1 - 1 6 9 , 7 0 ) . 1
4.
to the Warm up and calibrate CO meteraccording the instructions. metermanufacturer's heaterblower,rear idle COwith the headlights, Check off. cooling fan,and air conditioner windowdefogger, (Canada) Pull the parkingbrake lever up. Start the are engine, then checkthat the headlights off. i 0 C Om e t e rs h o u l d n d i c a t e . 1 %m a x i m u m .
{cont'd)
11 - 1 9 9
ThreeWay Catalytic Converter {TWCI(cont'd}
Diagnostic TroubleCode(DTC) P0420: systemefficiency Catalyst belowthreshold. 1P0420 Thescantool indicates DescriDtion This systemevaluates catalyst's the capacity meansof the HO2S(Primary by and Secondary) outputduring stabledriving lf has drivingcycles, MILcomeson and DTCP0420 the conditions. deterioration beendetected duringthreeconsecutive will be stored. NOTE:lf some of the DTCS listedbelow are storedat the same time as DTCP0420, troubleshoot those DTCS first. then DTCP0420. troubleshoot P0137, P0138: HO2S(Sensor 2) Secondary P0141: HO2S(Sensor Heater 2) Secondary PossibleCause . IWC Deterioration . Exhaust systemleakage Troubleshooting Flowchart
The MIL has been reDoriedon. DTCP0420is stored.
Problemverification: 1. Do the ECM/PCM Reset Proce dure, 2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutraliuntil the radiator comeson. fan 3. Connect SCSservice the con nector. 4. Test-drive - 55 mph (64- 88 40 km/h) approx. for lwo minutes. Then decelerate at least3 for with the throftle seconds com p l e t e l yc l o s e d .T h e n r e d u c e the vehicle peed o 35 mph s t 1 5 6k m / h ) ,a n d t r y t o h o l d i t u n t i l t h e r e a d i n e s sc o d e
indicated? ls DTCP0420
Intermittent tailure. system is OK at this time.
Checkthe TWC (seesection 9). lI nocessary, replacethe TwC.
11-200
Positive Grankcase Ventilation(PGVI System

Description T h e P o s i t i v eC r a n k c a s e e n t i l a t i o n( P C V )s v s t e m i s V designed to prevent blow-by gas from escaping to the atmosphere.The PCVvalve contains a spring-loaded plunger, When the enginestarts, the plungerin the PCV valve is lifted in proportionto intakemanitoldvacuum and the blow-by gas is drawn directlyinto the intakemanifold. Inspoction 1. Checkthe PCVhosesand connections leaksand for clogging.
'97 - 98 models:
i/lAlrllFOLD -: BLOW.BY VAPOR -: FRESH AIR
'99 - (X) models: BREATHER HOSE
(cont'd)
11-201
PositiveCrankcase Ventilation(PCV) System(cont'dl
2. At idle,makesurethere is a clickingsoundfrom the PCVvalve when the hose betweenthe PCVvalve and intakemanifoldis lightly pinchedwith your fingers or pliers.
'97 - 98 models:
Gently pinch here.
'99 - 00 modelsi
Gentlypinchhere.
lf there is no clickingsound, checkthe PCVvalve grocrmet for cracksor damage,lf the grommet is OK, reDlace PCVvalveand recheck. the
11-202
(EVAP) Evaporative Emission Controls

Description: The evaporative emissioncontrolsare designed minimizethe amount of fuel vapor escaping the atmosphere. to to The systemconsists the followingcomponents: of A. EvaporativeEmission(EVAPIControl Canister is An EVAPcontrolcanister usedfor the temporarystorageof fuel vapor until the luel vapor can be purgedfrom the EVAPcontrolcanister into the enqineand burned.
B. Vapor PurgeConirolSystem purgingis accomplished drawingfreshair throughthe EVAPcontrolcanister EVAPcontrolcanister by and into a pon on the intakemanifold. The purgingvacuumis controlled the EVAPpurgecontrolsolenoid by valve. E V A P P U R G EC O N T R O L O L E N O I D A L V E D U T Y C O N T R O L L E D F T E R S V A S T A R T I NE N G I N E G
(68'C) ENGINE COOLANT TEMPERATURE ABOVE154"F C. FuelTank Vapor Control System Whenfuel vapor pressure the fuel tank is higherthan the set valueof the EVAP in two way valve,the valveopensand regulates flow ot fuel vaporto the EVAPcontrolcanister. the '97 model:
EVAP PURGE CONTROL VALVE BLK/ YEL From No. 15 /ALTERNATOR I sP SENSOR At r7.s (in the under-dash fuse/relaybox) VARIOUS SENSOR FEESH AIF
BLK
FUEI-TANK
INTAKEMANIFOLD
(cont'd)
11-203
Emission GontrolSystem
(EVAP) Emission Evaporative Controls(cont'dl
'98 - 0Omodels:
EVAP THREE WAY VALVE
EVAP CONTROL CANISTER VENTSHUT VALVE
Frofi
BLK/WHT
15 < NO.
'EL/BLU ._^_-:.*,"..
GRN/BLK
<3|ltAIS"o[..^,
1inthe under-dash tuse/relay box)
BLU
L EVAPPURGE CONTROL SoLENOtO VALVE LT GRN/WHT , VARIOUS SENSOR
RED/YEL
SLK
EVAP TWOWAY VALVE
EVAP BYPASS SOLENOID
VALVE
FUELTANK
MANIFOLD
11-204
'97 model: Evaporative Emission(EVAP) control system Trouble Code (DTC)P0441: The scan tool indicatesDiagnostic purgeflow. insufficient Description EVAPcontrol system purge By monitoringthe purge line vacuumwith the MAP sensor,the PCM can detectinsufficient flow. PossibloCause . EVAPPurgeControlSolenoid Valve . EVAPPurgeControlSolenoid ValveCircuit . EVAPControlCanister . VacuumLines . PCM TroubleshootingFlowchart
Th MIL has ben reooited on. DTCP0441is .tored. Problemverificationl 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neut.al)until the radiator comeson. fan 2. Do the PCMResetProcedure. con3. Connect the SCSservice nector, 4. Test drive underfollowingcon' ditionson the road. - without any electrical load - Transmission @ or @ in position - Engine speed between 1,2OO 2,4OO rpfi. - Decelerate from 50 mph (80 km/h)to15mph (24km/h) ls DTCP0441 indicated? Intermittent trilure, sydern is OK at this time. Checkfor Door connections or loose wir3 at C108 IEVAP purge control solonoid valvol .nd at the PCM. CONTROL EVAPPURGE VALVE2P SO1TNOID (C108) CoNNECTOR
Checktor an open in the wire (lcl linel: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e E V A Pp u r g e valve2P concontrolsolenoid nector. ON 3. Turnthe ignition switch (ll). voltagebetweenbody 4. Measure ground and the EVAPpurge control solenoidvalve 2P connector terminal No. '1, ls there batlery voltage? Rpafuopen in thc wir6 btwen thG EVAP purge control solenoid valve and the No. 15 ALTEBNA(7.5A)fuse. TORSP SENSOR
(v)
YL
Wire side of female termrnals
(To page11'206)
(cont'd)
11-205
EmissionControl System
(EVAP) Evaporative Emission Controls(cont'dl
(Frompage11-205) PCMCONNECTOR (32PI A PG1(BLKI Chsck th6 EVAP purgo control solonoidvalve: ' L R e c o n n e ctth e E V A Pp u r g e controlsolenoid valve2P connector. 2. ConnectPCMconnector termi nals 415 and A10 with a
PCSIRED/YELI JUMPERwlRE Wire side of femaleterminais
Does the solenoid valve click when the jumper is connected?
Chscl to. an op6n or 3hort in th wiro (PCSlin6): Measurevoltage between PCM connector terminalA15 and body grouno,
Chockfor . .hort in tho wiJe IPCS line): 1. Turnthe ignitionswitchOFF. 2. Disconnect the PCMconnector A (32P). 3. Disconnectthe EVAP purge valve2P concontrolsolenoid nector, 4. Checkfor continuitybetween body ground and PCM connector terminal A15.
Rooair short in tho wir6 bctween the EVAP purge control 3olenoid valvo and tho PCM(A151.
Checkthe vacuum lin6: Check the vacuum linesof EVAP systemtor misrouting,leakage, brsakago clogging. and
Ropair open in the wir6 betwoon the EVAP pu]go control .olonoid v.lve end the PCM(A15).
Are the vacuumlinesOK?
(Topago11'207)
11-206
(Frompage11-206)
Chack iho EVAP purge control solenoidvalve: 1. Disconnect vacuum hose the trom the EVAP controlcanister. 2, Connect vacuumpump to the the hoseand applyvacuum, EVAPCONTNOL CANISTER
<\
VACUUM PUMPI GAUGE, 0-30 in.Hg 4973X 0il1 -
xxxxx
Doesit hold vacuum?
Chgckthg EVAPcontrol csnbter: 1. Reconnect vacuum hoseto the the EVAPcontrolcanister. 2. Connecta vac!um gauge to the purge air hose. 3. ConnectPCM connectorter m i n a l sA 1 5 a n d 4 1 0 w i t h a jumperwire. 4. Stanthe engine. 5. Check vacuum. the
JUMPEFWIRE wire side of femaleterminals
Checkthe EVAPtwo way valve (seepage11'224).
Doesthe EVAPtwo way valve work properly?
Rapbcethe EVAPtwo wey valve. VACUUM/PRESSURE GAUGE 0-4 in.Hg 07JA2 - ml(x)o8
Substitute a known-good PCM and rechock. It symptom/indication gocs away, roplacgtho originrl rcM.
{cont'd)
1 1-207
(EVAP) Evaporative Emission Controls(cont'd)
99 - 00 models: The scan tool indicatesDiagnostic Trouble Code {DTC)P0451: The Fuel Tank Pressure sensor circuit range/ oerformance Droblem.
The MIL har been rooortdon. DTCP0451b storod. ECM/PCMCONNECTORS
a t32Pl
Check lor th6 tu6l tank prssure len30r: 1. Do the ECM/PCM Reset Proce, oure. 2. Remove fuelfill cap. the 3. Turnthe ignition switch (ll). ON 4. Monitor the FTPSensorvolt a g e w i t h t h e H o n d aP G M T e s t e r ,o r m e a s u r ev o l t a g e between ECM/PCM connector terminals A29 and C18.
PTANKILT GRNI
SG2 {GRN/BLK) Wire sideof {emaleterminals Chock tho vacuum lin6s tor rGlriction o. blockago repair as necessary. OK, roplacethe fuel lf tank Drer3ursentor.
ls thereapprox. V? 2.5
Check for the fuel tank piessure Sensot: L Disconnectthe hose between the EVAPtwo way valve and the fuel tank pressure sensorat the EVAP two way valveend. 2 . C o n n e c t v a c u u mp u m p t o a the openend ofthat hose. 3. Turn the ignitionswitchON (lll. 4. Monitor the FTPSnsorvoltage with the Honda PGM T e s t e r ,o r m e a s u r ev o l t a g e between ECNI/PCNI connector t e r m i n a l s 2 9 a n d C 1 8 ,a n d A carefully appiyvacuumon the hose one strokeat a time. 5. The voltageshould smoothly dropfrom the staningapprox. 2.5 V down to approx. 1.5 V. STOPapplyingvacuumwhen the voltage drops to approx. 1 . 5 V o r d a m a g et o t h e t u e l t a n k p r e s s u r es e n s o r m a y
FUELTANK PRESSURE SENSOR
VACUUM -30 PUMP/GAUGE.0 in.H9 A973X- 041 XXXXX
WAYVALVE
Doesthe voltage drop to approx. 1 . 5V a n dh o l d ?
Intermittent tailuro. sv3tem is OK at this tim. Chack to. poor connction6 or 10036hose at fu6l tank pres3ure ionsor and fuel trnk.
11-208
'98 - 00 modls: P0452: low voltageproblemin the FuelTank Pressure A TroubleCode(DTC) The scantool indicates Diagnostic sensof. pressure into electrical signalsand inputsthe ECM/PCM. fuel tank absolute sensorconverts The fuel tank Dressure OUTPUT VOLTAGE tvl {.5
Th. MIL has been reoortedon. DTCm452 is stored. Checkthe vacuum lin6: Check vacuumlinesof the fuel the sensorfor misrout tank pressure and cloging, leakage, breakage ging. 0,5 -? KPA (-50 mmHg, -2 in.Hgl +7 kPr l5OmmHg, 2 in.Hgl PRESSURE
Are the vacuumlinesOK? A ECM/PCMCONNECTOR (32P) Problemveriticstion: 1. Do the ECM/PCM Reset Procedure2. Remove luelfillcap. the 3 . T u r n t h e i g n i t i o ns w i t c hO N flr). 4. Monitor the FTPSensorvolt' age with the Honda PGM T e s t e r ,o r m e a s u r ev o l t a g e b e t w e e nb o d y g r o u n d a n d ECM/PCM terminalA29. ls lhereapprox. V? 2.5
Intermittent failuro, system is OK at this lima. Chacklor Door connections or loose wi.es at C580 llocrted rt access panell, C646 lluel tank Daessuresensor) and at the ECM/PCM.
FUEL TANK PRESSURE SENSOR 3PCONNECTOR tc6a6l
Checklor an open in wir lVeC2 line): 1. Turnthe ignitionswitchOFF. 2. Reinstallthe fill cap. fuel 3. Disconnectthe fuel tank pressuresensor connector, 3P 4. Turnthe ignition switch (ll). ON 5- Measurevoltage betweenthe fLreltank pressuresensor3P No. 1 terminaland connector N o . 2t e r m i n a l . ls thereapprox.5 V? Replir opon in the wire btwen th6 tuel tank pressurelensot and the ECM/PCM{A29).
voc2 (YEL/BLUI
Wire sideol fsmaleterminals
(cont'd)
YES
( T op a g e1 1 - 2 1 0 )
11-209
(Frompagel1'209)
Check lor a short in the wire IPTANKIine}: Measurevoltagebetlveenthe fuel tank pressure sensor3P connector No.3terminal and No.2terminal.
FUEL TANK PRESSUNE SENSOR 3PCONNECTOR tc646l
ls thereapprox.5V? Wire side of female terminals Check for a short in the wire (PTANKline): 1. Turnthe ignitionswitchOFF. 2. Disco nect the ECM/PCM n connector {32P). A 3. Checkfor continuity between the fuel tank pressure sensor 3P connector No. 3 terminals and bodyground.
Repairshort in the wira betwgon the fuel trnk prossures6nsorand tho ECM/PCMlA29).
Sub.tituto a known-good ECM/ PCM and rcheck. lf 3ymptom/ indication goer !way. replace th6 original ECM/PCM.
11 -2 1 0
'98 - 00 modals: P0453: high voltageproblemin the FuelTankPressure A TroubleCode(DTC) Diagnostic The scantool indicates sensor.
Thc MIL has b6on ropottcd on. DTCmia53is dorcd.
Ch6cktho vacuum linos: C h e c kt h e v a c u u m l i n e s o f t h e lor sensor misfueltank pressure routing, leakage,breakageand cloggrng.
A ECM/PCMCONNECTOR {32PI
Are the vacuumlinesOK? PTANK ILT GRN) Problornverification: 1. Do the ECM/PCM Reset Procedute. the 2. Remove fuel fill cap. 3. Turn the ignition switch ON 4. Monitor the FTPSensorvoltage with the Honda PGM Tester, or measure voltage b e t w e e nb o d y g r o u n d a n d terminal429. ECM,PCM
trminals Wire sidoot fema16
{[).
2.5 ls thereapprox. V?
Intarmittent tailuro, sv3iom b OK at this timo. Chock for poor connection3 or loo$ wire3 at C580 (locstod .t .cc$r p.nell, C6a6 (fucl tank pros3ure son3orl and .t the ECM/FCM.
Check lor an open in tho wiro lSG2lin6l: 1. Turnthe ignitionswitchOFF. Iuel 2. R6installthe fill cap. 3. Disconnectthe Iu6l tank pres_ 3P suresensor connector, 4. Turn the ignitionswitchON (ll). 5. Masurevoltago between the sensor3P tuel tank pressure No. '! and terminals connector No.2. Replir opn in th. wi.c b{ween tha fuel tank Dio'sute sansot and tho EC|,/PCM {Cl8}.
FUELTANX Pf,ESSUBESENSOR {C6,a6l 3p CONNECTOR
vcc2
IYEL/BLUI
sG2
(GRN/BLK} terminals Wire sideot female
ls thereapprox.5 V?
Chck for an opon in tho wiro (PTANKlinel: M e a s u r ev o l t a g e b e t w e e nt h e 3P sensor confuel tank pressure nectorNo. 3 terminaland No. 2 terminal.
3 PTANK ILT GRNI (cont'd)
sG2 IGRN/BLKI
ls thereapprox.5 V?
\To page 11-212)
11-211
( F r o m a g e1 1 , 2 1 1 ) p ECM/PCMCONNECTORS Check fo. an open in the wire (PTANK linel: Measurevoltage betweenECM/ PCMconnectorterminalsA29 and c18. PTANK {LT GRNI ls thereapprox.5V? Ropairopen in the wire betweon the ECM/PCM{A291and tho fuol tank pressule3ensor.
Substitute a known-good ECM/ PCM and recheck. lf symptom/ indication goes away, rplace tho originrl ECM/PCM. SG2 (GRN/BLK} Wire sideof temaleterminals
11-2 1 2
-
'98 - 00 models: (EVAP) controlsystemleak Emission Evaporative P1456: Troublecode (DTC) Diagnostic The scantool indicates detected {fueltank system). Troubleshooting Flowchart
The MIL has been reported on. DTC P1456 is stored.
Check the fuel fill cap: Checkthe fuel fill cap (the caP must be a gray OEM cap and be "clicks" to t i g h t e n e d a t l e a s tt h r e e p r o p e r l y s e a lt h e s y s t e m ) -
ls the properfuel fill cap installed tightened? and properly
Replace tighton the cap. or
Checkthe lueltill cap seal: the Check fuel fill capseal.
ls the tuel fillerpipedamaged?
Replace luelfiller pipe. the
Fuel till caD is OK. Do the luel tank pressureSensortest (see (EVAP Purge conpage 11-2111. trol solenoid valve tsl (seePage 11-2151.1r
' : ' 9 9 - 0 0m o d e l s
(cont'd)
11-213
(EVAPI Evaporative Emission Controls(contd)
lP14s6l("ont,a)
Fueltank pros3uresensortost. (Thecontinuetion of DTCPl456 t.oubls3hooting.,
ECM/PCMCONNECTORS
Chockthe tusl trnk pr3suresensor: 1. Remove fuel fill csp. the 2. Turn the ignitionswitchON fll). 3. Monitor the FTPSensorvohage with th Honda PGM T e s t e r ,o r m e a s u r ev o l t a g e between ECM/PCMconnctor terminals A29and C18. SG2 IGRN/BLKI ls there approx. 2.5 V? Choct ths vacuum linsr for ra3triction o. blockago ropair a! nect*rary. It OK, replaca the fu6l tank praituJc sentot. Wire sideoI femaleterminals
Checkthe fuel t nk pressuae 3ensor: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe hose between the EVAPtwo way valve and the tueltank pressure sensorat the EVAP two way valveend. 3 . C o n n e c t v a c u u mp u m p t o a the openend ofthat hose. 4. Turn the ignitionswitchON 0l). 5. Monitor the FTPSensorvoltage with the Honda PGM Testet, or measure voltage between ECM/PCM connector t e r m i n a l s 2 9 a n d C 1 8 ,a n d 4 carefully applyvacuumon the hose one strokeat a lime. 6. The voltageshould smoothty drop from the staning approx. 2.5 V down to approx. 1.5 V. Stop applyingvacuum when the voltagedrops to approx. 1 . 5 V o r d a m a g et o t h e f u e l t a n k p r e s s u r es e n s o r f i a y occur,
FUEITANK PRESSURE SENSOR
A973X - ill -
VACUUM - 30 PUMP/GAUGE,0 in.Hg
xxxxx
EVAP TWO WAY VALVE
Doesthe voltage drop to approx. 1.5V and hold?
Fu.l tank pressu.c anlor b OK. Oo thc EVAP pulge control solenoid valve toat (3prgo 112151.
11-2 1 4
EVAP purge control 3olnoid valve test. {Tho continu.tion of DTC Plil56 trouble3hootin9.)
VACUUM PUMP/GAUGE,030 in.Hg A973X- 041 -
xxxxx
Check the EVAP purge control solenoidvalve: the 1. Disconnect vacuum hose trom the EVAPcontrolcanist e r , a n d c o n n e c ta v a c u u m pumpto the hose. ON switch (ll). 2. Turnthe ignition 3. Applyvacuumto the hose. EVAP purge contlol solenoid v.lvo is OK. Do the EVAP bypai3 solenoid valve test (see Page 112161
EVAP CONTROL CANISTER
Doesthe valvehold vacuum?
Check tho EVAP purge control solenoidvalve: 't. Turnthe ignition OFF. switch 2 . D i s c o n n e ctth e E V A PP u r g e valve2P concontrolsolenoid nector, 3. Checkfor continuity between t h e E V A P p ur g e c o n t r o l solenoidvalve 2P connector t e r m i n a lN o . 2 a n d b o d Y ground,
SOLENOID CONTROL EVAPPURGE (Cl08} VALVE2P CONNECTOR
Check for s short in the wire linel: {PCS 1 . D i s c o nn e c t t h e E C M / P C M A connector {32P). 2. Checkfor continuitybetween the EVAP purge control solenoidvalve 2P connector terminalNo. 2 and body ground. neprir short in tho wite bot$reon the ECM/FCMlAGl and thc EVAP purge control 3olenoidvalve.
ls there continuity?
Substitut a known-good ECM/ PCM and recheck. lf symptom/ indication goe3 away. repl.ce thc originsl ECM/PCM.
(cont'd)
1 1-215
Evaporative (EVAPI Emission Controls(cont,dl
(conro) 1T1456I
EVAPbypa3ssolenoid valve test. (The continuation ot DTC P1456 troubleshooting.l VAP BYPASS
SoLENOtO
VALVE ECM/PCMCONNECTOR I32P) A 2WBS (BLU}
/ 3
Checkthe EVAP bypasssotenoid 1. Disconnect vacuum hose the from the EVAPtwo way valve, and connecta vscuum pump to the hose, 2. Connecthe ECM/PCMonc nectorterminal 43 to the body groundwith a jurnper wire. 3. Turnthe ignition switch 0t). ON 4. Applyvacuumto the hose.
7,x , /
VACUUM PUMP/ GAUGE. 0 -30 in.Hg A373X041 -
4l
o /
1 6 1 7 1 8 't9 2 0 2 1 1 / 26 27 2A 29 solT
to z3
32
-/
JUMPERWIRE
xxxxx
Doesthe valvehold vacuurn?
EVAP bypass solenoid valve/ EVAP two way valve is OK. Do th6 EVAP control crnister vent shut vafvele3t lso page 11-2'111. EVAPBYPASS SOLENOID VALVE2P CONNECTOR lcorlTl
Check for an opn in the wir (2WBSline): 1. Turnthe ignitionswitchOFF. 2. Disconnect the EVAPbypass solenoid valve2P connector. 3. Checkfor continuity between t h e E V A P b y p a s s s ot e n oi d v a l v e2 P c o n n e c t o tre r m i n a l No.2 and body ground.
2WBS (BLU}
I
Wire sideof female termrnats Repairopen in the wire between the EVAP bypass solenoid valv. and ECM/PCMlA3). tGl IBLK/WHT}
Chack tor an op6n in the wire llcl line): 1. Turnthe ignition switchON l). 2. Measure voltagebetween the EVAPbypasssolenoidvalve 2 P c o n n e c t o tre r m i n a lN o . l and body ground.
Replacethe EVAP byps.,s solonoid vatus and O-ring3.
Ropairo,penin the wire botwoen th6 EVAP bypa$ sotenoid vatvo and No. 15 ALTERNATOR p S (7.5 SENSOR Altuso.
1 1 -2 1 6
EVAP control canister vent shut valvelst, lThe conlinualion ot DTC P1456 troubleshooting.) EVAP THREE Check the EVAP control cankter vent 3hut valve: the 1. Disconnect vacuum hose way valve, from the EVAPthree and connecta vacuumPUmP to the hose. switch (ll). ON 2. Turnthe ignition 3. Applyvacuumto the hose VALVE
VACUUM PUMP/GAUGE,0 30 in.Hg A973X- 041 XXXXX
EVAP CONTROL CANISTER
EVAP control crnisier vent lhul valve is OK. Do the v.cuum hoses and connections te3l lsee page11-218).
EVAPCONTROL VENT SHUT CANISTER IC361) VALVE2P CONNECTOR
r+ l 1
f
t 2 l
Chock the EVAP control canbtel vent shul valvo: 1. Turn the ignitionsw;tchOFF. the EVAPcontrol 2. Disconnect c a n i s t e rv e n t s h u t v a l v e 2 P connector. 3. Checkfor continuitybetlveen the EVAPcontrol canistervent termishutvalve2Pconnector nal No. 1 snd body ground. Roplac EVAPcontlol canbt] the venl shut valve and O-ring.
cnrulwxrt (o) tLT
1 VSV
1
Chock lor a short in the wire (VSV lino)r n 1. Disco nect the EcM/PCN4 A connoctor (32P). 2. Checkfor continuitybetween the EVAPcontrol canistervent termishutvalve2Pconnector nal No. 1 and body ground. Reorir 3hort in tho wiro bgtweon the EC1I/I/PCM lAal .nd the EVAP codrol canbtor vent shut valv6.
EVAP CONTROL CANISTER VENT SHUT VALVE O.RING Replace.
Substitute a known.good ECM/ PCM and recheck. lf symptom/ indicrtion goes awaY, replace the original ECM/PCM.
ILT GRN/WHT)
(cont'd)
1 1 217
Evaporative Emission Controls(cont'd) IEVAPI
lTi,t56l ("onto)
Vacuum hoses and connections
telit.
(The continuarion of DTC P1456 troubleshooiing.l
C h e c kt h e v a c u u m h o 3 e s a n d connect|ons: C h e c kt h e f o l l o w i n g p a r t s f o r l e a k sa t a t m o s p h e r i c r e s s u e p r {seepage11-204). . Fueltank . Fuelfill cap . F u e l f i lp i p e l . EVAPtwo way valve . Fueltankpressure sensor
Repairor replacothe parts.
Substitute a known-good ECM/ PCM and recheck.lf symptom/ indication goes away, replac the original ECM/PCM.
1 1 -2 1 8
'98 - 00 modls: (EVAP) systemleak Control Emission Evaporative Troublecode (DTc)P1457: Diagnostic The scantool indicates (EVAP system). controlcanister detected Troubl6shootingFlowchart
The MIL has been rePortedon. is DTCP1,157 storod.
('98 model only)
_]
sensor Do the fuel tank Pressure test {seepage11-214).
sensorOK? ls the {ueltankpressure
Do the EVAP Purge contlol solenoid valve test lsea Page 1l_ 220t.
(cont'dl
11-219
Evaporative (EVAP) Emission Controls(cont,dl
iTl457l ("ont'or
- The MIL has been reportedon. - DTCP1457is stored. {EVAP purge control solenoid valve test.l*
VACUUM PUMP/GAUGE, iN.Hg O-30 A973X 0rl -
xxxxx
'\)
AP CONTROL CANISTER
Check the EVAP purge conrrol 30lenoidvelve: L Disconnect vacuum hose the from the EVAPconlrol canis, t e r , a n d c o n n e c ta v a c u u m pump to the hose. 2. Connecthe ECM/PCM on c nector terminal to the body A6 groundwith a jumperwire. 3. Turnthe ignition switchON (tl). 4. Applyvacuumto the hose.
ECM/PCMCONNECTOR {32P} A PCS(RED/YELI

4 5 8 / ,/3 't6 1 7 1 8 l 9 20 ,,/ 14 ,/ ,/ 26 29 30 't0 24
JUMPER WIRE
Wire sideof lemaleterminals EVAPpurge control solenoid valve is OK. Oo the EVAPbypass solenoid valve t3t {see psge 1l221t.
EVAPPURGE CONTROL SOI.ENOID VALVE2P CONNECTOR (Cl08) PCS IRED/YELI
Check for an open in the wire (PCS line): 1. Turnthe ignition switch OFF. 2 . D i s c o n n e ctth e E V A Pp u r g e controlsolenoid valve2P con nector, 3. Checkfor continuitybetween t h e E V A P p ur g e c o n t r o l solenoidvalve 2P connector t e r m i n a lN o . 2 a n d b o d y grouno,
female termanals
ls therecontinuity?
Ropairopn in th6 wire between the EVAP purge control 3olenoid velve and ths ECM/PCM(A61.
Check for an open in the wire (lGl line): 1. Turnthe ignition switch ON t). 2. Measurevoltage between the EVAPbypasssolenoidvalve2p coonector terminalNo. 1 and body ground.
Repah open in lhe wir6 betwoen the EVAP pu.ge cont.ol solonoid vdlvo and No. 15 ALTERNATOR SP SENSOR {7.5Al fu!. *: Continued '98 model frr
1 -220
EVAPbypasssolenoidvalv test. {The continuation of DTC P1457 troubleshooting.l
EVAP BYPASS SOLENOID VALVE
FUELTANK SENSOR PRESSUBE TWOWAY EVAP

VALVE
Checkthe EVAP bypass 3olenoid hose the 1. Disconnect vacuLlm from the EVAPtwo way valve, and conned a vacuumPUmP to the hose. ON switch (ll). 2. Turnthe ignition 3. Applyvacuumto the hose EVAP bvpas3 30lsnoid vrlvo/ EVAPtwo way v.lve is OK. Do the EVAP control canisler vent 3hut v.lve te3l (seePsge11'2221. EVAPAYPASSSOLENOID (C647} VALVE2P CONNECTOR
t.'-+l
VACUUM PUMP/ GAUGE, 0-30 in.Hg A973X041 -
xxxxx
Does the valve hold vacuum?
Ch6ckthe EVAP byp.ss solenoid '1. Turnthe ignitionswitchOFF the EVAPbypass 2. Disconnect valve2P connector. solenoid 3. Check{or continuitybetween t h e E V A P b y p a s s s o l e n oi d v a l v e 2 P c o n n e c t o tre r m l n a l No.2 and body ground the ReDlace EVAPbypass 3olenoid valveand O-rings.
t1t?l
(d1terul
| 2wBs
Y -L
C h e c kf o r a s h o r t i n l h e w i r e {2WBSlinel: connec ECM/PCM 1. Disconnect tor A (32P). 2. Checklor continuity betlveen t h e E V A P b y p a s s s o l e n oi d valve 2P connectortermrnal No.2 and body ground.
q
Rcpsir short in th. wire bgtwoen the EcM/PCtrl lA3l lnd the EVAP bypa$ solenoidvalvo.
@)
2WBS (BLU}
ls therecontinuitY?
Sub3tiiute . known'good ECM/ PCM End recheck.lI sYmptom/ indication goe3 away, tePlace ECM/PCM. the original
(cont'd)
11-221
lT145il ("ont'o)
EVAP control canistor vent shut valve t6t. (The continuation of DTC p1457 troublahooting.) VACUUM PUMP/GAUGE,030 in.Hs A973X- 041 -
xxxxx
ECM/PCMCONNECTOR {32PI A
vsv
{LTGRN/WHT)
3
6
Chcck the EVAP control c.nirt6l vent ahut vrlve: 1. Disconnect vacuum hose the trom the EVAP threway valve, and connecta vacuum pump to the hose. 2. Connect ECM,PCM the conn6c, t o r t e r m i n a lA 4 t o t h e b o d y groundwith a jumper wire. 3. Turn the ignitionswitchON fil). 4. Applyvacuum the hose. to
10
23
EVAP THREE VATVE \ 't
l 4 / 1 6 1 7 l 8 't9 20 2l 26 27 2a 29 30
24
JUMPER
WIRE
EVAP CONTROL CANISTER EVAP control crni3ter v6nt shut velve b OK. Do the canistsr syslern loak test {3eepage 11-2231. EVAPCONTROL CANISTER VENT SHUT VALVE2P CONNECTOR {C361}
r+J
Check for an open in the wire IVSV linGll 1. Turnthe ignitionswjtchOFF. 2. Disconnect the EVAPcontrol c a n i s t e rv e n t s h u t v a l v e 2 p connector. 3. Check for continuity between the EVAPcontrol canistervent shul valve 2P connectorterminal No. l and body ground. Ropril op6n in tho wire botweon the EVAP control canister v6nt shut v.lve and the ECM/PCM (A41.
riEr
/A\ {Lr GRN/WHT|
I vsv
Y
I
EVAP CONTROL CANISTEF VENT SHUT VALVE

(}BING Replace.
Check tor an open in the wire (lGl line): 1. Turn the ignitionswitch ON l). 2. Measurevoltage between the EVAPcontrolcanister vent shut valve 2P connectorterrninal No. 1 and body ground.
RoplacethG EVAP cont.ol canister Yentshut velve and O-ring.
Repai. opon in the wire betwoen th6 EVAP control canister vont shut valve .nd No. 15 ALTERNATOB SP SENSOR t?.5 Alfus6.
ffil r c r
e
(BLK/wHr)
11-222
EVAP CONTROL Canbter system leak test {Thecontinuation of DTCP1457 trouble3hootin9.) EVAP FUELTANK BYPASS SENSOR SOLENOID TWOWAY EVAP VALVE VALVE EVAP THREE VALVE EVAP CONTROL CANISTER
VENT SHUT VALVE
Chock the EVAP control canister vent shut valve line and connoc' tonS: 1. Turnthe ignitionswitchOFF to 2. Connect three'waytee fit_ tings into the hose from the EVAPcontrol canisterto the EVAPtwo way valve. Connect sensor the fuel tank pressure to one of the tee fittings and the vacuum PumPto the other' 3. Removethe vent hose from the EVAPcontrol canistervent shut valveand cap the Pon to sealthe fresh air vent Ior the EVAPcontrol canister. ON switch (ll). 4. Turnthe ignition 5. While monitoring the FTP with the Honda voltage Sensor P G M T e s t e r ,o r m e a s u r a n g v o l t a g e b e t w e e nE C M / P C M terminalsA29 and connector C18slowly PumPthe vacuum pump using a strokeevery 1 2 seconds. 6 . C o n t i n u et o P u m P v a c u u m u n t i l t h a t v o l t a g ed r o P st o approx.1.5V. N O T E :M a k e s u r e t h a t t h e e n g i n ec o o l a n tt e m P e r a t u r e 95'F(35'Cland stillabove Your hasno leak vacuum PumP 7 . M o n i t o r t h a t v o l t a g ef o r 2 0 seconds.
ttrrL
t a VACUUM PUMP/ GAUGE, 0 - 30 in.Hg A973X041 XXXXX FITTINGS
ECM/PCMCONNECTORS A {32P)
PTANKILT GRN) Check the EVAP Pu.ge control solenoidvalve line and connections: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e P u r g e l a n e hose from the EVAPcontrol and Plugthe Port canister ON switch (lli. 3. Turnthe ignition 4. While monitoringthe FTP voltage with the Honda Sensor P G M T e s t e r ,o r m e a s u r i n g v o l t a g e b e t w e e nE C M / P C M terminalsA29 and connector Cl8 slowly PumPthe vacuum pump using a strokeevery 1 2 seconds. 5 . C o n t i n u et o p u m p v a c u u m u n t i l t h a t v o l t a g ed r o P st o approx.1-5V. N O T E :M a k e s u r e t h a t t h e e n g i n ec o o l a n tt e m P e r a t u r e and 95'F(35"C) Your stillabove pumphasno leakvacuum 6 . M o n i t o r t h a t v o l t a g et o r 2 0 seconds. c (31Pt
SG2 {GRN/BLK) Wiresideof femaleterminals
drop to 1.5V Doesthevoltage and holdsat least20 seconds?
lGpct the EVAPcontrol cani3tel vent 3hut valvo line and connec_ tion5.
Does the voltage drop to 1.5V and holds at least 20 seconds?
Inlpect tho EVAP Putge control solenoid valvo line and connec' tion3. It th6y lro OK, do the EVAP two way valve te3t (seo page 112211.
Reolacethe EVAPconirol canister.
{cont'd)
11-223
EvaporativeEmission (EVAP) Two Way Valve Testing '97 model: 1. 2. Remove fuelfill cap. the R e m o v et h e v a p o r I i n e f r o m t h e E V A Pt w o w a y valve on the fuel tank, and connectit to a T_fitting f r o m a v a c u u mg a u g ea n d a v a c u u m p u m p a s shown. VACUUM,/ PRESSURE GAUGE otJAz - 001 rDoB T-FITTING
VACUUM PUMP/ GAUGE,0 30 in.Hg A973X- 041 -
.98 1. 2.
0Omodels: Remove fuel fill cap. the R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y valve{located abovethe EVAP controlcanister). and c o n n e c ti t t o a T - f i t t i n gf r o m v a c u u mg a u g e a n d vacuumpump as shown.
VACUUM/PRESSUFE
VACUUM PUMP/GAUGE, 0 - 30 in.Hg A973X-041-XXXXX
xxxxx
T-FITTING T-FITTING
3 . A p p l y v a c u u ms l o w l y a n d c o n t i n u o u s l v h i l e w watching the gauge.The vacuum should stabilize momentarily 0.7- 2.0 kpa (5 - 1SmmHg,0.2_ 0.6 at in.Hg). l f t h e v a c u u m s t a b i l i z e s v a l v eo p e n s )b e l o w ( 0 . 7 k P a ( 5 m m H g , 0 . 2 i n , H g )o r a b o v e 2 . 0 k p a (15 mmHg,0.6 in.Hg), installa new valveand retest. 4. Move the vacuum pump hosefrom the vacuumfit_ ting to the pressurefitting, and move the vacuum gauge hose from the vacuum side to the pressure side as shown.
A p p l y v a c u u ms l o w l y a n d c o n t i n u o u s l y h i l e w watchingthe gauge. The vacuum should stabilizemomentarilyat O.g_ 2.1 kPa(6 - 16 mmHg,0.2- 0.6 in.Hg). l f t h e v a c u u m s t a b i l i z e s v a l v e o p e n s )b e l o w ( 0 . 8 k P a ( 6 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 1 k p a (16 mmHg,0.6 in.Hg), installa new valveand retest. Move the vacuum pump hosefrom the vacuumfitting to the pressurefitting. and move the vacuum gauge hose from the vacuum side to the pressure side as shown.
PiESSURE SIDE
5.
Slowly pressurize vapor line while watchingthe the gauge.The pressure shouldstabilize 1.3- 4.7 kpa at ( 0 - 3 5 m m H g ,0 . 4- 1 . 4i n . H g ) . . l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s v a l v e ( opens)at 1.3- 4.7 kpa (10 - 35 mmHg, 0.4 _ 1.4 in. Hg),the valveis OK. . lf th6 pressure stabilizes below 1.3kpa fio mmHg, 0.4 inrHg) above4.7 kpa (35 mmHg, 1.4 in.Hg), or installa new valve and retest.
5.
Slowly pressurize vapor line while watchingthe the gauge. The pressureshould stabilizemomentarilvabove 1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) . a l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s v a l v e ( o p e n s )a b o v e 1 . 0 k P a ( 8 m m H g .0 . 3 i n . H g ) t h e , valveis OK. . lf the pressure stabilizes below ,|.0kpa {g mmHg. 0.3 in.Hg), installa new valveand retest.
11-224
Transaxle
...........12-1 Clutch . . 3 .. M a n u a lT r a n s m i s s i o n. . . . . . . . . . . . . . . . . . . .1 . . - 1. . . T n A u t o m a t i c r a n s m i s s i o . . . . . . . . . . . . ..........14 - 1 ... 15-1 Differential ... 16-1 Driveshafts
Clutch
12-2 ..........' Tools....,..... Speciaf .'." 12'3 lndex........... lllustrated ClutchPedal ........."."."".12-4 Adjustment ClutchMasterCylinder '." 12'5 RemovaUlnstallation SlaveCylinder .'.. 12-6 Removal/lnstallation Plate Pressure ..'." 12-7 RemovaUlnspection ClutchDisc ."'.. 12-8 Removal/lnspection Flywheel 12-9 ...................... Inspection 12-9 ....................................... Replacement Plate ClutchDisc,Pressure 12-10 ....................' lnstallation Bearing Release 12'11 ...... Removal/lnspection 12-12 ..................... lnstaflation
SpecialTools
Rel.No.
Tool Number OTJAF PM70,I1A 07NAF- PR30l00 07LAB PV00100 or - PD20003 07924 07746 0010100 07749 0010000 07936 3710100
Description ClutchAlignmentDisc ClutchAlignmentShaft R i n gG e a rH o l d e r Attachment, x 35 mm 32 Driver H an dl e
Oty 1 1 1 |
PageReference t2-7 12-7 A, ' t0,11 , 1 2 - , 9 , 1 0 ,1 ' l 7
a
IA
@
!c, Lo,
1
1 1
I
I
12-10
12-10 1 2 - 7 a , 1 0 ,1 1 ,
b)
2-2
lllustratedIndex
NOTE: bearingslidingsurface the release . Whenever transmission removed, is cleanand grease the .lfthepansmarked*areremoved,theclutchhydraulicsystemmustbebled(seepage12-6). and . Inspect hosesfor damage.leaks. interference, twisting. the
*CLUTCHLINE 19 N.m (1.9kgj.m, 14 tbtft)
LOCKPIN
PEDALPIN 8 x 1.25mm 13 N.m {1.3kgf m,9.4lbtft) PEDAL CLUTCH page12-4 Adjustment,
.RESEFVOIR HOSE *RESERVOIR TANK
*CI-UTCH MASTERCYLINDER page Femoval/lnstallation, 12-5 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbf.ft)
WM\,".0-ffi-P"8Nmlloks{m'
.o-.9r
*CLUTCHLINE 15 N.m (1.5kgt m, 11 tbr.ft)
CLUTCH DISC page 12-8 Removal/lnspection, page12,13 Installation,
*CLUTCHLINE 24 N.m {2.4 kgf.m, 17 tbf.ft) 8 x 1.25mm 25 N.m {2.6kgt m,
19rbf.ftt
FLYWHEEL page12I Inspection, page12-9 Repiacement, 1 2x 1 . 0m m kgtm,75.9lbf ftl 103N.m (10.5 PLATE PRESSURE page'12-7 Removal/lnspection, page'12 13 Installation, RELEASE BEARING page Removal/lnspection, 12-1'! page12-12 Installation, *CLUTCHLINE 15 N.m (1.5kgt m, 11 tbf.ft) I x 1.25mm 22 N.m 12.2kgl'm, 16lbfft)
12-3
ClutchPedal
Adiustment
NOTE: . T o c h e c k t h e c l u t c h i n t e r l o c ks w i t c h a n d c l u t c h switch,seesection 23. . The clutchis self-adjusting compensate wear. to for CAUTION:lf there is no clearance bstwan the master cylinder piston and push rod, ths roloasebearing is held againsi the diaphragm spring, which can resuh in clutch slippageor other clutch probloms. 1. LoosenlocknutA, and backoff the clutchswitch(or sdjustingbolt) until it no longertouchesthe clutch peoar. LoosenlocknutC, and turn the push rod in or out to get the specifiedstroke (@) and height (@) at the clutchoedal. TightenlocknutC. Thread in the clutchswirch (or adjustingbolt) until it contacts clutchoedal. the
LOCKNUT B 9.8 N.m 11.0 kgf.m, 7.2 lbf.ftl CLUTCH INTERLOCK SWITCH CLUTCHSWTTCH {or ADJUSTINGBOLTI L(rcKNUT A 9.8 N.m {1.0kg{.m,7.2 lbf.ftl
5 . Turn the clutchswitch{or adjusting bolt} in an additional3/4to 1 full turn. Tightenlocknut A. 7 . LoosenlocknutB on the clutchinterlock switch. 8 . Measure the clearance betweenthe floor board and clutchpedalwiththe clutchpedalfully depressed.
q
2.
Release clutchpedal 15 - 20 mm (0.59- 0.79in) the from the fully depressed positionand hold it there, Adjustthe positionof the clutchinterlock switch so that the engine will start with the clutch pedal in this position.
1 0 .TightenlocknutB.
3. 4.
CLUTCH MASTERCYLINDER PUSHROD Pedal in contact with swhch LOCKNUTC 18 N.m (1.8kgf.m,13lbtftl
a_-_--/
@ @ @ o
at {STROKE PEDAL): - 1itsmm (5.31 5.71in} 135 (TOTAL CLUTCH PEDAL FREE PLAY)i7-22mm (0.28-0.87in) inctude the pedatptay 1 - 9 mm (0.0it- 0.35inl (GLUTC,H PEDALHE|GHTI: ltxt mm (7.20inl ro rhe ftoor (CLUTCH PEDALDTSENGAGEMENT HEtcHTl: 72 mm {2.txtinl minimum to the floor
12-4
GlutchMasterCylinder
Removal/lnstallation
CAUTION: . Do not spill brake fluid on the vehicle; it may damage the paint; if brake tluid does contact the paint. wash it off immediately with water. . Plug the end ol the clutch line and leservoir hose with a shop towel to prevent brake tluid trom coming out. ' t . The brakefluid may be suckedout through the top with a syringe. of the mastercylinderreservoir Disconnect clutch line and reservoirhose from the the clutchmastercylinder, 4. Prv out the lock pin, and pull the pedal pin out of the nuts. the voke.Remove
NUTS I x 1.25mm lbtft) 13 N.m t1.3kgt.m,g.il
kst 9.8N.m11.0 m, 7.2tbf.ftl
5,
Remove clutchmastercylinder. the
LINE CLUTCH 19 N'm 119 kgJm' 14 lbf.frl
Remove the reservoir from the engine compartment bulkhead.
MASTER CLUTCH CYLINDEF I n s t a l lt h e c l u t c h m a s t e rc y l i n d e r i n t h e r e v e r s e orderof removal. system{seepage NOTE:Bleedthe clutchhydraulic 12-61.
12-5
SlaveCylinder
RemovaUlnstallation
CAUTION: . Do nol spill braketluid on the vehicle; itmaydamage the paint; if brake fluid dos contast the paint, wash it off immediately with water. . Plug the end of the clutch line with a shop towel to prevcnt brake tluid from coming out. .6|l,Super High Temp Urea crease (p/N 087989002). : BrakeAssemblyLube or equivalentrubber grease. 3. I n s t a l lt h e s l a v ec y l i n d e ri n t h e r e v e r s eo r d e r o t removal. NOTErMake sure the boot is installed the slave on cylinder. CLUTCH LINE 15N.m(i.Skgf.m, tbf.ftl lt
SLAVECYLINDER
1.
Disconnect clutchline from the slavecvlinder. the
.-lG
(P/N08798 90021
E x 1.25mm 22 N.m (2.2kgt.m, 16 tbtft)
(Brake Assembly Lube) Bleed the clutch hydraulic system.
2.
Remove slavecylinder the from the clutchhousing.
Attacha hoseto the bleeder screw,and suspend the hosein a container brakefluid. of Makesurethere is an adequate supplyof fluid at the clutchmastercylinder, then slowly pump the clutchpedaluntil no more bubblesappearat the bleederhose. Refillthe clutch mastercylinderwith fluid when qone. A l w a y s u s e G e n u i n eH o n d aD O T 3B r a k eF l u i d . Using a non Hondabrakefluid can causecorrosion and decrease life of the system. the Confirm clutch operation,and checkfor leaking fluid.
BLEEDER SCREW 7.8 N.m (0.8 kgf.m.5.8 lbt.ft)
12-6
Plate Pressure
Removal/lnspection
springfingersfor heightusing 1 . Check diaphragm the the special tools and a feelergauge. StandardlNewl: 0.6 mm {0.02in) max. ServiceLimit: 0.8 mm (0.03in)
HANDLE 07936 3710100 DISC CLUTCH ALIGNMENT OTJAF PM7O11A ALIGNMENT SHAFT CI.UTCH 07NAF- PR30100
4.
plate surfacefor wear, cracks, Inspect the pressure a n db u r n i n g . springfor wear Inspect fingersof the diaphragm the bearingcontactarea. at the release
5.
FEELER GAUGE
PRESSURE PLATE
lf the height is more than the servicelimit, replace the pressure Plate.
2. a l n s t a l lt h e s D e c i a l l o o l s s s h o w n .
6.
for Inspect warpageusinga straightedge and feeler plate. gauge.Measure across the pressure in) StandardlNew):0.03mm 10.001 max. inl Service Limit: 0.15mm (0.006
PLATE PRESSURE
RINGGEARHOLDER ADJUSTER NUT ENGINEBLOCK
ADJUSTER BOLT BOLT NUT WASHER
GAUGE FEELER
p T o p r e v e n tw a r p i n g ,u n s c r e wt h e p r e s s u r e l a t e in a crisscrosspattern in several mounting bolts plate. steps.then removethe pressure
lf the warpage is more than the service limit, replace the pressure plate.
12-7
GlutchDisc
Removal/lnspection
'1. Remove the clutchdiscand specialtools. 4. Measurethe rivet depth from the lining surfaceto the rivets,on both sides. Standard(New):1.2- 1.7mm 10.05 0.07in) min. Service Limit: 0.2 mm {0.008inl
CLUTCH DISC
Inspect the lining of the clutchdisc for signsof slipping or oil. lf the clutch disc is burned blackor oil soaked, replace it. Measure clutchdiscthickness. the Standard(New):8.,1-9.1 mm (0.33 0.36in) ServiceLimh: 6.0 mm (0.2,1 in)
LINI G SURFACE
CLUTCH DISC
l f t h e r i v e t d e p t h i s l e s s t h a n t h e s e r v i c el i m i t , replace clutchdisc. the
lf the thickness lessthan the service is limit, reDlace the clutchdisc.
12-8
Flywheel
Inspection
L
Replacement
L
lnspect the ring gearteethfor wear and damage. Inspectthe clutch disc mating surfaceon the flywheelfor wear,cracks, and burning Measurethe flywheel runout using a dial indicator through at leasttwo full turns. Pushagainstthe flywheel each time you turn it to take up the crankshaftthrustwasherclearance. w N O T E :T h e r u n o u tc a n b e m e a s u r e d i t h e n g i n e installed. Standard (Newl: 0.05 mm (0.002in) max. inl Limit: 0.15mm {0.006 Service lf the runout is more than the servicelimit, replace the the flywheeland recheck runout FLYWHEEL
tool as shown. Installthespecial the flywheelmountingbolts in a crisscross Remove patternin several steps,and removethe flywheel.
2.
2.
3.
MOUNNNG BOLTS
FLYWHEEL
RINGGEAR HOLDER 07LAB PV00r00

ol
07924 - PD20003
3.
RINGGEAR
the from the flywheel. Remove ball bearing
with your Turnthe innerraceot the flywheelbearing finger.The bearingshould turn smoothly and quietly. Checkthat the bearingouter racefits tightly in the tlywheel.lf the racedoes not turn smoothly,quireplace bearing. the etly,or fit tight in the flywheel,
FLYWHEEL
BALLBEARING
(cont'd)
12-9
Flywheel
Drive the new bearing into the flywheel using the specialtools.
HANOLEDRIVER 07749-
Clutch Disc,PressurePlate
Installation
1. Install the ring gear holder.
CLUTCH ALIGNMENT SHAFT 07NAF- PR30100
ATTACHMET{T32x35mm 07746-O010100
DISC CLUTCH
FLYWHECI-
Align the hole in the flywheel with the crankshaft d o w e l p i n , a n d i n s t a l lt h e f l y w h e e l .I n s t a l lt h e mountingboltsfinger-tight. I n s t a l lt h e s p e c i a lt o o l , t h e n t o r q u e t h e f l y w h e e l mounting bolts in a crisscrosspattern in several stepsas shown.
RING GEAR HOLDER _ 07LAB pvoot(x) or _ 07924 PD20003
Apply greaseto the spline of the clutch disc,then installthe clutchdisc usingthe special tools. N O T E :U s e o n l y S u p e rH i g h T e m p U r e aG r e a s e (P/N08798 9002).
Torque: 12x 1.0mm r03 N.m(10.5 kgl.ln, 75.9tbtftl
plate. lnstallthe pressure
PRESSURE PLATE
12-10
Bearing Release
Removal/lnspection
4. patternas Torquethe mountingbolts in a crisscross shown.Tightenthe bolts in severalstepsto prevent spring. warpingthe diaphragm 1. fork boot from the clutchhousthe release Remove Ing.
RELEASE BEABING
8 x 1.25mm 25 N.m (2.6kgf.m,19lbfft) RELEASE FORK BOOT
RELEASE FORK
Removethe releasefork and releasebearingfrom the clutchhousing. bearingfor play by spinningit by Checkthe release h an d . NOTE:The releasebearingis packedwith grease. Do not wash it in solvent. 5. 6. tools. Remove special the Checkthe diaphragmspring fingersfor height (see page 12-7]'.
play, replacethe releasebearlf there is excessive ing with a new one.
12-11
Bearing Release
lnstallation
NOTE: Use only Super High Temp Urea Grease(P/N 08798 9002). bearthe fork slid bet\iveen release 1. With the release ing pawls. installthe releasebearingon the maint t s h a f tw h i l e i n s e r t i n g h e r e l e a s e o r k t h r o u g ht h e hole in the clutchhousing. 3. Move the releaselork right and left to make sure and that it tits properly againstthe releasebear'rng. bearingslidessmoothlY. that the release
(P/N08798-
-6.l
lPlN 08798- 9002) 0.,1-1.0I (0.01 0 04 ozl
RELEASE FORK BOOT
/\[w
| (,4\1t1t
4. Install the releasetork boot; make sure the boot fork and clutchhousing. sealsaroundthe release
r iz]))
(P/N08798 9002)
(P/N08798 9002) 1 . 0- 1 . 6g {0.0,1 0,06 ozl
fork with the release Align the detentof the release f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e release fork bolt sequarelv.
12-12
Manual Transmission
Diffrential l n d e x. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 - 3 8 . Backlash Inspestion..,....,.,.....................,......, 13-38 FinalDrivenGearReplacement .................... 13-39 TaperedRoller Bearing Replacement ............. 13-39 Bearing OuterRaceReplacement ......,.,........ 13-i10 TaperedRoller Bearing Preload Adiustment ............... 13-il1 Oil SealReolacement .................................... 13-/l:} TransferAssembly lllustrated Index ............. 13-il4 Inspection ..,....,.,......,...... 13-46 Disassembly ................... 13-47 Transfer Drive Gear Bearing Replacement ...,..................,....................... 13-ilg Transfer Driven Gear Shaft Bearing Replacement .............................................. 13-ilg TransferShaft Disassembly/ Reassembly .............. 13-50 Transler Cover A Bearing Outer Race Rep1acement.........,.,.,..........,....,...,.........,., 13-50 Transter Housing Bearing Outer Race R e D 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.-.5.1 . . . . . . . . . . . 1. . . Reassembly 13-52 ..-............,... Mainshaft Bearing/OilSeal Beplacement .................. 13-62 CountershaftBearing Replacement .,,.,.,., ..,...... 13-63 Mainshaft Thrust Clearance Adiustment .................... 13-6,1 TransmissionAssembly Reassembly 13-67 .,.,.,.,..,.,....,., fnstaffation 13-72 .,.,.............,... Gearshift Mechanism O v e r h a u.l. . . . . . . . . . . . . . . .........13-17
SpecialTools
SpecialTools
Ref. No. I Tool Number 07GAD- PG40100 07GAJ- PG20110 07GAJ- PG20130 07HAJ - PK40201 07JAC- PH80000 07JAD- PH80101 07JAD - PH80400 07LAD- PW50601 07RAB 0020000 07746 0010100 07746 0010300 07746 0010400 07746 0010500 07746 0010600 07746 0030100 07746- 0030300 07746- 0030400 07749- 0010000 Dsscription DriverAttachment Mainshaft Holder Mainshaft Base Preload Inspection Tool Adjustable Bearing Remover Set Driver Attachment Pilot,28 x 30 mm Attachment,40 x 50 mm FlangeHolder Companion Attachment,32 35 mm x Attachment,42 x 47 mm Attachment,52 x 55 mm Attachment,62 x 68 mm Attachment,72 x 75 mm Driver,40 mm l.D. Attachment. mm l.D. 30 Attachment, mm l.D. 35 Handle Oty 1 1 1 'l 1 1 1 1 1 1 'I 1 1 1 1 I Page Roterence 13-43 13-66 13-66 13-41 13-62.63 13-43, 53 13-43 13-39,49 13-48,54,57,58 13-18, 68 13-27,34, 62 13-40. 51 't3-40, 51,61, 50. oz, oJ 13-40 13-27 ,34,35, 49,
tJ-5C
o o
,6)
@ -o
\9'
a
@
6r
@ @ @ @ @ @ @
ll
Attachment MagnetStandBase * Must be usedwith commercially available 3/8" - 16SlideHammer.
@ @
07947- SD90200 07979- PJ40001
13-27,34 13-14,27.34, 40, 43, 49, 50, 51, 53, 61,62,63,68 '13-49 13-66
o@(9
ta\
G)
,d,
(oo@(9(}
. A
a5-z
I A
Maintenance
Fluid Transmission
NOTE:Checkthe fluid with the engineOFFand vehicle on levelground. 1. R e m o v et h e f i l l e r p l u g . t h e n c h e c kt h e l e v e l a n d conditionof the fluid. PLUG FILLER 33 44 N.m{4.5kgf.m. lbfftl \ ll
Light Switch Back-up

Test/Replacement
1. from the switch. the Disconnect connectors
sideoI Terminal malelerminals
Ptopet Level
/ \--ril HllllllTl / Hllllrlll / _rf-F{--rno."."

l l | | Replaco.
BACK.UP LIGHTSWTTCH kgt r 25 N.m 12.5 m, 18 lbf.ftl
The fluid level must be up to the filler hole. lf it is belowthe hole,add fluid until it runs out. then reinstallthe tiller plug with a new washer. fluid is diny, removethe drain lf the transmission plug and drainthe fluid. PLUG FILLEB kgf..n.33 lbt'ftl N.m 14.5 a,a
WASHER Replace.
Checkfor continuity betweenthe No. 1 and No. 2 terminals. . There should be continuitywhen the shift lever tnto reverse. . T h e r e s h o u l d b e n o c o n t i n u i t yw h e n t h e s h i f t leverin positionexceptreverse, lf necessary,replacethe switch.
DRAINPLUG 39 N m (4.0 kgf.m,29 lbf'ft)
WASHER Replace.
R e i n s t a ltl h e d r a i n p l u g w i t h a n e w w a s h e r .a n d fluid to the properlevel. refillthe transmission at NOTE:The drain plug washershouldbe replaced everyfluid change. the Reinstall filler plug with a new washer. Fluid Capacity 1.7/ {1.8US qt, 1.5lmp qtl at oil change 2.1 ! 12.2 qt, 1.Almp qtl at overhaul US Alwavs use GenuineHonda Manual Transmission Fluid (MTF).Using motor oil can causestiffershiftit ind because doesnot containthe properadditives.
13-3
Transfer Assembly
lnspection
Make sure tifts, iacks, and satety stands @ are placed properly (seesection 1). L Raisethe front of the vehicle,and support it with safetystands(seesection1). Set the parkingbrake,and block both rear wheels securely. Shiftto neutraloosition. Make a referencemark acrossthe DroDeller shaft and the transferassembly flanges, REFERENCE
COMPAf{ION FI-ANGE
6.
Set a dial indicator the transferassembly on flange, then measure transfergear backlash. the STANDARD: 0.06- 0.16 mm (0.002- 0.006in)
2.
3. 4.
1.
lf the measurement out of specification, is remove the transferassembly and adjusttransfergear backlash(seepage13-44 thru '13-61). C h e c kt h e t r a n s f e ro i l s e a l f o r d a m a g ea n d f l u i d teaKs. lf oil sealreplacement required, is removethe transfer assembly,replacethe oil seal, and adjust the total starting torque (seepage 13-44 thru 13-61). NOTE:Do not replace oil sealwhen the transfer the is assembly installed the transmission. on
8 x 1.25 mm 32N.m(3.3 kg{.m. 24 rbf.ftl Replace. 5. S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assemDty.
13-4
Removal
Make sure the lifts, i8cks. and safety stands !@@ placedproperly {seesection 1}. are 1. Raisethe front of the vehicle,and support it with safety stands (seesection 1). Set the parkingbrake,and block both rear wheels securely. n D r a i nt h e m a n u a lt r a n s m i s s i o f l u i d R e i n s t a ltlh e washer. drain plug with a new sealing conthe Disconnect heatedoxygen sensor (HO2S) nector. 6. Make referencemarks across the propeller shaft flanges' and the transferassembly
i'ARKS REFEREI{CE
2.
3.
4.
Replace.
7.
S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r flanges, assembly Removethe rear stiffener, then remove the transfer assembly.
SELF.L(rcKNG NUT Replace.

SELF-LOCKI'{G NUT Replac.
NOTE: While servicingthe transfer assembly,do to not allow dust or otherforeignparticles enterthe transmission.
5.
exhaustoipeA. Remove
Replace.
13-5
Assembly Transfer
lnstallation
1. Installa new O-ringon the transferassembly.
8 x 1.25mm 24 N.m (2.4 kgt m, 17 rbt.ftl 10 x 1.25mm 44 N.m (4.5 kgJ.m, GASKET EXHAUSTPIPEA
6.
Install the exhaustpipeA,
HO2SCONNECTOR
DOWELPIN
Replace.
TRANSFEB ASSEMBLY
2.
Cleanthe areaswhere the transferassemblycon tacts the transmissionwith solvent or carburetor air. Then apply cleaner,and dry with compressed MTFto the contactareas. Installthetransferassembly the transmission. on N O T E :W h i l e i n s t a l l i n g h e t r a n s f e ra s s e m b l y n t o the transmission, not allow dust or other foreign do particles enterthe transmission. to lnstallthe rearstiffener.
10 x 1.25 mm 54 N.m (5.5 kgt m, 40 tbtftt Replace. SELF.LOCKING
NUT 8 x 1.25mm 16 N.m {1.6kgf.m, 12 tbt.ft) Replace.
8 x 1.25 mm zzN.m l2.2kg!-m, 16rbf.trt Replace.
7. Installthe propellershaft to the transferassembly by aligningthe reference marks,

8 x1.25mm kg{.m, 32 N.m 13.3 24 tbf.ftl REFERENCE MARKS
connector. Connectthe heatedoxygensensor(HO2S) Relillthe transmission with MTF(seepage 13-3). Startthe engine,and run it to normaloperating temp e r a t u r e( t h e r a d i a t o r t a n c o m e s o n ) . T u r n t h e engineoff. and checkfluid level.
8. 9.
AssemblY Transmission
Removal
4. D i s c o n n e c t h e s t a r t e r c a b l e sa n d t r a n s m i s s i o n groundcable.
@ FMak.
sw. iack" and safety stands are placed propelly, and hoist bracketsare attached to collect position on the engine, . Apply parking brake and block rear wheels so vehicle will not roll off stands and lall on you while working under it.
CAUTION:Use fender coversto avoid damaging painted surfaces. 1. the {-) Disconnect negative cablefirst,then the positive(+)cablefrom the batterY. the intakeair duct and air cleanerhouslng Remove (seesection5). the Remove slavecylinderand clutchhosebracket' NOTE: . Do not operatethe clutch pedal once lhe slave cvlinderhas beenremoved. . Takecarenot to bendthe clutchline.
2.
3.
TRANSMISSION CABLE GROUND
the Disconnect back-uplight switch connectorand clamP. wire harness
CLAMP WIREHARNESS
(cont'd)
13-7
Transmission Assembly
(cont'dl Removal
6. R e m o v et h e c o t t e r p i n s , t h e n r e m o v e t h e s t e e l w a s h e r s ,p l a s t i cw a s h e r s .s h i f t c a b l e ,a n d s e l e c t cablefrom the levers. 9 . R e m o v et h e f o u r u p p e r t r a n s m i s s i o nm o un t i n g bolts.
MOUNNNG BOLTS
1 0 . Draintransmission fluid (seepage '13-3). 1. 8. Remove cablebracket the from the clutchhousing. Disconnect vehiclespeedsensor(VSS)connecthe tor.
-------------.2
1 1 . Remove guardbar and the splashshield. the
13-8
the 12. Disconnect heatedoxygen sensor(HO2S)connector, then removethe exhaustpipe A. GASKET Replace.
HO2SCONNECTOR
the cotter pins,and castlenuts.then sepa15. Remove rate the ball iointsfrom the lower arm (seesectlon 18).
PINCHBOLT OAMPER
NUT CASTLE NUT Replace. EXHAUST GASKET Replace. NUT Replace. FORK DAMPER EOLT FOFK
Replace.
SELF.LOCKING Replace.
Mark referencemarks on the joint of the transfer shaft. and the propeller
MABKS REFERENCE
1 6 . Removethe right damper tork bolt, then separate right damperfork and damPer. and 1 7 . Pry the right driveshaftout of the differential, shaft pry the left driveshaft out of the intermediate (seesection18). 1 8 . Pull out the inboardioint, and removethe right and (seesection18). left driveshaft 1 9 . Tie plastic bags over the driveshattends. Coat all with cleanengineoil precision finishedsurfaces
mm 8 x 1.25 Replace. 1 4 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assemDly.
{cont'd}
13-9
(cont'd) Removal
20. Remove the intermediate shaft. 23. Remove right front mounvbracket. the
2 1 . Tie plasticbagsoverthe both endsof the intermediate shaft. Coat all precisionfinished surfaceswith cleanengineoil. Removethe rear engine stiffene.and clutch housIng cover.
RIGHT FRONT MOUNT/BRACKET P l a c ea j a c k u n d e r t h e t r a n s m i s s i o nr,a i s e i t j u s t enough to take it off of the mounts, then remove the transmissionmount bracketand transmission mount.
TRANSMISSION MOUNT
MOUNT BRACKET
13-10
25. Removethe transmissionmounting bolts and the rearenginemountingbolts.
tork boot. releasebearing,and 28. Removethe release fork from the clutchhousing release
RELEASE BEANING
REARENGINEMOUNTINGBOLTS Replace. TRANSMISSION
away from the engine until it Pull the transmission then lower it on the transmisclearsthe mainshaft, sion jack. NOTE:Takecarenot to bendthe clutchline. the startermotor and hose clampfrom the Remove housing. transmission
STARTER MOTOR
13-1 1
lllustrated Index
Refer the drawingbelowfor the transmission to disassembly/reassembly. Cleanall the pans thoroughlyin solvent, and drv with comoressed air. I LuUri""r"uttthe partswith MTFbeforereassembly.
NOTE: t This transmission usesno gaskets betweenthe major housings; use liquid gasket(p/N 0g718- 0001or oE7l8 - 0003) (seepage 13-69, 71). . Alwayscleanthe magnet@ whenever transmissjon the housingis disassembled. . Inspect the bearings wear and operation. all for
C) sHrFr FoRKASSEMBLY . I n d e xp a g e l 3 - 2 1 , (a MAINSHAFT ASSEMBLY . I n d e xp a g e 1 3 - 2 3 , (9 28 mm WASHER ) 28 mm SPRTNG WASHER O BALLBEARING a6)OIL SEALReDlace. (D 14 x 20 mm DOWELptN G) couNTERSHAFTASSEMBLY .lndex page,13-28
aol NEEDLE SET PLATE
o OILGUIOEC PLATE
.lndex page,13-38
BEARING @ NEEDLE
@ MAGNET @ DIFFERENTIAL ASSEMBLY
(DO-nlNGBeplace. i9 TRANSFER '13,44 ASSEMBLY

.Index page,
@ OILSEALReplace. SPEED @ VEHICLE SENSOR HOUSING @ CLUTCH (9 REVERSE LOCKCAM @ REVEESE SHIFTHOLDER IDLEGEAR @ REVERSE GEARSHAFT @ REVERSE
15 @ COLLER, x 20 x 20
e3THRUSTWASHER,20x 36 x 2
13 -1 2
HANGER C) TRANSMISSION BOLT O INTERLOCK BOLT O 32 mm SEALING BALL{5/16 in.) @ STEEL in.l 26.1mm {1.03 ) SPRING @ wasHER Replace. O sET BALLscREw Replace. @ WASHER BOLT ) FLANGE @ oll SEALReplace. @ DRAINPLUG Replace. @ WASHER PLUG @ FILLER Replace. @ WASHER
(9 10 x 12 mm DOWEL PIN (D SPRING in.l 25.6mm 11.01 WASHER ' THRUST @} SHIFTARM C (3 CONICAL WASHER SPRING BOLT @ SPECTAL 8] SHIFTARM COVER @ OILSEALReplace. ! SHIFTLEVER CAP @I BREATHER (2! SHIFTARM SHAFTASSEMBLY PIN @ SPRING Replace. ARM O SELECT
!} THRUSTWASHER SELECT @ sTH/REVERSE SPRING RETURN SPRING RETURN @ SELECT PLATE ) OIL GUTTER @ 78 mm SHIM @ OIL GUIOEM PLATE BOLT SPRING @ SELECT @ OILSEALReplace. LEVER @ SELECT LIGHTSWITCH O BACK.UP Replace. @ WASHER HOUSING OOTRANSMISSION
13-13
Disassembly
1. Remove transferassemblv. the 3. Remove interlock the bolt.
SELECT ARM
O-RING Replace.
SHIFT ARMSHAFT Turn the selectlevercounterclockwise, remove then the shift arm A finger from the groove of the shift forks. 5. Turn the shift arm shaft counterclockwise nd a removethe selectarm fingerfrom the grooveof the shift arm A. then removethe shift arm shaft assemblv. Remove vehiclespeedsensor(VSS). the
Removethe shift arm cover assembly, and wiDe it cleanof the sealant.
SHIFTARM COVER ASSEMBLY
6.
ptN 10x 12 mm DOWEL
13-14
7.
springs,steel the set ball screws,washers, Remove light switch. and back-uP balls.
9. Removethe transmissionhousing mounting bolts steps. pauernin several in a crisscross
STEELBALL D. 5/16 in
LIGHTSWITCH
8.
the Remove flangebolt. drainplug, and filler plug
the 10. Remove 32 mm sealingbolt
PLUG FILLER DRAINPLUG WASHER Replace. WASHER Replace.
BOLT FLANGE
' It . Expandthe snap ring on the countershaft ball bearing, and removeit from the groove using a pair of snap ring plier. housingfrom the clutch the transmission Separate housing. t R e m o v e h e d o w e l p i n s ,a n d w i p e i t c l e a no f t h e sealant.
(cont'd)
13-15
(cont'dl Disassembly
1 4 . R e m o v e h e o i l g u t t e rp l a t e ,7 8 m m s h i m , a n d o i l t guide M plate. 1 6 . Removethe spring pin using the pin punch and a pair of diagonal cutters.
OIL GUTTER PLATE
PIN PUNCH, mm 5.0
Replace. OIL GUIDEM PLATE
17. Remove selectlever,springs, the washer,and select arm. 15. Remove selectspringbolt. the
SELCT LEVER
SELECT SPRING BOLT
OIL SEAL Replace.
THRUSTWASHER
SELECT ARM
18. Remove oil seal. the
13-16
lockcam. the reverse 19. Remove
assemblies and countershaft the mainshaft 23. Remove with the shiftforksfrom the clutchhousing. and counterNOTE;Beforeremovingthe mainshaft tape the mainshaftsplineto proshaft assemblies, tect it.
COUNTEBSHAFT
ASSEMBLY
checkthe clearanceof the reverseshift 20. lf necessary, holder(seepage13-20). shift holder. the 2 ' t . Remove reverse
Tapethe main' shaftsplines.
WASHER
WASHER SPRING
HOUSING
HOLOER
24. Removethe differential asssmbly.
22. '97 - 99 models: Removethe reversegear shaft and idler gear. the reverse '00 model: Remove the reverse gear shaft, reverse idler gear,thrustwasherand the coller.
13-17
Shift Arm Cover/ShiftArm Shaft Assembly

Disassembly/Reassembly
Shift Arm CoverAssmbly 1. Remove breather the cap and set ball screw,washer, spring.and steelball. 5. Install the oil seal in to the shift arm coverusinothe sDecialtools.
HANOLE 07749- 0010000 ATTACHMENT, 32x35mm 077a6- 0010100 BREATHER CAP STEELBALL D. 5/16 in, OIL SEAL Replace.
SPRING in.l L,25.6mm (1.01 T BALLSCREW 22 N.m 12.2 kgtm, 16lbf.ftl Remove the special bolt and conical spring washers.
6.
Reassemble shift arm cover in the reve.seorder the of disassembly.
Shift Arm Shaft Assembly 1. Removethe specialbolts and conicalspring washers.

SPCCIAL BOLT 8x1.0mm 29 N.m (3.0kgf.m, 22IbI.ftI
SHIFT ARM COVER
SHIFTARMA SHIFTLEVER
CONICAL SPRING
SHIFTARM SHAFT
THRUST WASHER
SHIFI ARM C WASHER 8x1.0mft
29 N.m13.0 kg{.m, z2 tbt.ftl R e m o v et h e s h i f t l e v e r , s h i f t a r m C , a n d t h r u s t washerfrom the shift arm cover. Remove oil seal. the NOTE: lnstallthe thrust washerwith the alloy surfacetoward shift arm cover.
2.
BOLT SPECIAL 8x1.0mm 29 N.m {3.0kgf.m,22 lbtft}
SPRING WASHER
Remove the interlock, shift arm A, and shift arm B from the shift arm shaft.
3.
Installin the reverse orderof removal.
13-18
InsPection Clearance
1. between the shift arm A and the clearance Measure selectarm. 0.05- 0 25 mm (0.002- 0'01 inl Standard: Limit:0.5mm (0.02in) Service 3. betweenthe shift arm B and Measure the clearance shift arm c. 0.05- 0.25 mm (0.002- 0.01 inl Standard: inl Limit:0,5mm (0.02 Seryice
SHIFTARM C ARM SELECT
SHIFT ARM A
SHIFTARM B
2.
a l f t h e c l e a r a n c e r e m o r e t h a n t h e s e r v i c el i m i t , of the measure diameter the selectarm pln 7.9 Standard: - 8.0 mm (0.311 0.315in)
a l f t h e c l e a r a n c e r e m o r e t h a n t h e s e r v i c el i m i t , of measure diameter the shift arm C. the 12.9- 13.0mm (0 508- 0.512in) Standard:
SHIFTARM C
SELECT ARM lf the diameterof the selectarm pin is lessthan the service limit, replacethe select arm wrtn a new one. lf the diameterof the selectarm pin is within the the shift arm A with a new servicelimit, replace one. lf the diameterof the shift arm C is lessthan the servicelimit, replacethe shift arm C with a new one. o lf the diameter f rhe shiftarm C is withinthe the shift arm B with a new servicelimit, replace on e .
13-19
Reverse Shift Holder

Clearance Inspection
1.
Measurethe clearances betweenthe reverseshift holderand sth/reverse shift Diece Din. A: 0.05- 0.35mm (0.002 0.014in) 8: 0.4 - 0.8 mm 10.02 0.03 inl Service Limit:A: 0.5 mm (0.02in) B: 1.0mm 10.0,[ in] Standard:
3.
Measure the clearancebetween the reverseidler gearand reverse shift holder. Standard: 0.5- 1.1mm {0.02 0.0i1 in} Service Limit: 1.8mm (0.07in) REVERSE IDLER GEAR
PIECE PIN
2.
l f t h e c l e a r a n c e a r e m o r e t h a n t h e s e r v i c el i m i t . s measurethe widths of the groove in the reverse shift holder. Standard:A: 7.05- 7.25 mm {0.278- 0.285inl B: 7.4- 7.7 mm (0.29 0.30inl
lf the clearance more than the servicelimit. meais surethe width ot the reverse shift holder. Standard: 13.0- 13.3mm (0.512-0521inl
REVERSE SHIFTHOLDER
lf the widths of the grooves are not within the standard, replacethe reverseshift holderwith a new one. lf the widths of the groovesare within the standard, replacethe sth/reverse shift piece with a new one.
It the width is not within the standard,replace the reverse shift holderwith a new one. lf the width is within the standard,reolacethe reverse idler gearwith a new one.
13-20
Shift ForkAssembly
Disassembly/ReassemblY
I to dry cleanall the pans in solvent, them, and apply lubricant any contactparts erior,o reassembling,
3RD/,|THSHIFTFoRK 1ST/2NDSHIFTFORK
5TH/REVERSE SHIFTPIECE
5.0 PIN PUNCH, mm
13-21
Shift ForkAssembly
Inspection Clearance
NOTE:The synchrosleeveand synchrohub should be reolaced a set. as 1. Measure the clearance betweeneach shift fork and its matchingsynchrosleeve. Standard: 0.35- 0.65 mm 10.01/t 0.026inl ServiceLimit: 1,0 mm {0.039inl 3. Measurethe clearancebetweenthe shift fork and the shift arm A. Standard; 0.2- 0.5 mm (0.008-0.020 in) ServiceLimit: 0.6 mm (0.02i1 in) sTH/REVERSE SHIFT PIECE ran,rru
lST/2ND SI{IFTFORK
FORK SHIFT
lf the clearance exceeds the servicelimit, measure the width of the shift arm A. Standard: 12.9- 13.0mm 10.508 0.512inl
2.
lf the clearance exceeds the servicelimit. measure the thickness the shiftfork fingers. of
Standard: 3rd/4th shift fork 1sv2ndshiftfork 5th shift fork 7 . 4- 7 . 6m m (0.29 0.30in) 6 . 2- 6 . 4m m (0.24 0.25in)
lf the thickness the shift fork finger is lessthan of the standard,replacethe shift fork with a new one. lf the thickness the shift fork tinger is within of the standard,replacethe synchrosleevewith a new one.
lf the width of the shift arm A is less than the standard, reDlace shift arm A with a new one. the lf the width of the shift arm A is within the standard, replacethe shift fork or shift piecewith a new ones.
MainshaftAssembly
lndex
Notethe Iollowingduringreassembly: with a press. . The 3rd/4th, and 5th synchrohubs,and the ball bearingare installed outer racefacingthe stop ring . Installtheangularball bearingwith the thin-edged The prior to reassembling, clean all the parts in solvent,dry them, and apply lubricantto any contactsurfaces. them' with a pressbeforelubricating shouldbe installed 5th svnchrohubs,however, 3rd/4thand
ANGULAREALLBEARING for Check wear and operation. Note the direction of installation.
RING SYNCHRO page l3 37 Inspection,
SYOPRING
HUB SYNCHRO page13-36 lnspection, SLEEVE SYNCHRO page13 36 Inspection, SPRING SYNCHRO Inspection, page13-37 3RDGEAR Inspeclton, page13 24,37
TAPERRING BEARING Ior Check wear and operataon. COLLAR RING page13-37 Inspection, SPRING SYNCHRO HUB SYNCHRO page13_36 Inspection, SLEEVE SYNCHRO page13 36 Inspection, SPFING RING page13_37 Inspection,
BEARING
Checkfor wear ano operalton.
GEAR page13_25, 37 Inspection, page13 26 Inspection, COLLAR page13-24, 25 Inspection, NEEDLE BEARING for Check wear and operat,on. GEAR
I n s p e c t i o n ,p a g e 1 3 2 4 , 3 7
13-23
MainshaftAssembly
ClearanceInspection
NOTE; lf replacementis required,always replacethe synchrosleeve and hub as a set. L Support the bearing inner race with a socket.and Dushdown on the mainshaft. Measure clearance the between2nd and 3rd oears. Siandard: 0.06- 0.21 mm 10.002 0.008in) ServicaLimit: 0.3 mm (0.01in) 4. Measurethe clearancebetween 4th gear and the spacer coIar, Standard: 0.06- 0.21 mm {0.002- 0.008in) ServicLimit: 0.3 mm {0.01inl
2.
is lf the clearance more than the servicelimit, measure distance on the spacer collar, @ Standard: 26.03- 26.08mm {1.025- 1.027inl ServiceLimit: 26.01mm {1.02,[in]
lf the clearance more than the servicelimit, meais surethe thickness 3rd gear. of Standard: 34.92 34.97mm {1.375 1.377 in) Limit 34.8 mm (1.37in) Service
3RD GEAR
o[-l:-g;;em
fp-rro.ERcoLLAR
6. tf distance is lessthan the servicelimit, replace @ the sDacer collarwith a new one. lf distance@ is within the service limit. measure the thickness 4th gear. of Standard: 31.42 31.'17 mm 11.237 L239 inl SarviccLimit:31.3mm {1.23in)
lf the thickness 3rd gear is lessthan the serof vice limit, replace gearwith a new one. 3rd lf the thickness 3rd gear is within the service of limit, replace 3rd/4thsynchrohub with a new the one.
lf the thickness of 4th gear is less than the service limit, replace 4th gear with a new one. lf the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one,
13-24
Disassembly
7. Measurethe clearancebetweenthe spacer collar and 5th gear. 0.06- 0.21 mm {0.002- 0.008in) Standard: ServiceLimit: 0.3 mm {0.01in)
MAINSHAFT
1.
S u p p o r t5 t h g e a r o n s t e e l b l o c k s ,a n d p r e s st h e mainshaft out of the 5th synchrohub, as shown.Do not use a jaw-type puller, becauseit can damage the gearteeth.
PRESS
I
ACHMENT
SPACER COLLAR
SOCKET
5TH GEAR
8.
is lf the clearance more than the servicelimit, meacollar suredistance on the spacer @ 26.03- 26.08mm 11.025 1.027in) Standard: (1.024in) SrvicoLimit: 26.01mm
SPACER COLLAR
In the same manneras above,supportthe 3rd gear on steel blocks.and pressthe mainshaftout of the 3rd/4thsvnchrohub, as shown.
PRESS
5TH GEAR SIDE
9.
lf distance is lessthan the servicelimit, replace @ the spacer collarwith a new one. lf distance@ is within the service limit, measure of the thickness sth gear. in) Standard: 30.92 30.97mm (1.217 1.219 Service Limit:30.8mm (1.21in)
gt
r--\
I l.J'-----!--\--J -
Fq
,,srH GEAR
of lf the thickness 5th gear is less than the service limit, replace gearwith a new one. 5th li the thickness sth gear is within the service of l i m i t , r e p l a c e h e s t h s y n c h r oh u b w i t h a n e w t one.
BLOCKS
MainshaftAssembly
Inspection
1.
I n s p e c t h e g e a r s u r f a c ea n d b e a r i n gs u r f a c ef o r wear and damage,then measurethe mainshaftat pointsA, B, and C. Standard: mm A (Ballbearingsurface): 27.987 28.000 i 1 1 . 1 0 1 81 . 1 0 2 4n l B (Needlebearing surfacel:37.984- 38.000mm (1.4954 1.4961 inl -27.990 mm C {Baflbearingsurfacel: 27.977 ( 1 . 1 0 1-5 1 . 1 0 2 0n l i in) Service Limit:A:27.94mm (1.100 B: 37.93mm (1.'193 inl C: 27.94mm 11.100 inl
2.
Inspect runout. for in) Standard: 0.02mm (0.0008 max. inl ServiceLimit: 0.05 mm 10.002 N O T E : S u p p o r tt h e m a i n s h a f a t b o t h e n d s t shown.
lf the runout is more than the servicelimit, reDlace with a new one. the mainshaft
I n s p e c t o i l p a s s a g e sI o r c l o g g i n g .
lf anv oart of the mainshaftis lessthan the service limit. reolace with a new one. it
Reassembly
sequence. for to NOTE:Refer page13-23 reassembly 1. Suppon 2nd gear on steel blocks as shown, then i n s t a l lt h e 3 r d / 4 t hs y n c h r oh u b u s i n g t h e s p e c i a l tools and a pressas shown. inspectthe operationof the NOTE:After installing, 3rd/ 4th synchrohub set.
PRESS 3RD/4TH HUB SYNCHRO HANDLE 07749- 0010000
3.
I n s t a l lt h e a n g u l a rb a l l b e a r i n gu s i n g t h e s p e c i a l tools and a oress.Notethe directionof installation.

PRESS
I
,l(} DRIVER, mm l.O. 00 07746 - 0030'1 ATTACHMENT, /Vl x a7 mm BALLBEARING Notethe diredion o{ installation.
077a6 0011x100
2NO GEAR
2.
Installthe sth synchro hub using the specialtools and a press.

PRESS
I
mm l.D. DRlvER,40 077{6 - 00301(x)
ATTACHMENT, 35 mm l.D. 077i16- lx)3ollx)
HUB sTH SYNCHBO
13-27
Assembly Countershaft
Index
with a press. NOTE: 3rd, 4th.and sth gearare installed The
surfaces. The 3rd, to Priorto reassembling, cleanall the partsin solvent, them, and apply lubricant any contact dry with a pressbeforelubricating them. 4th,and sth gears,however. shouldbe installed
Replace. LOCKNUT 127-o-127N.m 113-0- 13kstmi 9.trbtft/ \94-0WASHER AEARING Check wear and ooeration. for BEARING for Check wear and operation. GEAR SPNING 4TH GEAR DOUBI.f CONE page13-37 Inspection, 3RD GEAR 1STGEAR page13 29,37 Inspection,
HUB IST/2ND SYNCHRO page13 36 Inspection, DAMPER lor Check wear and damage.
GEAR page13-30, 37 Inspection, BEARING NEEDLE for Check wear and oPeration SPACER page13-30 Selection, DAMPER
C h e c kf o r w e a r a n d d a m a g e .
BEARING tor Check wear and operation. THRUSTWASHER page13-29 Inspection,
DOUBLECONE page13-37 Inspection,
SPRING
Inspection Clearance
NOTE: lf replacement required,always replacethe us and hub as a set. synchrosleeve 1. Measurehe clearance etween he lst oearand t t b thrustwasher. Standard: 0.06- 0.18mm (0.@2- 0.007in) ServicaLimit:0.23 mm {0.009in) 3. is reDlace the lf the thickness lessthan the standard, thrust washer with a new one. lf the thicknessis l t o w i t h i n t h e s e r v i c e i m i t ,m e a s u r e h e t h i c k n e s s f t h e 1 s tg e a r . inl Standard: 26.95 27.00mm (1.061 1.063
THRUST WASHER
lf the thickness 1st gear is lessthan the stanof dard,replace1stgearwith a new one. lf the thickness lst gear is within the standard. of 1sv2ndsynchrohub with a new one. replace
2.
lf the clearance more than the servicelimit, meais surethe thickness the thrustwasher. of Standsrd: 1.95- 1.97mm (0.077 0.078in)
{cont'd}
13-29
Countershaft Assembly
(cont'dl Clearance Inspection
4. Measurethe clearancebetweenthe 2nd qear and 3rd gear. Standard: 0.07- 0.1,1 mm (0.003 0.006inl Service Limit:0.18mm (0.007 inl 6. lf the thickness lessthan the standard, is reDlace the spacer wrln a new one. lf the thickness within the standard, is measure the thickness the 2nd gear. of Standald: 28.92- 28.97mm (1.139 1.141 in)
FEET.ER GAUGE
. -]
lf the thickness 2nd gear is lessthan the stanof dard,replace 2nd gearwith a new one. lf the thickness lst gear is within the standard, of replace1sv2ndsynchrohub with a new one.
lf the clearance more than the servicelimit. meais surethe thickness the spacer. of Standard: 29.07 29.09mm (l.14il- 1.145 inl
13-30
Disassembly
1.
a S e c u r e l yc l a m p t h e c o u n t e r s h a f t s s e m b l yi n a benchvisewith wood blocks.

CHISEL
4.
damperfrom the spacerusinga the Remove Jriction pressand a socket.

PRESS
WASHEF SPRIiIG BETICH
vtsE
W(X)DBLOCKS
2.
Raisethe locknuttab from the groove in the countershaft,then remove the locknut and the spring washer. Remove the ball bearingusinga pressas shown. 5.
FRICTION DAMPER lor Inspect wear and damage.
S u p p o r t l s t g e a r o n s t e e l b l o c k s ,a n d p r e s st h e out countershaft of 3rd gear.

PRESS
3RD GEAR
1STGEAR
13-31
Inspection
1. I n s p e c t h e g e a r s u r f a c ea n d b e a r i n gs u r f a c eI o r wear and damage,then measurethe countershaft at pointsA, B, and C. A: 36.000 36.015 mm - f.ill79 inl 11.,1173 B: 36.98/t- 37.000mm inl {r.4561 1.4567 C: 24.987- 25.000mm {0.98:17 0.9843inl Limit: A:35,95mm (1.'115 Servics in) B: 36.93mm (1.454 in) C: 24.94mm (0.982 in)
Standa.d:
2.
Inspect runout. for Standard: 0.02 mm 10.0008 max. inl ServiceLimit: 0.05 mm {0.002inl N O T E :S u p p o r tt h e c o u n t e r s h a fa t b o t h e n d s a s t shown.
Rotate two complete revolutions.
lf the runout exceeds the servicelimit, reDlace the with a new one. countershaft
for lnspect wear and damage.
lf anv part of the countershaft lessthan the seris vice limit.reolace with a new one. it
13-32
Reassembly
Notetheseitemsduring reassembly: . Pressthe 3rd, 4th, and sth gear on the countershaft without lubrication. . When installingthe 3rd, 4th. and sth gears,suppon the shaft on steelblocksand installthe gearsusinga press. . Refer page 13-28 reassembly sequence. for to 1. 1st Install the thrustshim, needlebearing, gear,and frictiondamper. NOTE: Reassembly friction damper on the lst the gearbeforeinstallation. 2. Install the doublecone synchro.
OUTER
----.-4O) orn,leen rnrcrroru

lST GEAR
NEEDLE BEARING
3.
THRUST SHIM
Installthe 1sv2ndsynchrohub by align the friction damperfingerswith 1svzndsynchrohub grooves.
lST/2ND
(cont'd)
13-33
(cont'dl Reassembly
4. Reassembly frictiondamperon the spacerusing the the sDecialtools and a Dress. 6. Supportthe countershaft a steel blockas shown on and install 3rd gear using the specialtools and a press.
PRESS
PRESS
ATTACHMENT, U2t 47 mfi 07716- 0010300
3ROGEAR FRICTION DAMPER Inspect wear and for damage.
7.
Install the 2nd gear by align the synchrocone the fingers with 2nd gear grooves.
lnstall4th gear usingthe special tools and a press.

PRESS
ATTACHMENT, 35 mm LD. 07746- 0030,100 GROOVE
13-34
8.
tools and a press. Installsth gear usingthe special

PRESS
tools and a 10. Installthe ball bearingusingthe special press. PRESS I
40 DRIVER, mm l.D. 07715- 0030300
DRIVER. mm LD. 40 07746- 0030100 ATTACHMENT, 30 mm LD. 077a6- 0030300
ATTACHMENT, 30 mm LD. 077,16 0030300
l I n s t a l lt h e n e e d l eb e a r i n gu s i n g t h e s p e c i a t o o l s then installthebearingouter race and a press,

PRESS
a 1 1 .S e c u r e l yc l a m p t h e c o u n t e r s h a f t s s e m b l yi n benchvisewith wood blocks.

LOCKNUT Replace.
I
40 DRIVER. mm l.D. 077{6 - 0030100
ATTACHMENT, 30 mm l.D. 07746- 0030300
NEEDLE BEASING
wooD slocKs
the 12. Install springwasher. Installthe new locknutto the correcttorque, then stakethe locknuttab into the groove. Torque:127+ 0 + 127N.m 113 0 +13 kgf.m, 94+0-94|bf.ft)
13-35
SynchroSleeve, SynchroHub
Inspection
1.
Installation
When assembling synchrosleeveand synchrohub, the b e s u r e t o m a t c h t h e t h r e e s e t s o f l o n g e rt e e t h ( ' 1 2 0 degrees apart)on the synchrosleevewith the three sets of deepergroovesin the synchrohub. Do not installthe synchrosleevewith its longerteeth in the lsv2nd synchro hub slotsbecause will damagethe springring. it
Inspectgear teeth on all synchrohubs and synchro s l e e v e sf o r r o u n d e d o f f c o r n e r s ,w h i c h i n d i c a t e
I n s t a l le a c h s y n c h r oh u b i n i t s m a t i n gs y n c h r o sleeve, and checkfor freedomof movement. N O T E :l f r e p l a c e m e ni t r e q u i r e d a l w a y sr e p l a c e s , the synchrosleeve and synchrohub as a set.
SYNCHRO SLEEVE
SYNCHRO
LONGER ?EETH
SYNCHBO HUB SYNCHBO SI.EEVE
13-36
Ring,Gear Synchro
Inspection
1. SPRING SYNCHRO
Inspect synchroring and gear. the Ar lnspect the insideof the synchroring for wear. B: lnspectthe synchro sleeveteeth and matching of0. teeth on the synchroring for wear (rounded WORN GOOO sleeveteeth and matching Cr Inspectthe synchro off). teethon the geartor wear (rounded
SYNCHRO
CC
,,\n
(-l u WORN GOOO

for the D: Inspect gear hub thrustsurface wear. lor E: Inspect conesurface wear and roughness. the F: Inspectthe teeth on all gearsfor unevenwear, galling,and cracks. scoring, 2. Coatthe cone surfaceof the gearwith oil, and place the synchro ring on the matchinggear. Rotatethe synchroring, makingsurethat it does not slip. Measurethe clearancebetween the synchro ring a n dg e a ra l l t h ew a y a r o u n d . the gearevenNOTE:Holdthe synchroring against the ly while measuring clearance. Clearance Synchro Ring-to-Gear 0.85- 1.10mm (0.033- 0.0,lil in) Standard: inl ServiceLimit: 0.,1mm 10.02 Clearance Double Cone Synchro-lo-Goar Standard: @: {Outer Synchro Ring to Synchto Conel 0.5- 1.0mm (0.02 0.04in) ): {synchro cone to Geal) 0.5- 1.0mm (0.02 0.0i1inl Ring to Gearl @: louter Synchro 0.95- 1.68mm (0.037 0.056inl ServiceLimit: @: 0.3 mm (0.01inl @: 0.3 mm {0.01in} @: 0.6 mm {0.02in) is lf the clearance lessthan the servicelimit, replace the synchroring and synchrocone.
RING OUTERSYNCHRO
13-37
Differential
lndex
NOTE: lf the * mark parts were replaced,the tapered roller bearing preloadmust be adjusted(see page 1341).
*THRUSTSHIM Adiustment, Page13'41 +BEARING OUTERRACE page13 40 Beplacement, Inspect wear and damage. for *TAPERED ROLLER BEARING pagel3-39 Replacement, Inspect wear and damage. for
Backlash Inspection
1. P l a c e t h e d i f f e r e n t i a l a s s e m b l yo n V - b l o c k sa n d install both axles.
PINIONGEARS
1 0x 1 . 0m m 103N.m {10.5kgf m, 75.9lbf.ft} Left-handthreads
CARRIER page13 38 Backlash inspection, lnspect cracks. for
FINALDRIVEN GEAR page13-39 Replacement, Inspect wear and damage for
V-BLOCK
TRANSFER DRIVEN GEAR page13-39 Replacement, {or Inspect wear and damage.
2.
Measure backlash both piniongears. the ot Standard(Newl:0.05- 0.15mm (0.002 0.006inl lf the backlashis not within the standard,reolace the differential carrier.
W-
,,4\
*TAPERED ROLLER BEARING page13'39 Beplacement, Inspect wear and damage. for IEEARINGOUTERRACE page13-40 Replacement, Inspect wear and damage. for .75 mm SHIM
13-38
FinalDrivenGearRePlacement
L
RollerBearing Tapered
Replacement
Notetheseitems: . T h e t a p e r e dr o l l e r b e a r i n ga n d b e a r i n go u t e r r a c e as shouldbe replaced a set. . Inspect and adiustthe taperedroller bearingpreload the taperedrollerbearingis replaced' whenever for . Check taperedrollerbearings wear and rough the are lf rotation. the taperedrollerbearings OK, removal is not necessary. 1. using a bearing the taperedroller bearings Remove as pullerand a bearingseparator shown.
patternin several Removethe bolts in a crisscross steps,and removethe final drivengearfrom the difcarrier. ferential NOTE: The final driven gear bolts have left-hand threads.
1 0x 1 . 0m m kgf 103N.m (10.5 m,75.9lbf'ftl threads Left'hand
BEARING BEARING SEPAFATOB {Commercially
FINALDRIVENGEAR lnsoect{or weal and damage
ORIVEN GEAR TRANSFER Inspectfor wear and damage.
Installnew taperedroller bearingsusingthe special tool as shown. o N O T E :D r i v et h e t a p e r e dr o l l e r b e a r i n g s n u n t i l carrter. the differential they bottomagainst
PRESS
Installthe final driven gear by tighteningthe bolts patternin several steps. in a crisscross
IJ
ATTACHMENT, ,10x 50 mm 07LAD - PWs060l
13-39
Differential
Bearing Outer RaceReplacement
Notetheseitems: . The bearing outer race and tapered roller bearing shouldbe replaced a set. as . lnspectand adjustthe taperedroller bearingpreload whenever taperedrollerbearingis replaced. the '1. Remove the oil sealsfrom the transmission housing and clutchhousing(seepagej3-43). Drivethe bearingouter raceand thrust shim out of the transmissionhousing, or remove the bearing outer raceand 75 mm shim from the clutchhousing b y h e a t i n gt h e c l u t c h h o u s i n gt o a b o u t 2 1 2 " F (100"C)with a heat gun. Do not reuse the thrust shim if the outer racewas drivenout. 3. Installthe thrust shim or 75 mm shim and the beari n g o u t e r r a c e i n t h e t r a n s m i s s i o n o u s i n ga n d h clutchhousingusingthe special tools. Notetheseitemsduringbearingreplacement: . Install the bearingouter racesquarely. . Check that there is no clearancebetween the bearingouter race,thrust shim or 75 mm shim and housing. TRANSMISSION HOUSING:
2.
TRANSMISSION HOUSING:
HANDI-E 07749 - 00 xxto
ATTACHMENT, 62x68mm 077ir6- 0010500 ATTACHMENT 52x55mm 07746- 0010400
THRUSTSHIM
BEARING OUIER RACE
THRUSTSHIM
BEARING OUTERRACE
CLUTCH HOUSING:
HANDLE 07749 - 001tXX)o ATTACHMENT. 72xt5mm 07745 - 00106{x)
CLUTCH HOUSING:
OUTERRACE 75 mm SHIM
4,
lnstalltheoil seal(seepage13-43).
13-40
Adiustment Preload TaperedRollerBearing

the lf any oJthe itemslistedbelowwere replaced, tapered preload must be adjusted. rollerbearing . . . o . . 1. housing Transmission Clutchhousing carrier Differential rollerbearingand bearingouter race Tapered Thrustshim 75mm sham R e m o v et h e b e a r i n go u t e r r a c e a n d t h r u s t s h i m housing(seepage 13-40)' from the transmission NOTE: . Do not reusethe thrust shim if the bearingouter racewas drivenout. il cool to room temperature . Let the transmission the bearingouter race was removedby heating the clutchhousing. 2. Do not use more than one thrust shim to adjustthe t a p e r e db e a r i n gp r e l o a d .F i r s tt r y t h e s a m e s i z e There are no shims thrust shim that was removed. usedon the clutchhousingside 5.
4.
After installingthe thrust shim, installthe bearing outer race in the transmissionhousing (see page 13-40). W i t h t h e m a i n s h a f ta n d c o u n t e r s h a f tr e m o v e d , a l i n s t a l lt h e d i f f e r e n t i a a s s e m b l y , n d t o r q u e t h e housing. housingand transmission clutch to NOTE:lt is not necessary use sealingagent betweenthe housings. 8 TOBOUE; x 1.25mm: 27 N'm (2.8kgf'm, 20 lbt'ftl Rotatethe differentialassemblyin both directions to seatthe taperedrollerbearings. Measurethe taperedroller bearingpreloadat northe startingtorque Measure mal room temperature. with in both directions assembly of the differential tool and a torquewrench. the special STANDAFD:1.4- 2.5 N'm {1/r- 26 kgf'cm, 12 - 23 lbf in)
THRUSTSHIM
/A
07HAJ- PK4020'1
(cont'd)
13-41
Differential
Tapered RollerBearingPreload Adjustment(cont'd)
7. lf the tapered roller bearing preload is not within the standard, selectthe thrust shim which will give the correcttaperedroller bearingpreloadfrom the followingtable. N O T E :C h a n g i n g h e t h r u s t s h i m t o t h e n e x l s i z e t w i l l i n c r e a s e r d e c r e a s e a p e r e dr o l l e r b e a r i n g o t p r e l o a da b o u t 0 . 3 - 0 . 4 N . m ( 3 - 4 k g f . c m ,2 . 6 3.5 lbf.in). THRUST SHIM Part Numbe. 41381 PX5 000 B 41382 PX5 000 Thickness 1 . 9 0 m ( 0 . 0 7 4 i8 ) m n 1 . 9 3 m { 0 . 0 7 6 i0 ) m n '1.96 mm (0.0772 in) 1 . 9 9 m ( 0 . 0 7 8 i3 ) m n 2 . 0 2m m ( 0 . 0 7 9 i5 ) n 2.05mm (0.0807 in) 2 . 0 8m m ( 0 . 0 8 1 i9 ) n 2 . 1 1m m ( 0 . 0 8 3 i1 ) n 2 . 1 4m m ( 0 . 0 8 4 i3 ) n 2.'17 mm (0,0854 in) 2.20mm (0.0866 in) 2.23mm (0.0878 in) 2.26mm (0.0890 in) 2.29mm (0.0902 in) 2.32mm (0.09'13 in) 2.35mm (0.0925 in) 2.38mm (0.0937 in) 2.41mm (0.0949 in) 2.44mm (0.0961 in) 2.47mm (0.0972 in) 1 . 6 6 m ( 0 . 0 6 5 i4 ) m n 1 . 6 9 m ( 0 , 0 6 6 i5 ) m n '1.72 mm (0.0677 in) 1 . 7 5 m ( 0 . 0 6 8 i9 ) m n
1 . 7 8m m ( 0 . 0 7 0 1 n ) i
9.
How to select the correct thrustshim: - 1 ) C o m p a r et h e t a p e r e dr o l l e r b e a r i n gp r e l o a d you get with the thrustshim that was removed, w i t h t h e s p e c i f i e dp r e l o a do f 1 . 4 - 2 . 5 N . m (14-- 26 kgfcm, 12-23lbtinl. -2) lf your measured taperedrollerbearingpreload is less than specified. subtractyours from the specified, l f y o u r s i s m o r e t h a n s p e c i f i e ds u b t r a c tt h e , specified from your measurement. For examplewith a 2.17 mm (0.0854 thrust in) shiml 2.5 N.m (26 kgf.cm,23 lbiin) @ specified - you measure N.m (6 kgf.cm,5lbf.in) 0.6 1.9N.m(20kgicm, 18 tbt.in) tess 3.3 lbf.in) @ you measure N.m (34 kgf.cm,30 - specified 2.5 N.m (26 kgncm,23lbf.in) 0.8 N.m (8 kgf.cm,7lbt.in) more E a c hs h i m s i z e u p o r d o w n f r o m s t a n d a r d m a k e sa b o u t 0 . 3 - 0 . 4 N . . ( 3 - 4 k g f ' c m , 2.6- 3.5 lbf.in)difference taperedrollerbearin ingpreload. I n e x a m p l e@ , y o u r m e a s u r e d a p e r e dr o l l e r t b e a r i n gp r e l o a dw a s 1 . 9 N . m ( 2 0 k g f . c m , 1 8 l b f . i n ) l e s s t h a n s t a n d a r ds o y o u n e e d a thrust shim five sizesthickerthan standard{try t h e 2 . 3 2 m m ( 0 . 0 9 1 3i n ) t h r u s r s h i m . a n d recheck). ln example@, your measurement was 0,8 N.m {8 kgf.cm,7 lbf.in)more than standard, you so need a thrust shim two sizesthinner (try the 2.1'l mm {0.0831 thrustshim,and recheck). in)
c
n
41383-PX5-000
41384-PX5-000 41385-PX5-000
E
F G
n
41386-PXs-000
41387-PXs-000 41388-PX5-000 41389-PX5-000
J K M N
41390-PXs-000
41391 PX5- 000 4'1392-PX5-000 41393-PX5-000 41394-PX5-000
o
P
4 1 3 9 5P X s 0 0 0 , 41396-PX5-000 41397-PX5-000
o
S
4' t398-PXs-000 41399-PXs-000 41400-PXs-000

41873-P16-000 41874-Pl6-000 41875 P16- 000 41876-P16-000 41877-P16-000 41878-P16-000 41879-P16-000 AH 8. 41880-P16-000
T AB
AC AD AE AF
1 . 8 1 m ( 0 . 0 7 ' 1n ) m i3 '1.84 mm (0.0724in) 1.87mm {0.0736 in)
Recheck taperedrollerbearingpreload. the
13-42
Oil Seal Replacement

Housing: Transmission 1. housing the Remove oil sealfrom the transmission
OIL SEAL
Clutch Housing: 1. the Remove oil sealfrom the clutchhousing.
Replace.
lnstallthe new oil seal into the clutchhousingusing tools. the special 2. houslnstallthe new oil seal into the transmission tools. ing usingthe special jn) NOTE:Installoil sealup to i0.5 mm (10.02 from housingend surface. transmission
TRANSMISSION HOUSING
NOTE:Installoil seal up to t0.5 mm (t0.02 in) from housingend surface transmission

CLUTCH HOUSING
PRESS
PRESS HANOLE - @1OCIO0 .--.'/'01119 ATTACHMENT DRIVER
f
OIL SEAL Replace.
HANDLE 07749 - tx)l(xxto ATTACHMENT DRIVER OTJAD PHM1Ol
- PG4()r00
x PILOT,28 30 mm 07JAO- PH80400
PILOT, x 30 mm 28 07JAD - PH8oaU)
13-43
Transfer Assembly
lllustrated Index
ea/
g B
,AC
HOUSING O TRANSFER Replace. @ O-RING HUB O DAMPER BEARING G) NEEDLE DRIVENGEAR G) TRANSFER SHAFT TRANSFER G) OUTERRACE BEARING ROLLER O TAPERED BEARING ROLLER @ TAPERED SHAFTCOLLAR ) TRANSFER part SHIM,25 mm selective THRUST @ GEAR) DRIVEGEAR(HYPOID 6D TRANSFER RePlace WASHER SPRING @ CONICAL replace' threads, x LOCKNUT.22 1.25mm Left-hand SHAFT TRANSFER GD BEARING ROLLER TAPERED E) OUTERRACE BEARING ROLLER @ TAPERED part sHlM. 68 mm selective @ THRUST O o.RlNG Replace. COVERA @ TRANSFER COVERB TRANSFER GD Replace. @ O-RING GEAR} DRIVENGEARSHAFT(HYPOID ) TRANSFER SHIM,35 mm Selective Part @ THRUST BEARING ROLLER @ TAPERED RepIace. SPACEB @ TRANSFEB OUTERRACE BEARING ROLLER @ TAPERED OUTERRACE BEARING ROLLER @ TAPERED BEARING ROLLER @)TAPERED @ olL SEALReplace. FLANGE @ COMPANION Replace. @ O-RING RING @ BACK-UP Replace. WASHEB @ coNtcAL SPRING (o TRANSFER DRIVENGEARSHAFTLOCKNUT,22x 1.25mm Replace.
TOROUESPECIFICATIONS Boh/Nut No. 6A 8C 22L 22H Torque Value 12 N.m (1.2kgf.m.8.7lbf.ft) 24 N.m {2.4kgf.m,17 lbf'ft) 118N.m (12.0kgf.m,86.8lbf'ftl 1 3 2- 2 1 6N . m( 1 3 . 5 2 2 . 0k g f ' m , - 159lbf.ft) 97.6 Size 6x1.0mm m 8 x 1.25 m 2 2 x 1, 2 5m m 2 2 x 1. 2 5m m Remarks
shaftlocknut: Transfer threads Lett-hand driven gear shaft locknut Transfer on torque:dePending Tightening Torquevaiue TotalStarting
13-45
Transfer Assembly
Inspection
N O T E : T o p r e v e n t d a m a g e t o t h e t r a n s f e rh o u s i n g , always use soft jaws or equivalentmaterialsbetween the transferhousingand the vise. Transter Gaar (Hypoid goar) BacklsshMasurement 1. S e t a d i a l i n d i c a t o ro n t h e c o m p a n i o nf l a n g e a s shown. TransferGear lHypoid gearl Tooth Contaqt Inspction 5. Removetransfercover B, then apply Prussian Blue to both sides of the translergear teeth lightly and evenlv.
DIALINDICATOR
TRANSFER DRIVEGEAR COMPANION FLANGE
2.
Measure transfergear backlash. the STANDARD: 0.06- 0.16 mm {0.002- 0.006in} 7.
Rotate companion the flangein both directions until the transfergear rotatesone full tuln in both directions. Checkthe transfer gear tooth contact pattern.
Total Sta.ting Torquo Msasuremont 3. Rotatethe companionflange severaltimes to seat the taperedrollerbearing. M e a s u r et h e s t a r t i n gt o r q u e ( c o m p a n i o n l a n g e f side)usinga torquewrench. STANDARD: 2.68- 3.47 N.m {27.3- 35.4 kgf.cm.23.7- 30.7 tbt.in) lf the measurements the tooth contact Dattern or are not within the standard. disassemble transthe fer assembly, replaceworn or damagedparts,and reassemble it.
4.
1 3 -4 6
Disassembly
1.
the Remove transfercoversA and B. TRANSFER
3.
Hold the transfershaft with a 14 mm Allen wrench clampedin a benchvise.
TRANSFEF
Replace.
14 mm ALLENWRENCH
Loosenthe transter shaft locknut.The transfer shaft threads. locknuthaslett-hand transferdrive Removethe transfershaft assembly, gear,25 mm thrust shim. transfershaft collar.and from the transferhousing. taperedrollerbearing
TRANSFER SHAFT ASSEMBLY
Keepa t l usinga chisel. Cutthe locktabsofthe locknut particlesout of the transferhousing of the chiseled
ROLLER TAPERED BEARING SHAFT TRANSFER COLLAR DRIVE TRANSFER GEAR THRUSTSHIM, 25 mm pan Selective
LOCKNUT
LOCKTAB
(cont'd)
13-47
Transfer Assembly
(cont'd) Disassembly
Secure the transfer housing in a bench vise with soft jaws. COMPANION FLANGE
HOLDER 07RAA-
9. Remove the transferdrivengear shaft,then remove the transfer spacer from the transfer driven gear shaft. TRANSFER ORIVEN GEAR SHAFT
7.
I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o n l a n g e , f then loosenthe transferdrivengearshaft locknut. Remove transferdrivengear shaft locknut, the conical spring washer, back-upring, O-ring,and compsnionflange.
Removethe oil seal and the taperedroller bearing from the transferhousing,
OIL SEAL Replace.
TAPEREO ROLIIR AEARING
TRANSFER HOUSING
TRANSFER DRIVEN GEARSHAFTLOCKNUT Reolace,
13-4 8
DriveGearBearing Transfer
Replacement
NOTE:Coatall partswith MTFduring reassembly. 1. the Remove taperedrollerbearingfrom the transfer tools and a press. drive gear usingthe special
DrivenGearShaft Transfer Replacement Bearing

NOTE:Coatall partswith MTFduring reassembly. 1. rollerbearingfrom the transfer the Remove taDered drivengear shaftusinga pressand a collar.
ATTACHMENT, 37x/Omm 07746- 0010200
SEPARATOR, BEARING o - 1112"

{ C o m m e r c i a l l ya v a i l a b l e )
GEAR
SEPARATOR, BEARING 0 - 1112' available) lCommercially lnstallthe 35 mm thrust shim on the transterdriven gear shaft. Install the new taperedrollerbearingon the transfer toolsand a press. drivengearshaftusingthe special NOTE:Use old transferspacerfor bearinginstallation, then discardit.
DRIVER mm l.D. 40 07746- 0030r00
Installthe new taperedrollerbearingin the transfer tools and a press drive gear usingthe special
ATTACHMENT, 40x50mm 07LAD - PW5lr601
13-49
Transfer Assembly
Transfer Shaft Disassembly/
Reassembly
1. Support the transfer driven gear on steel blocks, then pressthe transfershaftout of damperhub,
Transfer GoverA Bearing Outer

RaceReplacement
1. NOTE:Coatall partswith MTFduring reassembly. Bemovethe taperedroller bearingouter racefrom t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e r t o a l m o s t ) 2 1 2 " F( 1 0 0 o Cu s i n g a h e a t g u n . D o n o t h e a t t h e coverover 212"F(100'C),
BEARING OUTERRACE
2. Align the damper hub groovesand transferdriven gear teeth,and reassemble damperhub. needle the bearing, and transferdrivengear. Install transfershaftusinga press. the
Install 68 mm thrustshim in transfercoverA. the
BEARING OUTERRACE TRANSFER COVER A ATTACXMCNT, 52x68mft 07746- tD,t0500
Install the tapered roller bearing outer race u sI n g the special tools and a press.
13-50
Replacement OuterRace Bearing Housing Transfer

NOTE:Coatall partswith MTFduring reassembly. 1. Removethe taperedroller bearingouter racefrom the transferhousing. HOUSING TRANSFER
SectionalView
Bealing Outer RaceLocations and SpecialTool APP|ications
ATTACHMENT, 62x68mm 07746- 0010500
ATTACHMENT, 62x68mm 07?a6- 0010500 ATTACHMENT, 52x55mm 07715- 0010400
HOUSING TBANSFER
I n s t a l lt h e n e w t a p e r e dr o l l e r b e a r i n go u t e r r a c e tools and a press usingthe special
DRIVER 07749- 0o1(xD0
J i=
\ l
HOUSING TRANSFER ATTACHMENT DRIVER
OUTER BEARING RACE
13-51
Transfer Assembly
Reassembly
Notetheseitemsduring reassembly: . While reassembling transferassembly: the - Checkand adjustthe transfer geartooth contact. - Measure and adjustthe transfergear backlash. - Checkand adjustthe taperedroller bearingstartIng rorque. . Coatall partswith MTFduring reassembly. . R e p l a c eh e t a p e r e dr o l l e rb e a r i n ga n d t h e b e a r i n g t outer raceas a set if eitherpart is replaced. . Replace the transferdrive gear and the transferdriven gear shaftas a set if eitherpart is replaced, Outlineof Assembly
1. EXAMPLE: C: EXISTING mm 35 THRUSTSHIM Thicknoss: C=1.05mm X: REPLACEMET{T35 mm THRUSTSHIM Thickness: X=??mm
Number: A=+2
Number: B-l
Select 35 mm thrustshim. the Performthis procedureif the transler driven gear shaft or the tapered roller bearingon the transfer drivengearshaft is replaced. Preassemble parts to checkand adjust transfer the gear backlash and transfergeartooth contact. Disassemble parts,then assemblethe transfer the drivengear shaftand its relatedparts. Measure and adjustthe staningtorque of the transfer drivengear shafttaperedrollerbearing. Assemble transfershaftand jts relatedparts. the Measure and adjustthe total startingtorque.
A: EXISTING TRANSFER DRIVEN GEARSHAFT
B: REPLACEMENT TRANSFER DRIVEN GEAFSHAFT
2.
3.
x- = A - B - .' 100 100 2 - 1 '100 100 = 0.02+ 0.01+ 1.05 -'1.08 (mm) S e l e c t3 5 m m t h r u s t s h i m t h i c k n e s so t ' 1 . 0 8 m m (0.043 lf the taperedrollerbearingon the transfer in). drivengear shaftis replaced. M e a s u r e h e t h i c k n e s s f t h e r e p l a c e m e nb e a r i n g t o t and the existingbearing, and calculate difference the of the bearingthickness. Adjust the thickness the of existing35 mm thrust shim by the amount of differencein bearingthickness. and selectthe replacement 35 mm thrustshim. Do not use more than one 35 mm thrustshim to adjustthe transfergear backlash, THRUST SHIM.35 mm
4.
5. 6.
35 mm Thrust Shim Seleqtion 1. Selectthe 35 mm thrust shim if the transferdriven gearshaftor the taperedrollerbearingon the transfer drivengear shaft is replaced. C a l c u l a t t h e t h i c k n e s s f t h e 3 5 m m t h r u s ts h i m e o usingthe formulabelow.
Shim No.
ronrvruu:fi--fr-+c=x
A: Numberon the existing transferdrivengearshaft B: Numberon the replacement transferdriven gear shaft C: Thickness ofthe existing35 mm thrustshim X : T h i c k n e s s e e d e df o r t h e r e p l a c e m e n3 5 m m n t thrustshim N O T E : T h e n u m b e r o n t h e t r a n s f e rd r i v e n g e a r shaft is shown in 1/100 mm.
c
E
F n
0.78 mm (0.031in) 0.81 mm (0.032in) 41365-PS3-000 0.84 mm (0.033in) 4 r 3 6 6 - P S 3 - 0 0 0 0.87 mm (0.034in) 41367-PS3-000 0.90 mm (0.035in)
Part Number 41361 PS3 000 41362-PS3-000 41363-PS3-000 41364-PS3-000
Thickness
0.72 mm (0.028in) 0.75 mm (0.030in)
4 1 3 6 8 - P S 3 - 0 0 0 0.93 mm (0.037in) 4 1 3 6 9 - P S 3 - 0 0 0 0.96 mm {0.038in) 4 1 3 7 0 - P S 3 - 0 0 0 0.99 mm (0.039in)

41371- PS3- 000 1.02mm (0.040in)
L
N
4 1 3 7 2 - P S 3 - 0 0 0 1 . 0 5m m ( 0 . 0 4 1n ) i 4 1 3 7 3 - P S 3 - 0 0 0 1.08mm (0.043in)
41374-PS3-000 1 . 1 1m m ( 0 . 0 4 4n ) i
13-52
TransterGear BacklashInspectionand TransferGear Tooth Contaqt Inspection 2. lnstallthe 35 mm thrust shim on the transferdriven g e a r s h a f t ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g tools and a press. usingthe special NOTE:Use old lransferspacerfor bearinginstallation, then discardit.
5.
Installthe transferdriven gear shaft in the transfer housing. Do not install the transfer spacer on the transferdrivengear shaftin this step.
TRANSFER HOUSING
6, DRIVEN TRANSFER GAR SHAFT
flange.conicalspringwasher, Installthecompanion and locknut on the transfer driven gear shaft. Do r n o t i n s t a l lt h e O - r i n ga n d t h e b a c k - u p i n g o n t h e transfergearshaft in this step.
HOUSING TRANSFER
3.
Install the bearingouter race,then the taperedbearf i n g o n t h e c o m p a n i o n l a n g es i d e o t t h e t r a n s f e r housing.

OIL SEALDRIVER ATTACHMENT 07JAD- PH80101 CONICAL SPRING WASHER direction.
DRIVER 077/tg - 001qt00
COMPANION FLANGE
Replace.
ROLLER TAPERED BEARING
I n s t a l lt h e n e w o i l s e a l o n t h e t r a n s f e r h o u s i n g tools. usingthe special
(cont'd)
13-53
Transfer Assembly
(cont'd) Reassembly
7. S e c u r et h e t r a n s f e rh o u s i n gi n a b e n c hv i s e w i t h soft jaws, then installthe specialtool on the companion flange. To preventdamageto the transfer housing,alwaysuse soft jaws or equivalent materials between transferhousingand the vise. the COMPANION FLANGE HOLDER 07RAB 0020000 9. Installthe transfer shaft assembly in the transfer h o u s i n g ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g , t r a n s f e rs h a f t c o l l a r , 2 5m m t h r u s t s h i m , t r a n s f e r drive gear, conical spring washer, and locknut on the transfer shaft. NOTE: . C o a t t h e t h r e a d so f t h e l o c k n u t , n d t h e s h a f t a with MTFbeforeinstalling locknut. the . Do not stakethe locknutin this step.
TRANSFER SHAFT ASSEMBLY
TRANSFER
WRENCH THRUSTSHIM. 25 mm Selectivepart COLLAR TRANSFER DRIVE GEAR CONICAL SPRING WASHER Replace.
8.
T i g h t e nt h e l o c k n u tw h i l e m e a s u r i n g h e s t a r t i n g t torque so the starting torque is within 0.98 - 1.39 N.m {10.0 14.2kgf.cm. 8.68- 12.3lbf.in). NOTE: . C o a t t h e t h r e a d so f t h e l o c k n u t , n d t h e s h a f t a with MTFbeforeinstalling locknut. the . Do not stakethe locknutin this step. STARTING TOROUE: 0.98- 1.39N.m (10.0 14.2kgf.cm, 8.68- 12.3lbf.in)
Replace.
10. Hold the transfershaft with a 14 mm Allen wrench clampedin a benchvise.

TOROUE WRENCH '14.
Rotatethe companionflange severaltimes to seat the taperedrollerbearing. Set a dial indicatoron the companionflange,then the measure transfergear backlash. STANDARD: - 0.15mm 10.002 0.006in) 0.06
DIALINDICATOR
WRENCH lil mm ALLEN 1 1 .Tightenthe transfershaftlocknut. NOTE: threads, . The transfershaft locknuthasleft-hand . Do not stakethe locknutin this step. TOROUE:118 N.m (12.0kgf.m,86.8 lbf.ft) installthe transfercover A without the Temporarily O-ring.
FLANGE COMPANION l f t h e m e a s u r e m e n ti s n o t w i t h i n t h e s t a n d a r d , the removethe transfershaft locknutand replace 25 m m t h r u s t s h i m . S e l e c ta n d i n s t a l la n e w 2 5 m m Do the thrust shim. then recheck measurement. not use more than one 25 mm thrust shim to adjustthe transfergear backlash, THRUST SHlM,25mm
Shim No.
I
Part Numbel
Thickness
rl0ustNG
2 3
5
mm 10.067 in 2 9 4 1 r P 1 C 0 0 0 1.70 'L73 mm (0.068in 29412-PlC-000 2 9 4 1 3 - P 1 C - 0 0 0 1.76mm (0.069in 2 9 4 1 4 - P l C - 0 0 0 1.79mm (0.070in 2 9 4 1 5 - P 1 C - 0 0 0 1.82mm (0.072in
1.85mm (0.073in 2 9 4 ' 1 7 - P r C - 0 0 0 1.88mm (0.074in i 2 9 4 ' 1 8 - P 1 C - 0 0 01 . 9 1m m ( 0 . 0 7 5n ) 29416-PlC-000
6
7 8
'10
11 A COVER TRANSFER
12 13
l4 16 17 19
'18
2 9 4 1 9 - P l C - 0 0 0 1.94mm (0.076in) in) 2 9 4 2 0 - P 1 C - 0 0 0 1.97mm 10.078 in) 29421 P1C 000 2.00mm (0.079 mm (0.080 in) 29422-P1C - 000 2.03 in) 2 9 4 2 3 - P 1 C - 0 0 0 2.06mm (0.081 2 9 4 2 4 - P 1 C - 0 0 0 2.09 mm (0.082in) i 29425-P'tC-000 2 . 1 2m m ( 0 . 0 8 3n ) i 2 9 4 2 6 - P 1 C - 0 0 0 2 . 1 5m m ( 0 . 0 8 5n ) -P1C-000 i 29427 2 . 1 8m m { 0 . 0 8 6n ) 2 9 4 2 8 - P 1 C - 0 0 0 2.21 mm {0.087in) in) 2 9 4 2 9 - P 1 C - 0 0 0 2.24 mm 10.088
8xL25mm 24 N.m (2.4kgt.m. 17 lbnftl
(cont'd)
13-55
TransferAssembly
(cont'dl Reassembly
16. Apply PrussianBlue to both sides of the transfer gearteeth lightlyand evenly. 19. lf the transfergear tooth contactis incorrect, adjust the transfergear tooth contactwith a 35 mm or 25 m m t h r u s ts h i m . NOTE: . To selecta 35 mm thrust shim, referto page '13. Do not use more than one 35 mm shim to adjust the transfergeartooth contact. . To selectthe 25 mm thrust shim, refer to page 13-55. a Do not use more than one 25 mm shim to adjust the transfergeartooth contact. Toe Contact U s e a t h i c k e r3 5 m m t h r u s t s h i m t o m o v e t h e transferdriven gear shaft toward the transferdrive gear. Becausethis movement causesthe transfer gear backlashto change,move the transfer drive gear away from the transfer driven gear shaft to gearbacklash iollows; adjust transfer the as . I n c r e a s eh e t h i c k n e s s f t h e 2 5 m m t h r u s t t o shim. . R e d u c et h e t h i c k n e s so f t h e 6 8 m m t h r u s t shim bv the amount of increased thickness of the 25 mm thrustshim. Heol Contact Use a thinner 35 mm thrust shim to move the transfer driven gear shaft away from the transfer drive gear. Because this movement causesthe transfer gear backlash change,move the transto fer drive gear toward the transferdriven gear shaft to adjustthe transfergear backlash follows: as . R e d u c et h e t h i c k n e s so f t h e 2 5 m m t h r u s t s hi m . a I n c r e a s eh e t h i c k n e s s f t h e 6 8 m m t h r u s t t o shim by the amount of reducedthicknessof t h e 2 5 m m t h r u s ts h i m . Flank Contact Use a thinner thrust shim to move the transfer drive gear toward the transferdriven gear shaft. Flankcontactmust be adtusted within the limits o f t h e t r a n s f e rg e a r b a c k l a s h l. f t h e b a c k l a s h e x c e e d s h e l i m i t s ,a d j u s ta s d e s c r i b e d n d e r t u HeelContact. FaceContsct Use a thickerthrust shim to move the transfer drive gear away from the transfer driven gear shaft. Facecontactmust be adjustedwithin the limits of the transjergear backlash. the backlf l a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e d underToe Contact.
TRANSFER DRIVEGEAR
1 7 . Rotate companion the flangein both directions until the transfergear rotatesone full turn in both directions. 1 8 . Check transfergeartooth contactpattern. the CORREST TOOTH CONTACT PATTERN
PATTERN INCORRECT IOOTH CONTACT
TOECONTACT
HEELCONTACT
FLANKCONTACT
FACECONTACT
13-56
20. Remove the partson the transfershaft,and remove the transfershattfrom the transferhousinq.
TRANSFER SHAFT
Remove the transterdrivengear shaftand the companionflange. Installthe new transferspaceron the transferdriv e n g e a r s h a f t ,t h e n i n s t a l lt h e m i n t h e t r a n s f e r housing.
TRANSFER SPACER Install this direction. in
DRIVEN TRANSFER TRANSFER HOUSING GEARSHAFT
TRANSFER
TAPERED ROLLER BEARING TRANSFER SHAFT COLLAR TMNSFER DRIVE GEAR THRUSTSHIM,25 mm Selectivepart CONICAL SPRING WASHER Replace.
LOCKNUT Replace. Transter Driven Gear Shaft Starting Torque Inspection and Adlustment 21. Securethe transfer housing in a bench vise with soft iaws.
COMPANION FLANGE HOLDER
25. Installthe companionflange,O-ring,back-upring, conical spring washer and locknut on the transfer drivengear shaft. NOTE: . Coatthe threadsof the locknut, O-ringand transfer shaftwith MTFbeforeinstalling locknut. the . Installthe conicalspring washer in the direction shown. TRANSFER HOUSING
O.RING COMPANION FLANGE CONICAL SPRING WASHER Replace. BACK.UP LOCKNUT Replace.
22. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g ,
then removethe transferdriven gear shaft locknut and the conicalspringwasher.
(cont'd)
13-57
Transfer Assembly
(cont'dl Reassembly
26. Securethe transfer housing in a bench vise with soft jaws. COMPANION FLANGE HOLDER 07RAB 002tD00 28. Stakethe locknutinto the transferdriven oear shaft u s i n ga 3 . 5m m p u n c h .
0.7- 1.2mm (0.03- 0.05 inl PUNCH 3 . 0 - 3 . 5m m 10.12 0.1ainl
Point to be staked.
29. Installthe transfer shaft assemblv in the transfer h o u s i n g ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g , transfer shaft collar, 25 mm thrust shim, transfer drive gear,conicalspringwasher,and transfershaft locknuton the transfershaft. 2 7 . I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o n l a n g e . f then tighten the transferdriven gear shaft locknut while measuring the startingtorque of the transfer drivengearshaft. STARTING TOROUE: 0.98- 1.39N.m kgf.cm,8.68- 12.3lbf in} {10.0- 1i1.2 TIGHTENING TOROUE: 132- 216 N.m (13.5 22.0kgf.m,97.6- 159lbf.ft) NOTE: . R o t a t et h e c o m p a n i o n l a n g e s e v e r a lt i m e s t o f seatthe taperedrollerbearing, then measure the startrng torque. . l f t h e s t a r t i n gt o r q u e e x c e e d s1 . 3 9 N . m ( 1 4 . 2 kgf.cm, 12.3 lbf.in), .eplacethe transfer spacer a n d r e a s s e m b l eh e p a r t s . D o n o t a d j u s t t h e t torquewith the locknutloose. . l f t h e t i g h t e n i n g o r q u ee x c e e d s 1 6 N . m ( 2 2 . 0 t 2 kgf.m,159 lbf'ft),replace the transferspacerand reassemble parts. the . W r i t e d o w n t h e m e a s u r e m e no f t h e s t a r t i n g t torque: it is used to measurethe total starting torque. NOTE: . Coatthe threadsof the locknutand transfershaft with MTFbeforeinstalling locknut. the . lnstallthe conicalspringwasher in the direction snown.
TMNSFER SHAFT ASSEMBLY
TRANSFER HOUSING
TAPERED ROLLER BEARING TRANSFER SHAFT COLLAR TRANSFER DRIVE GEAR THRUST SHIM,25 mm Selectivepart
CONICAL SPRING WASHEB Replace. LOCKNUT Replace.
30. Hold the transfershaft with a 14 mm Allen wrench in clamDed a benchvise. threads. NOTE:The locknuthas left-hand 118 TOROUE: N.m (12.0kgt'm,86.8lbf'ft)
Totsl Starting Torquo Inspoctionand Adiustment 32. Temoorarilvinstalltransfercover A without the Oring. TRANSFER HOUSING
A TRANSFER COVER
l E /Eh
v
14 mm ALLENWRENCH
5t.
/E\ \g
8 x 1.25 mm 24 N.m (2.4kg{ m, 17 lbtftl
Securethe transfer housing in a bench vise with flange several soft jaws. then rotatethe companion times to fit the taperedrollerbearing,
31. Stakethe locknuton the transfershaft using a 3.5 mm Dunch.
PUNCH 3.0- 3.5 mm {0.12 0.14inl
WRNCH TOROUE
the 34. Measure total startingtorque. TOTALSTARNNGTOROUE: lbf 1.70- 2.08N.m 117.3 21.2kgf.cm,15.0- 18.i1 inl + Transter Driven Gear Shaft Starting Torque Value (wrot down in step 27).
(cont'd)
13-59
TransferAssembly
(cont'd) Reassembly
3 5 . Remove transfercoverA. is remove 36. lf the measurement out of specification, t h e 6 8 m m t h r u s t s h i m f r o m t r a n s f e rc o v e r A b y h e a t i n g h e c o v e rt o a l m o s t2 1 2 ' F( 1 0 0 ' C ) s i n ga u t heat gun. Do not heat the cover higher than 212F ( 1 0 0 " C )L e t t h e c o v e r c o o l t o r o o m t e m p e r a t u r e . beforeadjusting startingtorque. the go lI the measurement within the specification, to is step 40. 37. Select 68 mm thrustshim. the THRUST SHIM,68 mm
Shim No. Part Number 23914-P1C-020 23975-P1C-020 23916 PlC -020 -P1C-O20 23917 23978-PlC-020 23941 PW5 000
Thickne3s
zv
zw
zx
ZI
zz c
D E F G
1.41mm (0.056 in) '1.44 mm 10.057 in) '1.47 mm (0.058 in) 1.50mm (0.059 in) 1.53mm (0.060 in)
1.56mm {0.061 in) 1.59mm (0.063 in) 2 3 9 4 3 - P W 5 - 0 0 0 't.62mm (0.064 in) 23944 PW5- 000 1.65mm (0.065 in) 2 3 9 4 5 - P W s - 0 0 0 1.68mm (0.066 in) 23942-PWs-000 23946-PW5-000 23947-PW5-000 1.71mm 10.067 in) '1.74 mm 10.069 in) 23948-PWs-000 1.77mm (0.070 in) 2 3 9 4 9 - P W s - 0 0 0 1.80mm (0.071 in) 2 3 9 s 0 - P W 5 - 0 0 0 1.83mm (0.072 in) 23951 PW5- 000 1.86mm (0.073 in) 23952-PWs-000 23954-PW5-000 23955-PW5-000 23956- PW5, 000 1.89mm {0.074 in) 1.95mm (0.077 in) 1.98mm (0.078 in) 2.01mm (0.079 in)
HEAT GUN
COVER A
K L
N
2 3 9 s 3 - P W s - 0 0 0 1.92mm {0.076 ini
o
P
o
R BEARING OUTERRACE
2 3 9 5 7 - P W s - 0 0 0 2.04mm (0.080 in) 2 3 9 5 8 - P W s - 0 0 0 2.07mm (0.081 in)

23959-PW5-000 23960-PW5-000 23961- PW5- 000 23962-PW5-000 2.10mm (0.083 in) 2.13mm (0.084 in) 2.16mm (0.085 in) 2.19mm (0.086n) 2.25mm (0.089n) 2.31mm {0.091 in) 2.37mm (0.093 in) 2.43mm (0.096 in) 2.46mm {0.097 'n} 2.49mm (0.098 in) 2.52mm {0.099 ini 2.55mm (0.100 in) 2 . 5 8 m ( 0 . 1 0 i2 i m n
T U
2 3 9 6 3 - P W s - 0 0 0 2.22 mm (0.087 n)
X 23964-PWs-000 23966-PW5-000
2 3 9 6 5 , P W s - 0 0 0 2.28mm 10.090 ) n 2 3 9 6 7 - P W s - 0 0 0 2.34mm (0.092 in) AB

AC AD M BZ 23968-PWs-000 23970-PW5-000 23941- PW8- 000 23942-PW8-000 23943-PW8-000 23944-PW8-000 23945-PW8-000
2 3 9 6 9 - P W s - 0 0 0 2.40mm {0.094 in}
cz
DZ
EZ
13-60
3 8 . I n s t a l lt h e 6 8 m m t h r u s t s h i m u s i n g t h e s p e c i a l tools.
4 0 . C o a t t h e n e w O - r i n g sw i t h M T F , i n s t a l lt h e m o n transfercoversA and B, then installthe coverson the transferhousing.
DRIVER 077 - 001(xno
6x1.0mm kgf.m, 12 N.m 11.2 8.7 tbt.ft)
TRANSFER COVERB
TRANSFER
THRUSTS1{IM, 68 mm Selectivepart OUTERBACE BEARING ATTACHMENT. 62x68mm 077a6 - (x)10500
O.RING Replace.
O.BING Replace.
and the 39. After replacing 68 mm thrust shim, recheck m a k e s u r e t h e t o t a l s t a r t i n gt o r q u e i s w i t h i n t h e soecification.

TRANSFER A COVER
8 r 1.25mm 2,r N.m (2.4 kgl.m. 17 lbtft)
13-61
Bearing/Oil Seal Mainshaft

Replacement
1. the ball bearingusingthe specialtool. Remove 3. side Drivethe new oil seal in from the transmission tools. usingthe special
3/8" -16 SLIDEHAMMER (Commercially available)
ATTACHMENT,
12x 17 .nfi
07746- 0010300
mm PULLER.25 ,10 07736- A01000A
Drivethe new bali bearingin from the transmission tools. side usingthe special 2. Remove oil sealfrom the clutchhousing. the
ATTACHMENT. 62x68mm 07746- 0010500
BALLBEARING
13-62
Bearing Gountershaft
Replacement
1. platefrom the clutchhousing. Remove retaining the Position oil guide plate. the Drivethe needlebearingusingthe special tools.
Replace.
HOUSING CLUTCH PLATE HETAINING
Removethe needlebearingusing the specialtool, then removethe oil guide plate.

ATTACHMENT, 62x88mm 07746- 0t!105q)
3/8" -16 SLIDEHAMMER (Commercially available)
NEEDII AEARING
TIOUSING CLUTCH
Installthe retainingplate,and stakethe bolt heads plate into the groovein the retaining
^'
ADJUSTABI.fBEARING PULLER,25 40 mm 07736- A01(x)04
6x1.0mm 12 N.m (1.2 kgt m,8.7 lbtftl
NEEDLE BEARING
13-63
MainshaftThrustClearance
Adjustment
l. Removethe 78 mm shim and oil guide plate from housing. the transmission
78 mm SHIM
5,
Measuredistance betweenthe end of the clutch @ housingand bearinginner race. NOTE: . Usea straightedgeand depthgauge. . Measure three locations and avorage readthe at Ings.
END ot CLUTCH HOUSING
BEARING
Installthe 3rd/4th synchro hub, spacer collar, sth synchrohub, spacer,and ball bearingon the mainshaft.then installthe above assemblyin the transmissionhousing. lnstallthewasheron the mainshaft. 4. Measuredistance betweenthe end of the trans@ missionhousingand washer, NOTE: . Usea straightedgeand verniercaliper. . Measure three locations at and average the readIng. ENDot
TRANSMISSION MAINSHAFT
Selectthe proper 78 mm shim from the chan by usingthe formulabelow. Shim Slection Formula: you Fromthe measurements made in steps4 and 5: -1. Add distance (step5) to distance (step4). @ @ -2. From this number. subtract0.93 (which is the midpointof the flex rangeof the clutchhousing bearingspringwasher). -3. Takethis number and compareit to the availableshim sizesin the chart.
WASHER
(Forexample) A: 2.39 + Bi O.22

3RD/4THSYNCHRO HUB COLLAR SPACER HUB sTH SYNCHRO SPACER BALLBEARING
2.61 - 0.93 = 1.68
2.61
in) Try the 1.68mm (0.0661 shim.
13-64
78 mm SHIM Part Numbor 23941 P16 000 23942-P16-000 23943-P16-000 23944-Pt6-000 23945-P16-000 23946- 16 000 P 23947-P16-000 23948-P16-000 23949-P16-000 23950-P16-000 23951 P16 000 23952-Pl6-000 23953-P16-000 23954-P16-000 23955-P15-000 23956 P16 000 23957-P16-000 P 23958- 16 000 23959-P16-000 23960-P16-000 23961 P16 000 23962-P16-000 23963-P16-000 23964-P16-000 23965-P16-000 23966-Pl6-000 23967-Pl6-000 23968-P16-000 23969-Pl6-000 2397- Pl6-000 0 23971 P16 000 23972-P16-000 23973-P16-000 23974-P16-000 23975-P16-000 23976-Pl6-000 23977-P16-000 23978-Pl6-000 23979-Pl6-000 23980-P16-000
Thickness in) 1.20mm (0.0472 in) 1.23mm (0.0484 '1.26 in) mm (0.0496
7,
in Checkthe thrust clearance the mannerdescribed Delow. N O T E : M e a s u r e m e ns h o u l d b e m a d e a t n o r m a l t room temperature. -1. Installthe 78 mm shim selected and oil guide platein the transmission housing.
78 mm SHIM OIL GUIDEPLATE
c
u
F G H
mm (0.0508 in) 1.29 n 1.32 mm (0.0520 ) n 1.35 mm (0.0531 ) mm {0.0543 ) n 1.38

1.41mm (0.0555n ) in) 1.44mm (0.0567 in) 1.47mm (0.0579 1.50mm {0.0591 in}
K L
M N
in) 1.53 mm (0.0602

in) 1.56mm (0.0614 in) 1.59mm (0.0626
in) 1.62 mm (0.0638

in) 1.65mm (0.0650 1.68mm (0.066't in) 3 1 . 7 1m m ( 0 . 0 6 7 i n ) 1.74mm {0.0685 in) mm {0.0697 inl 1.77
- 2 . I n s t a l lt h e s p r i n g w a s h e ra n d w a s h e ro n t h e
ball bearing. NOTE: . Cleanthe spring washer,washerand thrust shim thoroughlybeforeinstallation. . Installthe spring washer,washerand thrust shim properly.
in) 1.80 mm (0.0709 in) 1.83 mm (0.0720 '1.86 (0.0732 in) mm

in) 1.89mm (0.0744 1.92mm (0.0756 in) in) 1.95mm (0.0768
X z AB AD AE
in) 1.98 mm (0.0780 in) 2.01mm (0.0791 in) 2.04mm (0.0803 n 2 . 0 7 m { 0 . 0 8 1i 5 ) m

in} 2.10 mm {0.0827
g
,-g
WASHER
SPRTNG*ASHER
in) 2.13mm (0.0839

in) 2.16 mm (0.0850
AH AI
AJ
AK
AN
in) 2.19mm (0.0862 4 2.22mm 10.087inl in} 2.25mm {0.0886 2.28mm {0.0898 in) in) 2.31mm (0.0909 2.34mm (0.0921 in) 2.37mm (0.0933 in)
in Install the mainshaft the clutchhousing. housingover the mainPlacethe transmission shaftand onto the clutchhousing. - 5 . Tightenthe clutch and transmissionhousings with several mm bolts. 8 to NOTE:lt is not necessary use sealingagent between the housings. with a plastichammer. Tap the mainshaft (cont'd)
13-65
MainshaftThrustClearance
Adjustment(cont'dl
-7. Slidethe mainshaft baseoverthe mainshaft. -12. Turn the mainshaftholder bolt clockwise; stop t u r n i n gw h e n t h e d i a l g a u g e h a s r e a c h e d t s i maximum movement,The readingon the dial gaugeis the amountof mainshaft end play. NOTE:Turningthe mainshaftholderbolt more t h a n 6 0 d e g r e e sa f t e r t h e n e e d l eo f t h e d i a l gaugestopsmoving may damagethe transmission.
MAGNETSTANDAASE 07979- PJ40001 DIALGAUGE
07GAJ- PG20130
-8. Attachthe mainshaft holderto the mainshaft as follows: NOTE: . B a c k - o u t h e m a i n s h a f t o l d e rb o l t a n d h loosenthe two hex bolts. . Fit the holderover the mainshaft its lip is so towardsthe transmission. . Align the mainshaftholder'slip around the groove at the insideof the mainshaft splines, then tightenthe hex bolts. HOLDER MAINSHAFT BOLT
MAINSHAFT HOLDER 07cru - PG20110
-13. lf the readingis within the standard, the clearancers correct. l f t h e r e a d i n gi s n o t w i t h i n t h e s t a n d a r d , recheck shim thickness. the Standard: 0.11- 0.18mm (0.00i10.007inl
l"\y I aors t____=__)"n-____"8

\
MAINSHAFT HOLDER 07GAJ- PG20110
t--E-Hl\. lf\f,A\
xex
MAINSHAFT EASE 07GAJ PG20130 -9. Seatthe mainshaft fully by tappingits end with a plastichammer. -10. Threadthe mainshaftholder bolt in until it just c o n t a c t st h e w i d e s u r f a c eo f t h e m a i n s h a f t base. - 1 1 . Z e r oa d i a lg a u g eo n t h e e n d o f t h e m a i n s h a i t .
Reassembly
1. Installthe differential assemblyin the clutch housIng.
ASSEMBLY DIFFERENTIAL
4.
'97 - 99 models: Installthe reverseidle gaar and reverse gear shaft in the clutch housing. '00 model: Installthe coller,thrust washer,reverse idler gear and the reversegear shaft in the clutchhousing.
model
THRUSTWASHER
Install the springwasherand washerwith the angle against clutchhousingas shown. the Tape the mainshaft splines. insert the mainshaft and countershaft into the shift forks, and install them as an assemblv. 5.
COLLER
NOTE:Installthe reversegear shaft ('00 model) in the direction shown. Installthe reverse shift holderin the clutch housing with the sth/reverse shift piecepin positioned the in slot of the reverseshift fork.
5x1.0mm 15 N'm 11.5 kgt.m, 11 lbf.ftl
Tapethe mainshatt splines.
REVERSE SHIFTHOLDER
(cont'd)
13-67
Assembly Transmission
(cont'dl Reassembly
6. Installthereverse lockcam on the clutchhousing.
6x1.0mm 15 N.m (1.5kgf.m, 11 lbf.ftl
10. Apply liquid gasket (P/N 08718- 0001 or 087180003)to the selectspring bolt threads,then install the selectspringbolt.
SELECTSPRINGBOLT 39 N.m la.o kgf'm,29lbtft)
LOCKCAM REVERSE
7.
l n s t a ltl h e o i l s e a l .
HANDLE 07749- 001mO ATTACHMENT, 32x35mm 07745- 0010100
'I1. I n s t a l t h e o i l g u i d e M p l a t e . 7 8m m s h i m , l and oil guner platein the transmission housing. N O T E : S e l e c tt h e 7 8 m m s h i m a c c o r d i n g o t h e t measurements madeon page13-64,
OIL SEAL Replace.
Installthe selectlever,spring washer,and springs on the selectarm. SELECT LEVER
SELECT BETURN SPRING 5TH/REVERSE SELECT RETURN
SPRING PIN Replace.
OIL GUIDEM PLATE
SELECT ARM 9. p I n s t a l l t h e e l e c a r m a n ds p r i n g i n . s t
13-68
12. Apply liquid gasketto the surfaceof the transmission housingas shown. Notetheseitems: . Use liquid gasket(P/N 08718- 0001 or 087180003). . Remove surface. the dirty fluid from the sealing . Sealthe entirecircumterence the bolt holesto of preventfluid leakage. . lf 20 minutes have passedafter applying liquid gasket, reapplyit and assemble housings. the a Allow it to cure at least20 minutesafter assemwith MTF. bly betorefillingthe transmission
housingwith the snap ring 15. Lowerthe transmission pliers.and set the snap ring into the groove of the countershaft bearing.
SNAPRINGPLIERS
DOWELPINS
r3. Installthe 14 x 20 mm dowel pins.

1 4 . Set the stopperring as shown. Placethe transmis-
1 6 . Checkthat the snap ring is securelyseatedin the grooveof the countershaft bearing. DimensionA as installod:3.6 - 6.3 mm (0.142- 0.2/8 in)
32 mm SEALINGBOLT kgf.m, 18 lbf.ftl 25 N m 12.5
sion housingover the clutchhousing,being careful to line up the shafts.Be sure to align the stop ring with the 5th shift fork fingertip.
SNAPRING
vk..*,
SHIFTFORK Align point
1 7 . A p p l y l i q u i d g a s k e t( P / N0 8 7 1 8- 0 0 0 1o r 0 8 7 1 8 then install 0003)to the 32 mm sealingbolt threads, (cont'd) the 32 mm sealingbolt.
13-69
Reassembly lcont'd)
18. Installtransmission hanger, then tightenthe bolts in patternin several a crisscross stepsas shown. 8 x 1.25mm bolis: 27 N.m 12.8kgf.m,20 lbf'ft}
TRANSMISSION HANGER
2 0 . I n s t a l lt h e s t e e l b a l l s ,s p r i n g s .w a s h e r s ,s e t b a l l light switch. screws,back-up WASHER Replace.

STEELBALL D,5/16 in
SPRING L.26.1mm 11.03 inl
1 9 . Install flange bolt, w a s h e r s d r a i n p l u g . a n d f i l l e r , plug. 21. Installthevehiclespeedsensor(VSS).

FILLER PLUG 4,r N.m (a.5 kgl.m,33lbtftl DRAINPLUG 39 N.m {4.0kg{.m,29lbtftl WASHER Replace. 8 x 1.25mm 22 N.m 12.2 kgl.m, 16 lbt.ftl WASHER VEHICI."E SPEEDSENSOR
13-70
22. Turn the selectlever and shift arm shaft counterthen insertthe shift arm shaft. clockwise,
EOLT INTERLOCK 39 N.m (4.0kqt ft, 29 lbf ft) ARM SELECT
the shift arm coverassembly. 26. Install
ASSEMBLY SHIFTARM COVER
->.-
10 x 12 mft DOWELPIN SHIFTARM A SHIFTARM SHAFT
mm I x 1.25 kgt 27 N m 12.8 m,20 lbf'ft)
23. Align the shift arm A groove and selectarm finger

by turn the shift arm shaft and select lever clockwise.then installtheshift arm shaftassembly. Apply liquid gasket (P/N 08718- 0001 or 08718 bolt' interlock then installthe to OO03) the threads, Apply liquid gasketto the surfaceof the shift arm coveras snown. Notetheseitems: . Use liquid gasket(P/N 08718- 0001 or 087180003). surface. . Remove dirtv oilfrom the sealing the of . Sealthe entirecircumference the bolt holesto preventoil leakage. . lf 20 minutes have passedafter applying liquid the gasket. reapplyit and assemble housings. a Allow it to cure at least20 minutesafter assemwith MTF. bly betorefillingthe transmission
t1
the Install transferassemblY. N O T E : L u b r i c a t eM T F t o t h e O - r i n g a n d c o n t a c t areas.
10x 1.25mm 44 N.m 14.5 kgf.m,33 lbl.ftl
13-71
Installation
1.
Checkthat the dowel pins are installed the clutch in housing. Apply greaseto the release fork and releasebearing.
5.
j P l a c et h e t r a n s m i s s i o n n t h e t r a n s m i s s i o na c k , o and raiseit to the enginelevel. Installthe transmission mountingboltsand the rear enginemountingbolts.
6.
{P/N 08798- 90021
{P/N 08798- 9002) 0.{ - 1.0g {0.0'l- 0.04ozl
TRANSMISSION MOUNTINGEOLT 12x 1.25mn 64 N.m {6.5 47 tbt.ft)
REARENGINE MOUNNNG BOLTS Replace. Itl x 1.5mm 8:l N.m 18.5kgt m, 61 lbf.ft)
RELEASE BEARING
(P/N 087989002)
7.
RELEASE FORK BOOT
Risethe transmission, then installthe transmission mount bracket and transmission mount. T o r q u et h e m o u n t i n g b o l t s a n d n u t s i n t h e sequence shown. . Check that the bushingare not twistedor offset. m O . @ : 1 2x 1 . 2 5 m 64 N.m (6.5 kgf.m, 47 lbf'ft) Temporary tightening O: 1 2x 1 . 2 5 m m @: 74 N.m (7.5kgf'm,54lbf.ft) .
(P/N08798 9002) '1.0 1.6g {0.0,1- o2l 0.06

?
Installthe releasebearing,release fork, and release fork boot to the clutchhousing. Install the startermotor and hoseclamp.
HOSE
10x 1.25mm 4{ N'm (4.5 kgf.m, 32 tbf.ftl
13-72
8.
Installtheright front mounvbracket.

12 x 1.25mm 64 N.m (6.5 kgf'm, 47 tbf.ftl Replace.
fluid of 1 literfrom the driveshaft 10. Pourtransmission hole. inserted shaft {seesection18).While 11. lnstallthe intermediate shaft in the differential. installingthe intermediate be sure not to allow dust and other foreignparticles to enterthe transmission.
RIGHTFRONT MOUNT/BBACKET 10 x 1.25mm 4,aN.m (4.5kgf m, 33 tbf ftl Install the clutch housing cover and rear engine stiffener. SETRING Replace.
10r 1.25mm 39 ttm 14.0kgf.m, 29 tbt ftl
SHAFT INTERMEOIATE
1 2 . l n s t a l l t h e d r i v e s h a f t s( s e e s e c t i o n 1 8 ) . W h i l e in be installing driveshaft(s) the differential, sure the to not to allow dust and otherforeignpanicles enter the transmission.
DRIVESHAFT
6xl0mm kgt.m. 12 N.m 11.2 8.7 tbf.ft)
HOUSING '12 1.25mm x 29 N.m 13.0kgf.m.22 lbf'ft) 8 x 1.25mm 24 N.m {2.5 kgf'm' 18 tbl.ft) 10 x 'l .25 mm 44 N.m {4.5kgf m,33 lbf ftl
SET RING Replace.
(cont'd)
13-73
13. Installthe balljoints onto the lower arms. DAMPER PINCHBOLT 10 x 1.25mm 43 N.m {a.a kgf.m, 32 rbfft)
Installthe exhaustpipe A, then connectthe heated oxygensensor(HO2S) connector.

GASKETS Replace.
HO2SCONNECTOR
SELF.LOCKING NUT '12x 1.25|nm 6il N'm 16.5kgtin, 47 lbtftl Reolace.
Replace.
10 x 1.25mm 5,1N.m15.5 kgtm. () tbt fil Replace.
NUT SELF.LOCKING 8 x 1.25mm 16 N.rn 11.6 kg{.m, 12lbtfr) Replace.
12x 1.25 mm ,19 59 N.m (5.0- 6.0kgi.m,36 - lbfttl 1 4 . Install the right damperfork bolt. 1 5 . Installthe propellershaft to the transferassembly by aligningthe reference marks.
REFERENCE MARKS '17.
SELF.LOCKING 8 x 1.25rr|ln 22 N.m (2.2 tgf.m, 16 lbl.ftl Replac6.
GASKET Replace.
Installthe guard bar and the splash shield.
E x 1.25mr'|
32 N.m 13.3 m, 2a lbf.ftl kst
SPLASHSHIEI.I) I x 1.25mm 24 N.m l2.a kgf.m. 17 tbtft) GUARDBAR
6x1.0mm 9.8 N.m (1.0 kgf.m,7.2 lbf.ft)
PROPELI"ER SHAFT
TRANSFER
13-74
fluid (seepage 13-3) 1 8 . Refillthe transmission mountingbolts. the 1 9 . Install four uppertransmission
from the clutchhousing. the 21, Install cablebracket

8 x 1.25mm 27 N.m (2.8 kgt'm. 20 lbtftl
COTTER PIN
Rplace. STEEL WASHER

COTTEN PIN Replace.
STEEL WASHER PLASTIC WASHER
12 x 1.25mm kgf 6it N.m 16.5 m, il7 lbf.ftl
SELECT CABLE
connector. the 20. Connect vehiclespeedsensor(VSS)
22. lnstallthe shift cableand selectcableto the levers, and cotsteelwashers, then installplasticwashers, ter prns,
)a
Connectthe back-up light switch connector.and clamP. installthe wire harness 6x1.0mm 9.8N.m{1.0kgf.m,
------------,-
VSS CONNECTOR
CLAMP HARNESS
(cont'd)
13-75
TransmissionAssembly
24. Connect the startercablesand transmission ground caore. 26. Turn the breather cap so that the "F" mark pointsat the right side of the vehicleas shown.
6x1.0mm 9.8 N.m (1.0kg{.m, 7.2 tbt.ttl
TRANSMISSION GROUND CABLE
Apply greaseto the push rod on the slavecylinder, then install slavecylinder the and clutchhosebracket, NOTE:Use only SuperHigh Temp Urea Grease {P/N08798 9002).
CI-UTCH HOSE BRACKET 8 x 1.25mm 22 N.m 12.2kgi-m, 16 tbr.f0
2 7 . I n s t a l l h e i n t a k ea i r d u c t a n d a i r c l e a n e rh o u s i n g t (seesection 5), 28. Connectthe positive(+) cablefirst. then the negative (-) cableto the battery. 29. Check levelof the transm the issionf luid. 30. Check clutchoperation. the 31. Shift the transmission and checkfor smooth operation. 32. Check front wheelalignment(seesectionl8). the
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 rbf.ftt
_G1
(P/N 08798- 9002)
13-76
GearshiftMechanism
Overhaul
Notetheseitemsl . InsDect rubberpartsfor wear and damagewhen disassembling' firmly. . Check that the new cotterpin is seated the guide pipe when removingthe cables' . Be carelulnot to damage
KNOS LEVER CHANGE 8 N.m (0.8kgl.m, 5.8 lbf.ft)
COTTEFPIN
CABLE SELECT
WASHEB (PlN PLATES Replace.
I
I
curur
I
\ \"1 a, I I
?-@ -.4'
-( I \
GUIDEPIPES SHIFTCABLE WASHER PLASTIC 6 x 'l.0mm 9.8 N.m {1.0 kgf.m, 7.2 lbf.ftl Guidepipe in the
DOOI,
(stLlcoNE GREASEI
ASSEMBLY LEVER 8 x 1.25mm ft) kgt'm,9.4lbf 13 N.m 11.3 FLOATING COLLAR
13-77
AutomaticTransmission
14'2 . S p e c i a lT o o l s Oescription . .... 143 G e n e r aO p e r a t i o n l '14_6 . . .. Power Flow .. .14_15 S y s t e m. . . . . . E l e c t r o n iC o n t r o l c .. 14 24 H y d r a u l i cC o n t r o l .. .. . 14_29 Flow....-....... . .... Hydraulic .'t4'39 .. Lock'upSyslem Electrical System 14 45 ComponenlLocdlrons P C M C i r c u i l D r a g r a m( A / T C o n t r o l S v s t e m ) '97 .14-46 - . ... M o d e l . . . . . . . . . . . . . . . . . . . . . ... . . ' 9 8 M o d e .l . . . . . . . . . . . . .. . . . . . . .1450 .. .. '99 00Models.... .... 1452 . . . C PCMTerminal Voltage/Measuring onditions ..14'48 ...... A " / T o n t r oS y s t e m - ' 9 7 M o d e l C l 14 54 00 Models . . .. . . A , / TC o n t r o l S y s t e m - ' 9 8 ... - 14_56 . ..... T r o u b l e s h o o t i nP r o c e d u r e s. g Svmotom to comoonent Charl 14 60 . E i e c t r , c aS y s l e m - ' 9 7 M o d e l . l 14_62 E l e c t r i c aS y s t e m - ' 9 8 - O OM o d e l s . . . . . l E l e c t r i c aT r o u b l e s h o o t i n g( ' 9 7 M o d e l ) l . T r o u b l e s h o o t i nF l o w a h a r t s. . . . . . . . . . . . . 1 4 _ 6 4 g E l e c t r i c aT r o u b l e s h o o t i n g( ' 9 8 - 0 0 M o d e l s ) l T r o u b l e s h o o t i nF l o w c l t " n " . . . . . . . . . - . . 1 4 - 9 3 q ElectricalTroublesliooting('99 00Models) Flowchart Troubleshootino 14 131 O / D O F F I n d i c a t o rL i g h t D o e s N o t C o m e O n O / D O F F I n d i c a t o rL i a h t O n C o n s t a n t l Y . . . . 1 ! - 1 3 2 O / D O F F I n d i c a t o rL i g h t D o e s N o t C o m e O n EvenThough O/D Switch ls Pressed . .... - 14_133 L o c k u p C o n t r o l S o l e n o i dV a l v e A , / BA s s e m b l y . .14-135 Test....................-......... .ll_135 . Replacement A S h i f r C o n t r o l S o l e n o i dV a l v e A y ' B s s e m b l , . .. 14-136 T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14'136 Replacement..............L i n e a rS o l e n o i dA s s e m b l Y .. T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .1 4 _ 1 3 7 .... 14138 .. . Replacement M a r n s h a f t l c o u n t e r s h a fS p e e d S e n s o r s l 14_138 ...-... Replacement A/T Gear Position Switch . .. 14-139 T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . .1.4 . . . 4 0 . .-1 Replacement A/T Gear Position l n d i c a t o r - ' 9 7 - 9 8 M o d e l s . . . . . . . . . . . . . . . _ . . . . . . .t.4 .1.4 2. . . .. Input Test '99 .4 .. . 3 0 0 M o d e l s . . . . . . . . . . . . . . . . . . . . . . . .1 . . - 1.4 . . . Input Test I n t e r l o c kS y s t e m l I n t e r l o c C o n t r o l U n i t n p u t T e s t .- . . . . . - . . . . . . . - 1 4 1 4 4 k * K e y I n t e r l o c k o l e n o i d e s t. -. . . . . - . . . . . . . . 1 4 _ 1 4 6 T S * S h i f t L o c k S o l e n o i dT e s t . . . . . . . . . . . . . . - ..-... . . . . . . . 1 4 1 4 7 . * S h i f t L o c k S o l e n o i d R e p l a c e m e n t . . . . .. . . . . . 1 4 1 4 8 * park pin Switch Test . . . . . . . .1 4 1 1 9 . ' Park Pin Switch Replacement - '97 - 98 Models . . . . . . .1 4 - 1 5 0 * Park Pin Swirch/Over Drive (O/Di Switch '99-00Models 14_151 . .. Replacemenl o v e r - D r i v e ( O / D )S w i t c h { ' 9 9 0 0 [ 4 o d e l s ] .......14-152 Test........_..................... Hydr.ulic System Symptom to-Component Chart H y d r a u l i cS y s t e m . . . . . . . . . . . . . . . 14 157 . RoadTest.............-...... .
Eody Valve . n e p a i r . . . . . . . . . . . . . . . . . . . . . ........... ... .. . . - . . . . . . 1 4 1 9 2 .. 1{_193 A s s e m b l .y. . . . . . . . . . . . . . . . . . . Caps Valve D e s c i i p t i o n . . . . - . . . . . . . . . . . . . . . . . . . . .. .. .. .. . . 1 4 1 9 4 ' . . 1 41 9 5 . t n s p e i t i o n. . . . . . . . . . . . . . . . . . ValveBody N4ain - ...... Disassembly/lnspection/Reassemblv .. 14_196 BodY Valve Secondarv 14 198 .. . Disassemblv4nspectron/ReassemblY Reoulator ValveBodv . 14199 bisassembtv,lnspiction/Reassemblv ServoEodv ... Disassembly/lnspection/Reassembly ....14'200 ValveBodY Lock'uo . 14_201 .... Dis;ssembly/lnspection/Reassembly Mainshaft .. .. Disassembly/lnspection/Reassembly .. ..14'202 ..11_203 . I n s p e c t i o.n. . - . . . . . . . . . . . . . . Rings Sealing ...... ..... . 14'204 Reilaceient Countershaft .. . . . . Disassembly/lnspection/Reassembly . 11-205 .m. . D i s a s s e m b l y / R e a s s e . .b.|.y . . . . . . . . . . . . 1 4 _ 2 0 6 1 42 0 7 .... . Inspedro............... . n Onewav Clutch ... 11_209 Disassembly/lnspection/ReassemblY Sub-shaft ... . Disassembly/lnspection/Reassembly.. . 14-210 . . o i s a s s e m b l y / R e 6 s s e.m b l.y . . - . . . . . . . . . . 1 4 - 2 1 1 Bearings Sub-shaft .......14'212 Replacement Clutch . . .14-213 Index.......... llfustrated .... .. .....14-216 Disassembly .... . .. .. . 14'218 Reassembfy Differential 14-222 " Index llfustrated . ..... .14'223 Inspection Backlash .. 11-223 Repiacement Bearing .. Replacement .. . . . .. ..11-2?4 Carrier Differe-ntial . .. 14'225 OifSealReplacement. . lnspection . - .. ... . - ....... .. 11'226 SideClearance Bearings Housing Transmission Eearings MainshaJVCountershaft .......14221 Repfacement .. Replacement . . . . . . . ..11'224 Eearing Sub'siralt Housing Bearings Converter Toroue . MainshattEearing/OilSe6lReplacement .. l4229 B t g C o u n t e r s h a fe a ; i n R e p l a c e m e n t..... . . . . . 1 4 - 2 3 0 ControlLeverAssembly . . . . . . . .1 . - 2 3 0 .4 R 6 p l a c e m e n t. . . . . . , . ,
R e v e r s el d l e r G e a r
.. 1 n s t a 1 | a t.i .o n. . . . . . . . . . . . . . ParkStop Inspeclion/Adjustmenl TransferAssemblY

lllustrated lndex
1 42 3 1 11-231 .......14.232 ........... 14-235 11-237 11-237 14-238 $-234
......... Disessembly
T r a n s f e rD r i v e G e a r B e a r i n g Replacement T r a n s { e rD r i v e n G e s f S h a f t B e a r i n g Replacement T r a n s f e rH o u s i n g R o l l e r B e a r i n g Replacement T r a n s f e rC o v r A B e a r i n gO u t e r R a c e Replacement T r a n s f e r H o u s i n g B e a r i n gO u t e r R a c e R e p l a c e m e n t. . . . . . - . . , , , , , . . . . .
StallSpeed T e s t. . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . FluidLevel
Checking Transmigrion
. . . . . 1.4 - 1 5 9 .
. . . . . . _ . . . . . . . . . . .1 . . '.1 . . 0 .4 .6.
14 164 . I n s p e c l r o n . . . ..,. . . . . . . . . . T r a n s f e rA s s e m b l y 14-165 Remova1,.,,,.............., 14,167 . l n s t a l l a l i o n. . . . . . . . . . . . Transmission 14-169 Removal ..., l l l u s t r a t e dI n d e x ( 4 W D ) 14'174 . End Cover/Transmissio ... .. . . .... .. 14-176 T r a n s m i s s i oH o u s i n g. . . . n B T o r q u e C o n v e r t e rH o u s i n g l y ' a l v e o d y . . - . . . - . 1 4 1 7 8 lllustrated lndex (2WD) 1 ....... 4 180 End Cover/Transmissio T r a n s m i s s i oH o u s i n g . . . . . . . . . . . . . . . 1 4 ' 1 8 2 n 14-184 B H T o r q u eC o n v e n e r o u s i n g / r ' a l v eo d y . . . . . . End Covef . . . . . .1 4 ' 1 8 6 . R e m o v a t. . . . . . . . . . . . . . . . . . . . . . T r a n s m i s s i o nH o u s i n g .. 14_188 R e m o v a l. . . . . . . . . . . . . . . . . . . . . . Torque Convener HousingA/alve BodY . - . . . .1 4 - 1 9 0 . R e m o v a t. . . . . . . . . . . . . . . . - . . . . .
11-239 14-240 Reassemblv Transmassaon ...-.. .... .14250 Beassembly C i le . T o r q u e o n v e r i e r / D rPv a t e . - . . . . . . . . . . . . . . . . 1 4 _ 2 5 8 Transmission 14'259 ....... .................. lnstatlation . . ......11-261 C o o l eF l u s h i n g r ATFCoolerHoses ....... 14-266 Connection.................. I Shift Lever . .. 14'261 Removal/lnstallation - '97 Disassemblv/Reassemblv - 98 Models . . 14_264 - 00 Models. -'99 14-269 Disassembli/Reassemblv (O/D) Wire Switch Over'Orive C l e a r a n c e A d j u s t m - n.t... . . . . . . . . 1 4 ' 2 7 0 e ... .14'271 D e t e n t p r i n R e p l s c e m e. n .t - . . S g *ShiftCable 14'272 ....... Adiustment . 11'273 Repfacement..............
Ref.No. ^
tl)
Tool Number 07GAB PF50101 or 07GAB- PF50100 07GAE PG40200 or _ OTGAE PG4O2OA 07HAC PK40102 07JAB- 001020A 07JAD- PH80101 07LAD- PW50601 07LAE PX40100 OTMAJ PY4O114 07MAJ- PY40120 07PAZ- 0010100 07RAB TB4010A or 07RAB.TB40lOB 07sAz - 001000A 07406- 0020400 07406- 0070300 07736 4010008or 07736 A010004 07746 0010100 - 0010200 07746 07746 0010400 07746 0010500 07746 07746 0774607749 0010600 0030100 0030400 0010000
Description Mainshaft Holder ClutchSpringCompressor BoltAssembly HousingPuller HolderHandle Oil SealDriverAftachment Attachment, x 50 mm 40 ClutchSpringCompressor Attachment Ay'T Pressure Hose, 2210mm IVT PressureHoseAdapter SCSServiceConnector Companion FlangeHolder Backprobe Set lVT Oil Pressure GaugeSetw/Panel A,/TLow PressureGaugew/Panel Adjustable Bearing Puller, - 40 mm 25 Anachment, x 35 mm 32 Attachment,37 x 40 mm Attachment.52 x 55 mm Attachment. x 68 mm 62 Attachment, x 75 mm 72 Driver40 mm l.D. Attachment, mm LD. 35 Driver
Oty I
PagoReferonc 14-181 254 ,
@
*rar
1 1 1 1 ,l
14-216,219 14-189 't4-236,242,245,246 't 4-225, 241 14-237 14-216,2't9 14-161 14- 61 1 14-57 14-236,242,245,246 14-58, 157 14-161 14-161 '14-229,230 14-211, 2't2 14-231 14-239 14-212, , 228,229,230, 238, 227 14-239, 249 14-221 ,229 't 4-207 , 223,226, 237, 241 14-237,241 1+21 1, 2't2, 225,227, 228, 229, 14-230, , 238, 239,24't, 249 237 't4-225
@ @
,-o
@
@ @ @ @ @ .--@ @ @ @ @ @ @ @ @ @
1 I 2 1 'l 1 I 1 1 1 1 1 1 I 1
SealDriverAftachment lf the top arm is too short,replace with 07SAC pOZ01OO1. it 07HAE PL50101 may be usedto substitute one of thesetools. Must be usedwith commercially available 3/8"-16 slide hammer.
07947- SD90200
E----G
tvj
@@@@@
@)
\r'
@ @
14-2
Description
Operation General
4 unit which provides controlled electronically and triple-shaft torqueconverter is transmission a 3-element The Automatic in The unit is positioned linewith the engine' speed forwardand 1 reverse speeds drive (4WD)model ('97- 00)' and the front-wheel the on transmission CR-V; four-wheel Thereare two tvoes of automatic model ('98- 00). drive (2WD) Toroue Converter,Gars,and Clutches is to in consists a pump.turbine.and statorassembly a singleunit.The torqueconverter connected of The torqueconverter is Thesepartsturn togetheras a unit as the engineturns.Aroundthe outsideof the torqueconverter the enginecrankshatt. as serves a flyassembly converter The torque with the starterpinionwhen the engineis started. a ring gearwhich meshes powerto the transmission mainshaft. wheelwhile transmitting is The mainshaft in line with and the shafts: the mainshaft. countershaft, the sub-shaft. has The transmission three parallel and 1st and gearslor 3rd,2nd,4th. reverse the 1st,2nd. and 4th clutches, includes The mainshaft crankshaft. the engine the gear). includes 3rd The countershaft gear is integral with the 4th while reverse (3rdgear is integral with the mainshaft, at to 4th gearscan be locked the countershaft its cenand 1st, clutchand gearsfor 3rd,2nd,4th, reverse, and park.Reverse dependingon which way the selectoris moved.The sub-shaftincludesthe lst-hold ter, providing4th gear or reverse, clutchand gearsfor lst and 4th. combinations Whencertain and meshwith thoseon the countershaft sub-shaft. are The gearson the mainshaft in constant to provideE, D!, tr, tr, to power is transmitted from the mainshaft the countershaft by of gearsare engaged the ctutches, and E. E, E, and E position('99- 00 models)' and E position('97- 98 models). Electlonic Control The electroniccontrot system consistsof the PowenrainControl Module (PCM),sensors,a linear solenoid,and four The PCMis drivingunderall conditions. for controlled comfortable valves.Shiftingand lock-upare electronically solenoid panelon the passenger's side. underthe kick locatedbelowthe dashboard, HydraulicControl valve body, the servo body, and valve body, the regulator The valve bodiesincludethe main valve body, the secondary the manualvalve, main valvebody contains The housing. the lock up valve body.They are boltedto the torque converter valve,the modulatorvalve,the servo Back-up) Pressure the 1-2 shift valve,the 2nd orificecontrolvalve.the CPB{Clutch valve body containsthe 2-3 shift valve,the 3-4 shift controlvalve.the reliefvalve,and ATF pump gears.The secondary valve Control)valve.The regulator Pressure valve,the 3,4 orificecontrolvalve.the 4th exhaustvalveand the CPC(Clutch valve,and the lock-upconcheckvalve,the coolerrelief valve,the torque converter regulator the pressure bodv contains shift tork, and the accumulators with the reverse the servovalvewhich is integrated trol valve.The servo body contains and the shift contiming valve.The linearsolenoid valveand the lock-up shift the lock-up valve body contains The lock-up is valveAy'B controlsolenoid housing,and the lock-up boltedto the outsideof the transmission are valveAy'B trol solenoid through the manualvalve to the to the outsideof the torque converterhousing.Fluid trom the regulatorpasses bolted circuit feed pipesor internalhydraulic fluid from their respective receive variouscontrolvalves.The clutches ShiftControl Mechanism valvethe PCMwill actiwhich shift controlsolenoid located throughoutthe vehicledetermines input from varioussensors causinga shiftvalveto move.This pressurizes modulatorpressure, valvechanges a vate.Activating shift controlsolenoid valvesA and B are gear.The shift controlsolenoid that clutchand its corresponding engaging a lineto one of the clutches. by controlled the PCM. Lock-up Mechanism positionin 3rd ('97- 98 tn E! position(,97- 98 modets)and in E position('99 - O0models),in 3rd and 4th, and in Del pressurized (O/D)is OFF(by pressing O/Dswitchl in 3rd ('99- 00 models), rhe models)and in El positionwith Over,Drive causingthe lock-uppiston to be held of the torque converterthrough a fluid passage, fluid is drainedfrom the back rotatesat the same speedas the enginecrankshaft. the mainshaft cover,As this takesplace, the against torque converter the control,the PcM optimizes timing of the lock-upmechanismThe lock-upvalvescontrolthe with hydraulic Together range of lock-upaccordingto lock-upcontrol solenoidvalves A and B, and the linear solenoid.When lock-upcontrol The lock-upcontrol solenoidvalvesA and B and the changes. the solenoidvalvesA and B activate, modulatorpressure by linearsolenoidare controlled the PCM. {cont'd)
14-3
Description
(cont'dl General Operation
Gsar Selection '97 - 98 Models The shift lever has sevenpositions; PARK, REVERSE, NEUTRAL, 1st through 4th ranges,lpq 1stth.ough 3rd El ts N Ell ranges, 2nd gear,and [ 1stgear P '99 - 00 Models The shitt lever has six positions; PARK, REVERSE, NEUTRAL. ,lst through 4th ranges,and 1st through 3rd El E E E (whenOver-Drive (O/D) OFF) is ranges. 2nd gear,and E 1stgear. @
Position Description
tll PARK
t!!l l|EvEn>E
Reverse; reverseselectorengagedwith countershaft reversegear and 4th clutch locked. Allclutches released. Generaldriving;startsoff in 1st,shifts automatically 2nd, 3rd, then 4th, dependingon vehiclespeed to and throftle position.Downshiftsthrough 3rd,2nd, and lst on deceleration stop. to The lock-upmechanismoperates;n3rd and 4th gear. used for rapid ccelerationat highway speeds and general driving; stans off in 1st, shifts automaticallyto 2nd_then dejending on vehiclespeedand throttleposition. 3rd, Downshifts throughlower gearson decelerationto stop.The lock-upmechanism comesinto operationin 3rd gear.
E NEUTRAL ('97 Ell DRrvE - sB) ('ss E DRrvE - oo) (1st through ) 4th E DRrvE - s8) {'97 with O DRTVE over(O/D) OFF Drive is ('99 00)
(1stthrough 3rd) E SECOND E FIRST
Driving in 2nd_gear; stays in 2nd gear,does not shift up and down. For engine brakingor bettertrac_ tion startingoff on loose or slipperysurfaces. Driving in 1st gear;stays in 1st gear,does not shift up. For engine braking.
Startingis possible only in @ and @ positions. usinga slide-type. neutral-safety switch. Automatic Transaxle(A/T) Gear Position Indicator This indicator the instrument in panelshowswhich gear has beenselected. Transler Mochanism {4WD} The transfermechanism consists the transfershaftdrivegear.the transfer of shaft.the transfer drivegear,the transfer driven gear shaft,and the companion flange,The transfermechanism assembly on the rearside ot the transmission. is beside the differential. transfer The shaftdrivegearon the final drivengeardrivesthe transfer shaftdrivenqear.poweris transmitted to the reardifferential the transfer via shaftand the Drooeller shaft. Clutches The four-speedautomatictransmissionuses hydraulically-actuated clutchesto engageor disengagethe transmissiongears. When the hydraulicpressureis introducedinto the clutch drum, the clutch piston moves.This pressesthe friction discs and steel platestogether,lockingthem so they don't slip. Power is then transmiftedthrough the engagedclutch pack to its hu$ mountedgear.When hydraulicpressureis bled from the clutchpack,the piston releases friction discsand steelplates,and the they are free to slide pasteachother.This allowsthe gearto spin independently its shaft,transmittingno power. on lst Clutch The 1stclutchengages/disengages gear,and is located the end ofthe mainshaft, lst just behindthe end cover. at The 1stclutchis suppliedhydraulic pressure its ATFfeed pipewithin the mainshaft. by lst-hold Clutch The 1st-hold clutchengages/disengages 1st-hold E position, or and is locatedat the middleof the sub-shaft. The 1st-hold clutchis suppliedhydraulic pressure its ATF feed pipewithin the sub-shaft. by 2nd Clutch The znd ciutchengages/disengages gear,and is locatedat the middleof the mainshaft. 2nd The 2nd clutchis joined backto-back the 4th clutch.The 2nd clutchis suppliedhydraulic to pressure throughthe mainshaft a circuitconnected the by to internalhydraulic circuit.
14-4
3rd Clutch opposite the end cover.The 3rd 3rd The 3rd clutchengages/disengages gear,and is locatedat the end of the countershaft, pressure its ATFfeed pipewithin the countershaft. by clutchis suppliedhydraulic ilth Clutch The 4th gear,and is located the middleof the mainshaft. at 4th The 4th clutchengages/disengages gear,as well as reverse pressure its ATFfeed pipewithin the by joined back-to-back the 2nd clutch.The 4th clutchis suppliedhydraulic to clutchis mainshaft. One-way Clutch 1st The one-wayclutchis positionedbetweenthe parkgear and the countershaft gear,with the parkgear splinedto the counterand the park gear providesthe inner racesurface The 1st shaft.The countershaft gear providesthe outer race surface, 1st one,way clutch locks up when power is transmittedfrom the mainshaftlst gear to the countershaft gear. The 1st gear rangesin the lo], pt, E, or E position The one-way clutchand gearsremainengagedin the 1st,2nd, 3rd, and 4th are when the 2nd, 3rd,or 4th clutches/gears appliedin the lor, [d, E, or E position' clutchdisengages "speedrange" of the the over-ride locking rotational speedof the gearson the countershaft because increased the This is when the lst clutchis engaged one-wavclutch.The one-wavclutchfree-wheels
2NOCLUTCH 4TH CLUTCH lST.HOLD CLUTCH
1STCLUTCH
MAINSHAFT 3RDCLUTCH
COUNTERSHAFT
TRANSFER SHAFTDRIVE GEAR ONE.WAYCLUTCH TRANSFER ASSEMBLY
OUTSIDE ONE.WAY OF CLUTCH INSIDEOF ONE.WAY CLUTCH

Splined with countershaft The sprags engage/ disengage outside and inside of the
s N O T E :T h e i l l u s t r a t i o n h o w s t h e 4 W D t a u t o m a t i c r a n s m i s s i o n s e c t i o n av i e w ) { l d the 2WDtransmission oes not havea transferassemblyand transfershaft drive gear on the differential assembly.
LOCKING CONDITION
OVER.RIOING LOCKING SPEED CONOITION
14-5,
Description
PowerFlow
*N
E E
N
1ST
TOROUE
4TH REVERSE PARK coNHOLD 1ST 2ND 3RD GEAR VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
1ST.
1STGEAR 2ND GEAR 3RDGEAR
Fi
or
2ND 3RD 4TH
o o o o o o o o o o o o o
o
X
o*, o*,
o*1 o*1
o o o o
tr
or
'tsT
o"
o*1
E
2ND OverDrive (o/D) 3RD is OFF
o o o
o*r o*r
tr tr
O: Operates, Doesn'toperate. x: * 1:Althoughthe 1stclutchengages, drivingpower is not transmitted the one_way as clutchslips. *2: The one-way clutchengages when accelerating. slipswhen deceleraung. and NOTE:p! and Ipj positions on the '97 - '98 models; positionis on the ,99- OO are models. El
14-6
E Po3ition pressure not appliedto the clutches. is Poweris not transmitted the countershaft. to Hydraulic The countershaft lockedby the parkpawl interlocking parkgear, is the E Position is but hydraulicpressure not appliedto the Enginepower transmittedfrom the torque converterdrivesthe mainshaft. 4th with the reverse selector hub Poweris not transmitted the countershaft. countershaft gear is engaged to The clutches. and the countershaft the reverseselector, by when the shift lever is shiftedin E positionfrom E or E position.The gear is engaged when shiftedfrom E position. countershaft reverse transmission identiis NOTE;The illustration shows the 4WD automatic transmission; oower flow of the 2WD automatic cal to the 4WD exceDtfor oarts relatedto the transfer assemblv.
PARKGEAR
SELECTOR
COUNTERSHAFT GEAR REVEBSE
(cont'd)
14-7
Description
Power Flow (cont'dl
E Position pressure appliedto the lst clutchand the lst-holdclutch. In E position, hydraulic is The powerflow when accelerating as follows: is pressure appliedto the lst clutchon the mainshaft, 1. Hydraulic is and power is transmitted the 1stclutchto the mainvia shaft 1stgear. pressure also appliedto the lst-hold clutchon the sub-shaft. Hydraulic is Powertransmitted the mainshaft1st gear to is conveyed the countershaft gear to the one-wayclutch,and via the sub-shaft1st gear to the 1st-hold via 1st clutch. The one-wayclutchis usedto drivethe countershaft, the 1st-hold and clutchdrivesthe countershaft the 4th gears. via Poweris transmitted the final drive gear,which drivesthe final drivengear,and the transfershaftdrive gear (4WD), to
4. The transfer shaftdrive geardrivesthe transfershaftand the transferdrivengearshaft(4WD).
NOTE;The illustration powerflow ot the 2WDautomatic showsthe 4WDautomatic transmissjon; transmission identiis cal to the 4WDexceptfor partsrelated the transferassembly. to TOROUE CONVERTER
SUB.SHAFT 4TH GEAR lST.HOLDCLUTCH SUB.SHAFT SU8-SHAFT 1STGEAR
1STGEAR
lST CLUTCH
COUNTERSHAFT
ONE.WAYCLUTCH FINALDRIVE GEAR PARK GEAB
COUNTERSHAFT 4TH GEAR FINALDRIVENGEAR GEAR{4WD} TRANSFER SHAFTORIVE TRANSFER SHAFT{4WD}
14-8
TRANSFER DRIVEN GEARSHAFT{4WD)
E Position is The powerflow when decelerating as follows: trom the road surfacegoesthroughthe tront wheels(and rearwheels:4WD)to the final drive gear. L Rollingresistance lst clutchwhich is appliedduringdeceleration. then to the sub-shaft gearvia the 4th gear.and 1st-hold of 2 . The one-wayclutchis free because application torque is reversed. the
J.
4th 4th gear.Since to 4th The counterforce conveyed the countershaft gear turns the sub-shaft gear via the mainshaft is hydraulicpressureis also appliedto the 1st clutch.counterforce also transmittedto the mainshaft.As a result, with'lst gear. enginebrakingcan be obtained powerflow of the 2WDautomatic is transmission identiNOTE:The illustration showsthe 4WDautomatic transmission; cal to the 4WD excepttor parts relatedto the transfer assembly.
lST.HOLDCLUTCH 1STGEAR SUB.SHAFT TOROUE CONVERTER SUB.SHAFT {TH GEAR MAINSHAFT lST GEAR
lST CLUTCH MAINSHAFT
COUNTERSHAFT
FINALDRIVEGEAR HUB SELECTOR REVERSE
SELECTOR REVERSE COUNTERSHAFT IITHGEAR FINALORIVEN GEAR TRANSFER SHAFTDRIVEGEAR{4WDI TRANSFEB SHAFT{{WD)
{cont'd}
TRANSFER DRIVEN GEARSHAFT{,lWDl
14-9
Description
PowerFlow lcont'd)
lst Gear(8. E or E positionl gearis selected In E, E, or D position, optimum the from 1st, 2nd,3rd,and4thgears, according conditions to suchas
the balancebetweenthrottle opening (engineload) and vehicle speed. pressure appliedto the 1st clutch,which rotatestogetherwith the mainshaft, 1. Hydraulic is and the mainshaft1st gear rotates. 2. Poweris transmitted the countershaft gear.which drivesthe countershaft the one-wayclutch. to 1st via 3. Poweris transm ittedto the final drive gear.whichdrivesthe final drivengearand the transfershaftdrive gear (4WD). 4. The transfershaftdrive geardrivesthe transfershaftand the transfer drivengearshaft(4WD). NOTE: o In @, @, @, or E position. pressure not appliedto the 1st-hold hydraulic is clutch. . The illustration power flow of the 2WD automatic showsthe 4WD automatic transmission; transmission identical is to the 4WD exceptfor parts relatedto the transfer assembly.
CONVERTER MAIiISHAFT 1ST
CLUTCH
MAINSHAFT
COUNTERSHAFT FINALOBIVEGEAR ONE.WAYCLUTCH
PARKGEAR
FINALDRIVEN GEAR TRANSFER SHAFTDRIVEGEAR{4WD}
14-10
2nd cesr (8, E. E, or E positionl 2nd gear and the mainshaft togetherwith the mainshaft, pressure appliedto the 2nd clutch,which rotates is 1. Hydraulic rotales. 2. Power is transmitted to the countershaft2nd gear, which drives the countershaft to 3. power is transmitted the final drive gear,which drivesthefinald rivengearand the transfershaftdrive gear (4WD) 4. The transfershaftdrive gear drivesthe transfershaftand the transferdrivengearshaft(4WD). NOTE: that of lst gear. pressure also appliedto the 1stclutch,but sincethe rotationspeedof 2nd gear exceeds . Hvdraulic is powerfrom 1stgear is cut off at the one-wayclutch. is power flow of the 2WD automatic transmission identical transmission; . The illustration showsthe 4WD automatic to the 4WD exceptfor parts relatedto the transfer assembly. TOROUE
CLUICH
GEAR FINALORIVE
COUNTERSHAFT
2NO GEAR
GEAF FINALDRIVEN SHAFTDBIVEGEAR{4WD} TRANSFER SHAFT{4WDI TRANSFER GEARSHAFT(4WD) TMNSFER DRIVEN
(cont'd)
14-11
Description
PowerFlow (cont'd)
3rd Gear {8. @, or @ position) 1. Hydraulicpressure appliedto the 3rd clutch.Powerfrom the mainshaft is 3rd gear is transmitted the countershaft to 3rd gear. 2. Poweris transm iftedto the final d rive gear,wh ich d rivesthe f inal drivengearand the transfershaftdrive gear(4WD). 3, The transfershaftdrive geardrivesthe transtershaftand the transferdrivengearshaft (4WD). NOTE: . Hydraulic pressure also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceeds is that of 1stgear, powerfrom lst gear is cut off at the one-wayclutch. . The illustration showsthe 4WD automatic transmission; Dowerflow of the 2WD automatic transmission identical is to the 4WDexceptfor partsrelated the transferassembly. to
CONVERTEF MAINSHAFT 3RDGEAR
COUNTERSHAFT
COUNTERSHAFT 3ROGEAR 3RDCLUTCH DRIVEN GEAR GEAR(4WO) SHAFTDRIVE SHAFT(,lwDl TRANSFER ORIVEN GEANSHAFT(4WD) TRANSFER
14-12
4th Goar (E or D positionl pressure appliedto the 4th clutch,which rotatestogetherwith the mainshaft, 1. Hydraulic is and the mainshaft4th gear rotates, 4th 2. Poweris transmitted the countershaft gear,which drivesthe countershaft. to 3. Poweris transm iftedto the f inal d rive gear,which drivesthe finaI drivengearand the transfershaftdrive gear (4WD). 4. The transfershaftdrive gear drivesthe transfershaftand the transferdrivengearshaft {4WD). NOTE: . Hydraulic pressure also appliedto the 1stclutch,but sincethe rotationspeedof 4th gear exceeds is that of 1stgear, powerfrom 1stgear is cut off at the one-wayclutch, . The illustration power flow of the 2WD automatic showsthe 4WOautomatic transmission; transmission identical is to the 4WD except for parts relatedto the transfer assembly.
ilTH GEAR
TOROUE CONVERTER
.TH CLUTCH
COU'{TERSHAFT
HUB SELECTOR REVERSE
REVERSE SELECTOR
FINALDRIVENGEAR TRANSFEBSHAFT DRIVEGEAB I'WD) TNANSFER SHAFTI4WDI GEARSHAFT(4WDI TMNSFER DRIVEN
{cont'd)
14-13
Description
PowerFlow (cont'dl
E position 1. Hydraulicpressureis switched by the manual valve to the servo valve, which movss the reverseshift fork to the reverseposition,The reverseshift fork engageswith the reverseselector, the reverseselectorhub, and the countershaft reversegear. 2. Hydraulicpressureis also appliedto the 4th clutch. Power is transmittedfrom the mainshaftreversegear via the reverseidler gear to the countershaftreversegear. gear ischangedviathe reverse 3. Rotational direction ofthe countershaft reverse idlergear. 4. Poweris transmitted the final drivegear,whichdrivesthefinald rivengear and the transfershaftdrive gesr (4WD). to 5. The transfer shaftdrive geardrivesthe transfershaftand the transferdrivengearshaft (4WD). NOTE:The illustrationshows the 4WD automatic.transmission; power flow of the 2wD automatictransmissionis identical to the 4WD exceptfor partsrelatedto the transferassembly.
TOROUE CONVERTER
REVERSE MAINSHAFT
COUNTERSHAFT REVERSE IDLER GEAR
FINALORIVE
COUNTERSHAFT REVERSE GEAR
REVERSESEITCTOR HUB REVERSE SELECTOR FINALOBIVEN GEAR TRANSFER SHAFTDRIVEGEAR {4WD) TRANSFER SHAFT{4WD) TRANSFER DRIVEN GEARSHAFTI4WD} SERVOVAI-VE REVEBSC SHIFT FORK
14-14
ControlSystem Electronic
sensors, linearsolenoid, a and four solenoid The electronic controlsvstemconsists a Powertrain of ControlModule(PCM), for driving under all conditions. The PCMis located valves.Shiftingand lock-upare electronically controlled comfortable underthe kickpanelon the passenger's side. belowthe dashboard, '97 - 98 Modls
Throttl Poshion Sensor Signal

PGM.FI Control Sy3t6m
VehicleSp.ed Sensor Signal
EnginoCoolantTampereture SonsorSignrl
ServiceCheckconnector
A/T Control Sy3tem INTERLOCK UNIT CONTROL Shift Control Solenoidvalve A
R
N Dr Ds
Shift Cont.ol
Shift Control SolenoidValve B
Linear Solenoid
Lock-upControl
2
1
Lock-upControl SolenoidValve A
Lock-upConirol Sol6noidvalvo B
-D! Indicator Light
M.inshaft SpoedSensor Signel
Selt-Oiagnosbsignel
Il
Sell-Diagnosis Function
CountrahaftSpeed sensorSignel
{cont'd)
14-15
Description
Electronic GontrolSystem(cont'd)
'99 - 00 Models
PCM
Throttle Position Sensor Signel
PGM.FI Control System
VehicleSpeedSensor Signal
EnginCoolsnt Tomperature Sen30rSignal
Service Chck Connectol
A/T Control Svstem INTERLOCK CONTROL UNIT
Shift Conlrol SolenoidValve A
R
N
Shift Control
Shift Control SolenoidValve B
D 2
Lock-upControl
Linear Solenoid
1
Over-Drive Switch Signal
Lock-upControl Solenoidvalve A
Lock-upControl SolenoidValve B
E Indicator Light
Mainshaft SpeedSensor Signal
Selt-Oiagnosis Signd
Self-Diagnosis Func{ion
CountershaftSpeed SensorSigntl
O/D OFF Indicetor Light
14-16
Shift Control The PCMdetermines which gear should be selected varioussignalssent from sensors, by and actuates the shift control valvesA and B to controlshifting. solenoid Also.a GradeLogicControlSystemhas beenadopted controlshiftingin E to anOE ('gZ- gg),and E ('99- 00) positionwhile the vehicleis ascending descending slope,or reducing or a speeo. Position Gear 'Ist Shift Control Solenoid Valve A OFF ON ON OFF ON
OFF
Shift Control Solonoid Valve B ON
E, E, Or
E
E orE
2nd 3rd
4th
ON
OFF OFF ON ON OFF
2nd 1st
tr
Reverse ON E*See page 14-37 reverse for inhibitorcontroldescription.
Lock-upControl From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol solenoidvalveA and/orB accordingly. Lock-up does not occur until the engineis warm. The combination driving sigof nalsto lock-up controlsolenoid valvesA and B and the linearsolenoidpressure shown in the table below. is Lock-upConditions
LOCK-Up \Jrr
Lock-upControl Solonoid Valve A OFF ON ON ON
Lock-upControl Solenoid Valve B OFF Dutyoperation OFF- ON
LinearSolenoid Pressuro High
Lock-up, Half Lock-up, Full Lock-up duringdeceleration
ON
Dutyoperation OFF- ON
Hish
Low
(cont'd)
14-17
Description
Electronic ControlSystem(cont'dl
Grade Logic Control System How it works: The PCMcompares actualdrivingconditions with memorized basedon the inputfrom the vehiclespeed drivingconditions, pressure sensor, throttleposition the sensor, barometric the sensor('98model). enginecoolanttemperature the sensor, the brakeswitch signal,and the shift lever positionsignal,to controlshiftingwhile the vehicleis ascending descending or a slope,or reducing speed.
SIGNALSDETECTED
Judgemont ot Controlling Aroa Driving Rcsisl.nce
. . . .
Normal Modo {Flrt ro.d mode} AscendingMode Mode Deacending Deceleration Mode
14-14
AscendingControl {37 Modol} When the PCMdetermines that the vehicleis climbinga hill in E] and E positions, systemextendsthe engagement the area of 2nd gar and 3rd gear to preventthe transmissionfrom frequentlyshifting between2nd and 3rd gears,and between 3rd and 4th gears,so the vehicle can run smooth and have more power when needed. NOTE: . Shift schedulesstored in ths PCM between 2nd and 3rd gears, and between 3rd and 4th gears. enable the PCM'sfuzzy gearaccording the magnitude 8 gradient. logicto automatically select the most suitable to of t Fuzzylogic is a form of artificialintslligence that lets computersrespondto changingconditionsmuch like a human mind would. 2ND- 3RD
3RD - tlTH
MODE:UFhift Sch.dulc ASCENoING
o 5 l )
. FLATROADMODE
-----------. : GRADUAL ASCENDING MODE - - - - - : STEEPASCENDING MODE CHARACTERISTICS FN1NS : 2ND-3RDSHIFTING AREA CONTROL
7,.,.7a | 3RD-aTHSHIFTINGCHARACTER|SnCS CONTROL AREA

62 mph km/h) 1100 Vehicle .o..d
AscondingConirol ('98 - 00 Mod.ls) When the PCMdetermines that the vohicleis climbinga hill in E] and E positions('98 model),and in E] position('9900 models),the system extendsthe engagementsrea of 2nd gear and 3rd gear to prevent the transmissionfrom frequently shifting between 2nd and 3rd gears, and between 3rd and 4th gears, so the vehicle can run smooth and have more power when needed. NOTE: Shift schedulssstored in the PCM between2nd and 3rd gears, and between3rd and 4th gears,enable to selsct the gear according th6 magnitude a gradint. most suitable to of
2ND + 3RD 3RD+ 4TH
ASCENDING MODE:Up.hift Sch.dul.
8 5 0
o
: 2ND-3RD SXImNG CHARACTERISTICS GoNTRoLAREA VVVVVZ:IRD-ITHSHIFnNGCHARACTERISTICS cot{TRoL AREA NN -
6:l mph 11fl)km/hl
Vahicl. sDctd
(cont'd)
14-19
Description
Electronic ControlSystem(cont'd)
Descending Control ('97- 98 models). When the PCMdetermines that the vehicleis going down a hill in E and @ positions and in @ position {'99 - 00 models), shitt-upspeedfrom 3rd to 4th gear and from 2nd to 3rd (whenthe throttleis closed)becomes the fasterthan the set speedfor flat road drivingto widen the 3rd gear and 2nd gear drivingareas. This, in combination with engine brakingfrom the deceleration lock-up, achieves smooth drivingwhen the vehicleis descending. Thereare three descending modeswith different 3rd gear drivingareasand 2nd geardrivingareasaccording the magnitude a gradito of ent storedin the PCM.When the vehicleis in 4th gear,and you are decelerating when you are applyingthe brakeson a steep hill, the transmission will downshiftto 3rd gear,When you accelerate, transmission the will then returnto higher gear.
2ND - 3RD 3RD- 4TH DESCENDING MODE:Downshift Schodule
: FLATROADMODE
----'-----' I GRADUAL DESCENDING MODE

o 5 0
- - - - - : MEDIUMOESCNOING MODE . . ... : STEEP DESCENDING MODE
62mph km/hl 1100 DecelerationControl
Vehicle sped
When the vehiclegoes arounda corner,and needsto decelerate and then accelerate, PCMsetsthe datafor deceleration first the control to reducethe number of times the transmissionshifts.When the vehicle is decelerating from speedsabove 27 mph (4i| km,ih), PCMshiftsthe transmission the from 4th to 2nd earlierthan normalto cope with upcomingacceleration,
14-20
Model and TerminalLocationsr9T CircuitDiagram

IGNITIONSWITCH
LOC( UPCONTROL
LOCK UPCONTROL B SOLEITOIDVALVE
sf Frc0|lltF0L SOLENOIDVALVE A
sHrFr c0r{TnoL
VALVE B SOLEI{OID
UNEASSOLINOID
14-21
Description
ElectronicControl System (cont'd)
CircuitDiagramand TerminalLocationsrgS Model
GNTIONSWITCN
LOCK-UPCONIFOL A SOLEIIO VALVE D
LOCK-UPCONTSOL SOLEI.IO vALvEB 0
SBIFICONTROL A SOLEI DVALVE
SHFTCONTFOL VALVE SOLEiDID 8
LINAA SOLiDID GNIION SWTCH tGr
14-22
Circuil Diagram and Terminal Locations-'gg- 00 Models
GN'ION SWITCN
pG2
LOC(UPC,ONTROL SOLEIDD VALVE A
IGPI IGP2
vcc2
LOCK.UPCON'IFO! SOLENOIOVALVE B
SNIFT CONTAOT VALVE A SOLNOID
SH]FT CONTROL
vArvE solEtiroro B
L NEAF SOLEI{OIO
rGNloN SWrlCH
GI
PCM Connclor Tehrial Loaabm
14-23
Description
Hydraulic Control
The hydraulic controlsystemis controlled the ATF pump,valves,accumulators, electronically by and controlled solenoids. The ATF pump is driven by splineson the end of the torqueconverter which is aftached the engine.Fluidfrom the ATF to pump flows throughthe regulator pressure, valveto maintainspecified throughthe main valve body,to the manualvalve, directingpressure each clutch.The valve body includesthe main valve body, the regulatorvalve body, the lock-up to valve body,the secondary valve body,the servo body,the linearsolenoid, shift controlsolenoidvalveAy'B the assembly, c v . v a n d t h e l o c k - u p o n t r o ls o l e n o i d a l v e A / B a s s e m b l yT h e s h i f t c o n t r o ls o l e n o i d a l v eA , / B s s e m b l y n d t h e l i n e a r a a solenoidare boltedon the outsideof the transmission housing. The lock-up controlsolenoidvalveA,/B assembly bolted is on the outsideof the torqueconverter housing.
SHIFTCONTROL VALVEA/B SOLENOID ASSEMBLY
LINEAR
REGULATOR VALVEBOOY
N
VALVEA/B SOLENOID ASSEMELY ATF PUMPGEARS
VALVE SECONDARY BODY
VALVEBODY
14-24
Main Valve Sody the manualvalve,the 1-2shift valve.the 2nd orificecontrolvalve.the CPBvalve,the moduThe main valve body houses lator valve.the servo controlvalve.and the reliefvalve.The primaryfunctionsof the main valve body are to switchfluid going to the hydraulic controlsystem. pressure pressure and off, and to controlthe hydraulic on
CP8 VALVE 2ND ORIFICE CONTROL VALVE
VALVE MODULATOR 1-2 SHIFTVALVE
VALVE RELIEF
MANUAL VALVE
MAIN VALVE BOOY
SERVO CONTROIVALVE
Secondaryvalve Body the valvebody houses 2-3 shift valve,the 3-4 valve body is locatedon the main valvebody,The secondary The secondary valve' valve,and the CPC valve,the 4th exhaust shiftvalve,the 3-4 orificecontrol
3.' SHIFTVALVE 2.3 SHIFTVALVE
.TH EXHAUSTVALVE
CPCVAL
CONTROL 3naORIFICE VALVE
VALVE
(cont'd)
14-25
Description
Hydraulic Control(cont'd)
RegulatorValve Body The regulator valve body is locatedon the main valve body.The regulator valve body consists the regulator of vatve,the torqueconverter checkvalve.the coolerreliefvalve,and the lock-up controlvalve.
COOLERRELIEF VALVE
Lock-upValve Body The lock-up valvebody,with lock-up shift valveand lock-up timing valve,is located the regulator on valvebody.
LOCK.UP SHIFTVALVE
NMINGVALVE
14-26
RegulatorValve while also controlsystem, pressure from the ATF pump to the hydraullc constanthydraulic valve maintains The regulator Fluid from the ATF pump flows through B and B'. Fluid systemand torque converter. furnishingfluid to the lubricating valveto the regulator of enteringfrom B flows throughthe valveorificeto the A cavity.This pressure the A cavitypushes the right side. and this movementof the regulatorvalve uncoversthe fluid port to the torque converterand the relief valve. The fluid flows out to the torque converterand the relief valve, and the regulatorvalve moves to the left side. valvechangesand the amountof pressure through B, the positionof the regulator to According the levelof the hydraulic the maintaining line pressure. is This operation continued, alsochanges. B,throughthe torqueconverter fluid from "|eft" or "right" indicates below. on direction the illustration NOTE;When used,
ENGINENOT RUNNING ENGINERUNNING CONVERTER Lubtication To TOROUE STATORSHAFTABM
Stator ReactionHydraulic PressursControl The valve usingstatortorque reaction. pressure to according torqueare performedby the regulator in Increases hydraulic the regulatorspring cap When the and its arm end contacts statorshaft is splinedto the stator in the torque converter, actson the statorshaft,and the stator Range), statortorque reaction Converter or vehicleis accelerating climbing(Torque spring The statorreaction to pushesthe regulator springcap in the directionof the arrow in proportion the reaction. arm its reaches maximum when the Line pressure the line pressure. and compresses, the regulatorvalve movesto increase its reaches maximum. statortorque reaction
TOROUE CONVERTER VALVE REGULATON
STATORREACTION
CAP TOR SPRING
STATON
STA
SHAFT
ATOF SHAFTARM
(cont'd)
14-27
Description
Hydraulic Control(cont'd)
Servo Body The servo body is located the secondary on valve body.The servobody contains servovalve(whichis integrated the with the reverse shiftfork),and the accumulators.
2ND ACCUMULATOR
3RD SUB ACCUMULATOR
SERVOBODY
1STACCUMULATOR
SERVO VALVE/SHIFT FORKSHAFT
14-28
HydraulicFlow
GeneralChart of Hydraulic Pressure Valve -a Regulator ATFpump | LL ModulatorPressureClutchPressure Pressure ToroueConverter Pressure LUbrication LinePressure 5 LinearSolenoid
Distribution ol Hydraulic Pressure . Regulator -"- TorqueConverter Pressure Valve Pressure LLubrication I LinePressure To regulate . . ManualValve Valve Modulator To selectLinePressure ModulatorPressure -ClutchPressure ---- ShiftControlSolenoid Valves valves ControlSolenoid Lock-up fL LinearSolenoid
. . .
--1-2ShiftValve 2-3 ShiftValve -tI 3-4 Shift Valve
ClutchPressure
NO, PORT
1
OF DESCRIPTIONPRESSURE LINE LINE LINE LINE LINE LINE LINE LINE LINE LINE MODULATE (SHIFT SOLENOIO CONTROL MODULATE VALVE A) (SHIFT SOLENOID CONTROL MODULATE B) VALVE (LOCK.UP SOLENOID CONTROL IVODULATE A) VALVE (LOCK-UP SOLENOID CONTROL MODUTATE VALVE B) (LOCK-UP SOLENOID CONTROL MODULATE B) VALVE
LIN E
NO, PORT
15
't' 2 3 3' 3"
17 18 20 20A 30 40
41
5 6A
90
91
OF DESCRIPTIONPRESSURE CLUTCH lST-HOLD CLUTCH 1ST-HOLD CLUTCH 1ST-HOLD CLUTCH 1ST-HOLD 2ND CLUTCH 2ND ACCUMULATOR 3RDCLUTCH 4TH CLUTCH 4THCLUTCH SOLENOID LINEAR TOROUE CONVERTER TOROUE CONVERTER CONVERTER TOROUE ATF COOLER CONVERTER TOROUE LUBRICATION TOROUE CONVERTER
92 93 94
95
6D'
7
97
8 I 10
LINE/CPC LINE 1STCLUTCH
99
x
HIX
CONVERTER TOROUE SUCTION DRAIN

DRAIN HIGHPOSITION
{cont'd)
14-29
Description
HydraulicFlow (cont'dl
lll Position As the engine turns, the ATF pump starts to operate.Automatictransmission fluid (ATF)is drawn from (99) and dischargedinto (1).Then,ATF flowing from the ATF pump becomesline pressure ('l). Line pressure js regulatedby the (1) regulator valve.Torqueconverter inlet pressure {92)enters(94)of the torqueconveTter throughthe lock-up shift valveand discharges into (90) The torque converter checkvalve prevents torque converterpressure from rising.Underthis condipressure not appliedto the clutches. tion, hydraulic is NOTE; . When used."|eft" o. "right" indicates direction the hvdraulic on circutt. . The hydraulic circuitshowsthe '97 - 98 models{7 positions}; '99 - 00 models(6 positions) similar. the is
'lF'.j.l
14-30
B Position (4) (1) to pressure changes line pressure and Line pressure flows to the manualvalve and the modulatorvalve,Line {1) valve Modulatorprespressure the modulator at to at clutchpressure the manualvalve,and changes modulator 1st-hold valveA is turned oFF shift controlsolenoid sure {6)flows to the left ends of the 1-2shift valve and 3-4 shift valve because (4) are moved to the right side. Line pressure becomes1st clutch by the PcM. The 1-2 shift valve and the 3-4 shift valve (10)is appliedto the 1st clutch,and the 1st clutchis engaged lst(10)at the 1-2 shift valve.1st clutchpressure pressure (18)flows to the lst-hol; clutchvia the 3-4 shift valve and the 1-2 shift valve Poweris transmitted hold clutchpressure clutch. throughthe 1st-hold only duringdeceleration NOTE: "right" indicates circuit' on direction the hydraulic . When used,"left" or is the '99 - O0models(6 positions) similar' circuitshowsthe'97 - 98 models(7 positions); . The hvdraulic
(cont'd)
14-31
Description
l?JPosition Line pressure flows to the manualvalve and the modulatorvalve.Line pressure changes line pressure at the (1} {1) (4) to manualvalve,and changesto modulatorpressure the modulatorvalve.But modulatorpressure does not flow to at {6} eachshift valvebecause shift controlsolenoid valvesA and B are turnedON by the PCM.Linepressure passes (4) through the CPBvalveand the CPCvalve,and changes line pressure then flows to the 'l-2shift valve.Line pressure from (5), to (5) (20)at the 2-3 shift valve.The 2nd clutchpressure the 1-2shift valvechanges 2nd clutchpressure to (20)is appliedto the 2nd clutch,and the 2nd clutchis engaged, (4) Line pressure passes throughthe 1-2shiftvalveand the orifice,and changes to lst clutchpressure. The 1stclutchpressure {10)also flows to the 1stclutch.However, power is transmitted no because of the one-wayclutch. NOTE: . When used,"left" or "right" indicates direction the hvdraulic on circuit. . The hydraulic circuitshowsthe '97 - 98 models(7 positions); '99 - OO the models(6 positions) issimilar.
14-32
E] or E Position ('97 - 98 Models), and D Position ('99 - 00 Modelsl 1. lst Gear flows to the manualvalve Line pressure circuitis the same as in E] position. Fluidflow throughthe torque converter (6) valveand to line pressure pressure at the modulator to changes modulator valve.Line pressure and the modulator pressure(6) flows to the left end of the 1-2 shift valve and the 3-4 shift valve {4) at the manual valve. Modulator valve A is turned oFF and B is turned oN by the PcM. The 1-2 shift valve is movedto shift controlsolenoid because (10}at the 1-2shift valveand the orifice The 1stclutch to 'lst clutchpressure {4) the right side.Line pressure changes the (10)is appliedto the 1stclutchand the 1st accumulator; vehiclewill move as the enginepower is transpressure mitted. NOTE: circuit. on direction the hydraulic . When used,"left" or "right" indicates '97 - 98 models(7 positions); '99 - 00 models{6 positions) issimilar. the . The hvdraulic circuitshowsth e
(cont'dl
14-33
Description
Hydraulic Flow (cont'dl
2nd Gsar As the speed of the vehiclereaches the prescribed value.shift control solenoidvalve A is turned ON by the pCM. (6A) in the left end of the 1-2shift valveis released turning shift controlsolenoidvalve Modulatorpressure by A ON. The 1-2shift valve is movedto the left side and uncovers port to allow line pressure to the 2-3 shift vatve.Line (5) the (5) pressure changes 2nd clutch pressure (20)at the 2-3 shift valve,The 2nd clutch pressure to {20)is applidto the 2nd clutch.and the 2nd clutchis engaged. Fluidflows by way of: - LinePressure + CPBValve- Line Pressure * 1-2ShiftValve(4) (5) (S) Linepressure * 2-3 ShiftValve - 2nd ClutchPressure - 2nd Clutch (20) The hydraulic pressure alsoflows to the lst clutch.However, power is transmitted no because the one-wavctutch. of NOTE: . When used,"|eft" or "right" indicates direction the hydraulic on circurr_ ' The hydraulic circuitshowsthe'97 - 98 models(7 positions); '99 - 00 models(6 positions) similar, the is
14-34
3.
3rd Gear value.shift control solenoidvalve B is turned OFF by the PCM. the prescribed As the speedof the vehiclereaches (6) valveA remainsON. Modulatorpressure flows to the right end of the 1-2shift valveand the Shift controlsolenoid (68) The 2-3 shift left end of the 2-3 shift valve.The 2-3 shift valve is movedto the right side by modulatorpressure (5) the prsssure to the 2nd clutch.and uncovers 3-4 shift valveas the 2-3 shift valve valvecoversthe port to stop line (30)at the 3-4 shift valve.The 3rd clutch (5) is moved to the right side, Line pressure becomes3rd clutch pressure (30)is appliedto the 3rd clutch,and the 3rd clutchis engaged. pressure Fluidflows by way of: (5) (5) - Line pressure - CPBValve- LinePressure * 1-2Shift Vaiv- LinePressure * 2-3 ShiftValve (4) (30) - Line Pressure * 3-4 ShiftValve- 3rd ClutchPressure * 3rd Clutch (5) of because the one-wayclutch. no alsoflows to the 1stclutch.However, power is trsnsmitted The hvdraulic Dressure NOTE: circuit. on direction ths hydraulic . When used,"|eft" or "right" indicates '97 - 98 models(7 positions); is the'99 - 00 models(6 positions) similar. . The hvdraulic circuitshowsthe
(cont'd)
14-35
Description
HydraulicFlow (cont'd)
4th Gear llQ! or E Posirion) As the speedof the vehiclereaches the prescribed value.shift controlsolenoidvalve A is turned OFF by the pCM, Shift controlsolenoidvalve B remainsOFF.Modulatorpressure flows to the left end of the 1-2shift valveand the (6) left end of the 3-4 shift valve.Modulatorpressure (64) in the left end of the 1-2shift valveequalsmodulatorpressure (68)in the right end of the 1-2shift valve.The 1-2shift valveremainsat left side by the tensionof the valvespring. The 3-4 shiftvalve is movedto the right side by modulatorpressure (6A).The 3-4 shift valvecoversthe pon to the 3rd clutch and uncovers the port to the 4th clutchas this valve is moved to the right side,The 4th clutch pressure (41) from the 3-4 shift valve becomes (40)at the manualvalve.The 4th clutchpressure 4th clutchpressure (40)is applied to the 4th clutch,and the 4th clutchis engaged. Fluidflows by way of: - Linepressure + CPBValve- Line Pressure + l-2 ShiftValve- LinePressure * 2-3 (4) (5) {5) Shift Valve - LinePressure + 3-4 ShiftValve- 4th ClutchPressure + ManualValve- 4th ClutchPressure (5) (41) (40) + 4th Clutch pressure The hydraulic alsoflows to the lst clutch.However, power is transmitted no because the one-wavclutch. of NOTE: . When used,"lelt" or " tight" indicates directionon the hydraulic circuit. . The hydrau circuitshowsthe '97 - 98 models(7 positions); '99 - 0Omodels(6 oositions) lic the issimilar.
14-36
E Position (3) (1) to Line pressure changes line pressure circuitis the same as in N position. Fluidflow throughthe torque converter (3') (3)changes line pressure at the 1-2shift valveand flows to the servo to and flows to the 1-2shift valve.Line pressure (3") the and uncovers port to allow line pressure rangeposition) vaive.The servovalveis movedto the right side (Reverse (3') from the 1-2 shift valve flows through the servo valve to the manualvalve and manualvalve. Line pressure to the (40)is appliedto the 4th clutch,and the 4th clutchis engaged. (40). The 4th clutchpressure to changes 4th clutchpressure RverseInhibitor Control while the vehicleis movingforwardat speedsover 6 mph (10 km/h),the PCMoutputsthe Whenthe @ positionis selected valveA is turnedOFF,shift controlsolenoid valvesA and B; shift controlsolenoid 1stspeedsignalto shiftcontrolsolenoid (3') coversthe port to stop line pressure to the valve B is turned ON. The 1-2 shift valve is moved to the right side and pressure to the servo valve,and 4th clutch pressure(40} is not appliedto the 4th servo valve. Line {3') is not applied direction. to clutch,as a result,power is not transmitted the reverse NOTE: circuit. on direction the hydraulic . When used,"lelt" ot " right" indicates '97 - 98 models(7 positions); '99 - 00 models(6 positions) similar' is the . The hvdraulic circuitshowsthe
(cont'd)
14-37
Description
E Position Fluidflow throughthe torqueconverter ( circuitis the same as in fl position. (3) Linepressure 1)changes line pressure to (3) and flows to the 1-2shift valve.Line pressure changes line pressure at the 1-2shift valveand flows to the servo to {3') valve.The servovalveis movedto the right side (Reverse (3") rangeposition) and uncovers port to allow line pressure the (3") from the servovalveis intercepted the manualvalve.Hydraulic to the manualvalveas in E position. Linepressure by pressure not supplied the clutches, is to and power is not transmitted. NOTE: . When used,"left" or "right" indicates direction the hydraulic on circuit. . The hydraulic circuitshowsthe '97 - 98 models(7 positions); '99 - 00 models(6 positions) the issimilar.
14-38
System Lock-up
In E position('97- 98 models)and in E position('99models)(3rdand 4th),and E position('97- 98 modOO (O/D)is OFF(by els) and in E positionwith Over-Drive ('99- 00 models)(3rd),pressurpressing O/Dswitch) the izedfluid is drainedfrom the backof the torque convertthe lock-uppistonto causing er througha fluid passage, cover,As this takes the be held against torqueconverter the mainshaftrotatesat the same speed as th8 Dlace, Togetherwith the hydrauliccontrol, engine crankshaft. the PCM optimizesthe timing of the lock-up system. Under certaincondltions.the lock-upclutch is applid in duringdeceleration, 3rd and 4th gear. sccordThe lock-up systemcontrolsthe rangeof lock-up ing to lock-upcontrol solenoidvalvesA and B, and ths When lock-upcontrol solenoidvalvesA linearsolenoid. and B activate.modulator pressurechanges.Lock-up valvesA and B are mountedon the outcontrolsolenoid s i d e o f t h e t o r q u e c o n v e r t e rh o u s i n g ,a n d t h e l i n e a r housing.They solenoidis mountedon the transmission bv are controlled the PCM. for conditions lock-up The table belowshowsthe lock-up valvesand linearsolenoidpressure. controlsolenoid Lock-upConirol Solenoid valve A Lock-upOFF MODULATOR Pf,ESSURE MAINSHAFT
RELIEF VALVE COUNTERSHAFT
CONVERTER TOROUE
CONTROL LOCK.UP ' VALVE
CONTROL LOCK.UP VALVE SOLENOID A B
Lock-up Conditions
B
OFF Dutyoperation OFF- ON ON Duty operation OFF- ON
Linaal Solenoid Prgssuls High Low High
OFF
Lock-up,Half Full Lock-up, Lock-up during deceleration
ON ON ON
TIMING LOCK'UP VALVE SUB.SHAFT
PRESSURE LINEARSOLENOID VALVE RELIEF COOLER
ATF PUMP ATF COOLER ATF STRAINER
(cont'd)
14-39
Description
Lock-up System(cont'dl
Lock-upClutch L (clutchon) Ooeration With the lock-upclutch on, the fluid in the chamber betweenthe torque convenercover and the lock-uDoiston is drained off, and the converterfluid exertspressure through the piston againstthe torque convertercover,As a result,the convener turbine is lockedto the convertercover.This bipassesthe converter,placingthe vehiclein directdrive.
LOCK,UP PISTON
The power flows by way of: Engine IOROUE COVER
Drive plate Torque convertercover I Lock-uppiston
t
Damper spring { Turbine Mainshaft
MAIf{SHAFT
(clutchoff) Operation With the lock-upclutch off, the fluid flows in the reverseof "clutch on." As a result,the lock-uppiston moves away from the convertercover,and the torque converterlock-upis released.
Engine COVER I plate Drive { Torque converter cover { Pump I Turbine { Mainshaft
TOROUE
{(1
\\ n1
To ATF cooler INLET
Jtl ort
MAII{SHAFT
14-40
No Lock-up . . . ValveA: OFF Lock-up ControlSolenoid ControlSolenoid ValveB: OFF Lock-up High LinearSolenoidPressure:
TOROUE CONVERTER
by The pressurized fluid regulated the modulatorworks shift valve.Underthis condion both endsof the lock-up working on both ends of the lock-up tion, the pressures s h i f t v a l v e a r e e q u a l . a n d t h e l o c k - u ps h i f t v a l v e i s m o v e d t o t h e r i g h t s i d e b y t h e t e n s i o no f t h e v a l v e spring. Fluid trom the ATF pump will flow through the the left side of the lock-up clutchto the torqueconverter; lock-up clutchis OFF. "|eft" and "right" indicates direction NOTE:When usd, circuit. on the hydraulic
LOCK.UP CONTROL SOI-ENOID VALVE
MOOULATOR PRESSURE MAINSHAFT VALVE RELIEF COUNTERSHAFT
TIMING LOCK-UP VALVE
+ VALVE RELIEF i COOLER
PRESSURE LINEAR SOLENOID
ATFPUMP ATF COOLER ATF STRAINER
(cont'd)
14-41
Description
Lock-up System(cont'dl
HalfLock-up
a Lock-up ControlSolenoid ValveA: ON a Lock-up ControlSolenoid ValveB: DutyOperation
OFF- ON LinearSolenoidPressure: Low The PCMswitchessolenoid valveA on to release modulator pressure the left cavityof the lock-upshift valve. in Modulator pressure in the right cavity of the lock-up shift valve overcomes the spring force,and the lock-up shiftvalveis movedto the left side. Line pressure then separated is into the two passages to the torque converter;torque converterinner pressure entersinto right side to engagethe lock-upclutch,and torque convener back Dressure enters into left side to disengage lock-up the clutch. Back pressure(F2) is regulatedby the lock-upcontrol valve,whereasthe positionof the lock-uptiming valve is determined linearsolenoidpressure by and tensionof the valvespring.Also the positionof the lock-upcontrol valve is determined the back pressure the lock-up by of control valve.torque converterpressure(regulatedby the torque convertercheckvalve),and modulatorpressure (determined the lock-upcontrol solenoidvalve by B). The PCM switcheslock-upcontrol solenoidvalve B on and off rapidly(duty operation), undercertajncondi(F2)and lockthe torque tions,to regulatebackpressur convertef. NOTE:When used,"left" and "right" indicates direction on the hvdraulic circuit.
TOFOUECONVERTER
L(rcK.UP CONTROL SOLENOID VALVE A B
VALVE RELIEF
MODULATOR PNESSURE MAINSHAFT

COUNIERSHAFT
L(rcK-UP TIMING VALVE
+ COOLER RELIEF VALVE
LINEAR SOLENOID PRESSURE
ATFPUMP ATFCOOLER ATF STRAINER
14-42
FullLock-up . . . Lock-up ControlSolenoid ValveA: ON Lock-up ValveB: ON ControlSolenoid LinearSolenoidPressure: High
TOROUE CONVEFTER
W h e n t h e v e h i c l e s p e e d f u r t h e r i n c r e a s e s l,i n e a r solenoidpressureincreases high in accordance to with the linearsolenoid which is controlled the PCM. by T h e l o c k u p t i m i n g v a l v e o v e r c o m e sh e s p r i n gf o r c e t and moves to the left side. Also, this valve closesthe fluid port leadingto the left side of the lock-upcontrol valve. Underthis condition, modulatorpressure the left side in of the lock-upcontrol valve had alreadybeen released by the lock-up controlsolenoidvalve B; the lock-upcontrol valve is moved to the left side. As this takes place, torqueconverter backpressure released is fully, causing the lock-up clutchto be engaged fully. NOTE:When used."left" and "right" indicates direction on the hydraulic circuit.
CONTROL LOCK-UP VALVE SOLENOID
MODULATOR PRESSURE MAINSHAFT RELIEF VALVE COUNTERSHAFT
TIMING LOCK.UP VALVE SUB-SHAFT
+ BELIEF VALVE COOLER
PRESSURE SOLENOIO LINEAR
ATFPUMP ATF COOLER ATF STRAINER
(cont'd)
14-43
Description
Lock-up System (cont'dl
DecelelationLock-up
a Lock-up ControlSolenoid ValveA: ON a Lock-up ValveB; DutyOperation ControlSolenoid
OFF- ON LinearSolenoidPressure: Low The PCM switchessolenoidvalve B on and off rapidly u n d e r c e r t a i nc o n d i t i o n sT h e s l i g h t l o c k - u pa n d h a l f . lock-upregionsare maintained lock the torque conto vener propeny.
TOROUE CONVERTER
NOTE:When used,"left" and "right" indicates direction on the hydraulic circuit.
MOOULATOR PRESSURE MAINSHAFT RELIEF VALVE COUNTERSHAFT LOCK.UP TIMING VALVE SUB.SHAFT
+ COOLER RELIEF VALVE
LINEAR SOLENOID PRESSURE
ATFPUMP ATF COOLER ATF STBAINER
14-44
ComponentLocations
CONTBOL UN]T ASSEMBLY
POWERTRAIN CONTROL MODULE{PCMI
COUNTERSHAFT SENSOR SPEED
AUTOMAIIC TRANSAXI.E (A/T} GEAR POSITION
swtTcH \
SHIFTCONTROL SOLEM)IDVALVE ASSEMBLY SPEED SCNSOR
14-45
PCMCircuitDiagram(A/T ControlSystem)
'97 Model
FUSAFELAY BOX UNDER.I]OOD EATTEFY
_YEL_ IGNITON SWITCH
UNDEF OASN FUSAFELAYSOX
-T T l
T-l ,
t_ -:
G101
oowEa-qar. MooLrE cor.lFo- rpcMr
F *1
ATP NP
r*--'l_____O_=_
IO! lrNo ,ATP lR
&
. A T D, A - P , A - P , A - P 101 103 12 ll
UNDER DASN M 25(7.54)
'Fr-r.04 P- r.-or..u L
P_ *+rr
F- onmrx F_ P_ eLu F-- enN pw
_a TMEALOC( -<< calTFoL BrKru
f-"".>
| ["'"]
CFUISE CONTFOL UNIT
I l,[-l , III ;
Ar'TGEAR POS]TION
swtcN
14-46
INTEFLOC( CONIFOL UNIT KEY LCICI( ACCPUSNSWSOLEIJOIO IGI SHIFILOCX SOLEIOD PPNSW LI] ATPF GND
YEI]BLK
]' I
YEITILX
I -[ l
I
l-f? POSrn0N PPOsITION
SEr!5OR
t,
I I
ENGINE CooL,ANT TEMPERATURE SENSOF
th. r
nf
I II r 1",,
I
8nN
l"
H I
BLX
I I
SEFVICECHECK CONNECTON
{
G101
PGMTerminal Voltage/MeasuringConditions
-'97 Model A/T ControlSystem
The PCMterminalvoltageand measuring conditions shownfor the connector are terminals that are related the Ay'T to conThe other PCMterminalvoltageand measuring trol system. conditions described section11. are in
PCMTerminalLocations
A {32P}Connector
B (25P1 Connectol
C {31PIConnector
D {16P}Connector
PCMCONNECTOR {32P} A Torminal Numbcr A9 A10 At1 Signsl LG1 PG1 IGPl Description ( Ground G101) Ground G101) { Power supply system With ignitionswitchON (ll):Battery voltage (under-hood Fuse44 via main relav) With ignitionswitchOFF:0 V Ground Ground 424 IGP2 Power supply system With ignitionswitchON (ll):Battery voltage (under-hood Fuse44via main relav) With ignitionswitchOFF: V 0 MeasuringConditions/TerminalVohage
422
FCM CONNECTOR (25P) B Terminal Number Signal LSM LSP SHA
Description
Linearsolenoidpowersupply negativeelectrode Linearsolenoidpower supply positive electrode Shift controlsolenoid valveA control
Measuring Conditions/TerminalVohage lgnitionswitchON (ll):Pulsing signa lgnitionswitchON (lll: Pulsing signa In @, @ position, 2nd and 3rd gear in E, in E position: Battery voltage In 1stgear in E. F! position, 4th gear in E in position: V 0 With full lock-up: Battery voltage With half lock-up: Pulsing signal With no lock-up: V 0 When lock-up ON: Baftery is voltage With no lock-up: V 0 In E position: 0V In otherthan E position: voltage Battery
B1 82 B3
B4
LCB
Lock-up controlsolenoid valve B control Lock-up controlsolenoid valveA control Not used ,VT gear position switch E position signalinput Not used
B5
86 to 87 B8 89 to 810
LCA
ATPD3
14-48
PCMCONNECTOR (25P)lcont'd) B TerminalNumbel 811 Signal SHB Description valveB Shift controlsolenoid control voltage Measuring Conditions/Terminal in In E, E position, 1stand 2nd gear in -q, voltage Er position: Battery in In B position, 3rd gear in qd, q:l,inatn gear in D. position: V 0 When ignitionswitchis ON (ll),brakepedal V deDressed accelerator and oedalreleased:0 When ignitionswitchis first turnedON (ll):6 V or more for tlvo seconds In lDllposition: or more 6V signal Depending enginespeed:Pulsing on When engineis stopped: V 0 ; I n E p o s i t i o nO V In otherthan E position: Battery voltage InEposition:0V Battery voltage In otherthan E position: InEposition:0V voltage In otherthan E position: Battery
812
ILU D 4I N D
lnterlock control D4 Indicator light control
B13
814 815 816 817 B18 8 1 9t o 8 2 1
NMSG NM ATP R
Mainshaft speedsensorground Mainshaft speedsensorsignal InpuI gear position switch E Ay'T positionsignalinput gear position switch E posiAy'T tion signalinput A/T gear positionswitchEl posit i o n s i g n a il n p u t Not used ground Countershaft speedsensor Countershaft speedsensorsignal Inpur A/T gear position switch iql position signalinput gear positionswitchE and Ay'T N positionsignalsinput on signal Depending vehiclespeed:Pulsing when vehicleis stooped: V 0 : I n E p o s i t i o n0 V In other than lgalposition: Bafteryvoltage
ATP2
ATP 1
B22
NCSG NC
824 825
ATP D4 ATP NP
0V In E andE positions: V Inotherthan andffi positions:5 @
PCMCONNECTOR {31PI C TerminalNumber Signal SCS Description Service checksignal Measuring Conditions/TerminalVoltage With ignitionswitchON (ll) and service check connectoropen: 5 V check With ignitionswitchON (ll) and service with special tool: 0 V connector connected Alwaysbatteryvoltage
c10
VBU
power system Back-up (under-hood Fuse47)
PCM CONNECTOR II6PI D Terminal Number

Signal
Description Brakeswitchsignalinput
Measuring Conditions/TerminalVoltage Battery voltage Brakepedalpressedr 0 Brakepedalreleased: V
STOPSW
14-49
PCMCircuitDiagram(A/T GontrolSystem)
'98 Model
FUSAFELAY sox UNOEF-HOOO
_YEL_
rGD2
I ocr
I oG2
| V8 S0.
I SIOPSW
I CAs
ATP NP UNOEF-DASH FUSE/BELAYBOX
IDl lrND
,ATP lR
, A T P, A - P , A T P, A _ P lD4 lD3 12 ll 09 lD0 lDl,llDl5 PNK BLU
F
F_
rronr
GFNTBLX
*,',,,)83Hf'L
PN(
f-'r'------}-'er'
F_ _______]_fcRN
f
I
*'-> 3111"?"
Gro]
F_
gnN
l l ,I I
1*[-l
sr{rTat
14-50
NIEFIOCX T CONTAOLI]N KEYLOCX ACC PUSN SW SOLEIOLO 6] SHFILOCK SOLENO1O PPINSW ILU ATP P GNO
YEUBLX
l ' l ' I'

WN I/8LI< V WHTELK
I' I
BLl(BLU ___L
YEL]BLK
T-T l l
-TlS0LEN00 | 4 vrL
IH q** lF I l:$"."
I s"'nLocr erx
l , l
L
,T
v
I t_
SPEED SENSOR
PosrTroN
PPOSITON
V I
tJFj
gLUA|/H'I
__t
;,
BLU/YEL GFNAiI/N]
Tl'
l l
I SNFTCONTFOL I SOLENOIDVALVE
,l
BFN
-T-
l*
I
SERVCECHECX CONNECTOF
--l
l
COTJNIEFSHAfI SPEEDSENSOA
LNEAFSOLEID
t*l t LI t ?
I I-:
AssEM4Y
I
BqNLK
BLK
I
Gr01
PCMCircuitDiagram(A/T ControlSystem)
'99- 00 Models
IJNOER'HOOD FUSE/FELAY EoX EATTERY
-]-
8LKryEL
T
l .
]T
BLX,'YEL
AIP,O,0,ATP,ArPlO/D 04 t5w t2 tr tN0 IJNOER DASII FUS'/FELAYBOX
D 9 1 0 0 | 0 r 4| D r t I B t g
GAUGEASSEMELY LTGRN BLKtsLU
Fffi[t** L'om
{ --1 sr&BrLr l-
F-lwr-i
FED
|--FED----.1
YEL 8LU |-BFN-LI BLU fLr sLrJ-l
d
G401
,I, -r
) { :-\
G4o1 POS]IION !r'TGEAF
14-52
.'1" .l' I
XEY LOCX ACCP1JSHSW SOLENOID 61 SHFILOCX SOLENO D 3 YEU8L(
NIEFLOCX UNIT CONTROL PPNSW LL] A'PP GND
l6
I SLTBL!
SPEEO SENSOn
T--[T
?
I
Posti0N
Y L
I
YEUBLK
rt--r
t,
| tr-r I
t9il LJA
LOCK 1SNTFl D SOTENO L YEL
i-l Jr
I
(PCM) POWEFTFALN CONTROL MODIJLE
0rr
012
lDro
I -tl t
8FN SERVCE CHECK CONNECIOF LOC(,I]PCON'IBOL SOLENOIDVALVE
BFN
i"']*
BLU/IEL BLI]IEL
Trt
l: I onx^* coNNEcroR tfJ
f7
G10r
BLK
PCMTerminalVoltage/Measuring Conditions
A/T ControlSystem-'98 - 00 Models
The PCMterminalvoltageand measuring terminals that are related the A"/T to conditions shownfor the connector are conThe other PCMterminalvoltageand measuring trol system. are in conditions described section11.
FCM ConnectorTerminalLocalions
NOTE:819 and C3terminals are applied to'99 - 00 models.
o (16Pt
T6rminal Number A5 A10
Signal CRS
Description Downshift signalinput from cruisecontrolunit Timing and adjustment service checksignal(5 V from PCM)
MeasuringConditions/TerminalVoltage Whencruisecontrolis used;Pulsing signal With ignitionswitchON (ll)and service check connector open:5 V With ignitionswitchON (ll) and service check jumpedwith special connector tool: 0 V When ignitionswitchis firstturnedON (ll): Batteryvoltage for two seconds In E position: Batteryvoltage When ignitionswitchis firstturnedON (ll): Bafteryvoltage for two seconds ln E position: Battery voltage When ignitionswitchON {ll),brakepedal pedalreleased: depressed, accelerator and Batteryvoltage Brakepedalpressed; voltage Battery Brakepedalreleased: V 0
scs
A14 ('98 model) A14 ('99- 00 models) 428
D4 IND
D4 indicatorlight control from PCMturns D4 light {Voltage
oN)
D IND
D indicator light control (Voltage from PCMturns D light
oN)
ILU Interlock control (Voltage from PCM) Brakeswitchsignalinput
A.32
STOPSW
FCM CONNECTOR I25P} B Terminal Number B1 Signal IGPl PG1 LSM IGP2 810 B17 819 ('99- 00 models) O/DIND PG2 Description Powersupplycircuitfrom main relayvia under-hood Fuse44 ( Ground G101) Linearsolenoidpower supply negative electrode Powersupplycircuitfrom main relay ( Ground G101) Linearsolenoidpower supply positive electrode (O/D) Over-Drive OFFindicator light control With ignitionswitchON (ll):Pulsingsignal When ignitionswitchis first turnedON (ll): 0 V for two seconds O/DOFFindicator light ON:0 V O/DOFFindicatorlight OFF:Battery voltage Always battery voltage With ignitionswitchON (ll):Baftery voltage With ignitionswitchOFF:0 V MeasuringConditions/TerminalVoltage With ignitionswitchON {ll):Battery voltage With ignitionswitchOFF: V 0
82 B8
s20
B21 B22 VBU
LG2
( Ground G101) powersupply Back-up (under-hood Fuse47) ( Ground G101)
14-54
D PCMCONNECTOR (16P) Terminal Numbor Signal LCA SHB Description valveA Lock-up controlsolenoid control valveB Shiftcontrolsolenoid control Measuring Conditions/TerminalVoltage Baftery voltage Duringlock-up conditions: condition: V 0 Duringno lock-up Battery voltagein followingpositions: . E, E and positions . E, -ql, and E positions lst and 2nd gear in 0 V in followingpositions: . E, E;, and E positions 3rd gear in . E and E positions 4th gear in . E, El, and El positions Battery voltage Duringfull lock-up conditions: conditions; Pulsing signal Duringhalf lock-up voltage With ignitionswitchON (ll);Battery 0 With ignitionswitchOFF: V In E position: OV Baftery voltage In otherthan E position: Battery voltagein followingpositions: . E position . E, E, and E positions 2nd and 3rd gear in . E position 0 V in followingpositions: . E position . E. E, and E positions lst gear in . Erl and E positions 4th gear in .EandEpositions
D1 D2
D3
LCB
valveB Lock-up controlsolenoid control Not used valves Powersupplyfor solenoid (Under-hood Fuse15) gear position switch Ay'T B positioninput valveA Shift controlsolenoid control
D4 D5 D6
D7 VB SOL ATP R SHA
D8 {'98model} D8 ('99 00 models)
ATPD3 O/DSW
gear position switch Ay'T E positioninput Over-Drive(O/D)switch signal input
In E position: 0V voltage Baftery In other thanE position:

When Over-Drive {O/D)is OFF(O/DOFF light is ON):0 V indicator is When Over-Drive {O/D) ON {O/DOFF light is oFF):Battery voltage indicator : I n E p o s i t i o n0 V 5 In otherthan E position: V signal Depending vehiclespeed:Pulsing on Approx.0 V when vehicleis stopped: signal Depending vehiclespeed:Pulsing on Approx.0 V When engineis stopped: I n E a n d E p o s i t i o n s0 V : 5 In otherthan E and m position: V
D9
D10 Dl1
ATP D4 NC NM NMSG ATP NP AlP 2 ATP 1 NCSG
A/f gear position switch E positioninput sensorinout Countershaft sDeed Mainshaft speedsensorinput Mainshaft speedsensorground A,/Tgear position switch E and input El positions A/T gear position switch El positioninput A,/Tgear position switch E positioninput Countershaft speedsensor grouno
D12
D13 D14 D15 D16
InE position; 0V Battery voltage In other thanE position:

InEposition:0V Battery voltage ln otherthan El position:
14-55
Checkingths DiagnosticTrouble Code (DTC) with an O8D ll Scan tool or Honda PGM Tsster Whenthe PCMsenses abnormality the input or outputsystems, El ('97- 98) or E ('99- O0)indicator an in the light in the gaugeassmbly (DLC){locatedunderthe dash on the passenger's will blink.When the 16PData Link Connector side) is connected the OBD ll ScanTool or Honda PGM Testeras shown, the scan tool or testerwill indicate to the Diagnostic TroubleCode(DTC) when the ignitionswitchis turnedON(ll).
DATA LINKCONNECTOR {16PI
[ -=.r,
v,.,/ i , i
,i
ili
HONDA PGMTESTER ol OBD SCAN II TOOL
lf the E or E indicatorlight or the MIL has been reported problemis suspected, on, or if a driveability follow this procedure: 1. Connect OBD ll ScanTool (conforming SAEJ1978)or HondaPGMTesterto the 16PDLC.(Seethe OBD ll Scan the to Tool or HondaPGMTesteruser'smanualfor specific instructions. you are usingthe HondaPGMTester,makesure lf it is set to the SAE DTCWpe). Turn the ignitionswitchON (ll),and observethe DTCon the screen Record allfuel and emissionDTCS, DTCS, freeze A,,/T and data. lf there is a fuel and emissions DTC, first checkthe fuel and emissions systemas indicated the DTC(except DTC by for P0700). DTCP0700 meansthere is one or more Ay'T DTC,and no Droblems were detectedin the fuel and emissions circuitof the PCM. Wire down the radio station presets. Reset the memorywith the PGMTestero. by removingthe BACKUP fuse in the under-hood fuse/relay box for more than 10seconds. Drive the vehicle for several minutes at speeds over 30 mph (50 km/hr), and then recheckfor DTCS.lf the A/T DTC returns,9o to the Symptom-toComponent Charton pages14-60and 14-61 the '97 models,and pages14-62 for and 14-63 '98 - 00 models.lf the OTCdoes not return,there was an intermittent for problemwithin the circuit.Makesure all pinsand terminalsin the circuitare tight, and then go to step8. Reset radioDreset the stations, and setthe clock.
2. 3. 4.
5. 6. 7.
8.
1 4 -5 6
Checkingthe DiagnosticTrouble Code IDTCI with the ServicCheckConnestoland SpecialTool light in the ('97- 98) or E (gS - OO) indicator the in an when the PcM senses abnormality the input or outputsystems' E gaugeassembly may blink. with the specialtool side)is connected (2P)(located underthe dash on the passenger CheckConnector When the Service when the ignitionswitchis turned ON TroubleCode(DTC) as shown,the E or E indicatorlight will blinkthe Diagnostic { ). tool to the light has beenreponedon, connect servicecheckconnector(2P) the special when the E or E indicator light' the E or E indicator Thenturn ON (ll)the ignitionswitchand observe
.AUGE AssEMaLY
$1,"^f:tT"'ff,
'99 - O0models
'97 - 98 models
CONNECTOR SCSSERVICE 07PAz- (x!l0100
by short blinks.codes 1o and aboveare indicated a seriesof long and short by codes 1 through9 are indicated individual the code.After deterblinks.Add the long and short blinkstogetherto determine blinks.one long blink equals1o short '97 model, for and 14-61 the chart on pages14-60 systemsymptom-to-component code,referto the electrical miningthe '98- 00 models. tor and 14-63 the and pages14-62
Short blinl lonc.)
Sr. DTC1
S.. DTC2
Long blink Shori blink! {fiv. timt l
Sc. DTC 15
(cont'd)
14-57
(cont'dl
L 2. Remove kickpanelon the passenger's the side (seesection2O), Remove the PCM,and turn it over.
KICK PANEL
Inspect circuiton the PCMaccording the troubleshooting the to flowchartwith the special tools and a digitalmultimeter. How to Use the BackplobeSet Connect the backprobe adapters the stackingpatchcords,and connectthe cordsto a multimeter. to Usingthe wire insulation a guide for the contoured of the backprobe as tip gentlyslidethe tip into the connector adapter, from the wire side until it comesin contact with the terminalend of the wire.
BACKPROBE
EACKPROBE SET 07sAz- 001000a {tworequired)
DIGITAL MULTIMETER (Commercially .v.ilablel KS-AHM-32-003 ot oquivalont
14-58
PCMResetProcedure '1. Turn the ignitionswitchoff 2. to box for 10 seconds resetthe PCM. fuse/relay Remove the BACKUP fuse (7.5A) from the under-hood NOTE: the radio presetstationsand clock setting Make note of the radio . Disconnecting BACKUp fuse also cancels the presets fuse so you can resetthem beforeremovingthe . The PCMmemorvcan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester'
{7.5AI FUSE BACKUP IRADIO}
UNDER.HOOD BOX FUSE/RELAY Final Proceduro This proceduremust be done after any troubleshooting. 1. Turn the ignitionswitchOFF. 2. 3. Reset the PCM. (16P), removethe special tool or the Disconnect OBD ll ScanTool or HondaPGMTesterfrom the DataLinkConnector (2P). CheckConnector from the Service and clocksetting' Turnthe ignitionswitchON (ll),and set the radio presets over 30 mph minutesat speeds the test-drive vehiclefor several To verifythat the problemis repaired. (48 km/h).
4. 5,
14-59
Symptom-to-Component Chart
Electrical System-'97
DTC*
P1753 (1) P1758 \21 P1 7 0 5 (5) P1706 (6) P0753 \11 P0758 (8) E Indicatol Light Blinks Bl i n k s Blinks OFF Bl i n k s Blinks Blinks Bl i n k s Blinks OFF OFF
Model
MIL Detection ltem Lock up controlsolenoid valveA Lock-up controlsolenoid valve B gear positionswitch(shortto ground) A,/T gear positionswitch{open) A,/T Shift controlsolenoid valveA Shift controlsolenoid valveB Countershaft speedsensor Mainshaft speedsensor Linearsolenoid Lock-up controlsystem Shift controlsystem Page (seepage 14-64) (seepage14-66) (seepage14-68) (seepage14-70) (seepage 14-72) (seepage14-74) {seepage14-76) (seepage l4-78) (seepage 14-80) (seepage14-82) (seepage 14-84)
ON
ON ON ON
ON
ON ON
P0720 (9)
P0715 (15) P17 68 (1 6 ) P0740 {40) P0730 (41)
ON
ON
ON
ON
DTC*:The DTc in parentheses the codethe loaindicator is rightindicates when the DataLink Connector connected the HondapGM Tester. is to
14-60
controlsystem' transmission for NOTE:When the OBD ll ScanTool or HondaPGMTesterindicateDTC(s) the automatic of meansa detection some automatictransmiscode P07oo simultaneously. code P0700 the scantool or testerindicates controlsystem sion problemin the PGM-Fl to according the table below. light does not blink,performan inspection lf the self-diagnostic indicator E Symptom (not blinking) the ignition whenever light is on constantly E indicator switchis ON (ll). afterignition light does not come on for two seconds E indicator switchis first turnedON (ll). Shift levercannotbe movedfrom @ positionwith the brakepedal Dressed, to {0) lgnitionkey cannotbe movedfrom ACC(l) position LOCK posi tion with the shift leverin E position. Inspection Ref.page 14-86 't 4-41 shift locksystem Check system CheckkeYinterlock 14-89 14-91
NOTE: lf a customer describesthe symptom for code P1706(6), it will be necessaryto recreatethe symptom by test-drivthe ing, then recheck OTC.
14-61
Electrical System-'98 - 00 Models
DTC*
P1753 (1) P1758 (21 P1705 (5) P1706 (6) P0753 (71 P0758 (8) Et Indicatol Lighr (98) E Indicator Light ('99 - 00) Blinks Blinks Blinks OFF Blinks Blinks Blinks Blinks Blinks OFF OFF MIL Detestion ltom Page
ON
Lock-up controlsolenoid valveA Lock-up controlsolenoid valveB gear positionswitch(shonto grounol A,/T gear positionswitch(open) A,/T Shiftcontrolsolenoid valveA Shift controlsolenoid valveB Countershaft speedsensor Mainshaft speedsensor Linearsolenoid Lock-upcontrol system Shiftcontrolsystem
{seepage14-93) (seepage 14-96) (seepage14-99) (seepage 14-103) (seepage14-106) (seepage14-109) { s e ep a g e1 4 - 1 1 2 ) ( s e e a g e1 4 - 1 1 4 ) p ( s e ep a g e1 4 - 1 1 7 ) (seepage 14-119) ( s e e a g e1 4 - 1 2 1 ) p
ON
ON ON
ON
ON ON
P0720 (9)
P0715 {15) P1768 (16) POl40 (40)
ON
ON ON ON
P0730 (41)
DTC*;The DTCin the parentheses the codethe E or E indicatorlight indicates is when the DataLink Connector connected the HondapGM Tester. is to
14-62
controlsystem, transmission for NOTE:When the OBD ll ScanTool or HondaPGMTesterindicateDTC(S) the automatic transmisof meansa detection some automatic CodeP0700 simultaneously. code P0700 indicates the scantool or tester controlsystem. sion problemin the PGM-Fl to according the table below. light does not blink,performan inspection lf the self-diagnostic or E indicator E Symptom afterignition light does not come on for two seconds E or E indicator switchis first turnedON (ll). (not blinking) the whenever E or E] indicatorlight is on constantly ignitionswitchis oN {ll). Shift levercannotbe movedfrom E positionwith the brakepedal presseo. lgnitionkey cannotbe movedfrom ACC(l) positionto LOCK(0)position with the shift leverin E position. after ignition light does not come on for two seconds O/DOFFindicator switchis first turnedON (ll).('99- 00 models) the ignition whenever The O/DOFFindicatorlight is on constantly switchis ON (ll).('99- 00 models) light does not come on eventhoughthe OverThe O/DOFFindicator ('99- 00 models) in Drive(O/Dlswitchis pressed E position. CheckOver-Drive{O/D} switchcircuit Inspection Ref.page 14-123 14-125 Checkshift locksystem system Checkkey interlock 14-'t26 14-129 14-131 14-132 14-133
(6), NOTE: lf a customer describesthe symptom for code P17OO it will be necessaryto recreatethe symptom by test-drivthe ing.then recheck DTC.
14-63
('97 Model) Electrical Troubleshooting

Troubleshooting Flowchart Lock-up ControlSolenoidValveA
. OBD ll ScanTool indicatesCode P1753. . S e l f - d i a g n o s i si @ i n d i c a t o r light blinksonce. PossibleCause . Disconnectedlock-up control solenoid valve A/B assembly . Short or open in lock-up control solenoid valveA wire . Faulty lock-up control solenoid Checkand recordthe freezedata rn caseit is needed laterfor problem verification.
lf the Honda PGM Tester is available:
P e r f o r mt h e l o c k , u p c o n t r o l s o l e n o i d a l v eA t e s t u s i n gt h e v HondaPGMTester.
Did the solenoid pass the test?
The solenoidis OK at this time. Verify that all connectors in the circuil are making good contact,
NO
PCMCONNECTORS Checkfor a Short to Power: r. I urn rne tgntUon swttchut-f. 2. Disconnecr A (32P)and B the ( 25 P ) c o n n e c t o r sr o m t h e f PCM. 3. Turnthe ignition switch (ll). ON 4. Measure voltagebetween the t h e 8 5 a n d A 9 o r A 2 2t e r m i nals. Wiresideof femaleterminals
ls there voltage?
Repairshort to power in the wire between the 85 terminal and the lock-upcontrol solenoidvalveA.
Measure Lock-upControl Solenoid Valve A Resistance: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance between 85 and A9 or A22 the
ls the resistance 25 ()? 12
Checkfor loose terminal fit in the PCM connectors, ll necessary, substitulea known-goodsolenoid valve assembly or PCM and recheck,
To page14 65
14-64
From page 14-64
PCMCONNECTORS Check Lock-up Control Sol6noid Valve A tor a Short Circuit: tt 1 . D i s c o n n e ch e 2 P c o n n e c t o r controlsole from the lock-up noidvalve4!/Bassembly. 2. Checkfor continuitybetween the 85 andA9 or A22termi nals. Wiresideof femaleterminals
Reprir short to ground in the wire between the 85 terrninal and the lock-uDcontiol solenoidvalveA.
SOLENOID CONTROL LOCK.UP CONNECTOR VALVEA/B ASSEMBLY
MeasuroLock-upControl Soleat noid Valve A Resistance the solenoid valve Connector: between the resistance Measure the No. 2 terminalof the connector and body ground.
----E-
lFr] .=-A LcA IYELI (nJ Y
sideof maleterminals Terminal
12 ls the resistance - 25 O?
Check for open in the wire belwen the 85 teiminal and the lock-uocontrol solenoidvalve A
Replacethe lock-np control solenoid valve A/B assembly.
14-65
('97 Electrical Troubleshooting Model)

Troubleshooting Flowchart Lock-up ControlSolenoidValveB
. OBOll ScanTool indicatesCode P1758. . Self-diagnosis indicatorlight prblink3twice. PossibleCauso . Disconnoctedlock-up control solnoid valve A/B assembly . Short or opn in lock-upcontrol 3olenoidvrlve B wi.e . Faulty lock-up control solenoid valve B
Check and record the {reeze data jn case it is needed later for prob, lem verification.
Did the code return?
The system is OK at this time. Verify thet dll connectors in the circuit are makinggood contact.
Checktor a Short to Powerl 1. Turnthe ignition switch OFF. 2. Disconnect A (32P)and B the ( 2 5 P )c o n n e c t o r sf r o m t h e PCM. 3. Turnthe ignition switch {ll). ON 4. Measure the voltagebetween the 84 and Ag ot A22 tetmi nals,
PCMCONNECTORS
Wire sideof femaleterminals Repairshort to power in tho wire bstween the 84 terminal and the lock-upcontrol rolenoid valve B.
MeasureLock-upControl Solenoid Valve B Resistance: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance b e t w e e nt h e 8 4 a n d A g o r A22terminals.
l s t h e r e s i s t a n c e1 2 2 5 O ?
Checktor looseterminal tit in the PCM connectors, It necessary, subslitute a known-good solenoid valve assemblyo. PCM and rechck.
To page14-67
14-66
Frompage14 66
PCMCONNECTORS
Check Lock-up Control Solenoid Valve B lor a Short Circuit: the 2P connector 1. Disconnect controlsole from the lock-up noid valveA/8 assembly. 2. Checkfor continuitybetween the 84 and A9 or A22 lermi_ nals-
Repairshort to ground in the wire between the 84 lerminal and the lock-upconlrol solenoidvalve B.
SOLENOID CONTROL LOCK-UP CONNECTOR VAI-VEA/B ASSEMBLY Me6aureLock-upControl Sole_ at noid Valve B Resistance the SolenoidValve Connector: between Measurethe resistance the No. 1 terminalof the connector and body ground.
LC B (GRN/BLK)
12 ls the resistance - 25 0?
Check lor open in the wire bctween the 84 terminal and the lock-upcontrol solenoidvolva B.
Replacethe lock-up conttol solenoid valve A/B ass6mbly.
14-67
Electrical Troubleshooting Model} {'97

Troubfeshooting Flowchart- AIT GearPositionSwitch (Short)
. OBOll ScanTool indicatsCode P1705. ' Selt-diagnosis indicatortight p1blinb Iive times. Po$ible Cause ' Short in A/T gear position switch . Faulty A/T gear position switch NOTE:Code P1705(5) is causedwhen the PCMreceives wo gear position t anputs the sametime. at
Checkand record the freeze data in caseit is needed laterfor problem verification.
Observethe A/T Gar Po3ition Indicator: 1. Turnthe ignition switch lll). ON gear position 2. Observe A./T the indicator, nd shilt to each a position separately.
Doesany indicator stayon when the shift leveris not in that position?
The system is OK .t this time. Ch6ck ihe wii6 harnessfor dam490,
Do allgear position indicators go out?
PCMCONNECTORS
MeasureATP R Voltago: 1. Shittto all positions otherthan 2. lMeasure voltagebetween the the 816 and Ag or A22 terminals.
tr.
Check tor 3hort in the wire betwaenthe 816torminal and tho A/T gear pGilion switch or A/T gsar posiiion indicator. ff wire is OK, checkfor 10036 torminal flt in lhe PICMconnectoB. It necessary, substitute a known-9ood PCM and recheck.
MeasureATP NP Voltage: 1. Shiftto all positions otherthan
NorE.
2. Measure the vohagebetween lhe 825 and Ag or A22 terminals. Chock for ahort in the wire betwentho 825 torminal end the A/T 96.r pGition indicstor, or a sho.t in tha wiro! btween the A/T gear po3ition indicator and the A/T gar position lwitch. lf wircs ar OK, ch6ck for loos terminal fit in the PCMconnectors. It nece3sary,substitute a knowngood PCMand recheck.
ATP NP {LT GRNI
ls there battery vohage?
To page14-69
14-6 8
Frompage14-68
MeasureATP D4 Voltage: otherthan 1. Shiftto all positions 2. [/leasurethe voltage between the 824 and Ag or A22 terminals.
Eil
MasureATP D3 Voltage: otherthan L Shiftto all positions 2. Measure the voltagebetween the 88 and A9 or A22 termi nats.
Check tor short in the wire betweenthe 824 terminal and the A/T geai position indicator. or a 3hort in the wir6s between the A/T gear position indicttor and the A/T gear position switch. lf wires are OK, checklor loose ter' minal fit in the PCMconneclo.s.lf substitute a known' necessary, good PrCM and recheck.
tr.
ls there bafteryvoltage?
Check for short in the wi.e between the 88 torminal and the A/T gear position switch or A/T gear position indicator. lf wire i3 OK,checklor looseterminaltit in the PCM connectors. lf necessarY,3ubslitute a known'good PCMand recheck.
MeasurATP 2 Vohage: otherthan 1. Shiftto all positions l; 2. Measure the voltagebetween the 817 and Ag or A22 termi' nals. Check for short in the wire bstwen the 817 terminal and the A/T gear posilion switch or A/T gear position indicator. lf wire is OK, checklor looseterminal fit in th6 PCM connctoF. lf necssaty, substitute a known-good PCM and recheck. Mersure ATP 1 Volt.ge: otherthan 1. Shiftto all positions 2. Measure the voltagebetween t h e 8 1 8 t e r m i n a la n d A 9 o r A22terminals. Check lor short in the wire betw.en the 818 torminal and the A/T gear position switch or A/T gear position indicator. lI wiro is OK. check for loose terminal fii in the PCM connectorc. lf necessary.substitute a known' good PCMand recheck.
El.
Checkfor loose terminalfit in the PCM connectors, lf neces3aty, substitute e known-good PCM end rocheck.
14-69

Troubleshooting Flowchart A/T GearpositionSwitch (Openl
. OBD ll ScanTool indicat6 Code P1706. . Setf-diagnGb Dl indicatortight blinks six tim$. Po$iblo C.u3e . DisconnectedA/T gear position switch connectol . Open in A/T goar position switch . Faulty A/T goar position switch Check and recordthe freeze data in caseit is neededlaterfor problem verilication.
Test the A,/Tgear position switch p { s e e a g e1 4 1 3 9 ) .
Measu.eATP R Voltage: '1. Turnthe ignition switch (ll). ON 2. Shiftto E position. 3. Measure the voltagebetween the 816 and Ag or A22 terminals.
Repeir opn in the wire botween the 816trminaland the A/T g.r po3itionswitch.
MeasureATP NP Voltage: 1. Shiftto E or E position. 2. Measure the voltagebetween the 825 and A9 or A22 termin al s , ATP NP ILT GRNI Repai. open in th6 wir6 bctwoan the 825 terminal and tho A/T gear polition indicltor or tho A/T gea. Doshionswhch.
MoasureATP 04 Voltage: 1. Shiftto E position. 2. Measurethe voltage between the 824 and A9 or A22 terminars,
Ropai. opcn in tho wiro betwoen the B24torminal .nd the A/T gcar Dosition switch.
To page14-71
14-70
Frompage14-70 FCM CONNECTORS
MeasureATP D3 Vohag: 1. Shiftto E position. the 2. Nleasure voltagebetween the 88 and Ag or A22 termi nals, Wire sideof femaleterminals
Repairopen in the wirg bstween the 88 tolminal and tho A/l gear oo3ition 3witch.
MsasureATP2Volttg6: '1. Shiftto position. E 2. Measurethe voltage between the 817 and A9 or A22 termi' nals.
Repairopen in lhe wire between the 817 terminaland tho A/T gear position switch.
MoasureATP1Voltage: 1. Shiftto A position. the 2. Measure voltagebetween the 818 and Ag or A22 terminats,
Rpairopon in the wiro between the 818 terminll and the A/T goar poshion switch.
Checktor looso terminal fit in the PCM connectors. lf necossarY, substitute a known-good PCM and rechock.
ElectricalTroubleshooting('97 Model)
Troubleshooting Flowchart Shift ControlSolenoidValveA
. OBD ll ScanTool indicatesCode P0753. . Self-diagnoskE indicator light blinks seventims. PossibleCauso . Disconnected shift control solenoid valve A/8 a$embly connector . Short or open in shift control solenoid valve A wire shift controlsolenoidvalveA
Checkand record the freezedata in caseit is needed laterfor prob lem verification.
I
Perform shiftcontrolsolenoid the v a l v eA t e s t u s i n gt h e H o n d a PGMTester.
Did the solenoid passthe test?
The solnoid is OK at this time. Verify that all connectors in the circuit are making good contact.
PCMCONNECTORS Checktor a Short to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect A (32P)and B the ( 25 P ) c o n n e c t o r sf r o m t h e PCM. 3. Turnthe ignition switch lll). ON 4. Measure the voltagebetween the 83 and Ag or A22terminals.
Wire sideof female termin6ls Repairshort to power in the wire between the 83 terminal and the shift control solenoid valve A.
Measure Shift Control Solenoid Valve A Resistanco: 1. Turn the ignitionswitchOFF. 2, Measure the resistance betweenthe 83 and A9 or A22 termrnals,
ls the resistance 25 {)? 12
Checktor loose terminal tit in the PCM connectors, lf necessaay, subslituie e known-good solenoid valve assemblvor PCM and rechck.
To page l4-73
14-72
Frompage14-72
C h e c kS h i f t C o n o l S o l e n o i d Valve A for a Short Circuit: 1. Disconnect the 2P connector from the shiftcontrolsolenoid valve Ay'B assembly. 2. Checkfor continuitybetween the 83 andA9 orA22terminals.
Repai.short to ground in the wire belwen th6 83 terminal and the shift cont.ol solenoidvalveA.
SHIFTCONTROLSOI.ENOID CONNEC1OR VALVEA/B ASSEMALY MeasureShift Control Solenoid Valv6 A Resistanceat the Solenoid Valve Connector: Measure the resistance between the No. 1 terminalof the connec tor and bodyground.
lffil l-SHA IBLU/YELI (o)

T I
ls the resistance - 25 0? 12
Check lor ooen in the wire between the 83 terminal and the shift control solnoidvalve A.
Replace the shift control solenoid valve A/B assemblv.
14-73
('97 Troubleshooting Model) Electrical

Flowchart Shift ControlSolenoidValveB Troubleshooting
. OBOll ScanToot indicrt8 Codo P0758. . Setf-diagnGisE indicatorlight blinks oight tim93. Po33ibla Crusa . Disconnec{ed shift cont.ol solenoid valve A/B dssomblyconnector . Short or open in shift conlrol solenoid valvg B wire ' Faultvshift comrol 3olenoidvalvo B
Checkand rcord the lreere data in case it is neededlater for prob lem verilication. lf the HondaPGM Tsteris available: Test solenoid valve B with the Honda PGM Tester in the FLrnc tion test mode. The 3olonoid is OK at this time. Verifv that all connoctors in the circuit are making good contlct.
Did the solenoid Dass test? the
PCMCONNECTORS Chocktor a Sho.t to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect A (32P)and B the connectors Irom the PCM. {25P) ON 3. Turnthe ignition switch (ll). 4. Measurothe voltage botveen the 811 and Ag or A22 terminats.
Wiresideot female terminals R.p.ir 3hort to power in the wire botwon the 811 iormin.l and tho shift control sol.noid valve B.
M.6sure Shift Control Solonoid Valve B Reaistanco: 1. Turnthe ignitionswitchOFF. 2. Measure the rsistance b e t w e e nt h e 8 1 1 a n d A 9 o r A22terminals.
ls the resistance - 25 O? 12
Checl lor loosc terminal fil in the PCM connactors. It nocessarv, substitute a known-good aolenoid vllvo asssmbly or PCM and r6chsck,
To page14-75
14-74
Frompage14-74 PCMCONNECTORS C h e c kS h i f t C o n t r o l S o l e n o i d Valvo B tor a Short Circuil: 1. Disconnect the 2P connector from the shift control solenoid valvey'y'8 assembly. 2. Checkfor continuitybetween the 811 and Ag or A22 terminals,
Ropairshort to ground in the wire b64wn 811 torminal and lhg tho shift control solenoidvalvo B. SOLENOID SHIFTCONTROL VALVE A/B ASSEi'BLY CONNECTOR
Meesure Shift Control Solenoid Valve B Rosistanceat lh Solenoid Vrlve Connector: Measure the resistance between the No. 2 terminalol the connec tor and bodyground.
ti;Tll
o Y
I
I
I sH B |GRN/W{T|
Terminal sideof maleterminals Check tor open in the wire bdtweonthe 811 torminal and the shift control solnoidvalv6 B.
Reolace the shift control solenoid valve A/B asJembly,
14-75
Flowchart Countershaft Troubleshooting SpeedSensor
. OBO ll Scan Tool indicatesCode m720. ' solt-diagnosis iD!' indicator light blink3 nine tim6s. PossibleCause . Looseor faulty connectionbetween ih PCMand vehicleharness . Disconnected countershaft spoed sensorconneclor . Short or open in countershaft speed . FaultycounteBhaft speedlensor
data Checkand recordthe freeze in case it is neededlater for prob lem verification.
I
Connectthe Honda PGM Tester, t a n d t e s t - d r i v e h e v e h i c l ew i t h the tester in Data Link or snap' Shot mode,Makesure the countershaftspeed sensor readsthe sameas the vehiclespeedsensor lVSS). The countershaftsooed sensor is OK sr this time. Veritv that all c o n n e c l o a si n t h e c i r c u i t a r e making good contacl.
C h e c kt h e c o u n t e r s h a f t p e e d s sensor installation, and check it for damage.
ls the countershaft speed senproperly, sor installed and not damaged?
neinstall or roDlaco and recheck. SENSOR SPEED COUNTERSHAFT CONNECTOR
MeasuroCountoBhaftSpeedSensor Relbtance at the Sensor Connector: 1. Disconnect the 2P connector from the countershaft speed sensor connector. 2. Measure the resistance the of countershaft speedsensor.
ll-'T,ll -rT
ral
YI L__l
Terminal sideof maleterminals ls the resistance400- 600 o?
To page14-77
14-76
B PCMCONNECTOR I25PI
Chck CounteGh!ft Spocd Sonsoi for a Short Cirruit: 1 . D i s c o n n e ctth e B 1 2 5 P c o n ' ) nectorlrom the PCM. 2. Checkfor continuity botween the body ground and the B23 t e r m i n a la n d 8 2 2 t e r mi n aI individually. Repair short in tho wirgs btwoen tho 823 ,nd 822 te.minals and thc countaBhaft spd senso..
Mersuro Countorrhrtt Spoed Sonsor qrcuit tor an Open: '1.Connect the countershaft speedsensor connector, 2P 2, Measure the resistance betweenthe 823 and 822 ter mrnals. Rapair loor t.rminll or opon in tho wircs betwoon tho 823 .nd 822 terminrl! .nd th. countaF shaft specd san3or.
ls the resistance400- 600 0?
Checkfor loo3eterminsl fit in the PCM connecto13.It necess!ry, sub3titulg s known-good PCM and rochock.
14-77
Electrical Troubleshooting Model) {'97

Troubleshooting Flowchart MainshaftSpeedSensor
. OBD ll Scan Tool indic.t6 Code m715. . Self-diagnosis indic.tor light E indicatagCode 15. Po$ible Cau3o . Disconnocted mainshaft speod sensot connectot . Short or open in mainsh.ft sp6ed ' Faulty meinshaftspoedsensor Checkand record the freeze data in case it is neededlater {or prob, lem verification. N O T E : C o d e P 0 7 1 5 1 1 5 )n t h e P C M o doesn'talwaysmeanthere'san electrical problemin the mainshaft counlersharl or speedsensorcircuit; code P0715(15) may problemin the also indicate mechanical a transmission. Checkthe freeze data with a Honda PGM Tester. lf the mainshaft speed sensor rpm was 0, proceedwith this troubleshooting. not, the probable lf problomwithinthe causeis a mechanical transmission,
Check mainshaft the and countershaft speed sensor installation, and checkthesensors damage. for
Are the mainshaft and countershaft speedsensorsinstalled properly, and not damaged?
Reingtallor reolaceand recheck.
SPEEO MAINSHAFT CONNECTOR SENSOR MeaaureMaiNhatt SpoedSen3or R6sist!nce at the Sensor Connecaor: 1. Disconnect the 2P connector from the mainshaft speed sensor connector. 2. lreasurethe resistance the of mainshaft speedsensor.
ItiT,ll -F=r
_ E _
9t
LJ
Terminal sideof maleterminals B PCMCONNECTOR {25P'
ls the resistance - 600O? 400
Check MainahaftSpeed Sensor tor a Short Circuit: 1. Disconnect B (25P) the connector lrom the PCM. 2. Checkfor continuitybetlveen bodygroundand 815terminal and the 814 terminalindividu-
ReDairshort in the wir6 bt\ reen the 815 and 814 torminals and the mainsh!ft sped sensor.
To pagel4-79
14-78
Frompage14'78 PCMCONNECTOR {25P} B
MoasuroMrin3haft SpoedSanlor Resktanco: 1. Connect the mainshaft speed sensor2P connector, 2, Measure the resistance between the 815 and 814 terminals, Wir sideof female terminals Run the Electricrl Troubloshooting Flowchs tor codo m72O l9l. Chockfor loo3etorminal fh in the PCM conn6cto.s. It necessarY, substitute a known-good PCM and rochgck. MAINSHAFT SPEED SENSOR CONNECTOR
ls the resistance 400- 600 O?
CheckNM Wiro Continuity: 1. Disconnect the 2P connector from the mainshaftspeedsensor connector. 2. Checkfor continuitybetween t h e 8 1 5t e r m i n a l a ntd e N o . 2 h terminal of the mainshaft speeosensorconneoor.
Ropairopen in the wir6 betwon the 815 terminal and the mainshaft sDood$nsoa.
CheckNMSG Wire Continuity: Checkfor continuity between the 814 terminal and the No. 1 terminal of the mainshaftspeedsensor connector.
Rpai. opon in the wi.o between the Bltl terminal and tho main' 3haft sDedsensoa,
Ch.ck lor loos. t6rminallit in the PCM connecto13,lf neca3sary, substitute a known-good PCM and rochock.
14-79
('97 Electrical Troubleshooting Modell

Flowchart LinearSolenoid Troubleshooting
. OBD ll Scan Tool indicatesCode P1768. . S.lt-diagnosis E indicator light indicat* Code 16. PossibleCaus . Disconnoctedlinear solenoid con. Short or oDen in linear solenoid . Fsultv linear solenoid Checkand record the freezedata in case it is neededlater for prob lem verification. LINEARSOLENOID CONNECTOR
t-TTI t]]lt
t lI ?r l -T r
Mssurc Linear Solanoid Re3istance ei th SolonoidConnoctor: 1. Disconnect 2P connector the from the linear solenoidconnector, 2, Measure the resistance the ol linearsolenoid.
at
l
L_l
Terminal sideot maleterminals
ls the resistance about5.0O? B PCMCONNECTOR I25PI LSM {WHTI CheckLinearSolenoid{or a Short Cileuit: 1. Disconnect B (25P) the connec tor from the PCM. 2. Checkfor continuitybetween t h e b o d y g r o u n da n d t h e B 1 terminaland 82 terminalindi vidually. Wiresideof lemaleterminals Rooairshort in the wires between the Bl end 82 terminek .nd the linearsolenoid. LSP{RED)
To page14-81
ChckGround Lin: c 1. Disconnect e A (32P) onth nector from the PCM. 2. Checklor continuitybetween A terminals g and A10and b e t w e e nt e r m i n a l sA 2 2 a n d A.23.
PGl IBLKI
PG2(ALKI
Wiresideof temaleterminals Repair loose terminal or opon in th wires between terminals A9, A10,A22 and A23 and g.ound,and G4011. repairpoor ground lG101,
Measure Linear Solenoid R*istance: 2P 1. Connect linearsolenoid the connector. 2. Measure the resistance between the 81 and 82 termi nals,
ls the resistance about5.00?
Ropair loos terminal or op6n in the wiles between th 81 and 82 l6rminals and the linear solenoid.
Chocklor loose tarminalfit in the PCM connectors. lf necosaarv, subsiituto a known-good PCM and recheck.
14-81
('97 Troubleshooting Model) Electrical

Flowchart Lock-up ControlSystem Troubleshooting
. OBD ll ScanTool indicrt6 Cod6 P0740. . Self-diagno3b indicatorlight E indicatos Codc 40. PossibloCause Faulty Lock-upcontrol sy3t6m
data Checkand recordthe freeze laterlor probin caseit is needed lem verification
Checktor Another Code: w C h e c k h e t h e rt h e O B D l l s c a n l t o o l o r t h e E i n d i c a t o ri g h t indicates another code.
Doesthe OBDll scantool or light indicate the E indicator code? another
Perlorm the Troubleshooting Flowchart lor th indicatd Codo{s).Rochecktor code P0740 {ilol after troubl$hooting. NOTE:Do not continuewith this troubleshooting until the causesof any other DTCS have beencorrected. * Even if yotl cannot reproducecode P0740.test the line pressure,test the clutch pressures, i{ necessary, valveassembly replace lock-up the controlsolenoid and
Tesl Line Pressure: ( Measurehe linepressure see t p a g e1 4 - 1 6a n d 1 4 - 1 6 2 ) . 1
ls the line pressure withinthe limit? service
R6pairtho hydraulicaystm as necessary{seepage 14-162}.
Test lst, 2nd, 3rd, and 4th Clutch Pressure: Measure 1st,2nd,3rd,and 4th the (seepage 14161 clutch pressure thru 14''163).
ls eachclutchpressure within limit? the service
Repairthe hydraulicsystem ds necessary {see pago 14-152rnd 14-163).
To page14-83
1 4-82
From page14 82
R e p l a c et h e L o c k - u p C o n t r o l S o l e n o i dV a l v e A s s e m b l ya n d Recheck: 1 . R e p l a c eh e l o c k - u pc o n t r o l t solenoidvalve A/B assembly (seepage14-'135). 2 . T u r n t h e i g n i t i o n w i t c hO F F s and reset the PCM by removing the BACKuP (7.5A) fuse fuse/relay in the under-hood box for morethan 10seconds. 3. lJsingthe scantool, checkto coolant be surethatthe engine is or temperature 176"F 180'C) above, 4 . D r i v et h e v e h i c l ea t 5 5 m p h (88 km/h)constantly more for tnan one mrnute. (40). 5. Recheck code P0740 for
Doesthe OBDll scantool indicate codePO74O doesthe El indica or tor light indicate code40?
The svstem is OK ai this time.
R e p l a c et h e L i n e a r S o l n o i d A$embly and Recheck: ' 1 . B e p l a c e h e l i n e a rs o l e n o i d t assembly {seepage14-138). 2. Turn the ignition switch OFF and resetthe PCMmemory by removing BACK (7.5A) the UP fuse in the underhood fuse/ r e l a yb o x f o r m o r e t h a n 1 0 seconds. 3. Usingthe scantool, checkto be surethatthe engine coolant (80'C) temperature 176"F is or above. 4. Drivethe vehicleat 55 mph (88 km/h)constantly more than for oneminute, 5. Recheck codeP0740 for {40).
Does the OBD ll scan tool i n d i c a t e c o d e P 0 7 4 0o r d o e s the E indicator light indi cate code 40?
The svsteo is OK at this tim.
Replacethe transmission and torque convertorassembly.

Troubleshooting Flowchart Shift ControlSystem
. OBD ll ScanTool indicatesCode P0730. . Selt-diagnosis ,l indicator E light indicatesCode41. PossibleCause F""lty "t lft ".tttr"l "y"t..
Check and record the freeze data in case it is needed later for problem verification.
Checktor Another Code: w C h e c k h e t h e rt h e O B D l l s c a n t o o l o r t h e P l l i n d i c a t o rl i g h t indicates another code,
Doesthe OBDll scantool or the E indicator light indicateanother code?
P e r t o r mt h e T r o u b l e s h o o t i n g Flowchart for the indicated Codels). Do not conlinu with this troubleshooting ntil the u causesof anv other DTCShave been corrected.Recheck code for P0730 {41)after troubloshooting. + E v e n i t y o u c a n n o tr e p r o d u c e o d e c P0730, test drive the vehicle,test the , c l u t c h p r e s s u r e sa n d i f n e c e s s a r y , replace shiftcontrolsolenoid the valve
Test lst. 2nd, 3rd. and 4th Clutch Pressure: M e a s u r e h e 1 s t ,2 n d , 3 r d , a n d t (seepage 144th clutchpressure 1 6 1 h r u1 4 - 1 6 3 ) . t
ls eachclutchpressure within the service limit?
Repairthe hydraulicsvstem as necessary lsee page 1,1-162 and r4-1631.
To page 14-85
Frompage14-84
ReplaceShift Control Solenoid vslve Assemblyand Recheck: 1. Replacethe shift control solenoidvalve A/B assembly (see page'14 136). 2. Turn the ignitionswitch OFF and resetthe PCMmemoryby removing BACKUP (7.5A) the fuse/ fuse in the under-hood relaybox for more than 10 seconds. 3 . D r i v et h e v e h i c l ea t o v e r 1 2 mph (20km/h)in 1st,2nd,3rd, and 4th qear for more than 30 seconds E position. in (41). for 4. Recheck codeP0730
Does OBDll scantool the indicate codeP0730 does or light indi the E indicator catecode41?
The svstem is OK at this time.
ReplaceLinea. Solenoid Assmbly and Recheck: 1 . R e p l a c e h e l i n e a rs o l e n o i d t assembly lseepage14-138). 2 . T u r n t h e i g n i t i o n w i t c hO F F s and resetthe PcM memory by A) removing BACKUP 17.5 the fuse in the underhood fuse/ relayboxtor morethan 10sec' onos. '12 3 . D r i v et h e v e h i c l ea t o v e r mph {20km/h)in 1st,2nd,3rd, and 4th geal for more than 30 secondsin -Daposition. (41). 4. Recheck codeP0730 for
Doesthe OBDllscantool indicate code P0730 does or lightindithe Di indicator catecode 41?
The syslem is OK at this time.
14-85
('97 Troubleshooting Modell Electrical

Troubleshooting Flowchart E IndicatorLight On Constantly
The E indicator light is on constantly {not blinking) whenever the ignitionswitch b ON (lll. B PCMCONNECTOR I25PI
MeasureD4 IND Voltage: '1. Turnthe ignitionswitchOFF. 2 . Disconnect I (25P) the connector lrom the PCM. 3. Turnthe ignition switch lll). ON 4. Measure the voltagebetween the 813 terminaland body grouno,
IGRN/8LKI
Wire sideof temaleterminals Ropairshort to powor in the wire betwean tho B13 terminal and tho gauge assembly.
Maa3ureATP D4 Voltage: 1. Turnthe ignitionswitchOFF. 2. Connect B (25P) the connector to the PCM. 3. Turn the ignitionswitchON (ll). 4. Shiftto any positionother than 5. Measurethe voltage between the 824 terminaland body ground.
E.
Test the lVT gear position switch (seepage'14139).
Check lor a short to g.ound in the wire betwoen tho B2rlte.mi nal and A/T gear position switch. It wira i3 OK, substitute a knowngood PCMand rcheck.
Flowchart E IndicatorLight DoesNot ComeOn Troubleshooting

The E indicator light doos not como on whon the ignition switch is first turned ON {lll. (lt should come on lor about two aaclnd!.I
Checkthe SorviceCheckConnectori Make sure the specialtool 1SCS is ServiceConnector) not connected tothe servicecheckconnector,
(SCS Service ls the specialtool Connectorlconnected the serto vicecheck connector?
Di3connectthe spccial tool trom the servica chock connoctor and rechsck.
chock th. El IndicatorLight: Shift to E position.
Ch6ckfor looie terminal fit in the PCM connoctors. ll nocesssry, sub.titule a known-good PCM and rechock. A PCM CONNECTOR {32PI
LGl IBRN/BLKI Checkthe Ground Circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnect A {32P)connecthe tor from the PCM. 3. Check for continuity between the A9 terminal and body ground and tho A22 terminal and body ground.
LG2(BRN/BLKI
Rpair opon in the wire3 between the Ag or A22torrninab and G101. Repairthe body ground (G1011.
To page14-88
(cont'd)
14-87
('97 Electrical Troubleshooting Modell

Troubleshooting Flowchart E IndicatorLight DoesNot GomeOn (cont'dl
Frompage14-87
IYEL/BLK)
Measure Power Supply circuit Voltage: 1. Turnthe ignition swatch (ll). ON 2. Measure the voltagebetween t e r m i n a lA g a n dA 1 1 a n d s b e t w e e nt e r m i n a l sA 2 2 a n d A24. Repair open or short in the wire botwon the A11 and/or A24 terminals, the PGM-FImain relav, and ih6 fuse box.
IGP2IYEL/BLK)
voltageT ls therebaRery
MeasurDil INOVoltag6: L Turnlhe ignitionswitchOFF. 2. Connect A 132P) the connector to the PCM. 3. Connecta digital multimeter to the 813 and A9 or A22 ter mtnals, 4 . T u r n t h e i g n i t i o ns w i t c hO N (ll),and makesurethat voltage is available two seconds. for Check for an opn in the wire between the 913 terminal and the gauge assembly. lf wire is OK. check tor a faulty E indicator lighl bulb or a taulty gauge a$embly printed circuil bo.rd.
CheckD4IND tor a Short Circuit: Check continuity for between the 813terminaland body ground.
Ropairshort in the wiro between the 813 lerminal and the gauge assembly.
Checktor looseterminal frt in the PCM connector3. Chock the A/T gear position switch. ll necessary, substitute a known-good PCM and recheck.
14-88
Flowchart InterlockSystem- Shift LockSystem Troubleshooting

Shift lever cannot be moved from E] position with the brake Pdel preiseo.
ChockBrakeLight Operation: Press brakepedal. the
Are the brakelightsON?
Repsirfauhy brake switch circuit {seosction231. PCMCONNECTORS
MasureSTOPSW voltage: l Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e A ( 3 2 P )a n d lrom the D (16P)connectors PCM. 3. Measlre the voltagebetween the D5 and Ag or A22 terma nals with the brake Pedal pressed, Wire sideof lem6letermanals
Repair opon in the wi.e be{w.en the D5 terminal and the br.ke switd!. UNIT CONTROL INTERLOCK CONNECTOR I8P) MeasurILU vohage: 1 . C o n n e c tt h e A { 3 2 P )a n d D to connectors the PCM. 116P) the 8P connector 2. Disconnect from the interlockcontrol unit ON switch (ll). 3. Turnthe ignition 4. Measurethe voltage between the No.7 terminaloftheinter lockcontrol unit and body ground with the brake Pedal pressed,
ILU IWHT/REDI
Chckfor an opon or thon in the wire Mwoon tho No. 7 terminrl of the inte ock control unit and the 812 termin.l of the PcM. ll the wirs is OK, check tor loo3e terminal fit in the PCM connec_ to13. ll nece3sary,3ubstitutea known-good PCM and rechock.
(cont'd)
To page14 90
14-89
Troubleshooting Flowchart Interlock System- Shift LockSystem(cont'd)
Frompage14.89 INTERLOCK CONTROL UNIT CONNECTOR {8P) Measu.eATP P Voltage: Measurethe voltage betweenthe N o . 6 t e r m i n a lo f t h e i n t e r l o c k controlunit and body ground. NOTE:Shiftlevermust be in E.
ATPP IBLK/BLU'
Repai. open in the wir6 betwoen tho No.6 termin.l olthe intorlock control unit and the A/T geal po.ition rwitch.
Chock Shitt Lock Solenoid lor .n Opon Circuit: 1. Turn the ignitionswitchOFF. 2. Disconnect shift locksole the notoconnoctor. 3. Checkfor continuitybetween the No. 3 terminal of the interlock contrcl unit and the No. 2 terminal ot the shift lock solenoid connector.
SHIFTLOCKIYEL/BLK} 1 2
5 6 7 8
o
SHIFT LOCKSOLENOID LOCK! CONNECTOR 1
YEL/BLK
Wiresideof femaleterminals Rapair opon in the wiro bstwcen tho No. 3 torminal and tho shift lock solenoid.
Check Shift Lock Solenoid Operation: '1. Connect No. 1 terminalof the the shiftlocksolenoid connector to the battery positive ter minal. and connectthe No. 2 terminalto the batterynegative terminal. 2. Chockthe shift lock solenoid operation.
NOTE:Do not connect the No. 2 terminalto t h e b a t t e r yp o s i t i v et e r m i n a l o r y o u w i l l damagethe diode insidethe shift lock solenoid.
SHIFTL@K SOI.ENOID CONNECTOB ldir.sily on .olrnoidl
of Terminalsido maleterminals Doesthe shift locksolenoid oprateproperly? Replsctho .hift lock solonoid.
Check tor looso terminal frt in th6 interlock cont.ol unit connectoB. ll ngcara,lary, sutEtitut a knowngood interlockcontrol unit and rocheck.
Flowchart Interlocksystem - KeyInterlocksystem Troubleshooting

lgnition key cannot be moved Irom ACC (l) pGition to LOCK(0) positionwhile Pushingthe ignition kev with the shift lever in lll posifio;, and the shift lever button rcleased. 6P SW]TCH CONNECTOR IGNITION C h e c k K e y I n t e r l o c kS o l e n o i d Opration: the 1. Disconnect ignitionswitch (6P). connector the 2. Connect No. 4 terminalof the ignitionswitch6P connector to the battery Positiveter minal, and connectthe No. 3 terminalto the batterynega tiveterminal. 3. Checkthe key interlocksole n o i d o p e r a t i o nA c l i c k i n g so!nd sho!ld be heard.
KEYLOCKSOL {WHT/BLU)
ACCPUSHSW (WHT/YELI
Wire sideoI femaleterminals
Doesthe keyinterlock properly? operate solenoid
Faulty koy interlock solenoid. the ignition key cylinder/ Replace steedng lock as36mbly
Check Key Interlock Switch OPer' adon: the No. 5 terminalof 1. Connect the ignitionswitch connector termi to the batteryPositive the nal,and connect No 3 ter minal to the bafterynegative termrnal, 2 . T u r n t h e i g n i t i o ns w i t c h t o ACC(l),then pushrt. 3. Checkthe key interlocksole' n o i d o p e r a t i o n .A c l i c k i n g sound shouldbe heardwhile pushing ignitionkey. the
KEYLOCKSOL (WHT/BLUI
Doesthe key interlock operate solenoid ProPerlY?
Faulty key inte.lock switch the ignition key cylindor/ Replaco stoering lock a3r.mblY.
To page14 92
(cont'd)
14-91
Electrical Troubleshooting Model) {'97

Troubleshooting Flowchart- InterlockSystem- KeyInterlockSystemlcont'dl
F r o mp a g e1 4 - 9 1 INTERLOCK CONTROL UNIT CONNECIOR{8PI Check Key Interlock Solenoid for a Short Circuit: 1. Disconnect interlock the control unitconnector. 2. Checkfor continuitybetween t h e N o . l t e r m i n a la n d b o d y groundand between No.5 the terminaland bodygroundindividually. KEYLOCKSOL {WHT/8I-UI
ACCPUSHSW IWHTI
Wire sideof femaleterminals Repairshort in the wire between the No. 1 or No. 5 terminal and the ignition switch 6P connector.
ls therecontinuity?
CheckParkPin Switch ODeration: Checkfor continuity between the No. I terminal and body ground.
ls therecontinuity?
Check tor shori in the wire betwon the No. 8 terminal ot the interlock control unit and the park pin switch. lf wire is OK, ch6ckthe park pin switch.
Measu16 ATP P Voltage: 1. Turnthe ignition switch lll). ON 2. Measure vohagebetween the the No.6 terminaand body l ground.
Shiftlevermust be in E.
ATP P (BLK/BLU)
R6pei. open in the wire between the No. 6 irminal and the A/T gea. position switch.
Check looseterminalfit in the for interlock control unil connectors. lf necessery, substitute a knowngood interlockcontrol unit and r6check.
14-92
('98 Troubleshooting - 00 Models) Electrical

Troubleshooting Flowchart - Lock-up Control Solenoid Valve A
.OBD ll Scan Tool indicates Code Pl753. . Self-di.gnosis E or E indicator light blinks once. Poslible Cause . . . ' connector Dbconnectedlock-up control solenoidvalve A/B assemblY Short or open in lock-up control solenoid valve A wire Faulty lock-upcontrol solenoid valve A Open in vB SOLwire
l f t h e P G M T e s t e ri s a v a i l a b l e , Data, then retrieve M Freeze the clearthe PCM.
Test-drive the vehicle under the Data the Freeze same conditions
lntermittent failul.. The system is OK at this time. Check the fit of the Din3in all connectorsaffected by thb code.
Checkfor a Short to Power: '1. Turnthe ignitionswitchOFF. the 2. Disconnect B (25P)and D ( 1 6 P )c o n n e c t o r st r o m t h e PCM, switch (ll). ON 3. Turnthe ignition 4. Measlre the voltagebetween the D1 and 820 or 822 terminals,
A t32Pl
i I r rrilt l,1 I I ltDrste,0n,, 2 .t 3 r B ' r ! 5 1 r .
LGl IBRN/BLKI LG2 (BRN/BLKI Wire sideof femaleterminals npair short lo power in the wire betwn the Dl terminal and the lock-upcontrol solenoidvalve A
Mg.sure Lock-up Control Solenoid Valve A Rssistance: 1. Turnthe ignitionswitchOFF. 2 . M e a s ur e t h e r e s i s t a n c e b e t w e e nt h e D 1 a n d 8 2 0 o r 822 terminals.
A {32P)
LGI|BRN/BLK) LG2IBRN/BLK) 12 ls the resistance - 25 o?

To page 14 95
To page14-94
(cont'd)
14-93
('98 Electrical Troubleshooting - 00 Models)

Troubleshooting Flowchart Lock-up ControlSolenoidValveA (cont'dl
Frompage14-93 FCM CONNECTORS
a t32P)
Checktor continuity between the B20 terminal and body ground, a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground.
B {25P}
C t31Pl
D l16Pl
Wire sideot femaleterminals Ropair open in the wire3 btweon tha 820 and 822 terminalsand groundlG101l.
Ch6ck Lock-up Control Solonoid Valv6 A tor a Short Ci.cuit: '1. Disconnect the 2P connector from the lock up control solenoid valveA/B assembly. 2. Checkfor continuitybetween the Dt and B2Oor 822 te(mi nals.
a l32Pl
c t3lPl
LGlIARN/ALKI LG2IBRN/BLKI
Ropai.lhort to g.ound in the wire btwen the Dl terminal and the lock-upcontrol solonoidvslvg A.
SOLENOID CONTROL LOCK-UP CONNECTOR VALVEA/B ASSEMBLY Mersurg Lock-up Co|ttrol Solonoid Valvo A Rolktanco at tho Solonoid Connoctor: Measure the resistancobetween the No. 2 terminalof the lock,up control soleno;d valve A/B a s s e m b l yc o n n e c t o ra o d b o d y ground.
tFttl ._T=
(o) Y
A LCA (YELI
Terminal sideof maleterminals ls the resistance - 25 0? 12 R e p l a c et h e l o c k - u p c o n t r o l solonoid vrlve A/B a$ambly,
Chsck for open in th wirc bctwen tho Dl terminal lnd th6 lock-up cont.ol solonoid v.lve A.
14-94
PCMCONNECTORS Moa3uraVB SOLVoltago: ON switch (ll) 1. Turnthe ignition 2. lreasure the voltage between the D5 and 820 or 822 terminats.
a t32Pl
B (25P1
c (31P1
D {16P1
Wire side of lemalo terminals Chockfor blown No. 15 (7.5 Al luse in tho undor-dr.h lusa/lel.Y box. lf tho fulo i! oK, roprir opn in the wiro betw6on th. D5 tor' minal and the und.r_dtah tuao/rohY box.
Chockfor looto torminrl fit in the PCM connectoJr. ll nocot3a.Y, rubstitut. . known-good PCM and rschock.
14-95

Troubleshooting Flowchart Lock-up ControlSotenoid ValveB
.OBD ll Scan Tool indicates Code P'l758. . Sell-diagnosis Dl or E indicator light blinkstwic. PossiblCause . . . . Disconnected lock-up control solenoidvalve A/8 assemblyconnector Short or open in lock-upcontrol solenoidvalve B wire Fauhy lock-upcontrol solenoidvalve B Open in VB SOL wir
l f t h e P G M T e s t e ri s a v a i l a b l e , relrievethe A,/TFreezeData,then clearthe PCM-
Test-drive the vehicle under the same conditions the Freeze Data
Did the codereturn?
Intermittant tailure.The lystem is OK at this time. Check the tii ot tho pin3 in all connectorsathed by this code.
Checkfor a Short to Powr: 1. Turnthe ignitionswitchOFF. 2. Disconnect B 125P) the and D ( 1 6 P )c o nn e c t o r sl r o m t h e PCM. 3. Turnthe ignition switch 1ll). ON 4. Measurethe voltage betlveen the D3 and 820 or 822 terminals.
PCMCONNECTORS LC B {GRN/8LKI
LG1{BRN/BLK}I-G2{BRN/BLK) Wire sideof femaleterminals
Repairshon to power in the wire between tho D3 terminal and the look-upcontrol solenoidvalve B.
MeasureLock-upControlSolanoid ValveB Resistanc: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance between the D3 and 820 or 822terminals.
A {32P1
To page14 98
To page 14-97
Frompage14-96 PCMCONNECTORS B (25Pt CheckIor continuity betlveenthe B2Oterminal and body ground, a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground. c (31P1 D (16P1
rc1rBRN/BLKk' c$G2 t
{BRN/BLKI
Wire sideol femaleterminals Bepair open in the wirea between the 820 and 822 te.minalsand ground(G1011.
Check Lock-up Control Solenoid Valve I fo. a Short Circuit: the 2P connector 1. Disconnect u f r o m t h e l o c k _p c o n t r o l valveA,/B assembly solenoid 2. Checkfor continuitybetween the D3 and 820 or 822 termi nats.
A {32P1
ls therecontinuity?
Rep.ir short to ground in the wiie between the D3 terminal and the lock-uDcontrol solenoidvalve B.
SO1TNOID CONTROL L(rcK.UP CONNECTOR A/B ASSEMBLY VALVE

Measure Lock-up Control Solenoid valve B Resistanceat the solenoid Connedo between the resistance Measure the No. 1 terminalof the lock_up control solenoid valve A/B a s s e m b l yc o n n e c t o ra n d b o d Y ground.
LC B IGRN/BLK)
12 ls the resistance - 25 O?
R e p l a c et h e l o c k _ u p c o n i r o l solenoidvalve A/8 a$embly.
Check for open in the wiro betwoen the D3 terminal and the lock-upcontrol solenoidvalve B.
(cont'd)
14-97
Electrical ('98 Troubleshooting - 00 Modelsl

Troubleshooting Flowchart Lock-up ControlSolenoidValveB (cont,d)
Frompage14 96
PCM CONNECTORS MeasuroVB SOLVoltago: 1. Turnthe ignition switch llt). ON 2. Measurethe voltage betlveen the D5 and 820 or 822 termi nals, VB SOL (BLK/YEL} A l32P)
LG1 (BBN/8LKI
LG2 (BRN/BLKI
Wire sideof Iomaleterminals
Check tor blown No. t5 (7.5 Al fuse in the underdash fu36/.elay box. lf th6 fuse is OK, ..pair open in the wire betwooo tho D5 t.rminel and thg underdash two/relay Itox.
Checkfor loose terminal lit in the PCM connectors. ll nces3a.y, substitute a known-good pCM and .check.
14-9 8
Ffowchart Troubleshooting
' O8O ll ScanTool indicatasCode P1705. . self-diagnGi3 E or El indica' tor light blinks five time3
AIT GearPositionSwitch {Short)

PossibleCau3e . short in A/T gear position switch wire . FaultyA/T gear pGition switch
two gear positioninputsat NOTE:Code 1705(5) is set when the PCMreceives the sametime,
Obsrvethe A/T Goar Position lndicalor: ON switch (ll). 1. Turnthe ignition the 2. Observe A/T gearPosition and shift eachPosi' indicator, tion seParatelY.
stayon when Doesany indicator the shiftleveris not in that position?
The system is OK at lhis time. Checkthe wir harne3sfot dam' age.
PCMCONNECTORS
A (32P1 Moasu.eATP R Voltage: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E. 2. Measurethe voltage between the D6 and 820 or 822 terminals,
LGl IBRN/BLK) LG2 (BRN/BLK) Wire sideof femaleterminals
Check for short in the wire betwoon thc DSterminal and tho A/T gear position switch or A/T gear porition indicatol, and check for open in the wires batween the 820 and 822 t6lmi' lf nals and body ground 1G1011. wires are OK, checklor loos ir_ minel fit in the PCM connectors. lf necBsarv, substittlle a known' good PCMand recheck.
To page'14-100
(cont'd)
14-99
('98 Electrical Troubleshooting - 00 Modelsl

Troubleshooting Flowchart A/T Gearpositionswitch (short) (cont'dl
From page 14-99 FCM CONNECTORS
A t32Pl
Measur. ATP NP Voltago: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E or E. 2. Measurethe voltage belween the 013 and 820 or 822 terminats.
B t25Pl
c (31P)
LGl {BRN/BLK)
ATP NP ILT GRNI
Check for short in the wir6 b.twoen tha Dl3 terminal and the A/T go.r polition 3witch, and in th6 El and E poiition signal wir.! betwoen the A/T garr po3ition indicetor and the A/T garr position switch. lf wi.6s are OK, checkfor loole torminal fit in tho PCM connccto.s, lf neccasary, lubstituto a known-good PCMand rocheck.
Mcrsure ATP D4 Vohrg6: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E {'98)or El ('99 - oo). 2. Measurethe voltage between the Dg and 820 or 822 terminals.
a t32Pl
LGl IERN/BLK}
Check tor Bhort in the wi.. bctw6cn thg Dg torminal and the A/T ge.r position .witch or A/T geor poaition indicator. lf wiaaa are OK, ch.ck lor loose torminal fit in the PICMconn.cto6. lf nce3sary, subgthute r lnown-good rcM and roch6d(.
To page14-101
14-100
From page 14 100
PCMCONNECTORS
B (2sP) ' t d. , lll;

Measure ATP D3 Vollage l'98 model): 1 . S h i f t t o a l l p o s i t i o n so t h e r t h a nE . the voltagebetween 2, Measure the D8 and 820 or 822 terminalsLGl (BRN/BLK}
c (31P}
D t16P)
;l';nl, :if
LG2IBRN/BLK)
ATPD3 {PNK)
voltage? ls therebattery
Check for shott in the wire belween lh6 08 terminal and the A/T gear posilion switch or A/T gear position indicator ('98) lf wires are OK, checklor loose terminal tit in rhe PCM connectors. substitute a known_ ff necessary, good PCMand recheck.
A (32P1 Mearure ATP 2 voltage: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E. the voltagebetween 2. Measure the D14and 820 or 822 termi nals.
B l25Pl
c (31P1
D {16P1
LGl IBRN/BLKI
Check for short in the wire between tho D1{ terminal and the A/T gear posilion switch or A/T gear position indicalor. lf wiles are OK, checkfor loose tr' minal fit in the PCM connectors. substitute a knownIt necessarv, good PCMand recheck.
To page14-102
(cont'd)
14-101
Electrical ('gg Troubleshooting - 00 Modelsl

Troubleshooting Flowchart A/T Gearpositionswitch {short) (cont,d)
Frompage14 101
MeasureATP 1 Voltag: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E. 2. Measure the voltagebetween the D15and 820 ot 822 tetminals.
PCM CONNECTORS
B t25Pt
c t3lPl
D {16P1
LGl {BRN/BLK)
Chock lor short in the wire between the D15 terminal and the A/T gear position switch or A/T gear position indicator. lf wires a.e OK, ch6ckfor loos t6rminal fil in tho PCM connectorc. ll neco$ary, substiiute a knowngood PCMand rechsck.
Chockfor loose terminalfit in the PCM connectors. lf nocessary, sub3titut s known-good PCM and recheck. The system 3hould be OK at this point. lf any indicators stay on when the shift lever is not in ihe selectdposition, pertorm this troubleshootingtlowchart again.
Flowchart A/T GearPositionSwitch (Open) Troubleshooting

. OBD ll Scan Tool indicates Codo Pl706. . Self-diagnosisFl or E indicato. lighl blinks six times.
Po$iblg Cause
. DbconnectedA/T gear position switch connoctor . Open in A/T gear po3ition switch wiro . Faulty A/T gar position switch
indi Are any ofthe gearposition catorsnot workingwhen you shiftthem?
The systemis OK.tthis time. Checkfor oth6r problms such as harne3sdamage.
Test the A/T gear position switch (seepage14-139).
P,CM CONNECTORS MeasureATP R Vohago: ON switch (ll). 1. Turnthe ignition 2. Shittto E position. 3. Measureihe voltage between the D6 and 820 ot 822 tetfii nals,
LGT(BNN/BLKI LG2IBRN/BLK) terminals Wire sideof female
Repairopen in tho wiro betwoen the D6 terminal and the A/T gear oosition switch.
A {32P) MeasureATP NP Volt.g: 1. Shiftto Elor E position. 2. Measure the voltagebetween the D13and 820 or 822termi nals,
c l31P)
LGl {SRN/BLK)
ATP NP (LTGRN}
Repairopen in the wiro between t h D l 3 t e r m i n a la n d t h A / T gesr posilion awitch.
To page14-104
{cont'd)
14-103
('98 Electrical Troubleshooting - 00 Model)

(cont'd) Troubleshooting Flowchart A/T GearPositionSwitch (Open)
Frompage14-103 PCMCONNECTORS Me.sure ATP D4 Vohrge: 1. Shift to E 1'98) E ('99or 00) position. 2. Measurethe voltage between the Dg and 820 or 822 terminats.
B {25Pt
c (31P|
LGl IERN/BLKI
Repairopon in th6 wire between tho m tarminal and the A/T geal position swhch.
Me..ure ATP 03 Vohage l'98 modell: 1. Shiftto E position. 2. Measurethe voltage between the DB and 820 or 822 tetminals,
LGl {BRN/BLKI
Repairopen in the wire botwoon th6 08 terminal .nd the A/T geat position switch (381.
MeasuroATP 2 Voltage: 1. Shilt to E position. 2. Measurethe voltage between the D14and 820 or 822termi nats.
LGl {BRN/ELXI
Repairopon in the wire between the D14 t.minal end the A,/T gear po3ition switch,
To page 14 105
Frompage14-104 FCM CONNECTORS MeasureATP 1 Voliag: 1. Shiftto E position. 2, Measure voltagebetween the the D15and 820 or B22terminals. B t25Pl
c t3lPt
D tl6Pl
LGl IBRN/BLKI
Repairopen in the wire between t h e D 1 5t e r m i n a l a n d t h e A / T gear poaition switch.
Check LG Wire tor an Open Circuit: '1. Turnthe ignitionswitchOFF. 2. Checklor continuitybetween t h e 8 2 0 t e r m i n a la n d b o d y ground,and between the 822 terminaland body ground.
A (32P1
B (2sP)
c (31P|
LGl (BRN/BLKI
ls therecontinuity?
Repair open in th. wires between the B20 and 822 tarminals and body ground. and repair poor ground{G101).
Checktor loose terminaltit in the PCM connectors. lf n6cassary, substitute d known-good PCM and recheck.
14-105

Troubleshooting Flowchart Shift ControlSolenoidValveA
. OBD ll Scan Tool indicates Code P0753. . Self-diagnosisEl or E indicator light blihk5 ievon times. Po$ible Caus
'
. Short or open in shift control solenoid valve A wire . Faulty3hift control 3olenoidvalvo A . Ooen in VB SOL wire
It the PGM Tester is available, retrievethe A"/TFreezeData,then clearth PCM.
Test drive the vehicle under the sameconditions the Freeze Data
Intermittent tailure. The system b OX at this timo. Check the fit o{ the pins in all connectora .ttected by this code.
Ch6ckfor a Short 1o Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect B (25P)and D the ( 1 6 P i c o n n e c t o r sf r o m t h e PCM, 3. Turnthe ignition switchON (ll). 4. Measure the voltagebetween the D7 and 820 or 822 termi nals.
A t32P)
8 {2sPl
Ct3lPt
ll Dll6Pt
LG1IBRN/BLKI LG2IBRN/BLK} Wi16sideof femaleterminals
Repairshort to power in the wire betwoen tho D7 terminal and the shift control solenoid valve A.
Moasure Shift Control Solenoid Valv6 A Resistanco: 1. Turnthe ignitionswitchOFF. 2 . [ r e a s ur e t h e r e s i s t a n c e between the D7 and 820 or 822terminals.
A (:l2Pl
a t25Pl
c {31P}
LGl
(BRN/BLKI LG2 (BRN/BLKI
ls the resistance - 25 0? l2
To page 14-108
To page14-107
14-106
F r o mp a g e1 4 - 1 0 6 A l32Pl Checkfor continuity between the 8 2 0 t e r m i n a la n d b o d y g r o u n d . a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground.
PCMCONNECTORS B (25P1 C (31P) c (31
D {16P)
LGl IERN/BLKI
LG2 {BRN/BLK)
Ropairopen in the wir.s betweon the 820 and 822 terminal3 and ground(G1011.
C h e c kS h i l t C o n t r o l S o l e n o i d Valve A for . Short Circuit: 1. Disconnect the 2P connector from the shiftcontrolsolenoid valve !y'B assembly. 2. Checktor continuitybetween the D7 and B2Oot 822 tetminals.
LGl IBRN/BLK} LG2 (BRN/BLK}
ls therecontinuity?
Repairshort to ground in the wire be{wenthe D7 terminal and the 3hift control solonoidvalvo A.
SHIFTCONTROISOLENOID CONNECTOR VALVEA/B ASSEMBLY Measure Shift Control Solenoid Valve A Resistanceat ihe SolenoidConnector: Measurethe resistance between t h e N o . I t e r m i n a lo f t h e s h i f t c o n t r o l s o l e n o i d v al v e A / B a s s e m b l yc o n n e c t o ra n d b o d y ground,
IiiE-]
"*otrau/"aalF
I
Termanal of maleterminals side Replace the shrft control solenoid valve A/B assembly.
l s t h e r e s i s t a n c e1 2 2 5 Q ?
Check for op.n in the wire betwoon tho D7 terminal and the shift control solenoidvalve A.
(cont'd)
14-107

Troubleshooting Flowchart Shift ControlSolenoidValveA (cont'd)
Frompage14-106
MoasureVB SOLVoftago: 1 . T u r n t h e i g n i t i o ns w i t c hO N flr). 2. Measure the voltagebetween the D5 and 820 or 822 terminals,
VB SOL IBLK/YEL)
ls therebattery vohage?
Checklor blown No. 15 (7.5 Al fuse in the under-dashfuse/relay box. lf the tuse is OK, repair open in the wi.e between the D5 terminal and the under-dash fuse/ relay box.
Checkfor loose terminalfit in the PCM connectors. lf necessary, subltitute a known-good PCM and recheck.
14-108
Flowchart Shift ControlSolenoidValveB Troubleshooting

. OBD ll ScanTool indicatosCode P0758. . Self-di.gnosis E or E indicalor lighf blinb 6ight times. Po3sibleC.us .Dt . Short or oDenin shift control solenoidvalve B wira ' F.ulW shitt cont.ol solonoidvalvc B . Opon in VB SOLwir6
lf the PGM Tester is available. retrievethe A/f FreezeData,then clearthe PCM.
Intermittent failu16. Tha 3yltgm is OK at thi3 time. Check the fit of the Dins in all connectors affocted by this codo.
Checklol o Short to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect B 125P) the and D ( 1 6 P )c o n n e c t o r sr o m t h e f PCM, 3 . T u r n t h e i g n i t i o ns w i t c hO N 0ll. 4. Measu.e the voltagebetween the D2 and 820 or 822 terminals.
PCMCONNECTOBS
a l32Pl
B {2sPl
c t3tP}
LGl {BRN/BLKI
LG2 {BRN/BLK}
Wire side of lemale terminals
Ropairshort to powor in lhe wire betwoon the D2 termin.l .nd tho shift cont.ol solenoid vslv6 B.
Measuro Shift Control Solonoid Valve I Rosbtance: 1. Turnthe ignitionswitchOFF. 2 . M e a s ur e t h e r e s i s t a n c e between tho D2 and 820 or 822terminals. LGI {8RN/BLKI
c (31P1
LG2IBRN/BLKI
ls the resistanc - 25 O? 12
T o p a g e1 4 - 1 1 1
(cont'd)
To page14-110
ElectricalTroubleshooting('98- 00 Models)
Flowchart Shift ControlSolenoidValveB {cont'd) Troubleshooting
Frompage14-109 PCMCONNECTORS A (32P1 Checkfor continuity between the 8 2 0 t e r m i n a la n d b o d y g r o u n d , a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground. a {25P)
c 13lPl C t31
D tl6Pl
Wire sideof l6maleterminals Repairopen in the wire! btwoen th6 B20 and 822 terminals and groundlG101l.
C h e c kS h i l t C o n t r o l S o l e n o i d Valve B for a Sho.t Circuit: 1, Disconnect 2P connector the from the shiftcontrolsolenoid valve !VB assembly. 2. Checktor continuitybetween the D2 and B2Oo( 822 tetminals,
a t32Pt
c {31P1
LG1IBRN/BLKI
LG2IBRN/BLKI
R e p a i rs h o r t t o g r o u n d i n t h e wir btwe6n th D2 terminal and the shift control solenoid valve B. SOLENOID SHIFTCONTROL CONNECTOR VALVEA/B ASSEMBLY
Measu.e Shift Control Solenoid Valve B Rasistanceat tha Solonoid Connector: between Measure the resistance the No.2 terminal the shiftcon of valve NB assemblv trol solenoid connector and body ground.
lF-E]
I SH B IGRN/WHTI
(ol
Y
I
sideof maleterminals Terminal 12 ls the resistance 25 O? ReDlac.the shift control solenoid valve A/B r$embly.
Check for oDen in the wire btwoen ths D2 torminal and the shift control 3olenoidvalve 8.
1 4 -1 1 0
Frompage14-109
PCMCONNECTORS M6r3ure vB SOLvoltage: 1. Turn ihe ignition switch ON flr). 2. Measurethe voltage between the D5 and B20or B22terminals. A l32Pl B (25Pt C (31P1 o (16P)
Ch6cktor blown No. '15{7.5 Al fuse in tho undo.-dashtuso/telay box. It the fu3s is OK, tepair open in the wire bctweon the D5 terminal and the under-dash fose/ rolaYbox.
Chackto. loo3ete.minal fit in lho PCM connectols. lf nccoa3ary, substituto a known-good PCM snd rechock.
14-111
. OgD ll Sc.n Tool indicat* Code m720. ' selt-diagnosis E or E indicator light blinks nin6 time3.
Po$ibl Csuse . . . . Loo3or tauhy connctionbatween the PCMand vehicle harness Diaconnected countetshaft3Deod sensorconnectoa Short or opon in countershaltspegdsensorwiro Faulty countershattspoedsensol
It the PGM Tester is available, retrievethe A"/T FreezeData,then clearthe PCM.
Intormittent failuro. The systom is OK .t thb time. Checkthe Iit of the pins in rll connsctors .fLctod bv thi! code.
C h e c kt h e c o u n t e r s h a f t p e e d s sensor installation. and check it for damage.
ls the countershaftspeedsensor properly. installed and not damaged?
Reinstallor replaceand rechcck.
Measure Countershaft Sp6d SonsoaRsistsncat the Senlor Connector: 1. Disconnect the 2P connector from the countershaft speed 2. Measurecountershaft speed sensorresrstance the sensor at connector.
COUNTERSHAFT SPEED SNSORCONNECIOR
ttt'l -T-Trol Y I
LI
ls the resistance 400 - 600 0?
T o p a g e1 4 - 1 1 3
14-1 1 2
F r o mp a g e1 4 ' 1 1 2
Check Countershaft Speed Sensor for a Short Circuit: '1. Disconnect e D (16P) on th c nector from the PCM. 2. Checklor continuitybetween body groundand the D10term i n a la n d D l 6 t e r m i n a i n d i l vidually.
PCMCONNECTORS
NCIBLUI
D {16P1
A t32Pl
B (25P1
c l31P)
ial,tu]g
NCSGIGRNI
Repairshort in the wire3 botweon the Dl0 and D16 terminals and the countershaft 3Dedsensor.
M e a s u r eC o u n t e r s h a t tS p e e d S6n3orCircuit to. an Open: 1 , C on n e c t t h e c o u n t e r s h a f t speeosensor connector, 2 . M e a s ur e t h e r e s i s t a n c e between the D10and D16termrnals,
a l32Pl
B (25P1
c (31PI
NCSGIGRN}
Repair loose terminal or open in the wiies between the D10 and O16 terminals and th. countetshaft sDedsensor.
Checktor loos. terminal fit in the PCM connctoas.It necessary, substitute a known-good PCM and recheck.
14-113

Troubleshooting Flowchart MainshaftSpeedSensor
. OBD ll ScanTool indicat$ Code m715. . Slf-diagnosi3E or @ indicator light indicatosCode 15. PorsibleCruse . Disconnsctdmsinsh.ft 3pood3gnlor conncctol . Short or open in mainshaft 3poedsensorwire . Faultv mainshrtt speedsonsot NOTE:Codo P0715(15)on the PCM doesn'talwaysmoan there'san electrical problemin the mainshaft countershaft (15) or speedsensorcircuit;code P07'15 problemin the transmission. problemcausmay also indicate mechanical a Any ing irregularcountershaftto mainshaftspoeddifferencecan causethis codo;this can sometimesbe seen in A'/TFree2e Data.FreezeDatacan also indicatean electrical problemin the sensorcircuits one of the sensors ;f reads0 mph duringa test dnve.
l f t h e P G M T e s t e ri s a v a i l a b l e , retrievethe A/f FreezeData,then clearthe PCM.
Test-drive the vehicle under the sameconditions the FreereData
Intermittont tailuro. Tha sy3tem b OK at this tims. Checkthefit of tho pins in .ll connoctoB alt6cted bv this code.
Check mainshaft the and countershaft speedsensorsinstallation, and check them for damage.
Are the mainshaft and countershaft speedsensorsinstalled properly, and not damaged?
Reinstallor ropllce and rochock.
MoasureMainshattSpedSenror Rsirtancoat ths Snsol Connoctor: 1. Disconnect the 2P connector from the mainshaftspeedsen sor. 2. Measuremainshattspeedsensor resrstance the sensor at connefior.
MAINSHAFT SPEED SENSOR CONNECTOR
ls the resistance 400 600 0?
To page14-115
14-1 1 4
Frompage14-114 PCMCONNECTORS Check Mainshaft Speed Sensor for a Short Circuit: 1. Disconnect e D (16P) onth c nectortrom the PCM. 2- Chcktor continuity between body groundand the D11terminal and Dl2 terminal indi vidually.
A {32P}
c t3lPl
-'lTZ
D t16Pt
v v v v v l.t1lLtLt?!/]|,1tut larrlrllllpr=r tavtq tptntat EElt [1!]t! pl NM (RCD| (O)
lit4'l Fl l'1tilFTil ,'l unr
NMSG
(o)Y
Y =
wire sideol femaleterminals
ReDairshort in tho wiros botwen th Dl1 and D12 torminal3.nd tho main3haft 3Doedaonlor.
MoasureMainshaftSp6dSonsor Rosi3tancei 1. Connect the mainshaft speed sensor conn6ctor. 2. Measure the resistance between the Dl1 and D12termrnals,
B l25Pt
Run the Eloctricl Troubldhooting Flowdrrrt for co& F0720(codo 91. Chocklor loo3otorminrl fit in the PCM connectors. It necos3ary, substitute r known-good PCM and rchck.
ChockNM Wire Continuity: 1. Disconnect the 2P connector trom the m6inshaftspeedsen2. Checkfor continuitybetween the D11terminal andthe No.2 terminal of the mainshaft speeosensorconnector,
v,1zzfififinffiiFr
F/l,6t FFF| LrLrEll
c {31P1 -1-\ 2 1 |1 - -/ / 1 _ 1 ,s
st/
NM {REDI
MAINSHAFT SPEEO SENSOR CONNECTOR
Wire sideof temaleterminals Rcpair opon in tho wire betw.en th6 Dll tarminal and the mainshaft lpood sonsor.
To page'14-1'16
(cont'd)
14-115
ElectricalTroubleshooting('98 - 00 Models)
Troubleshooting Flowchart MainshaftSpeedSensor(cont'd)
Frompage14 115
PCMCONNECTORS
Ch6ckNMSG Wire Continuitv: Chockfor continuity between the Dl2 terminaland the No. 1 terminal of the mainshaftspeedsensor connctot. MAINSHAFT SPEED SENSOR CONNECTOR Wire sideof femaleterminals
ls therecontinuity?
Ropai. opn in the wi.e hn eon the D12 terminal and the mainshaft sDeedlensor,
Checkfor looso terminal fit in the PCM connoctorc. lf necessary, substitute a known-good PCM and aech6ck.
14-1 1 6
. OBD ll ScanTool indic{t.. Cods P1768. . selt-diagnosis El or E indicator light indicrt.. Codo 16.
Po$ible Cau3e ' . . . . Disconnectsdlinoar solenoid conneclol Short or open in linear solenoidwire Faulty linear3olenoid Open in VB SOL wire Open in PGI and PG2wires or poot g.ound {G101).
l f t h e P G M T e s t e ri s a v a i l a b l e . retrievethe A/T FreezeData,then clearthe PCM.
Test drive the vehicleunder the the Freeze Data same conditions
Inlermittont tailure, The 3yrtom is OK at thb time. Checkthe tit ot lhe oins in all connectoE affoctod by this code. LINEARSOLENOIDCOiINECTOR
Meaaure Linear Solenoid Rsistanc at the SolenoidConnector: 1. Disconnect the 2P connector from the linearsolenoidlinearsolenoid resis2. Measure tanceat the solenoidconnec tor.
t-rtt
(9l t t
Terminal sideol maleterminals
ls the resistance about5 O?
Chock Lino.r Sol.noid to. a Short Circuh: 1 . D i s c o n n e ctth e B ( 2 5 P ) o n c nectorlrom the PCM. 2. Checktor continuity between body ground and the 88 terminal and the 817 terminal individually.
A l32Pt
B {2sP)
LSP(REDI
wire sideoI temaleterminals Repair 3ho to ground in the wires belween the 88 rnd B17 terminalsand tho linaar3olenoid.
ls therecontinuity?
T o p a g e1 4 - 1 1 8
(cont'd)
14-117
('98 ElectricalTroubleshooting - 00 Models)

Troubleshooting Flowchaft - Linear Solenoid (cont'dl
F r o mp a g e1 4 - 1 1 7
MeasureLinea. SolenoidResistance: 1 . C o n n e c t h e l i n e a rs o l e n o i d connector, 2. Measure the resistance betweenthe 88 and 817 ter mrnals,
a t32Pl
c t3lPl
LSP(REO) Wire sideof female terminals
ls the resistance about5 O?
Repair loose torminal oi open in the wires between rhe 88 and 817 terminalsand the linear solenoid.
MeasureVB SOLVoltago: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c t e D 1 1 6 Pc o n th ) nector trom the PCM. 3. Turnthe ignition switch (ll). ON 4. Measure the voltagebetween the D5 and 920 ot B22 tetminals.
a l32Pl
ls therebaftery voltsge?
Checkfor blown No. 15 17.5Al fuse in the under-da3h tus/relay box. lI the fuse is OK, rap.ir open in the wire betwen the D5 terminal and th under-dash tuso/ relav box. A (32P1
B l2sP)
c 13lPl
D l16P)
Check LG Wire for.n Open Circuit: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuitybetween t h e 8 2 0 t e r m i n a la n d b o d y ground,and between the 822 terminaland body ground.
LGl IBRN/BLK}
LG2{BRN/BLKI
ls therecontinuity?
Repair op6n in the wiros betwen the 820 and 822 terminals and body ground, and repair poor g.oundiG101).
Chacktor loose terminel fit in the PCM connecto13.It nocosaary, substitute a known-good PCM .nd recheck,
1 4 -1 1 8
ControlSystem Flowchart Lock-up Troubleshooting

. OBD ll Scan Tool indicates Code P07,10. . selt-diagnGis El or E indicator light indicates Code40. PossibleCaus6 Faultylock-up control system
l f t h e P G M T e s t e ri s a v a i l a b l e , retrievethe A/T FreezeData,then clearthe PCM.
Test-drive the vehicle under the Data same conditions the Freeze
Did the codereturn?
lntermittent failur6. The system is OK at this time, Check the fil ol the pins in all connectors affectedbv lhis code.
Checkfor Another Codc: whetherthe OBDll scantool Check lightindi or rhe E or E]indicator catesanothercode,
Doesthe OBD ll scan tool or the @ or E indicator light indicateanothercode?
P e r f o r mt h o T r o u b l e s h o o t i n g Flowchart for lh6 indicated Codolll. Rechocktor code P0740 (,lO) er troubleshooting. aft N O T E :D o n o t c o n t i n u et h i s t r o u b l e s h o o t i n gu n t i l t h e c a u s e so f a n y have beencorrected. other DTCS
Test Lin Pres3uro: Measurethe line pressure(see page14'161 and 14-162i.
ls the line pressure within limit? the service
Repairth6 hyd.aulic system as necessary {see page 14-161and 14-152).
T o p a g e1 4 - 1 2 0
(cont'd)
14-119
Troubleshooting Flowchart Lock-up ControlSystem(cont'd)
F r o mp a g e1 4 - 1 1 9
R e p l a c et h e L o c k - u p C o n t r o l Solenoid Valve A/B Assombly and Recheck: 1 . R e p l a c eh e l o c k - u pc o n t r o l t solenoidvalve A,/Bassembly (seepage14-!35). 2. Turn the ignition switch OFF and reset the PCMmemoryby removing BACK (7.5A) the UP f u s e i n t h e u n d e F d a s hu s e / f relaybox for more than 10 seconds. 3. Usingthe scantool, checkto be surethatthe engine coolant temperature 176"F is {80'C)or above. 4 . D r i v et h e v e h i c l ea t 5 5 m p h (88 km/h)constantly more tor than one minute. (40i. 5. Recheck code P0740 {or
Doesthe OBDll scantool indicate code P0740or does the [9i] or E indicator lightindicate code40?
The system is OK at this time.
14-120
Flowchart Shift ControlSystem Troubleshooting

. OBD ll Scan Tool indicates Code P0730. . Self-diagnosisJir or E indicaCode41. tor light indicates PossibleCause Faultvshift control sYstem
lf the PGM Tester is available, retrieve the AJ.I Freeze Data, then clear the PCM.
the vehicle under the Test-drive Data the Freeze same conditions
Didthe codereturn?
lntermittent failure. The system is OK at this time. Chck the fit of the pins in all connectors atfectedby this code.
Checkfor Another Code: w C h e c k h e t h e rt h e O B D l l s c a n or tool or the l-Drl E] indicator code. another light indicates
Doesthe OBD ll scan tool or the Da or E indicator code? another lighlindicate
P e r l o r mt h e T r o u b l e s h o o t i n g Flowchart for the indicaled Codets).Recheckfor code P0730 6ft6r troubleshooting. {411 N O T E :D o n o t c o n t i n u et h a s t r o u b l e s h o o t i n gu n t i l t h e c a u s e so f a n y havebeencorrected. otherDTCS
MeasureEachClutch Pressure: M e a s u r e h e 1 s t ,2 n d , 3 r d , a n d t (seePage14 4th clutchPressure 1 6 1 h r u1 4 1 6 3 ) . t
l s e a ch c l u t c h P r e s s u r e limit? withinthe service
Repairthe hydraulicsYstem as necessary (se page 14-162and 14-163).
(cont'd)
T o p a g e1 4 - 1 2 2
14-121
Electrical Troubleshooting - 00 Models} {'gB

Troubleshooting Flowchart Shift ControlSystem(cont,d)
Frompage14 121
ReplaceShilt Cont.ol Solenoid Valve A$ambly and Recheck: '1. Replace the shift control solenoidvalve A/B assembly (seepage 14-136) and the lin, e a r s o l e n o i da s s e m b l y( s e e p a g e1 4 1 3 8 ) . 2. Turn the ignition switch OFF and resetthe PCMmemory by removing BACKUP (7.5A) the tuse in the !nder-hood luse/ r e l a yb o x f o r m o r e t h a n 1 0 seconos. 3. Drive the vehicle at over '12 mph (20km,/ti) lst,2nd,3rd, in and 4th gear tor more than 30 seconds E position. in (41). 4. Recheck codeP0730 for
Doesthe OBD ll scantool indicate codeP0730 does or the E orE indicator light indicate code41?
Tho system is OK .l this tim.
Flowchart Df or @ IndicatorLight DoesNot ComeOn Troubleshooting

The E or El indicator light doe3 not cofie on when the ignitaon switch is first turned ON {ll). {lt should como on for about two s.cond3 and ihen go out.l Check ths Service Check Conneclor: Make sure the specialtool (SCS S e r v i c eC o n n e c t o r i)s n o t c o n nectedto the servicecheckcon nector. ls the specialtool (SCSService to connected the ser_ Connector) vice checkconnector? Disconneclthe special lool lrom tha service check connoctor and recheck.
check the E or E Indicator Ught: Shiftto E or E position. Doesthe E or P indicator lightcome on? Checkfor loo3et6lminal tit in the PCM connectors. lf necessary. substitute a known-good PCM and recheck. PCMCONNECTORS (31 c (31P)
A l32Pl
Checkthe Gtound Circuil: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e B ( 2 5 P )c o n nectorfrom the PCM. between 3. Checkfor continuitY l t h e 8 2 0t e r m i n a a n d b o d y ground,and between the 822 and body ground. terminal
B t2sPl
D (16P)
f -t l r p r i i r r 6 3 r o l , : 11/ / l//| $fe?0?r/a)1 e 'oI 13 I , rrr ltelx ?r2? r,/ i - T _
l*f4tr8-
LG1 {8RN/BI-KI I
I
LG2 (BRN/BL()
@@ I
+ +
Wiresideof lemaleterminals Repairopen in the wires between the 820 and 822 terminals and ground {G1011, and rPair Poor ground(G101).
ls therecontinuity?
c (31P)
Measure Power Supply Circuit Voltage: switch 1ll). ON 1. Turnthe ignition 2. Measure the voltagebetween terminalsB1 and 822 and betweenterminalsBg and 820.
YES
To page14-124
Repairopen or short in tho wi.e between the 81 and/or Bg torminals and the PGM-FImain rlay, .nd between tho PGM-FImain relay and the under-hoodtuse/ relay box.
(cont'd)
14-123

Troubleshooting Flowchart E or @ Indicator LightDoesNot come on (cont'd)
F r o mp a g e1 4 - 1 2 3 PCMCONNECTORS B {25P} Measure D4IND or D lNDVoh.ge: 'L Turn the ignitionswitchOFF. 2. Connect B (25Plconnector the to the PCM. 3. Connecta djgital multimeter to the A14 and 820 or B22ter minals, 4 . T u r n t h e i g n i t i o ns w i t c hO N (ll),and makesurethatvoltage is available two seconds. for
c (31P) C (3
D (16P1
n f,-ff n t f,Fjrti.trnn mflnr

LG2 (BRN/BLKI D4 INOor D IND IGRN/BLKI
Check lor open in the wire btweenthe Al/t terminal .nd the geugo a$eftbly. lf wi.a is OK. check tor a fautty E or E indicator light bulb or a faulty gauge assmbly p.inted circuit board.
D {16P) CheckD4 IND or D IND for a Short Circuiti Check continuity for betweenthe A14terminaland body ground.
D4 IND or D IND
Ropairshort in tha wiro btwesn the A14 termin.l and th gaugo .ssemblv.
Checktor looso telminal tit in the PCM connoctors. Chock the A/T gear position swiich. It neces3ary, substitute a known-good PCMand rechck.
14-124
Flowchart E or E IndicatorLight On Gonstantly Troubleshooting

The E or E indicator light is on constantly(not blinkingl whenevr lhe ignition switch is ON 0. PCMCONNECTORS A {32P) Me.3rtreD4IND o. D INDVottage: 1. Turnthe ignitionswitchOFF. c th 2. Disconnect e A (32P) onfrom the PCM. nector ON switch (ll) 3. Turnthe ignition the voltagebetween 4. Measure t h e A 1 4 t e r m i n a la n d b o d y ground. B (25P)
1 1 t r . / / a t tonl /1! /1/ /llt /
c (3'tP)
D lr6Pl
t',lxr uu?lLrfr4
D4 IND or D IND {GRN/BLKI
F't!4[r
Repairshort to power in the wire biween th A14 terminal and the gaugea$.mbly.
A l32Pl
MeasuroATP D4 voltage: 1. Turnthe ignitionswitchOFF 2. Connectthe A (32P)connector to the PCM. 3. Turn the ignitionswitchON (ll) 4 . S h i { t t o a n y p o s i t i o no t h e r than E or E. the voltagebetween 5. Measure t h e D 9 t e r m i n a la n d b o d y ground. T6st the A/T g.ar Po3ition indicator at the gauge e$embly con_ lor '98 nectorc (se P.go 1,1-139 '99 - 00 14-140for model .nd modelsl, f the A/f gear Poshion indicator is OK, replacethe FCM.
c t3lPl _ = - - - r - : = eV ?
t rl3l/ 5/,
t\ r?V
t/l,4lzulErt!t!!j!t!u3t ll]]lll1lglt]| r.i

b AE A.W6l ld$!'lLM.l1t I
ATPD' (YEL) I I
O)
ls thereapprox.5V?
Test the A/T gear position switch (seepage14-139i.
Checkfor r 3hofi to ground in the wire betweon tho IXI teYminal and A/T gear position switch. lf wire is OK subBtihrte a known-good PCM and recheck.
14-125,
Electrical ('98 Troubleshooting - 00 Modelsl

Troubleshooting Flowchart InterlockSystem- Shift LockSystem
Shift levor cannot be mov6d llom the E po3ition when th6 blako pedal is pre3sed. NOTE:li the MIL is on, ropairthe PGM-FI controtsystem {seesection11),and recheck.
ChckBJakeLight Oporation: Press brakepedal. the
Are the brakelightsON?
B6pair tlutty brrko 3whch circuit l..e rection 231.
PCM CONNECTORS
a (25P1
Me.sure ILU Voltage: 1. Turn the ignitionswitchON (ll1, andshifttoE position. 2 . P r e s st h e b r a k e p e d a l ,a n d releasethe acceleratorpedal. 3. Measurethe voltage between t h e A 2 8 t e r m i n a la n d b o d y grouno.
c l3lPl
1 tttt/
D {16P1
5t/ 1 a t /tlt 1 t\/t , . / VVV tl t ttj,r\1e\10l211nI 3 rholr1t?
m@-@Effilil"
Wire side of femalelerminals
Chock tor an open or short in the wi.o botwoen tha A28 t6rminrl and thc intorlod( control unit, rnd check tor loose torminrl fit in the intorlock conftol unh connoctor. lf nocassaryraubstitute a knowngood intollock control unit rnd roch6d(
Mor3uro STOPSW vohsgo: 1. Turnthe ignitionswitchOFF. 2. Disconnect A (32P1 the and B ( 2 5 P )c o n n e c t o r s{ r o m t h e PCM. 3. Measurethe voltage between the A32 and 820 or 822 terminals,
c t3lPt
wE
D (lCPl
| 2ttt/ ;t /n) ).tt)/ 1 21:/ t vvvvv nnvl.lnl2\n I r r ero 12
gp]P] polr EI!l!!i r.
LGl {8RN/ALKI
Repairop6n in tho wir betwsen the A32 t6.minal and th6 brake 3witch.
fo page 14-121
14-126
Frompage14-126 FCII CONNECTOFS MeasureTPSVoltage: the 1. Reconnect A (32P)and B (25P) to connectors the PCM ON switch (ll) 2. Turnthe ignition the voltagebetween 3. Measure the C27 and B20ot 822 te(mi' nats. B {25P1
A t32Pl
c (31P)
LG1 (BRN/BLKI
wire sideof femaleterminals
0.5 ls thereapprox. V?
To page'14-128
Check Throttlo Position Sensol Ground Line: '1. Turnthe ignitionswitchOFF the 2. Disconnect throftleposition sensorconnector. 3. Checktor continuitybetween t h o N o . 1 t e r m i n a lo f t h e throttle positionsensorconnector and the 820 and 822 terminslof the PCM.
LGl IBRN/BIXI
LG2IBRN/BIXI THROTTTIPOSMON SENSORCONNECTOR
SG2IGRN/BLK}
rL2l3t
ls therecontinuity?
Checktor continuity betlveenthe C18and 820 or 822terminals
B {25P1
c l3lPl
D (16P1
n l,I-il n FFFTI,T';T;I EFML"|

LGl IBRN/BLKI SG2 {GRN/BLK}
ls therecontinuity?
Rgpsir opan in lhe wire botween the Cl8 torminal .nd the throttle gosiiion Sensor.
Checklor looss tetminalfit in the PCM connctoia. It nece3sarY, subslituta a known-good PCM and .echock.
(cont'd)
14-127

Troubleshooting Flowchaft- InterlockSystem- Shift LockSystem{cont'dl
Frompage14-127 INTERLOCK CONTROL UNTT CONNECTOR ISPI Check Shift Lock Solenoid tor an Open Ci.cuit: 1 . D i s c o n n e c tt h e s h i l t l o c k solenoid connector, 2. Checkfor continuitybetween the No. 2 terminalof the shift l o c ks o l e n o i d o n n e c t oa n d c r the No. 3 terminalof the inter lockcontrolunit connector, SHIFTLOCKIYEL/BLX {YEL/BLKI
1
2
6
3
8
o
SHIFTLOCKt SOLENOID CONNECTOR 1 2 Repairopen in the wir6 between th No. 2 termin.l oI ihe interlock control unit and ahift lock solenoid. YEL/BLK
ls therecontinuity?
Wire side of female termtnals
Measu.e Shift Lock Solenoid Voltage: 1 . T u r n t h e i g n i t i o ns w i t c hO N flr). 2. Measure voltagebetween the the No. 1 terminal and body ground. Checklor blown No.25 {7.5 Al fuse in the underdash fuse/relay box. It the tuse i3 OK, repair opon or short in lhe wire betwen the No. 1 terminal of tho shift lock solenoid connector rnd the under-dashfuso/rlaybox,
SHIFT LOCK SOI.ENOID CONNECTOR " l -irrz
YEL]
!
(v)
I
ls therebattery voltage?
Wiresideof female terminsls
Check Shift Lock Solenoid Operrtion: 1. Connect No. 1 terminalof the t h e s h i t t l o c k s o l e n o i dc o n nector to the battery positive terminal, and connect the No, 2 terminal to the battery neg, ativeterminal. 2. Check that the shift lock solenoid operates.
NOTE: not connect Do the No. 2 terminalto t h e b a t t e r yp o s i t i v et e r m i n a l ,o r y o u w i l l d a m a g et h e d i o d e i n s i d et h e s h i f t r o c K solenoid.
SHIFTLOCKSOLENOIO CONNECTOR (dir.ctly on $lenoidl
Does shiftlocksolenoid the operateproperly?
Terminal sideof maleterminals Roplace the shift lock solenoid.
Checktor looso torminal tit in th6 interlock control unit connector. lf necessary, substitute a knowngood intrlockcontrol unil and recheck.
14-128
system system - Key Interlock Flowchart Interlock Troubleshooting

lgnition ksy cannot be moved from ACC (l) pGition to LOCK(01 position while Pushing it with the shift lever in E PGition.
Check Key lntorlock Solenoid Operation: the 1. Disconnect ignitionswitch (6P). connector the 2. Connect No. 4 terminalof the ignitionswitch6P connecter_ tor to the battery Posative minal, and connectthe No. 3 terminalto the batterynega tiveterminal. 3. Checkthe key interlocksolen oi d o p e r a t i o n A c l i c k i n g . soundshouldbe heard.
6P SWITCH CONNECTOR IGNITION
KEYLOCKSOL IWHT/BLU)
ACCPUSHSW (WHT/YEL}
Doesthe keyinterlock operate solenoid ProPerlY?
F.ulty key interlock solenoid. tho ignition key cylinder/ Replace steering lock asembly.
Chck Key |motlock Switch OPer' etion: 1. Connect the No. 5 terminalof th ignitionswitch connector termito the batteryPositive No.3 teF nal,and connectthe minal to the bafterynegative termrnal, t 2 . T L r r n h e i g n i t i o ns w i t c h t o it. ACC(l),then PUsh 3. Checkthe key interlocksolen o i d o p e r a t i o n .A c l i c k i n g sound should be heardwhile pushing ignitionkev. the
KEYLOCKSOL IWHT/BLUI
+B KEY LOCK (WHT/GRN)
Doesthe keyinterlock solenoid operate Properly?
Faulty key interlock 3witch. the ignidon key cylinder/ Roplaco steoring lock tssamblY.
To page14-130
(cont'd)
14-129
Troubleshooting Flowchart- InterlockSystem- KeyInterlockSystem(cont,dl
Frompage14'129 INTERLOCK CONTROL UNITCONNECTOR {8PI Check Key Intorlock Solonoid tol a Short Circuit: 1. Disconnect interlock the control unit connector, 2. Checkfor continuitybetween t h e N o . l t e r m i n a la n d b o d y groundand between No.5 the terminal and bodygroundindi vidually. KEYLOCKSOL (WHT/BI-U}
ACCPUSHSW {WHT)
Wire sideof female terminals Repairshon in thc wire betweon the No. 1 or No. 5 terminal and th ignhion switch 6P connector.
ls therecontinuity?
Check Park Pin Switch Operation: Checkfor continuity between the No.I terminaland body ground.
ls therecontinujty?
Check for short in the wir6 between the No. 8 terminal of the intrlock control unit and tho park pin switch. ll wire is OK, ch6ckthe park pin switch.
MoasureATP P Voftegel 1. Turnthe ignition switch (lli. ON 2. Measure the voltagebetween the No. 6 terminal and body ground.
Shiftlevermust be in E.
ATP P IBLK/BLUI
Repairopen in the wiro between the No. 6 termin.l and the A/T gear position 3witch.
Checkfor looseterminal fit in th interlock control unit connoctors. lf necosssry, substitute t knowngood interlock control unit and recheck.
14-130
('99 Troubleshooting - 00 Modelsl Electrical

Flowchart- o/D oFF IndicatorLight DoesNot GomeOn Troubleshooting
The O/D OFFindicator light doos not come on when the ignition switch i3 tiBt tulned ON {lll. {lt should come on lor about two secondsand then go outl
C h e c kt h e O / D O F FI n d i c a t o l Light: ON switch (ll). 1. Turnthe ignition and Press 2. Shiftto E position, the Over-Drive(O/D)switch.
Does the O/D OFF indicator lightcome on?
Chocklor looaet.rmin.l tit in tho PCM connoctor3. lf nocesstrY, substitute a known'good PCM and r.chock. PCMCONNECTORS A (32Pt B t25Pl
c (3rPt c (31
Chck O/O IND lor an OPen Circuit: OFF switch 1. Turnthe ignition 2. Disconnectthe B (25P)con' nectorIrom the PCM. the 3. Disconnect 14Pconnector from the gaugeassemblY. 4. Check {or continuity between the 819 terminaland the No. 6 terminal of the gauge 14P assembly connector.
GAUGEASSEMBLY CONNECTOR I14P)
O,/DIND ILT BLU}
Wire sideoI lemaleterminals Replir open in the wiro botween the 819 terminal and gauge .ssemblY | 4P connector.
ls therecontinuitY?
Check for a fauhv O/o OFF indi' cator light bulb or . laulty gluge a3semblyprinted circuit bo.rd.
a
14-131

Troubleshooting Flowchart O/D OFFIndicator LightOn Constantly
The O/D OFFindicator light is on constanllv whenever the ignition switch is ON {ll),
C h e c kt h e O / D O F F I n d i c a t o r Lighti '1. Turn the ignitionswitchOFF. 2 . D i s c o n n e ctth e B ( 2 5 P )c o n nectorfrom the PCM. 3. Turnthe ignition switch flt). oN
Doesthe O/D OFFindicator lightcomeon?
Fepair short to ground in lhe wire between the B'19terminal a n d t h e g a u g e a a s o m b l y1 4 p GOnnectot,
14-132
LightDoesNot ComeOn Flowchart O/D OFFIndicator Troubleshooting EvenThoughO/D Switch ls Pressed

The O/D OFFindicator light does not come on evn though the Over-Driv6 lO/Dl 3witch is pre$ed in E position. lThe o/o OFF indicatol light come on wh6n the ignition switch is fir3t turned on tor two seconds,then 9o out.l
Checkthe Over-Drivs {O/D) Switch al lhe Switch Connector: 1. Turnthe ignitionswitchOFF. 2. Disconnect the park pin/O/D connector. swrtch 3. Checkfor continuitybetween t h e N o .1 a n dN o . 2 t e r m i n a l s whale of the switchconnector p r e s sn g t h e s w i t c h , a n d i when released at.
CONNECTOR PARKPIN/O/D SWITCH
of Terminalside maleterminals while ls therecontinuity pressingthe switch, and no it? when released continuity Checklor loose torminallit in the O/O switch connestor. lf termin a 1 3a r e O K , r e p l a c et h e O / D switch and pa]k pin switch as a se.t lseep.go l+1511.
CheckO/D Switch fol an Opsn Circuit: c 1 . D i s c o n n e ctth e D ( 1 6 P ) o n nector from the PCM. 2. Checkfor continuitybetween the D8 terminaland the No. 1 terminalo{ the switchconnec' tor,
PCMCONNECTORS A {32P1 B l25Pl
c (31P)
O/D SW (PNKI PARKPIN/
o/D swtTcH
CONNECTOR termanals Wire sideof female
Ropairopen in the wire batwean the D8 te.minal and the park pin/O/D Bwhchconnocto..
To page14-134
(cont'd)
14-133

Troubleshooting Flowchart- o/D oFF lndicatorLight DoesNot come on EvenThoughO/D Switch ls pressed(contd)
Frompage14-133
Check O/D Switch Ior a Sho.t Circuit: Checkfor continuity between the D8terminaland body ground.
PCMCONNECTORS
O/D SW{PNKI
Wiresideof femaleterminals Repair short to ground in the wire betweon the D8 terminal and the park pin/O/D.witch connectoa,
ls therecontinuity?
Chck O/D Switch G.ound Circuit: Check continuity lor between the No. 2 terminalof the switchconnectorand body ground.
PAFKPIN/O/D SWITCH CONNECTOR
Wiresideot femaleterminals
Repairopon in the wire btween th No. 2 terminal of the park pinlO/D 3witch connector snd ground 1G401. c402), or rep.ir poor ground (G401,4021.
14-134
ControlSolenoidValveA/B Assembly Lock-up

Test
the 1 . Disconnect 2P connectorfrom the lock-upcon' valveA'lBassembly. trol solenoid 2. betweenthe No. 2 terminal the resistance Measure ( s o l e n o i d a l v e A ) o f t h e c o n n e c t o ra n d b o d y v ground. and bet\iveen No. 1 terminal (solenoid the valveB) and body ground. 12 STANDARD: - 25 o LOCK-UP CONTROL VALVE SOLENOID CONNECTOR I2P)
Replacement
valvesA and B must be controlsolenoid NOTE:Lock-up as removed/replaced an assembly. 1. the mountingbolts and the lock-upcontrol Remove assembly. valveA,,/B solenoid CONTROL LOCK.UP VALVE SOLENOIO A/B ASSEMBLY
6 x 1.0mm lbf.ft) kgf.m,8.7 12N.m11.2
of Terminalside maleterminals
oa
Replace.
Clean mountingsurface the and fluid passages.
2.
CONTROL LOCK.UP
and Cleanthe mountingsurfaceand fluid passages, valveIVB with lock-up controlsolenoid installa new a new filter/gasket. for Checkthe connector rust,dirt, or oi!, and reconnectit securely.
R e p l a c e h e l o c k - u pc o n t r o l s o l e n o i d v a l v e A / B t is if assembly the resistance out of specification connectthe is lf the resistance within the standard, No. 1 terminal of the connectorto the batterypositive sound shouldbe heard Connect A terminal. clicking the No. 2 terminal to the battery positiveterminal. A the clickingsound shouldbe heard.Replace lock-up assemblyif no clicking control solenoidvalve Ay'B to sound is heardwhen eitherterminalis connected terminal. the banervDositive Checkthe lock-upcontrol solenoidvalve fluid passagesfor dust or debris,and replaceas an assem bly, if necessary.
14-135
Shift ControlSolenoidValveA/B Assembly

Test
'1. Disconnect 2P connectorfrom the shift control the solenoid valveAy'B assembly.
Replacement
NOTE: Shift control solenoid valves A and B must be removed/replaced an assembly. as 1. 2. Remove shiftcontrol the solenoid cover. Remove the mountingbolts,the clamp and the shift controlsolenoid valveAy'B assembly, then disconnect the connector.
w
Terminalsade of maleterminals
6x1.0mm 12 N.m {1.2k9 .m,8.7lbtft}
CLAMPARACKET
qK
SHIFTCONTROL SoLENO|OCOVEn SHIFTCONTROL SOLENOID VALVEA/B ASSEMBLY
\--
-!t'">,,
FILTER/GASKET
Measure the resistance betweenthe No. 1 terminal (solenoid valveA) of the shift controlsolenoidvalve connector and body ground,and between the No. 2 terminal(solenoid valveB) and body ground. STANDARD: - 25 O 12 Replace shift controlsolenoidvalveA,/Bassemthe bly if the resistance out of specification. is lf the resistance within the standard. is connectthe N o , I t e r m i n a lo f t h e s h i f t c o n t r o ls o l e n o i d a l v e v connector the batterypositive to terminal.A clicking sound should be heard.Connect the No. 2 terminal to the battery positive te.minal. A clicking sound should be heard.Replace shift control solenoid the v a l v e A / B a s s e m b l yi f n o c l i c k i n gs o u n d i s h e a r d w h e n e i t h e rt e r m i n a li s c o n n e c t e do t h e b a t t e r v t positive terminal.
Replace.
Clean mounlingsurface the and fluid passages.
Cleanthe mountingsurfaceand fluid passages. and installa new shift controlsolenoidvalveAy'B assembly with the clampand a new filter/gasket. Install the shiftcontrolsolenoid cover. Checkthe connector rust,dirt. or oil, and reconfor nectit securely.
14-136
LinearSolenoidAssembly
Test
1. connector. Disconnect linearsolenoid the lf a clickingsound is not heard,removethe linear solenoidassembly. for Checkthe linear solenoidfluid passage dust or orn.
LINEARSOLENOIO
1.
to Connect the No. 1 terminalof the connector the batterypositiveterminaland the No. 2 te.minal to the battery negativeterminal. Make sure that the valvemoves. Disconnect negative the batteryterminal.and make You can see valve movesure the valve releases. i m e n t t h r o u g ht h e f l u i d p a s s a g e n t h e m o u n t i n g surface the linearsolenoidassembly. of LINEAR SOLENOID
Measurethe resistance betweenthe No, 1 and the No. 2 terminals. STANDARD: About 5.0 o replacethe lf the resistance out of specification, is linearsolenoidassembly. Connect the No. 1 terminalof the connectorto the batterypositiveterminal and the No. 2 terminalto t h e b a t t e r y n e g a t i v et e r m i n a l ,A c l i c k i n gs o u n d shouldbe heard.
VALVE
lf the valvebinds,or movessluggishly. if the linear or replace linearsolenoid the solenoid doesnot operate, assemotv.
14-137
LinearSolenoidAssembly
Replacement
'1. Remove the mountingbolts and the linearsolenoid assemblY.
Mainshaft /Countershaft SpeedSensors

Replacement
1. sDeed Removethe 6 mm bolt and the countershaft sensorfrom the end cover.
surface Clean mounting the

and fluid passages.
6x1.0mm 12 N.m (1.2kg{.m. 8.7tbtftl
5x1.0mm 12 N.m 11.2kgf.m, 8.7 rbf.frl
COUNTERSHAFT SPEED SENSOR
@ @
O.RING Replace.
GASKET
6x1.0mm
kgl.m, 12N'm 11.2 8.7tbf.ftl
Cleanthe mountingsurface and fluid passage the of linearsolenoidassembly and transmission housing. Installa new linear solenoidassemblvwith a new gasket.Do not pinch the gasketduring installation, properlyin the mountand makesure it is installed ing grooveof the linearsolenoid. Checkthe linearsolenoidconnector rust.dirt, or for oil, then connectit securelv.
R e m o v et h e 6 m m b o l t a n d t h e m a i n s h a f s p e e d t sensorfrom the transmission housing. Replace O-ringwith a new one beforeinstalling the the countershaft speedsensoror the mainshaftspeed sensor,
14-138
A/T GearPositionSwitch
Test
the IVT gear position 1. Removethe A,/Tgear position switch connsctorfrom the connectorbracket, then disconnect (10P). connector switch for to 2. Check continuitybetween terminalsin eachswitchpositionaccording the table below. the POSITION A/T GEAR CONNECTOR SWITCH (10P1
Wire side oI female terminals
A/T Gear PGition Swhch Coniinuity Ch6ck '97 - 98 Models
\_-__l"'ry1
Position
'l
10
tr tr
t!l!l
E E E E
'99 - O0Models
ooo-o_ o_ oo-
-o -----o ---o ----o -----o ---o ----o
\______lg,-r4
Position
.'
l0
tr tr
E E E E
oc\ooo o_
---o ---o ----o - o o ----c
NOTE:TerminalNo.3: Neutraloositionswitch
14-139
A/T GearPositionSwitch
Replacement
Make 3ure lifts, iacks, and safety stands @ ar placod properly lsoo soction 1). 1. Raisethe front of the vehicle,and support it with safety stands (see section 1). Set the parking brake,and block both rear wheels securely. Shiftto E position. Remove the A/T gear position switch connector from the connector bracket, then disconnect it. Removethe AfI gear position switch harnessclamp. A/T GEAF POSITION swrTcHcovER
6x1.0mm 12 N.m 11.2 m. kgt 8.7 lbf.ftl
6.
R e m o v et h e h a r n e s sc l a m p f r o m t h e e n d c o v e r , then remove the Aff gear position switch cover and gear position switch. Ay'T
2.
3.
6x1.0mm 12 N.m {1.2 kg{.m,8.7 lbtftl
1.
Set the IVT gear position switch to E position. The AfI gear position switch clicks in E position.
5x1.0mm 12Nm11.2kgf.m, 8.7 tbf.ftt
BRACIGT
POSmON
swlTcH
14-140
then installthe 8. Set the control shaft to E] position. A,/Tgear position switch on it. SHAFT CONTROL
12, Start the engine. Move the shift lever through all gears. and verifythe following: . . . The shift lever cannot be moved to E] position from E positionunless the shift leveris pulled. The engine will not start in any position other than E or E. The back-uplightscome on when the shift lever is in El position.
gear positionswitch cover and har9 . Installthe Ay'T nessclampon the end cover. 1 0 . Connect the A,/Tgear position switch connector. bracket. then installit on the connector 1 1 . Turn the ignitionswitchON (ll).Move the shift lever through all gears,and checkthe AfI gesr position with the A/T gear position switch synchronization indicator.
A/TGEARPOSMON INDICATOR '99 - 00 MODELS
A/T GEARPOSITION INDICATOR '97 - 98 MOOELS
14-141
A/T GearPositionIndicator
fnput Test-'97 - 98 Models
(seesection20).and disconnect 14Pconnector 1 . Removethe gauge assembly from the dashboard the from the gauge (seesection23), assemblv Inspect connector the and socket terminals be surethey are all makinggood contact. to . . lf the terminals are bent,loose,or corroded, repairthemas necessary, recheck system. and the lf the terminalslook OK, makethe following inputtestsat the 14Pconnector. - lf I test indicates problem, a find and correct the cause, then recheck system. the - lf all the input testsproveOK, but the indicator faulty.replace printedcircuitboard, is the
GAUGEASSEMBLY 14PCONNECTOR
Cavity
Wirs Color
YEL
Test Condition lgnitionswitchON (ll)
Test: DesirdResult Check voltageto ground: for Thereshouldbe battery voltage, Check voltagebetweenNo. 2 for a n d N o .3 t e r m i n a l s ; Thereshouldbe batteryvoltage.
PossibleCause {lf rosult is not obtainod) . Blown No. 25 (7.5A) fuse in the under-dash fuse/relay box . An open in the wire Blown No. 47 (7.5A) fuse in the under-dash fuse/relay box Faultycombination Iightswitch Faultydash iight brightness controller An open in the wire
Combination light
RE D/BLK switchON and dash

lightsbrightness control dial on full bright RED
4
BLU
BRN YEL BLK
Shift leverin E Shift leverin E Shift leverin @ Underall conditions
7 8
' Faulty Ay'T Check continuity ground: for gear position switch to . An open in the wire Thereshouldbe continuity. NOTE:Thereshouldbe no continuity in any other shift lever position. Check continuity ground: for to Thereshouldbe continuity Check voltageto ground: for Thereshouldbe battery voltage for two seconds afterthe ignition switchis turned ON {ll),and less than 1 V two seconds later, Check continuity ground: for to Thereshouldbe continuity. NOTE:Thereshouldbe no continuity in any othershift leverposiUOn. . Poorground{G401) . An open in the wire ' FaultyPCM . An open in the wire
lgnitionswitchON {ll) and shift leverin any GRN/BLK position except E
10
1'l 12
GRN RED WHT
Shift leverin E Shift leverin @ Shift leverin E Shift leverin E
. Faulty A,ff gear position switch . An open in the wire
BLVBLU NOTE:Do not push

the brakepedal. lgnitionswitchON {ll) and shift leverin any positionexceptE and Check voltageto ground: for Thereshouldbe about5 V. . FaultyPCM . An open in the wire
14
LT GRN
14-142
InputTest-'99 - 00 Models
from the dashboard the from the gauge L Removethe gaugeassembly {seesection20), and disconnect 14Pconnector (seesection23). assembly Inspect connector the and socket terminals be surethey are all makinggood contact. to a lf the terminalsare bent.loose,or corroded. repairthem as necessary. recheck system. and the . lf the terminalslook OK, makethe followinginput testsat the 14Pconnector. - lf a test indicates problem, a find and correctthe cause, then recheck system. the - lf all the input testsproveOK, but the indicator faulty,replace printedcircuitboard. is the
GAUGEASSEMBLY14PCONNECTOR
Cavity
Wire Color
YEL
Test Condition lgnitionswitchON (ll)
Test: DesiredResuh Check voltageto ground: for Thereshouldbe batteryvoltage. Check voltagebetweenNo. 2 for a n dN o . 3 t e r m i n a l s : Thereshouldbe batteryvoltage.
PossibleCaus6 {lf resutt is not obtainod) . Blown No.25 (7.5A) fuse in the fuse/relay under-dash box . An open in the wire Blown No. 47 {7.5A) fuse in the under-dash fuse/relay box Faultycombination light switch Faultydash light brightness controller An open in the wire
Combination light RED/BLK switchON and dash lightsbrightness control dial on full bright RED BRN Shift leverin E Shift leverin E Shift leverin E
7 '10
YEL BLU
. FaultyA/T gear positionswitch Check continuity ground: for to . An open in the wire Thereshouldbe continuity. NOTE:Thereshouldbe no continuity in any othershiftleverposition. Check continuity ground: for to Thereshouldbe continuity. FaultyO/Dswitch FaultyA/T gear positionswitch FaultyPCM An open in the wire . Poorground(G401) . An open in the wire . FaultyPCM . An open in the wire
lgnitionswitchON (ll), shift leverin E. and LT BLU Over-Drive OFFby is pressing O/Dswitch. 8
BLK
Underall conditions lgnitionswitchON (ll) and shift leverin any positionexceptE
Check continuity ground: for to Thereshouldbe continuity for Check voltageto groundl Thereshouldbe batteryvoltage for two seconds afterthe ignition switchis turnedON (ll).and less later. than 1 V two seconds for to Check continuity ground: Thereshouldbe continuity. NOTE:Thereshouldbe no continuity in any other shift leverposiIton.
Check for voltage to groundl There should be about 5 V,
a:FI\|/Et| ta
11 12
RED
WHT
Shift leverin S Shift leverin E Shift leverin E
. FaultyA/T gear positionswitch . An open in the wire
BLI(BLU NOTE:Do not push

the brakepedal. lgnitionswitchON (ll) and shift leverin any positionexceptE and
14
LT GRN
. FaultyPCM . An open in the wire
14-143
InterlockSystem
InterlockControlUnit Input Test
precautions, in and procedures the SRS are locatedin this area.Reviewthe SRScomponentlocations, SRScomponents repairs service. or section(24)beforeperforming '1. Remove instrument panellower cover(seesection20). the from the interlock controlunit. the 2. Disconnect 8P connector terminals be surethey are all makinggood contact. to and connector 3. Inspect connector the . . and the repairthem as necessary, recheck system lf the terminalsare bent,loose,or corroded, lf the terminalslook OK, makethe followinginputtestsat the connector. - lf a test indicates problem, the then recheck system find and correctthe cause, a - lf all the input tests prove OK, substitute known-good the controlunit, and recheck system.lf the checkis OK, a it. the controlunit must be faulty;replace
the clickswhen the ignition switchis tu rned ON (ll)while pressing brakepedalwiththe NOTE: lf the shift locksolenoid test the A/T position, the shift lock system is OK. lf the shift lever cannot be shiftedfrom E position. shift lever in E gear positionswitch.
14-144
1
4
Cavity
Wire Color
Test Condhion lgnitionswitchturned to ACC(l), ignitionkey pushedall the way in
Tost: DesiredRosult Check voltageto ground: for There should be battery voltage.
PossibleCause (lf result is not obtainedl Blown No. 48 {30A} fuse in the under-hoodfuse/relaybox Blown No.33 (7.5A) fuse in the under-dashfuse/relaybox Faultysteeringlockassembly solenoid) {keyinterlock An open in the wire Blown No.25 (7.5A) fuse in the under-dash fuse/relay box An open in the wire Blown No. 25 (7.5A) fuse in the under-dash fuse/relay box Faultyshift locksolenoid An open in the wire . Poorground(G401) . An open in the wire Blown No.48 (30A) fuse in the under-hoodfuse/relaybox Blown No. 33 (7.5A) fuse in the under-dashfuse/relaybox Faultysteeringlockassembly (keyinterlock switch) An open in the wire gear position switch Faulty Ay'T Poorground(G101) An open in the wire Faultyparkpin switch Shon to ground
WHT/BLU
lgnitionswitchON (ll) YEL lgnitionswitchON (ll)
Check voltageto ground: for Thereshouldbe batteryvoltage. for Check voltageto ground: There should be baftery voltage.
YEUBLK
Underall conditions lgnitionswitchturned to ACC(l), ignitionkey pushedall the way in 5
BLK
Check continuity ground: for to Thereshouldbe continuity. Check voltageto ground: for There should be battery voltage.
WHT
Shift leverin E BLI(BLU Shift leverin @ and pulled toward steering wneel WHT/BLK Shift leverin E
Check continuity ground: for to Thereshouldbe continuity, Check continuity ground: for to Thereshouldbe continuity. for Check continuity ground: to Thereshouldbe no continuity.
Reconnect interlock the controlunit 8P connector.

lgnition switch ON (ll) and brake pedal presseo
Checkfor voltage to ground: Thereshouldbe 1 V or less.

Check for voltage to ground: There should be baftery voltage,
WHT/RED lgnition switchON (lll, brakepedal and acceleratorpedal pressedat the sametime
Faulty brakeswitch Faultythrottleposition(TP) sensor Faulty PCM An open in the wire Faultyinterlock controlunit
14-145
lnterlock System
KeyInterlockSolenoidTest
SRScomoonentsare locatedin this area. Reviewthe SRS precautions. procedures the locations, and in component SRSsection(24)before pertorming repairsor service. 1. Removethe instrumentpanel lower cover (seesection 20). Disconnect the ignition switch 6P connectorat the connector holder. 3. Checkfor continuitvbetweenthe terminalsin each key positionaccording the table. to
IGNITION SWITCH CONNECTOR 6P
2.
\____________r{r4
Position lgnition Key pushedin switch Key released ACC0)
o o- ---o
---'o
Check that the key cannot be removed with power connected the No. 5 terminaland ground connected to to the No. 3 terminal. lf the key cannot be removed.the key interiock solenoidis OK. lf the key can be removed,replacethe steering lock assembly(the key interlocksolenoidis not available separately).
6P CONNECTOR
14-146
Shift LockSolenoidTest
SRScomponentsare locatedin this area.Reviewthe SRS component locations,precautions,and proceduresin the SRSsection(24)before performingrepairsor service, '1. Remove the instrumentpanel lower cover (seesection 20). 2. 3. Remove steering columncovers(seesection17). the Disconnect shift locksolenoid2P connector. the Connect the No. 1 terminalof the shift locksolenoid connector the batterypositivetgrminal,and conto nect the No. 2 terminalto the batterynogative termrnal. Check that the shift levercan be moved from the E o o s i t i o n .R e l e a s eh e b a t t e r vt e r m i n a l sf r o m t h e t shift lock solenoidconnector.Move the shift lever backto the E position, and makesure it locks. NOTE:Do not connectpower to the No. 2 (-) termipolarity)or you will damagethe diode nal {reverse insidethe solenoid. 6. when the release Checkthat the shift lock releases lever is pushed,and checkthat it locks when the release leveris released,
7.
lf the solenoid it. does not work, replace
2P CONNECTOR SHIFTLOCK
14-147
InterlockSystem
Shift LockSolenoidReplacement
are in the SRScomponents located this area.Review SRS precautions, procedures the locations, and in component (24)beforeperforming repairs service. or SRSsection 'L Remove the instrumentpanel lower cover (seesection 20). Removethe upper and lower steeringcolumn covers (seesection17). B e m o v et h e f l a n g e n u t s a n d b o l t s s e c u r i n gt h e column,then lowerthe steering column. steering Disconnect shift lock solenoidand the park pin the switchconnectors. Remove the bolts securing the shift leverassembly, then removethe shift leverassemblv. Remove the screwssecuring the shift locksolenoid, then removethe shift locksolenoid. 7 . Installthe new shift lock solenoid by aligning the joint of the shift lock solenoidplungerwith the tip of the shift lockextension with the screws, Secure shift locksolenoid the 9 . Installthe shift lever assemblyin the reverseorder of the removal. 1 0 Checkthe operationof the shift lever and the shift lock.
2.
3.
4.
2.5 N.m {0.25 kgl.m,1.8lbf.ft}
14-148
ParkPinSwitch Test
SRScomponentsare locatedin this area. Reviewthe SRS and proceduresin the compongnt locations,precautions, SRSsection(24)before performingrepairsor service, 1. Remove tho instrumentpanel lower cover (seesection 20). Removethe upper and lower steeringcolumn covers (seesection 17). Disconnect parkpin switchconnector. the Shift the shift lever into E position, then checkfor continuitybetwsgntheseconngctor terminals: . '97 - 98 models;No. 1 and No, 3 terminalsof the parkpin switchconnector. . ' 9 9 - 0 0 m o d e l s N o .3 a n d N o . 4 t e r m i n a l s o t h e : f park pin switch/Over-Drive{O/D) switch connector. Thereshouldbe continuity, 37 - 98 MODELS: Shiftthe shift leverout of the E position, and check for continuity betweenthe terminalsas in step 4. Thsreshouldbe no continuity. it. lf the parkpin switchis faulty,replace
PAR( PIN
'99 00 MODELS:
PARKPIN SWITCH/ oVER-DRTVE {O/D) SWTTCH CONNECTOR
.qI
14-149
InterlockSystem
-'97 - 98 Models ParkPinSwitch Replacement
precautions, SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, and procedures the SRS in section(24)beforeperforming repairsor service. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove instrument the lower cover(seesection 20). Danel Remove upperand lowersteering the columncovers(seesectionli,. Remove flangenutsand boltssecuring steering the the column.then lowerthe steering column. Disconnect shift locksolenoidand the park pin switchconnectors. the Remove harness the clamp bracket. Remove boltssecu the ring the shift leverassembly,then removetheshiftleverassembly. Remove screwssecuring shift locksolenoid. the the then removethe shift locksolenoid, Remove parkpin switchconnector the from the shift levercontrolbracket. Removethe control checkerfrom the shift lever control bracket. Remove parkDinswitchfrom the controlchecker. the
PARKPIN SWITCH PARKPIN SWITCH CONNECTOR
scnEw
2.5 N m 10.25 kgt.m, 1.8 lbtftl
9.3 N.m 10.95 kgf.m, 6.9 lbl.ft) BRACKET CONTROL CHECKER
11. Install the new DarkDinswitchon the controlchecker. 12. lnstallthe controlchecker the shift levercontrolbracket. on 13. Routetheparkpin switchharness throughthecutoutofthe shift levercontrolbracket, then installthe parkpin switch connectoron the bracket. 14. Installthe shift locksolenoidby aligningthe joint of the shift locksolenoidplunger with the tip of the shift lock extension. 15. Secure shift locksolenoid the with the screws. 15. Install shift leverassembly the reverse the in orderof the removal. '17. Check operation the shift leverand the shift lock. the of
14-150
-'99 - 00 Models (O/DlSwitch Replacement ParkPin Switch - Over-Drive

precautions, in and procedures the SRS SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, performing repairsor service. section{24)before replace them as a set. NOTE:lf replacement the parkpin switchor the O/Dswitchis required. of 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. panellowercover(see section20). Remove the instrument columncovers(seesection17). the upperand lowersteering Remove column. the column.then lowerthe steering Remove flangenuts securing steering the and the parkpin switch- O/Dswitchconnectors Disconnect shift locksolenoid the clamp bracket. Remove harness the then removethe shift leverassembly. the Remove the boltssecuring shift leverassembly, then removethe shift locksolenoid. the Remove screwssecuring shift locksolenoid, the removethe connectorfrom the shift levercontrolbracket Cutthe O/Dswitchwires (REDandBLK),then from theshift levercontrolbracket Remove controlchecker the Remove oarkoin switchfrom the controlchecker. the Remove shift leverknobfrom the shift lever,then removethe O/Dswitchfrom the shift leverknob. the
CONTROL SHIFTLEVER BRACKET PARKPIN SWITCH SCREW kgtm, 1.8lbf,ft) 2.5 N.m 10.25
o/DswlTcH
CONNECTOR
2.5 N.m (0.25kgt m, 1.8 tbf.fr)
SHIFTLEVER kgl.m. 9.3 N.m 10.95 6.9 tbf ft) KNOB SHIFTLEVER 6-12N,m {0.6- 1.2kgt.m.4- 8.7 lbf ftl
o/o swlTcH
HABNESS CLAMPBRACKET
then install 12. Routethe new O/D switchwires through the shift lever knob,shift lever,and shift lever control bracket, the knob on the shift lever,and installthe switchin the knob. on then installthe controlchecker the shift levercontrolbrack13. Installthe new parkpin switchon the controlchecker, et. 14. Routetheparkpin switchharnessthroughthecutoutoftheshiftlevercontrolbracket. The wire terminalscan be installedin cavity cavities securely. 15. Installthe O/D switchwire terminalsin the connector N o .1 o r N o . 2 . and the harness clampon the bracket. 16, Install the connector 17. tnstallthe shift locksolenoidby aligningthe joint ot the shift locksolenoidplunger with the tip of the shift lockextenwith the screws, sion,then secure shift locksolenoid the inthe reverse orderof removal. 18. lnstallthe shift leverassemblv (seepage 14-270). the 19. Adjustthe clearance between O/Dswitchwires and the edgeof the shift levercontrolbracket lockoperation. and shift 20. Check shift leveroperation the
14-151
(O/Dl Switch ('99- 00 Modelsl Over-Drive

Test
SRS componentsare located in this area. Review the precautions, SRScomponentlocations, and procedures in the SRSsection(24)beforepertormingrepairsor servtce.
1.
Remove the instrumentpanel lower cover (seesection 20). Removethe upper and lower steeringcolumn covers (seesection17). Disconnectthe park pin switch - O/D switch connector.
4.
Checkfor continuity betweenthe No, 1 and No. 2 t e r m i n a l sw h i l e p r e s s i n g n d h o l d i n gt h e O / D a switch,and when it's released. Thereshouldbe continuity while pressing and holding the switch,and no continuity when it's released.
PARK SWITCH PIN
lf the O/D switch is faulty, replaceit and the park pin switchas a set (seepage14-1511.
14-152
Chart Symptom-to-Component
HydraulicSystem
Dl system, checkthe self-diagnosis ('97 - 98) or Lq ('99 - 00) indicator a Beforetroubleshooting problemon Hydraulic according to troubleshooting a lf light indication. the El or E indicatorlight indicates troublecode,performthe electrical a light does not indicate troublecode and failureis not Chart.lf the Ol or E indicator System-to-Component the Electrical followingthe chart. performthe hydraulic troubleshooting troubleshooting, found on the electrical SYMPTOM Engineruns,but vehicledoes not move in any gear. theseitemson the Check List CAUSE PROBABLE
1 r 2 F A t ? 8 2 ?
theseitemson Check List the NOTES K,L.R,S
in moves El. @, butnotin lE. E, E, or E, position 6, 8, 9, 10,29, 52 Vehicle moves [D!.E, E. E, E, butnotinE] position. in Vehicle
Vehiclemovesin .&1,E. E, E, E, but not in E position Vehiclemovesin E position. idle Excessive vibration flareson startingoff in E, Di position Pooracceleration; or E position 4 , 6 ,1 4 ,1 5 'l4, '16,2A,32, 33, 34 10, 12, 13, 44, 1,2, 18,3'1,35, 46,41
c,M,o
a l
c,L.o
B,K,L
Stallrpm hishin El, El, E, E, E Position Stallrpmhiqhin E, E, E, E position

Stall rpm high in E position Stallrpm high in hl position Stall rpm low No shift from 1stto Failsto shift in Pr, E positionor E position; 3rd gear from 1stto Failsto shift in EJ, E positionor E position; 4th gear Erratic upshifting fz upshlft. ,3 ripshlft, 3r. up+ilft
40 1,2,3,6,37, 6 ,8 , 1 0 14 17,31,44,46,47 18, 19,39, 47,48 21, 48 2 1 , 2 24 7 ,
K,L,R
C,D
c,D
N
R G,L
57 20,47 21, 4A 22, 47 50, 12,18, 19,2A,49, 56,57 13,1A,19,23,26,28,49,50,56,57 49, 14,1A,19,24,27,28, 50,56. 57 18,19,23,42,53,56,51 5 1 2 ,1 8 , 1 9 , 2 4 , 4 1 , 4 2 ,4 .5 6 ,5 7 ,5 8 13,'1A, 25, 41, 42,55,56,57 19, 13,1A,19,23,26,50 1 4 ,1 A ,1 9 , 2 4 , 2 7 , 5 0 13. '18,19, 23, 26, 42,49, 50, 51 14,1A,19,24,27 42,49,50,51 , 10,29 4,14,20,51 2,36 11 (cont'd) C,D.E,H,L C , D ,E ,I , L
ffi
il
3-4 upshift Harshupshift('l-2) Harshupshift(2-3) Harshupshift{3-4) Harshdownshitt(2-1) Harshdownshift(3-2) Harshdownshift(4-3) Flares 2-3 upshift on Flares 3-4 upshift on Excessive shockon 2-3 upshift Excessive shockon 3-4 upshift or to Lateshiftfrom N position ld or Erl position. to E position Lateshift from E positionto E position in Noisefrom transmission all shift leverpositions more than 3l mph (50 km/h). Vehicle does not accelerate
o
C, D, E, I
F I
E,L,N E.L.N E,L,N M
o
K,L.O
14-153
HydraulicSystem (cont'd)
SYMPTOM Shift leverdoes not operatesmoothly. Failsto shift;stuckin 4th gear. Transmission not shiftintoparkin E position. will Stallrpm high;all clutchpressures in specification. are Lock-up clutchdoes not disengage. Lock-up clutchdoes not operate smoothly. Lock-up clutchdoes not engage. Vibrationin all positions. No enginebrakingin I position. Shift positionindicator does not indicate anv position,
o, Jd
Check theseitemson the PROBABLE CAUSE List 14, 41, 48 6, 38,61 40 18, 43,44,45, 46,49,50,57 14, 40, 43, 44, 45, 46, 49, 50. 57 't8, 40, 43, 44, 45, 46, 49,50, 56, 57 59 6. 38, 60
Check theseitemson the NOTES Lisr P P D,K,O
PROBABLE CAUSE ATF pump worn or binding Regulatorvalve stuck or regulator valve spflng worn Servovalvestuck Mainshaft worn/damaged Shiftcablebroken/out adjustment of Finalgearsworn/damaged (sprag) One-way clutchworn/damaged 1stgearsworn/damaged gears) {2 lst clutch defective (2 2nd gearsworn/damaged gears) 2nd clutch defective 3rd clutchdefective 4th clutch defective gearsworn/damaged gears) Reverse (3 Excessive ATF Torque converter one-way clutch defective Linearsolenoidassemblv (,98- OO defective models) CPCvalvestuck l-2 shift valvestuck 2-3 shiftvalvestuck 3-4 shift valve stuck 2nd accumulator defective 3rd accumulator defective 4th accumulator defective 2nd orificecontrolvalvestuck 3-4orificecontrolvalvestuck Foreignmaterialin main orifice Foreignmaterialin lst orifice Foreignmaterialin reverse orifice Engineoutput low Needlebearingworn/damaged
5tt
33
34
Thrust washer worn/damaged Clutchclearance incorrect Drive plate delective or transmission mtsassembled Torqueconverter housingor transmission housingbearingworn/damaged ATF strainer clogged Shift cableis worn where it attaches the to transmission at the body mounts or Modulator valvestuck Torque converter checkvalve stuck Foreignmaterialin separator plate CPBvalve stuck Lock-up timing valvestuck Lock-up shift valvestuck Lock-up controlvalvestuck Lock-upclutch Distondefective Shift control solenoid valve A defecttve Shift control solenoid valve B dsfectrve Lock-upcontrol solenoid valve A defective Lock-upcontrol solenoid valve B deleqtve Servocontrolvalvestuck lst accumulator defective Foreignmaterialin 2nd exhaust orifice Foreignmaterialin 3rd exhaustorifice Foreignmaterialin 4th exhaust orifice Mainshaft speedsensordefective Countershaft speedsensordefective 3rd sub accumulator defective lst-holdclutchdefective A/T gear position switch defectiveor out of adjustment Parkgear mechanism defective
7 I 10 11
38
39
40
41 43
44
't2
t5
14
tc
16 17 18 '19 20 21
46 47 48 49 51 52 53 54 56 58 59 60 61
26 27
2a
29
30
31 32
14-154
The followingsymptomcan be caused by improperrepairor assemblY creepsin N position. Vehicle or Vehicle does not move in E, [D.lj, E position. locksup in E position. Transmission drag in transmission. Excessive
theseitems Check . lmproperclutchclearance . lmpropergearclearance (sprag) upsidedown clutchinstalled One-way upsidedown Parkleverinstalled Shiftfork bolt not installed ATF pump bindingand seizure the Usepropertools when replacing ATF pump gears,and be carefulnot to damagethe ATF pump when torquedown the main valvebody. on Check that the shiftfork bolt is installed the shiftfork shaft in not Torqueconverter fully seated ATF pump upsidedown hub installed Reverse selector oil Mainshaft sealimproperlyinstalled housing lf oil lnstallthemainshaft sealtlushwith the torqueconverter housinguntil into the torqueconverter oil the mainshaft sealis installed and resultin damage it bottoms.it will blockthe fluid returnpassage . Springsimproperlyinstalled . Valvesimproperly installed valveballsnot installed Check
vibration, rpm related. Excessive Noiseonly with wheelsmoving. oil Mainshaft sealpo9s out.
Variousshiftingproblems. Harshupshift.
(cont'd)
4-15 5
ponentChart Symptom-to-Com
Hydraulic System(cont'd)
NOTES Seeflushingprocedure, page l4-264and 265, B Set idle rpm in gearto specified idle speed.lf still no good,adjustmotor mountsas outlinedin engine section this manual. of lf the largeclutchpistonO-ringis broken,inspect the pistongroovefor rough machining. lf the clutchpackis seized is excessively or worn. inspect other clutches wear,and checkthe orifice the fot controlvalves,CPC valve,and linearsolenoid free movement. for lf the linearsolenoidis stuck,inspect clutches wear. the for lf the 1-2shift valveis stuckclosed. transmission not upshift.lf stuckopen,the transmission the will has no lst gear.
H
c
D
lf the 2nd orificecontrolvalveis stuck,inspect 2nd and 3rd clutchDacks wear. the for lf the 3-4 orificecontrolvalveis stuck,inspect 3rd and 4th clutchpacks wear. the for lf the clutchpressure controlvalveis stuckclosed. transmission not shift out of lst gear. the will lmproperalignment main valve body and torqueconverter of housingmay causeATF pump seizure. The symptomsare mostlyan rpm-related tickingnoiseor a high-pitched squeak. lf the ATF straineris cloggedwith particles steelor aluminum,inspect ATF pump and differential of the pinionshaft.lf both are OK and no causefor the contamination found,replace torqueconverter. is the lf the lst clutchfeed pipe guide in the end cover is scoredby the mainshaft. inspect ball bearingfor the excessive movementin the transmission housing.lf oK, replace end coveras it is dented. the The o-rino underthe guide is probablyworn. ' Replace mainshaft the bushing the 4th feedpipeis looseor damaged, the 4th feed pipeis the if for lf darrF agedor out of round.replace end cover. the ' Replace mainshaft the bushing the l st feedpipe is looseor damaged. the 1stfeedpipe the if for lf is damagedor out of round,replace it. A worn or damaged spragclutchis mostlya resultof shiftingthe transmission E!. E, or E position in while the wheelsrotatein reverse. suchas rockingthe vehiclein snow. Inspect framefor collisiondamage. the lnspect damageand wear: for gearteethchamfers. l. Reverse selector 2. Engagement teethchamfers countershaft and reverse of gear. 4th 3. Shift fork for scuff marksin center. 4. Differential pinionshaftfor wear underpiniongears. 5. Bottomof 3rd clutchfor swirl marks. Replace items1,2, 3. and 4 if worn or damaged. transmission lf makesa clicking, grinding, whirringnoise, or alsoreplace mainshaft gear,reverse 4th idlergear,and countershaft gearin addition 1,2, 3, or 4. 4th to lf differentialpinion shaft is worn, overhauldifferentialassembly,replaceATF strainer,and thoroughlycjean transmission, flushtorqueconverter. cooler, and lines, lf bottom of 3rd clutch is swirled and transmissionmakesgear noise.replacethe countershaft and final driven oear, Be very carefulnot to damagethe torqueconverter you housingwhen replacing main ball bearing. the may also damagethe ATF pump when you torquedown the main valvebody.This will resultin ATF pump seizure not detected. if Usethe Drooer tools.
J K L M
o
P
Install the main sealflush with the torqueconverter housing. you push it into the torqueconverter lf housinguntil it bottomsout, it will blockthe fluid returnpassage and resultin damage.
RoadTest
(the radiator comeson). tan temperature NOTE:Warm up the engineto normaloperating 1. 2. fluid level,see page14-160. testing,checkthe transmission Before Apply the parkingbrakeand blockthe wheels.start the engine,then shift to E {'97 98) or E {'gg 00) position not stall. The engineshould pedaland release suddenly. it the the while pressing brakepedal.Press accelerator sametest in E position('97- 98 models). Repeat Test-drivethe vehicle on a flat road in the E or E position. Checkthat the shift points occur at approximate speeds shownon a flat road.Also checkfor abnormalnoiseand clutchslippage. the Throttlepositionsensorvoltagerepresents throttleopening.Monitorit with the HondaPGMTesteror as follows: to a. Unboltthe PCMfor roadtesting;reJer page14-58. on theseterminals the PCM: to throttlepositionsensorvoltagebetween b. Setthe digitalmultimeter check (+)and A9 (-) or A22 {-} . '97 Model:Between terminalsD'! . '98 - OO Models; Betweenterminals C27 (+) and 820 (-) or 822 {-)
3. 4.
BACKPROBE ADAPTER
SET BACKPROBE (two roquircdl
orsAz- 001moA
PATCH STACKING CORD DIGiTALMULTIMETER {CommrcirllY.vailablc} KS-AHM-32-003, or equival.nt
'97 Model:
PCMCONNECTORS
'.
o a 2r / /
//B
11111t1.t nait la t1 t213tr / t6t, tl / / / /
t-'a:IM-&E
-Llfiffi-fl)\"".'E
l'o ti
, jl. t
1 3 / 10n v
'98 - 0OModels:
PCMCONNECTORS
A l32Pt
B {25Pt
c l31P}
(cont'd)
LGl (BRN/BLK)
termanals Wire sideot female
14-157
RoadTest
(cont'd)
or lgrr E Position: Upshift
Throftle Opsning Throttlepositionsensor voltage: 0.75V Throttlepositionsensor voltage; 2.25V Fully-opened throttle, Throttlepositionsensor voltage:4.5V Downshift Throttle Opening Fully-closed throttle, Throttlepositionsensor voltage;0.5V Fully-opened throttle, Throttlepositionsensor voltage:4,5V Unit ot speed mpn km/h
mph km/h
Unit of spsd mph km/h mph km/h

mph
lsi + 2nd
2nd * 3rd
3rd + ilth
Lock-up ON
9-12 15-19
20-23
43-49 69-79
28-33
45-53
oz - ott
34-40
68-74 109 118 9 0- 1 0 1 1 4 5- 1 6 3
22-26
35-41 37-43 60-69
9 9- 1 0 8 101 111
k-/h
111- 124
1 6 3- 1 7 9
Lock-upOFF
i{th + 3rd
3rd * 2nd
znd + lst
19-23
5t-5D
1 A- 2 ' l
6 - 10 {3rd- 1st) 1 0- 1 5( 3 r d* 1 s t ) 57-64 9 2- 1 0 3 26-32 42-51
29-34
86-96 1 3 8- 1 5 4
88-99 142- 't59
NOTE: . Lock-upON:The lock-up controlsolenoid valveA turns ON. . Lock-up OFF: The lock-up controlsolenoid valveA turns OFF. 4. Accelerate about 35 mph (57 km/h)so the transmission in 4th. then shift from to is E The vehicleshouldimmediately beginslowingdown from enginebraking. Check abnormalnoiseand clutchslippage the followingpositions. for in E {1stGear)Position Accelerate from a stop at full throttle,Makesurethere is no abnormalnoiseor clutchslippage. Upshifts shouldnot occurwith the shift leverin this position. E (2ndcear) Position Accelerate from a stop at fuI throttre. Makesurethere is no abnormar noiseor crutch srippage. Upshifts and downshifts shouldnot occurwith the shift leverin this position. Position E (Reverse) Accelerate from a stop at full throttle.and checkfor abnormalnoiseand clutchslippage. 6. Testin E (Park) Position Parkthe vehicleon slope(approx.16"),applythe parkingbrake, and shift into E position. Release brake; vehithe the cle shouldnot move. or E positionto E position.
5.
14-158
Stall Speed
Test
CAUTION: . To prevent transmission damage,do not te3t stall speedfor mors than 10 sondsat a time' . Do not shift the lever while raising th engine spsed. . Be sure to remove tho pressurogauge bofore testing stall speed, fluid level,sepage 14-160. 1. Before testing,checkthe transmission the 2. Engage parkingbrakeand blockall four wheels and startthe engane. the 3. Connect tachometer, switch is OFF 4. Make sure the Ay'C (the radiator comeson),shiftinto@ position. fan temperature 5. Afterthe enginehaswarmedupto normaloperating ' and noteenginespeed for 6. Fullypressthe brakepedaland accelerator 6 to 8 seconds, Stallspeedshould j. A|ow 2 minutesfor cooling,then repeatthe test in E, E ('97- 98).E {'99- 00},and E positions. be the samein E, E, E, tr. and E positions Stall Speedrpm: Specitication:2,550rpm SrviceLimit: ?,400- 2.700rpm CAUSE PROBAELE ATF pump outputis low ATFstrainer Clogged valvestuckclosed regulator Pressure Slippingclutch clutch,or 1stgearone-wayclutch of Slippage 1stclutch,1st-hold of Slippage 2nd clutch of Slippage 1stclutchor 1stgearone-wayclutch of Slippage 4th clutch . Engineoutput low . Torqueconverter one-wayclutchslipping
TROUBLE
Stallrpm highin El, E, E, E andE positions
Stallrpm high in E position Stallrpm high in E position stall rpm high in E! or E position Stallrpm high in E position
Stallrpmlow in [dd, E, E, anaE E. positions
14-159
FluidLevel
Checking
NOTE: Keep all foreign particlesout of the transmisston, 1. Warm up the engineto normal operatingtemperature (the radiator comeson) fan Parkthe vehicle on level ground. Turn off the engine. Removethe dipstick(yellow loop) from the transmission, and wipe it with a cleancloth. Insertthe dipstickinto the transmission.
DIPSTICK FRONT
7.
Insertthe dipstickback into the transmission the in direction shown.
-'-Y'
Insrall dipstick the within DIPSTICK
R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l .l t shouldbe between the upperand lower marKs.
lt
El--
UPPER MARK MARK
lf the level is below the lower mark. pour the recommendedfluid into the filler holeto bring it to the upper mark,Alwaysuse Genuine HondaPremiumFormula AutomaticTransmission Fluid (ATF).Using a nonHondaATFcan affectshift oualitv.
14-160
Testing Pressure
Changing
NOTE: Keep all foreign particlesout of the transmission. 1. temperature up Bringthe transmission to operating (the radiatorfan comes on) by driving the vehicle. P a r kt h e v e h i c l eo n l e v e lg r o u n d .t u r n t h e e n g a n e off. then removethe drain Plug. NOTE: lf a cooler flusher is to be used, see page 14-264 and 14-265.
a Wlrile testing, be careful of the rotaling wheols. a Mako sure lifts, iacks, and safety stands ar placed
properly (seescction 11.

1.
f B e f o r et e s t i n g ,b e s u r e t h e t r a n s m i s s i o n l u i d i s to the proPerlevel. filled 4WD: the Raise vehicle(seesection11. 2WD: Raisethe front of the vehicle,and make sure it is and block Set supported. the parkingbrake, securely both rearwheelssecurely. Allow all four wheels {4WD)or front wheels (2wD} to rotate freely. Warm up the engine (the radiatorfan comes on), the then stop it and connect tachometer.
2.
TRANSMISSION END COVER
5.
gaugesto each inspection the oil pressure Connect and do not allow dust or otherforeign holesecurely, holes. particles enterthe inspection to TOROUE:18 N'm ll.8 kgf'm, 13 lbf'ft)
DRAIN 1 8x 1 . 5m m
WASHEB SEALING Replace.
49 N.m{5.0kgt.m, lbf.tl) 36
the Reinstall drain plug with a new sealingwasher, with the recommended then refill the transmission Always use fluid to the uDpermark on the dipstick. G e n u i n eH o n d a P r e m i u m F o r m u l aA u t o m a t i c ATF Fluid (ATF) Using a non-Honda Transmission can affectshiftquality. Automatic TransmissionFluid Capacity: 4WD; 2.9 { (3.1 US qt. 2.6 lmp qt) 8t change 5.8 ? {7.2 US $, 6.0 lmp qt} at ovethaul 2WD: 2.7 | l2.SUS qt,2.1lmp qtl ai change 5.9 ? {6.2 US $, 5.2 lmp qtl at ovolhaul
A/T OIL PRESSURE GAUGESETW/PANEL 07{06 - 0020400
HOS, A/T PRESSURE 2210mm 07MAJ - PYiOllA {4 Requircd}
\-J--
/4\
\r+..\.-.\ -'-\
W'
'/"' ,a
,4
A/T LOW PBESSURE GAUGEw/PANEL 07406 - 0070300
HOSE A/T PRESSURE ADAPTER 07MAJ - PYt0120 (il Rcquiledl
6.
the Measure followingPressure: ..........,14-162 . L i n eP r e s s u r e . P e . 1 s t .1 s t - h o l C l u t c h r e s s u r . . . . . . . . . . . . . '1 4 - 1 6 2 d . P e . 2 n d , 3 r da n d 4 t h C l u t c h r e s s u r . . . . . . . . .1 4 - 1 6 3 Installnew sealingwashersand the sealingbolts in the inspectionholes, and tighten to the specified toroue. kgf'm, 13 lbf'ft) 18 TOROUE: N'm 11.8 (cont'd)
7.
14-161
Pressure Testing
(cont'd)
Line Proslure, lst Clutch, lst.hold Clutch prsssuro Measuromont 1. 2. Startthe engine,and shiftto E or @ position. Run the engine at 2,000rpm, then measureline pressure. Higherpressuremay be indicatedif measurements are madein shift leverpositions otherthan E or @ position. shift to E ('97- 98) or E ('99- oo) positionand holdthe engineat 2.ooorpm, then measure1stclutchpressure.
4.
Shiftto E positionand hold the engineat 2,000rpm, then measurelst-hotdctutchDressure.
LOCK.UP CONTROL SOLENOID VALVE A/B ASSEMBLY
PRESSURE Line
SHIFTLEVER POSmON
SYMPTOM No (or low) line pressure
PROBABLE CAUSE
Standald
FLUIDPRESSURE ServiceLimit 780 kPa 'l10 psi) {8.0kgf/cm,,
Eor@
Torque converter. ATF pump,pressure regulator, torque converter checkvalve lst Clurch 1st-hold Clutch
830 - 880 kPa (8.5* 9.0 kgflcm,, 120- '130 psi)
1stClutch lst-hold Clutch
E ('se oo)
E (97 - 98) No or low 1st

pressure No or low lsthold pressure
tr
14-162
znd, 3rd, and ,lth Clutch PressursMeasuremenl '97 - 98 Modols: 1. 2. Stan the engine,and shiftto E position.
'99 - 00 Models: 1. 2. Startthe engine,and shiftto El position. R u n t h e e n g i n e a t 2 , 0 0 0r p m . t h e n m e a s u r e2 n d clutchpressure. (O/D) Shift to E position,and turn the Over-Drive (O/O OFF indicator OFF by pressing the O/D switch light comeson). Hold the engine at 2,000 rpm, then measure 3rd clutchPressure. Turn the Over-DriveON by pressingthe O/D switch ( O / DO F F i n d i c a t o rl i g h t g o e s o u t ) , a n d h o l d t h e engineat 2,000rpm, then measure4th clutch pressure. Shift to E position,and hold the engine at 2,000 4th rpm, then measure clutchprgssure
R u n t h e e n g i n ea t 2 , 0 0 0r p m , t h e n m e a s u r e2 n d clutchpressure. 3. Shift to E position,and hold the engine at 2'000 3rd rpm, then measure clutchpressure. Shift to E position,and hold the engine at 2,000 4th rpm, then measure clutchpressure. Shift to @ position,and hold the engine at 2,000 4th rpm, then measure clutchpressure. 4.
3.
4.
5.
5.
6.
PRESSURE 4TH CLUTCH HOLE INSPECTION
PRESSURE 2ND CLUTCH HOLE INSPECTION
"..# '"r.,-ur"" HOLE INSPECTION

SHIFTLEVER POSmON
--t"1' -.
PRESSURE 3RDCLUTCH HOLE INSPECTION
FLUIDPRESSURE SYMPTOM No or low 2nd pres$ure No or low 3rd pressure CAUSE PROBABLE 2nd Clutch Standard 800 - 850 kPa \A.2- 8.1 kgtlcm2, '120- '124psil Servico Limit 760 kPa (7.7kgf/cm' ,110psi)
PRESSURE 2nd Clutch
tr
E (97 - s8) Elwith Overis Drive OFF (99 - 00) E (97,98) E (99 - oo)
3rd Clutch
3rd clutch
4th clutch
No or low 4th pressure
4th Clutch ServoValveor 4th Clutch
14-163
Transfer
Inspection
Mako suro lifts, jacks, and safety stands @E are placod properly lsoe section t). 1. Raisethe front of the vehicle,and make sure it is supported securely. Set the parkingbrake,and block both rear wheels securely. Shift to E position.
4. COMPANION FLANGE
6. Set a dial indicator the transferassembly on flange. then measure transfergear backlash. the STANDARD: 0.06- 0.16 mm (0.002- 0.006inl
2.
Make a referencemark acrossthe propeller shaft and the transferassembly flanges. S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assembly.
7. lf the measurement out of standard,removethe is transferassembly and adjusttransfergear backlash '14-232 {see page thru 14-2491. 8. Checkfor fluid leaks betweenthe mating faces of transfer cover A and cover B. 9. lf there is a fluid leak,removethe cover,and reDlace the O-ring. '10.
8 x 1.25mm 32 N.m 13.3 kgl,m, 24 lbf.ftl Replace.
Checkfor fluid leaks betweenthe mating face of the transferassembly and transmission.
11. lf there is a fluid lak, removethe transfrassembly, and replace O-ring, the 1 2 . C h e c kt h e t r a n s f e ro i l s e a l f o r d a m a g ea n d f l u i d le8ks. 13, lf oil sealreplacement required. is removethe transfer assembly,replacethe oil seal, and adjust the total starting torque (see page 1+232 thtu ]'4-249||. NOTE:Do not replacethe oil seal with the transfer assembly the transmission. on
14-164
Assembly Transfer
Removal
Make sure the lifts, iacks, and safety @ stands are placed properly (seesection 11. 1. Raisethe front of the vehicle,and make sure it is securely. supported Set the parkingbrake,and block both rear wheels securelv. fluid (ATF). transmission Drainthe automatic plug with a new sealing washer' the Reinstall drain 5. Disconnect he primary heatedoxygen sensor HO2S) connector. {Primary exhaustpipeA. Remove
2.
SELF-LOCKING NUT Beplace. SEI-F.LOCKING NUT Replace.
DRAINPLUG '18 x'1.5rnm 49 N.m 15.0 kgf.m, 36 lbl.ftl
NUT Replace 7. Remove shift cablecover. the the snap pin and controlpin, then separate Remove the shift cablefrom the control lever.Do not bend the shift cableexcessively.
4.
Remove guard bar and the splashshield. the
GUARD 8AR
(cont'd)
14-165
Transfer Assembly
(cont'dl Removal
9, Make referencemarks across the prooeller shaft and the transferassembly flanges. 1 0 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r assembly flanges.
REFERENCE MANKS
PROPELLER SHAFT
'l
l. Remove the rear stiffener. then removethe transfer
assembly. NOTE: While servicingthe transfer assembly,do not allow dust or otherforeignparticles enterthe to transmission.
REARSTIFFENER
14-166
lnstallation
1.
Install new O-ringon ths transferassembly. a Clsan the areaswhere the transferassemblycontacts the transmissionwith solvent or carburetor air. Then apply cleaner,and dry with compressed ATF to the contact areas. on Install transterassembly the transmission. the NOTE: while installingthe transfer assembly,do to not allow dust or other foreignparticles enterthe transmission. lnstallthe rearstiffener.
5.
Installthe propellershaft to the transferassembly marks by aligningthe reference
REFERENCE MARKS
PROPELLER SHAFT
8 r 1.25mm 24 N.m {2.4 kgf m, r7 bl.ftl 10 x'l.25 mm ara N.m 14.5 kgtm, 33 tbf trl
8 xl,25]nm 32 N.m(3.3kgl.m, 2a tbf.ftl Replace.
I n s t a l lt h e s h i f t c a b l e w i t h t h e c o n t r o l p i n , t h e n secureit with the snap pin. Do not bend the shift cableexcessively. 7. lnstalltheshift cablecover.
SHIFTCABLE O.RING TNANSFER ASSEMALY
8 xl.25 mm 22 N.m 12.2 kd-m, 16 tbt.ftl
(cont'd)
14-167
Transfer Assembly
Install exhaustpipe A. the Connect the primaryheatedoxygensensor(Primary H02S) connector, GASKET
Replace.
'I 'I.
Refillthetransmission with ATF (seepage14-161).
12. Startthe engine,and run it to normaloperating temp e r a t u r e( t h e r a d i a t o r f a n c o m e s o n ) , T u r n t h e engineoff and checkATF level.
EXHAUSTPIPEA
SELF.LOCKING NUT 10 x 1.25mm 54 N.m {5.5kgf.m, 40 rbf.ft) Replace. SELF-LOCKING NUT 8 x 1.25mm 22 N.m (2.2kgl.m, 16 rbr.ftt Replace.
-LOCKING NUT 8 x 1.25mm 16Nm11.6kgf.m, 12 lbf.fO Replace.
1 0 . I n s t a l l t h e p l a s h h i e l d n dt h e g u a r db a r . s s a
6x1.0mm 9.8N.m {1.0kgt.m, 7.2 tbt.ftt
14-168
Transmission
Removal @
6. Make sure lifts. iacks, and safety stands aro placed properly, and hoist brackets are attached to the colrest position on the engine lsee section 11. Apply th parking brake and block the rar wheels, so vehicls will noi roll off the stands and fall on you while working under it. Disconnect vehicle speedsensor(VSS), counthe the tershaft speed sensor, and the A/T gear position switch connectors.
A/T GEARPOSITION SWITCH CONNECTOR
VEHICLE SPEED SENSOR |VSS'
NOTE: Use fender covers to avoid damaging painted surfaces. ' 1 . Disconnect the negativeterminal,then disconnect terminalfrom the battery. the positive 2. Remove the intakeair duct and the air cleanerhousing assembly, R e m o v et h e s t a r t e rc a b l e s .R e m o v et h e h a r n e s s clampfrom the clampbracket.
CLAMP CONNECTOR BfiACKET SPEED SENSOR CONNECTOR
7.
Remove the transmission housing mounting bolts.
STARTER CABLES
g R e m o v et h e t r a n s m i s s i o n r o u n d c a b l et e r m i n a l and the radiatorhose clamp lrom the transmission hanger. 5. Disconnect lock-upcontrol solenoidvalve conthe nector,then remove the harnessclamp from the clamp bracket. HARNESS CLAMP
RADIATOR HOSE
CLAMP
MOUNTINGBOLTS
CONTROL SOLENOID VALVE CONNECTOR
(cont'd)
14-169
Transmission
(cont'd) Removal
8. Disconnectthe mainshaftsped sensor, the shift controlsolenoidvalve,and the linearsolenoidconnecrors, 10. Remove guard bar and the splashshield. the
CONNECTOR SENSOR
R e m o v et h e d r a i n p l u g . a n d d r a i n t h e a u t o m a t i c t r a n s m i s s i o nl u i d { A T F ) .R e i n s t a ltlh e d r a i n p l u g f with a new sealingwasher.
1 1 . Removethe cotter pins and castlenuts, then separatethe ball joints from the lower arms (seesection 18).
12. Removethe right damper fork bolt, then separate

right damperfork and damper.
DAMPER PINCHBOLT
4eN.m ksr.m. rbrft) rs.o 36
DRAIN 1 8x 1 . 5m m
;:i:$:
*o"*."
SELF.LOCKING NUT
Replace.
CASII.E NUT DAMPER FORK BOLT
FORK OAMPER
Replace.
14-170
and 1 3 . Pry the right driveshaftout of the differential. orv the left driveshaft out of the intermediate shaft {seesection16). 1 4 . Pull out the inboardjoint, and removethe right and (seesection18). left driveshaft Tie plastic bags over the driveshaftends. Coat all with cleanengineoil. finishedsurfaces Drecision
ORIVESHAFT
the 1 8 . Remove shift cablecover. the 1 9 . Remove shift cable. ilWD: Remove the snap pin and controlpin, then separate the shift cable from the control lever. Do not bend the shift cableexcessively.
Replace.
16. Disconnect he primary heatedoxygen sensor (Primary HO2S) connector.
't7 RemoveexhaustpipeA. .
GASKET Replace. 2WD: Removethe control lever, then separatethe shift cablefrom the control shaft. Do not bend the shift cableexcessivelv.
SHIFT CAELE
EXHAUST
Replace.
14-171
Transmission
(cont'dl Removal
Make referencemarks across the transfer assemblv (4WD) and propeller shaftflanges. 2 1 . S e p a r a t et h e p r o p e l l e r s h a f t f r o m t h e t r a n s f e r (4WD) assembly. 2 4 . Remove right front mounvbracket. the Remove the ATF cooler hoses at the ATF cooler lines.Turn the ends of the cooler hosesuo to orevent ATF from flowing out, then plug the linesand hoses.Checkfor any sign of leakageat the hose ioints.
REFERENCE MARKS
I x 1.25 mm Replace.
RIGHT FRONT MOUNT/BRACKET
2 2 . Remove the intermediate shaft, Tie plasticbagsover the both ends of the intermediate shaft. Coat all precisionfinished surfaceswith cleanengineoil. R e m o v et h e r e a r s t i f f e n e ra n d t o r q u e c o n v e r t e r cover.
27. Removethe eight drive plate bolts, one at a time.

pulley. while rotatingthe crankshaft
DRIVE PLATE
COVER
14-172
28. Place a jack under the transmission,raise it just enough to take it off of the mounts, then remove mount bracket. the transmission
30. Rmove the rear side transmission housingmounting bolt and the rearenginemountingbolts.
REARENGINEMOUNTINGBOLTS
3 1 . Pull the transmission away from the engine until it 29. Remove front sidetransmission the housinomounting bolt. clearsthe dowel pins,then lower it on the transmissionjack. Remove thg torque converter assemblyfrom the transmission. Remove starterfrom the transmission the housing.
14-173
lllustratedIndex(4WDl
EndCover/Transmission
O O O @
ENDCOVER olL SEAL Replace. BALLBEARING A/T GEARPoSITIoN swITcH coVER
PosrloNswrrcH ) A/TGEAn
@ ROLLER O coLLAR G) o-RING Replace. {9) FEEDPIPEFLANGE @ O-RINGReplace. O SNAPRING FEEDPIPE @ 3RDCLUTCH (D CoUNTERSHAFT LOCKNUT x 1.25mm Replace. 23 (} coNtcAL SPR|NG WASHER Reptace. @ PARKGEAR @ ONE.WAYCLUTCH (, COUNTENSHAFT GEAR lST (D NEEOLE BEARING (O COUNTERSHAFT GEARCOLLAR lST @ o-RING Reptace. FEEDPIPE @ lST CLUTCH @ O-RINGReptace. PIPEFLANGE @} FEEO @ SNAPRING @ DOWELPIN @ ENDcoVER GASKET Feplace. @ PARKPAWLSToP @ PARKPAWL @ PARKPAWLSPRING @ PARKPAWLSHAFT SWITCHHARNESS CLAMP O} A/T GEARPOSITION @ PARKLEVER @ LOCKWASHER Replace. @ PARKSTOP Selectivepart SPRING @ PARKLEVER @ DRAINPLUG WASHER Reptace. O SEALING @) MAINSHAFTLOCKNUT2l x 1.25mm Replace. WASHER Replace. SPRING @ CONICAL ASSEMBLY @ lST CLUTCH
i!, O-RING Replace. WASHER @ THRUST BEARING @ THRUSTNEEDLE BEARING @ NEEDLE @ MAINSHAFI 1STGEAR 1sT GEARcoLLAR @ MAINSHAFT @ o-RING Replace. SPEED SENSOR 6!, COUNTERSHAFT @ ROLLER @) COLLAR @ o-RtNG Replace. FLANGE 6A FEEoPIPE @ o-RtNG Reptace. @ SNAPR|NG @ IST.HOLDcLUTcH FEEDPIPE LOCKNUT x 1,25mm Reptace. 19 @ SUB-SHAFT WASHERReptace. O coNtCALSPR|NG lST GEAR E! SUB.SHAFT SOLENOID ASSEMBLY } LINEAR soLENotD aSSEMBLyGASKET Reptace. @ LTNEAR BBACKET @ HARNESS WASHERS Feptace. @ SEALING LINE @ ATF COOLER @ LIN BoLT @ ATF DIPSTICK LINE @ ATF COOLER @ LINEBoLT WASHERSReptace. @ SEALING SPEED sENsoR (vss) @ VEHICLE @ o-RtNG Beptace.
TOROUE SPECIFICATIONS
Bolt/Nut No. 6B 8A 12J 18D 19S 21M 23C
Torque Valuo '12N'm ('1.2 kgf.m,8.7lbf.ft) 14 N.m (1.4kgf.m,10lb{.ft} 22 N.m 12.2kgf.m, 16 lbf.ft) 28 N'm (2.9kgf.m,21lbf.ft) 49 N.m (5.0kgf.m,36lbf'ft) 93 N'm {9,5ksim.69 lbf.ft) 78 N.m {8.0kgnm,58lbf.ft) 103* 0- 103N{n {10.5* 0+ 10.5 kgfn, 75.9-0-75.9 lbf{t)
Size 6x 1.0 m m 6x1.0mm 8 x 1.25 m m 1 2x 1 . 2 5 m m 1 8x 1 . 5m m 1 9x 1 . 2 5 m m 2 1x 1 . 2 5 m m 2 3x 1 . 2 5 m m
Remarks
Linebolt Drainplug Sub-shaft locknut Mainshaft locknut: Left-hand threads Countershaft locknut: Left-hand threads
14-175
lllustratedIndex(4WD)
Transmission Housing
{;
r] REVERSE IDLERGEARSHAFT/HOLDER 'A NEDLE BEARING HOUSING ..] TRANSMISSION HOUSING OIL SEAL Replace. al TRANSMISSION g SETBING.80mm Selecrive part GEARCOLLAB O REVERSE GEAB E couNTERSHAFTREVERSE BEARING .9,]NEEDLE i9 LOCKWASHER Replace. .1!i REVERSE SHIFTFORK O REVERSE SELECToR HUB SELECTOR iJ. REVERSE 4TH ii' COUNTERSHAFT GEAR BEARING .14 NEEDLE coLLAR,28 mm Selectivepart iD D|STANCE (i3 COUNTERSHAFT GEAB 2NO BEARING i7-]THRUSTNEEDLE (10COUNTERSHAFT GEAR 3RD (9 NEEDLE BEARING GEABCOLLAR E9 COUNTERSHAFI3RD .li THRUSTNEEDLE BEARING WASHER .?) SPLINEO ,,O 3RDCLUTCH ASSEMBLY 1 O-RINGBeplace. i23 COUNTERSHAFT SOLENOID COVER 4i SHIFTCONTROL CLAMPBRACKET ?Z]HARNESS VALVEA/B ASSEMBLY SOLENOID ?9]SHIFTCONTROL CLAMPBRACKET 8 HARNESS SOLENOID VALVEFILTER/GASKET GI SHIFTCONTROL ReplaceSNAPRING THRUST WASHEB THRUSTNEEDLE BEARING 4TH 04MAINSHAFT GEAR NEEDLE BEARINGS BEARING @ THRUSTNEEDLE MAINSHAFT 4TH GEABCOLLAR ASSEMBLY @ 2NO/4THCLUTCH @ O-RINGReplace. :.ro) part THRUST WASHER,36.555 mm Selective x BEARING ai THRUSTNEEOLE
(4 MAINSHAFT 2ND GEAR BEARING i49 NEEDLE NEEDLE BEARING @ THRUST (49 MAINSHAFT R|NG,35 mm @r SEAL|NG RING,29 mm O SEALING BEARING @ NEEDLE .49SET RING ASSEMBLY ) lST.HOLDCLUTCH O o-RING Replace. WASHER 6E THRUST BEARING 9 THRUSTNEEDLE EEARING 6' NEEDLE 4TH GEAR ir SUB-SHAFT BEARING 6 THRUSTNEEDLE 4TH GEARCOLLAR @ SUB.SHAFT @ sUB-sHAFf BARING STOP 6I NEEDI-E BEARING @ NEEDLE (6t ATF GUIDECAP Replace. (64TRANSMISSION HANGEB CAP @ BREATHER SPEED SENSOR i@ MAINSHAFT 6i O-RINGReplace. IDLER GEAR 6D REVERSE @r DOWELPlN, 14 x 25 mm .6d SNAPRINGS TRANSMISSION HOUSING BEARING QlI SUB.SHAFT TRANSMISSION HOUSING BEABING E) MAINSHAFT TRANSMISSION HOUSING .2, COUNTERSHAFI BEARING DOWELPlN, 14 x 25 mm BRACKET @ CONNECTOR [E ATF MAGNET DOWELPlN, 14 x 20 mm TRANSMISSION HOUSING GASKET Replace. ASSEMBLY t, DIFFERENTIAL PlN, n9DOWEL 10x 12 mm t0 O-RINGReplace. ASSEMBLY @)TRANSFER CONVERTER HOUSING OIL SEAL Replace. @)TOROUE ,lDTOROUE CONVERTER HOUSING
TOROUESPECIFICATIONS
Bolt/Nut No.
Torque Value 1 2 N . m( 1 . 2 g f . m , 8 . 7b f . f t ) k l 1 4 N . m( 1 . 4 g f . m 1 0 l b i f t ) k , 44 N.m (4.5kgf.m,33lbf.ft)
Size m 6x 1.0 m m 6x 1.0 m m 1 0x 1 . 2 5 m
Rgmarks
6A 6B 10A
14-177
TorqueConverter Housing/Valve Body
37-94
6A
a^\
14-178
o ATFFEEDPIPE,8x 145mm a;\ a
ATF STRAINER ,6 SERVO BODY PLATE G)SERVOSEPARATOR VALVEEODY !o, SECONDARY DOWELPIN PLATE SECONDARY SEPARATOR BASE('97- 98 model3 onlyl @ SERVODETENT ,6 ATF FEED PIP,8 x 145 mm PIPE,8 40 mm x @ ATFFEED ATF FEED PIPE. x 62 mm 8 ATFFEED PIPE.8 112mm x PIPE, x 192.5mm 8 @ ATF FEED (} ATF FEEO PIPE. x 105.8mm I STOPSHAFTBRACKET PLATE @ ATF LUBRICATION ATF FEEO PIPE @ DOWELPIN VALVEEODY @ LOCK-UP SEPARATOR PLATE @ LOCK-UP VALVEBODY @ REGULATOR @ DOWELPIN RELIEF VALVESPRING @ COOLER RELIEF VALVE @ COOLER VALVESPRING CONVERTER CHECK 6 TOROUE CONVERTER CHECK VALVE @ TOROUE SHAFT @)CONTROL ARM SPRING @ OETENT ARM @ OETENT ARM SHAFT @ DETENT @ FILTERReplace. BALLS @ CHECK CHOKE @ lST ACCUMULATOR @ O"RING Replace. @ STATORSHAFT @ STOPSHAFT I @ ATF FEEDPIPE, x 112 mm @ MAIN VALVE BOOY @ ATF PUMPDRIVENGEARSHAFT @ ATF PUMPDRIVENGEAR
PLATE @ MAIN SEPARATOR @ DOWELPIN @ ATF PUMPDRIVEGEAR @ SUCTIONPIPECOLLAR TOROUE CONVERTER HOUSING @ COUNTERSHAFT BEARING
o (a a
@ ATF GUIDEPLATE @ LOCKWASHER Replace. LEVER ASSEMBLY @ CONTROL CONVERTER HOUSING @ TOROUE @ CHANGESHAFT @ OIL SEAL Reolace. OIL @ MAINSHAFT SEAL Reolace. HOUSING TOROUE CONVERTR @ MAINSHAFT
BEARING VALVEA/B CONTROL SOLENOID @ LOCK.UP FILTER/GASKET Replace. CONTROL SOLENOID VALVEA/B @ LOCK.UP ASSEMBLY
TOROUE SPECIFICATIONS Bolt/Nut No. 64 6B Torque Valug 12 N'm (1.2kgf.m,8.7lbf.ft) 14 N.m (1.4kgf.m,10 lbf.ft) Size 6x1.0mm 6x1.0mm Romarks
14-179
EndCover/Transmission
O ENDCOVER iLl OILSEAL Beplace. O BALLBEARING SWITCH COVER i.) A/T GEARPOSITION SWITCH i5] A/T GEARPOSITION aq)RoLLER ? COLLAB i0 o-BtNG Replace. PIPEFLANGE ) FEED f,o)o-RING Replace. 1' SNAPRING FEEDPIPE 1A 3RDCLUTCH 23 LOCKNUT x 1.25mm Replace. O COUNTERSHAFT WASHERReplace. [} coNtcal SPRING iO PARKGEAR (!I ONE.WAYCLUTCH lST E COUNTERSHAFT GEAR BEARING @ NEEDLE 1ST @ COUNTERSHAFT GEARCOLLAR Or o-RtNGS Reptace. FEEDPIPE ?] lST CLUTCH @ o-RING Replace. PIPEFLANGE e3 FEED 4I SNAPRING i DOWELPIN i?0 END COVER GASKET Replace. ?7)PARKPAWLSTOP E9 PARKPAWL C9 PARKPAWLSPRING D PARKPAWLSHAFT SWITCH HARNESS CIAMP OI A/T GEARPOSITION @ PARKLEVER 3 LoCK WASHER Replace. 04 PARKsToP Selectivepart (!' PARKLEVER SPRING PLUG @ DRAIN WASHER Replace. Ot SEALING LocKNuT 21 x 1.25mm Replace. 60 MA|NSHAFT (9 CONICAL WASHER Replace. SPRING ASSEMBLY @ lST CLUTCH
,!4!O-RING Replace. WASHER @I THRUST NEEDLE BEARING @ THRUST i.!' NEEDLE BEARING lST GEAR i MAINSHAFT @i MAINSHAFT1STGEARCOLLAR !r, O-RINGReplace. SPEED SENSOR iO COUNTERSHAFT E ROLLER @, coLLAR Ct o-RING Replace. PIPEFLANGE 5.] FEED 09 o-RING Replace. 6A SNAPRING FEEDPIPE 5' IST.HOLDCLUTCH LOCKNUT x 1.25mm Replace. 19 SUB-SHAFT @-] WASHERReplace. SPRING !t CONICAL lST GEAR 6i' SUB-SHAFT ASSEMBLY G) LINEARSOLENOID (6!)LINEARSOLENOID GASKET Replace ASSEMBLY BRACKET G] HARNESS WASHERSReplace. 6a SEALING LINE C' ATF COOLER @ L|NEBoLT GI ATF DIPSTICK LINE GI ATF COOLER O LINEBOLT wasHERs Replace. @ SEALING SENSOR aoo VEHICI.E SPEED IVSS) f,E O-RING Replace.
TOROUE SPECIFICATIONS
Bolt/Nut No. 6A 6B 8A 12J '18D 195 21M
Torque Value 12 N.m (1.2kgf.m,8.7lbf.ft) 14 N.m (1.4kgf.m,10lbf.ft) kgim, 16lbf.ft) 22 N.m 12.2 28 N.m (2.9kgim,21 lbf.ft) 49 N'm (5.0kgim,36 lbf.ft) 93 N.m (9.5kgf.m,69lbf.ft) 78 N.m (8.0kgf.m,58lbf.ft) + kSfm, 103+ 0+ 103N{n (10.5 0+ 10.5 75.9' 0 - 75.9lbfft)
Size 6x1.0mm 6x1.0mm m 8 x 1.25 m 1 2x 1. 2 5m m 1 8x 1 . 5m m 1 9x 1 . 2 5 m m m 2 1x 1 . 2 5 m m 2 3x 1 . 2 5 m
Remarks
Line bolt D r a i np l u g locknut Sub-shaft Left-hand threads Mainshaft locknut: locknut: Left-hand Countershaft threads
14-181
6A
Lt--"
&""--
IDLER o REVERSE GEARSHAFT,/HOLDER

atl ,6
NEEOLE BEARING TRANSMISSION HOUSING HOUSING OIL SEAL Rplace. @ TRANSMISSION part mm Selective !., SETRING,80 REVERSE GEARCOLLAR COUNTERSHAFT REVERSE GEAR NEEDLE BEARING 6l LOCK WASHER Replace. SHIFTFORK @ REVERSE REVERSE SELECTOR SELECTOR HUB @ REVERSE 4TH @ COUNTERSHAFT GEAR BEARING @ NEEDLE COLLAR,28 mm Selectivepan @ DISTANCE 2ND @ COUNTERSIIAFT GEAR THRUSTNEEDLE BEARING 3RD @ COUNTERSHAFT GEAR AEARING @ NEEDLE 3RD @)COUNTERSHAFT GEARCOLLAR BEARING @ THRUSTNEEOLE WASHER @ SPLINEO ASSEMBLY @ 3RDCLUTCH Replace. @ O-RINGS @ COUNTERSHAFT SOLENOID COVER @ SHIFTCONTROL CLAMPBRACKET @ HARNESS SOLENOID VALVEA/B ASSEMBLY @ SHIFTCONTROL CLAMPBRACKET @ HARNESS VALVEFILTER/GASKET SOLENOID @)SHIFTCONTROL Replace. @ SNAPRING WASHER @ THRUST BEARING @ THRUSTNEEDLE @)MAINSHAF ,ITH GEAR BEARINGS @ NEEDLE BEARING @ THRUSTNEEDLE 4TH GEARCOLLAR @ MAINSHAFT ASSEMBLY @ 2ND/4THCLUTCH @ O-RINGS ReDlace. x WASHER,36.5 55 mm Selectivepart @ THRUST BEARING @ THRUSTNEEDLE
a o o
2ND GEAR @ MAINSHAFT BEARING @ NEEDLE BEARING @ THRUSTNEEOLE @ MAINSHAFT mm RINGS,35 @ SEALING RING.29 mm @ SEALING BEARING @ NEEDLE @ SETRING ASSEMSLY @ lST-HOLDCLUTCH @ O-RINGSReplace. @ THRUSTWASHER BEARING @ THRUSTNEEDLE BEARING @ NEEDLE 4TH @ SUB.SHAFT GEAR BEARING @ THRUSTNEEDLE @ SU&SHAFT,ITHGEARCOLLAR @ SUB.SHAFT BEARING STOP @ NEEDLE BEARING @ NEEDLE @ ATF GUIDECAP Replace. HANGER @ TRANSMISSION CAP @ BREATHER SENSOR SPEED @)MAINSHAFT @ O-RING Reolace. IDI.fR GEAR @ REVERSE @ DOWELPlN, lil x 25 mm @ SNAPRINGS AEARING HOUSING @ SU&SHAFTTRANSMISSION HOUSING BEARING TRANSMISSION @ MAINSHAFT HOUSING TNANSMISSION @ COUNTERSHAFT
@ @ @ @ @ @ @
BEABING DOWELPlN, 14 x 25 mrn BRACKET CONNECTOR DOWELPlN, 14 x 20 mm TRANSMISSION HOUSING GASKET Replace. DIFFERENTIAL ASSEMBLY OIL SEAL Replace. TOROUE OONVERTER HOUSING HOUSING TOROUE CONVERTER
TOROUE SPECIFICATIONS Boli/Nut No. Torque Value 12 N.m (1.2kgf.m,8.7lbf.ft) '14N.m (1.4kgim, 10 lbf'ft) 44 N.m (4.5 kgim, 33 lbf.ft) Size 6 x 1 . 0m m 6x1.0mm m 1 0x ' 1 . 2 5 m Remarks
6B 10A
14-1A3
lllustratedIndex(2WD)
to\
I @
ATF ai_l FEEDPIPE,I a2', STRAINER ATF
x 145 mm
SERVOBODY (41 SERVOSEPARATOB PLATE /4. SECONDABY VALVE BOOY

:4.
PLATE i4ll MAIN SEPARATOR (4dDOWELPIN @ ATF PUMP DRIVEGEAR PIPE COLLAR @ SUCTION .!!l COUNTEBSHAFT HOUSING TOROUE CONVERTER ATF art) GUIDEPLATE BEARING
DOWELPIN PLATE SEPARATOR \7) SECONDARY BASE('98 model onlvl SERVODETENT PIPE, x 145mm 8 ATFFEED PIPE.8 40 mm x ATFFEED 1.0) PIPE,8 62 mm x tl ATFFEED I ATFFEED PIPE, x 112mm (3] ATFFEED mm PIPE, x 192.5 8 mm PIPE, x 105.8 8 ATFFEED t9 STOPSHAFTBRACKET PLATE .1qATF LUERICATION ATF FEEDPIPE DOWELPIN VALVEBODY ID LOCK-UP PLATE SEPARATOR @,LOCK-UP VALVEBOOY 8! REGULATOR Itt\ DOWELPIN ,29 COOLER RELIEF VALVESPRING VALVE BELIEF 4 COOLER VALVESPRING CHECK CONVERTER TOROUE VALVE CHECK CONVERTER 69 TOROUE CONTNOL SHAFT aaDETENTARM SPRING .21DETENT ARM ARM SHAFT 60 DETENT Replace. 0t FILTER BALLS CHECK CHOKE 1STACCUMULATOR 04O-RINGReplace. STATOR SHAFT 6!)STOPSHAFT ATFFEED PIPE. x 112mm 8 t0 MAIN VALVE BODY 0t ATF PUMPDRIVENGEARSHAFT .@ ATFPUMPDRIVEN GEAR
@ ATF MAGNET
o o,
HOUSING CONVERTER @ TOBOUE @ OILSEAL Beplace. OIL @ MAINSHAFT SEAL Replace. li]t MAINSHAFT HOUSING TOROUE CONVERTER BEARING VALVEA/B SOLENOID CONTROL LOCK.UP Replace. FILTER/GASKET VALVEA/B SOLENOID LOCK-UP CONTROL ASSEMELY
oa
en
TOROUESPECIFICATIONS Bolt/Nut No. Torque Value 12 N.m (1.2kgim,8.7 lbf'tt) Size 6x1.0mm Remarks
14-185
End Cover
Removal
NOTE: o The illustration showsthe 4WDautomatic transmission; 2WD is similar. the . cleanall partsthoroughlyin solventor carburetor cleaner, and drythem with compressed air. . Blow out all passages. . When removingthe transmission end cover,replace following: the - End cover gasket - Lockwasher - O-rings 6 x 1.0 rhm EOLTS - Shaftlocknuts - Conical springwashers - Sealing washers
A/T GEARPOSMON SwlTCH COVER
A/T GEARPOSITION
ENDCOVER GASKET A/T GEARPOSMON SW|TCH HARNESSCLAMP MAINSHAFT LOCKNUT CONICAL SPRING WASHER 1STCLUTCH ASSEMBLY THRUSTWASHER THRUSTNEEDLE AEARING NEEDI.T BEARING SUB.SHAFT LOCKNUT CONICAL SPRING WASHER PARKPAWL PAWL
O.RINGS
lt1/ sroe
Y plwl f
L/'SPRING
PAwL 'sHAFr \ \
!' -l!\
Locx wASHER 7// ?ARK srop 9/ couNTERsHAFr o-- Ay' LocKNUr LOCKNUT G-
/ ..t,"o, "oo CONICAL SPRING WASHCR
SUB.SHAFT 1STGEAR MAINSHAF?'ST GEAR MAINSHAFT 1ST GEARCOLLAR SEALING WASHERS
I"EVER SPRING
PARKGEAR Y CLUTCH
lST GEAR LINEAOLT NEEDLE BEARING COUNTERSHAFT lST GEARCOLLAR
ATF COOI.fB LINES LINEBOLT SEALING WASHERS
14-186
1.
R e m o v et h e A / T g e a r p o s i t i o n s w i t c h h a r n e s s cramp. gear position switch cover. Removethe y'VT Removethe bolt securingthe ly'T gear positionswitch harnessclamp on the end cover,then removethe A/T gear positionswitch. Removethe 12 bolts securingthe end cover.then removethe cover. as tool onto the mainshaft shown. Slip the special
PIN 8 mm pin, commercially
SUB-SHAFT LOCKNUT Replace.
MAINSHAFT LOCKNUT Replace. COUNTERSHAFT LOCKNUT 2\ Replace.
Irot)
WASHERS SPNING CONICAL Replace.
6. 7.
Engage parkpawlwith the parkgear. the Cut the locktabsof eachshaft locknutusing a chiselas out of the transmisshown. Keepall chiseledparticles ston.
M=tt"
Align the hole of the sub-shaft1st gear with the hole of the transmissionhousing.then insert a pin to lock locknut. while removingthe sub-shaft the sub-shaft Remove the locknutsand conicalspring washersfrom eachshaft. NOTE: Mainshaftand countershaftlocknuts have lefthandthreads. locknut.lt is used to Cleanthe old countershaft installthe pressfit parkgear on the countershaft.
to 9. Removethe lock pin that was installed hold the sub-shaft. tool from the mainshaft. the 10. Remove special 1st the 1stclutch,mainshaft gearassembly, 11. Remove 1st and mainshaft gearcollar. '12. Remove sub-shaft gear. 1st the the park pawl, pawl spring,pawl shaft.and 13. Remove pawl stoP. the 14. Remove park leverfrom the controlshaft. two jaw puller, removethe park 15. Using a universal t g e a r , o n e - w a yc l u t c h ,a n d c o u n t e r s h a f 1 s t g e a l assemblv.
PULLER available) {Commercially
1SY GEAR Removethe needlebearingand countershaft1stgear co ar. the 1 1 . Remove ATFcoolerlines,
14-187
Removal
NOTE: . The illustration showsthe 4WDautomatic transmission; 2WD is similar, the . Cleanallpartsthoroughlyin solventor carburetor cleaner. and drythemwith compressed air. . Blow out all passages. . When removingthe transmission housing, replace lollowing: the - Transmission housinggasket - Lockwasher - O-rings TRANSMISSION HOUSINGMOUNTINGEOLT
TRANSMISSION HANGER
REVERSE GEANCOLLAR CONNECTOR BRACKET MAINSHAFT SPEED SENSOR MAINSHAFT SUB.ASSEMBLY REVERSE GEAR LOCKWASHER REVERSE SHIFT
TRANSMISSION HOUSING GASKET
DIFFERENTIAL ASSEMBLY
TOROUE CONVERTER HOUSING
O-RING t4wDl
TRANSFER ASSEMBLY t4wDt
10 x 1.25mm BOLTS
l4wo)
14 -18 8
from the torque conthe transferassembly 1 . Remove verterhousing.(4WD) speedsensorfrom the transRemove the mainshaft missionhousing. housing mounting bolts, Removethe transmission bracket. hanger, and connector transmission 8.
4.
gearcollar,needle reverse Remove countershaft the bearing, and countershaftrevsrse gear from the countershaft, 7. Removethe lock bolt securingtho reverseshift fork, t h e n r e m o v e t h e r e v e r s es h i f t f o r k a n d r e v e r s e together. selector sub-assemblv and mainRemovethe countershaft together, shaftsub-assembly
Align the spring pin on the control shaft with the housinggrooveby turningthe control transmission shaft.
SPRING PIN
9. t I n s t a l lt h e s p e c i a lt o o l o v e r t h e m a i n s h a f t . h e n housingas shown. removethe transmission
Removethe differential assembly.
14-189

Removal
NOTE: . The illustration showsthe 4WDautomatic transmission; 2WD is similar. the ' cleanall partsthoroughry sorvent carburetor in or creaner, and drythem with compressed air. . Blow out all passages. . When removingthe valvebodies,replace following: the - Lockwasher - O-ring
ATF FEEDPIPE SERVODETENT BASE 137 - 98 models only) 6x1.0mm '97 - 98 models: 2 Bolts '99 - 00 modeb: 1 Bolt ATF STRAINER
DOWELPIN LOCK.UP VALVE BOOY
LOCK.UP SEPARA PLATE REGULAIOR VALVE BOOY DOWELPIN
COOLER RELIEF VALVE
TOROUE CONVERTER CHECK VALVE

STATOR SHAFT O.RING
6x1.0mm 37 - 98 models: 7 Bolts 'gg - 0Omodels: 8 Bolts SERVOBODY 137 - 98 modelsl SERVO SEPARATOR PLATE
5x1.0mfi 3 Bolts
6x 1.0 5 Bolts MAIN VALVEBODY ATF PUMPORIVEN GEARSHAFT ATF PUMPDRIVEN GEAR
SECONDARY VALVEBODY DOWELPIN SECONDARY SEPARATOR PLATE
\
CONTROL LEVER MOUNTING BOLT {awD)
14-190
1 . Removethe control lever mounting bolt trom the housside of the torque converter torque converter ing. (4WD) Removethe ATF feed pipes from the servo body, valvebody,and main valvebody,lock-up secondary valvebody. For'97 - 98 models: and the the Remove two boltssecuring ATF strainer servodetentbase,then removethe strainerand the base. For'99 - 00 models; {one bolt). the Remove ATFstrainer 4. For'97 - 98 models: Removethe seven bolts securingthe servo body, then remove the servo body and separatorplate' For'99 - 00 models: Removethe eight bolts securingthe servo body, plate' then removethe servobody and separator 5 . B e m o v et h e t h r e e b o l t s s e c u r i n gt h e s e c o n d a r y valve body, then remove the secondaryvalve body' stop shaft bracket,and separatorplate. the the 6. Remove eight bolts securing ATF lubrication plate and lock-upvalve body, then removethe ATF plate,lock-upvalve body' and separator lubrication plate. 7. Removethe one bolt securingthe regulatorvalve valvebody' body,then removethe regulator 8. Removethe stator shaft and stop shaft. the 9. Remove detentspringfrom the detentarm, then remove the control shaft from the torque converter houslng. 10. Removethe detentarm and detentarm shaft from the main valvebody. 1 1 . R e m o v et h e f i v e b o l t s s e c u r i n gt h e m a i n v a l v e body,then removethe main valvebody. When removingthe main valve body, do not let the eight checkballsfall out. 1 2 . R e m o v et h e A T F p u m p d r i v e n g e a r s h a f t , t h e n removethe ATF PumPgears. 13. Removethe main separatorplate with two dowel prns.
14, Cleanthe inlet opening of the ATF strainer thorair, oughly with compressed then checkthat it is in good condition, and the inletopeningis not clogged or damaged.
INLET OPENING
1 5 . Test the ATF strainer by pouring clean ATF through the inlet opening,and replaceit if it is clogged or damaged.
14-191
Valve Body
Repair
NOTE:This repair is only necessary one or more of if the valvesin a valve body do not slidesmoothlyin their bores.Usethis procedure free the varves. to '1. S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r about30 minutes. Carelullytap the valve body so the stickingvalve drops out of its bore. lt may be necessary use a to small screwdriver pry the valve free. Be careful to not to scratch bore with the screwdriver. the Inspect the valve for any scutf marks.Use the ATFsoaked#600 paper to polish off any burrs that are on the valve,then wash the valvein solventand dry it with compressed air. Roll up half a sheet of ATF-soaked #600 paper and insertit in the valve bore of the sticking valve. Twist the paper slightly,so that it unrolls and fits the bore tightly,then polishthe bore by twistingthe paperas you push it in and out. N O T E :T h e v a l v e b o d y i s a l u m i n u ma n d d o e s n , t requiremuch polishing removeany ourrs. to 5. R e m o v et h e # 6 0 0 p a p e r . T h o r o u g h l y w a s h t h e entire valve body in solvent,then dry it with compressed ar. Coatthe valvewith ATF,then drop it into its bore, lt shoulddrop to the bottomof the bore underits own weight. lf not, repeatstep 4, then retest.lf the valve still sticks, replace valvebody. the
2.
,l
4.
w
1. Removethe valve.and thoroughlyclean it and the valve body with solvent. DrV all parts with compressed then reassemble air, usingATFas a lubricant.
14-192
Valve
Assembly
NOTE; Coatall partswith ATF beforeassembly. . l n s t a l t h e v a l v e ,v a l v es p r i n g ,a n d c a p i n t h e v a l v e l with the roller. body.and secure . Set the spring in the valve,and installit in the valve b o d y . P u s ht h e s p r i n g i n w i t h a s c r e w d r i v e rt,h e n installthe springseat.
SEAT
u>o
VALVE EODY
the Install valve,spring,and cap in the valve body. then installthe cliP. Pushthe caD,
VALVE BODY
VALVE
CAP
14-193
ValveGaps
Description
C a p sw i t h o n e p r o j e c t e d i p a n d o n e f l a t e n d a r e t i n s t a l l e d i t h t h e f l a t e n d t o w a r d t h e i n s i d eo f t h e w valvebody. Capswith a projectedtip on each end are installed w i t h t h e s m a l l e rt i p t o w a r d t h e i n s i d eo f t h e v a l v e b o d y . h es m a l lt i p i s a s p r i n g u i d e . T g Capswith hollow ends are installedwith the hollow end awayfrom the insideof the valveooov. Capswith notchedends are installedwith the notch towardthe insideof the valvebodv. Capswith flat ends and a holethroughthe centerare installedwith the smaller hole toward the inside of the valvebody.
TOWARD OUTSIDE VALVEAODY OF
TOWARO OUTSIDE VALVEBODY OF
EEEE
TOWARDINSIDEOF VALVEBODY TOWAROINSII'C OF VALVE BODY
C a p sw i t h o n e p r o j e c t e d i p a n d a h o l l o w e n d a r e t installedwith the tip toward the inside of the valve body.The tip is a springguide. Capswith one projected and flat end are installed tip with the tip toward the insideof the valve bodv. The tip is a spring guide. The groove is a valve cao clio g ui d e .
Capswith flat ends and a groovearoundthe cap are installed with the groovedside toward the outsideof the valvebody.
TOWARD OUTSID OF VALVE BOOY
TOWARD OUTSIO VAIVE BODY OF
TOWARDI'{SIDEOF VALVEEOOY
TOWARDINSIDEOF VALVEBOOY
14-194
ATFPump
Inspection
1. I n s t a l t h e A T F p u m p g e a r sa n d A T F p u m p d r i v e n l a gear shaftin the main valve body Lubricate ll p a r t sw i t h A T F , a n d i n s t a l lt h e A T F p u m p d r i v e n sidefacingup gearwith its groovedand chamfered 2. of Measurethe side clearance the ATF pump drive and drivengears. ATF Pump Gears Side {Radial}Cloarance: Standard (Newl: ATF Pump Drive Gear mm {0.004 0.005in} 0.105 0.1325 ATF Pumo Driven Gear in) mm {0.0014 0.0025 0.035 0.0625
MAIN VAI-VEBOOY
ATF PUMP ORIVE
fl
L /
ATF PUMP DRIVEGEAR
ATF PUMP DRIVENGEAR teeth{or wear and damage Inspecl
I n s p e c tt e e t h f o r w e a r a n d d a m a g e ,
3.
Removethe ATF pump driven gear shaft Measure of the thrust clearance the ATF pump driven gearto-valvebody. GearThrust (AxiallClearance: ATF Pumo Drive/Driven Standard (Nw): 0.03- 0.05 mm {0'001- 0 002 inl in) ServiceLimit: 0.07 mm 10.003
MAIN VALVE AOOY
ATF PUMP GEAR ORIVEN
14-195
Main Valve Body

Disassembly/lnspection/Reassembly
NOTE: . Do not usea magnetto removethe checkballs;it may magnetize balls. the t clean all partsthoroughlyin solventor carburetor cleaner, and dry them with compressed Blow out all passages. ai.. . Replace valvebody as an assembly any partsare worn or damageo. the if . C h e c k a lv a l v e s f o r f r e e o v e m e n tl . a n y f a i l t o s l i d e f r e e l y , s e e V a l v e B o d y R e p a i r o n p a g e . t 4 _ 1 9 2 . l m f . Coatall partswith ATF during reassembly.
I-2 SHIFTVALVE VALVECAPCLIP 2ND ORIFICE CONTROL VALVE SPRING SEAT
@ U K
BALLS,8
ACCUMULATOR CHOKE
VAI-VE FELIF VALVE
MAIN VALVEBOOY Inspectfor wear, scratches, and sconng.
sERVO CONInOL
:,/\^._.^,
14-196
BALL CHECK
i) ) L
lo
BALLS CHECK
lST ACCUMULATOR CHOKE
MAIN VALVEBODY (Sectionalview)
EALL CHECK
SPRINGSPECIFICATIONS Standard {New) No. Springs valvespring Relief Modulator valvespring CPBvalvespring 1-2shift valvespring 2nd orificecontrolvalvespring Servo control valve sPring Wire Dia. 1 . 1( 0 . 0 4 3 ) 1.4(0.055) 0.9 (0.03s) 0.9 (0.035) 0.7 (0.028) 1.0t0.039)
U n i t :m m ( i n )
o.D.
8.6 (0.339) 9.4 (0.370) 8 . 1( 0 . 3 1 9 ) 7.6 (0.299) 6.6 (0.260) 8 . 1{ 0 . 3 1 9 )
FroeLength 3 7 . 1( 1 . 4 6 1 ) 35.0(1.3781 41.2 \1.8581 4 1 . 3( 1 . 6 2 6 ) 34.8(1.370) 5 2 . 1( 2 . 0 5 1 )
No. of Coils
o
@ @ @
'13.4 10.9
20.8
14-197
SecondaryValve Body
NOTE: ' clean all partsthoroughlyin solventor carburetor cleaner. and dry them with compressed Blow out aUpassages, air. . Replace valvebody as an assembly any partsare worn or damaged. the if t checkall valvesfor free movement. anyfair to sridefreery. rf seevarveBody Repair page14-192. on . Coatall partswith ATFduring reassembly. . The CPCvalveis installed the secondary in valve body,held in placeby the lockbolt.
VALVECAP
t*-1
2.3 SHIFTVALVE
@,..t'tr.,
,rr'^'//u
"/
3-' SHIFTVALVE
./
ilTH EXHAUSTVALVE
SECONOARY VALVEBODY Inspectfor wear, scratches, and scorang.
3.4 ORIFICE CONTROL VAL
N"*,"o"*
VALVE SLEEVE
ROLLER
SPRINGSPEC!FICATIONS U n i t :m m ( i n ) No. Springs Wire Dia. 3 4 shiftvalvespring 2-3shift valvespring 4th exhaust valvespring 3-4 orificecontrolvalvespring 0.9 (0.035) 0.9 (0.035) 0.9{0.035) 0.6 {0.024}
Standald {Nswl
o
@
o.D.
7.6 (0.299) 7.6 (0.299) 6.1 (0.240t 6.6 (0.2601
FreeLength 57.Oi.2.2441 57.O12.244J 3 6 . 4( 1 . 4 3 3 ) 37.9(1.492)
No. of Coils 26.A 26.8 19.5 31.6
14-198
Valve Body Regulator

NOTE: o Cleanall parts thoroughlyin solventor carburetorcleaner,and dry them with compressed Blow out all passages. air. . Replace valvebody as an assembly any partsare worn or damaged. if the on . Checkallvalvesforfreemovement. anyfail toslidefreely,seeValveBody Repair page l4-192. lf '1. Holdthe regulator springcap in placewhile removingthe stop bolt. The regulatorspringcap is spring loaded Once release springcap slowly so it does not pop out. the the stop bolt is removed, 2. is orderof disassembly. Reassembly the reverse NOTE: . Coatall partswith ATF during reassembly. . Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe spring cap into the valve body,and tightenthe stop bolt. SPSING CAP REGULATOR
BOLT STOP 6x1.0mm 12N.m11.2
8.? tbt.fil
REGULATOR VALVEBODY lnspect wear,scratches, for ano scoflng.
REGULATOR VALVE
Standard {New}
No,
Springs wire Dia. Regulator valvespringA Regulator valvespring B Statorreaction spring Coolerreliefvalvespring Torque convertercheckvalve spring '97 Model '98 - 00 Models Lock-up controlvalvespring 1 . 8( 0 . 0 7 1 ) 1 . 8( 0 . 0 7 1 ) 4 . 5( 0 . 1 7 7 ) 1.0{0.039) 1.1(0.043) 1.2lO.O47l 0.7 t0.028)
o.D.
14.7(0.579) 9.6 (0.378) 35.4(1.394) 8 . 4{ 0 . 3 3 1 ) 8 . 4( 0 . 3 3 1 ) 8 . 4( 0 . 3 3 1 ) 6.6 (0.260)
F ee Length 87.8(3.457) 44.0t1.7321 3 0 . 3( 1 . 1 9 3 ) 3 3 . 8( 1 . 3 3 1 ) 36.4(1.433) 32.4 11.2761 38.0(1.496)
No. ot Coils
o
@ @
,6
'11.0 1.9 't2.0 12.7 14.'l
a,
14-199
ServoBody
NOTE: ' cleanall partsthoroughly in solventor carburetorclea ner,and dry them with compressed Blow out all passages. air, . Replace valve body as an assembly any partsare worn or damaged. the if . Coatall partswith ATF during reassembly.
ACCUMULATOR COVER
3ROSUBACCUMULATOR
O-RING Feplace. 1STACCUMULATOR PISTON
RETATNER SPR|NG
@"-.t
-tP l@
,/
3RDACCUMULATOR
g
\_)
SNAPRING
fi, il
SERVO RVOVAL\ VE/SHIFT IRKSHAFT FORKS
O.RING
Replace.
SNAPRING
SPRING SPECIFICATIONS U n i t :m m { i n ) No. Springs Wire Dia, 1staccumuiator spring 4th accumulator springA 4th accumulator spring B 3rd accumulator springA 3rd accumulator springB 2nd accumulator springC 2nd accumulator springA 2nd accumulator springB 3rd sub accumulator spring 2.1 (0.083) 2.6 {0.102) 2 . 3( 0 . 0 9 1 ) 2 . 8( 0 . 1 1 0 ) 2.1 (0.083) 2.2 (0.087l2.4 (0.094) r.6 (0.063) 2 . 7{ 0 . 1 0 6 ) Standard lNewl
o.D.
16.0(0.6301 17.0(0.669) 't0.2 t0.402] 17.5(0.689) 3 1 . 0( 1 . 2 2 0 ) 14.5 0.571) { 29.0 11.1421 9.0 (0.354) 17.0(0.669)
o
@
J6
FreeLongth 89.r (3.508) 88.4(3.480) 5 1 . 6( 2 . 0 3 1 ) 94.3(3.713) 38.2(1.504) 68.0{2.677) 39.0fi.535) 20.7(0.815) 39.0(1.535)
No. of Coil3
@
.A \o,
o
@ @
14.2 13.8 15.9 2.6 13.9 2.9

o.l
6.3
14-200
Lock-upValve Body
bly Disassembly/lnspection/Reassem
NOTE: air. cleaner, and dry them with compressed Blow out all passages. . Cleanall partsthoroughlyin solventor carburetor . Replace valvebody as an assembly any partsare worn or damaged. if the p B f , . C h e c k a lv a l v e s f o r f r e e o v e m e n tl . a n y f a i l t os l i d e r e e l y s e e V a l v e o d yR e p a i r o n a g e1 4 - 1 9 2 . m f l . Coatall partswith ATF duringreassembly.
LOCK.UP SHIFTVALVE
'\
\
,^ ,As'.
@-tr
\"o...*
\-.xlO
VALVEEODY LOCK-UP lor Inspect wear,scratches, and scoring.
VALVECAP
LOCK-UP TIMINGVAL
\uo.*"or".,,
SPRINGSPECIFICATIONS Standard lNewl No. Springs Lockup shiftvalvespring Lock-up timing valvespring Wire Dia.
Unit:mm (in)
o.D.
7.6 (0.299) 8 . 1( 0 . 3 1 9 )
Fle Length
No. of Coils
O
(
0.9(0.035) 0.9(0.035)
73.1 t2.902), 8 1 . 4( 3 . 2 0 5 )
32.0 47.8
14-201
Mainshaft
NOTE: . Lubricate partswith ATFduring reassembly. all .Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement, . Beforeinstalling O-rings. wrap the shaftsplineswith tapeto prevent the damagingthe O-rings. . Locknuthas left-hand threads. . Installthe conicalspringwasherin the directionshown. . Inspect conditionof the sealingrings.lf the sealingrings are worn, distorted, ordamaged,replace them (seepage 142041.
LOCKNUT IFLANGE NUT) 19 x 1.25mm 78 N.m {8.O kgf.m,58 lbl.ftl
Replace. Left-hand threads
CONICAL SPRINGWASHER Replace.
SNAP RING
lST CIUTCH ASSEMBI.Y
o-Rtt{Gs
THRUST NEEDLE BARING THRUST WASHEB
4TH GEAR Replace. THRUST WASHCR THRUST NEEOI BEARIl{G I{EEDLEBEARIIIG MAINSI{AFT Check splinesfor excessive wear ano damage. Check bearingsurfacetor scoring, scratches and excessive wear. lST GEAR
BEARII{GS
rST GEAR COLLAR

TXBUST 1{EEDLE BEARIl{G 4TH GEAR COLLAR 2ND/4TH CLUTCX
TnANSMtSSIOt{ HOUSII{G BEARII{G
o-Brr{Gs
THRUSTWASHER,36.5 r 55 mm Selective part
THRUSTNEEDLE SEARING 2NO GEAR SEALINGRltrlG, 29 mm NEEDLE EEARING THRUST NEEDI-E BEARING
Install the sealing ring mating faces as shown
NEEDLE EEARING
SET RING
14-202
Inspection
Clearance Measurement 1. Removethe mainshaftbearingfrom the transmission housing lsee page 14-227l.. parts,but do not installthe Assemble the mainshaft O-rings, 3. Tightenthe mainshaftlocknutto 29 N.m (3.0kgf.m, 22 tbf.ft). The mainshaft locknuthas left-hand threads.
2.
CONICALSPRING WASHER
29 N.m (3.Okst.m, 22 lbt.frl

lST CLUTCHASSEMELY THRUST WASHER 1ST GEAB COLLAR TRAI{SMISSION HOUSIf{G BEARING SNAP RII{G THRUST WASI{ER GEAR COLLAR 2[{D/4TH CLUTCH ASSEMALY THRUST WASHER .5r55mm
Selective part
Hold 2nd gear againstthe 2nd clutch,then measure the clearance between2nd gear and 3rd gearwith a feelergauge. Take measurements at leastthree in places, and usethe average the actualclearance. as STANDARD: 0.05- 0.13 mm (0.002- 0.005in) 3RD GEAR 2'{D GEAR
THBUST IIEEDLE EEARII{G 2ND GAR EEARIt{G TI{RUST NEEOLE BEARII{G FEELER GAUGC THRUSTWASHER. 36.5 x 55 mm
MAII{SHAFT
(cont'd)
14-203
Mainshaft
(cont'dl Inspection
I t t h e c l e a r a n c ei s o u t o f s t a n d a r d ,r e m o v e t h e thrustwasherand measure thickness. its
SealingRings
Replacement
The sealingrings(35 mm and 29 mm) are synthetic resin with chamfered ends.Checkthe conditionof the sealing rings,and replace them only if they are worn, distorted, or oamageo. NOTE:Apply ATFto all partsduringassembly. 1. For a better fit, squeezethe sealing ring together slightlybeforeinstalling them.
Selectand install a new washer,then recheckthe clearance, makesure it is within standard. and THRUSTWASHER36.5 x 55 mm No.
1
Part Number 90441 PG4,010 90442-PG4-010 90443-PG4-010 90444-PG4-010 90445-PG4-010
Thickness 4 . 0 0m m ( 0 . 1 5 7n ) i 4 . 0 5m m ( 0 . 1 5 9n ) i 4 . 1 0m m { 0 . 1 6 1n ) i 4 . 1 5m m { 0 . 1 6 3n ) i 4 . 2 0m m ( 0 . ' 1 6i5 ) n 4 . 2 5m m { 0 . 1 6 7n ) i 4 . 3 0m m ( 0 . 1 6 9n ) i 4 . 3 5m m ( 0 . 1 7 1n ) i 4 . 4 0m m ( 0 . 1 7 3n ) i 4 . 4 5m m ( 0 . 1 7 5n l i Installnew sealingrings on the mainshaft. After installingthe sealingrings, verify the following: . . . The sealingringsare fully seatedin the groove. The sealingringsare not twisted. T h e c h a m f e r e de n d s o f t h e s e a l i n g r i n g s a r e properlyjoined.
6 1 8 I 10
90446-PG4-010 90447-PG4-010 90448-PG4-010 90449-PG4-010 90450-PG4-000
SEALINGRING Install sealing the ring matingfacesas shown.
14-204
Countershaft
NOTE: . Lubricate pans with ATF beforereassembly. all .Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement. . Beforeinstalling O-rings, with tapeto preventdamaging O-rings. the the wrap the shaftspllnes . Locknut has left-hand threads. . Install conicalspringwasherin the direction shown. the
LOCKNUTIFLANGE NUTI 23 x 1.25mm 103-0-103N.m t 1 0 . 5- 0 - 10.5 kgl.m, 7 5 . 9- 0 - 75.9 lbt.lr)
Replace. Lelt.hand threads
RVERSE GEAR
CONICAL SPRING WASHER Replace.
NEEOLE BEARING REVERSE SELECTOR

REVERSE SELECTOR HUB lST GEAR COUNTERSHAFT Check splinesfor excessive wear and damage. Check bearingsurfacefor scoring, scratchesand excessive wear. 4TH GEAR EEARING NEEDLE OISTANCECOLLAR. 28 mm Selective part 2NO GEAR
I{EEDLEBEARING lST GEARCOLLAR
TRANSn SSTON HOUSI G BEARING
3RD GEAR NEEDLE BEARING 3RD GEARCOLLAR THRUSTNEEOLE BEARING SPLINED WASHER 3RO CLUTCHASSMBLY
14-205
Gountershaft
1. Removethe reverseselectorhub and countershaft 4th gear using a universaltwo-jaw lor three-jaw) puller as shown. Placea shaft protector between t h e p u l l e ra n d c o u n t e r s h a ftto p r e v e n td a m a g i n g the countershaft. 2. Assemblethe parts on the countershaft shown as below. NOTE; . Lubricate partswith ATF during reassembly. all . B e f o r e i n s t a l l i n gt h e O - r i n g s .w r a p t h e s h a f t s p l i n e sw i t h t a p e t o p r e v e n td a m a g i n gt h e O rings.
{ C o m m e r c i a l l ya v a i l a b l e )
4TH GEAR BEARI'{G DISTANCECOLLAR, 28 mm Selective oart GEAR
REVERSE SELECTOR HUB
THRUST ]{EEOLAEARIIIG
SEARII{G .TH GEAR GEAR COLLAR THRUST I{EEDLEEEARII{G WASHER 3RO CLUTCH ASSEMBLY
O-RINGS Replace.
14-206
Inspection
3. Installthe reverse selectorhub on the countershaft sub-assembly, and pressthe hub using the special tool and a pressas shown. Clearance Measurement NOTE: Lubricate partswith ATF duringassembly. all 1. Removethe countershaftbearing from the transmissionhousinglsee page14-227). Assemblethe countershaft parts using the special tool and a pressas described this page. Do not on installthe O-ringsduring inspection.
2.
to DRIVER mm l.D. 07746- 0030100
RVERS SELECTOR HUB GEAR NEEDLE BEARING DISTANCECOLLAR, 28 mm Selective part
REVERSE SEI.ICTOR HUB
2NO GEAR THRUST NEEDLEBEARING GEAR NEEOLE BEARING GEAR COLIAR BEARING THRUSTNEEDLE WASHER
COUNTERSHAFT SU&ASSEMBLY
CLUTCHASSEMBLY
(cont'd)
14-207
Countershaft
(cont'd) Inspection
3. t y I n s t a l lt h e c o u n t e r s h a fs u b - a s s e m b lp a r t s ,t h e n p a i n s t a l l t h e a r kg e a ru s i n ga p r e s s n da c o l l a r . Tightenthe locknutto 29 N.m (3.0 kgf.m,22 lbf.ft). The countershaft locknuthasleft-hand threads. 5. Measurethe clearancebetweenthe 2nd gear and the 28 mm distance collarwith a feelergauge. in NOTE:Takemeasurements at leastthree places, and usethe average the actualclearance. as 0.10 STANDARD: - 0.18mm (0.004 0.007in)
LOCKNUT Le{t-hand threads SPRING CONICAL WASHER 2NO GEAR COLLAR, OISTANCE 28 mm
4.
PABKGEAR/ONE.WAY GEAR CLUTCH/1ST ASSEMBLY BEANING NEEDLE lST GEARCOLLAR TRANSMISSION HOUSING AEARING
REVERSE GEAR COLLAR
6.
FEELER GAUGE lf the clearance out ot standard, is removethe distancecollar,and measure width. its Select and installa new distance collar, then recheck.
7.
COUNTERSHAFT SUB.ASSEMBLY
DISTANCE COLLAR,28mm No. 1 Part Number
widrh
3 9 . 0 0 m ( ' 1 . 5 3i5 ) m n 3 9 . ' 1m m ( 1 . 5 3 9n ) 0 i 3 9 . 2 0 m { 1 . 5 4 3n ) m i 3 9 . 3 0 m ( l . 5 4 7i n ) m m 3 9 . 0 5 m ( l . 5 3 7i n ) 3 9 . 1 5 m ( l . 5 4 1n ) m i 3 9 . 2 5 m { 1 . 5 4 5n ) m i m 3 8 . 9 0 m { L 5 3 1i n ) 3 8 . 9 5 m ( 1 . 5 3 3n ) m i
90503-PCg-000
90504-PCg-000 90505-PCg-000 90507-PCg-000 90508*PCg-000 90509-PCg-000
2
?
7 8 9 8.
90510-PCg-000 90511-PCg-000 90512-PCg-000
After selectinga new distancecollar. recheckthe clearance makesureit is within standard. and
14-208
One-way Glutch
Disassembly/lnspection/Reassem bly
1. Separate countershaft gear from the park gear 1st by turningthe parkgear in the direction shown. 3. Inspect oartsas follows; the
PARKGEAR Inspect wear Ior
andsconng.
PARKGEAR
COUNTERSHAFT GEAR lST
ONE.WAYCLUTCH Inspectfor damage and taultymovement,
2.
Remove the one-wayclutchby prying it up with the tip of a screwdriver.

ONE.WAYCLUTCH Install this direction. in lST GEAR for Inspect wear and scortng.
COUNTERSHAFT GEAR IST
4.
After the parts are assembled, hold countershaft lst gear. and turn the park gear in the direction shown to be sure it turns freely. Also make sure the park gear does not turn in the opposite direction.
ONE.WAYCLUTCH lST GEAR
,IST COUNTERSHAFT GEAR SCREWDRIVER
14-209
Sub-shaft
NOTE: . Lubricate partswith ATF beforereassembly. all . Inspect thrust needlebearings for the and the needlebearings gallingand rough movement. . Beforeinstalling O-rings, with tapeto preventdamaging O-rings. the the wrap the shaftsplines
TRAi{SMTSStON tl()UStNG
IST.HOLO CLUTCH ASSEMBLY 6 x 1.0 mrr 12 1{.m ll.2 ksl.m, 8.7 lbt.ftl
SUB.SHAFT Check splines tor excessive wear ano damage, Check bearing surlace for scoring, scralches and excessive wear-
o,Rtl{GS
Replace. TI{RUST WASI{ER THFUST TEEOLC BEARI G I{EEDLE BARI G
t{EEDLEBEARING STOP
14-210
1.
Remove ATF guidecap by pushingthe sub-shaft the housing. insidethe transmission b R e m o v e h e 1 s t - h o l d l u t c ha s s e m b l y y p u l l i n g , t c then removingthe sub-shaft. Installnew O-ringson the sub-shaft. NOTE:Wrap the shaft splineswith tape to prevent damaging O-rings. the h P l a c et h e s u b - s h a f t n t h e t r a n s m i s s i o n o u s i n g , i and installthe'lst-holdclutchassembly, I n s t a l lt h e n e w A T F g u i d e c a p u s i n g t h e s p e c i a l shown. tools.Installit in the direction
ATTACHMENT, 32x35mm 07746- 0010t00
14-211
Sub-shaftBearings
Replacement
NOTE:Lubricate partswith ATF beforereassembly. all 1. E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s .t h e n push the bearing out of the transmissionhousing usingthe special tools and a pressas shown. 4. Installa new needle bearing in the housing using the sOecial tools and a oressas shown.
c
I
32x35mm 077/46 qt10t(x, ATTACHMENT, ai:lx 68 mm 07746 - 00105q)
Remove the needlebearing stop. Removethe needlebearingfrom the transmission housingusinga drift.
E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n insert the ball bearing part-way into the housing using the specialtools and a pressas described in step 1. Installthe bearingwith the groove facing outsidethe housing. Release pliers,then push the bearingdown into the t h e h o u s i n gu n t i l t h e s n a p r i n g s n a p si n p l a c e aroundit. 7. After installing ball bearingverifythe fottowing: the . . The snap ring is seatedin the bearingand housIng grooves. The ring end gap is correct.
ENDGAP:0-7mm l0 - 0.28 inl
SNAPRING
14-212
Glutch
lllustratedlndex
3RDCLUTCH
CLUTCH PISTON SPRING RETURN PLATES NETAINER CLUTCH Standardthicknoss: RING 2.00 mm 10.079 inl
DISCS CLUTCH Standardthickne$: 1.94mm (0 0?6 inl
SNAPFING
lST CLUTCH
DISCS CLUTCH Standardthicknca3: inl 1.9amm 10.076
SNAPRING
CLUTCH DRUM
CHECK VALVE
(cont'd)
14-213
Clutch
lllustratedIndex(cont'dl
2ND/4THCLUTCH
CLUTCH PLATES Stendardthickness: OISCSPRING 2.00 mm {0.079in)
[*
CLUTCH 2ND CLUTCH CLUTCH PISTON
Repl6ce.
sPl
uoavEnr"
PLATES CLUTCH Standardthicknesai 2.00 mm {0.079inl
SNAPRING
14-214
lST-HOLDCLUTCH
thickness:
RETURN SPRING
cLUTCHPISTON
O.RINGS
14-215
Clutch
Disassembly
l. Removethe snap ring, then removethe clutch end plate,clutchdiscsand plates.
SCREWORIVER
3.
I n s t a ltlh e s p e c i atlo o l sa s s h o w n .
CLUTCH SPNING COMPRESSOR ATTACHMENT 07LAE- PX40100
SNAP RING
-'=*.=:--
'..p
2. Remove discspring. the 1ST,2ND, 4TH lST-HOLDCLUTCH:
DISCSPRING CLUTCH COMPRESSOR AOLTASSEMBLY 07GAE- FGao2OO or . OTGAE PG4O2OA CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE- PX4010O or 07HAE- PL50100
SPRING CLUTCH COMPRESSOR ATTACHMENT 07LAE- PX40t00 CLUTCH DBUM
3RDCLUTCH:
DISCSPRING
CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE- PX4010O or 07HAE- PL50100 CLUTCH SPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG0200 or OTGAE PG4O2OA
14-216
CAUTION: lf either end ot the specialtool issetover an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. B sure the specialtool is adiusted to have lull contact with the spring retainer.
5.
Removethe snap ring, Then removethe specialtools, and springretainer returnspring.
Do not s6t h6re.
SPRIlIG RETAINER
Wrap a shop rag aroundthe clutchdrum, and apply to to air pressure the ATF passage removethe piston. Placea finger tip on the other end while applying arr pressure.
OSHA.APPROVED SPRING RETAINER
4.
Compress returnspring. the
14-217
Glutch
Reassembly
NOTE: . Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. . Blow out all passages. o Lubricateall parts with ATF before reassembly. 1. Inspect checkvalve;if it's loose,replace the the pis_ ton. 3. Installth pistonin the clutchdrum. Apply pressure and rotate it to ensure proper seating, Lubricatethe pistonO-ringwith ATF betoreinsta ing the piston. NOTE:Oo not pinchthe O-ringby installing pis_ the ton with too muchforce.
CLUTCH DRUM
CHECK VALVE
2.
4.
Installnew O-ringson the clutchpiston.
Installthe return spring, and spring retainer,then position snap ring on the retainer. the
SI{AP RING
SPAI'{G RETAIIIER
REIURN SPRING
CLUTCH DRUM
PtsTot{
14-218
5.
as Install specialtools shown the
SPRING CLUTCH COMPRESSOR ATTACHMENT 07LAE- PX40100
CAUTION:It sither end of the spscial tool is sot over an area of the spring retainl which is unsup' ported by the return spring, the retainer may be damaged. Be sure the specialtool is adiusted to have full contaqt with th spring ratainel.
CLUTCH SPRING COMPRESSOR BOLTASSEMALY 07GAE- PG{0200or OTGAE PG|(IMA
SPRING CLUTCH COMPRESSOR ATTACHMENT or 07LAE- PX40100 O?HAE PL5O1OO
Set here.
Do notsethere.
TOOL SPECIAL
CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE- PXaOI 0o
SPRING RETAINER
6.
the Compress returnspring.
CLUTCH SPRING COMPBESSOR AOL| ASSEMALY 07GAE- PG/9t200 ot OTGAE PG/(,20A
CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE- PX4010O ol 07HAE- PL50100
(cont'd)
14-219
Clutch
(cont'd) Reassembly
7. I n s t a l l t h e n a pr i n g . s
1 0 . Soakthe clutchdiscsthoroughlyin ATF for a mini_
m u m o f 3 0 m i n u t e s . B e f o r ei n s t a l l i n g h e p l a t e s t and discs,make sure the insideof the clutchdrum is free of din or otherforeignmatter
' t 1 . Starting
with a clutch plate, alternatelvinstall the clutch platesand discs.Installthe clutch end plate with its flat sidetowardthe disc.
CLUTCH EI{D PI.ATE Installin this directior.
S AP RIIG 8. 9, Remove special the tools. Install discspring in the direction the shown.
1ST,2ND, 4TH, lST-HOLDCLUTCH:
otsc sPfitl{c
CLUTCH
CLUTCHEI{D PLATE
12. Install snap ring. the
SCREWDRIVER 3RD CLUTCH:
Dlsc sPRrrtc
CIUTCH ORUM
14-220
the clutchend plate between the 13. Measure clearance Zerothe dial indiand top disc with a dial indicator. and lift it up end platelowered, catorwith the clutch to the snap ring. The distancethat the clutch end betweenit and the top plate movesis the clearance dtsc. in NOTE:Takemeasurements at leastthree places' as and usethe average the actualclearance. Clutch End Ptate-to-TopDisc Clearance: Clutch 'l st 2nd 3rd 4th lst-hold ServiceLimit 0.650.400.400.400.500.85mm (0.026 0.60mm (0.016 0.60mm (0.016 (0.016 0.60mm (0.020 0.80mm 0.033in) 0.024in) 0.024in) 0.024in) 0.031in)
lST CLUTCHEND PLATES

Mark
'I
Thicknass 2 2 5 5 1 P 5 6- N 0 0 22552-P56-N00 22553 - P56 N00 22554-P56-NOo 2 2 5 5 5 P 5 6- N 0 0 22556 P56- N00 22557 - P56 N00 2 2 5 5 8- P 5 6 N 0 0 2 2 5 5 9- P 5 6 N 0 0
n 2 . 1 m ( 0 . 0 8i3 ) m in) 2.2mm (0.087

i 2 3 mm (0.091n) i 2.4mm (0.094n) i 2 . 5m m { 0 . 0 9 8 n ) i 2 6 m m ( 0 . 1 0 2n ) i 2.7mm (0.106n) i 2 . 8m m ( 0 . 1 1 0n ) i 2 . 9r n m ( 0 . 1 1 4n ) i 3 . 0m m ( 0 . 1 1 8n )
3
5 6 7 8 I
10
22s60 P56 N00
2ND and 4TH CLUTCHEND PLATES

Mark
6 1 8 Parl Number Thickness
22556-P56-N00 22557 P56 N00

22558-P56-N00 22559-P56-N00 2 2 5 6 0- P 5 6 N 0 0
n 2 . 6m m ( 0 . 1 0i2 ) n 2 . 7m m ( 0 . 1 0i6 ) 2 . 8m m ( 0 . 1 1i0 ) n

i 2 . 9m m ( 0 . 1 1 4n ) i 3 . 0m m ( 0 . 1 1 8n ) i 3 . 1m m ( 0 . 1 2 2n l
10
'11
12 13
22561 PDM 22562- PDM22563 PDM22564 PDM
000 000 000 000
n 3 . 2m m { 0 . 1 2i6 ) n 3 . 3m m ( 0 . 1 3i 0 )
i 3.4mm (0.134n)
2 2 5 6 5 P D M- 0 0 0 22566 PDM- 000 17 22567-PDM-000
n 3 . 5m m ( 0 . 1 3i8 ) i2 3 . 6m m 1 0 . 1 4 n )
i 3 . 7m m ( 0 . 1 4 6n )
SNAPRING
3RDCLUTCHEND PLATES
Mark I 9 Part Number 2 2 5 5 8 P 5 6- N 0 0 2 2 5 5 9 P 5 6- N 0 0 Thiclness i 2 . 8m m ( 0 . 1 1 0n l i 2 . 9m m ( 0 . 1 1 4n )
10
11
22560 P56 N00

22561 PD[4 - 000
12 t3
'14
22562 PDM 000

22563-PDM-000
n 3 . 0m m ( 0 . 1 1i 8 ) n 3 . 1m m ( 0 . 1 2i2 ) in) 3.2mm (0.126 n 3 . 3m m ( 0 . 1 3i0 )

i 3 . 4m m ( 0 . 1 3 4n ) i 3.5mm (0.138n) i 3 . 6m m ( 0 . 1 4 2n ) i 3 . 7m m { 0 . 1 4 6n )
15 't1
22564-PDN4-000 22565-PD[,l-000 22566 PDM 000 - PoM- 000 22567
limits,select is 1 4 . lf the clearance not within the service a new clutchend platefrom the followingtable NOTE: lf the thickestclutch end plate is installed, is but the clearance still over the standard,replace the clutchdiscsand clutchplates.
MARK
lST-HOLDCLUTCHEND PLATES
Thickness i 2.1mm (0.083n) i 2.2mm {0.087n)
2255r-PS5-003
2 2 5 5 2- P S 5 - 0 0 3 3
22553 PS5 003

2 2 5 5 4 , P S 5- 0 0 3 2 2 5 5 5 P S 5- 0 0 3 2 2 5 5 6 P S 5- 0 0 3
in) 2.3mm (0.091

i 2.4mm (0.094n) i 2.5mm (0.098n) i 2 . 6m m { 0 . 1 0 2n ) i 2 . 7m m ( 0 . 1 0 6n )
--l----T
I CLUTCHEND PLATE
rnictness
6
22557 PSs 003
14-221
Differential
lllustratedIndex
'lWD: SET RING, mm 80 part Selective
10x 1.0mm 103N.m (10.5kgt.m, ?5.9 tbtftl
2WDl SET nlNG,80 mm

Sel6ctive part
A ,U
,gBc
1 0x 1 . 0m m 103N.m {10.5kg[.m, 75.9 tbt.ftl Left-handthreads
FINALORIVEN GEAR lnspectfor excessive wear, Install this direction. in
FINALORIVEN GEAR Inspectfor excessive wear, Install thls direction. in
BALLBEARING Inspect rough for
BALLBEABING Inspect rough for DIFFERENTIAI. CARRIER Inspectfor cracks.
DIFFERENTIAI. CARRIER lnspectfor cracks. TRANSFER SHAET DNlvE GEAR Inspectfor excessive
ROLLER,5 10 mm x
SPEEDOMETER
DRIVE GEAR Install this in direction.
SPEEDOMETER DRIVEGEAR Install this in direction.
SNAPRING Install this in direction. BALLBEARING
SNAPRING Install this in direction.
BALLBEARING Inspectfor rough movement,
14 -2 2 2
Inspection Backlash
1.
Replacement Bearing
for NOTE:Checkbearings wear and rough movement. are lf bearings OK, removalis not required. 1. usinga bearingpuller. the bearings Remove PULLER BEARING (Commercially available)
on assembly V-blocks. Place differential the shaft on the and intermediate lnstallthe driveshaft assemblY. differential of the backlash both piniongears. Check 0.05- 0.15 mm (0.002- 0.006in) STANDARD:
DIALINDICATOR
ASSEMBLY OIFFEBENNAL
l n s t a l l n e w b e a r i n g s u s i n g t h e s P e c i a lt o o l snown.
PRESS
It the backlashis out of standard, replacethe difterentialcarrier.
14-223
Differential
Differential CarrierReplacement
NOTE:The illustration shows the 4WD automatictransmissiondifferential; 2WDdifferential similar. the is 1. Remove snap ring from the differential the carrier. Install final drivengearon a new differential the carrier with its chamferedside facing the carrier and the transferdrive gear (4WD), Tightenthe boltsto the specified torque. N O T E : T h e 2 W D d i f f e r e n t i a tb o l t h a s l e f t - h a n d threads,
1 0x 1 . 0m m 103N.m 110.5 kd.m, 7s.9 rbr.ft)
FINALDRIVEN GEAR
Removethe 5 x 15 mm roller (4WD)or 5 x 10 mm roller(2WDland the speedometer drive gear. SPEEDOMETER GEAR DRIVE RoI I FP
5 x 15 mm (/tWD) TRANSFER SHAFT {4WDl
5 x 10mm {2WDl
Installthe speedometerdrive gear with its chamfered side facingthe carrier. Align the cutout on the bore of the speedometer drive gear with the 5 x 15 mm roller(4WD)or 5 x 10 mm roller(2WD). 7. A l i g n t h e h o o k e de n d o f t h e s n a p r i n g w i t h t h e spring pin in the pinion shaft.then installthe snao ring in the differential carriergroove
SNAP RING Install this direction. in
Hookedend
PINIONSHAFT
Remove the bolts securing final drivengear and the the transfershaft drive gear (4WD), then replace the differential carrier.
SPRING PIN
GROOVE
14-224
Oil SealReplacement
1. housing. the Remove oil sealfrom the transmission 3. housingusing lnstallthe oil seal in the transmission tools as shown. the special
DRIVER 077a9- 0010000
OIL SEAL Replace.
ATTACHMEMT
079r? slx[ax)
R e m o v et h e o i l s e a l f r o m t h e t o r q u e c o n v e r t e r housing.
4.
Installthe oil seal in the torque converterhousing as usingthe specialtools shown.
-.].
OIL SEAL Replace.
TOROUE CONVERTER HOUSING
14-225
Differential
Side ClearanceInspection
1. Instsllthe 80 mm set ring in the transmission housIng, 4. Tap on the transmission housingside of the diffsr entialassembly with the special tool to seatthe differential assemblv.
ilo DBIVER m.n LO. 0t746 - 0030100
SET RING,80 mrn
Measure the clearancs betweenthe 80 mm set ring and the bearing outer racewith a feelergauge, Installthe differentialassemblyin the torque converterhousingusingthe specialtool. STANDARD: - 0.15 mm (0 - 0.006inl 0
FEEI..ER GAUGE lf the clearance out of standard,removerne set is ring and measurs its thickness. 7. Selectand instslla new 80 mm set ring. SETRING,80 mm Part Numbor 90414-689-000 90415-689-000 90416-689-000 90417-689-000 90418-689-000 90419-PH8-000 Thicknoss 2.50mm (0.098 in) 2.60mm (0.102 in) 2.70mm (0.106 inl 2 . 8 0m m ( 0 . 1 1 0n ) i 2 . 9 0m m ( 0 . 1 1 4n ) i 3.00mm (0.t'18inl
Installthe transmission housingon the torque converter housing,and tighten the transmission housing mountingbolts (seepages14-252 and t4-253). TOROUE: N.m l/r.5 kgf.m, 33 tbt.ftl 4a
Recheck the clearance, and make sure it is within standard.
14-226
Bearings Housing Transmission

Mainshaft/CountershaftBearingsReplacement
1. Expandeach snap ring with snap ring pliers,then housing push the bearingsout of the transmission and a pressas shown. tools usingthe special Do not removethe snap rings unlessit's necessary to cleanthe groovesin the housing. Expandeach snap ring with snap ring pliers,then coat the new bearingswith ATF and insert them part-way into the housing using the specialtools and a pressas shown. Installthe bearingswith the groovefacingoutsidethe housing. d R e l e a s eh e p l i e r s ,t h e n p u s h t h e b e a r i n g s o w n t i n t o t h e h o u s i n gu n t i l t h e r i n g s s n a p i n p l a c e a r o u n dh e m . t
077/49 0010000
BEARING MAINSHAFT
DFIVER 077a9 001(xx)o

ATTACHMENT
ATTACHMENT . Mainshaft BearingInstallation: x ATTACHMENT,72 75 mm 07746- 0010600 . CountershaftBearing Instsllation: 52 ATTACHMENT, x 68 mm 077'16 0010500 4. verifythe following: the After installing bearings, T h e s n a p r i n g s a r e s e a t e di n t h e b e a r i n ga n d grooves. housrng . The snap ringsdo not bind. . The ring end gapsare correct, .
ENDGAP:0-7rnm l0 - 0.28in)
ATTACHMENT . Mainshaft Bearing Romoval: 72 ATTACHMENT, x 75 mm 077/16 0010600 . CountqrshaftBearing Removal: ATTACHMENT, x 68 mm 62 07746 0010500
SNAPRING
14-227
Transmission HousingBearings
Sub-shaft BearingReplacement
1. Expand the snap ring with snap ring pliers, then push the bearingout of the transmissionhousing usingthe special tools and a pressas shown. Do not removethe snap ring unlessit,s necessary to cleanthe groovein the housing. E x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n coat the new bearingwith ATF and insert it partway into the housingusing the specialtools and a pressas shown. lnstallthe bearingwith the groove facingoutsidethe housing. Release pliers,then push the bearingdown into the the housinguntilthe ring snapsin placearoundit.
DRIVER 07743- 0010mo
ATTACHMENT, {i:l x 68 mm 07746- 0010500 GROOVE
After installing bearing, the verifythe following:

ATTACHMEI{T, 5:l x 68 mm 07r{5 - @10500 SNAP RI]TG
. . .
The snap rjng is seatedin the bearingand hous_ ing grooves. The snap ring does not bind. The ring end gap is correct,
DRIVER 07749- tDl(xx)o ATTACHMENT, 6:l x 68 mm 077a6- (X,r0500
ENDGAP:0-7mm
SNAPRING
14-228
HousingBearings TorqueGonverter
MainshaftBearing/Oil Seal Replacement
1. R e m o v e h e m a i n s h a f b e a r i n ga n d o i l s e a l u s i n g t t the soecial tool. 3. Installa new oil sealflush with the torqueconverter housing.
07749- 0010000 SLIDEHAMMER, 3/8" - 16 (Commercially available)
ATTACHMENT, ADJUSTABLE EEARING PULLER,25 40 mm 07736- A010008or 07736- A01000A 07?46- 0010m0
Installa new mainshaftbearinguntil it bottoms in the torqueconverter housing.
ATTACHMENT, 62x68mm 07746- 0010500
14-229
TorqueGonverter Housing Bearings

Countershaft BearingReplacement
1. Removethe countershaft bearingusing the special tool.
GontrolLeverAssembly
Replacement
Checkthe conditionand movementof the control lever assembly,lf the control lever assemblybinds or does not move smoothly.replace it. 1. Remove 6 x 1.0mm bolt and lockwasher. the Remove the changeshafttrom the torqueconverter housing. Remove controlleverassembly the from the control shaft. Install the new controlleverassembly the reverse in order of disassembly, until it bottoms in the torque converter housing.
SLIOEHAMMER, 3la" -16 (Commercially available)
2.
3.
4.
ADJUSTABLE BEARING - 40 PULLER,25 mm 07736 A0100OB ol 07736 A01m0A
COUNTERSHAFT BEARING
Install ATF guide ptate. the I n s t a l la n e w c o u n t e r s h a fb e a r i n g i n t h e t o r q u e t converter housing.
DRIVER 077i19 001m00
LOCKWASHER Replace.
ATF GUIDEPLATE
14-230
ldler Gear Reverse

lnstallation
1. idler gear' lnstallthe reverse
ParkStop
ustment Inspection/Adi
't. Setthe parkleverin the E position.
Measurethe distancebetweenthe park pawl shaft and the parkleverrollerpin as shown. 72.9 STANDARD: - 73.9mm {2.87 2.91in)
',.A\
Measuring
\t/
PARKSTOP
idler gear shaftholderand needle lnstallthereverse housing,then tighten into the transmission bearing the bolts.
6 x 1.0 mm 12 N.ft ll.2 kgl']n, a.7 rbl.frl
SHAFT PAWL PARK
lf the measurementis out of standard,selectand i n s t a l lt h e a p p r o p r i a t ep a r k s t o p f r o m t h e t a b l e below.

PARKSTOP
PARKSTOP Mark
1
Part Number
Lt
L2
m 24537-PAg-003 11.00 m (0.433 in) m 2 4 5 3 8 - P A g - 0 0 3 10.80 m (0.425 in) m 24539-PAg-003 10.60 m ( 0 . 4 1 7n ) i
11.00 m m (0.433 in) mm 10.65 ( 0 . 4 1 9n ) i
1 0 . 3m m 0 (0.406 in)
After replacingthe park stop. make sure the distanceis within standard.
14-231
Transfer Assembly
lllustrated Index
HOUSING O TRANSFER O o-RINGReplace. BEARING HOUSINGROLLER O TRANSFER TRANSFER SHAFT @ ROLLER BEARING OUTERRACE O TAPERED ROLLER BEARING @ TAPERED SHAFTCOLLAR O TRANSFER part SHIM,25 mm Selective @ THRUST DRtvE GEAR(HYPoIDGEAR} ) TRANSFER WASHER Reptace, @ coNtcAL SPRtNG replace. SHAFT LOCKNUT,22 1.25mm Left-hand x rhreads, @ TRANSFER (D TAPERED ROLLER EEARING ROLLER EEARING OUTERRACE @ TAPERED (} THRUST part SHIM,68 mm Selective Replace. @ O-RING coVER A @ TRANSFER (} TRANSFER COVERB @ o-RINGReplace. (9 TRANSFER DRIVENGEARSHAFT(HYPOID GEAR) part SHIM,35 mm Selective @ THRUST ROLLER BEARING @ TAPERED Reptace. SPACER @ TRANSFER RoLLERBEARTNG OUTERRACE @ TAPERED ROLLER BEARING OUTERRACE @ TAPERED BOLLER BEARTNG @ TAPERED @ olL SEALReplace. FLANGE @ COMPANION @ o-RINGReplace. RING @ BACK-UP WASHER Reptace. @ coNtcAL SPRtNG DRIVEN LOCKNUT,22 1.25mm Replace. x GEARSHAFT @ TRANSFER
TOROUE SPECIFICATIONS Boh/Nut No. 6A 8C 22L 22H Torque Value 1 2 N ' m ( 1 . 2 g f . m , 8 . 7b f . f t ) k l 24 N.m (2.4kgf.m,17 lbnft) 1 1 8N . m( 1 2 . 0 g i m , 8 7 I b i f t ) k 132 216 N.m (13.5 22.0kgf.m, 98 - 159lbift) Size 6x1.0mm 8 x 1.25 m m 22 x 'l.25mm 2 2x 1 . 2 5 m m Remarks
Transfer shaft locknut: Left handthreads Transfer driven gear shaft locknut Tightening torque:depending on Torquevalue Total Starting
14-233
Transfer Assembly
Inspection
N O T E : T o p r e v e n td a m a g et o t h e t r a n s f e rh o u s i n g , always use soft jaws or equivalentmaterialsbetween the transferhousingand the vise. Trsnsfer Gear (Hypoid gear) Backl8shMasuremnt 1 . S e t a d i a l i n d i c a t o ro n t h e c o m p a n i o nf l a n g e a s snown. 2. Measure transfergear backlash. the STANDARD: 0.06 - 0.16 mm {0.02- 0.06 in)
DIALINDICATOR
TransferGear (Hypoid gear) Tooth Contact Inspection 5, Removetransfercover B, then apply Prussian Blue to both sides of the transfergear teeth lightly and
TRANSFER DRIVEGAR
6.
COMPANION FLANGE
Rotate companion the flangein both directions until the transfergear rotatesone full turn in both directions. Checkthe transfergear tooth contact pattern.The pattern should be centered on the gear tseth as snown.
7. Total Starting Torque Meagurgmnt 3, Rotatethe companionflange severaltimes to seat the taperedrollerbearing. M e a s u r et h e s t a r t i n gt o r q u e ( c o m p a n i o nf l a n g e side)usinga torquewrenchas shown, STANDARD: 2.68- 3.,17 N.m (27.3- 35.,1 kgf.cm,23.7- 30.7 lbf.inl TRANSFER SHAFT
4.
8.
lf the statrting torque measurementor the tooth contact pattern are not correct, disassemblethe transferassembly, replaceworn or damagedparts, and reassemble it.
14-234
Disassembly
1. Remove transfercoversA and B. the P u t a 1 4 m m A l l e nw r e n c hi n t h e g e a r s i d e o f t h e transfer shaft, then secure the Allen wrench in a benchvise. Removethe transfershaft locknut and the conical spring washer.The transfershaft locknut has left handthreads.
1a mm ALLENWRENCH
5.
Removethe transfer shaft, transfer drive gear, 25 mm thrust shim, transfershaft collar,and tapered rollerbearing from the transferhousing.
TRANSFER SHAFT
2.
Cutthe locktabs of the locknutusinoa chisel.
LOCKTAB
THRUSTSHIM, 25 mrn part Selective
CONICAL SPRING WASHER Replace.
(cont'd)
14-235
Transfer Assembly
Securethe transfer housing in a bench vise with soft iaws. To preventdamageto the transferhousing, always use soft jaws or equivalentmaterials between transferhousingand the vise. the 7. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o n l a n g e , f then loosenthe transferdrivengearshaft locknut. COMPANION FLANGE HOI.DER
07RAB- TB4lll0A or OTRAB TB&TOB
9. Remove transferdriven gear shaft,then remove the the transfer spacer from the transfer driven gear shaft.
TRANSFER DRIVEN GEAR SHAFT
HOLDER HAITDI..E _ 07JAB (x)1020a Remove transferdrivengear shaft locknut, the conical spring washer, back-upring, O-ring.and companionflange. 1 0 . Removethe oil seal and the taperedroller bearing from the transferhousing.
OILSEAL Feplace-
O.RING Replace. BACK-UP RING CONICAL SPRING WASHEN Replace.
TAPEREO ROLLER BEARING
TRANSFER HOUSING
GEARSHAFTLOCKNUT Replace.
14-236
Transfer DriveGearBearing Replacement

NOTE:Coatall partswith ATFduring reassembly. 1. Remove taperedrollerbearingfrom the transfer the drive gear usingthe special tools and a press.
Transfer DrivenGearShaft BearingReplacement

NOTE: Coat all parts with ATF during reassembly. 1. Remove taperedrollerbearingfrom the transfer the drivengearshaft usinga pressand a collar.
(Commercially available) Install the new taperedroller bearingin the transfer drivegear usingthe specialtools and a press. 2.
BANf{GSEPARATO 0 - 1112' (Comm6rcially availablel Installthe 35 mm thrust shim on the transferdriven gear shaft, Install the new taperedrollerbearingon the transfer d r i v e n g e a r s h a f t u s i n g t h e s p e c i a lt o o l s a n d a press.
PNESS iO DRIVER mm l.D. 0t7a5 - 00:I)100
3,
ATTACHMENT, l()x50mm 07LAD- PWSo6o1
n
GEAR ATTACHMENT. 35 mm l.D. 0t715 - 0030400
ru
14-237
Transfer Assembly
TransferHousingRollerBearing Replacement
NOTE;Coatall partswith ATF du.ing reassembly. 1. Removethe roller bearingfrom the transferhous
Ing.
Transfer CoverA Bearing Outer

RaceReplacement
NOTE:Coatall partswith ATF during reassembly. 1. Removethe taperedroller bearingouter racefrom t r a n s f e rc o v e r A b y h e a t i n gt h e c o v e r t o a l m o s t 212"F llOO"Clusing a heat gun. Do not heat the coverover 212"F(100"C).
Install the 68 mm thrustshim in transfercoverA. Installthe new roller bearingusingthe special tools and a press. Installthe tapered roller bearing outer race using the special tools and a p.ess.
ATTACHMENT, 62x68mm 07746- 0010500
TRANSFER HOUSING
14-238
Transfer HousingBearing OuterRaceReplacement

NOTE: Coat all parts with ATF during reassembly. 1. Removethe taperedroller bearingouter racefrom the transferhousing. HOUSING TRANSTER vi.w Sacttonal
ATTACHMENT, 62x68mm 077a5- @105dt
Bearing Outer Rac6Locations and SpecialTool Applications
ATTACHI'E'{T, {i:l x 6t mm 07746 - rDl05rr0 TRANSFER HOUSING ATTACHMENT, 52x55mm 07t46 - dtroa{x,
Install th new tapered roller bearing outer race usingthe specialtools and a press.
DRIVER 077$ - 0010(ro0
14-239
Transfer Assembly
Reassembly
NOTE: . While reassembling transferassembly: the . Checkand adjustthe transfergeartooth contact. . Measure and adjustthe transfergear backlash. . Checkand adjustthe taperedroller bearingstaning torque. . Coatall pans with ATFduring reassembly. . R e p l a c eh e t a p e r e dr o l l e rb e a r i n g n d t h e b e a r i n g t a outer raceas a set if eitherpart is replaced. . Replace the transferdrive gear and the transferdriven gearshaftas a set if eitherpart is replaced. Outline of Assembly 1 . Selectthe 35 mm thrusi shim. Psrtorm this procedute if the transter driven gar shaft or the tapered roller bearing on the transfer driven gear shaft is replaced. 2. Prea$emble the parts to check and adiust transtel gear backlashand transfer gear tooth contact.
EXAMPLE: C: EXISTING mm 35 THRUST SHIM Thickness: C=1.05 mm X: REPLACEMENT mm 35 THRUST SHIM Thickness:X=??mm
Number: A=+2
Numbe.: B=-'l
TRANSFER Ar EXISTING DRIVEN GEARSHAFT
B: REPLACEMENT TRANSFER DRIVEN GEARSHAFT
3 . Disassemblethe parts, then assemble the transler

driven gsar shaft and its related pans. 4. Measure and adjust the starting torque oI the transfer driven gear shaft tapered roller bearing. Assemblethe transfer shaft and its related parts. Measureand adiust the total starting torque.
x " = A - B .c 100 100 2 - 1 '100 100 = 0.02+ 0.0'l+ 1.05 =1.08 {mm) S e l e c t3 5 m m t h r u s t s h i m t h i c k n e s s f l 0 8 m m o (0.043 lf the taperedroller bearingon the transfer in). drivengear shaftis replaced. M e a s u r e h e t h i c k n e s s f t h e r e p l a c e m e nb e a r i n g t o t and the existingbearing, and calculate difference the of the bearjngthickness. Adjust the thickness the of existing35 mm thrust shim by the amount of difference in bearingthickness, and selectthe replacement 3 5 m m t h r u s ts h i m . THRUST SHIM,35 mm
Shim No. Part Number
5. 6.
35 mm Thrust Shim Selection L Selectthe 35 mm thrust shim if the transferdriven gearshaftor the taperedrollerbearingon the transfer drivengearshaft is replaced. C a l c u l a t eh e t h i c k n e s s f t h e 3 5 m m t h r u s t s h i m t o usingthe formula below.
* F o R M U L A :-+ - + c = x
A: Numberon the existingtransferdrivengear shaft B; Numberon the replacement transferdriven gear shaft C: Thickness ofthe existing35 mm thrustshim X : T h i c k n e s s e e d e df o r t h e r e p l a c e m e n3 5 m m n t t h r u s ts h i m N O T E : T h e n u m b e r o n t h e t r a n s f e rd r i v e n o e a r shaftis shown in 'll100mm.
c
D
F H
41361 PS3 000 41362-PS3-000 41363-PS3-000 41364-PS3-000 41365-PS3-000

41366-PS3-000
Thickness 0 . 7 2 m ( 0 . 0 2i8 ) m n
0.75 mm {0.030in} 0.78 mm (0.03'1 in) 0.81 mm (0.032in)
0.84mm (0.033 an)
0.87 mm (0.034in) 4 1 3 6 7 - P S 3 - 0 0 0 0.90 mm (0.035in) 4 1 3 6 8 - P S 3 - 0 0 0 0.93 mm (0.037in)
K
M
N
41369-PS3-000 41370-PS3-000 4 r371 PS3 000 41372-PS3-000 41373-PS3-000

41374-PS3-000
0.96mm 10.038 in)

0.99 mm (0.039in) 1 . 0 2m m ( 0 . 0 4 0n i 1 . 0 5m m ( 0 . 0 4 1n i 1.08mm (0.043in '1.11 m m 1 0 . 0 4 i4 n
14-240
Transfer Gear BscklashInspectionand TransferGear Tooth Contact Inspection 2. Installthe 35 mm thrust shim on the transferdriven g e a r s h a f t ,t h e n i n s t a l lt h e t a p e r e dr o l l e r b e a r i n g usingthe special tools and a press.
5.
Installthe transferdriven gear shaft in the transfer housing.Do not install the transfer spaceron the transferdrivengearshaft in this step.
TRANSFER
DRIVER mm LD. {0 077146 0030100
TRANSFER DRTVEN GEAR SHAFT
;;. 745 0O304O0 u,
6.
Install flange,conicalspringwasher, the companion and locknut on the transfer driven gear shaft. Do not install the O-ring and the back-upring on the transfergear shaftin this step.
Place taperedrollerbearing the bearing the on outer race of the companionflange side of the transfer housrng. I n s t a l lt h e n e w o i l s e a l o n t h e t r a n s f e r h o u s i n g usingthe special tools.
TRANSFER HOUSING
OIL SEALDRIVER ATTACHMENT 07JAD- PH80101
COMPANION FLANGE
{cont'd)
14-241
TransferAssembly
(cont'd) Reassembly
7. Securethe transfer housing in a bench vise with soft jaws, then installthe specialtool on the companion flange. To preventdamageto the transfer materihousing,alwaysuse soft jaws or equivalent als between transferhousingand the vise. the Tighten the locknut while measuringthe starting '1.39 torque so the startingtorque is within 0.98- 12.3lbnin). N.m (10.0 14.2kgf.cm, 8.68 NOTE: Coat the threads of the locknut, and the shaft the with ATF beforeinstalling locknut. Do not stakethe locknutin this step. STARTING TOROUE: 0.98- 1.39N.m {10.0- 14.2kgrf.cm,8.68 12.3lbf'inl 9. I n s t a l lt h e t r a n s f e rs h a f t i n t h e t r a n s f e rh o u s i n g , transfershaft then installthe taperedrollerbearing, collar.25mm thrust shim, transferdrive gear,conical springwasher,and locknuton the transfershaft. NOTE: . Coat the threads of the locknut. and the shaft with ATF beforeinstalling locknut. the . Do not stakethe locknutin this step.
COMPANION FLANGE HOLDER
TRANSFER
THRUSTSXIM, 25 mm pan Selective
DRIVE TRANSFER GEAR SPRING CONICAL WASHER Replace. 07JAB- @1020A
14-242
1 0 . Put a 14 mm Allen wrench in the gear side of the transfer shaft, then secure the Allen wrench in a benchvise. 1 1 . Tightenthe transfershaftlocknut. NOTE: . The transfershaftlocknuthas left-hand threads. . Do not stakethe locknutin this step. TOROUE: 118 N'm 112.0 kgf.m, 87 lbf.ftl
TOROUE WRENCH
1 3 . Rotatethe companionflange severaltimes to seat

the taperedrollerbearing.
1 4 . Set a dial indicatoron the companionflange,then
measure transfergear backlash. the STANDARD: 0.06- 0.16mm {0.02 0.06inl

DIAL INOICATOR
FLANGE COMPANION 1 5 . l f t h e m e a s u r e m e n ti s n o t w i t h i n t h e s t a n d a r d . removethe transfershaft locknutand replace 25 the m m t h r u s t s h i m . S e l e c ta n d i n s t a l la n e w 2 5 m m thrust shim. then recheck measurement. not the Do use more than two 25 mm thrust shims to adiust the transfergear backlash. THRUST SHIM,25 mm
Shim No.
1 2 . Temporarilyinstallthe transfercoverA without t h e O-ring.

TRANSFER HOUSING
2
4 6 7
d
Part Numbor Thickness 2 9 4 1 1 - P 1 C - 0 0 0 1.70mm (0.067in) 2 9 4 1 2 - P 1 C - 0 0 0 1.73mm (0.068in) 2 9 4 1 3 - P 1 C - 0 0 0 1.76mm (0.069in) 2 9 4 1 4 - P 1 C - 0 0 0 1.79mm (0.070in) 2 9 4 1 5 - P l C - 0 0 0 1.82 mm (0.072 in) 2 9 4 1 6 - P 1 C - 0 0 0 1.85mm (0.073ini
29417-PlC-000 1.88mm (0.074in)
10
11
2 9 4 1 8 - P 1 C - 0 0 0 1 . 9 1m m { 0 . 0 7 5n ) i 2 9 4 1 9 - P 1 C - 0 0 0 1.94mm (0.076in) 2 9 4 2 0 - P t C - 0 0 0 1 . 9 7 m ( 0 . 0 7 i8 ) m n
29421- P1C- 000 2.00 mm (0.079in)
14 TRANSFER COVER A 16 17 18
2 9 4 2 2 - P 1 C - 0 0 0 2.03 mm 10.080 in) 2 9 4 2 3 - P ' 1 C - 0 0 0 2.06 mm (0.081in) 29424-P1C-000 2.09mm 10.082 in) 2 9 4 2 5 - P 1 C - 0 0 0 2 . 1 2 m ( 0 . 0 8 i3 ) m n
29426-P1C-000 2.'15 mm (0.085in)
g
/Fr E
tt
el
19 | kgt.m, 17 lbf.ftl 24 N.m12.4 24 N.m 12.4
29427 P1C-O00 2 . 1 8m m ( 0 . 0 8 6n ) i 29428-PlC-000 2.21 mm (0.087in) 2 9 4 2 9 - P 1 C - 0 0 0 2.24mm {0.088 in)
g 9-r'r.ru-g (cont'd)
14-243
Transfer Assembly
(cont'dl Reassembly
16. Apply PrussianBlue to both sides of the transfer gearteethlightlyand evenly. 19. lf the transfergear tooth contactis incorrect, adjust the transfergear tooth contactwith a 35 mm or 25 m m t hr u s ts h i m . NOTE: . To selecta 35 mm thrust shim, referto page 14, 240. . D o n o t u s e m o r e t h a n t w o 3 5 m m s h i m st o adjustthe transfergeartooth contact. . To selectthe 25 mm thrust shim, refer to page 14-243. . D o n o t u s e m o r e t h a n t w o 2 5 m m s h i m st o adjustthe transfergeartooth contact. Toe Contact U s e a t h i c k e r3 5 m m t h r u s t s h i m t o m o v e t h e transferdriven gear shaft toward the transferdrive gear. Because this movement causesthe transfer gear backlash change,move the transferdrive to gear away from the transferdriven gear shaft to adjustthe transfergear backlash follows: as . I n c r e a s eh e t h i c k n e s s f t h e 2 5 m m t h r u s t t o shrm. . R e d u c et h e t h i c k n e s so f t h e 6 8 m m t h r u s t shim by the amount of increased thickness of the 25 mm thrustshim. Heel Contact U s e a t h i n n e r3 5 m m t h r u s t s h i m t o m o v e t h e transfer driven gear shaft away from the transfer d r i v e g e a r .B e c a u s eh j s m o v e m e n t a u s e s h e t c t transfer gear backlashto change,move the transfer drive gear toward the transferdriven gear shaft gearbacklash follows: to adjust transfer the as . R e d u c et h e t h i c k n e s so f t h e 2 5 m m t h r u s t shim. . I n c r e a s eh e t h i c k n e s s f t h e 6 8 m m t h r u s t t o shim by the amount of reducedthicknessof t h e 2 5 m m t h r u s ts h i m . Flank Contaqt Use a thinner thrust shim to move the transfer drive gear toward the transferdriven gear shaft. Flankcontactmust be adjustedwithin the limits o f t h e t r a n s f e rg e a r b a c k l a s h l. f t h e b a c k l a s h e x c e e d s h e l i m i t s ,a d j u s t a s d e s c r i b e d n d e r t u Heel Contact. FaceContaqt Use a thickerthrust shim to move the transfer drive gear away from the transfer driven gear shaft. Facecontactmust be adjustedwithin the limits of the transfergear backlash. the backlf l a s h e x c e e d st h e l i m i t s , a d j u s t a s d e s c r i b e d underToe Contact.
1 7 . Rotate companion the flangein both directions until the transfergear rotatesone full turn in both directions. 1 8 . Check transfergeartooth contactpattern. the
CORRECT TOOTH CONTACT PATTERN
NCONRECTTOOTH CONTACTPATTERN
TOE CONTACT
HEELCONTACT
FLANKCONTACT
FACECONTACT
14-244
20. Remove the partson the transfershaft,and remove the transfershaftfrom the transferhousinq.
TRANSFER SHAFT
23. Remove the transterdrivengear shaftand the companionflange, 24. Installthe new transferspaceron the transferdriv e n g e a r s h a f t ,t h e n i n s t a l lt h e m i n t h e t r a n s f e r housrng.
TRANSFER DRIVEN GEARSHAFT
HOUSING TRANSFER ROLLER TAPEFED BEARNG
SPACER TFANSFER lnstallin this direction. Replace.
TRANSFER COLLAR TRANSFER DRIVE GEAR THRUSTSHIM,25 mm Selectivepan CONICAL SPRING WASHER Replace.
Replace.
Transfr Driven Gear Shaft Starting Torque Inspsction and Adjustment
25. Installthe companionflange, O-ring,back-upring.

21. Secure the transfer housing in a bench vise with soft jaws, To preventdamage, alwaysuse soft jaws or equivalentmaterialsbetweenthe transferhousing and the vise. 2 2 . I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o n l a n g e , f then removethe transferdriven oear shaft locknut and the conicalspringwasher. COMPANION FLANGE HOLDER 07RAB TB,010A ol 07RAB TB,010B conical spring washer and locknut on the transfer drivengear shaft. NOTE: . C o a t t h e t h r e a d so f t h e l o c k n u t ,a n d t r a n s f e r shaftwith ATF beforeinstalling locknut. the . Installthe conicalspring washerin the direction shown,
TRANSFER HOUSING
O.RING Replace. CONICAL SPRING WASHER Replace.
BACK.UP RING
LOCKNUT Replace.
(cont'd)
14-245
Transfer Assembly
(cont'd) Reassembly
Secure the transfer housing in a bench vise with soft jaws. To preventdamage,alwaysuse soft jaws or equivalentmaterialsbetweenthe transferhousing and the vise. 28. Stakethe locknutinto the transferdriven gear shaft usinga 3,5 mm punchas shown.
27. I n s t a l lt h e s p e c i a lt o o l o n t h e c o m p a n i o nf l a n g e ,
then tighten the transferdriven gear shaft locknut while measuring the startingtorque of the transfer drivengearshaft. STARTING TOROUE: 0.s8- 1.39N.m {10.0 14.2kgf.cm,8.68 12.3lbf.in) TIGHTENING TOROUE: 132- 216 N.m {13.5- 22.0 kgf.m, 98 - 159 lbf.ft) NOTE; . Rotatethe companion flange several times to seatthe taperedrollerbearing, then measure the startingtorque, . l f t h e s t a r t i n gt o r q u e e x c e e d s1 . 3 9 N . m ( 1 4 , 2 kgf.cm, 12.3 lbf.in), replacethe transfer spacer a n d r e a s s e m b l eh e p a r t s . D o n o t a d j u s t t h e t torquewith the locknutloose. . lf the tightening torque exceeds216 N.m (22.0 kgf.m,159 lbf'ft),replace the transferspacerand reassemble parts. the . W r i t e d o w n t h e m e a s u r e m e no f t h e s t a r t i n g t torque: it is used to measurethe total starting rorque. COi'PANIOI{ FLANGE HOLDER
07MB - TBi(tloA ot O'RAB - TB,.|}IOB 0.7- 1.2mm {0.03- 0.05 inl PUNCH 3.0- 3.5 mm 1 0 . 1-2 0 . 1 {i n l
.,.,.,\
t)
--/./
Point to be staked.
29. Install the transfer shaft in the transfer housing, then installthe taperedroller bearing, transfershaft collar,25 mm thrust shim,transterdrive gear,conical springwasher,and transfershaft locknuton the transfer shaft, NOTE: . Coatthe threadsof the locknutand translershaft with ATF beforeinstalling locknut. the . Installthe conicalspring washer in the direction snown.
TRANSFER SHAFT
TRANSFER HOUSII{G
THRUSTSHIM.25 mrt| Selectivepart
TOFOUE WRENCH
HOLDER HANDLE 07JAB- 001020A CONICAL SPRING WASHER Replace. Replace.
14-246
30. Put a 14 mm Allen wrench in the gear side of the transfer shaft. then secure the Allen wrench in a benchvise. Tightenthe transfershaft locknut.{The locknuthas left-hand threads,) TOROUE:118 N.m (12.0kgf.m, 87 lbt.ft)
Total Starting Tolqu Inspctionand Adiustment installtranstercover A without the O32. TemDorarilv
flng.
HOUSING
TMNSFER COVER A
e v
E -
8x1.25mm r? 24 N'm {2.i1kgt'm, bt'ftl
14 mm ALI-ENWRENGH
5J.
al
Stakethe locknuton the transfershaft using a 3.5 mm ounch.
Securethe transfer housing in a bench vise with soft jaws, then rotatethe companionflangeseveral times to fit the tapered roller bearing.To prevent materidamage,alwaysuse soft jaws or equivalent als betlveen transferhousingand the vise. the
34. Measure total startingtorque. the

TOROUE: TOTALSTARTING lbf.in} 1.70- 2.08N.m {17.3 21.2kgl.cm,15.0 18.i1 Driven Gear Sh8ft Starting Torque Value + Transler lwroto down in step 27).
0.7- 1.2.nm {0.0:1-0.C5in} PU CH 3.0 - 3.5 rnm
(cont'd)
14-247
Transfer Assembly
Reassembly(cont'dl
35. Remove taansfer coverA. 37. Select the 68 mm thrustshim. THRUST SHIM,58 mm Shim No. Part Number Thickness
36. lf the measurement out of specification, is remove

t h e 6 8 m m t h r u s t s h i m f r o m t r a n s f e rc o v e r A b y ) h e a t i n g h e c o v e rt o a l m o s t2 1 2 " F( 1 0 0 " Cu s i n ga t heat gun. Do not heat the cover higher than 212"F ( 1 0 0 ' C ) . e t t h e c o v e rc o o l t o r o o m t e m p e r a t u r e L beforeadjusting startingtorque, the go lf the measurement within the specification, to is step 40.
zv zw zx
ZY
2 3 9 7 4 - P 1 C - O 2 0 1.41mm (0.056 in) 2 3 9 7 5 - P 1 C - O 2 0 1.44mm (0.057 in) '1.47 23976-P1C-020 mm (0.058 in) 23977- P1C- O20 23978-P1C-020 23941 PW5- 000 23942-PWs-000 23943- PWs 000 23944-PW5-000 1.50mm (0.059 in) 1.53mm 10.060 in) '1.56 mm {0.061 in) 1.59mm 10.063 in) 1.62mm (0.064 in) 1.65mm {0.065 in} 1.68mm (0.066 in) 1.71mm (0.067 in) 1.74mm (0.069 ini 1.77mm (0.070 ini 1 . 8 0 m ( 0 . 0 7 i1 , m n 1.86mm (0.073 in 1.89mm (0.074 in 1.92mm (0.076 in 1.95mm (0.077 in 1.98mm (0.078 in 2.01mm (0.079 in 2.04mm (0.080 in 2.07mm (0.081 in 2.10mm (0.083 in 2 . 1 3 m ( 0 . 0 8 i4 m n 2 . 1 6 m ( 0 . 0 8 i5 m n 2 . 1 9 m ( 0 . 0 8 i6 m n 2.22mm (0.087 in 2.25mm (0.089 in 2.28mm (0.090 in 2.31mm (0.091 in 2.34mm (0.092 in
zz
B
c
D HEATGUN
E
F G
23945 PWs 000 23946 PWs- 000 23947 PWs 000

23948-PW5-000 23949 PW5 000
J K
L
2 3 9 5 0 - P W s - 0 0 0 1.83mm {0.072 ini

23951 PWs- 000 23952 PW5- 000
23953 PWs 000

N
o
P
23954 PW5- 000 23955 PW5 000 23956- PWs 000 23957-PW5-000
o
R
23958, PWs 000

23959-PW5-000 23960 PW5- 000 2396'1 PW5- 000
s
T U
23962 PWs 000

X 23963- PW5 000 23964- PW5 000 23965 PW5- 000
z
AB
AC AD M BZ
23966 PWs 000

23967-PWs-000 23968-PWs-000
2.37mm (0.093 in) 2 3 9 6 9 - P W s - 0 0 0 2.40mm (0.094 in) 23970-PW5-000 2.43mm (0.096 in) 23941 PW8 000 2.46mm (0.097 in) 23942-PW8-000 23943- PW8 000 23944 PW8- 000 23945-PW8-000 2.49mm (0.098 in) 2.52mm (0.099 in) 2 . 5 5 m ( 0 . 1 0 i0 ) m n 2 . 5 8 m ( 0 . 1 0 i2 ) m n
cz
DZ
EZ
14-248
3 8 . I n s t a l lt h e 6 8 m m t h r u s t s h i m u s i n g t h e s p e c i a l tools.
40. Installthe new O-ringson transfercoversA and B, then installthecoverson the transferhousing
PRESS
DRIVER 07743- 0010000
6x1.0mm 12 N.m 11.2 kgt.D, 8.7 rbf.ftl
B COVER TRANSFEN
Replace.
O.RING AEARING OUTERRACE ATTACHMENT, 62x68mrr| 077a6- (x)10500

Replace.
and the 39. After replacing 68 mm thrust shim. recheck m a k e s u r e t h e t o t a l s t a r t i n gt o r q u e i s w i t h i n t h e specification.
8 r 1.25rnm kgl.m, 17 lbf'ftl 24 N.m 12.4
Transmission
Reassembly
NOTE: . The illustration showsthe 4WDautomatictransmission; 2WDis similar. the . Cleanall partswith ATF. . Replace followingparts: the - O-rings - Lockwashers - Gaskets - Sealing washers - Locknuts and conicalspringwashersof eachshaft
6x1.0mm ATF FEEDPIPE ATF LUBRICATION PLATE
SERVO DETENT
ATF FEEDPIPES BASE (37 -98 modebonlyl 1 4 5m m 6x1.0mm 2 Bolts '99 - 00 models: 1 Bolts
/
DOWELPIN
LOCK.UP VALVE BODY LOCK.UP SEPARATOR PLATE REGULATOR VALVE BODY DOWELPIN VALVESPRING COOLER BELIEF VALVE TOROUE CONVERTER CHECK VALVE STATORSHAFT O.RING STOPSHAFT CHECK BALLS18'
ATF FEEO PIPE
ATF STRAINER
j
I
coNrRoL
SHAFT
'-\t
6x1,0mm '97 - 98 models: 7 Bolts '99- 00 models:8Bolts SERVOBODY ('97- 98 models) SERVO SEPARATOR PLATE 6x1.0mm 3 Bolts STOPSHAFT BRACKET
40 mm
6x1.0mm 18olts DETENT ARM SHAFT
'112mmll,
r l T
ATF FEEDPIPE 112 m m 6x1.0mm 5 Eolts MAIN VALVEEOOY ATF PUMP DRIVEN GEARSHAFT ATF PUMPDRIVEN d---.) (./ ,/ / 105.8
/,,!.,::
SECONDARY VALVEBODY OOWEL PIN 8x40mm SECONDARY SEPARATOR PLATE --.CONTROL I.EVER MOUNTINGBOLT 6x1.0ftm 14 N.m (1.4 kgt.m, 10 tbf.ft) (4WD)
afF FEEO ptpEs
EP,--!ir{+*a\
SERVO BODY ('99- 00models)

r
MAIN SEPARATOR PLATE ATF PUMP DRIVEGEAR DOWELPIN
fpffi4 i
_ \zl
TOBOUE
HOUSING
x*hi
14-250
1 . Installthe suction pipe collar and the ATF magnet {2WD)in the torque converter housing, if necessary. lnstallthe main seDarator Dlateand the two dowel pins on the torqueconverter housing, Installthe ATF pump drive gear.ATF pump driven gear,and ATF pump drivengear shafton the torque housing.InstalltheATF pump drivengear converter sidefacingdown. with its groovedand chamfered
ATF PUMP GEAR
8. Installthe servo body and separatorplate on the secondaryvalve body ('97 - 98 models: seven bolts, '99 - 00 models:eight bolts). 9 . lnstallthe servo detentbase ('97- 98 modelsonly) and the ATF strainer('97 - 98 models:two bolts,'99 one boltl. 00 models:
1 0 . Tightenthe five bolts on the main valve body to 12

N'm (1.2kgf.m,8.7 lbf.ft). 1 l . Makesure the ATF pump drive gear and ATF pump d r i v e n g e a r s h a f t m o v e s m o o t h l y .l f t h e y d o n ' t , loosenthe bolts on the main valve body,and disasthe semblethe valve bodies.Realign ATFpump drivthe en gear shaft and reassemble valve bodies,then retightenthe boltsto 12 N.m (1.2kgim, 8.7 lbf.ft). CAUTION: Failureto align the ATF pump driven gear shaft corroctly will rosult in a seizsd ATF pump drive gear or ATF pump drivon gear shaft.
ATF PUMP D{IVEf{ GEARSHAFT ATF PUi'P GEAR ORIVEN Grooved and chamtered side faces separator plate.
MAIN SPAR/ATOR PLATE
Loosely install the main valve body with five bolts. smoothly Makesurethe ATFpump drivegearrotates direction, and the ATF pump in the normaloperating driven gear shaft moves smoothly in the axial and normal operatingdirections. 5. Installthe secondaryvalve body, separatorplate, and two dowel pins on the main valve body. Do not installthebolts. Installthe control shaft in the housing along with the manualvalve. lnstall the detent arm and arm shaft in the main valve body, then hook the detentarm spring to the detentarm.
SEBVOSEPARATOR PLATE ATF PUMP DRIVEGEAR ATF DBIVENGEAR GEAR SHAFT
Installthe stator shaft and stop shaft
o.
1 3 . Installthe bolts and the stop shaft bracketon the

secondaryvalve body, then tighten the bolts (three bolts). checkvalve,coolerrelief 1 4 . Install the torqueconverter valve body, valve,and valvespringsin the regulator then install the regulatorvalve body on the main valvebody {one boltl. 1 5 . Installthe lock-upvalve body, separatorplate,two plate(eightbolts). dowel pins and lubrication
7.
DETENT ARM SHAFT
CONTROL SHAFT
ARM OETENT ARM SPRING OETENT
1 6 . Installtheone ATFfeed pipe in the main valvebody, the three ATF feed pipes in the secondaryvalve, the three ATF feed pipes in the servo body and the one ATF feed pipe in the lock-upvalve body. NOTE:lnstallthe 105.8mm ATF feed pipe with its filter side away from the secondaryvalve body; the filter is on the 105.8mm ATF feed pipe, which is (cont'd) onlv on the '98 - 00 models,
MANUAL VAIVE
14-251
Transmission
(cont'd) Reassembly
TRANSMISSION HOUSING MOUNNNG BOLT 10 x L25 4,1N.m {/ 4WD: 19 2WD: 18 TRANSMISSION HANGER
f,
6xl.0mm 12 N.m (1.2 kgl.m,
8.7rbt.ft)
MAINSHAFT SPEED SENSOB
ll gf , / il
l
COUNTERSHAFT BEVERSE GEAB
LOCKWASHER MAINSHAFT SUB.ASSEMBLY REVERSE SHIFT FORK
DOWELPIN 14x 20 rnm
NEEDLE BEARING REVERSE SELECTOR
OOWELPIN 14x25mm TRANSMISSION HOUSING GASKET
COUNTERSHAFT SUB.ASSEMBLY DIFFERENTIAL ASSEMBLY
DOWELPIN 14x25mm
TRANSFES ASSEMBLY (4wDl
14-252
1 7 . Installthe sub-shaftassemblyin the transmission and 14-2'111. housing(seepage 14-210 1 8 . lnstall the ATF magnet (4WD) in the transmission if housing, necessary. 1 9 . Installthe reverseidler gear and gear shaft holder (seepage 14-231). assemblyin the torque con20. Installthe differential verterhousing. s 21. A s s e m b l et h e m a i n s h a f ta n d c o u n t e r s h a f t u b then install and 14 207],, assembly(seepage 14-206 houslng. them togetherin the torqueconverter
Installthe reversegear with the collar and needle bearingon the countershatt. 2 4 . Align the spring pin on the control shaft with the housinggroove by turningthe control transmission shaft. SHAFT CONTROL SPRING PIN PIN SPRING
COUNTERSHAFT SUB-ASSEMBLY
TRANSMISSION HOUSING housingon the torque con25. Placethe transmission v e r t e r h o u s i n gw i t h a n e w g a s k e ta n d t h e t h r e e dowel pins, Make sure that the mainshaftspeed sensor is not h i n s t a l l e do n t h e t r a n s m i s s i o n o u s i n g b e f o r e h t i n s t a l l i n gh e t r a n s m i s s i o n o u s i n go n t h e t o r q u e housing. converter h 2 6 . I n s t a l lt h e t r a n s m i s s i o n o u s i n g m o u n t i n g b o l t s hangerand the connecalongwith the transmission tor bracket,then torque the bolts in two or more shown. steosin the seouence NOTE:The illustrationshows the 4WD automatic housThe 4WD has 19 transmission transmission. ing mountingbolts;the 2WD has 18 bolts. 44 TOROUE: N.m {,[.5kgf.m, 33 lbf'ft)
TNANSMISSION SHIFI FORK LOCK WASHER Beplace. 'l.O mm 6 r 4 N.m (1.4 ksl.m. 1O lbt.ft)
Turn the shift fork so the large chamferedhole is facing the fork bolt hole. then installthe shift fork with the reverseselectorand torque the lock bolt. the Bendthe locktab against bolt head.
Large chamfered hole
{cont'd)
14-253
Transmission
(cont'd) Reassembly
Install the mainshaft speed ssnsor (with new Oring)on the transmission housing. 33. Install the old locknut and the old conical spring washeron ths countershaft. Tightenthe old locknut to seat the park gear to the specifiedtorque,then remove th washer and locknut. The locknut has left-handthreads. Do not use an impact wrench. Always usea torquewrenchto tightenthe locknut. TOROUE:103 N.m {10.5kgf.m, 75.9 lbnft)
28. I n s t a l lt h e p a r k l e v e r o n t h e c o n t r o l s h a f t , t h e n
installthe lock bolt with a new lock washer.Do not bend the lock tab of the lock washer in this step; bend it after checking the park pawl engagement in step45. Assemble the one-wayclutchand the park gear on the countershaft gear(seepage l4-2Og). 1st Lubricatethese pans with ATF: . Countershaft threads . Old locknut threadsand flat end . Old conicalspringwasher . Park gear contact area with conical spring wasner
3 1 . Installthe countershaft gear collar,needlebear1st

ing, and the countershaft gear/park gear assem1st bly on the countershaft. Installthe park pawl shaft. pawl spring, pawl. and p a w l s t o p o n t h e t r a n s m i s s i o n o u s i n g ,t h e n h engage the pawl with th parkgear.
PARKGEAR PARXGEAR PAWL STOP
ONE.WAYCLUTCH
I I
34. Slip the specialtoolontothe mainshaft.
LOCK BOLT
PAWLSHAFT
BEARING COUNIERSHAFT COUNTERSHAFT lST GEARCOLLAR MAINSHAFT 07GAB- PF50101 or 07GAB- PF501q)
14-254
5C.
lst Install the sub-shaft gear on the sub-shaft.
36. Installthe mainshaft1st gear collar, mainshaft1st

and the gear,needlebearing, thrust needlebearing, thrustwasheron the mainshaft. Wrap the shaft splineswith tape to preventO-ring damage, then installnew O-ringson the mainshaft
,te
4 1 . T i g h t e nt h e l o c k n u t st o t h e s p e c i f i e dt o r q u e . locknutshave left-hand Mainshaft and countershaft threads.Do not use an impactwrench.Always use a torquewrenchto tightenthe locknuts. TOROUE: LOCKNUT 78 N.m (8.0 kgf'm, 58 lbf'ft) MAINSHAFT: 103 COUNTERSHAFT: N.m (10.5kgf.m, 75.9 lbf'ft) 93 N.m {9.5 kgf'm, 69 lbf'ft| SUB-SHAFT:
MAINSHAFT SU8-SHAFT LOCKNUT LOCXNUT Left-handthreads PIN COUNTENSHAFT 8 mm pin, LOCKNUT commercially threads Left-hand available
on lnstallthe1stclutchassemblv the mainshaft
lST CLUTCH ASSEMELY SUB.SHAFT lST GEAR
.A/.b"' "wt
O.RINGS THRUSTWASHER IHRUST NEEDLE BEANING NEEDLE BEARING

MAINSHAFT 1ST GEAR
WASHRS SPBING CONICAL lnstallin this directionMAINSHAFT 1STGEAR COLLAB 42. Stake each locknut using a 3.5 mm punch.
39. A l i g n t h e h o l e o f t h e s u b - s h a f tl s t g e a r w i t h t h e housing,then insert an 8 hole of the transmission while tighteningthe mm pin to hold the sub-shaft sub-shaft locknut. 40. Install new conical spring washers and new locknuts on each shaft.Installthe washersin the direction shown.
0.7- 1.2mm {0.03 0.05inl PUNCH 3.0- 3.5mm 10.12 0.1ilinl
LOCKNUT Pointto be staked.
(cont'd)
14-255
Transmission
Reassembly lcont'd)
Set the parklever in @ position, then verifythat the parkpawl engages parkgear. the 44. lf the pawl does not engage fully, checkthe distance b e t w e e nt h e p a r k p a w l s h a f t a n d t h e p a r k l e v e r rollerpin (seepage 14-231). Tightenthe lockbolt and bendthe locktab. 47. Install the control lever assemblv on the control shaft. (4WDl
6 r 1 . Om m
1o tbf'frl
6x1.0mm 14 N.m 11.4kg{.m, 10 tbf.ftl PARKGEAR PARKPAWL
CONTROL LEVER ASSEMBLY
46. Installthe end coverwith two dowel pins and a new gasket {twelve bolts). TOROUE:12 N.m (1.2 kgf.m, 8.7 tbf.ft)
48. Set the A/f gear position switch to E] position. NOTE: The Aff gear position switch cticks in N] position,
6 x 1.0mm EOLTHOLE {Usedin step50.)
END COVER A/T GEARFOSMON SWNCH
14-256
49. Set the control shaft to E position,and installthe gear positionswitchon it. A,/T
SHAFT CONTROL
Cleanthe areaswhere the transferassemblycontacts the transmissionwith solvent or carburetor air, dry cleaner, with compressed then coatthe conwith ATF. (4WD) tact areas with a new O-ring.Do Installthe transferassembly to not allow dust or otherforeignparticles enterthe transmission. {4WD)
O.RING Replace-
,. ((,,, l( *
$*\.t+T
N
'gtt - 00 MoDELS {6 position3}
50. I n s t a l lt h e A / T g e a r p o s i t i o n s w i t c h c o v e r , t h e n gear position installthe harnessclamps of the AviT switch harnesson the end cover and the transmiss i o nh o u s i n g .
6x1.0mm kgt.m, 12 N.m 11.2 8.7 tbf.ftl
10 r 1.25mm a,aN'm 14.5kgt'm, 33 lbf'ftl
6xl.0mm kgf'm, 12 N.m 11.2 8,7
lnstallthe cooler lineswith the line bolts and new washers. sealing 28 TOROUE: N.m 12.9kgif'm.21 lbf'ft) the 54. Install ATF dipstick.
CONTROL SHAFT
55. lnstallthe breathercap on the breatherpipe so its hanger. arrow pointsto the transmission
HARNESS CLAMP
HARNESS CLAMP
TRANSMISSION
14-257
TorqueConverter/Drive Plate
6 x 1.0 rnin 12 N..t| {1.2 kgt.m, 8.7 lbt.frl
12 x 1.0mm 74 .m (7.5 lgt.m, 54 tbt.ft) Torque in I crisscross oattern.
o 0o
DBIVCPTATE
14-258
Transmission
lnstallation
1.
Flushthe ATF cooler as describedon page 14-264 and 14-265. Installthe torque converterassemblyon the mainshaftwith a new O-ring. housing,and lnstallthe starteron the transmission installthe 14 mm dowel pins in the torqueconverter housing.
44 N.m {{.5 kgf.m, 33 rbf.f0
6.
Install the transmission housing mounting bolt (front side). HOUSINGMOUNNNG BOLT TRANSMISSION SIDE) {FRONT 12x 1.25mm 6,1N m (6 5 kgl m, 47 lbf'ftl
14 mm DOWELPIN
7.
Tightenthe mount bracket. Installthe transmission bolt loosely,then tighten the nuts to the specified torque. torque,and tightenthe bolt to the specified
12 x 1,25mm 6,aN.ft (6.5kgtm,47 rbf.ft)
t@
o P l a c et h e t r a n s m i s s i o n n a j a c k , a n d r a i s e i t t o enginelevel. to Anach the transmission the engine,then install the rear engine mounting bolts and the transmission housingmountingbolt (rearsidel.
REARENGINEMOUNTINGBOLTS la x 1.5mm 8:l N.m (8.5 kgf.m, 61 lbf.ftl MOUNT TRANSMISSION BRACKET
12 x 1.25 mm 74 N.m (7.5 kgf.m, s{ tbtftl TBANSMISSION MOUNT
SIDEI MOUNTINGBOLT{REAR 12x 1.25mm 6il N.m 16.5kgd.m,47 tbt.ttl
(cont'd)
14-259
Transmission
8. Install transmission the housingmountingbolts. 1 3 . C o n n e c t h e A T F c o o l e r h o s e st o t h e A T F c o o l e r lines(seepage14-266).
. ATF COOLER LINE
' , : , . )-
'i'l'r
10 x 1.25mm 44 N.m (4.5kgf.m, 33 tbtftl
TRANSMISSION HOUSING MOUNTING BOLTS 12x 1.25 mm 54N.m16,5 kgf.m, lbtftl a7 9. Remove transmission jack. the 10. Attach the torque convenerto the drive plate with eight bolts. Rotatethe crankshaftas necessarv to tightenthe bolts to 'll2 of the specified torque,then to the final torque, in a crisscrosspattern. After tightening the last bolt. check that the crankshaft rotatesfreelv.
6x1.0mln 12 N.m (1.2tgt m, 8.t lbf.frl DRIVEPLATE
FRotrtT MOUNT/ARACKET
CLAMP 12x 1.25mm 64 N.m 16.5kg{.m, a7 tbt.ftl
't4. Install the rightfront mounvbracket.

1 5 . Installnew set rings on the ends of the intermediate shaftand the driveshaft. 1 6 . Cleanthe areaswhere the intermediate shaft con_ tacts the transmission {differential) with solvent or carburetorcleaner,and dry with compressedair. Then installthe intermediate shaft in the differen_ tial, While installing the intermediate shaft,be sure not to allow dust or other foreign paniclesto enter the transmission.
8 x 1.25mm 2a N.m 12.5 kgf'm, 18 tbt.ftl 6x1.0mm 12 N.m {1.219{.m, 8.7 tbtft,
STIFFENER 12 x t.25 mm 34 N.m 13.5kgf.rn,25 lbf.ft) l0 x 1.25mm 39 N.m 14.0 kgt.n, 29 tbf.ftl
44 N.rn (4.5kgt m, 33 lbtftl
SETRING Replace.
1 1 . Installthe torque convenercover and the rear stiff_ ener. 1 2 . Tightenthe crankshaft pulleybolt as necessary (see section5).
INTERMEDIATE SHAFT
14-260
(seesection18). 17. Install the right and left driveshafts While installing the right driveshaftin the differential, be sure not to allow dust or other foreignparticlesto enterthe transmission. NOTE: . Cleanthe areaswhere the right driveshaftcon(differential) with solvent tacts the transmission or carburetor cleaner,and dry with compressed air. . Turn the right and left steeringknuckle fully outward, and slide the right driveshaftinto the differentialuntil you feel its spring clip engagethe into the interside gear. Slidethe left driveshaft mediateshaft until you feel the spring clip of the the left driveshaft, intermediate shaftengage 18. Installright damper fork, then installthe right and left ball joints on each lower arm with the castle nutsand new cotterpins (seesection18).
19, Installthe propellershaft to the transferassembly marks(4WD). by aligningthe reference

MARKS REFERENCE
8 x 1.25mm 32 N.m (3.3 kgt'm,2ir blft) Feplace. \
@_
DAMPER PINCHBOLT 10 x 1.25mm 43 N.m 14.{kgf.m, 32 rbr.ftl
SHAFT PROPELLER 20. lnstallthe shift cable. 4WD: I n s t a l lt h e s h i f t c a b l e w i t h t h e c o n t r o l p i n , t h e n secureit with the snap Din. Do not bend the shift cableexcessivelv.
DAMPER FORX
SELF.LOCKING NUT 12 x 1,25mm 6/t N m (6.5kg{.m,a7 lbtft) Replace.
Replace.
CONTROL LEVER
CASTLE 12 x 1.25mm 49 - 59 N.m 15.0 6.0 kgl m, 36 - {3 lbtftl 8 x 1.25mm 22 N.m 12.2l'glm, 16 rbt.ftl
SHIFTCAALE COVER
(cont'd)
14-261
Transmission
2WD: Install controlleverwith a new lockwasher the the to control shaft. not bend shiftcable Do the excessivelv.
SHIFTCABLE
24. Installthesplashshieldand guard bar,
8 r 1.25mm 22 N.m |'2.2 kgt.m, 16 rbf.ft) SI{IFT CAELE COVER
8 x 1.25 24 N.m {2.akgl.m, 17 tbt.ftl
SPLASH SHIELD GUAROBAR
LOCK WASHER Replace.
6 x 1.0 mm 14 N.m 11.4kgt.m, 10 tbr.frl
6r1.0|r|m 9.8N.ml1.0lgf.m, tbtftl 7.2
25. Connectthe mainshaftspeedsensor,the shift control solenoidvalve,and the linearsolenoidconnec_ tors,
lnstalltheshift cablecover. 22. Installexhaustpipe A.
23. Connect primaryheatedorygen sensor(primary the

HO2S) connector. GASKETS Replace. SHIFTCONTROL SOLENOID VALVECONNECTOR
10 x 1.25m.n 5r N.m {5.5 kgf.m, 40 tbtftl Replace. SELF.LOCKING 8 x 1.25mm 22 N.m {2,2kgt.m, l5 lbt.ftl
SELF-LOCKING NUT 8 ! 1.25mm 16 N.m {1.6kgf.m, 12 lbf.ftt Replace.
14-262
the counthe vehiclespeed sensor(VSS). 26. Connect tershaft speed sensor. and the A,/Tgear position switch connectors,
28. Instailthe transmissionground cable terminal on h t h e t r a n s m i s s i o n a n g e r ,a n d i n s t a l lt h e r a d i a t o r hanger, hoseclampon the transmission 29. Connect the startercablesto the starter,and install Makesure the harness clamDon the clamDbracket. the crimpedside of the startercablering terminalis facingout.
CLAMPBRACKET
VEHICLE SPEEO
STARTEB CABLE
SPEED SENSOA CO'{NECTOR STARTER CAAtf, 30. I n s t a l lt h e a i r c l e a n e rh o u s i n ga s s e m b l ya n d t h e intakeair duct. with ATF (seepage 14-161). 3 1 . Refillthe transmission Connectthe batterypositiveterminaland negative terminal. Startthe engine,and shift the Setthe parkingbrake, throughall gearsthreetimes. transmission
2 7 . Connectthe lock-upcontrol solenoidvalve connect o r , t h e n i n s t a l lt h e h a r n e s sc l a m p o n t h e c l a m p bracket.

HARNESS CI-AMP HOSE RADIATOR CLAMP
34. Checkthe shift cable adjustment (see page 14-271]-.

C h e c kt h e t r o n t w h e e l a l i g n m e n ta n d a d j u s t i t i f needed(seesection18). temperature Let the engine reachnormal operating (the radiator in fan comeson) with the transmission or N position, then turn it off and checkthe ATF E level{seepage14-160). and 14-158). 37. Performa roadtest (seepage 14-157
TRANSMISSION GROUND CAB1I TERMINAL 6x1.0mm 12 N'm (1.2kgi.m, 8.? tbtftl
OONTROL LOCK-UP VALVE SOLENOID CONNECTOR
14-263
Transmission
Cooler Flushing
To prevent in;ury to face and eyos, atways @@ wear safety glassesot a face shield when using the tlansmission flusher. This procedure should be performedbeforereinstalling the transmission.
L
7. With the water and air valvesoff, attachthe water and (Hotwaterif available.) air supplies the flusher. to
Checkequipmentfor wear and cracksbeforeusing. Replace worn or cracked any components. Usingthe measuring cup.fill the tankwith 21 ounces {approximately lull) ol biodegradable 213 flushing fluid (J35944 20). Do not substitute with any other f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r e n t h e f l u i d o contaaner. S e c u r et h e f l u s h e r f i l l e r c a p , a n d p r e s s u r i z eh e t flusherwith compressed to 550 - 829 kpa (5.6_ air 8 . 4 5 k g f / c m , , 0 - 1 2 0 p s i )T h e a i r l i n e s h o u l d b e 8 . equippedwith a water trap to ensurea dry air system. Hangthe flusherunderthe vehicle.
2.
8 . Turn on the water valve for 1Oseconds.lf water does not flow through the cooler, it is completely plugged, cannotbe flushed, and must be replaced. Depress triggerto mix the flushingfluid into the the water flow. Usethe wire clip to hold the trigger down. 1 0 . While flushingwith the water and flushingfluid for two minutes,turn the air valve on for five seconds every 15- 20 seconds createa surgingaction. to AIR PRESSURE: MAX 845 kpa(8.45kgf/cmr,t20 psi) 1' I. Turn the water valve off. Release trigger,then the reverse the hosesto the cooler so you can flush in the oppositedirection. Repeat steps8 through 10.
5.
Attachthe flusherdischarge hose to the return line of the transmission coolerusinga clamp. Connect drain hoseto the inlet line on the transthe missioncoolerusinga clamp. IMPORTANT: Securely clampthe opposite end ofthe drainhoseto a bucketor floor drain.
12. Release trigger,and rinsethe coolerwith wate. the

for one minute. 1 3 . Turn the water valve off, and the water supplyoff.
DISCHARGE HOSE 1 4 . Turn the air valve on for two minutes,or until no
moistureis visibleleavingthe drain hose.Residual m o i s t u r e i n t h e c o o l e r o r l i n e s c a n d a m a g et h e transmission. Remove the flusherfrom the cooler line.Attachthe drain hoseto a container.
Air lp Water TnAI{SrfiSStoN coot"R FLUSHER {Comm.rcidly.v.il.bt.l K.r -Moor. J38,t{15.A or aquival.nt
to.
Installthe transmission, and leave the drain hose attached the coolerline. to
14-264
is 1 7 . Makesurethe transmission in E position. F i l l t h e t r a n s m i s s i ow i t h A T F ,a n d r u n t h e e n g i n e n 0.951 {1.0US for 30 seconds until approximately or qt., 0.8 lmp qt.) is discharged. 1 8 . R e m o v e h e d r a i n h o s e ,a n d r e c o n n e ctth e c o o l e r t (seepage14-266). returnhoseto the transmission 1 9 . Refillthe transmission with ATF to the proper level ( s e e a g el 4 ' 1 6 1 . p )
TOOL MAINTENANCE 1. mpty and rinse the flusher after each use. Fill the it, flusherwith water and pressurize then flush the lineto ensure that the unit is clean. discharge lf discharge liquiddoes not foam, the orificemay be blocked. To clean,disconnect largecouplingnut from the the flusher.
2.
3.
FILLERCAP
FILTER
COUPLING NUT
I - 0 - - D -@q
I
\
O.RING
I I
\
ORIFICE
4.
sideand Remove in-linefilterfrom the discharge the cleanit if necessary. The fluid orificeis locatedbehindthe filter. Clean it with the pick stored in the bottom of the or tank handle, blow it cleanwith air. Reassemble parts. all
5.
6.
14-265
ATFCoolerHoses
Gonnection
'1. Connect ATF the coolerhosesto the ATF coolerlines.then secure them with the cliDs.
2. Facethe tabs of the clips of the transmission side toward the radiator, and facethe tabs of the ATF coolerside downward.
CLIP F a c et a b s t o w a r d r a d i a t o r .
ATF COOLER LINE TRANSMISSION
ATF COOLER LINE
6-8mm (0.2- 0.3 inl
ATF COOLER
HOSECLAMP
2-rlmm 10.1 0.2inl
CLIP Face tabs downward.
14-266
Shift Lever
SRS componentsare located in this area. Reviewthe precautions, SRS componentlocations, and procedures in the SRSsection(24)beforeperformingrepairsor servrce. 1. Removethe instrumentpanel lower cover and the columncovers(seesection171. Shift to N position, then removethe lock pin from the cableadjuster. Separate shift cablefrom the cableadjuster, the Do not bendthe shift cableexcessively. R e m o v et h e f l a n g e n u t s a n d b o l t s s e c u r i n gt h e steering column,then lowerthe steering column.
22 N.m (2.2kgf.m, 16 lbt.ftl
2.
3.
ADJUSTER ROD
SHIFTCABLE
NUTS FLANGE kgl 16N m (1.6 m, 12lbt'ftl Disconnect shift lock solenoidand the park pin the switchconnector. Remove the bolts securing the shift leverassembly, then removethe shift leverassembly. 7. lnstallthe shift lever assemblyin the reverseorder of removal. NOTE; . Make sure the lock pin is seatedsecurelyin the cableadjuster. . Replace lock pin if it does not snap over the the cableadjuster securely. Checkthe cableadjustment after installing the shift lever(seepage14-27'l).
14-267
Shift Lever
-'97 Disassembly/Reassembly - 98 Models
SRScomponents precautions. are locatedin this area.Reviewthe SRScomponentlocations. and procedures the SRS in section(24)beforeperforming repairsor service. grease theseparts' Apply silicone to . Movablepartsof the shift lever, . Movablepartsof the shift lock mechanism. . Slidingsurfaces the detentof the controlchecker on and detentguide.
SHIFTLOCKSOLENOID SPRING SHIFTLOCK SCREW 2.5 N.m {0.25kg{.m, 1.8rbf.ft) SPFING DETENT SHIFTLEVER CONTROL BRACKET SCREW 2.5 N.m {0.25kgtm, 1.8 lbtftl SHIFTLOCKSOLENOID PLUNGER SHIFTLOCK EXTENSION STOP DETENT GUIDE 9.3 N.m 10.95 kgtm, 6.8 tbrft)
PARKPIN SWITCH CONNECTOR SHIFTLOCK RELEASE LEVER SPRING 9.3 N.m {0.95kgf.m, 6.8 tbf.ftl
SHIFTLEVER LINK 9.3 N.m (0.95kgt.m, 6.8 tbf.ftl
SHIFTCAALE
7 N.m {0.7 kgf.m.5 tbt.fr}
KNOB I N.m 10.9 kgt.m, 7 rbf.ftl
14-268
-'99 Disassembly/Reassembly - 00 Models

precautions, SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, and procedures the SRS in section(24)beforeperformingrepairs service. or grease theseparts: Apply silicone to . Movablepartsof the shift lever. . Movablepartsof the shift lockmechanism. . Slidingsurfaces the detentof the controlchecker on and detentguide. NOTE:Adjustthe clearance between the O/Dswitchwires and the edge ofthe shift levercontrolbracket after reassembly (seepage 14-270).
SHIFTLOCK RELEASE LEVER SHIFTLOCKSOLENOID SHIFTLOCKSOLENOID SPRING SCREW 2.5 N.m {0.25 kgf.m,1.8lbtft) SHIFTLOCKSOLENOIO PLUNGER SCREW 2.5 N.m (0.25kgl.m, 1.8 lbl.ft) DETENT SPRING
SHIFTLEVER CONTROL BRACKET _ PARKPIN SWITCH
SHIFTLOCKEXTENSION STOP DETENT GUIDE 9.3 N.m {0.95kgf.m, 6.9 lbl.ftl SCREW 2.5 N.m {0.25kgt m, 1.8 tbf.ftl
o/DswtTcH
CONNECTOB
SHIFTLOCKBELEASE LEVER SPRING 9.3 N.m {0.95kgl.m, 6.9 lbtfr) HARNESS CLAMP ERACKET
PARK PIN
swrTcH
SCREW 2.5 N.m {0.25kgf.m, 1.8 tbl.f0 9.3 N.m 10.95 kgtm, 6.9 tbf.ft) CONTROL CHECKER
LOCKNUT 7 N.m {0.7kgl.m, 5 tbf.ftl
SHIFT LEVER BUSHING
KNOB SHIFTLEVER 6 - 1 2N . m {0.6- 1.2 kgt'm, 4 - 8.7 tbnft)
o/DswtTcH
14-269
Shift Lever
(O/DlSwitch Wire Clearance Over-Drive Adjustment-'99 - 00 Models
NOTE: Be sure to adjust the clearancebetween the O/D switch wires and the shift lever control bracket after replacing the O/D switch and park pin switch,and after reassembling shift lever. lf there is the slack in the the wires or the wires are kept tight, the wires may have Dreaks. 1. 2. Shiftthe shift leverinto E positron. Pull or push the wires to adjust the clearance betweenthe wires and the edge of the shift lever controlbracket 13 mm (0.5in). to 7.
SHIFTLEVER BRACKET
Secure wireswith the harness the clamp. Move the shift leverto eachposition, and verifythat there is a clearance betweenthe wires and bracket in eachposition. lf the wires are kept tight in any position,read.iust the clearance. Installthe shift lever assemblyon the steeringcolumn. Move the shift lever to each position, and make sure that the wires are kept away from any parts suchas the steering column.
14-270
DetentSpringReplacement
1.
Installthe detent spring on th shift lever control bracket, and installthescrewloosely. Shift the shift lever to E position. lnssrt a 0.5 mm (0.02 in) wire gap gauge between the control chockerdetent and the shift lever,then hold the shift lever againstthe El position in the controlchecker.
4.
Put the detent spring roller in E position on the detentguide,then tightenthe screwto the specified torque,
'97 - 98 Modeb: SPRING DETENT
SHIFI LEVER
2.5 N.m 10.25 kgf.m, 1.8lbl.ftl
GAPGAUGE
SCREW 2.5 N.m 10.25 kgl.m, 1.8lbtftl
14-271
Shift Gable
Adjustment
in SRScomponents located this area.Review SRS are the precautions, procedures the in componentlocations, and (241 beforeperforming repairs service. SRSsection or 1. 2. Release steering lever. the tilt Removethe accesscover from the lower column cover. 4. Checkthat the hole in the cable adjusteris aligned with the hole in the adjusting rod. There are two holes in the cableadjuster. They are positioned 90" apart to allow cable adjustments l/4 turn increln ments.
CABLEADJUSTER LOCKPIN AOJUSTING
noo
6-,> /* 1 snenrftc Y
LEVER TILT
COVER ACCESS
K\ffi
I
Cabls Too Short
Cable Too Long
Exact Alignment
ADJUSTER 7 N.m(0.7 kg{.m, 5 tbf.ft) 3. Shift to E position. then removethe lock pin from the cableadjuster.
lf not perfectlyaligned, loosenthe locknut on the shittcable.and adjustas required. Tightenthe locknut. 7 . Installthe lock pin on the adjuster.lf you feel the lock pin bindingas you reinstallit, the cable is still out of adjustment and must be readjusted. M a k e s u r e t h e l o c k p i n i s s e a t e ds e c u r e l y n t h e i R a d j u s t e r . e p l a c eh e l o c k p i n i f i t d o e s n o t s n a p t over the cableadjuster securely.
a
Move the shift leverto eachgear,and verifythat the A/T gear position indicator follows the A"/Tgear position switch.
1 0 . S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l gears.lf any gear does not work properly,refer to troubleshooting page 14-'153 14-156. on thru ' l1 . Insertthe ignition key into the key cylinderon the upper column cover, and verify that the shift lock teverreteases.
14-2 7 2
Replacement
SRScomponents located this area.Review SRS are in the precautions, procedures the component locations, and in SRSsection{24}before performing repairsor service. 1. Removethe instrumentpanel lower cover and the columncovers(seesection17). Shift to E position, then removethe lock pin from the cableadiuster.
CONTROLPIN CABLEADJUSTER LOCKPIN SHIFTCABLE
Remove shift cablecover. the Remove shiftcable. the 4WD: Remove the snap pin and control pin,then separate the shiftcablefrom the controllever.
2.
LOCKNUT 29 N.m {3.0 kgl.m, 2j2lbf.trl
ADJUSTING SHIFTCABLE ROO BRACKET
SHIFT
COVER
t r 1.25 mm 22 N.n 12.2 *glrn. 16tbf.trl
L o o s e nt h e l o c k n u t , h e n r e m o v et h e s h i f t c a b l e t from the shift cablebracket. R e m o v et h e n u t s e c u r i n gt h e s h i f t c a b l e h o l d e r , then removethe shiftcable.
2WDi Removethe control lever, then separatethe shift cablefrom the controlshaft.
SHIFT CABI-E
CONTROL SHAFT
STUO BOLT
8 x 1.25mm 22 N.m 12.2 kgl-m, 16 tbf.frl SHIFTCABLE COVER LOCKWASHER 6x LOmm 14 N.m {1.4kgf.m,
6x1.0mm 12 N.m {1.2 kgf.m, 8.7tbtfrl
10 tbt.lrl
(cont'd)
14-273
Shift Gable
7. Removethe nuts securingthe shift cable holder, then removethe shiftcable.
GROMMET
STUDBOLT
SHIFTCABLE
f-'
6x 1.0mm 12 N.m 11.2 kgtm, 8.7 tbf.ftl
I n s t a l lt h e s h i f t c a b l e l n t h e removat. NOTE: . Do not bent the shift cable excessivelywhen installing it. . Make sure the lock pin is seatedsecurelyin the cableadjuster. . Replace lock pin if it does not snap over the the cableadjustersecurely. Check cableadjustment the afterinstalling it.
14-274
Differential
Rear Differential S p e c i aT o o l s . . . . . . . . . . l ...........15-2 Description R e a rD i f f e r e n t i a . . . . . . . . . . . . . . . . . . . . . . . . 1.5.-.4. . . l . . . Hydraulic low ............ F , . .1 5 - 6 Real-time4WD-DualPump System T r o u b | e s h o o t i n . . . . . . . . . . . . . . . . . . . . . . . . 1.5.-.1.0 . 9 . . . . RearDifferentialAssembly T r o u b l e s h o o t i n . . . . . . . . . . . . . . . . . . . . . . . . 1.5.-.1.3 . g . . . . Maintenance D i f f e r e n t i a l l u i d. . . . . . . . . . . F . 15-14 Rear DifferentialAssembly l l l u s t r a t e dn d e x . . . . . . . . . . I .. 15-15 Removal/lnstallation ....15-16 DifferentialCarrierAssembly L e a kR e p a i r . . . . . . . . . . . . . . . 1.5.-.1 8 . . OilSeals R e p l a c e m e n.t. . , . . . . . . . . . . . . . . . . . . . . . . . . . . 5.-.1.9. . . 1. . . RearDifferentialAssembly Disassembly . . . . . . . . . . , . . . . . 5.-,2 0 1. Reassembly . . . . . . . . . . . . . . .1.5.-.2 3 . .
Tools Special
Ret. No.
Tool Number J - 38592 07GAD- PH7020'1 07JAB- 0010204 OTRA_TB40lOB B 07749 0010000 07965 6920101
Oescription Transfer CaseOil Seallnstaller SealDriver Holder andle H Flange older H Driver Hub Dis/Assembly Tool
otv
1 1 1 1 1 1
PageRelernce
o
@ aa @
/il tol
15-20 15-19
tc-zt, z9
15-21,25 15-19 15-19
6\
15-2
15-3
Description
RearDifferential
Outline mechanism the rear differential in Pump Systemmodel has a hydraulic clutchand a differential The Real-time 4WD-Dual on depending to the drivingforce assembly. Under normalconditions, vehicleis driven by the front wheels.However, the drivingforce to the rear wheels of the front wheels and the road conditions. the systeminstantlytransmitsappropriate The switchingmechawithout requiring the driverto switchbetween2WD (trontwheel drive)and 4WD(fourwheel drive). nism between 2WD and 4WDis integrated into the reardifferential assembly makethe systemlight and compact. to forcewhen brakingin a forwardgear.This allowsthe ln addition, the dual-pump systemswitches the rear-wheel-drive off with an Anti-lock Braking System(ABS). brakingsystemto work properlyon modelsequipped Construction carrier The rear differential case assemblyand the rear differential assemblyconsistsof the torque control differential assembly.The torque control differentialcase assemblyconsistsof the differentialclutch assembly,the companion mechanism. The consists the differential of flange,and the oil pump body assembly. The reardifferential carrierassembly differential drive and drivengearsare hypoidgears. and the The oil pump body assembly controlmechanism, consists the front oil pump, the rear oil pump,the hydraulic of providesthe differential with a preset clutch piston.The clutch piston has a disc spring that constantly clutchassembly torqueto Drevent abnormalsound. The clutchguide in the differential clutchassemblyis connected the propellershaft via the companionflange,and it to receives drivingforce lrom the transferassembly. The clutchguide rotates the clutchplate and the front oil pump in the the oil pump body. The clutchhub in the differential clutchassemblyhas a clutchdisc that is splinedwith the hypoid drive pinion gear.The hypoiddrivegear drivesthe rearoil pump. pumps.The rearoil pump capacity 2.5 percentlargerthat the front oil pump is The front and rearoil pumpsare trochoidal to handlethe rotationdifference betweenthe front and rear wheelscausedby worn front tires and tight corner braking. when the oil pumps rotatein reverse. Genuine The oil pumps are designed the fluid intakeworks as a fluid discharge so HondaCVTfluid is usedinstead differential of fluid. Operation Whenthere is a difference rotationspeedbetween front wheels(clutchguide)and rearwheels(hypoiddrivengear), in the hydraulicpressure clutch,and drive force from the transler from the front and rear oil pumps engagesthe differential assembly appliedto the rearwheels. is 4WD mode when the vehicleis startedabruptly, The hydraulicpressure controlmechanism the oil pump body selects in or when accelerating a forward or reversegear (causingrotationdifference in betweenthe front and rear wheels).or gear {whendecelerating). switches 2WD modewhen the vehicleis drivenat a constant when brakingin reverse lt to speed gear (whenthere is no rotationdifference in forwar! or reverse betweenthe front and rearwheels), when brakingin a or fo rward gear (whendecelerating). generated the oil pumps in by To protectthe system,the differential clutchassemblyis lubricated hydraulicpressure by pressure the clutchpistonand cancels on 4WD both 4WDand 2WD modes.Also,the thermalswitchrelieves hydraulic the mode if the temDerature the differential of fluid risesabovenormal.
REARDIFFERENTIAL ASSEMBLY
OIFFERENTIAL TOROUE CONTROL OIFFERENTIAL CARRIER OILPUMPBODY OIFFERENTIAL CLUTCH ASSEMBLY HYPOID DRIVE PINIONGEAR DIFFERENTIAL GUIDE CLUTCH HYPOID RINGGEAR
COMPANION FLANG HUB CLUTCH REAROIL PUMP CLUTCH PLATE FRONT OIL PUMP HOUSING DIFFERENTIAICLUTCH DISC
HYDRAULIC CONTROL SYSTEM

DISCSPRING CLUTCHPISTON
FRONT OIL PUMP REAROII- PUMP
DIFFEREMT|AL CLUTCH ASSEMBI-Y THERMAL SWITCH RELIEF VALVE OIL STRAINER
15-5
Description
HydraulicFlow
Forward Start and Accelerationl4WD) Duringa forwardstartand forwardacceleration, dual pump systemcan engagefour wheeldrive. the lf the front wheelsspin fasterthan the rearwheels,the front oil pump spinsfasterthan the rearoil pump.The front pump draws fluid through checkvalve B and discharges Some of the discharged it. fluid is drawn in the by the rear oil pump. The remaining fluid will passthroughcheckvalve E into the clutchpiston.There,hydraulic pressure regulated two is by orifices. The regulated pressure the clutchpistonpushes hydraulic at the platesand discsof the clutchtogetherto form a connection. The engaged clutchthen passes drivingforcefrom the transferassembly the rearwheels,producing to 4WD.
oRrFtcEs
FRONT OIL PUMP
REAR PUMP OIL
Forward Driving at Constant Speed lzWD) When drivingforwardat a constant speed(cruising), dual pump systemfunctions two wheeldrive mode. the in The rotationspeedof the front and rearwheelsis the same,so the speedof the front and rearpumps is alsothe same. Fluid discharged the front oil pump is drawn in by the rear oil pump and is circulated by through the system.Because there is no pressure built up at the clutchpiston,the clutchdoes not engage, and the vehicleremainsin 2WD (frontwheel drive).
FRONT OIL PUMP
15-6
Forward Decelerationl2WDl in the Duringforwarddeceleration, dual pump systemfunctions two wheeldrive mode. the the Because brakingcharacteristics, speedof the rearwheels may exceed speedol the front wheelsduring decelerof ation.lf so, the rearoil pump spinsfasterthan the front oil pump. de e F l u i dd i s c h a r g eb y t h e r e a ro i l p u m p i s s i m p l yd r a w n i n a g a i nb y t h e r e a rp u m p a n d r e c i r c u l a t e B . c a u s t h e r ei s n o d pressurebuilt up at the clutch piston.the clutch piston does not engage,and the vehicleremainsin 2WD (front wheel drive).
REAR PUMP OIL
ReverseStart and Acceleration(4WD) four wheeldrive. acceleration, dual pump systemcan engage the Duringreverse startand reverse lf the front wheelsspin fasterthan the rear wheels,the front oil pump spinsfasterthan the rear oil pump. The front oil pump drawsin fluid throughcheckvalveA and discharges {Notethat in reverse, direction the pumps is the oppoit. the of site of that duringforwarddriving.) Some of the fluid that is discharged the front oil pump is drawn in by the rear oil pump. The remainingfluid passes by by throughcheckvalveF into the cylinderof the clutchpiston,where it is regulated two orifices. pressure the clutchpistonmay forcethe platesand discsof the clutchtogetherto form a conat hydraulic The regulated to drivingforcefrom the transferassembly the rearwheels,producing4WD. The engaged clutchpasses nectlon.
oRtFtcEs
FRONT OIL PUMP
{cont'd)
15-7
Description
ReverseDriving at Constant Speed l2WD) when driving in reverse a constant at speed, dual pump systemfunctions two wheeldrive mode. the in The rotationspeedof the front and rearwheelsis the same,so the speedof the front and rearpumps is alsothe same, Fluiddischarged the front oil pump is drawn in by the rearoil pump and is circulated by throughthe system.But,because the there is a difference the capacity in betweenthe two pumps,fluid flows through checkvalve E, and then through oriIices.This fluid lubricates and coolsthe clutchassembly and bearings. ls this condition, only a low pressure built up at the clutchpiston.Therefore clutchdoes not engage, is the and the vehicle remainsin 2WD (frontwheeldrive).
ReverseDecelerationl/tWDl Duringreverse deceleration, dual pump systemcan engagefour wheeldrive. the When decelerating reversedirection, in the speedof the rear wheels may exceedthe speedof the front wheels (due to enginebraking). this condition, In the rearoil pump drawsfluid throughcheckvalvesB and C. Fluid discharged from the rearoil pump then flows throughcheckvalveE to the clutchpiston.There,pressure regulated two orifices. is by The regulated hydraulicpressure the clutchpiston may forcethe platesand discsof the clutchtogetherto form a con, at nection. The engaged clutchpasses drivingforcefrom the transferassembly the rearwheels,producing to 4WD.
oRtFtcEs
REAROIL PUMP
Thermal Switch Operation l2WD) pressure-regulated is in contactwith the clutchpistonand the thermalswitch. fluid During4WDoperation, goes too high, the thermalswitch pushesopen the reliefvalve R. This of lf the temperature the fluid in the differential in causes pressure the clutchpistonto drop, and 4WD mode is disengaged. the
THERMAL SWITCH
RELIEFVALVE
RelietValve Operation appliedat the clutch goes higherthan the reliefvalvespringforce,checkvalve R opens.Pressure When the fluid pressure excessive the pistonis held constant. This featureadds stabilityby preventing rearwheeldrive systemfrom experiencing to rque.
RELIEFVALVE
15-9
Real-time 4WD-Dual PumpSystem

(Automatic Troubleshooting Transmissionl
When starting and accelerating in forward gesrs {4WD model 1. L i f t u p t h e v e h i c l es o a l l f o u r w h e e l sa r e o f f t h e ground (seesection1). When starting and accelerating in revGrsggear {4WD model 1. L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e ground (seesection1).
2.
Makea mark on eitherNo. ' I o r N o . 2 p r o p e l l e r shaft.
Makea mark on eitherNo. 1 or No. 2 propeller shaft.

PROPELLER SHAFT
PROPELLER SHAFT
Startthe engine,and let it run until it warms up (the radiator comeson at leasttwice). fan With the engineat idle.shiftto the E position. A p p l y t h e p a r k i n gb r a k ef i r m l y . a n d m e a s u r e h e t time it takesthe propeller shaftto rotate10 times. . lf the measuredtime is more than 10 seconds, the 4WDsystemis normal. . l f t h e t i m e i s l e s st h a n 1 0 s e c o n d s t h e r e i s a , problem in 4WD system. Checkthe differential f l u i d . l f t h e d i f f e r e n t i af l u i d i s n o r m a l ,r e p l a c e the torquecontroldifferential casekit.
Startthe engine.and let it run until it warms up (the radiator comeson at leasttwicei. fan With the engineat idle,shift to the E position. A p p l y t h e p a r k i n gb r a k ef i r m l y , a n d m e a s u r e h e t time it takesthe proDeller shaftto rotate10times, . lf the measuredtime is more than 10 seconds, the 4WDsystemjs normal. . l f t h e t i m e i s l e s st h a n 1 0 s e c o n d s t h e r e i s a , problem in 4WD system. Checkthe differential fluid. lf the differentialfluid is normal, reolace the torquecontroldifferential casekit.
15-10
(Manual Transmissionl Troubleshooting

When starting and acceleratingin forward gears (4WD mode) 1. L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e ground{seesection1) in When starting and accelerating reversegear (4WD model 1. L i f t u p t h e v e h i c l es o a l l f o u r w h e e l s a r e o f f t h e ground (seesection1).
2.
Startthe engine,and let it run until it warms up (the fan radiator comeson at leasttwlce). W i t h t h e e n g i n ea t i d l e , s h i f t i n t o 1 s t g e a r a n d the release clutch. Applythe parkingbrakefirmlY . . the lf the enginestalls, 4WDsystemis normal. lf the enginecontinuesrunning,there is a probfluid. lf the Check differential lem in 4WDsystem. the fluid is normal,replace torque the differential casekit. controlditferential 3.
Startthe engine,and let it run until it warms up (the fan radiator comeson at leasttwice) With the engine at idle, shift into reversegear and the release clutch. Apply the parkingbrakefirmlY . . the lf the enginestalls, 4WDsystemis normal. lf the enginecontinuesrunning,there is a probfluid lf the Check differential lem in 4WD system. the fluid is normal,replace torque the differential casekit. controldifferential
3.
Real-time 4WD-Dual PumpSystem

(Automatic Troubleshooting Transmission/Manual Transmission)
Whon d6c6l6ratingin a torward gear {2WD mode} 1. Blockthe front wheels,raisethe left rearwheel.and supportit with a safetystandas shown. When deceleratingin reversegear (4WD mod) 1. Blockthe front wheels.raisethe left rearwheel,and suppo( it with a safetystandas shown.
WHEELCHOCKS
WHEELCHOCKS
Hold the tire and turn it counterclockwise continuouslvfor more than one rotation.
Hold the tire and turn it clockwise continuouslv for more than one rotation.
lf the rotation of the wheel does not gradually feel heavywhile rotating, the 2WD systemwhen decelerating a forwardgear is normal. in lf the rotationof the wheelgradually feelsheavy, there is a problem in the system.Checkthe differentialfluid, lf the fluid is normal,reDlace the torouecontroldifferential casekit.
lf the rotation of the wheel gradually feels heaw. the 4WD systemwhen decelerating reversegear in is normal, lf the rotation the wheeldoes not gradually of feel heavy,there is a problem in the system.Check t h e d i f f e r e n t i afl l u i d . l f t h e f l u i d i s n o r m a l . reolace torquecontroldifferential the casekit,
15-12
AssemblY RearDifferential
Troubleshooting
from the gearsor bear'ngs' noises by Most problemsin the unit are to be diagnosed identifying components' noiseswith thosefrom otherdrivetra'n not duringdiagnosis to confusedifferential care shouldbe taken Symptom Will not go into 4WD mode Will not returnto 2WD mode Gearor bearingnoises ProbableCause . Fluidleveltoo low . Incorrect fluid type fluid type Incorrect Fluidleveltoo low fluid type Incorrect or Damaged chippedgears . Fluidleveltoo low . Incorrect fluid type Fluidleveltoo high hose breather Clogged oil Worn or damaged seal washer sealing Damaged Loosemountingboltsor inadequatesealing
. Add fluid . Replace
Remedy
Drainand fill the differential

Add fluid Drain and fill the differential Replacethe differential carrier assemory . Add fluid . Drain and fill the differential
Overheating l Fluideak
Lowerto properlevel Cleanor replace Replace Replace sealant torqueor aPPIY Recheck
15-13
Maintenance
DifferentialFluid
!@ section 1). 1. Make sure lifts are placed properly lsee C l e a nt h e d r a i n p l u g , t h e n r e i n s t a l il t w i t h a n e w washer, and refill the differentialwith the recommendedfluid to the properlevel. NOTErlf you disassembly differential, the checkthe fluid levelagain after the 4WD systemcheckis finished.Add fluid if necessary. Reinstall oil filler plug with a new washer. the Fluid Capacity 1.0/ {1.1US $, 0.9 lmp qt) at tluid change 1.2/ {1.3US $, 1.1lmp qt) at oyerhaul Recommended fluid: GenuineHondaCVT Fluid
With the vehicleon levelground,inspect differential f l u i dw i t h e n g i n e F F . O Removethe oil filler plug, then checkthe leveland conditionof the fluid.
2.
Proper Level
o|I FII.IIR PI-UG 4t N.m la.8kgl.m,35 lbl.ftl
T h e f l u i d l e v e lm u s t b e u p r o t h e f i l l h o l e .l f i t i s below the hole, add the recommended fluid until it runs out, then reinstall oil filler plug with a new the wasner. 4. l f t h e d i f f e r e n t i atll u i d i s d i r t y , r e m o v et h e d r a i n p l u g ,a n d d r a i nt h e f l u i d .
DMIN PLUG a7 N.m 14.8 kgl.m, 35 lbt.ftl
1 5 -1 4
RearDifferentialAssembly
lllustratedIndex
6xl.0m 12 N.m (1.2 kgf m,8.7 lbt'ftl DOWELPINS FLANGE COMPANION O.RING Replace. RING BACK-UP LOCKNUT, mm 24 Replace. 118N.m (12.0 kgtm. 87 rbt ft) OIL SEAL Replace.
6x1.0mm kgt'm,8.7 lbf'ft| 12 N.m 11.2
PRESSURE PLATE
HUB/PLATES/DISCS CLUTCH CLUTCH DIFFERENNAL ASSEMBLY
OIL PUMPDRIVESHAFT
""t",at\(
THBUST NEEDLE AEARING
'd'
GUIDE CLUTCH
OILPUMP PIN
e
MAGNET OIL STRAINER
15-15
RearDifferential Assembly
Make sure tifts are ptaced property lsee l!!@ section 11. 1. 2. Drainthe differential flujd (seepage 15-14). Mark the propellershaft and companionflange of the rear differential assemblyso they can be reinstalledin theiroriginalpositions.
PROPELLER SHAFT COMPA'{IONFLANGE
5,
jack underthe rear differential Placea transmission assembly, then removethe right mountingbracket B andthe left mountingbracket 8.
12 POtt'lT BOLI 8 x 1.25mm 32 N.m 13.3tgf.m. 2a lbtft,
Mark
Removethe breathertube from the breathertube fitting. BREATHER TUBEflTNNG
Remove propeller the shaftfrom the reardifferential assemory. Remove reardifferential the damper.
12x 1.25mm 5,1N.m 15,5kgf.m, iO tbf.fO
15-16
7.
Insertthe edge of the screwdriverinto the groove housing Pry out the locatedunder the differential with a screwdraver. inboardioint driveshaft oil NOTE:Take care not to damagethe differential ring when prying out the differsealand differential entialinboardjoint.
10. Remove the rear difterentialmounting bracketA assembly. from the reardifferential
12 x 1.25 fifi
N.m {7.0 lgf.m. 5l lbl.tt) REARDIFFERENTIAL A MOUNTINGBRACKET
DIFFERENTIAL
REANDFFERENTI,AL ASSEMBLY
assemblyin the reverse 1 1 .Installthe rear differential orderof removal. Notetheseitemsduringreassembly tube joint . lnstallthe breather tube to the breather properly. align the . Duringthe propellershaft installation, p r o p e l l e rs h a f t a n d c o m p a n i o n m a r k so n t h e flange. with the recommended . Reiillthe rear differential fluidto the properlevel{seepage15-14).
8.
Remove the mountingboltsand the washers.
DRIVESHAFT
BOLTS MOUNTING '10 1.25mm x ,19N'm (5 0 kgf m, 36 lbtftl Lower the rear differentialassemblyon the transfrom missionjack,then removethe reardriveshafts assembly. the rear difterential
15-17
Differential CarrierAssembly
LeakRepair
'1. Remove t h e b o l t s i n a c r i s s c r o s so a t t e r n .t h e n removethe differential housing.
I x 1.25mm 22 N.m 12.2 kgl.m, 16 tbtftl
Install the differential housing. then torquethe bolts in a crisscross patternin several steps. ( I n s t a ltlh e o i l s e a l s s e ep a g e1 5 - 1 9 ) .
DIFFERENTIAL HOUSING
2.
Apply liquid gasketto the sealingsurfaceof the ditferentialhousing, and notetheseitems: . Use liquidgasket(P/N08718 000'1). . R e m o v ea n y d i r t o r f l u i d f r o m t h e s e a l i n gs u r lace. . lf 20 minutes have passedafter applying liquid gasket, reapplyit beforeyou assemble housthe ings. Allow it to cure at least 30 minutes after assembly beforefilling differential with ftuid.
DIFFERENTIAL HOUSING
15-18
Oil Seals
Replacement
1. housing. Remove oil sealsfrom the differential the 2. Installthe oil sealssquarelyusingthe specialtools. Be carelulnot to damagethe lip ol the oil seals. depth of the oil seal is 9 mm Rightside:Installation (0.35in) belowthe edgeof the differential housing.
Right side:
OILSEAL
TOOL HUB DIS/ASSEMBLY 07965- 6920101 OIL SEAL
Left side:
Left side: Installthe oil seal flush with the edge of carrierassembly. the differential
OIL SEAL
(cont'd)
15-19
Oil Seals
3. Removethe oil seal from the toroue control differentialcase.
Disassembly
1. Remove breather the tube,the drain plug and the oil f i l l e rp l u g .
BREATHER TUBE
OIL FILI.IRPLUG
DRAIT{PLUG
Install the oil sealsquarelyusingthe special tool. carefulnot to damagethe lip of the oil seal. Raisethe locknuttab from the groove of the clutch guide, making sure that the tab completelvclears the grooveto preventdamaging clutchguide. the
L(rcKNUT, mm 24 Replace.
15-20
3.
flange, Installthespeclaltools the companion on

HOIIIER HANDTI o'JAB - OO102nA
7.
t R e m o v et h e l o c k n u t , h e d i s c s p r i n gw a s h e r ,t h e flange. ring,the O-ringand the companion back-up

LOCKNUT, mm 24 Feplace. DISCSPRING WASHER, mm 24 BACX.UP RING O.N|NG Replace.
ao/
@r/ v-.,.
rA*..-
h\@fr\
8 x 1.25mm
zzft
COMPANION FLANGE
32 N m {33 tgt m,24lbf ftl so Loosenthe locknutcounterclockwise that its tab comesout from the groovein the clutchguide.
24 LOCKNUT, mm
8.
caseand the Remove the torque controldifferential dowel pins.
5. 6.
till Tightenthe locknut its tab alignswith the groove. Removeany dirt from inside of the groove in the the clutchguide, then loosen locknut.
LOCKNUT. mm 2,1
Tab
(cont'd)
Rear DifferentialAssembly
q t 9 . R e m o v eh e s h i ma n dt h e c l u t c h u i d e . b a t 1 1 . R e m o v eh e t h r u s tn e e d l e e a r i n g n d t h e o i l p u m p driveshaft.
d"HIM'30mm
CLUTCH GUIDE
and 1 0 . Remove clutchhub/plates/discs the pressure the prare.
the 1 2 . Removethe oil pump body assembly, oil pump pin,the magnet, and the oil strainer.
OIL PUMPBODYASSEMBLY CLUTCH HUB/PLATES/OISCS
ffi
-:*
_zz
PRESSURE PLArE
MAGNET
@OIL STRAINER Inspect damage for or clogging.
OIL PUMPPIN
15-22
Reassembly
1. Apply CVTfluid to the rubberof the oil strainer, then installthe oil strainer, magnet,and the oil pump the pin to the differential carrier.
3. Tightenthe oil pump body assemblymounting bolts. I n s t a l lt h e o i l p u m p d r i v e s h a f tb y a l i g n i n g t h e p r o jection of the oil pump driveshaftwith the groove of the front oil pump in the oil pump body assembly.
4.
MAGNET THRUSTNEEDLE BEABING
-n
CWfluid DIFFERE]TTIAL CARRIER ASSEMBLY
OIL PUMPPIN
lnstallin thisdirection. Projection 6x1.0mm 12 N.m 11.2 kg{.m,8.7 lbl.ft}
2.
Alignthe oil pump pin with the grooveof the rearoil pump in the pump body assembly, then install oil the pump body assembly the differential to carrier assemoty.
OIL PUMP BODYASSEMBLY
5.
Install thrust needlebearing. the Installthe pressureplate assemblyby aligningthe projectionof the pressure plate with the groove of the oil pump driveshaft.
PRESSURE PLATE
OILPUMP DRIVESHAFT
(cont'd )
15-23
(cont'dl Reassembly
7. then Install clutchhub/plates/discs, alignthe prothe jectionof the plates with the discs. 10. lnstallthe dowel pins and toroue controldifferential case.
TOROUE CONTNOL 6x1.0mm 12 N.m 11.2 m,8.7lbt.ftl tgf
sHl 30 mm M, ,/
.A-\,/r \-7
CLUTCH GUIDE
CLUTCH HUA/PLATES/
Dtscs
8. 9.
g I n s t a l l t h e l u t c h u i d ea n dt h e 3 0 m m s h i m . c A p p l y l i q u i d g a s k e tt o t h e s e a l i n gs u r f a c eo f t h e t o r q u e c o n t r o l d i f f e r e n t i a l a s e ,a n d n o t e t h e s e c rlems: . Use liquidgasket(P/N08718 0001). . Removeany dirt or fluid from the sealing surface. . lf 20 minutes have passedafter applying liquid gasket, reapplyit beforeyou assemble housthe ings. Allow it to cure at least 30 minutes after assembly beforefilling differential with fluid.
TOBOUE CONTROL DIFFERENNAL
11. Installthe companionflange,O-ring,back-upring, and the locknut. discspringwasher, NOTE:Apply CW fluid to the O-ring.
,24mm DISCSPRING WASHER, 2a mm
@+-_alcr-upnwc
lnstallin this direction.
K@#/
FLAI{GE COMPANION
/r-
---
Apply liquidgaskot
15-24
1 2 . I n s t a lt h e s p e c i at o o l st o t h e c o m p a n i o n l a n g e , l l f then tightenthe locknut specified to torque. TOROUE: N.m (12.0kgf-m,87lbf'ft) 118
14. lnstallthe breather tube.
BREATHER TUAE
HOLDEB HANDLE 07JAB- @1020A OIL FILI..ER PLUG 47 N.m 14.8kgf.m, 35 tbt frl
WASHENS Replace.
DRAIN PLUG 4? N'm l4.E tgf.m, 35 lbf'ftl I x I .25 mm 32 N'm (3.3kgt m, 24 lbtftl
t5.
Stakethe locknuttab into the groove in the clutch guide.
Installthedrain plug and the oilfiller plug with wasners.
Driveshafts
Special Tools.......... ........... 16-2 Driveshafts Inspection ...................... l6-3 FrontDriveshafts Removal ....16-3 Disassembly ................... 16-5 Reassembly .................... 16-g Installation ..................... 16-17 Intermediate Shaft Removal ....16-19 Disassembly ................... 16-19 Reassembly .................... 16-20 Installation ..................... 16-21 RearDriveshafts Removal .... 16-22 Disassembfy ................... 16-22 Reassembfy .................... 16-24 Installation ..................... 16-29 Propeller Shaft Inspection . 16-29 RemovaUlnstallation ....16-30
Rf. No.
Tool Number 07JAF- SH20400 07LAD- PW50601 07MAC- S100200 07746 0010300 07746 0010400 07746 0030400 07749 0010000 07965 SD90100 07xAc - 0010200
Dscription Attach ment Attachment,40 50 mm LD. x B a l lJ o i n tR e m o v e r , 2 m m 8 Attachment, x 47 mm 42 Attachment, x 55 mm 52 Attachment, mm l.D. 35 Driver Suppon Base T h r e a d e d d a p t e r , 2 4 1 . 5m m A x
Otv 1 'l 1 1 1 1 ,l 'I 1
PageRolsrenca 16-16 16-18 16-4 16-16 1 6 - 1 71 8 , 16-17 1 7 ,1 8 16-16 16-7
o
@
\D'
o
@ @
arl
!.,
o)
16-2
Driveshafts
Inspection
Boot Damago Check the boots on the driveshaft for cracks, damago, leakinggrease,and loose boot bands.lf any damagsis found, replacethe boot and boot bands. Looso Splines Turn the driveshaftby hand,and make sure th splins and joint are not excessively loose.lf damageis found, replace inboardjoint. the Twisting or Crscking Make sure the driveshaftis not twisted or crackod. Replaceit if necessary.
DRIVESHAFT
Front Driveshafts
Removal
1 . Loosen wheel nutsslightly. the Raisethe front of the vehicle,and suppon it with (seesection1). safetystandsin the properlocations
?
Remove wheel nuts and front wheels. the
SPINDLE NUT 24 x 1.5mm Replace.
FRONT WHEEL
lf the right driveshaftis to be removed, drain the transmission fluid {seesction13or 14).lt is not necessaryto drain the transmission fluid when the left driveshaftis removed. Lift up locking tab on the spindle nut, then remove the nut, 6. Remove self-locking and flangebolt, the nut
FLANGEBOLT 10 x 1.25mm
SELF"LOCKING NUT 12 x 1.25mm Replace. 7. Remove the damper fork,
(cont'd)
16-3
Front Driveshafts
Removal (cont'd)
the cotterpin from the lower arm ball ioint Remove castlenut, and removethe nut. 12. Pull on the inboardjoint, and removethe driveshaft from the differential case or bearingsupportas an assembly. not pull on the driveshaft, inboard Do the joint may come apart. Pull the driveshaftstraight out to avoid damagingthe differential sealor the oil intermediate shaftouter seal.
07MAC SLm2m Installa 12 mm hex nut on the ball joint. Makesure the hex nut is flush with the balljoint pin end,or the threadedsectionof the ball joint pin might be damaged by the special tool. '18 i0. Usethe special tool as shown in section to separate the ball joint and lower arm, Be caretulnot to apply pendamagethe ball joint boot, lf necessary, to etratingtype lubricant loosenthe ball joint, 1 l . Pry out the driveshaftassemblywith a pry bar, as shown, to force the set ring at the driveshaftend past the groove. Be careful not to damagethe oil sealswhen prying.
PRY BAR
Left driveshaft: from the bearingsuppon Remove the left driveshaft by tapping on the inboard joint of the driveshaft with a olastichammer.
BEARING SUPPORT
16-4
Disassembly
13, Pullthe knuckle outward,and removethe driveshaft inboard joint from the differentialcase or bearing suoDort. InboardJoint Sid: 1, Carefullyclamp the driveshaftin a vise with soft jaws, then remove the set ring from the inboard joint. Removethe boot bands.Take care not to damage the boot, . lf the boot band is a lockingtab type, pry up the lockingtabs with a screwdriver, and lift up the end of the band. . l f t h e b o o t b a n di s a w e l d e dt y p e o r a l o w p r o f i l e type, carefullycut the boot band with a pair of diagonal cutters. . lf the boot band is a double loop type. lift up the band bend.
KNUCKLE 2.
Locking Tab
DRIVESHAFT
1 4 . Remove driveshaft the outboardjoint from the front wheel hub usinga plastichammer.
PLASTIC HAMMER
SET BING Replace. Welded
DRIVESHAFT
{cont'd)
16-5
Front Driveshafts
Double Loop 4, Mark the rollersand spiderto identifythe locstions of the rollerson the sDider, then removethe rollers. BEARING REMOVER (Commercially available)
DRIVESHAFT DRIVESHAFT
Mark
Remove circlip, the Mark the spider and driveshaft to identify the position ofthe spideron the shaft. 7. Mark each roller and inboard joint to identify the locationsof the rollersand groovesin the inboard joint. Thon remove the inboard ioint on the shop towel. Be careful not to drop the rollers when sepajoint. ratingthem from the inboard Remove spiderusinga bearingremover, the Wrap the splines on the driveshaftwith vinyl tape to preventdamageto the bootsand dynsmicdamper,
INBOARD BOOT INBOARD JOINT Check splines wearor damage. for Checkinside bore for wear. Inspectfor cracks.
DRIVESHAFT
DYNAMICDAMPER
Rsmove the inboard boot and dvnamic d a m p e r . Take care not to damage the boot and d y n a m i c damDer.
16-6
Outboard Joint Side: 1. L i f t u p t h e t h r e e t a b s w i t h a s c r e w d r i v e r ,t h e n remove the boot bands,Take care not to damage the boot. NOTE: . lf the boot band is a double loop type, lift up the bandbend. . lf the boot band is a welded type, cut the boot band. . l f t h e b o o t b a n di s a l o c k i n g t a b s t y p e .r y u p t h e p tabswith a screwdriver, and lift up the end of the oano. EarClamp
TAB PAINTMARK
DRIVESHAFT
5,
Carefullv clamDthe driveshaft a vise. in

THREADED AOAPTER,2iI 1.5 mm x 07xAc - 0010200
EAR CLAMP BAND Replace.
Slidehammc..5/8'x lS Throad (Commerically, available)

o.
2.
Slidethe outboardboot to the inboardioint side.
Removethe outboardjoint using a specialtool as shown. Remove driveshatt the trom the vise Remove stop ring from the driveshaft. the
7. 8.
DRIVESHAFT
Wipe off the greaseto exposethe driveshaftand the outboardjoint innerrace. Markthe driveshaft the same positionof the outat boardjoint end with paint.
STOPRING Replace.
Front Driveshafts
Reassembly
Notetheseitemsduringreassembly . Cleanthe disassembled parts with solvent,and dry them thoroughlywith compressed air. Do not wash the rubber partswith solvent. o *4@] . :Thoroughlypackthe inboardand outboardjoints and both joint bootswith the joint greaseincludedin the new driveshaft set. The'98 Canada model andall '99 - 00 modelsusea TPE(Thermoplastic Polyester lastomer) E outboardjoint boot. Usethe ear clamptype boot band in the outboardboot set.
Greasequantity: Inboard Joint: All models 120- 130 g (i1.2 4.6 oz) Left inboard joint splines (Al: 0.5 - 1.0 g (0.018- 0.035oz) Outboard Joint: '97 model and'98 USA model 130- 140 g (4.6-,1.9 oz) '98 Canadamodel and all '99 - 0Omodels 140150 g 14.9 5.3 oz)
SETRING Replace. LEFTINBOARO JOINT (Al SPLINES: INBOARO JOINT
SPIOER
BOOT INBOARD
-6r
P a c kc a v i t y w i t h g r e a s e .
wtn grease. BANDS DYNAMICDAMPER
STOPRING Replace.
OUTBOARD BOOTITPE)*I
-611
-/
DOUELE
Replace.
BAND+'
Pack cavity with grease. EARCLAMPBAND*1
Replace.
__G1
P a c k c a v i t y wrtn grease.
OUTBOARD BOOT*' (RUBBERI
-Grj
Pack cavity wtrn grease.
*l: '98 Canada models,all '99-00models *2: '97- 98 models(except'98 Canada model)
16-8
Inboard Joint Side: 1. Wrap the splineswith vinyl tape to preventdamage to the boot and dynamicdamper.
5.
Fit the rollers the spider. to NOTE: . Reinstall rollersto their originalpositionson the the spiderby aligningthe marks. . Hold the driveshaft pointed up to prevent the rollersfrom fallingoff.
DRIVESHAFT
,..',NYL rAPE
uu.oa.Dsoo. V6
,",^_Y,C@
I n s t a l lt h e i n b o a r d b o o t t o t h e d r i v e s h a f t , h e n t removethe vinyl tape.Takecare not to damagethe boot. Installthe spideronto the driveshaft aligningthe by markon the spiderand the end of the driveshaft. Pack the inboardjoint with the joint greaseincluded in the new driveshaft set, Greasequantity: 120- 130 g {4.2- 4.6 oz) Left inboad ioint splines@:0.5 - 1.0 g (0.018 0.m5 ozl
@+-crncr-rr
4.
F i t t h e c i r c l i p i n t o the driveshaft groove. Always rotatethe circlipin its grooveto makesure it is fully seated.
(cont'd)
16-9
Front Driveshafts
Reassembly {cont'd)
7. Fit the inboard joint onto the driveshaft,and note theseitems: Reinstall inboardjoint onto the driveshaft the by aligningths markson the inboardjoint with the markson the rollers. Holdthe driveshaft the inboardjoint pointsup so to prevent it from falling off. Left: 508 - 513 mm 120 2O.2inl
Right: AT model 520 - 525 mm {20.5- 20.7 in) MT mod6l 515 - 520 mm (20.3- 20.5 inl
/\
/,?:..{
t
\
9.
Sptine airection
-flm+dm@
Positionthe dynamic damper to the specifications as snown. Left:299.5t 2 mm 111.8 O.l inl r Right:299.5t 2 mm 111.810.1 inl
lffi l t Y
:\
ROLLER HOLDER
Adjustthe lengthof the driveshafts the specificato tions shown. then adjustthe boots to halfway Make betweenfull compression and full e)dension. surethe endsof the bootsseat in the groovesof the driveshaft and Ioint.
OUTBOARO JOINT
16-10
10. Set the double loop band onto the boot or dynamic damper with the band end toward the front of the vehicle.
1 3 . Threadthe free end of the band through the nose

sectionof a commercially availableboot band tool ( K D - 3 1 9 1 r e q u i v a l e n t )a n d i n t o t h e s l o t o n t h e o . winding mandrel. '14. Place wrench a on the winding mandrelof the boot b a n d t o o l . a n d t i g h t e nt h e b a n d u n t i l t h e m a r k e d spot on the band meetsthe edgeof the clip.
OOUBLE LOOPBAND
BOOTBANDTOOL (KD-3191 or equivalentl
Markon band.
WINDING MANDREL
11. Pull up the slackin the band by hand. 12. Make a mark on the band 10 - 14 mm (0.4- 0.6 in) from the clip.
CLIP
1 5 . Lift up the boot band tool to bend the free end of the band 90 degreesto the clip, Center-punch the clip,then fold over the remaining onto the clip. tail
HAMMER
(cont'd)
16-1 1
Front Driveshafts
(cont'd) Reassembly
16. Unwind the boot band tool. and cut off the excess free end of the band to leavea 5 - 10 mm (0.2- 0.4 from the clip. in) tail protruding
5 - 1 0m m 10.2 0.4 in,
Outbosrd Joint Sids: 1. Wrap the splineswith vinyl tape to preventdamage to the boot.
OUTBOARDBOOT
VINYLTAPE
1 7 . Bendthe band end by tappingit down with a hammer, NOTE; . Makesurethe band does not move, . Removeany greaseremainingon the surrounding surfaces.
2,
I n s t a l lt h e b o o t b a n d a n d o u t b o a r d b o o t , t h e n removethe vinyl tape.Takecare not to damagethe boot. groove. Install the stop ring into the driveshaft
3.
DRIVESHAFT
18, Install the new set ring.
16 -1 2
4.
into the outboardioint until the lnsertthe driveshaft stop ring is closeon the joint.
6.
Check the alignmentof the paint markwith the outboardjoint end.
DRIVESHAFT
DRIVESHAFT
1. To completelyseat the outboardjoint, pick up the driveshaft and joint. and drop them from about 10 cm (4 to 5 inches) onto a hard surface, not use a Do hammeras excessive force may damagethe driveshaft.
joint with the joint grease Pack outboard included the in the new joint boot set. Greasequantity: Outboard ioini: '97 model and '98 USA model 130- 140 g {,1.6 ,0.9oz} '98 C8n8d8 modsl 8ndall '99- 00 models ll0 - tso g {i1.9 5.3 ozl
DRIVESHAFT
i/,,,t| :l,r;;:,:.'i,,1;'/l
(cont'd)
16-1 3
Front Driveshafts
Reassembly(cont'd)
8. Fit the boot ends onto the driveshaft and outboard lornt.
BOOTfiPE) OUTBOARD
11. Closethe ear portion of the band with a commercially availableboot band pincersKENT-MOORE J-35910 or equivalent.
OUTBOARD BOOT
OUTBOARD BOOT
OUTBOARD JOINT Install the boot bands, . F o r a l l ' 9 7 m o d e l sa n d ' 9 8 USA models, go to step 13. . For'98 Canadamodelsand all '99 - 00 models, go to step 10. 10. Set the ear clamp band by threading tab into the the holesof the band.
BOOTBAND PINCERS KENT.MOORE J-35910 or equivalent EARPORTION
12. Checkthe clearancebetween the closed ear Dortion

of the band, lf the clearance not within the stanis dard,closethe ear portionof the bandfurther.
6.0 mm 10.24 MAX in)
3.0mm {0.12 MAX in}
16 -1 4
13. Fit the boot ends onto the driveshaftand the outboardjoint.
1 5 . Pull up the slackin the band by hand. 1 6 . Mark a positionon the band 10 - 14 mm (0.4- 0.6 in.)from the clip.
CLIP
14. Fit the doublelooDboot bandsonto the boot ends 1 7 . Threadthe free end of the band through the nose availableboot band tool sectionof a commercially ( K D - 3 1 9 1 r e q u i v a l e n t la n d i n t o t h e s l o t o n t h e o , winding mandrel.
BOOTBANDTOOL (Commercially available) or KD-3191 equivalent
Mark spot.
(cont'd)
16-15
Front Driveshafts
(cont'dl Reassembly
1 8 . Placea wrenchon the winding mandrelof the boot b a n d t o o l , a n d t i g h t e nt h e b a n d u n t i l t h e m a r k e d spot on the band meetsthe edgeof the clip. 1 9 . Lift up the boot band tool to bend the free end of the band90" to the clip. Center-punch clip,then the fold over the remaining onto the clip. tail 21, Bendthe bandby tappingit down with a hammer. N O T E :M a k e s u r e t h e b a n d a n d t h e c l i p d o e s n o t i n t e r f e r ew i t h a n y t h i n g ,a n d t h e b a n d d o e s n o t m o v e , R e m o v e n y g r e a s er e m a i n i n g n t h e s u r a o roundingsurfaces.
BAND END
CLIP
20. Unwind the boot band tool. and cut off the excess free end of the bandto leavea 5 - 10 mm (0.2- 0.4 in) tail protruding from the clip.
16-16
Front Driveshafts
lnstallation
1. Install the outboardioint into the knuckle. 4. Cleanthe areaswhere the driveshaftcontactsthe differentialthoroughly with solvent or carburetor a c l e a n e r , n d d r y w i t h c o m p r e s s e d i r . I n s e r tt h e a or into the differential inboardend of the driveshaft s i n t e r m e d i a t e h a f t u n t i l t h e s e t r i n g l o c k si n t h e groove. INBOARD JOINT
KNUCKLE
INBOARD JOINT
Replace.
JOINT OUTBOARD
grease to Apply0.5- 1.0g (0,02 0.04oz)of specified shaft. surfaceof the intermediate the whole sDlined After applyinggrease.removethe greasefrom the groovesat intervals 2 - 3 splines and from of splined the set ring groove so air can bleed from the inboard ioint.
SETRING Replace.
5.
lnstallthe knuckleon the lower arm. Be careful not to damagethe ball joint boot. Wipe off the greasebefore tightening the nut at the ball joint.Torquethe castle then tightenit nut to the lower torque specification. only far enoughto alignthe slot with the pin hole.Do lnstall new cotterpin. a not alignthe nut by loosening.
SET RING
or Installa new set ring onto the driveshaft intermediateshaftgroove.
NUT CASTLE 12 x 1.25mm 49-59Nm (5.0- 6.0 kgl'm, 36 - 4:l lbl.ft)
PIN COTTER Replace. On reassembly, bendthe cotterpin
(cont'd)
16-17
Front Driveshafts
Installation {cont'd}
Installthe damperfork over the driveshaft and onto t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r fork so the aligning tab is alignedwith the slot in the damperfork. FLANGE BOLT 10x 1.25 mm N.m{4.i1kst.n,32 lbf.ftl ALtcNtNG TAB
Intermediate Shaft
Removal
1 . Drainthe transmission or fluid (seesection13 or oil 14). (seepage16-3). Remove left driveshaft the Remove threedowel bolts. the
12x 1.25mm 64 N.m {6.5 kgf.m, 47 lbf.ftl Replace. 7. Loosely install the flange bolts and the new selflocking nut. 8. Apply oil to the seating surface of the new spindle nut. FRONT WHEEL i WHEEL NUT 12 x 1.5mm 108N.m (11.0 kgf.m,80lbf.ftl
Removethe intermediateshaft from the differential. Holdthe intermediate shaft horizontal until it is clearof the differentialtopreventdamageto the differential oil seal.
INTERMEDIATE SHAFT
SPINDLE NUT 24 x 1.5mm 245 N.m {25.0ksf.m, 181 lbf.ft)
NOTE: Atter tightening. a driftto use stake spindle shoulder the nut against driveshaft. the 9. Installa new spindlenut,then tightenthe nut. 10. Cleanthe mating surfaces the brakedisc and the of wheel. then install the front wheel with the wheel nuts, 1'1. Tighten the flange bolts and the new setf-locking nut with the vehicle's weight on the damper. 12. Refillthe transmission with recommended fluid (see section13or 14). 13. Checkthe front wheel alignment. and adjust if necessary(seesection 18).
16-18
Disassembly
NOTE:Be carefulnot to damagethe metal rings on the shaftduringdisassembly. intermediate '1. Remove set ring. the 6. shaft bearingout of the bearthe Press intermediate and a press ing supportusingthe specialtools
ORIVER 07749- 001q)00 RUBBER FLOATING DAMPER Checkfor deterioration ano oamage,
ATTACHMENT, tl2x 17 mm 07745- 0010300
SEAL OUTER RePlace
SET RING Replace.
shatt outer seal from the Removethe intermediate bearingsupport. circlip. the Remove e)dernal 4. shaft out of the shaft bearing Press intermediate the and a press. usingthe specialtools
Press CIRCLIP INTERNAL
ATTACHMENT o?JAF_ SH20it00
SHAFT INTERMEDIATE lor Check damage. 5. Remove the internal circlip.
16-19
Intermediate Shaft
Reassembly
Notetheseitemsduring reassembly: . Cleanthe disassembled parts with solvent,and dry them thoroughlywith compressed air. Do not wash the rubber partswith solvent. . Be carefulnot to damagethe metal ringson the intermediate shaftduring reassembly.
BEARING SUPPORT RING
DOWELEOLT 10 x 1.25mm 39 N.m 14.0 m, 29lbf.ft) kg't
EXTERNAL CIRCLIP
INTERMEDIATE SHAFTRING
Packthe interior of the outerseal. -0.r2 oz} 2.0-3.5 g {0.07
INTERNAL CIRCLIP
BEARING SUPPORT
OUTERSEAReplace.
'L
Pressthe intermediate shaft bearinginto the bearing supportusingthe special tools and a press.
Prcss
Seat the internal circlip in the groove of the bearing support. Press
W-L!
SHAFT INTERMEDIATE
ATTACHMENT, 52x55mm 07746- 0010400
ATTACHMENT.35 l.D. mm 07746 0030400 Pressthe intermediate shaft into the shaft bearing usingthe special tools and a press.
16-20
lnstallation
4. Seatthe externalcirclip in the groove of the intermediateshaft.
Press
1.
+
Pack interior the of the outerseal. 2.0- 3.59 {0.07 0.12oz)
DRNER
07749- 0010000
shaft conCleanthe areaswhere the intermediate (differential) thoroughlywith tactsthe transmission solvent or carburetorcleaner,and dry with compressedair. Insen the intermediate shaft assembly shaft horHoldthe intermediate into the differential. oil preventdamageto the differential seal. izontal to
ATTACHMENT, 52x55mm 07746- 0010400
INTERMEOIATE SHAFT
SEAL OUTER
EXTERNAL CIRCLIP
ATTACHMENT. 40 x 50 mm l.D. 07LAD- PW50601
Installthe outer seal into the bearingsupportusing the specialtools. The seal should be flush with the bearingsupport. 6. s I n s t a l lt h e n e w s e t r i n g i n t h e i n t e r m e d i a t e h a f t groove.
2.
Install three dowel bolts,then torquethem. the
BOLTS OOWEL 10x 1.25mm 39 N.m {4.0kgf.m,29 lbtftl
16-21
RearDriveshafts
Removal
't. Loosenthe rear whel nuts slightly.
Raisethe rear of the vehicle,and support it with safety stands in the proper locations(seesection 1), Remove wheel nuts and rearwheets. the
Disassembly
NOTE: a Due to the amount of work requiredto replaceone damaged boot, it is best to replace both boots at the sametime. . Theseinstructions for the inboardjoint.The same are procedure joint. applies the outboard to 1, Remove set ring from the inboardjoint, the
BOOTBAND Replace.
SPINDLE NUT 22 x 1.5mm Replace.
WHEEL NUT 1 2x 1 . 5 m m
INBOARD JOINT
2.
Remove boot band. the lf the boot band is a double loop type, raisethe band bendas shown,
4.
L i f t u p t h e l o c k i n gt a b o n t h e s p i n d l e n u t . t h e n removethe nut. Remove the rear driveshaftsfrom the rear differen(seesection15), tial assembly Removethe rear driveshaft outboard joint from the trailingarm and rear hub usinga plastichammeror a puller if necessary.
DOUSLELOOPBAND Replace.
OUTBOARD JOINT
TRAILING ARM
16-22
3.
Mark each roller and inboard joint to identify the locations rollersand groovesin the inboardjoint. of Then removethe inboardjoint on the shop towel.
JOINT INBOARD ring Check splines and driveshaft for wearor damage, insideborefor wear. Check {or Inspect cracks,
with vinyl tapeto 8. Wrap the splineson the driveshaft preventdamageto the boots.
RING DRIVESHAFT M.rks
BOOT INEOARD for Inspect cracking, and wear. splitting
DRIVE
SHOPTOWEL Marks
Markthe rollersand spiderto identifythe locations then removethe rollers, of the rollerson the sgider,
ROLLER DRIVESHAFT
Remove the boot band and boot from the driveshaft. Take care not to damagethe boot.
1 0 . Remove vinyl tape. the '1 Inspect driveshaft damageand otherfaults. for 1. the
0\
CIRCLIP
t I
Mark
Remove circlip. the to Mark the spider and driveshaft identifythe position of the spideron the shaft. 7. the Remove spiderusinga bearingremover.
16-23
RearDriveshafts
Reassembly
Notetheseitemsduring reassembly: . Cleanthe disassembled parts with solvent,and dry them thoroughlywith compressed air. Do not wash the rubber partswith solvent, o r''..@El: Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft set.
Greasequantity: fnboard Joint/Outboard Joint: 80 - 90 g 12.8 3.2 ozl

LEFTINBOARD JOINT (withsmalldriveshaft ring) CIRCLIP
SETRING Replace.
\@
DRIVESHAFT RINGS
BOOTBANOS Beplace.
DRIVESHAFT
RIGHTINBOARD JOINT (withlargedriveshaft ring) Packcavity with grease.
BOOTBANOS Replace. ROLI.ER
.6{
Pack cavity with grease.
OUTBOARD JOINT
16-24
'1. Wrap the splineswith vinyl tape to preventdamage to the boots.
6.
on the Reinstall rollersto their originalpositions the make spider by aligning the marks.After installation, sure to hold the driveshaftpointed straight up to prevent the rollersfrom fallingoff.
ROLLER
VINYLTAPE
and seat the lnstallthe boots onto the driveshaft, smallend of the bootsinto the grooveson the drivein shaft,lf the smallendsof the bootsare not seated w t h e g r o o v e s ,t h e b o o t l e n g t h a d i u s t m e n t i l l b e rncorrect. Remove vinyl tapefrom the end of the driveshaft. the by Install the spideronto the driveshaft aligningthe mark on the spiderwith the mark on the end of the driveshaft.
7.
Packthe joint and the boot with the joint grease included with the new boot. Greasequantity: 80 - 90 s {2.8- 3.2 o2)
lnstalla new circlip into the end g.oove on the driveshaft. Rotatethe circlip in its groove to make sure its fullv seated. (cont'd)
16-25
RearDriveshafts
(cont'd) Reassembly
8. Install the joint by holdjngthe driveshaft straightup and aligningthe markson the joint with the marks on the rollers, 10. Set the double loop band onto the boot with the bandend towardthe front of the vehicle,
9.
Adjustthe positionof the jointsto the specifications shown. then adjustthe boots halfwaybetweenfull compression and full extension. Makesurethe ends of the bootsare seatedin the groovesin the joints. 1 1 . Pull up the slackin the band by hand. Inboard ioint lngth: 153- 157mm {6.02 6.18inl
12. M a k ea m a r ko n t h e b a n d 1 0 - 1 4 m m ( 0 . 4- 0 . 6 i n )
from the clip.
CLIP
Outboard ioint l6ngth: l/l:' - 147 mm {5.63- 5.37 in}
16-26
1 3 . Threadthe free end of the band through the nose

sectionof a commerciallv availableboot band tool ( K D - 3 1 9 1 r e q u i v a l e n t )a n d i n t o t h e s l o t o n t h e o , winding mandrel, 1 4 . Placea wrench on the winding mandrelof the boot band tool, and tighten the band until the marked spot on the band meetsthe edgeof the clip.
16. Unwind the boot band tool, and cut off the excess free end of the band to leavea 5 - 10 mm (0.2- 0.4 in) tail protruding from the clip.
5-10mm (0.2- 0.4in)
BOOTBANDTOOL (KD-3191 or equivalent)
Markon band.
WINDING MANDREL
Lift up the boot band tool to bend the free end of the band 90 degreesto the clip, Center-punch the clip,then fold overthe remaining onto the clip. tail
17. Bendthe band end by tapping it down with a hammer. NOTE: . Makesurethe banddoes not move. . R e m o v ea n y g r e a s er e m a i n i n g n t h e s u r r o u n d i n g o surfaces.
HAMMER
(cont'd)
16-27
RearDriveshafts
(cont'd) Reassembly
groove. 18. Install the new set ring into the driveshaft
lnstallation
'1. lnstall the outboardjoint into the trailingarm.
SETRING Replace.
I CI
SET RINGGROOVE
Installthe rear driveshafts into the rear differential (seesection15). assembly Apply a small amount of engine oil to the seating surface the new spindlenut. of
WHEEL NUT 12x 1.5mm 108N.m (11.0 kgt.m,80lbtftl
SPINDLE NUT22 x 1.5mm 181 N.m (18.5kgf.m, 134lbl.ftl Replace.
Installa new spindlenut, then torquethe nut. After tightening, a driftto stake spindle shoulder use the nut against driveshaft. the Cleanthe mating surfaces the brakedisc and the of wheel, then install the rear wheel, and torque the wheel nuts.
16-2A
PropellerShaft
Inspection
UnivarsalJoint and Boots 1. 2. Shiftthe transmission Neutral. to Raise vehicleoff the ground,and supportit with the (seesection1). safetystandsin the properlocations play Check the cente.supportbearingfor excessive or rattle.It the centersupporthas excessive play or raftle,replace propeller the shaftassembly. PropellorShaft Runout 6. Install dial indicator a with its needle the centerof on No, 1 or No.2 propeller shaft. Turn the other propeller shaft slowly and checkthe runout.Repeat this procedure the other propeller for shaft. No. 1 PropellerShaft Runout: ServiceLimit: t.5 mm (0.06in)
7.
3.
No.1 PROPET_LER SHAFT Checkthe universaljoint boots for damageand deterioration. the boots are damagedor deteriorated, lt replace propeller the shaftassembly. Checkthe universaljoints for excessiveplay or rattle. joints have excessive play or rattle, lf the universal replace propeller the shaftassembly. No. 2 PropellerShaft Runout: ServiceLimit: 1.5 mm {0.06inl
lf the runout on either oroDeller shaft exceeds the limit, replac propeller service the shaftassembly.
16-29
Propeller Shaft
RemovaUlnstallation
1, Remove propeller the shaftprotectors.
No. 1 PROPELLER SHAFT
4,
Remove centersupportbearingmountingbolts. the
SHAFT PROPELLER PROTECTOR
BOLT FLANGE I x 1.25 mm 22 N.m (2.2kg{.m. 16lbl'ft) SHAFT No. 2 PROPELLER
SELF-LOCK|NG BOLT 10x 1.25 mm 39N'm14.0 kg{.rn,29 lbtftl Replace.
uErrrEnDurrr.r'rI I'EAnrNu
FLANGEBOLT 8 x 1.25mm 22 N.m 12.2 kgf.m, 16lbf.ft)
Mark the No. I propellershaft and transferassembly across their jointsas shown.
o.
PNOPELLER SHAFT PROTECTOR 2. Mark the No. 2 propellershaft and rear differsntial across theirjointsas shown. Removethe four 12-pointbolts. and remove the No. 2 propellershaft from the rear differential.
Removethe four 12-pointbolts, and remove the No. 1 propellershaft from the transferassembly,
No. 'l PROPELLER SHAFT
No.2 PROPELLER SHAFT
12.POINT BOLT 8 x 1.25mm 32 N.m 13.3 m, 24 lbtftl kst
12.POINT BOLT 8 x 1.25mm 32 N.m 13.3kgt'm, 2,1lbf.ft)
TRANSFER ASSEMBLY
7.
REARDIFFERENTIAL
Installthe propellershafts in the reverseorder of removal.Make sure to align the marks on the propller shafts with the marks on the rear differential and the transferassemblv.
16-30
Steering
Special Toofs ............. 17-2 *SteeringColumn ComponentLocations Removal/lnstallation ................ 17-2O ....... Index................ ....... 17-3 lnspection .............. 17-21 Troubleshooting SteeringLock Replacement............ -22 17 GeneralTroubleshooting................ 17-4 Power Steering Hoses,Lines Noiseand Vibration......................... 17-8 FfuidLeakage Inspection................. -23 17 FluidLeaks ............. 17-10 Repfacement .......... 17-23 Inspection and Adiustment Power SteeringPump Steering Operation.......................... 17-12 Repfacement .......... 17-24 Power Assist Check Disassembly ...........17-25 With Vehicle Parked.................... 17-12 fnspection .............. 17-26 SteeringLinkageand Gearbox .......17-13 Reassembly ............ 17-28 Pump Belt 17-14 Power Steering Gearbox RackGuideAdjustment................... 5 l7-1 Removal ................. 17-31 FluidRep|acement ...................,,.,.... 17-15 Disassembly ........... 17-34 PumpPressure Check.................,,... 17-16 Reassembly ............ 17-40 *SteeringWheel Ball Joint Boot Replacement.......... 17-50 Removal ................. 17-18 Installation ............. 17-51 Disassembly/Reassembly............... 17-18
4'%/b
.......... -r'-7--a/
(SRS\ SUPPLEN\EN\AL RES\RA(N\ SYSTES{\

This model has an SRSwhich includes driver'sairbagin the steering a wheel hub. a passenger's airbagin the dashboard ('98 - 00 models).Information abovethe glove box ('97 - 00 models), and seat belt tensioners the seat belt retractors in necessary safelyservice (*) to the SRSis includedin this ServiceManual.ltems markedwith an asterisk on the contents pageinclude, are locatednear,SBScomponents. or Servicing. disassembling replacing or theseitemswill requirespecial precautions tools,and shouldonly be done by an authorized and Hondaoearer.
To avoid rendering the SRS inoperative, which could lead to peFonal iniury or death in the event of a sevore trontal collision. allSRS servicework must be performod by an authorized Honda dealer. lmproper service procedurgs, including incorrect removal and installalion of the SRS, could lead to personal iniury causedby unintontional deployment of th airbags {'97 - 00 models),and seat belt tensioners ('98 - 00 modelsl. Do not bump the SRS unit. Otherwise, the system may lail in case ot a collision, or the airbags may deploy when the ignition switch is ON (lll. SRS electricalwiring harnessesare identitied by yellow colof coding. Ralatedcomponents are located in the steering column, front console,dashboard,dashboard lower panel, and in the dashboardabove the glove box. Do not use electrical test equipment on these cilcuits,
Ret. No,
Tool Numbel 07GAF PH70100 07HAG SF10100 or 07GAG SD40200 OTGAG SD4O2OA 07JGG 001010A 07MAC S100200 _ OTNAD SR3O2OA or 07NAG SR30900 07NAG, SR3OgOA 07RAK 50401 10 07RAK 5040120 07406 0010001 or 07406 0010004 07725 0030000 07746 0010100 07749 0010000 07916 SA50001 07974 SA50200 or 07974- SA5050A 07974- SA50800
Description PilotCollar PistonSealRingGuide PistonSealRingSizing Tool BeltTensionGauge B a l lJ o i n tR e m o v e r , 2 m m 3 Cylinder EndSealRemover Attachment ValveSealRingSizing Tool P/SJoint Adaptor(Pump) P/SJoint Adaptor(Hose) P/SPressure Gauge Universal Holder Attachment, x 35 mm 32 Driver Locknut Wrench,40 mm Sleeve SealRingSizingTool
o o
-@ r
fty 'l 1 1
1 1 1 1 1 1 1
PageReference 11-39 17-44 11-44 1 7- 1 4 't]-31 17-37 't7-4'l 1 7 - ' t 61 7 , 1 7 - 1 61 7 , 11-16, 17 17-26,30 't]-42,43 't1-42, 43 11-15 't]-42 11-42, 50
o
@
rol
o
@ @ (} @
1 1 1 ,l 1
1
BallJoint BootClip Guide @ * Included the BeltTensionGaugeSet 07TGG 001000,4 in
\J
,/:\
=tt
@ @
,l-
aA)
l:I
o
/\L----.--.--------_
(D
(9
17-2
ComponentLocations
lndex
Notetheseitemsduringdisassembly: ' lf an intactairbagassemblyhas been removedfrom a scrapped vehicleor has beenfound defective damagedduror ing transit,storageor service. shouldbe deployed (seesection24), it a Beforeremovingthe gearbox, removethe driver.sairbagassembly and steering wheel. . After installing gearbox, the checkthe wheelalignmentand adjustif necessary. SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, precautions, and procedures the SRs an section(24)beforeperformingrepairs servrce. or
STEERING WHEEL page17,18 Removal, Disassembly/Reassembly, 1?,18 page page17-19 Installation, DRIVER'S AIRBAGASSEMBLY Removal/lnstallation, section24 see
STEERING GEARBOX Rack GuideAdjustment, page17-15 page17-31 Removal, page17-34 Disassembly, page17,40 Reassembly, page17,51 Installation, VALVEBODYUNIT page17-38 Overhaul,
STEERING COLUMN page Removal/lnstallation. 17-20 pagel7 21 Inspection, page17 22 Steering LockReplacement, CABLEREEL Removal/lnstallation, section24 see
tcNrnoN swtTcH
See sction23 STEERING HOSES, LINES Replacement. page l7-23
RESERVOIR page17 15 FluidR6placement. Fluid Leakagelnspection,page 17-23 PumpBeltInspection and Adjustment, pag t7-14 PumpPressure page17-16 17-1j Check, ot Replacemont, page17-24 Disassembly, pa96 17,25 Inspection,page 17-26 Reassembly. page17-28
END BALLJOINT BallJointBootReplacement, page17-50
17-3
Troubleshooting
g Troubleshootin General
Check followingbeforeyou begin: the . Hasthe suspension beenmodifiedin a way that would affectsteering? . Are tire sizes, varietyand air pressure correct? tire . ls the steering wheeloriginalequipment equivalent? or . ls the power steeringpump belt properlyadjusted? . ls steering filledto properlevel? fluid reservoir . ls the engineidle speedcorrectand steady?
(Check powerassist, page17-12. the forceis over 29 N (3.0kgl 6.6 lbfl, proceedwith this troubleshooting.i lf HardSteering the see
Check he pump fluid pressure t (seepage17-16 17-17). or Measuresteadystate lluid pressure at idle with the pressure control valve and the shut-offvalve (it so equipped) open. fully The fluid pressure should be 1,500 psi)orless. kPa(15kgf/cm,,213
Abnormalthiid (Iluid pressure pressureis too high)
Checkthe teed and return circuit lines and hose betweenthe gearbox and pump for clogging and deformation.
Normallineand hose
Normal Faulty valvebody unit
Check he pump fluid pressure t (seepage17-16 l7-17). or pump reliefpressure Measure at i d l e w i t h t h e p r e s s u r ec o n t r o l valve and the shut'off valve lil so equipped) closed. fully The fluid pressure should be 6,900 7,800kPa (70- 80 kgflcm,, 1,000 - 1,140 psi).
Reliefpressure too low
Check flow controlvalve(seepage17 26). the . Check the valvlor smooth movementin the housing. . Checkthe relief valve for leaks.
Normalreliefpressure
Abnormal
Go to page 17 5
pump assembly Faulty
Faultyflow control valve
1 7 -4
Checkthe force required turn to the wheellseepage17 12). Startthe engineand measure the force requiredto turn the wheel to the right and left.Difference of t h e f o r c e r e q u i r e dt o t u r n t h e wheel to the right and to the left shouldbe 2.9 N (0.3 kgf,0.7 lbt) or less,
Abnormal
Deformed
Not deformed
Faulty lines cylinder
Readjust rackguide the (seepage17-15)
Adjustment OK Normal Bent
gearbox Faulty steering
Compairthe steeringto another alikevehicle.
(cont'd)
17-5
Troubleshooting
(cont'dl Troubleshooting General
Assist(excessively steering) light at high speed. Checkthe rack guide for proper (seepage17-15). adjustment lf the problemis not corrected by adjustingthe rack guide, adjust t h e f r o n t w h e e l a l i g n m e n t( s e e section18).
Shockor vibration when wheelis turnedto full lock.
Checkthe rack guide for proper (seepage17'15). adjustment
Adjustthe rackguide. guideis adiusted properly. Rack lf the problemis not corrected by adjusting the rack guide,replace the gearbox.
C h e c k h e b e l tf o r s l i p p a g e n d t a (see adjust necessary page17-14). as
wheelwill not return Steering smoothly.
A a n d B c y l i n d e rl i n e sa r e n o r mal, checkwheel alignment(see section18).
W h e e l a l i g n m e n ti s a b n o r m a l , adjustas needed.
Wheelalignment normal. is Checkthe steeringwheel operation and power assistcheck(see page 17-121.
l f t h e m e a s u r e m e n ta r e o u t o f s s p e c i f a c a t i o na d j u s t t h e r a c k s, guade.
lf the problemis not corrected by adjusting the rackguide,replace the gearbox,
Uneven roughsteering. or
gu page17Ad,ust rack ide(see the 15).
ll the problemis not corrected by adjusting the rack guide,replace the gearbox.
Beltslipping pulley. on
Adjustthe belttension.Replace the (see belt,if necessary page17-14).
ldlespeedlow or erratic.
l f t h e e n g i n es t a l l sw h e n t h e wheel is turnedwhile the vehicle is stopped or moving at low speed,adjustthe idle speed(see section111.
Air in reservoir, check power or steering tluid level.
Checkpower steeringlluid level.lf the level is excessively low check for leaks in the system.Add fluid to the specified level.
lf fluid levelis OK, checkO-rings a n d s e a l so n b o t h e n d s o f t h e p u m p i n l e t h o s e ,a n d t h e P / S p u m p h o u s i n gm a t i n gs u r l a c e s and drive shaft oil seal for suc tion leaks. Check reservoir the for cracks,Replaceparts as neces-
Steeringwheel kicksback duringwide turns.
P u m p b e l t s l i p p i n go n p u l l e y (pumpstopsmomentarily).
Adjustthe belt tension(seepage 17-14) replace or belt.
Installthe power steeringpressure gauge, Closethe pressure control valve and shut off valve (if so equipped)fully and measure (seepage 17-16 the pump pressure ot 17 17).
Checkif pump pressureis normal and the gauge needletravel is 500 k P a ( 5 k g l / c m , ,7 1 p s i ) o r l e s s . Checkthe flow controlvalve if the needletravelexceeds 500 kPa (5 kgflcm',71 psi). lI the flow control valve is normal, replacethe pump as an assembly,
7-7
Troubleshooting
NoiseandVibration
NOTE:Pumpnoisein first 2 - 3 minutesafterstartingin cold weatheris normal.
Humming due to pulsationof fluid is normal, particularly when the wheel is turnedwith the vehicle stooDed.
Humming
lf equipped with automatic transmission,he hum couldbe the t torqueconverter pump noase. or
Confirm by temporarily removing the pump belt.
Feedhose (high-pressure) touching the frame.
Beposition the feed hose.
Rattleor chattering
Loosesteeringshaft connector, tie-rod, balljoint. or
C h e c ka n d t i g h t e n , o r r e p l a c e parts as necessary,
Columnshaftwobbling.
Roplace columnassembly. the
Checkthe rack guide for proper (seepage17-15). adjustment
Adjust,if necessary.
Rattlingsound and feeling when turning the steeringwheel right and left with th engine OFF normal. is
Pump noise,though not loud,from the valvebody unit can be heardwhen turning the steering wheelto full lockin eitherdirection. This is normal.Do not hold the steering wheelat full locklor morethan five seconds when inspecting.
17 -8
Pumpnoise
Grating nois trom pump
Cavitation causedby air bubbles in the fluid.
Check fluid lev1. the l t l o w , f i l l t h e r e s e r v o i rt o t h e properlevel.and check leaks. for Tightenor roplace necessary, as
Check a crushedinlet hoseor for a loose hose clamp allowing air into the suctionside of the sys t e m . C h e c kt h e r e s e r v o i rf o r cracks.Tighten or replaceas nec-
Check driveshaftoil seal. the
Pumpnoise
Pump noise up to 2 - 3 minutes after starting in cold weather is normal,Comparepump noiseat operatrngtemperatureto another vehicle.
ll pump noiseis abnormally loud, removeand inspect pump for the wear and damage(see page 17251.
Raftleor chattering
Tighten replace pulley. or the l I s h a f t i s l o o s e , r e p l a c et h e pump.
17-9
Troubleshooting
FluidLeaks
Checkthe gearboxassembly oil leakscarefully. can leakout ot variouspoints,depending locationof the faulty for Oil on oil seals/seal rings.Check followingbeforeremovingthe gearbox the from the frame.
Steering Gearbox
Leaking from the oil seal on the top of the valvehousing.
Replace the valve oil seal from the valve housing.
Leakingfrom cylinder end into left tie rod boot.
Replace the valve oil seal from the pinion shaft.
Replace cylinderend seal on the the valvebody unit side.
Leakingfrom cylinder end into right tie-rod boot.
Replace cylinderend seal on the the cylinderend side.
Leaking lrom the shaftupperend sectionor pin engagement section of the pinionshaft.
R e p l a c et h e v a l v e b o d y u n i t .
Leaking from cylinderlineA or B (at connections tlarenut).
Tightenthe connector. it's still It leaking, replace line,cylinder the or valvehousing.
L e a k i n g a u s e db y a d a m a g e d c cylinder lineA or B.
Replace cylinder lineA or B.
Leakingfrom pump outlet hose and returnlinejoint fittingon the valvebody unit {attlarenut}.
Tightenthe connector. it's still ll leaking, replace the line,joint fitting or valvehousing,
17 -1 0
B e p l a c et h e h o u s i n g O - r i n g s . if the housing still leaks, replace the pump.
is Reservoir overfilled. P u l l o f f t h e h o s e a n d d r a i nt h e reservoir the properlevel. to
Air leakin suction sideof the syspump inlet hose, tem (reservoir, front pump seal).
PumpoLrtlet hose (high-pressure)
L e a k i n ga t t h e t h r e a d e d f i f t i n g .
Tightenthe fifting. lf it's still leaking, replace the O-ringor pump outlethose,
joint. Leaking the swaged at
Replace pump outlethose. the
Pumpinlet hose (low pressure)
of Leakingbecause damage,dete' assembly, rioration, improper or
Replace repairas necessary. or
17-1
Inspection and Adjustment

Steering Operation
Placethe front wheels in the straight ahead position. and measurethe distancethe steering wheel can be turnedwithout movingthe front wheels. ROTATIONAL PLAY:0 - 10 mm (0 - 0.39 inl lf the play exceeds the limit, perform rack guide adjustment (seepage17-15). lf the play is still excessive after rackguide adjustment, inspectthe steeringlinkageand gearbox as described on the nextpage.
PowerAssistCheckwith VehicleParked
1. Checkthe power steeringfluid level (see page 1715)and pump belttension(seepage 17-14). Startthe engine,allow it to idle, and turn the steering wheel from lock-toiockseveraltimes to warm u p t h ef l u i d . Aftacha springscaleto the steering wheel,With the engine idling and the vehicleon a clean.dry floor, pull the scaleas shown and read it as soon as the tires beginto turn.
2.
3.
ROTANONAL PLAY
+i r
f::1-t
SPRING SCALE (Commercially available)
The scaleshould read no more than 29 N (3.0 kgf, 6 . 6 l b f l . l f i t r e a d sm o r e , c h e c kt h e g e a r b o xa n d oumo.
17-12
SteeringLinkage and Gearbox
PINIONSHAFTGROMMET Inspoctfor damageand deterioration.
STEERING JOINTS Checkfor loosejoint bolts.
NE-RODLOCKNUT CheckIor loose locknut. BALLJONT AOOT Inspoctlor damageand deterioration. Se page 17-50for replacemont.
Inspectfor loose mounting bolts. GEARBOX MOUNTINGCUSHIONS lnsp6ctfor dgterioration.
BOOT lnspect damag dterioration. for and

END AAtL JOINT Inspectfor faulty movement ano oamag.
17-13

PumpBelt
When using a new belt.first adjustthe deflection tenor sion to the values for the new belt, then readjustthe deflection tensionto the valuesfor the used belt after or runningenginefor five minutes. Measurementwithout Belt Tension Gauge: Apply a force ot 98 N (10 kgf,22 lbt) and measurethe deflectionbetweenthe power steering pump and the crankshaft oullevs. Deflection: mm {0.'(l - 0.57in) UsedBelt:11.0- 1i1.5 New Belt: 7.5 - 10.0mm {0.30- 0.39 in)
Inspection
Notetheseitemsduring inspection: a lf there are cracks any damageevidenton the belt, or replace with a new one. it . Followthe manufacturer's instructions the tension lor gauge. '1. Remove the P/Sreservoir from the bracket, and set it aside. 2. Attach the belt tension gauge to the belt with the gaugefacetowardthe engine,and measure tenthe sion of the belt. Removethe belt tension gauge carefullyto avoid hittingthe gaugeresetlever.
here. Measure
PULLEY CRANKSHAFT
Tension: Used Belt: New Belt:
390 - 540 N {40 - 55 kgf, 88 - 121 lbf) 7,[0- 840 N (75 - 90 kgf, 165- 198 lbf)
Adiustment
'1. L o o s e nt h e p o w e r s t e e r i n gp u m p m o u n t i n g b o l t and pump lockbolt. PUMP MOUNNNG BOLT 24 N'm(2.4kgf'm,17lbfftl
PUMP LOCK BOLT 24N.m12.4 kgf.m, lbf.ftl 17 Adjust the belt tensionby moving the power steering pump with a 1/2" drive breaker to obtainthe bar p r o p e rb e l t t e n s i o n ,t h e n r e t i g h t e n h e m o u n t i n g t bolt and lockbolt. Start the engine and turn the steeringwheel from lock-to-lock several times,then stop the engineand recheck deflection the belt. the of
PULLEY CRANKSHAFT
17 -1 4
RackGuide Adjustment
1 . Setthe wheelsin the straightaheadposition. Loosenthe rack guide screw locknutwith the specialtool,then loosenthe rackguidescrew. For'98 - 00 models,removethe rack guide screw. R e m o v et h e o l d s e a l a n tf r o m r a c k g u i d e s c r e w to and apply new sealant the first threadedsection, three threads.Looselyinstallthe rack guide screw gearbox. on the steering
Fluid Replacement
and add the recat the reseryoir regularintervals, Check fluid as necessary. ommended CAUTION: Always use Gsnuine Honda Power Steering Fluid-V or S. Using any other type of power steering tluid or automatic transmissionfluid can causeincreassd wear and poor steering in cold w3athel. SYSTEMCAPACITY: 0.85 liter {0.90US. qt. 0.75 lmp.qtl at disasssmbly CAPACITY: RESERVOIR 0.,1liter (0.42US. gt, 0.35 lmp.qi)
RACKGUIDESCREW LEVELLINE UPPEN
LOWER LEVELLINE
the then disconnect returnhose 1 . Raisethe reservoir. Takecare not to spill the fluid to drainthe reservoir. on the body and parts.Wipe off any spilledfluid at once.
LOCKNUT 25 N.m kgt 12.5 m, 18lbtftl
5.
Tightenthe rack guide screwto 25 N.m (2.5 kgf'm, 18 lbf.ft), then loosenit. R e t i g h t e nt h e r a c k g u i d e s c r e w t o 3 . 9 N ' m ( 0 . 4 kgf.m, 2.9 lbf.ft),then back it off to specifiedangle. 2, SpecifiedReturn Anglo: 10 r 5" 37 model: '98 - 00 modeb: 20' Max T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e screw.
4.
3.
6.
Checkfor tight or loose steeringthrough the completeturningtravel. followinginspections: Perform (seepage17-12). . Steering operation . Powerassistwith vehicleparked
4. 5. 6.
7.
7.
Connecta hose of suitablediameterto the disconnectedreturn hose,and put the hose end in a suitablecontainer. Stan the engine.let it run at idle,and turn the steering wheel from lock-to-lockseveral times. When f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e the engine.Discard fluid. returnhoseon the reservoar. Beinstallthe to Fillthe reservoir the upperlevelline, Startthe engineand run it at fast idle.then turn the several times to bleedair steeringfrom lock-to-lock from the system. Recheck fluid leveland add some if necessary. the beyondthe upperlevelline. Do not fill the reservoir
lnspection and Adjustment

PumpPressure Gheck With T/N 07406 0010001
Checkthe fluid pressureas follows to determinewhether the troubleis in the pump orgearbox. 1. Checkthe powsr steeringfluid level (see page 1715),and pump belttension(seepage17-14). Disconnect the pump outlet hose from the pump outlet with care so as not to spill the powr steering iluid on the frame and other pans. thon installthe P/Sjoint adapter(pumplon the pump outlet. 6 x 1.0mm BOLT {Part oftool)
FEEDHOSEFITTING
5. Fully open the shut-off valve.

PRESSURE CONTROLVALVE
2.
PUMP OUTLET HOSE
11 N.m ll.1 kgl.m, E lbf.ftl P/S PRESSURE GAUGE 07('6 - 0010001 6 x t.0 mm BOLT {Partoftool) 11 N.m (1.1kgt m, 8 lbf.tr)
6. Fullyopenthe pressure controlvatve. 7. Startthe engineand let it idle. 8. Turn the steeringwheel from lock-to-lock several times to warm the fluid to operating temperature. 9, Measuresteady-state fluid pressurewhile the engine is idling. lf the pump is in good condition,the gauge should read lessthan 1,500kPa(15 kgf/cmr,213 psi). lf it reads high, checkthe outlet hose or valve bodv unit (seeGeneral Troubleshooting). 10. Close the pressure control valve, then close the shut-off valve gradually until the pressuregauge nsedle is stable.Readthe pressure. CAUTION: Do not kap tha prca3un control valvo clorod mo.c thon 5 srconds or thc pump cluld bo damEgodby ovor-hoating.
Connectthe P/Sjoint adapter (hose)to the p/S pressure gauge,then connectthe pump outlet hose to the P/Sioint adspter(hose). I n s t a l l t h e P / S p r e s s u r eg a u g e t o t h e p / S j o i n t adapter(pump),
11. lmmodiately openthe pressure controlvalvefullv. lf the pump is in good condition, the gaugeshould read at least 6,900- 7,800 kpa (70 - 80 kgflcmr, '1,000 1.140psi). A low readingmeanspump output is too low for full assist.Repairor replacethe
DUMD.
17-1 6
CheckWith T/N 07406 001000A PumpPressure

Checkthe fluid pressureas follows to determinewhether the troubleis in the pump or gearbox. 1. Checkthe power steeringtluid level (see page 17and pump belttension(seepage 17-14). 151, the pump outlet hose from the pump Disconnect with careso as not to spill the power steering outlet fluid on the frame and other parts,then installthe P/Sjoint adapter(pump)on the pump outlet.
6 x 1.0mm BOLT (Partoftool) 5. Open the pressure controlvalve fully.
PRESSURE VALVE CONTROL
2.
FEEDHOSEHfNNG
PUMP OUTLET HOSE
kgf.m,8lbfft) 1'l N.m 11.1 GAUGE P/S PRESSURE 07406- 001000A 6 x 1.0 mm BOLT (Part tool) ol 11 N.m (1.r kg{.m,8lbf'ft|
Startthe engineand let it idle. several 7 . Turn the steering wheel from lock-to-lock temperature. timesto warm the tluid to operating fluid pressurewhile the engine Measuresteady-state the is idling.It the pump is in good condition, gauge psi).lf it reads kPa(15koflcm' ,213 shouldread1,500 high. checkthe outlet hose or valve body unit {see Troubleshooting), General controlvalve graduallyand read Closethe-pressure the oressure. CAUTION: Do not keep the pressurs control valve closed more then 5 seconds or the pump could bo damaged by overheating. fully. controlvalve openthe pressure 1 0 . lmmediately the gauge should lf the pump is in good condition, read at least 6,900 - 7;800 kPa (70 - 80 kgflcm' , 1,000 1.140psi), A low readingmeanspump outDut is too low for {ull assist.Repairor replacethe oumo.
Connectthe P/Sjoint adapter (hose)to the P/S pressure gauge,then connectthe outlet hoseto the P/S joint adapter(hose). I n s t a l l t h e P / S p r e s s u r eg a u g e t o t h e P / S j o i n t adapter(pumpl.
17-17
SteeringWheel
Removal
SRS componentsare located in this area. Reviewthe precautions, SRScomponentlocations, and procedures in the SRSsection(24)beforeperformingrepairsor service. 1. Align the front wheelsstraightahead.then remove the driver's airbag assembly(seesection24) from the steering wheel. Disconnect the horn connectorand cruise control switch connectors. 3. Loosenthe steeringwheel bolt, then install a steering wheelpulleron the steering wheeland removeit. Notetheseitemswhen removing steering the wheel: . Do not tap on the steeringwheel or the steering columnshaftwhen removingthe steering wheel. . lf you threadthe puller bolts into the wheel hub morethan five threads, boltswill hit the cable the reel and damageit. To preventthis, installa pair of jam nutsfive threadsup on eachpullerbolt.
STEERING WHEELBOLT kgt.m,29 lbtftl 39 N.m 14.0
2.
CONTROL CONNECTOR SWITCHES
WHEELEOLT STEERING
WHEEL STEERING
EOSSCOVERPLATE
WHEEL BODY COVER
_^M
@,
ACCESS PANEL
"\
h
BODYOVERCAP C
17- 1 8
lnstallation
1. the steeringwheel, make sure the Beforeinstalling front wheelsare alignedstraightahead,then center the cablereel.Do this by first rotatingthe cablereel clockwise until it stops. Then rotate it counterclocktwo turns. The arrow mark on wise approximately the cablereel labelshouldpoint straightup. 2. wheel on to the steeringcolumn Install the steering wheel shaftengages shaft,makingsurethe steering sleeve.Do not tap on the cable reel and canceling the steeringwheel or steeringcolumn shatt when wheel the instailing steering
CABLEREEL ARROWMARK
HOLE Installthe steeringwheel bolt, and tighten it to 39 N.m (4.0 kgf.m, 29 lbf.ft). the horn connectorand the cruisecontrol Connect connectors, switch Installthe driver's airbag assembly,and confirm (seesection 24). propersystemoperation
17-19
Steering Column
SRS componentsare located in this area. Review the precautions, SRScomponentlocations, and procedures in the SRSsection(24)beforeperformingrepairsor service. Notetheseitemswhen removingthe steering column: . Before removing the steering column, remove the driver'sairbag assemblyand cable reel (seesection 24). . Beforeremovingor installing, the columnshaft in set the neutralpositionby pullingup the steering column to uppermostposition,then lower it 8 mm (5/16in). Tightentilt lever.
FULLSTROKE: 23 mm 10.9 in) MAXIMUMUPPER POSTTTON 8 mm (5/16) 1.
Remove steering the wheel (seepage 17-18). Remove the driver's side dashboard lower cover and kneebolster(seesection 20), Remove columncovers. the With A"/T,move the shift lever to the E position, and removethe shift cable from the column. and set it aside(seesection14). Remove the combination switchassembly from the steeringcolumn shaft by disconnecting connecthe tors, and removing the two screws. Disconnect steeringjoint from the enginecomthe panment.
7.
R e m o v et h e s t e e r i n g c o l u m n b y r e m o v i n g t h e attaching nuts and bolts.
MAXIMUM LOWER POSTTTON SHAFTCENTER
TILT LEVER
1 1 1m m
1 0 0m m
5mm
UPPER COLUMN COVER
JOINT COVER
COMAINANONSWITCH ASSEMBLY BOOTBAND
9,8 N.m l r .0 kgf.m,7 lbf.fO JOINT DUSTSEAL 22 N.m (2.2kgl.m, 16lbtftl
JOINT COLUMNBMCKET LOWERATTACHINGBOLTS 39 N.m lir,o kgf.m, 29 lbf.ft) UPPER ATTACHING NUTS 16 N.m lr.6 kgf.m, 12 lbf.ftl LOWER COLUMNCOVER
17-20
22 N.m (2.2 kgf.m, 16lbt.ftl
8.
ofthe removalprocedure. is Installation the reverse Notetheseitemsduring installation: . Be sure the wires are not caught or pinchedby the any partswhen installing column. a Make sure the wire harnessis routed and fastened properly. . Make sure the connectorsare properlyconnected. as . Make sure the steeringjoint is connected follows: joint onto a. lnsertthe uDperend of the steering (line up the bolt hole with the steeringshaft the flat ot the shaft). b. Slip the lower end of the steeringioint onto the Dinionshaft (lins up the bolt holewith the and installthelower groovearoundthe shaft). Be sure that the lower joint bolt is ioint bolt. in securely the groovein the pinionshaft' joint to makesurethat the c. Pullon the steering joint is JullY seated. steering Then installthe upperjoint bolt and tightenit.
SIEERING JOIMT
JOINT BOLT UPPER Bolt must IineuP with fl6t on shaft. Flatponion. JOINT STECRING
BOLT LOWER JOINT line Boltmust upwith groove on around shaft,
Inspection
the Check steeringcolumn ball bearingand the steering joint bearingsfor play and proper movement.lf play,replace the there is noisyor if there is excessive column as an assemblY steering Checkthe retainingcollar for damage.lf it is damcollar. the aged,replace retaining PLASl'tC INJECTIONS ABSOBBING PLATE . Checkthe absorbingplates,absorbingplate guides Jor and slidingcapsules distortionand breakage. the ReDlace column as an assemblyif they are distorted or broken.
CAPSUII SLIDING This part is attached to the column bracket with the plastic injections.
FETAINING COLLAR ABSORBING PLATEGUIDE |GNMON SWTTCH See section23.
SHIFT I.EVER Seesection 14.
(cont'd)
17-21
SteeringColumn
(cont'dl Inspection
1 . Move the tilt lever from the loose position to the l o c k p o s i t i o n3 t o 5 t i m e s ; t h e n m e a s u r et h e t i l t lever preload10 mm (0.4in) from the end of the tilt rever. Preload:70 - 90 N (7 - 9 kgf, 15 - 20 lbf) l f t h e m e a s u r e m e n ti s o u t o f t h e s p e c i f i c a t i o n . adjustthe preloadusingthe tollowingprocedures. a. Loosen the tilt lever,and set the steeringcolumn in the neutralposition. b , R e m o v et h e 6 m m l o c k b o l t . a n d r e m o v e t h e stop. Be carefulnot to loosenthe tilt leverwhen installingthe stop or tighteningthe 6 mm lock bolt.
SPRING SCALE NLT LOCKBOLT Tighten the lock bolt with the tilt leverraised. SHEARBOLT Replace.
SteeringLockReplacement
1 . Bemovethe steering column (see page 17-20). Centerpunchthe shearbolt, and drill bolt head off with a 5 mm (3/16in) drill bit. Removethe shear bolt from the switch body. Be carefulnot to damagethe switchbody when removing the shearbolt. Insertthe ignitionkey and turn it to "1". Push the lock pin down, and pull out the steering lockbody from the steering column.
L-_
6 mm LOCK BOLT 7 N.m(0,7kgf.m, tbtftl S Adjustthe preloadby turningthe tilt lockbolt left or ri9ht.
d . Pull up the tilt lever to the uppermostposition.
I n s e r t t h e i g n i t i o n k e y t o t h e n e w s t e e r i n gl o c k body,and turn it to "1". 7 . Push the lock pin down, and insen the steering lock body into the steeringcolumn until it clicksinto place. 8 . Loosely installthenew shearbolt.
and installthe stop. Checkthe preloadagain. lf t h e m e a s u r e m e n its s t i l l o u t o f s p e c i f i c a t i o n , r e p e a tt h e a b o v e p r o c e d u r e s . t h r o u g h c . t o a adjust.
Checktor proper operation of the steeringwheel lock,and that the ignitionkeyturns freely. 1 0 . Tightenthe shearbolt untilthe hex headtwistsoff. TWIST.OFF PORNON
SHEARBOLT
1 7- 2 2
Lines PowerSteeringHoses,
Inspection Fluid Leakage
HOSESand LINES and twisting . lnspecthosesfor damage.leaks.interference . Inspect fluid linesfor damage,rustingand leakage. . Check leaksat hoseand line joints and connections. for HOSE FEED 27 kgf.m, lbtft) 37N.m13.8
CYLINDER LINES 17 N.m (1.7kgf.m. 12 lbf.ftl FOWER STEERING PRESSURE SWITCH 12 N.m (1.2kgf.m,8.7 lbtft) RETURN LINEJOINT 28 N.m (2.9kgf.m.21 lbf.ftl
GEARBOX .nd VALVEBODYUNll Checkfor leaksat the mating surface and flare nut connections.
CYLINDER 26 N.m (2.7 kgf.m, 20 lbf.ft)
FEEDHOSE 11 N.m ('1.1 kgt.m, 8 lbf.ftl
HOSE SUCTION PUMPASSEMBLY Check leaks for atthe pump seal.inletand outletfittings.
Replacement
Notetheseitemsduring installation: line . Connect eachhoseto the corresponding securely the until it contacts stop on the line. Installthe clamp from the distance clampat the specified or adjustable hoseend as shown. . Checkall clamDsfor deteriorationor deformation; replace with the clampsnew onesif necessary. . Add the recommendedpower steering fluid to the and checkfor leaks. levelon the reservoir specified HOSECLAMP:la) ADJUSTABLE . P o s i t i o n h e a d j u s t a b l e o s e c l a m p sa t t h e p o i n t s h t indicated (a) in the drawingabove. by . Slidethe hoseoverthe line until it contacts stop. the HOSECLAMP:lbl . Positionthe hose clamps at the points indicatsdby (b) in the drawingabove. . Slidethe hoseoverthe line until it contactsthe stop,
10.01 0.22 in)
2.0 - 4.0 mm 10.08 0.16inl
2.5- 5.5mm {0.01- 0.22 in}
17 -23
PowerSteeringPump
Replacement
1.
Place suitable a container underthe vehicle. Drainthe powersteering fluid from the reservoir. Removethe belt by looseningthe pump mounting bolt and pump lock bolt.
PUMPOU'I.TT HOSE
7 . Connect pump inlet hoseand pump outlethose. the Tightenthe pump fittingssecurely. Looselyinstallthe pump in the pump bracketwith the mountingbolt and lockbolt. Install the pump belt.
PUMP MOUNNNG BOI.T 24 N.m12.4 m, 17lbl.ftl kgt
11 N.m (1.1 kgf.m, E rbf.ti)
Notetheseitemsdu.ing belt instsllation: . Make sure that the power steering belt is properly positioned the pulleys. on . Do not get power steering fluid or greaseon the power steering belt or pulley faces,Cleanoff any fluid or greasebeforeinstallation
FOWER STEER G EELT PUTrlY
1 0 . Adiustthe pump belt (seepage17-141.

'l l. Fill the reservoirto the upper level line (see page
't7-151..
PUMP LOCK BOLT 24 N.m(2.4 kg{.m, tbfttl 1, Cover the IVC compressorwith several shop towels to protectit from spilledpowersteering fluid. Disconnect the pump inlet hose and pump outlet hose from the pump, and plug them. Takecare not to spill the lluid on the body or parts.Wipe off any spilledfluid at once. R e m o v et h e p u m p m o u n t i n gb o l t a n d p u m p l o c k bolt, then removethe pump. Do not turn the steering wheelwith the pump removed. Coverthe openingof the pump with a pieceof tape to preventforeignmaterialfromentering the pump.
17-24
Disassembly
Notetheseitemsduringdisassembly: duringassembly. . The powersteering are components madeof aluminum,Avoid damagingthe components air. partswith a solvent,and dry them with compressed Do not dip the rubber parts in a sol. Cleanthe disassembled vent. . Always replace O-ringsand rubbersealswith new ones beforeassembly. the procedures. in power steering fluid to the partsindicated the assembly . Apply recommended power steering system. to . Do not allow dust,dirt, or otherforeignmaterials enterthe areworn ordamaged. with asterisk(*) . Replace pump as an assemblyifthe partsindicated the
BOLTS FLANGE kgt'm, 20 N.m 12.0 1a tbf,ft) ROLLER SEAL PUMPCOVER
.PUMP COVER
*OUTERSIDEPLATE .PUMP CAM RING
*PUMPHOUSING 5l x 2.4 mm O-RING Repiace.
13x 1.9mm O-RING Replace. PUMPSEALSPACER INLETJOINT PUMPDRIVESHAFT FLANGE BOLTS 11 N.m 11.1 m, kgt 8 tbf.ft)
PULI.-EY NUT fl N.m (6.5kgf.m, /r7 lbf.ftl
(cont'd)
17 -25
PowerSteeringPump
1 . Drainthe fluid from the pump.
Inspection
Flow Control Valve 1. Checkthe flow control valve for wear, burrs, and other damageto the edges of the grooves in the
valve. '97 model: FLOW CONTROL VALVE
Hold the steering pump in a vise with soft jaws. hold the pulley with the specialtool, and remove the pulleynut and pulley.Be carefulnot to damage the pump housingwith the jaws of the vise. UNIVERSAL HOLDER 07725 0030000
'98 - 0Omodls: FLOW CONTBOL VALVE
Check for damage edges. to
Check damage for to edges.
Inspd the bore of the flow controlvalvetor scratches or wear. Slip the valve back in the pump, and checkthat it moves in and out smoothly.lf OK, go to step 4; if not, replacethe pump as an assembly.The flow controlvalveis not available separately.
L o o s e nt h e f l o w c o n t r o l v a l v e c a p w i t h a h e x wrench,and removeit. Remove O,ring,flow controlvalveand spring. the Remove inletjoint and O-ring. the Remove the pump coverand pump coverseal. 7 . Remove the outer side plate,pump cam ring, pump rotor,pump vanes,side plateand O-rings. 4. Removethe snap ring, then removethe sub-valve from the pump housing. 9 . Removethe circlip, then remove the pump drive shaft by tappingthe shaft end with the ptastichammer. 1 0 . Remove the pump sealspacer and pump seal.
CONTROL VALVE
Attacha hoseto the end of the valveas shown. FLOW CONTROL VALVE HOSE
17-26
5.
Submergethe valve in a containerof power steerand blow in the hose.lf air bubing fluid or solvent, bles leakthroughthe valve at lessthan 98 kPa (1.0kgflcm' ,14.2psi),repairit as follows('97model). For'98 - 00 models,the flow control valve cannot the replace pump as an assembly be disassembled;
AIR PRESSURE
Ball Bearing: '1. Inspectthe ball bearingby rotatingthe outer race slowly. lf any play or roughnessis felt, replacethe b a l lb e a r i n g .
BALLEEARING
POWER STEENING FLUIDor SOLVENT
6.
For'97 model only, hold the bottom end of the valvewith a open end wrench.Unscrewthe seatin the top end of the valve,and removeany shims,the relielcheckball,reliefvalveand reliefvalvespring.
RELIEF ALVE
2.
Replace ball bearingusinga press. the
{w@r
SEAT 9 N.m (0.9kgf.m, 6.5 lbfft) VALVE RELIEF SPRING
Hold this end with a open eno wrencn.
BALL RELIEF CHECK
Remove
lnstall Press
I
Press
VALVE FLOWCONTBOL
7.
C l e a na l l t h e p a r t s i n s o l v e n t ,d r y t h e m o t f , t h e n and reassemble retestthe valve. T h e r e l i e f p r e s s u r ei s a d j u s t e da t t h e f a c t o r y b y addingshims underthe checkball seat lf you found shims in your valve,be sure you reinstallas many as you took out.
lnstallwith the s red shaelded ide facing down.
the NOTErSuPPort innerrace with the tool securelY-
8,
lf the flow control valve tests OK, reinstallit in the pump. It the flow controlvalvestill leaksair, replace The flow controlvalve is the pump as an assembly. separately. not available
17-27
PowerSteeringPump
Reassembly
'1.
Align the pin of the sub-valve with the oil passage in pump housing, and push down the sub-valve. Install snsp ring properly. the
OIL PASSAG Alignthe pin of the oil passage.
5.
Coatthe pump coversealwith power steering fluid, and installit into the groovein the pump cover.
ROLLER SET HOLES
OUTER SIDEPLATE
PUMPHOUSING
#q ;1..*
SNAP RING
5 mrh ROLLER
Install the new pump seal(with its groovedside facing in) into the pump housingby hand,then install the pump sealspacer. Position the pump drive shaft in the pump housing, then drive it in usinga 29 mm socket shown, as
PUMPCOVER
lnstallthe oute. side plateoverthe two rollers. PUMP CAMRING
29 mm SOCKET
H go
/ /ffi\
,O mm CIRCLIP
DRIVE BALL BEARfNG /=\ PUMPun.t SHAFT grlu,e
ROLLER SET HOLES
1 /\
#
t/\ Y ry^\ d iI F
t\v4
PUMP SEALSPAC,ER
@.--#$i":*'
ROLLERS
PUMPHOUSING
7.
Set the pump cam ring over the two rollerswith the "' " markon the cam ring upward.
4,
Installthe 40 mm circlipwith its radiusedside facIng out.
17 -2A
8. Asssmble pump rotor to the pump cover, 9. Set the 10 vanes in the groovesin the rotor, Make surethat the round ends of the vanesare in contact of with the slidingsurface the cam ring.
fluid, and posi12. Coatthe O-ringwith power steering tion it into the pump housing.
FLANGEBOI-TS 20 N.m (2.0kgt m, 14 tbf.ft)
PUMPROTOR
51 x 2.4 mm O-RING Replace.
1 3 . lnstallthe pump cover assemblyin the pump housing. 1 4 . Coat the tlow control valve with power steering fluid. FLOW CONTROL VALVE 137modol)
1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d installit into the groovesin the side plate.

SII'E PLATE
Eg
I
15.2 x 2-1 ftm GRING Replace. Gfooves.
SPRING
15.2x 2.4 mm O.RING ('97 modell 16.7x'1.8mm O-RING
ROL1IR SET HOI,E
SETHOTT
FLOW CONTBOL VALVE l'98 - 0Omodeltl FLOW CONTROL VALVE CAP 49 N.m (5.0kgl.m, 36 tbf.ft)
BOLI-ERS
'15. Install flow controlvalveand springin the pump the housing. 1 6 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d installit on the flow controlvalvecap.
1 1 . Install the side plateon the cam ring by aligningthe
with the rollers. rollerset holesin the side Dlate
1 7 . Install flow controlvalvecap on the pump housthe (cont'd) ing,and tightenit.
17-29
PowerSteeringPump
Reassembly(cont'dl
'18. C o a t t h e O - r i n g w j t h p o w e r s t e e r i n gf l u i d , a n d installit into the groovesin the inletjoint. 21. Holdthe pulleywith the speciat toot, and tightenthe pulley ut. n
FLANGE BOLTS 11 N.m 11.1 kgf.m, 8 rbf.ft)
'13x '1.9 Replace. r
1 9 . Install the inletjoint on the pump housing. 20. I n s t a l lt h e p u l l e y a s s h o w n b e l o w . t h e n l o o s e l y installthe pulley nut. Hold the steeringpump in a vise with soft jaws. Be careful not to damagethe pump housingwith the jaws of the vise.
Checkthat the pump turns smoothlyby turning the pulleyby hand.
17-30
PowerSteeringGearbox
Removal
Notetheseitemsduring removal: . Using solventand a brush,wash any oil and dirt off the valve body unit its lines,and the end if the gearair. box. Blow dry with compressed . Be sure to removethe steeringwheel beforedisconnectingthe steeringjoint. Damageto the cable reel can occur. . With 4WD.tilt the enginewith a jack to expandthe clearancebetween the transfer assembly and rear beam when removingthe steeringgearboxfrom the rearoeam. Do not removethe steeringgearboxby removingthe transferassembly from the transmission. 1. fluid as described page on Drainthe power steering '17-15. Raise vehicle,and suppon it on safetystandsin the (seesection1). the properlocations Remove front wheels, the Removethe drive/s airbagassembly{seesection24). wheel{seepage 17-18). Remove steering the Removethe steeringjoint bolts, then disconnectthe steeringjoint by moving the joint toward the column. 7. Remove cotterpin from the nut, and removethe the castle nut {'97 - 98 models) or hex nut ('99 - 00 models).
COTTER PIN Replace. Installthe 10 mm hex nut on the ball joint. Be sure that the 10 mm hex nut is flush with the ball joint pin end, or the threadedsectionof the ball joint pin tool. Referto secmight be damagedby the special Be tion 18 for ball joint removerusageinstruction, carefulnot to damagingthe ball joint boot. the Separate tie-rodball joint and knuckleusingthe tool. special
UPPER JOINT BOLT
1 0 . Removethe right and left tie-rodends,then extend

the rackall the way to the right. 9). 1 1 . Remove TWC(seesection the the Disconnect shift linkagefrom the transmission (M/T:see section 13,A/T: see section 14).
1 3 . With 4WD. separatethe propeller shaft and transfer

(seesection161. assembly
LOWER JOINT BOLT
(cont'd)
17-31
(cont'dl Removal
1 4 . L o o s e nt h e 1 4 m m f l a r e nut, and disconnectthe pump outlethose.
AN'USTABLEHOSECLAMP
4WD:Stepr 18-22 18. Removetherighttront mount,then applyvinyl tape to the sideframe to protectit from the transmission coverand stop bolt.
12 x 1.25 fiiA Replace.
x 1,25mm
RIGHTFRONT MOUNT
NUT 14mm FLARE 15. Loosenthe adjustablehose clamp and disconnect the returnhose, 16. Loosenthe 16 mm flare nut, and removethe return hosejoint. 17. After disconnecting hosesand lines,plug or seal the to them with a pieceof tape or equivalent prevent foreign maisrialsfrom enteringthe valve body unit. NOTE: . Do not loosenthe cylinderline A and B between the valvebody unit and cylinder. . With 2WD, continue to step 23.
Vinyltapeor equivalgntmaterial.
SIDEFRAME
'19. Remove the left front mount, then apply vinyl tape to the side frame to protect it from the stop bolt.
Vinyltapor m6terial. equivalnt STOPBOLT
10x 1.25mm
17 -32
20. Remove the rearmount bracket and rear mount. MOUNT REAR
12x 1.25mm Replace.
22. Jack up the engineand tilt the enginebackuntil the 40 transferassemblyis loweredapproximately mm ( 1 . 5 7n ) . i Notetheseitemswhen tiltingthe engine: . Checkthat the wire harnesses, hosesand pipes parts. are not caughtby any surrounding . Do not tilt the enginemore than necessary.
.Lowerapproximately '40 mm (1.57 in)
REARMOUNT BRACKET
12 x 1.25mm Replace.
14x 1.5mm Replaco. 2 1 . P l a c ea j a c k u n d e r t h e e n g i n e b l o c k i n t h e a r e a shown,
ASSEMBLY
Remove stiffener the olate. platemountingbolts a.e also NOTE:Somestiffener used as gearboxmounting bolts.The gearboxwill tilt to the sidewhen theseboltsare removed.
STIFFENER PLATE
?*
JACK.UPPOINT
(cont'd)
17-33
(cont'dl Removal
24. Remove mountingbrackets. the
Disassembly
Steering RackDisassembly Notetheseitemswhen disassembling: . Beforedisassembling the gearbox,wash it off with solventand a brush. . Do not dip sealsand O-ringsin solvent. 1. 2. gearbox(seepage 17-31). Remove steering the airtube and clips. Remove
MOUNTINGBRACKETS AIR TUBE
25. lvlovethe steeringgearboxto the right so the left rack end clearsthe rear beam, then placethe left rackend belowthe rearbeam. 3. Remove boot bandsand tie-clips. the
GEARBOX STEEBING
Move the steeringgearboxto the left, and tilt the left sidedown to removeit. With 4WD. remove the steering gearbox through the clearancebetweenthe transfer assemblyand propeller shaft.
4.
Pullthe bootsawayfrom the endsof the gearbox.
17 -3 4
5.
Hold the steeringrackwith a wrench {'98- 00 models: left end onlv), and unscrewthe rack end with anotherwrench,Be carefulnot to damagethe rack surface with the wrench,
cylinderlinesA and B from the gearbox, 8. Remove
WASHER LOCK
LINE CYLINDER A 9 . Drain the fluid from the cylinderfittings by slowly movingthe steeringrackbackand {orth. Remove two tlangebolts,then removethe valve the body unit from the gearbox. (See page 17-38for valvebody unit disassembly.)
DUSTCOVER VINYLTAPE RACK GUIDE FLANGE BOLT
6.
L o o s e nt h e l o c k n u t , h e n r e m o v et h e r a c k g u i d e t screwand O-ring('97model).
LOCKNUT
1 1 . Apply vinyl tape to stepped portion of the pinion
1.
Removethe spring and the rack guide from the gearDOX.
shaft,and removethe dust cover. (cont'd)
17-35
Disassembly {cont'd}
12. Drill a 3 mm (0.12in) diameterhole approximately 2.5 - 3.0 mm (0.10- 0.12in) in depth in the staked point on the cylinder.Do not allow metal shavings to enter the cylinder housing.After removing the cylinderend, removeany burrsat the stakedpoint. '12 14, Assemble 12 x 1.25mm flangenut onto a a x 175 mm grade 10 flangebolt as shown,Wrap the flange portion of the bolt with vinyl tape to protect the cvlinder,
D.oth: 2.5- 3.0mm 10.10 0.12inl
12mmFLANGENUT VINYL TAP tp/N90177 SLO OOOI 1 5 . Installthe flange bolt into the end of the steering r a c k u n t i l i t b o t t o m s i n t h e h o l e .t h e n b a c kt h e flange bolt out 1/4 turn. Hold the flange bolt, and tightenthe flangenut against the rackby hand. Installthe bearingseparatoron the gearbox housing as snown.
CYUNOER
BEARING SEPARATOR 0- 1112' (Commercially available)
13. Hold the gearboxusing using a C-clampas shown, Loosen and removethe cvlinderend.
STEERINGRACK CYLINDER ND
1 7 . Set the gearbox in a press so the lelt side points upward,then pressthe cylinderend seal and steering rack out of the gearbox.Hold the steeringrack clear.Be careto keep it from fallingwhen pressed f u l n o t d a m a g et o i n n e r s u r f a c eo f t h e c y l i n d e r housingwith the flangebolt.
17-36
18. Removethe 12 mm bolt and nut trom the stsering rack, 19. Remove the cylinder end seal from the steering racK.
22. Carelully pry the piston sesl ring and O-ring off the piston rack.Be carefulnot to damagethe insideof seal ring groove and piston edgeswhen removing the sealring.
Replace.
CI
20. lnsert a 24" long,3/8" drive extension and the special tool into the cvlinderfrom the left side. Make sure that the specialtool is securelypositionedon the backup ring edges. Be careful not damage to innersurface the cylinder of with the special tool.
Prass 24 'LONG 3/8' DRIVEEXTENSION (Commerciallv available) Replaco.
I I
BACKUPRING END SEAL CYLINDER
ENDSEAL CYLINDER ATTACHMENT REMOVER 07NAD- SR3020A
2 1 . Set the gearboxin a press, then pressout the cylinder end sealand backupring from the gearbox. Note these items when pressingthe cylinder end seat: . K e e pt h e t o o l s t r a i g h tt o a v o i d d a m a g i n gt h e cylinder wall.Check tool angle, the and correct if it necessary, when removing cylinder the end seal. . Use a pressto removethe cylinderend seal.Do not try to removethe seal by strikingthe tool. lt will breakthe backupring, and the cylinderend sealwill remainin the gearbox.
(cont'dl
17-37
Valve Body Unit Dbassembly 23. Beforeremovingthe valvehousing, applyvinyltape to solinesof the Dinionshaft.
VALVEHOUSING
2 6 . C h e c kf o r w e a r , b u r r s a n d o t h e r d a m a g et o t h e edgesof the groovesin the sleeve. NOTE:The pinion shaft and sleeveare a precision m a t c h e ds e t . l f e i t h e r t h e o i n i o n s h a f t o r s l e e v e must be replaced, replace both partsas a set.
SEALRINGS SLEEVE Checkfor Deeloff or
Separate the valve housingfrom the pinion shafv valveusinga press. Check the innerwall of the valve housingwhere the seal ring slideswith your finger.lf there is a step in t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c eh e t valve housing. Notetheseitemsduringinspection: o There may be the sliding marks from the seal ring on the wall of the valve housing. Replace the valvehousingonly if the wall is stepped. . When the valve housingis replaced, installnew shim{s)on the bearingsurfaceof the housingto adiustthe thickness.
C h e c kt h e i n s i d e o f v a l v e h o u s i n g for a step in the wall.
from the pinionshaft. 27. Remove circlipand sleeve the
17-38
28. Usinga cutte. or an equivalent tool, cut and remove the four seal ringsfrom the sleeve. carefulnot to Be damagethe edgesot the sleevegroovesand outer surface when removingthe sealrings.
3 0 . R e m o v et h e v a l v e o i l s e a l a n d b a c k u pr i n g ( ' 9 7 model)or wave washer ('98 - 00 models)from the pinionshaft. Notetheseitemsduringdisassembly: . Inspect ball bearingby rotating the the outer race slowly. lf there is any excessiveplay, replacethe pinionshaftand sleeve an assembly. as . The pinion shaft and sleeveare a precise do fit; n o t i n t e r m i xo l d a n d n e w D i n i o ns h a f t sa n d sreeves,
BALLBEARING WAVE WASHER l'98 - 0Omodelsl
SLEEVE
29. Using a cutter or an equivalenttool. cut the valve s e a l r i n g a n d O - r i n ga t t h e g r o o v e i n t h e p i n i o n shaft. Removethe valve seal ring and O-ring. Be carefulnot to damagethe edgesof the pinion shaft grooveand outer surfacewhen removingthe valve sealrjng and O-ring.
PINION SHAFT
Replace. 3 1 . Pressthe valveoil sealand roller bearingout of the valve housing using a hydraulicpress and special tool shown below.
BACKUPRING {'97 modell
VALVEOIL SEAL
Cuftingslot position. PILOTCOLLAR
ROLLER SEARING
Reassembly
Notetheseitemsduring reassembly . Cleanthe disassembled partswith a solvent,and dry them with compressed Do not dip the rubberparts in a solair. vent. . Always replace O-ringsand rubbersealswith new ones beforeassembly. the procedures. . Apply the recommended powersteering in fluid to the partsindicated the assembly . Do not allow dust.dirt, or othertoreignmaterials enterthe power steering system. to . Usethe appropriate specialtools where necessary. FLANGE BOLTS 20N.m(2.0 kgl.m, 14lbtftl
CYLINDERLINE A FLARE NUTS 17 N.m 11.7 12 rbl.ftl
VALVEHOUSING
VALVEOIL SEAL Beplace. ROLLER BEARING END SEAL CYLINDER Replace. \ BA.KUP RING CIRCLIP Replace.
WAVEWASHER
HOUSING
RING BACKUP Replace. 97 model: VALVESEALRING Replace.
\/^"
O.RING Replace. 32 mm SHIMS '97 mod6l only: RACKGUIDESCREW
@---r-ocxr'rur
'97 model: O-RING Replace. '9? model only: '98 model: '99 - 0Omod6ls:
END CYLINDER 69 N.m (7.0 kgf.m, 51 lbf.ft)
'98 - (x) models:
PISTON SEALRING Replace.
STEERING RACK
17-40
Valve Body Unh Roa$embly 1. Apply vinyl tape to the steppedportion of the pinof ion shaft,and coat the surface the vinyl tape with fluid. the power steering VALVEOIL SEAL
Vinyl tape (Stopp6d portion) Serling Replace. Makesurethe springis seatedin the oil seal.
8. Apply power steering fluid to the surface of the v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n shaft. Apply power steeringfluid to the insideof the special tool. Set the largerdiameterend of the special tool overthe valvesealring.
VALVESEALRING SIZNG TOOL 07NAG - SR309q' ot 07NAG - SR3oltoA
E
PINIONSHAFT BACKUP RING 137 modell
\ /
WAVEWASHER {'98- 00modelsl Installthe backupring {'97 model)or wave washer ('98- 00 models). Coat the inside surface of the new valve oil seal with powersteering fluid. Install the valveoil sealwith its groovedside facing oppositethe bearing,then slide the valve oil seal over the pinion shaft, being carefulnot to damage l t h e s e a l i n gi p . Apply vinyl tape to the splinesand steppedponion of the shaft, and coat the surfaceof the vinyl tape with the power steering fluid.
PINIONSHAFT
Usgth6 largr diameter end of the special toollirst to make th valve seal ring tit in the pinion shaft.
tffifrE-r 7 r.] r\-'']
Mak the valve seal ring fit snuglyin the pinion shatt using th6 other end diameter end)ot {smaller the specialtool.
Vinyl trp
times to 1 0 . Move the special tool up and down several makethe valvesealring fit in the pinionshaft,
1 1 . Remove the soecial tool.
12. Turn the special tool over,and set the smallerdiameter end of the specisltool over the valveseal ring. times to Move the special tool up and down several m a k et h e v a l v e s e a l r i n g f i t s n u g l yi n t h e p i n i o n shaft.
O.RING Replace. Do not twist. RplaceDo not over-expand.
Fit the new O-ringin the grooveof the pinion shaft. Then slide the new valve seal ring over the shaft and in the grooveon the pinionshaft, 7 . Remove vinyl tape from the pinionshaft. the
(cont'd)
17-41
(cont'd) Reassembly
fluid to the surfaceof the spe1 3 . Apply power steering tool cialtool. Set the new sealrings overthe special f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l . a n d e x p a n dt h e s e a l r i n g s .I n s t a l l w o r i n g s a t a t i m e t Jromeachend ofthe sleeve. Notetheseitemswhen installing sealring: the . Do not over-expand sealring. Install the resin the seal rings with care so as not to damagethem. A f t e r i n s t a l l a t i o nb e s u r e t o c o n t r a c t h e s e a l , ringsusingthe specialtool{sizing tool). . There are two types of sleeveseal rings: black and brown. Do not mix the different types of sleevesealringsas they are not compatible. 1 4 . Align the specialtool with each groove in the sleeve, and slide a sleeveseal ring into each groove.After installation, compressthe seal rings with your fingerstemporarily.
BALLJOINT BOOTCLIPGUIDE 07974- SA508q) SLEEVE
18. Apply power steeringfluid to the surfaceof the pinion shaft.Assemble sleeveover the Dinionshaft the b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e sleevewith the cutout in the shaft.Then installthe in new circlipsecurely the pinionshaftgroove. Notetheseitemsduring reassembly: . B e c a r e t u l n o t t o d a m a g et h e v a l v e s e a l r i n g when inserting sleeve. the . Install circlipwith its radiused sidefacingout. the
CIRCLIP
fluid to the seal ring lip of the 1 9 . Apply power steering valveoil seal.then installthe seal in the valvehouspressand special tools. Install ing using a hydraulic the valve oil sealwith its groovedside facingthe tool.
ATTACHMENT, 32x35mm 077i16 (x)10100
1 5 . Apply power steeringfluid to the seal rings on the of sleeve, and to the ehtireinsidesurface the special tool.
SLEEVE SEALRING SIZINGTOOL 07974- SA502O0 or 07974- SA5020A
1 6 . Insertthe sleeveinto the special tool slowly.
't1. Move the sleeve each direction several times to

makethe seal rings snuglyfit in the sleeve. sure Be that the seal ringsare not turned up,
VALVEOIL SEAL Replace. Makesurethe springis in the oilseal.
20. Pressthe new bearinginto the valve housingwith press the stampedletterfacingup usinga hydraulic and soecialtool.
DRIVER ATTACHMENT, 32x35mm 07746 0010100
2 4 . P r e s st h e p i n i o n s h a f t / s l e e v e s i n g a h y d r a u l i c u p r e s s . C h e c kt h a t t h e p i n i o n s h a f t / s l e e v eu r n s t smoothlyby turningthe pinionshaft,
BEARING ROLLER Letterstampedface
21. Apply vinyl tape to the pinion shaft, then coat the vinyltape with powersteering fluid.
Sealinglip tace.
VALVEOIL SEAL
VALVEHOUSING
PINION SHAFT
E
SEAL SLEEVE 8e surethat the sealringsare not turnedup,then install.
22, Insertthe pinion shaft into the valve housing. Be carefulnot to damage the valvesealrings. 23. Removethe vinyl tape from the pinion shaft,then removeany residue from the tape adhesive. (cont'd)
17-43
(cont'dl Reassembly
Stecring RackR8assembly 25. Coatthe pistonseal ring guide with power steering fluid,then slideit onto the rack,big end first. 26. Position new O-ringand new pistonseal ring on the the sDecial tool, then slide them down toward the big end of the tool. Notetheseitemsduring reassembly: a Do not over expandthe resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, sure to contract be the sealring usingthe special tool (sizing tool). a Replace piston'sO-ringand sealring as a set. the 27. Pull rhe O-ringoff into the pistongroove,then pull the pistonsealring off into the pistongrooveon top of the O-ring.
PISTON
31. Wrap vinyl tape aroundthe rackteeth and rack end edges,then coat the surface of the tape with the power steeringfluid. Make sure that the vinyl tape is wrappedcarefully that there is no steppedporso tion.
Coatthe insidesurfaceof the new cvlinderend with powersteering fluid. Installthe cylinderend seal onto the steeringrack w i t h i t s g r o o v e d s i d e t o w a r d t h e p i s t o n .W h e n installing cylinderend seal,be carefulnot damthe agethe sealinglip faceof the sealwith the edgesor teethof the steeringrack. CYLINDER SEAL END
24. Coatthe pistonseal ring and the insideof the specialtool with power steering fluid.
PISTON Replace
E
07GAG SO4O200 or OTGAGSD'()2OA Carefullyslide the tool onto the rack and over the pistonsealring. 30. Move the specialtool backand fonh severaltimes to makethe pistonseal ring fit snugly in the piston.
Make sure the spring is in lhe cylinder eno seal
Removethe vinyl tape from the steeringrack,then removeany residue from the tape adhesive.
17-44
35. Install the new backup ring on the steering rack, then placethe cylinderend sealagainst piston. the
RING BACKUP Replace.
37. Installthe flange bolt into the end of the steering f a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h e f l a n g eb o l t o u t 1 / 4 t u r n . H o l d t h e f l a n g eb o l t a n d the rackby hand. tightenthe flangenut against
Prers
12 x'175 mm FLANGEBOLT lP/N 90177- SLo- 0001 12 mm FLANGE NUT
to.
Grease steeringrackteeth,then insertthe steerthe ing rack into the gearboxhousing,Be carefulnot to damageto inner surfaceof the cylinder wall with the rackedges.
CYLINDER ENDSEAL Replace.
GEARBOX HOUSING
38. Installthe cylinderend seal into the bottom of the

cylinderby pressing the bolt with a press,Do not on p u s h o n t h e b o l t w i t h e x c e s s i v eo r c e a s i t m a y f damagethe cylinderend seal.
ia
R e m o v et h e f l a n g e b o l t , a n d c e n t e rt h e s t e e r i n g rack.
40. W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s ,a n d coatthe surfaceof the tape with the power steering fluid. Makesurethat the vinyl tape is wrappedcarefully so that there is no steppedportion.
(cont'dl
17-45
(cont'dl Reassembly
4l. Coatthe insidesurfaceof the new cvlinderend seal with powersteering fluid.
ENOSEAL CYLINDEB Replace. Makesurethe spring is in the cylinder end seal.
46. Greasethe insidesurtaceof the cylinderend, then installthe cylinderend by screwingit into the cylinder. 41. Remove C-clamp the from the gearbox. 48. After tighteningthe cylinderend, stakethe point of the cylindershown below.Stakethe cylinderin the position oppositefrom where the stakewas removed duringdisassembly, go NOTE:For '98- 00 models, to step54.
Stake point, Depth: 1,0 mm (0.04inl
Staked
posrtron. 4.0mm {0.16 in) Grooved side.
42. Installthe cylinderend seal onto the steeringrack with its groovedsidetowardthe piston.
43. P u s h i n t h e c y l i n d e r e n d s e a l w i t h y o u r f i n g e r .
When installing cylinderend seal,be carefulnot the damagethe sealing faceof the sealwith the threads a n d b u r r s a t t h e s t a k e dp o s i t i o n o f t h e c y l i n d e r housing. 44. Removethe vinyl tape from the steeringrack,then removeany residue from the tape adhesive. 45. Holdthe gearbox usinga C-clamp shown. as
BUSHING CYLINDER END 69 N.m (7.0kgf.m,51 lbtft)
-tG
8e careful to damage not the bushing when inserting the cylinder end.
49. Select the 32 mm shim(s)('97 modelonlv). N O T E :O n l y r e i n s t a l t h e o r i g i n a l3 2 m m s h i m ( s ) l when the steeringgearboxis reassembled without replacing the pinionshaft.valve housing,and gearbox housingwith new ones. l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x housingare replaced, selectthe new shim{s)as follows. Shim selection: Set the four 32 mm shims on the bearingsurfaceof the g e a r b o x h o u s i n g .T o t a l t h i c k n e s so f t h e f o u r s h i m s shouldequalno more than 0.70mm. Shim set: four 32 mm shims (Thickness: 0.10 mm, 0.15 mm, 0.20mm, 0.25mm respectively) N O T E :T h e f o u r 3 2 m m s h i m s d o n o t h a v et h i c k n e s s identification marks.Measure thickness eachshim the of usinga micrometer, markthe shim for identification. and
C.CLAMP
GEARBOX
17-46
5 0 . I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x .a n d torque. tightenthe flangeboltsto the specified VALVE BODY FLANGE BOLT 20 N.m12.0 kgt.m, 14lbtft)
Example: is in); Measurement 0.28mm (0.011 1 i m 0 . 7 0 - 0 . 2 8 = 0 . 4 2 m ( 0 . 0 2 8 - 0 . 0 1= 0 . 0 1 7n ) i T h e s e l e c t e d h i m s s h o u l db e 0 , 2 5m m ( 0 . 0 1 0 n l a n d s in) 0.15mm (0.006 in thickness. lf the required shim thicknessis 0.10 mm or less, no shrmsare necessary. 32 53. Set the selected mm shims on the bearingsurfaceof the gearboxhousing.
SHIM SET (fourshims)
VALVEBODY UNIT
FLANGE BOLT 20 N.m (2.0 kgf.m, la lbl.frl
E?
a)
/
O.RING Replace.
-6{
ct.
Measurethe clearancebetween the gearbox and valve body unit using a feelergauge.Measurethe c l e a r a n c e t t h e p o i n l m i d w a y b e t w e e nt h e t w o a mountingbolts.
GAUGE BEARING NEEDLE
-6lr
fit and carefully it 54. Coatthe new O-ringwith grease, on the valvehousing. Apply greaseto the needlebearingin the gearbox housing. t D e t e r m i n e h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m obtainedin the the shims by subtracting clearance of step "c" from the total thickness the four shims. ) ( T o t a lt h i c k n e s s f t h e 4 s h i m s ) - ( C l e a r a n c e= o Reouired thickness the shims of is Selectthe shims so that the total thickness close thickness. to, but lessthan,the required 56. Installthe valve body unit on the gearboxhousing by engaging the gears. Note the valve body unit position(direction line connection). of installation torque. 5 7 . Tightenthe flangeboltsto the specified
(cont'd)
17-47
(cont'dl Reassembly
58. InstallthecylinderlinesA and B Notetheseitemsduring reassembly: . C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e sA a n d B thoroughly.The joints must be free of foreign material, . lnstall the cylinder lines A and B by tightening the flare nuts by handfirst,then tightenthe flare nutsto the soecified torque.
12lbf.ttl 17 N.m 11.7kgd.m,
(
6 3 . I n s t a l lt h e n e w l o c k w a s h e r n t h e g r o o v e i n t h e i steering rack.
LOCKWASHER Replace. STEERING RACKENO 54 N.m (5.5kgf.m,40 lbtftl
26 N.m {2.7 kgl.m, 20
STEERING
64. Screwthe rackends into the rack. Hold the steering rack with a wrench ('98 - 00 models: left end only), and tighten the rack ends. Be careful not to damage the rack surface with the wrench. After tighteningthe rack ends, stakethe four sections of lockwasherwitha drift and a mallet. . Place wood blockon the presstable,then set the the lock washer section of the rack end on the wood block securely. Be sure the tool is aligned with the flat sections of the steering rack end before pressing. Stake the lock washer in the center of the flat section of the steering rack end,
ROLLPIN PUNCH lCommorcially.Y.il.blel Snap-OnNo. PPR8or oquival.nt.
CYLINDEF A LINE Greasethe sliding surface of the rack guide, and installit onto the gear housing.
60. For'97 model,applya thin coatof grease the new to

O-ring,and installit on the rackguidescrew. For'98 - 00 models.removethe old sealantfrom the threadsof the rackguide screw.then apply new sealant the first threethreads. to
RACK GUIOE
. .
-6r
SCREW LOCKNUT
nlcr cutDE R"Pl""u'
O-RING
37 model:
38 model:
NOTE: This drift has a flat shoulderto prevent puncturing metalwasher. of

ot.
Installthe spring, rack guide screw and locknuton the gear housing. Adjustthe rack guide screw (seepage 17,15). After adjusting,checkthat the rack moves smoothly by slidingthe rackright and left.
STEERING RACK
WOODEN BLOCK
17-48
of 67. Apply greaseto the circumference the rack end housing.
70. Adiust the air hose fitting positionof the boots by turning it as shown below. LEFT BOOT fromthe {Viewed leftside)
RIGHTBOOT (Viewedtrom the rightside)
ro
''rT.a'.
Front
+
GROOVE END RACK .={@ GREASE SILICONE 68. A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t grooveson the rackends. 69. lnstall the boots in the rack end with the tie-rod clips. NOTE:Installthe bootswith the rackin the straight ahead position (right and left tie-rodsare equal in length).
RACK ENO
\,'tAr-
, tri"
\
{,1@}tr )Fr1
FIT'I'ING
BOOT AIR HOSEFITTING
71. Installnew boot bandson the boot, and bend both setsof lockingtabs. CAUTION: Stake the band locking tabs firmly.
NOTE: Wipe the greaseoff the threadsection.
portionsto reduce Lightlytap on the doubled-over their height. Slide the rack right and left to be cenain that the bootsare not deformedor twisted. (cont'd)
TIE.ROD CLIP
17-49
(cont'd) Reassembly
7 4 . C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t boot,
CYLINDER LINEA
BallJoint Boot Replacement

't. Remove boot set ring the and the boot.
CAUTION:Do not contaminatethe boot inslallation section with graase. Pack the interiorof the boot and lip with grease. Wipe the greaseoff the sliding surfaceof the ball pin.then packthe lower areawith freshgrease. CAUTION: . Keep greaseoff the boot installation section and the tapered section of th ball pin. . Do not allow dust, dirt, or other to.eign materials to enter the boot.
EALLPIN TAPERED SECTION Wipe olf the grease.
CYLINDER LINE
75. Installthe clips on the cylinderlines,then clampthe air tube with the clips.
B(X)T IT{STALLATION
76. Apply vinyl tape to around the pinion shaft, and coat the surfaceof the tape with grease. DUST COVER
Vinyl Tsp
sEclroN
Wipe off the grease.
BOOT INSTALLATION SECTION Wipe offthe grease.
Install the boot in the grooveof the boot installation section securely. then bleedair. Adjust the specialtool with the adjustingbott until the end of the tool aligns with the groove on the boot. Slidethe set ring over the tool and into posiI|on. CAUTION: After installing the boot, chock the batl pin lapered section for grease contamination and wipe it it ncessary.
VALVEBODYUNIT ADJUSTINGBOLT Adiustthe depth by turningthe bolt.
VALVEOIL SEAL
77. P a c kt h e i n t e r i o r o f t h e d u s t c o v e r a n d l i o w i t h grease, then installdustcoveron the valvebodv unit. Remove vinyl tapef.om the pinionshaft. the
SET RING
17-50
lnstallation
1. extendthe rackall the the Beforeinstalling gearbox, right. waYto lnstallthe mounting cushion on the steerlnggearbox. Passthe right side of the steeringgearbox above and throughthe right sideof the rearbeam.Be careful not to bend or damagethe two power steering 5. I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x mounting bolts and stiffenerplate attachingbolts. Be sure the air tube is not caught or pinched by stiffener plate. Installthe bolts loosely first. then tightenthem securely. to NOTE:With 2WDcontinue step 11.
PLATE STIFFENER MOUNTINGBOLTS 38 N.m
2.
3.
:/
GEARBOX STEERING
I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t i n g c u s h i o n .t h e n i n s t a l lt h e t w o g e a r b o xm o u n t i n g b o l t s .P o s i t i o nt h e s p l i t p o r t i o no f t h e m o u n t i n g cushionas shown.
MOUNTINGBBACKETS
With 4WD,lower the iack,and returnthe engineto the originalPosition. 1. l n s t a l lt h e r e a r m o u n t a n d r e a r m o u n t b r a c k e t . Tightenthe mountingbolts in order:A, B and C.
8.12 x 1,25mm 59 N.m (6.0 kgt.m. *l lb{'ftl Replace. 10 x 1.25mm 6,aN.m 16.5kst.m, 47 lbl'ft) Rplace.
) \ ^
o ( ]
MOUNTING GEARBOX BOLTS 39 N.m kgf.m, 29 lbf.ft) 14.0
17-51
8, Installthe left front mount. Tighten the mounting boltsin order:A and B.
B-12x 1,25mm 59Nm (6.0 kgtm,, lbl.ftl Replaca.
11. Installthereturnhosejoint by tightening the 16 mm flare nut.
LEFTFRONT MOUNT
AD.'USTAB[THOSECLAMP (Forinstallation reterto page 17,23)
RETURN HOSEJOINT: 16 mm FLARE NUT 28 N.m kg{.m.21 lbt{t) 12.9
A-10x 1.25mm 4,1N.m la.s kgt m, 33 lbf.ft)
9.
Instsllthe right front mount, Tightenthe mounting bolts in order:A and B.

14 mm FLARE NUT 37 N.m (3.8 ksf.m, 27 lbl'frl A-10x 1.25mm a,aN.m
B-12x 1.25mm 59 N.m 16.0ks[.m, ,|:| lbf.ftl Replace.
't2. Connectthe return hose securely. and tighten the

adjustable hoseclamp.
1 3 . Connectthe pump outlet hose, and tighten the l4

mm flare nut. NOTE: Makesure that there is no interference betweenthe fluid lines,the rear beam or any other parts.
10. Removethe vinyl type from the side frame (both sides).
17-52
't4. Center steeringrackwithin its stroke. the

the 1 5 . Installthe steeringjoint, and reconnect steering shaftand pinionshaft. as NOTE:Make surethe steeringjoint is connected follows. joint onto the a. Insenthe upperend of the steering steeringshaft (line up the bolt hole with the flat on the shaft). JOINT BOLT UPPER 22 N.m 16lbl.ft, kgf.m, 12.2
17. Wipe off any greasecontaminationtrom the ball joint taperedsectionand threadsthen reconnect the For'97 - 98 tie-rod ends to the steeringknuckles. models;torque the castle nut to the lower torque s p e c i f i c a t i o nt,h e n t i g h t e n i t o n l y f a r e n o u g h t o alignthe slot with the pin hole.Do not align the nut Installnew cotterpins. by loosening.
END TIE.ROO
HEX NUT l'g!t - 00 modeb)

JOINT STEERING
il:l N.m
CAST1TNUT (9t - 98 modol!) 39 - iU N'm lil.o - 4.8 kgl.m, 29 - 35 tbf.ftl
ksl.m, 14.4 32 tbf.f0
'99 - lD modeb:
COLUMN SHAFT
LOWER JOINTBOLT 22 N.m 16lbtftl kgf.m, 12.2

UPPER JOINT BOLT Bolt must line up with tlat on shatt.
PIN COTTER RePlace. bend on reassembly, thecotter asshown. Pin 1 8 . With 4WD,connectthe propellershaft and transfer (seesection16). assembly (M/T: 1 9 . Connectthe shift linkageto the transmission 13,A,/T;see section 14). see section 91. 20. InstalltheTwc (seesection 2 1 . lnstallthe front wheels, 22. Fill the systemwith power steeringfluid, and bleed air from the system(seepage 17-15). performthe followingchecks. 23. After installation. . S t a r t t h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e steering wheel from lock-to-lockseveraltimes to warm up the fluid. Checkthe gearboxfor leaks (seepage17-23). Adjustthe front toe (sesection18). Checkthe steeringwheel spokeangl.Adjust by turning the right and left tie-rodsequally,if necessary.
LOWER JOINT BOLT Bolt must lineup with groove around on shaft. PINION SHAFT
b, Slip the lower end of the steeringioint onto the pinionshaft. c. Installthe lower joint bolt (line up the bolt hole with ths groove around the shaft).Be sure that the lower joint bolt is securelyin the groove in the pinionshaft. d. Pull on the steeringjoint to make sure that the joint is fully seated. steering e, Install the upperjoint bolt, wheel{seepage'17-19). 1 6 . Reinstall steering the
. .
17-53
Suspension
............. 18-2 Tools Special ComponentLocations ...... 18-3 lndex ................ WheelAlignment 18-4 Service lnformation......................,.. .................. 18-4 Camber ...... 18-5 Caster............... Front Toe Inspection/ ........ 18-5 Adiustment RearToe Inspection/ 18-6 ........ Adiustment Turning Angle Inspection/ 18-6 ........ Adiustment Wheel/HubInspection 18-7 Bearing End Play .......................,...... ....... 18-7 WheelRunout Front Suspension Arms Replacement.....18-8 Suspension 18-9 ............. Knuckle/Hub Replacement ....... 18-15 LowerBallJoint Replacement .......... 18-16 BallJoint Boot Replacement Front Damper 18-16 ................. Removal 18-1 .................. 7 Disassembly/lnspection 18-18 ........... Reassembly 18-18 ............. lnstallation RearSuspension Arms Replacement.....18-19 Suspension ......18-20 Hub BearingUnit Replacement Upper Arm Bushing .....18-23 Replacement RearDamper 18-23 ................. Removal 18-24 .................. Disassembly/1nspection 18-25 ........... Reassembly ............. 18-25 lnstallation
S p e ci a l T ools
Ref.No.
Tool Number 07GAF SE00l00 07GAG SD40700 07JAF SH20200 07LAD SM40100 07MAC- S100200 07746 0010200 07749 0010000 07947 6340400 07965 SA50100 07965- 5400600 07965 S800100 07965 S800200 07965 SD90100 07974 SA50700 Hub Dis/Assembly Tool B a l lJ o i n tB o o tC l i pG u i d e BallJoint Remover Base DriverAttachment, mm 60 B a l lJ o i n tR e m o v e r , 2 m m 3 DriverAttachment,3T 40 mm x Driver DriverAttachment, x 64 mm 62 Hub Dis/Assembly Tool DriverAttachment BallJoint Remover/lnstaller BallJoint Installer Base SupportBase BallJoint BootClip Guide
1 1 1 1 1 1 1 1 'l I 1 1 I 1
o
/a @
/6
r 8-'13 ' 1 81 6 18-15 1A-22 1a-1't,12 1a-21 1 8 - 1 31 4 , 2 1 , 2 2 , 18-13 1a-22 18- 4 1 18- 5 1 18-15 l8-14 18-16
o
@
6r
lol
@ @ @
f1 U
.4.@
@,@,@,@
o,o
c0
18-2
ComponentLocations
FrontSuspension:
BAR STABILIZER
LOWER ARM
Rear Suspension:
REAROAMPER BAR STABILIZER ARM UPPER
LOWER ARM
COMPENSATOB ARM
TRAILING ARM
18-3
WheelAlignment
Caster
F o r p r o p e ri n s p e c t i o n / a d j u s t m eo f tt h e w h e e l a l i g n n ment, checkand adjustthese items beforecheckinq the alignment: . Check that the suspension not modified. is . Check tire sizeand tire pressure. the . Check runoutof the wheelsand t;res, th( . Checkthe suspension ball joints.(Hold a wheel with your hands,and move it up and down and right and leftto checkfor wobbling.)
Camber
Inspection
U s e c o m m e r c i a l l y - a v a i l a b lo m p u t e r i z e l o u r w h e e l ce d alagnment equipment measure to wheel alignment(cast, e r , c a m b e r , o e , a n d t u r n i n ga n g l e ) . o l l o wt h e e q u i p , t F ment manufacturer's instructions. 1 . C h e c kh e c a m b e r n g l e . t a Camberangle: Front: 0'00' 1 1" Rear: 1' :! 1" 2. lf out of specification, checkfor bent or damaged suspensron components.
Inspection
U s e c o m m e r c i a l l y - a v a i l a b lo m p u t e r i z e f o u r w h e e l ce d a l i g n m e ne q u i p m e nt to m e a s u r e h e e la l i g n m e n(tc a s t t w e r , c a m b e r , o e , a n d t u r n i n ga n g l e ) . o l l o wt h e e q u i p t F ment manufacturer's instructions.
1. Check the caster angle. Caster angle: 2'10':t 1" lf out of specificationcheckfor bent or damaged , suspension omponents. c
18-4
FrontToe Inspection/Adjustment
ce d U s e c o m m e r c i a l l y - a v a i l a b lo m p u t e r i z e f o u r w h e e l (caster, wheelalignment to alignment equipment measure toe, and turning angle).Follow the equipment camber, instructions, manufacturer's
1.
RearToe Inspection/Adjustment
ce d U s e c o m m e r c i a l l y - a v a i l a b lo m p u t e r i z e f o u r w h e e l (caster, wheelalignment equipment measure to alignment camber.toe, and turning angle).Follow the equipment instructions. manufacturer's
1.
Check tire pressure. the Centerthe steeringwheel spokes.
Releaseparking brake to avoid an incorrectmeasurement. the Check toe.
3.
C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t ahead. Fronttoe-in:0 i 3 mm {0 t 1/8 inl go is lf adjustment required, on to step 4. lf no adjustmentis required,remove alignment equipment.
Ro8rtoe-in:2 :1 mm {lN l/16:t 1/16 in, go is lf adjustment required, to step2. lf no adiustmentis required.remove alignment equrpmenr.
note the locationsof adjusting Beforeadjustment, arms. boltson the right and left compensator Loosenthe adjustingbolts, and slide the compensatorarm in or out. as shown,to adiustthe toe.
FLANGEBOLT '10 1.5mm x kgf.m, 47 lbf'ftl 6a N.m 16.5
and turn both tie-rods Loosenthe tie-rod locknuts, i n t h e s a m e d i r e c t i o nu n t i l t h e f r o n t w h e e l s a r e pointingstraightahead.
sir N m (5.5kgJ.m,'O lbf.ft)
ARM COMPENSATOR the After the reartoe inspection, wheel is 2 Example: mm (0.08in) out of the specification. M o v e t h e a r m s o t h e a d j u s t i n gb o l t m o v e s 2 m m beforethe {0.08in) inwardfrom the positionrecorded adjustment. The distancethe adjustingbolt is moved should be equalto the amountout-of-specification. bolts. Tightenthe adjusting
5.
Turn both tie-rodsequally until the toe readingon computeris correct. the wheel alignment , A f t e r a d j u s t i n g t i g h t e n t h e t i e - r o d l o c k n u t sa n d repositionthe tie-rod boots if they are twisted or displaced.
5.
18-5
WheelAlignment
TurningAngle Inspection
U s e c o m m e r c i a l l y - a v a i l a b lo m p u t e r i z e f o u r w h e e l ce d alignment equipment measure (caster, to wheelalignment c a m b e r t o e , a n d t u r n i n ga n g l e ) F o l l o wt h e e q u i p m e n t , . manufacturer's instructions.
1. Turn the wheel right and left while applying the brake, and measure the turning angle of both wneets.
Turningangle: Inwardwheel:37.00' Outwardwheel lreference): 31.30'
2.
l f t h e t u r n i n ga n g l eis not within the specifications, c h e c kf o r b en t o r d a m a g e ds u s p e n s i o n o m p o c nenIs.
18-6
Wheel/Hub lnspection
Bearing EndPlay
1 . Raise vehicleoff the ground,and makesure it is the securely supported. Remove wheels,then reinstall wheel nuts. the the Attachthe dial gaugeas shown. Measure bearingend play by movingthe discor the drum inwardor outward. Front/Rear; Standard:0 - 0.05 mm (0 - 0.002in)
WheelRunout
1.
Raise vehicleoff the ground,and makesure it is the securely supported, for Check bent or deformedwheels. Attachthe dial gaugeas shown. Measure wheel runoutby turningthe wheel. the Front and RearWhoel Axial Runout: Standard: Steel Wheel: 0 - 1.0 mm {0 - 0.0i[ in] AluminumWheel:0 - 0.7 mm l0 - 0.03in) inl ServiceLimit: 2.0 mm 10.08
Measureend play at the hub flange.
Rear:
Front and RearWheel Radial Runout: Standard: Steel Whoal: 0 - 1.0 mm (0 - 0.04 inl Aluminum Whoel: 0 - 0.7 mm {0 - 0.03 in} 1.5mm (0.06inl Servics Limit:
Measureend play at centerof the hub flange.
108 N.m {11.0kgf.m, q} lbf.ftl
is It the bearingend play measurement more than the standard, replace wheelbearing. the
lf the wheel runout is more than the servicelimit, reolace wheel. the
18-7
FrontSuspension
Suspension ArmsReplacement
Notetheseitemsduring replacement: . Replace self-locking the nuts afterremoval. . The vehicleshouldbe on the ground beforeany boltsor nuts connected rubbermountsor bushings tightened. to are . Beforetightening the upper and lower mountingnuts on the stabilizer link,adjusrthe locationof the link with the susp e n s i o n n d e r e h i c l eo a d . u v l . After insta lling the suspension (seepage 18-4|. arm, checkthe front wheel alignment, and adjustif necessary
FLANGE EOLTS 10x 1.25mm 54 N.m (5.5kgf.m, 40 tbf.ft)
STABILIZER BAR Alignthe stabilizer mark with end of stabilizer bushing.
STAEILIZER
STABILIZER Check bending for and damage. UPPER ARM Check bushing deterioration damage. the for and
FLANGE BOLT 1 { x 1 . 5m m kgf.m, 103N.m {10.5 76 tbf.ft)
BALLJOINT BOOT . Check deter'oration for ano oamage, Seepage18 16for boot replacement. FLANGE BOLT 8 x 1.25mm 22 N.m {2.2kg{.m, 16 tbf.ftl
LOWER ARM RUBBER BUSHING Check deterioration for

and damage.
..'.{l@3 GREASE SILICONE RUBBER BUSHINGS

SELF-LOCKING NUT 10 x 1.25rr|m 29 N.m (3.0kgf.m,22 lbf.ft) Feplace. Holdthe ballioint pin usinga hex wrenct
SELF.LOCKING NUT 1 4x 1 . 5m m Replace. 83 N.m (8.5 kgt.m,61 lbt.ftl FLANGE BOLT 1 4x 1 . 5m m 89 N.m (9.'l kgl.m, 66 tbf.ft) DAMPER FOBK Check damage. for
o\
BOOT Checkfor deterioration ano oamage,
STABILIZER LINK Checkfor daftage.
AOLT 10x 1.25mm !$ N.m (4.4 kgt.m, 32 rbf.ftl
29 N.m {3.0 kgl.m, 2.2 lbf.ftl Before tightening llangenut, the position balliointpin the in the middleof its rangeof travel, with the suspension load. undervehicle
DAMPER FORK RUBBER BUSHING Check deterioration damage. for and
SELF.LOCKING NUT 12 x 1.25mm Beplace. 64 N.m (6.5kgt.m, 47 lbf.ft)
18-8
Knuckle/Hub Replacement
Notetheseitemsduring replacement: . Replace selt-locking the nuts afterremoval. . The vehicleshouldbe on the ground beforeany boltsor nutsconnected rubbermountsor bushings tightened. to are . Torquethe castlenuts to the lowertorquespecifications, tightenthem only far enoughto alignthe slotswith each then pin hole.Do not alignthe nuts by loosening. o Use only genuineHondawheel weightsfor aluminumwheels.Non'genuine wheel weights may corrodeand damage t h ea l u m i n u m h e e l s . w . Onthealuminumwheels,removethe centercap from the insideof the wheelafter removingthe wheel. . Beforeinstalling brakedisc,cleanthe matingsurfaces the front hub and brakedisc. the of . Beforeinstalling wheel.cleanthe matingsurfaces the ofthe brakediscand wheel. . Wipe off the greasebeforetightening the nuts at the balljoints.
CALIPER MOUNTINGBOLT 1 2x 1 . 2 5 m m 108N.m (11.0 kgtm.80 lbt.ftl
NUT CASTLE 1 0x 1 . 2 5 m m 39 - 47 N.m (i1.0 4.8 kgf.m,29 - 35 lbf.ftl COTTER PIN Replace.
WHEEL BEARING Beplace. page18-13 Replacement, CIRCLIP SPLASH GUARD SCREW 5x0.8mm 4.9N.m {0.5kgf.m,3.6lbf.ft)
F R O N TH U B C h e c kf o r d a m a g e a n d Replacement, page 18 10
BALLJOINT LOWER Inspect faulty for movement and wear, page'1815 Replacement, SETRING BALLJOINTBOOT
Checkfor deterioration ano oamage.
PIN COTTER Replace.
CASTLE NUT 12x 1.25fim 49 - 59 N.m 15.0 6.0 kgt.m.36 - lbf.ft)
SPINOLE NUT 24 x 1.5mm 245 N.m {25.0kgI.m, 181 lbtft} Replace. . Before installing spindlenut,apply the engineoil to the seating surface the nut. of . Aftertightening, a driftto stake use the spindlenut shoulder against spindle. the
BRAKE DISC for Check wear and rust.

R e p l a c e m e n t ,p a g e 1 8 - 1 0 I n s p e c t i o n ,s e c t i o n 1 9 .
WHEEL NUT 1 2x 1 . 5m m 108N.m kgt {11.0 m, 80 tbf.ftl
6 mm BRAKEDISCRETAINING SCREW 9.8 N.m (1.0kgtm, 7.2 lbtftl
(cont'd )
18-9
FrontSuspension
(cont'dl Replacement Knuckle/Hub
1 . Loosen wheel nuts slightly. the Raisethe front of the vehicle,and make sure it is supported. secu.ely Remove wheel nuts and wheel. the
6 mm BRAKEDISC RETAINING SCREWS 9.8 N.m (1.0 kgl.m,7.2 lbf.ftl
7. Remove 6 mm brakedisc retaining the screws,
8 x 1.25 mm BOLTS 8. Screwtwo 8 x 1.25mm bolts into the discto push it awav from the hub. Turn each bolt two turns at a time to prevent cockingthe disc excessively, NUT SPINDLE 24x 1,5mm 245N.m(25.0 kgf.m, lbtft) 181 Replace. Raisethe lockingtab on the spindle nut, then remove the nut. Remove brakehosemountingbolts. the
BRAKEHOSEMOUNTINGBOLT 8 x 1.25mm 22 N.m {2.2kgt m, 16 lbtft)
Remove the brakediscfrom the knuckle. the Check front hub for damageand cracks. 1 1 . R e m o v et h e w h e e l s e n s o rf r o m t h e k n u c k l e( f o r vehicleswith ABS). Do not disconnectthe wheel sensor connector.
9.8 N.m (1.0 kgf.m, 7.2 tbttrl
CALIPER MOUNTING BOLTS 12x 1.25 mm 108N.m(11.0 kgl.m, lbl.ft) 80

MOUNTING BOLTS 9.8 N.m lr.0 kgf.m, ?.2lbf.ftl
Removethe caliper mounting bolts, and hang the caliperassembly ona side.To preventdamaggto to t h e c a l i p e ra s s e m b l yo r b r a k e h o s e , u s e a s h o r t pieceof wire to hangthe caliperfrom the undercarriage.
18-10
12. Cleanany dirt or greaseoff the ball joint. 1 3 . Removethe cotter pin from the steeringarm, and
removethe nut.
14. Apply greaseto the specialtool on the areasshown.
17. Oncethe specialtool is in place,turn the adjusting to bolt as necessary make the jaws parallel.Then h a n d - t i g h t e nh e p r e s s u r eb o l t , a n d r e c h e c k h e t t jaws to makesurethey are still parallel.
This will ease installationof the tool and prevent damageto the pressurebolt threads.
PRESSURE BOLT
ADJUSTING BOLT
tc.
lnstalla 10 mm hex nut on the ball joint. Makesure the hex nut is flush with the ball joint pin end to prevent damage to the threaded end of the ball joint. REMOVER, mm 28 BALL JOINT 07MAC SL(x)2(x) HEXNUT
After makingthe adjustmentto the adjustingbolt, make sure the head of the adjustingbolt is in this position allow the jaw to pivot. to 1 8 . With a wrench, tighten the pressurebolt until the ball joint shaft pops loosefrom the steering arm. wear eye protection. The balt ioint @ can break loose suddenly and scatter dirt or other dsbris in your eys.
1(|
HEX NUT 10x 1.25mm ('99 modcll 43 N.m lit.a kgl.m. 32 tbtft)
6:)
Remove the tool, then removethe nut from the end of the ball joint, and pull the ball joint out of the arm. Inspectthe ball joint boot. steering/suspension and replace if damaged. it
29- 3s rbtftt
CASTLE NUT 10x '1.25 mm l'97 - 98 modcls) 39 - 47 N.m {4.0- 4.8
COTTER Replace.
37 -98 models:
'99 -00 modol:
Onre6ssmbly, bendthe cofterpin 16. Install the special tool as shown. Insert the jaws carefully, makingsure you do not damagethe ball joint boot. Adiust the jaw spacing by turning the pressurebolt. lf necessary, type apply penetrating lubricant loosenthe ball ioint. to
(cont'dl
18-1 1
FrontSuspension
(cont'd) Knuckle/Hub Replacement
the cotterpin from the lower arm ball joint 20. Remove castlenut, and removethe nut.
COTTER PIN Replace. On ra6ssembly, bend the cofter pin
23. Remove the cotterpin from the upper ball joint castle nut, and removethe nut.
COTTER PIN Replace. On reassembly, bend the cotterpin as shown.
CASTI.ENUT 12 x 1.25mm ilg - 59 N.m (5.0 - 6.0 kgf.m, 36 - a3 lbf.ftl
CASTLE NUT 10 x 1.25mm 39 - 47 N.m kgt 14.0 ,4.8 m, 29 - 35 tbt.ftl
10 mm
nEMOVER, mm 28 _ 07MAC SLtD2(xl 24. Install the 10 mm hex nut on the ball joint. Makesurethe hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin might be damagedby the balljoint remover. 25. Usethe special tool as shown on page 18-11 septo aratethe ball joint and knuckle.lf necessary, apply penetrating type lubricant loosenthe ball joint. to 26. Pull the knuckleoutward, and remove the driveshaft outboardjoint from the knuckleby tapping the driv+ shaft end with a pl8stichammer,then removethe knuckle.
KNUCKI.E lor Check damage.
CASTLE NUT 12 x 1.25mm COITER PIN Replace.
BALL JOINT REMOVER, mm 28 07MAC Sl(xr2(x,
Installa 12 mm hex nut on the ball joint. Make sure the hex nut is flush with the balljoint pin end,or the threadedsectionof the ball joint pin might be damaged by the balljoint remover. Usethe special tool as shown on page 18-11 septo a r a t et h e b a l l j o i n t a n d l o w e r a r m . l f n e c e s s a r y , apply penetrating type lubricantto loosenthe ball joint.
18-12
27. Separate hub from the knuckle the usingthe special tool and a hydraulicpress.Takecare not to distort the splashguard.Hold on to the hub to keepit from fallingwhen pressed clear.
29. Press wheel bea.ingoutofthe knuckle the usingthe soecialtools and a Dress.
HUBDIS/ASSEMELY TOOL 07GAF 5800100
DRIVER 077,19 0010000
ORIVER ATTACHMENT, 62x64mm 07947- 6340400
FRONT HUB
SETTING POINT
28. Removethe circlip and the splashguard from the

knuckle. 30. Pressthe wheel bearing inner race from the hub using the specialtool, a bearing separator,and a press.
Check bending for and damage.
HU8OIS/ASSEMBLY TOOL 07GAF SE00100

EEARING SEPARATOR O-1112in. (Commercially available)
{cont'd}
18-13
Front Suspension
(cont'dl Replacement Knuckle/Hub
3 1 . Wash the knuckleand hub thoroughlyin high flash
point solvent before reassembly, Pressa new wheel bearinginto the knuckleusing t h e o l d b 6 a r i n g ,a p l a t e .t h e s p e c i a lt o o l , a n d a press.Placethe wheel bearingon the knucklewith the pack seal side facing (metal color) toward the inside.Be careful not to damagethe sleeveof the Dack seal. usingthe specialtools 35. lnstallthe hub on the knuckle shown and a hydraulicpress.Be carefulnot to distort the splashguard.
ORIVER 077irg 0010000
DOUBLELIPSEAL IBLACKCOLORI
SPLASH GUARO
BASE SUPPORT 0?965 SD90t00
lnstall the knuckle in the reverse order of removal, and pay particular attention to the following items: . Be careful not to damage the ball joint boots when installing the knuckle. r Torque a\\ mount\ng hardv{are to ths speci{ied torquevalues, o Torque the castle nuts to the lower torque speci fications, then tighten them only iat enough to align the slots with each pin hole. Do not align the castlenut by loosening. a lnstall new cotter pins on the castle nuts or hex nut aftertorquing. . Avoid twisting the sensorwires when installing the wheel sensor. . Before installing the brake disc, clean the mating surfacesof the front hub and the inside of the brakedisc. . Beforeinstallingthe spindle nut, apply a small amount of engine oil to the seatingsurfaceoJthe nut. After tightening, use a drift to stakethe spinthe against driveshaft. dle nut shoulder the . Beforeinstalling wheel.cleanthe matingsurfaceof the brakediscand the insideof the wheel. and adjust it if . Checkthe front wheel alignment, necessary {seepage 18-4).
33. Installthe circlip securelyin the knucklegroove.
scREws
kgl 5 N.m 10.5 m, 4 lbl'tt)
CIRCLIP
the splashguard and tightnthe screws. 34. Install
18-14
Lower BallJoint Replacement

'1.
(seepage 18-10). Remove knuckle the Removethe boot by prying the set ring off. Checkthe boot for deterioration and damage.and replace if necessary. it lnstallthe special tools on the ball joint, and tighten the castlenut.
8AI.I JOINT REMOVEN/INSTALLER
8.
Installthe ball joint boot and set ring usingthe specialtool {seepage18-16}.
BAII JOINTBEMOVER BASE 07JAF SH2oe00 P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s shown. then set the assemblyin a vise. Pressthe ball joint out of the knuckle. Place ball joint in positionby hand. the 7. Installthe special tools over the ball joint as shown, then pressthe balljoint in.
BAII JOINT INSTAL1IR BASE o
Installthe knucklein the reverseorder of removal. and pay particular attention the followingitems: to Be careful not to damage the ball joint boots when installing knuckle. the . Torque all mounting hardwareto the specified torouevalues. a Torquethe castlenuts to the lower torque specifications,then tighten them only far enough to align the slot with the pin hole. Do not align the castlenut by loosening. . Install new cotter pins on the castle nuts after IOrqurng. Avoid twisting the sensorwires when installing the wheelsensor. Beforeinstalling brakedisc,cleanthe mating the surfacesof the front hub and the inside of the brakedisc. Beforeinstalling wheel.cleanthe matingsurthe faceof the brakediscand the insideof the wheel. Checkthe front wheel alignment, and adjust it if (seepage18-4). necessary .
SURFACE BALLJOINT HOUSING
18-15
FrontSuspension
BallJoint Boot Replacement
1 . Remove set ring and the boot. the Do Packthe interiorof the boot and lip with grease. not contaminate sectionwith the boot installation grease.
BALL PIT{TAPEFEOSCTION
Front Damper
Removal
1, 2. Remove front wheels(seepage 18-10). the Removethe damper pinch bolt from the top of the damperfork.
DAMPER FORK
DAMPER PINCH BOLT '10 1.25 x
B{rcYHSI
wip6 off tho gr6aso.
SECTIO
BOOT |NST
Wipo otf th6 grors.
SECTION
Wipe the greaseoff the sliding surfaceof the ball pin, and pack it with fresh greass. Keep grease off the boot installation section and the taoered section of the ball pin. Do not allow dust, dirt, or other foreign materialsto enter the boot. Install the boot in the grooveof the boot installation sectionsecurelv, then bleedair. Installthe upper and lower ball joint boot set rings usingthe special tools as follows: Lower ball joint: Adjust the special tool with the adjustingbolt until the end of the tool alignswith the groove on the boot. Slidethe set ring over the tool and into oosition. Upper ball joint: Hold the tool over the ball joint, then slidethe set ring overthe tool and into position. EAII JOINT B(X)TCUP GUttrE AD'USN G BOLT Adjustth6 depthby turningthe bolt.
SELF.LOCKING NUT 12x 1.25 fifi Replace. Removethe damper fork bolt and self-locking nut from the bottom of the damper fork, then remove the damperfork. Remove damperby removingthe two nuts. the
DAMPER
Jott'trBoor:
UPPERBAI.I
07GAG - SO407q) LOWEF BATI JOIIYI EOOTI 0t97il - SA507lXl
After installing the boot, check the ball pin tapered section for greasecontamination,and wipe it if necgssary.
18-16
Disassembly/ Inspection
Disass.mbly 1 . C o m p r e s s h e d a m p e rs p r i n gw i t h a s p r i n g c o m t pressor accordingto the manufacturer'sinstructions,then removethe self-locking nut. Do not compressthe spring more than necessary removethe to nur.
SELF-LOCKING NUT 10 x 1.25mm 29 N.m (3.0kgl.m,22lbtftl
Replace.
DAMPER MOUNTING WASHER DAMPER MOUNTING
RUBBER Check for

10 mm SELFLOCKING Replace.
ano oamage.
DAMPER MOUAMNGCOLLAR DAMPER MOUNTING BASE MOUNTING DAMPER RUBBER Check detrioration for ano oamage.
STRUT
COMPRESSOR: lComm6rciallyavailablo) BRANICK@T/N MST-580A or Mod6l 7200 or equivalent
Release the pressure from the spring compressor, then disassemble damperas shown in the next the cotumn. Inspection
1. MOUNTING SPRING
Reassemble parts,exceptfor the spring. all Pushon the damperassembly shown. as

BUMPSTOPPLATE
2.
BUMPSTOP g
..rg
DUST
weaknessand
C h e c k for bending and damage. damage,
Checkfor smooth operationthrough a full stroke, b o t h c o m p r e s s i o na n d e x t e n s i o n .T h e d a m p e r should move smoothly.lf it does not (no compress i o n o r n o e x t e n s i o n ) , e g a s i s l e a k i n ga n d t h e th , dampershouldbe replaced. Check oil leaks, for abnormalnoises, bindingduror ing these tests.
Front Damper
Reassembly
1. Install damperunit on a springcompressor. the
STRUTSPflNG COMPBESSOR: lcomm.rcillly .vrilrble) T/N MST.sEOA BRANICKC or Mod.l 7200 or oquivtla
lnstallation
1 . Loosely install the damper on the frame with the t a l i g n i n g a b f a c i n ginside,then loosely install tne two flangenuts. NUT FLANGE
g*-__---a-"10 x 1.25mm 59 N.m {5.0 kgt m, 43 tbf.ftl
.46 ./
| -,./ --...
-4 ADAMPER ASSEMBLY
SPRINGLOWERSEAT
Assemblethe damper in reverseorder of removal exceptthe damper mountingwasherand self locking nut. Align the bottom of the damperspring and the springlower seatas shown. Position the damper mountingbaseon the damper unit as shown.
ALIGNING TAB
and onto 2, Installthe damperfork over the driveshaft t h e l o w e r a r m . I n s t a l lt h e f r o n t d a m p e r i n t h e damperfork so the aligningtab is alignedwith the fork, slot in the damDer
10x 1.25mm il3 l+m {4.4kgf'm,
the Compress damperspring, Install dampermountingrubber,dampermountthe ing washer,and a new 10 mm self-locking nut. NUT SELF-LOCKING 10x 1.25 mm
Zt N.m 13.0kgf.m, 22 lbf.ft) Replace. DAMPER MOUNfING WASHER
Hold the dampershaft,and tightenthe 10 mm selflockingnut.
3. Looselyinstallthe damper pinch bolt on the top of the damperfork. 4. Looselvinstallthe damperfork bolt and a new selflockingnut on the bottom of the damperfork. 5. Raisethe knucklewith a floor iack until the vehiclejust lifts off the safetvstand. The lloor iack must b socurely positioned or personal iniury may result. 6. Tightenthe damperpinch bolt. nut. 7. Tightenthe damperfork bolt and self-locking 8. Tightenthe flangenuts on top of the damper. 9. Installthe brakehose mounts with the brake hose mountingbolts. 10. Installthefront wheel.
Replace.
18-18
RearSuspension
Suspension ArmsReplacement
when the suspensionarms are to be removed, plsce additional weight in lhe trunk beto.o hoisting. when @ substantial weight is removed from the rear of the vehicle, the center ot grsvity m8y chango causing the vehicle to tip forward. Notetheseitemsduring replacement: . Replace self-locking the nuts afterremoval. . Any boltsor nuts connected rubbermountsor bushings to shouldbe tightened with the vehicleon the ground. . Makesurethe toe adjusting boltson the compensator in arm are installed the samedirection, . After installing suspension the arm, check the rearwheelalignment,and adjustif necessa (seepage 18-4), ry
FLANGE BOLT 10 x 1.25mm 54 N.m (5.5kgt.m, 40 lbf.ftt. BAR STABILIZER for Check bending or oamage. STABILIZER 8AR
--1/
FLANGE EOLT 10 x 1.25mm 64 N.m 16.5kgf.m,47 lbf.ft)
\A1(\
t \
\a'v..:r
UPPER ARM BUSHING Checkfor deterioration and damage. il ,
FLANGE BOLT 'l0 r 1.25mm 54 N.m (5.5 kgf.m,
8 mm EOLTS 22 N.m {2.2 kgf.m, 16 bl.ftl
40rbtft)
TRAILING ARM for Check bending 'anooamage.
stLtcoNE
-6l
UPPER ARM BUSHING FLANGEBOLTS 10 x 1.25mm 39 N.m 14.0 kgf.m, 29 lbf.ft) UPPER ARM lor Check bendingor damage. BOLT ,/ FLANGE 10 x 1.25mm kst'm, 40 lbf ftl s4 N.m 15.5 FLANGE NUT 10 x 1.25mm 29 N.m {3.0kg{.fl,22 lbf.ft} Before tightening flangenut, the position balljoint pin the in the middleof its rangeof travel, with the suspension under vehicle load. FLANGE BOLT 10 x 1.25mm 54 N.m {5.5 kgf.m, 40 lbf.ft} Check damage. tor LOWER ARM BUSHING Check deterioration damage. for and LOWEN ARM BUSHING
stLtcoNE .@i COMPENSATOR ARMBUSHING
// COMPENSATOR ARM BUSHING ^/
64 N.m 16.5 kgf.m, 47 lbtftl SELF.LOCKING NUT 10 x 1.25mm 29 N.m (3.0kgl.m, 22 tbf.ft) Replace. Holdthe ballioint pin usinga hexwrenct,, and tightenthe self-locking nut. STABILIZER LINK . Check bending for and damage. . Check bushing deterioration the tor and damage.
stLrcoNE
-6il
RearSuspension
HubBearing Unit Replacement
Notetheseitemsduring replacement: . Use only genuineHondawheel weightsfor aluminumwheels.Non-genuine wheel weights may corrodeand damage t h ea l u m i n u m h e e l s . w . Beforeinstalling brakedrum, cleanthe matingsurfaces the rearhub and the brakedrum. the of . Beforeinstalling wheel,cleanthe matingsurfaces the brakedrum and wheel. the of
FLANGEBOLI 12x 1,25mm 103N.m 110.5 kgf.m, 76 tbtfr) BACKING PLATE SPINDI-E NUT 2 2x ' 1 . 5 m m 181 N.m {18.5kgf.m, 134 lbf.ftl Replace. NOTE:Altertightening, a drift use punchto lockthe spindlenut shoulder intothe spindle.
BRAKESHOE TRAILING ARM Check cracking {or ano oamage.
FLANGEBOLT 10x 1.25mm 64 N'm 16.5 kgf.m, 4? lbt.ft)
Check cracking for ano oamage. BRAKEDRUM Checkfor wear ano oamage,
NUT WHEEL 1 2x 1 . 5m m 108N.m {11.0 m,80lbtftl kgt
1A-20
't. Raisethe rear of the vehicle,and make sure it is

securely supponed. Remove the rearwheel. Removethe brakedrum from the hub by threading 8 x,r.25 mm bolts into the drum to push it away from the hub bearingunit. Turn each bolt two turns at a time to preventcocking drum excessively. the
8 x 1.25mm BOLTS
7 . Disconnect brakeline from the wheelcylinder. the

6.
Removethe wheel sensorfrom the backing plate ( f o r v e h i c l e sw i t h A B S ) . D o n o t d i s c o n n e c t h e wheelsensorconnector. Remove the 12 mm flangebolts.
i+/3 ',1
-->-
\ .'--7 J
"@,1 /
NUT SPINDLE r81 N.m t18.5kgt m, 134lbt'ftl Replace. 4.
WHEEL NUT 12 x 1.5 mm 108N m 111.0 kgf'm, 80 lbf ftl
R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n removethe nut. Remove the brakeshoes. Removethe parking brakecable from the backing plateusinga 12 mm offsetwrenchas shown. BACKING PLATE PULLER available) lCommercially
5. 6.
1 0 . 4WD; Removethe backing plate/hubbearing unit

from the rearaxlewith a pullerif necessary.
1 1 . Separatethe rear hub from the hub bearing unit
usingthe specialtools and a press. Notethe followingitemsduring disassembly: . Takecare not to distort the backing plate. . Hold on to the hub to keep it from falling when
DRIVER ATTACHMENT, 37 x ilo mm 07746- 0010200
ARAKE PARKING CABLE
(cont'd)
1a-21
RearSuspension
(cont'd) Hub BearingUnit Replacement
12, Pressthe wheel bearing inner race from the hub and usingthe tools,a bearingseparator, a press.
TOOL HUB DIS/ASSEMBLY 07965- SA50100 BEARING SEPARATOR mml 0 -,t 1/2 in {0 - 11i1.3 qvailable) (Commercially
't7. Installthe hub bearingunit onto the rear hub using

the specialtools and a press.
DRIVER ATTACHMENT, 60 mm 07LAO- SM40100 Prcss
DRIVER 07749- 0010000
BEARING
the 12 mm flangebolts. 13. Remove

REARHUB
HUB BEARING UN]T
O.RING
1 8 . I n s t a l l t h e b a c k i n g p l a t e / h u b b e a r i n gu n i t o n t h e trailing arm. BOLTS FLANGE 12 x 1.25mm kgf'm,75lbfft) 103N.m 110.5
1 4 . R e m o v et h e h u b b e a r i n g u n i t f r o m t h e b a c k i n g plate. 15. Installa new O-ringon the hub bearingunit.

FLANGE BOLTS 10x 1.25mm 64 N.m (6.5kgf.m, 47 lbf.ftl
plate. 16. Install the hub bearingunit on the backing
19. Installthe hub bearingunit in the reverseorder of attentionto the followremoval,and pay particular ing items: . Before installingthe spindle nut, apply a small of amountof engineoil to the seatingsurface the nut, After tightening, use a drift to stakethe spinthe dle nut shoulderagainst driveshaft. . Avoid twisting the sensorwires when installing the wheelsensor, . Fill the brakereservoir and bleed the brakesystem {seesection19). . Adjustthe parkingbrake(seesection191. . Checkthe rear wheel alignment,and adjust it if (seepage 18-4). necessary
18-22
RearDamper
UpperArm BushingReplacement
1.
Removal
't. Remove rearwheels(seepage '18-21), the
Removethe damper accesspanel and the damper cap.
5.
R e m o v et h e u p p e r a r m b u s h i n g a n d u p p e r a r m innerbushingas shown. UPPER ARM INNER BUSHING UPPER ARM AUSHIT{G
Removethe two flange nuts.

ACCESS PANEL
REARUPPER ARM Mark a scribeline on the upper arm inner bushing so it is in linewith the bolt mountingsurface.
OAMPER CAP
4.
Remove flangebolts. the
BOLT MOUNTII{G SURFACE
Makea mark on the upperarm at two pointsso the marks are in line and at a right angle with the arm as shown in the drawing. Drive in the upper arm inner bushingwith the marks aligned until the leadingedge is flush with the uoDer arm. Lowerthe rear suspension, nd removethe a damper.
Drive the upper arm bushing into the upper arm untilthe leadingedge is flush with the upperarm.
1a-23
RearDamper
Disassembly/lnspection
Disassembly
L Compress the damper spring with the spring comp r e s s o ra c c o r d i n g o t h e m a n u f a c t u r e r 'is s t r u c n t nut. Do not comtions,then removethe self-locking pressthe spring more than necessary removethe to self-locking nut.
SELF-LOCKING NUT 10 x 1.25mm Replace. OAMPER MOUNTING WASHER OAMPER MOUNTING SELF-LOCKING NUT 10x 1.25mm 29 N.m {3.0kgf.m,22 lbf.ft)
Beplace.
RUBBER
C h e c kf o r deterioration ano oamage.
DAMPER MOUNTING COLLAR DAMPER MOUNTINGBASE DAMPER MOUNTING RUBBER for Check deterioration ano oamage.
STRUTSPRING COMPRESSOR: lCommercirlly avaihblo) BRANICKO MSI-580A I/N or Mod6l/7200or equivalent
2.
Release the pressure from the spring compressor, then disassemble damperas shown on page 18the 25.
DAMPER Checkfor weakness, compressron
Inspection
1. 2. Reassemble parts,exceptthe spring. all Pushon the damperas shown.
DUSTCOVERPLATE
'"dd"^.s"' //F,
SPRING MOUNTING RUBBER Check deterioration Ior and damage. BUMP STOP Check weakness for ano oamage. BUMP STOPPLATE
DUSTCOVER Check bending for and damage. DUSTCOVENBOOT for Check deterioralion ano oamage. WOODEN ELOCK DAMPER
3.
4.
Checkfor smooth operationthrough a full stroke, b o t h c o m p r e s s i o n n d e x t e n s i o nT h e d a m p e r a . should move smoothly.lf it does not (no compress i o n o r n o e x t e n s i o n ) , e g a s i s l e a k i n ga n d t h e th , dampershouldbe replaced. Check oil leaks, for abnormalnoises, bindingduror ino thesetests.
Reassembly
1.
lnstallation
1.
u c I n s t a ltlh e d a m p e r n i to n a s p r i n g o m p r e s s o r ,
orderof disas2 . Assemble reardamperin reverse the sembly except the damper mounting washer and self-lockingnut. Align the bottom of the damper springand the springlower seatas shown.
COMPRESSOR: STRUTSPBING (Commorcislly !v.ilablel T/N MST.s8OA BRANICKC
, L o w e r t h e r e a r s u s p e n s t o n a n d p o s i t i o nt h e d a m p e r .T h e s p r i n g s t o p o n t h e r i g h t d a m p e r s should face rearward,and the s p r a n g t o p o n t h e left dampershouldfaceforward.
DAMPER MOUNNNG
SPRING STOP 2. Loosely install the two flange nuts.
FLANGE NUTS 10x 1.25mm . .: kgf.m,36 lbtft}- :',,{9 N.m 15.0 ----.-* rigf't"n if'"""_nrr. in qla^ 7 Step7.
3. 3. Position the dampermountingbase on the damper u n i ta s s h o w n . Compress the damper spring with the spring compressor. I n s t a l l h e d a m p e rm o u n t i n gw a s h e r ,a n d l o o s e l y t nut. installa new self-locking
installthe flangebolt. Loosely

FLANGE EOLT 10 x 1.25mm 54 N.m 15.5 kgt.m, 40 tbI.ft)
NUT SELF.LOCKING 10x 1.25mm 29 N.m (3.0 Replace.
with a floor jack until the Raisethe rear suspension just lifts off the safetystand. vehicle The floor iack must be securely posi@ iioned or personal iniury may result. Tightenthe flangebolt. 6. Tighten the two flange nuts on the top of the torque. damperto the specified panel. Install dampercap and access the and adjustif necesCheck the rearwheelalignment. sary (seepage 18-4).
7. Holdthe dampershaftwith a hex wrench,and tightnut. en the self-locking 8.
18-25
Brakes . . . . . . . . .1.9 - 1 . Anti-lockBrakeSystem (ABS) ............. 19-25
Brakes
19-2 ............. Tools Special ComponentLocations ...... 19-3 lndex ................ Inspectionand Adlustment BrakeSystem RubberParts 19-4 and BrakeBooster..........,,,.......... ............ 19-5 BrakePedal ........ 19-6 Brake Parking 19'7 ................. Bleeding 19-8 ................... BrakeSystemIndicator Front BrakePads 19-9 and Replacement.......... Inspection Front BrakeDisc ................... 19-11 DiscRunoutInspection and DiscThickness 19-1 ........,........ 1 Parallelism Inspection Front BrakeCaliper ............... 19-12 Disassembly/Reassembly Booster MasterCylinder/Brake 19-13 ....................... Removal/lnstallation Master Cylinder .............. 19-14 Inspection/Disassembly Adiustment ......19-14 PushrodClearance 19-1 BrakeBoosterInspection...,.,,,,....... 5 RearDrum Brakes 19-15 .............. Inspection BrakeShoes .....19-r8 Replacement 19-20 Wheel CylinderReplacement......... BrakeHoses/Lines ... Specifications 19-21 Inspection/Torque ..,,,19-22 ....,...,............. HoseReplacement ParkingBrakeCable 19-23 Inspectionand Replacement..........
SpecialTools
Ref. No. (, |
Tool Number 07JAG. SD40100 |
Description Pushrod Adiustment cauge I
ety r I
psge Reference tg_rt
19-2
Gomponent Locations
lndex
ERAKESYSTEMINOICATOR page't9-8 Circuit Diagram, BRAKE PARKING page19-6 Adjustment, '19-8 ParkingBrakeSwitchTest, page PARKINGBRAKECABI..E and Inspection Replacement, page19-23 BRAKEBOOSTER page19-15 Inspection, Brake Booster page Removal/lnstallation, 19 13
)i't
' -"''
1...,.
\,,,. 'a., i ,.' I

.)
/'"''t,'.., ,
t ^fl)
..)
REARDRUM BRAKE pago19-16 Inspection, Brake ShoesReplacement, page19-18 WheelCylinder page19-20 Replacement, MASTERCYLINDER page Removal/lnstallation, 19-13 lnspection/Disassembly. p a g e1 9 - 1 4 Pushrod Adjustment, Clearance p a g e1 9 l d Brake FluidLevelSwitch Test, page19-8 pag'19-21 Specification, Inspection/Torque Hose Replacement, Page19-22 page19-9 FrontBrake Pads, FrontBrake Disc.page19-11 page19-12 FrontBrake Caliper,
19-3

BrakeSystemRubberPartsand BrakeBooster
@-BrakeBooster Checkbrakeoperation applyingthe brakes. by lf the brakesdo not work properly,checkthe brake booster. Replace brakeboosteras an assemblyif the it does not work properlyor if thereare signsof leakage. @-Piston Cup and PressureCup Inspection . Check brakeoperation applyingthe brakes. by Visuallycheckfor damageor signs of tluid leakage. R e p l a c eh e m a s t e rc y l i n d e ra s a n a s s e m b l y f t h e t i pedaldoes not work properlyor if there is damageor signsof fluid leakage. . Checkfor a difference brakepedalstrokebetween in q u i c ka n d s l o w b r a k ea p p l i c a t i o n R.e p l a c eh e m a s - . s t ter cylinderif there is a difference pedalstroke. in (9-BrakeHoses Visually checkfor damageor signsof fluid leakage. Replace the brake hose with a new one if it is dama g e do r l e a k i n g . O-Caliper Piston Sal and Piston Boots Checkbrakeoperation applying by the brakes. Visuallycheckfor damageor signsof fluid leakage. lf the pedaldoes not operateproperly, the brakes drag, or there is damageor signs of fluid leakage, disass e m b l ea n d i n s p e c t h e b r a k ec a l i p e r .R e p l a c e h e t boots and sealswith new ones wheneverthe brake caliperis disassembled. @-WheelCylinder Piston Cup and Dust Cover Checkbrakeoperation applying by the brakes. Visuallycheckfor damageor signsof fluid leakage. lf the pedaldoes not operateproperly, the brakes drag, or there is damageor signs of fluid leakage, replace the wheelcvlinder.
19-4
Brake Pedal
Pedal Hoight 1. Disconnect the brakeswitch connector,loosenthe brake switch locknut, and back off the brake switch until it is no longertouchingthe brakepedal. 2. Lift up the carpet,At the insulatorcutout,measure the pedalheightfrom the middleof the right side of the oedalpad.
SWITCH BRAKE
4.
Screw in the brakeswitch until its plunger is fully p r e s s e d( t h r e a d e d n d t o u c h i n g t h e p a d o n t h e e pedal arm), Then back otf the switch 1/4 turn to make 0.3 mm (0.01 in) of clearancebetween the threadedend and pad. Tighten the locknutfirmly. Connectthe brake switch connecto.. Make sure that the brakelights90 off when the pedalis released
ERAKESWITCH
5.
below Checkthebrakepedalfreeplay as described
Pedal FreePlay 1. With the engine off. inspect the free play on the pedalpad by pushingthe pedalby handStandard Pedal Height (with floor m8i removed): A/T: 161mm (5 5/16 in) M/T: 155 mm {6 U8 in} 2. and screwthe pushrod Loosen the pushrodlocknut, in or out with pliersuntil the standardpedal height from the floor is reached.Do not adjustthe pedal After adiustment, heightwith the pushrodpressed. firmly. tightenthe locknut FreePlay:1 - 5 mm (1/16- 3/16 in) adiust lf the pedalfree play is out of specification, the brake switch. lf the pedal free play is insufficient,it may resultin brakedrag.
swtTcH
PAD PEOAL
PUSHRODLOCKNUT 15 N.m kgj 11.5 m, 11 lbf ftl
PEDALFREEPLAY
19-5

ParkingBrake
Inspeqtion 1. Pull the parkingbrake lever with 196 N (20 kqf, 44 lbfl forceto fully applythe parkingbrake. The parkingbrakelevershould be lockedwithin the specified numberof clicks. L.var LockodClicks:2 - 6 3. Release parkingbrakelever. the
Adjust the parking brake by turning the adjusting nut. Check that the parkingbrakes not drag when the do rearwheelsare turned.Readjust necessary. if Makesurethe parkingbrakes fully appliedwhen are the parkingbrakeleveris pulledup fully. 7. Installtheparkingbrakecover.
2.
Adjustthe parkingbrakeif the leverclicksare out of specification.
Adiustment 1. Raisethe rear wheels off the ground. and support the vehicle on safety stands.
@@
2.
up the rear ot tho vohicle.
Bbck tho front whots betore iacking
Remove parkingbrakecover the

PARKING BRAKECOVER
19-6
Bleeding
CAUNON: . Do not spill brake tluid on the vehicle. it may damage the paint; if brake fluid does contaqt th paint, wash it otf immodiately with water. . Maks sure no dirt oy other forsign matter is allowsd to contaminate the brake fluid. NOTE: . Do not reusethe drainedfluid. . Always use GenuineHondaDOT3 BrakeFluid.Using b a n o n - H o n d a r a k ef l u i d c a n c a u s ec o r r o s i o na n d the decrease life of the svstem. . The reservoiron the mastercylindermust be at the MAX (upper)level mark at the start of bleedingproafter bleedingeach brakecaliper cedureand checked Add fluid as required. and wheelcylinder. 1, is Makesure the brakefluid levelin the reservoir at levelline. the MAX (uDDer)
FRONT:
LEVEL MAX {UPPER) LINE RESERVOIR CYLINDER MASTER
2. 3.
4.
Havesomeoneslowly pump the brakepedalseveral times,then applysteadypressu.e. Loosen the brakebleedscrewto allow air to escape f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w securely. for Repeat procedure eachwheelin the sequence the shown below until air bubblesno longer appearin the tluid. Refill the reservoir on the master cvlinder to the MAX (upper)levelline.
ALEEDING SEOUENCE: O Front Right Gt RearRight
BLEEO SCREW 7 N.m(0.?kgf.m, lbf.ftl 5
O Front Lefl
O Rear Left
first in the bleeding NOTE:Bleedthe front calipers procedure.
19-7

BrakeSystemIndicator
Circuit Diagram lNuLR.HorJD
r l l A N l ] 24 ! A 4 GNrT 0ll St!ITCH
UNDEB.DASH FUSE]NEtAY BOI
GBNiBEO
P A F N CB R A ( E \ I ' I C H K S
o\ I E R A KuEU0 r E V E9r! 1I( N t lt j

| BIK o P t ^ r ' f . r1 ,'
-o:
G401
Parking BrakeSwitch Test 1. 2. Remove parkingbrakecover, the Disconnect the connectorfrom the parking brake switch.
Brake Fluid Level Switch Test 1. R e m o v et h e r e s e r v o i rc a p . C h e c kt h a t t h e f l o a t movesup and down freely;if it doesn't,replace the reservoir cap assembly. Checkfor continuitybetweenthe terminalsin each switchpositionaccording the table. to
2. 3. Check continuitybetweenthe terminaland body for ground in eachpositionaccording the table. to \ Terminal LeverPosition \ LeverUp Lever Down Positive Terminal Body Ground
\ --o
r9''r
FLOATUP
Position FLOATDOWN
RESERVOIR CAP
GROUND
NOTE(Canada): the parking brakeswitch is OK, but lf the brake system indicatordoes not function, perform the input test for the daytimerunninglightscontrol unit (seesection23).
Switch contacts open at proper fluid level.
19-8
Front BrakePads
Inspectionand Replacement
4. Nsvgr u9e an air hose or dry brush to clean brake assemblies. Use an OSHA approved vacuum cleaner to avoid broathing brake dust.
1.
o m t U s i n g v e r n i e rc a l i p e r s , e a s u r e h e t h i c k n e s s f does not each brake pad lining.The measurement include the pad backingplatethickness. Brake PadThickness: Standard: 10.5- 11.5mm {0.,11 0.45in) Servics Limit: 1.6 mm (0.06in)
Loosenthe front wheel nuts slightly,then raisethe s v e h i c l e ,a n d m a k e s u r e i t i s s e c u r e l y u p p o r t e d . Remove front wheels. the Removethe caliper bolt, and pivot the caliper up out of the way. Checkthe hosesand pin boots for damageand deterioration.
i)n.
CALIPER BOLT 3. CALIPER BODY Remove the pads, pad shims, and pad retainers. PADSHIMS INNEB for Check weakness.
PLATE EACKING
lf the brake pad thicknessis less than the service limit. replace front padsand shimstogetheras a the set. Cleanthe caliperthoroughly;removeany rust, and checkfor groovesand cracks. 7. L Check brakediscfor damageand cracks. the Install the pad retainers.
'.'..i
OUTERPADSHIM for Check weakness.
# I
PAD RETAINERS
(cont'd)
19-9
Front BrakePads
(cont'dl Inspection Replacement and
9 . A p p l y M o l y k o t e M 7 7 g r e a s e o r D a i k a l u b5 2 8 D greaseto both sidesof the pad shims and the back grease the shims. of the pads.Wipe excess off '11. Pushin the piston so that the caliperwillfit over the pads. Make sure the piston boot is in position to p r e v e n td a m a g i n g i t w h e n p i v o t i n g t h e c a l i p e r down. CALIPER BOLT 49 N.m(5.0 kgf.m, lbf.ftl 36
INOICATOR Apply Molykote M77 or 0aikalub 528D to both sidesof shim.
Apply Molykote M77

to both sides of shims.
INNERPAD
OUTER PAD
Pivot the caliperdown into position,being careful not to damagethe pin boot. Installthe caliperbolt and tightenit, 1 3 . Pressthe brake pedal severaltimes to make sure the brakeswork, then test-drive. N O T E : E n g a g e m e no f t h e b r a k em a y r e q u i r ea t greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 1 4 . After installation, check for leaks at hose and line joints and connections,and retighten if necessary.
1 0 . l n s t a l lt h e b r a k e p a d s a n d p a d s h i m s c o r r e c t l y . Install the pad with the wear indicator the inside. on
When reusing the pads, always reinstall the brakepads in their originalpositionsto prevent loss of braking efficiency. . Contaminated brake discs or pads reducestopping ability.Keepgrease the discsand pads. off
19-10
Front BrakeDisc
DiscRunoutInspection
l.
DiscThickness Parallelism and Inspection

1.
Loosenthe front wheel nuts slightly,then raisethe v e h i c l e ,a n d m a k e s u r e i t i s s e c u r e l ys u p p o r t e d . Remove front wheels. the Remove brakepads{seepage 19-9). the I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s . and removeall .ust. Cleanthe discthoroughly, Use wheel nuts and suitableplain washersto hold againstthe hub, then mount a dial the disc securely i n d i c a t o ra s s h o w n , a n d m a a s u r et h e r u n o u t a t 10 mm (0.4in) from the outer edgeof the disc. BrakeDi3c Runout: in) ServiceLimit: 0.10 mm {0.00,0
Loosenthe front wheel nuts slightly,then raisethe vehicle, and make sure it is securely supported. Remove front wheels. the Remove the brakepads(seepage 19-9). discthickness eight at measure Usinga micromater, points,approximately 45'apan and 10 mm (0.4 in) the in from the outeredgeof the disc.Replace brake disc if the smallest measurementis less than the limit. max. refinishing
NUT WHEEL AND PLAIN WASHER 108N.m{11kg{m, 80 lbf.ft) lf the disc is beyond the servicelimit, refinishthe brake disc with an on-car brake lathe. The KwikLathe produced by Kwik-way ManufacturingCo. and the "Front Brake Disc Lathe" offered by Snapon ToolsCo. are approved this operation. for M8x. RofinishLimit: 21.0 mm l0.8il in) NOTE:A new disc shouldbs refinished its runout if is greater than 0.10mm (0.004 in).
Brake DiscThickness: Standard: '97 - 98 modsls: 22.9 -23.1mm {0.90- 0.91 inl '99 - 00 modls: 23.6- 23.8 mm {0.93- 0.94 in} Max. RefinishingLimit:21.0 mm (o.txlin) Brake Disc Parallelism: 0.015mm {0.0006in} max. NOTE:This is the maximum allowabledifference betweenthe thicknessmeasurements, lf the disc is beyondthe servicelimit for parallelism, refinishthe brake disc with an on-car brake lathe. The Kwik-Latheproduced by Kwik-WayManufacturing Co. and the "Front BrakeDiscLathe" offered by Snap-on Tools Co. are approved for this operatron. NOTE:Seesection18for brakedisc replacement.
19-1 1
Front BrakeCaliper
. Never use an air hose or dry brush to clean brake assemblies. . Usean OSHAapproved vacuumcleaner avoidbreathingbrakedust. to . Contaminatedbrake discs or pads reducestopping ability. . When reusingthe pads,alwaysreinstallthebrakepadsin their originalpositionsto preventlossol brakingefficiency. CAUTION: . Do not spill brakefluid on the vehicle; may damagethe paint; if brakefluid does contactthe paint,wash it off immeit diatelYwith water. NOTEI . To preventspills,coverthe hosejointswith ragsor shoptowels. . C l e a n l l p a n si n b r a k e l u i da n d a i r d r y ;b l o wo u t a l l p a s s a g ew i t h c o m p r e s s ea i r . s f a d . Beforereassembling, checkthat all partsare free of dust and otherforeignparticles. . Replace partswith new oneswhenever specified do so. to . Makesure no dirt or otherforeignmatteris allowedto contaminate brakefluid. the . D o n o t r e u s e h e d r a i n e dl u i d . f t . A l w a y su s e G e n u i n e o n d aD O T3 B r a k e l u i d . s i n ga n o n - H o n d b r a k e l u i d c a n c a u s e o r r o s i o n n d d e c r e a s t h e H F a f c a e U life of the system. . C o a t h e p i s t o np i s t o n e a l , n dc a l i p e b o r ew i t h c l e a n r a k e l u i d . , a r f s b . ReDlace rubberoartswith new oneswhenever all disassembled. . After installing front brakecaliperdo the following. the - Check leaksat hoseand linejointsand connections, retighten necessary. for and if - Check brakehosesfor interference twistinq. the and
t".:jil ,,.'.1!!!!9!il: Rubber grease (Use recommended grease in the caliper set)
--6,
grease(use recommended Silicone sealgreaseand p,n greasein the caliperset)

I N N E RS H I M B I N N E RS H I M
EANJO BOLT 34 N.m {3.5kgf m,25 lblftl SEALING WASHERS Replace.
.@ \ iirf"i:;;T::fl,-J'I",0 ft i l 1 #
PIN B
WEABINDICATOR
12 mm FLANGE BOLTS 113N.m (11.5 kgtm,83lbf.ftl
PAOSHIM OUTER
PIN BOOT
4dd*
6-
-Cr
ERAKEPADS
'f,-rre
t
/ tto*l "o"\
PADSPRING
PIN A
>
{
AFACKET PADRETAINERS
I
' \
CALIPER BOOY SEAL PISTON Replace.
-6,
/ \ sLreo 6cnew
kStm, 6.5lbnft) I N m 10.9 \ CALIPER EOLTS 49 N.m {5.0kgl.m, 36lbf.ftl
AOOT PISTON Replace. "..-a=a-. PISTON ..,--"sEqri
19-1 2
Master Cylinder/BrakeBooster
1, 2. 3. 4. Disconnect brakefluid levelswitchconnectors. the Remove reservoir the cap from the mastercylinder. R e m o v e h e b r a k ef l u i d f r o m t h e m a s t e rc v l i n d e r t reservoir with a syringe. Disconnect brakelinesfrom the mastercylinder. the To preventspills,cover the line joints with rags or shop towels. R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d wasners. Remove master from the brakebooster. the cylinder CAUTION: Be careful not to bend or damagethe brakelineswhen removingthe mastercylinder. Do not spill brake fluid on the vehicle; it may dam. age the paint; it brake fluid does cont.ct the paint, wash it oft immediately with water. 7. 8. Disconnect vacuumhosefrom the brakebooster. the Remove cotterpin and clevispin from the clevis. the Do not disconnectthe clevis by removing it from the operatingrod of the brakebooster.lf the clevis i s l o o s e n e d ,a d j u s t t h e p u s h r o d l e n g t h b e f o r e installing brakebooster(seepage 19-15). the 9. Remove four boostermountingnuts. the ' 1 0 .P u l l t h e b r a k eb o o s t e rf o r w a r d u n t i l t h e c l e v i si s clearof the bulkhead. 1 1 . R e m o v e h e b r a k eb o o s t e rf r o m t h e e n q i n ec o m t panment. 12. Installthe brakeboosterand mastercylinderin the reverse orderof removal, and notetheseitems: . When connecting brakelines,makesure that the there is no interference betweenthe brake lines and other parts. . Be carefulnot to bend or damagethe brakelines when installing mastercylinder. the . lf replacing mastercylinderor brakebooster, the checkand adjust the pushrod clearancebefore installing mastercylinder(seepage19-14). the 1 3 . F i l l t h e m a s t e rc y l i n d e rr e s e r v o i r a n d b l e e d t h e , brakesystem(seepage 19-7). checkthe brakepedal height and 1 4 . After installation, and adjust if brakepedalfree play (seepage 19-5), necessary.
5. 6.
15N.m{1.5 kgtm, r r rbf.ft) /

(Without ABS) To FrontCaliper
vAcuuM HosE | BRAKE FLUTD LEvEL |

I
swrrcHcoNNEcroRs
I PIN COTTER
/l
/ /
|
I
t r o R e aw h e ec y l i n d e r s r /
neotace
I
To Master Cylinder (Without ABS) To Modulator Unit (with ABs)
h *s./-'''
Yli
l,/--
@-\
\
^ To FrontCaliper
(.S I /r:
//
/. I
-#q
CLEVIS PIN
) :-,/
9i \.
13 N.m 11.3 kg{.m, I rbf.ft) PROPORTIONING VALVE CONTROL
CYLINDER MASTER BRAXEBOOSTER
15 N.m (1.5kgf.m,11 lbl.ftl
Master Cylinder
Inspection/Disassembly
CAUTION: Do not spill brake fluid onthe vehicle;it may damsge the paint; il brake fluid does contact th6 paint. wash it off immodiately with water. NOTE: . Beforereassembling, checkthat all parts are free of dust and otherforeignparticles. . Do not try to disassemble mastercylinderassemthe bly. Replace mastercylinderassembly the with a new pan it necessary, . Make sure no dirt or other foreign matter is allowed to contaminate brakefluid. the
RESERVOIR SEAL Check damaoeand for
deterioration,
Pushrod Clearance Adjustment

NOTE:Mastercylinderpushrod-to-piston clearance must be checkedand adjustments made, if necessary.before installing mastercylinder. the 1. Set the specialtool on the master cylinder body; push in the centershaft until the top ot it contacts piston by turning the adthe end of the secondary justingnut.
PUSHROD ADJUSTMENT GAUGE 07JAG- SD{o100 SECONDARY
MASTERCYLINDER ADJUSTING NUT
Without disturbingthe center shaft's position, installthe special tool upsidedown on the booster.
RESERVOIR Check damage. for RODSEAL Check damage for and deterioration.
Install the mastercylindernuts,and tightenthem to the sDecified toroue. Connect boosteriniine with a vacuumgauge0 the 101 kPa (0 - 760 mmHg, 30 in Hg) to the booster's e n g i n e v a c u u m s u p p l y , a n d m a i n t a i na n e n g i n e speedthat will deliver66 kPa(500mmH9,20 in Hg) vacuum. With a feeler gauge, measurethe clearancebetween the gaugebody and the adiusting as shown. nut
--1
SILICONE GREASE MASTERCYLINOER Check borefor wear,rustand damage.
Clearanco: - 0.4 mm (0 - 0.02 inl 0

VACUUM GAUGE lCommo.cidly 6vailablcl 0 - 101 kPt l0 - 760 mm Hg, 30 in Hgl
MASTER CYLINDER NUT 15 N.m 11.5kgt m, 11 lbt.ftl
19-14
BrakeBoosterInspection
l f t h e c l e a r a n c e e t w e e nt h e g a u g e b o d y a n d b adjusting nut is 0.4 mm (0.02in), the pushrod-topistonclearance 0 mm. However. the clearance is if between the gaugebody and adjusting nut is 0 mm, the pushrod-to-piston clearance 0.4 mm (0.02in) is o r m o r e . T h e r e f o r ei t m u s t b e a d j u s t e da n d recheckd. 6. lf clearance incorrect, is loosenthe star locknut, and turn the adjusterin or out to adjust. . . Adjustthe clearance while the specified vacuum is appliedto the booster. Holdthe cleviswhile adjusting. 3. FunctionalTest 1. With the enginestopped,pressthe brakepedalseve r a l t i m e s t o d e p l e t et h e v a c u u m r e s e r v o i rt.h e n pressthe pedal hard, and hold it for 15 seconds. lf t h e p e d a l s i n k s ,e i t h e r t h e m a s t e r c y l i n d e r i s bypassinginternally,or the brake system (master cylinder,lines, modulator,proportioningvalve. or caliper) leaking. is 2. Startthe enginewith the pedalpressed. the pedal lf sinksslightly.the vacuumboosteris operatingnormally.lf the pedalheightdoes not vary,the booster or checkvalveis faultv. With the enginerunning,pressthe brakepedallightly. Apply just enough pressureto hold back automatic transmissioncreep. lf the brake pedal sinks morethan 10 mm (3/8in.) in threeminutes, masthe ter cylinderis faulty.A slightchangein pedalheight when the Ay'C compressor cycles on and off is normal. (TheAy'C compressor loadchanges vacuum the available the booster.) to
7 . Tightenthe star locknutsecurely. 8. Remove special the tool. - 0.4mm (0- 0.02inl 0
STARLOCKNUT 22 N.m 12.2kgt m. 16 lbtftl
Leak Test 1 . Press the brakepedalwith the enginerunning,then stop the engine. lf the pedal height does not vary while pressedfor 30 seconds,the vacuum booster is OK. lf the pedal rises,the booster is faulty. With the engine stopped, press the brake pedal severaltimes using normalpressure. Whenthe pedalis first pressed. shouldbe low, On consecutive it applications, pedalheightshouldgradually the rise.lf the pedal position does not vary. check the booster checkvalve. Boostor ChockValve Test 1. Disconnect the brake boostervacuum hose at the booster. Startthe engine,and let it idle.Thereshouldbe vacuum. lf no vacuum is available, the checkvalve is not working properly. Replacethe brake booster vacuumhoseand checkvalve.and retest.
ERAKEBOOSTER VACUUM HOSE (Check valveis built-in) PUSHROD LOCKNUT kgf.m.'11 lbtfl) 1.5N.m 11.5
9 . Adjust the pushrodlength as shown if the booster is removed,

11610.5 m m {4.6 t 0.02 inl
2.
1 0 . Install the master cylinder (see page 19-13).
RearDrum Brakes
Inspection
a a rl a 1.
Never use an air hose or dry brush to clgan brake assemblies, Use an OSHA approved vacuum cleanerto avoid breathing brake dust. Contaminatedbrake linings or drums reduce stopping ability. Block the front wheels betore iacking up lhe rear ot the vehicle, Blockthe front wheels,loosenthe rear wheel nuts slightly,then raisethe vehicle,and make sure it is securely supponed.Remove rearwheels. the Release parkingbrake, the and removethe rearbrakedrum.
2.
I N.m {0.9kgl.m,5.5rbr.ft)
\ \ \ 196 @
BACKING PLATE Markedleftand right. PARKINGEBAKE I-EVER Marked and right. left ADJUSTER BOLT Check ratchet teeth for wearand damage. UPPER RETURN SPRING Check weakness for and damage. B CLEVIS CLEVIS A
\L;
64 N.m 16.5 kgl.m, 47 lbt.ftl
'l-'-'
u-cllP
Replace.
6d/
t /
WHEEL
Inspect leakage. for Replacement, see page19-20
BRAKE SHOE Inspection, page19 17 see lf brakeshoesareto be reused, markand reassemble in sameposition.
SPRING C h e c kf o r w e a k n e s s ano oamage.
LOWER RETURN SPRING Check weakness for a n oo a m a g e . RETAINER SPRING Install on securely p lensron rn.
19-16
Check wheelcylinderfor leakage. the glazing,wear, Checkthe brakeliningsfor cracking, and contamination. Measurethe brake lining thickness.Measurement does not includebrakoshoethickness. BrakeLining Thicknoss: Standard: 3.9-,1.5 mm {0.15 0.18inl SorviceLimil: 2.0 mm {0.08in}
8. Measure the inside diameter of the brake drum with insideverniercalioers, Drum Insido Diamoter: 219.9- 220.0mm (8.657- 8.661in) Standard: ServiceLimit: 221.0mm {8.700inl
WHEELCYLINOER
BRAKEDRUM
LININGS
lf the inside diameter of the brake drum is more than the service limit, replaca brakedrum. the
1 0 . Check the brake drum for scoring, grooves, and

cracKs. lf the brakelining thickness lessthan the service is limit, replace brakeshoesas a set. the 7. Check the bearings the hub unit for smooth operin ation; if the bearingrequireservicing.referto section18.
19-17
RearDrum Brakes
BrakeShoesReplacement
1. Remove the upperreturnspringwith the tool. 7.
l@
war eye protestionwhen using the
Removethe wave washer,parkingbrakelever.and pivot pin from the brakeshoe by removingthe UcliD.
brske spring wrench.

U.CLIP Replace.
\ \
w \n
BRAKESHOE
RETAINER SPRING TENSION PIN
BRAKESPRING WBENCH available) {Commerciallv
Removethe tension pins by pushing the retainer s p r i n g n dt u r n i n g h e m . a t Lower the brake shoe assembly,and remove the lower return spring, Make sure not to damagethe dust coveron the wheel cylinder, Disconnect parkingbrakecablefrom the parking the brakelever. 5.
o.
Apply brakecylindergrease(P/N:08733 80202)or equivalentrubber greaseto the sliding surfaceof the pivot pin, 8nd insertthe pin into the brakeshoe. Installthe parkingbrakelever and wave washeron them with a new U-clip. the pivot pin, and secure . . lnstall the wave washer with its convex side facIng our. Pinchthe U-clipsecurely preventthe pivot pin to from comingout of the brakeshoe.
U-CLIP Replace. WAVE WASHER Replace.
Remove the brakeshoe assembly, Remove the upper returnspring,self-adjuster lever, and self-adjusterspring, and separatethe brake shoes.
LEVER SELF.ADJUSTER UPPER RETURN SPRING
19-18
1 0 . C o n n e c tt h e p a r k i n g b r a k e c a b l e t o t h e p a r k i n g
brakelever, 1 1 , Clean threadedportionsof clevises and B. the A Coat the threads of the cleviseswith grease.To shortenthe clevises, turn the adiusterbolt.
UPPER RETURN SPRING
15. Apply greaseon each sliding surface.Keepgrease or oil off the brakelinings.Wipe any excessgrease off the parts. . Apply brakecylindergrease(P/N:08733 8020E) o r e q u i v a l e nr u b b e rg r e a s e o t h e s l i d i n gs u r t t facesas shown.
..4
S l r d r ns u r f a c e g
Apply rubbergrease to slidingsurface.
1 2 . Hook the self-adjusterspring to the self-adjuster leverfirst,then to the brakeshoe, Installthe clevisesand upper return spring noting the installation direction.Be carefulnot to damage the wheelcylinderdust covers. 1 4 . Installthelower returnspring.
Apply Molykote 44MA to the brake shoe ends and oppositeedgesof the shoesas shown.
.. a Opposite edgeof the shoe .: a) Brake shoeends (Shoesideendsand backing platecontact surface)
(cont'd)
RearDrum Brakes
(cont'd) BrakeShoesReplacement
16. Installthe brake shoes onto the backingplate. Be carefulnot to damagethe wheel cylinderdust covers. 17. Install tensionpins and the retainer the springs.
WheelCylinderReplacement
CAUTION: . Do not spill brake fluid on th6 vehicle; it may damage the paint; if brako fluid doos contact tho paint, wash it off immedialely whh water. . To pr6v6ni 3pills, cov6r th6 hose ioinls with rags ol shop lowels, . Use only a genuine Honda whoel cylinder spocial bolt. 1 . Remove brakeshoes{seepage '19-18). the
SPRING RETURN UPPER
Disconnect brakeline, the
SEALANT PLATE BACKING
15 N,m 11.5 m, kgt 11 tbf.ftl
WHEELCYLINDER TENSIONPINS
kgf'm. 9 N.m 10,9 6.5 rbtft)
18. Hookthe upperreturnspringwith the tool. wsar eye proieclion whon using tho @ brtko spring wronch. 1 9 . lnstallthebrakedrum. 20. lf the wheel cylinder has been removed,bleed the brakesystem (see page 19-7). Removethe bolt and the wheel cylinder from the plate. backing Apply sealant betweenthe wheel cylinder and backing plate,and installthe wheelcylinder. Install the removed parts in the reverseorder of removal. Fill the brakereservoir and bleedthe brakesysup. tem {seepage 19-7). 7. After installation. checkfor a leak at the line joint. and retighten if necessary.
21. Pressthe brake pedal several times to set the selfadjusting brake. Adjustthe parkingbrako(seepage 19-6).
19-20
BrakeHoses/Lines
Specif ications Inspection/Torque
interference, twisting and deterioration, leaks, 1. Inspect brakehosesfor damage, the Also checkfor bent brakelines. rusting,and leakage. 2. Check brakeIinesfor damage, the if for and 3. Check leaksat hoseand line jointsand connections, retighten necessary. proportioning controlvalve.and ABS modulatorunit for damageand leakage. 4. Checkthemastercylinder, the brakehoseis serviced. NOTE:Replace brakehoseclip whenever the
LINE MASTER CYLINOER.Io.BRAKE 15 N.m 11.5 m, 11 lbnftl kgt PROPORTIONING CONTROL VALVE. Io-BRAKELINE 15 N.m (1.5 kgf.m. 11 lbl.ftl HOSE BRAKELINE-Io-BRAKE kgd.m,11 lbf'ft) 15 N.m 11.5
BRAKEHOSE-to-CALIPER {8ANJO BOLTI 34 N.m (3.5kgf.m,25 lbf.ftl BLEED SCREW 9 N.m 10.9kgf.m, 6.5 lbf.ftl
CYLINDER kgf.m, 11 lbf.ft) 15 N.m 11.5 BLEED SCREW 7 N.m 10.7 kgf.m, 5 lbt.ftt
with ABS:
19-21
BrakeHoses/Lines
HoseReplacement
CAUTION: Do not spill brak fluid on the vehicl;it m8y damage th paint; if brak lluid doos contact tho paint, wash it off immediately with water. NOTE: . Beforereassembling, checkthat all pans are free of dust and otherforeignparticles. . Replaceparts with new ones wheneverspecifiedto qo so,
'1.
first, then conthe brakehose on the knuckle 6. Install with the banjobolt nectthe brakehoseto the caliper washers. and new sealing
6 mm HOSEBRACKET EOLTS 9.8Nm (1.0kgf.m,7 lbf.ftl
BRAKE HOSE
Replace brakehose ifthe hose is twisted,cracked. the or if it leaks. Disconnect brakehosefrom the brakeline using the a 10 mm flarenut wrench.
NUT FLARE WRENCH (Commercially available)
BANJO BOLT 34 N.m kgf.m, 25 lbl.ftl 13.5
WASHERS SEALING Heplace.

BRAKEHOSE
Removeand discardthe brake hose cliD from the brakehose.
7. Installthe brakehose on the upper brakehose bracket with a new b.akehoseclip.

Replace.
1 tbtftl
F
) /
BRAKE HOSE ARACKET 8. Connect brakelineto the brakehose. the the brakehose,bleedthe brakesys9 . After installing '19-7). tem (seepage Performthe followingchecks; . Check and the brakehoseand line joint for leaks, tighten if necessary. . Checkthe brake hoses for interferenceand twistIng
Removethe banjo bolt, and disconnectthe brake hosefrom the calioer. 5. Remove brakehosefrom the knuckle. the
19-22
Parking BrakeCable
Inspection and Replacement
Inspection This will leadto stiff operation and premature cablefailure. The parkingbrakecablesmust not be bent or distorted, Replacoment l. 2. Disconnect parkingbrakeswitchconnector. the the Release parkingbrakelever.and disconnect the parkingbrakecable. Bemove the parkingbrakeleverassembly. Remove the parkingbrakeshoes{seepage '19-18).
3, 4. 5.
Removethe parkingbrake cable from the backing plateusinga '12mm offsetwrenchas shown. Installthecablein the reverse orderof removal.
6.
PARKINGBRAKECABI-E
BRACKET ARAKECABLE PABKING or corroston, Checktor PARKINGBRAKELEVER

Checkfor smooth operation,
,"u/n*UM
-6l
(Sliding surface)
19-23
Anti-lockBrakeSystem (ABSI,'97- 00 Models

Special Tools ............. 19-26 Component Locations ......................... 19-27 Anti-lockBrakeSystem (ABS) Features/Construction ............. 19-2A ......, CircuitDiagram ......... 19-32 ABS Control Unit Terminal Arrangement ......... 19-34 Troubleshooting Precautions............. 19-36 Diagnostic TroubleGode(DTC) DiagnosticTroubleCode (DTC) (SCSModel ................ Indication 19-38 (MESMode) ............... DTGErasure 19-39 Troubleshooting lndex .................... 19-40 Troubleshooting ABS IndicatorLight DoesNot ComeOn ............ 19-41 ABS IndicatorLight DoesNot Go Off (No DTC)........................... 19-43 DTC1r - 18: Wheel Sensor .... 19-45 - 38: DTC31 Solenoid ............. 19-47 - 53: DTC51 ABS PumpMotor ......................... 19-49 DTC 54: Main Relay ......... 19-52 DTC61: lgnitionVoltage ........................... 19-54 DTC81: CentralProcessing Unit (CPU).... 19-55 Modulator Unit Removal/lnstallation ....................... 19-56 ABS Control Unit Replacement ..,...... 19-57 Pulsers/WheelSensors Inspection .............. 19-57 Wheel SensorReplacement ............ 19-58
S p e ci a l Tools
Rel. No.
Tool Number 07PAZ 0010100
Description SCSService Connector
Oty 1
PageRelerence 19-38
19-26
ComponentLocations
NOTE:The illustrations show the '97 - 98 models. The '99 - 00 modelsare similar.
SERVICE CHECK CONNECTOR {2PI ABS CONTROL UNIT RIGHT-REAR WHEELSENSOR
UNDER.HOOD ABS FUSE/RELAY BOX
RIGHT.FRONT WHEEL SENSOR CONNECTOR
RIGHT-FRONT WHEELSENSOR
WHEEL RIGHT-REAB SENSOR CONNECTOR FUSE,/RELAY 8OX UNDER.DASH
MODULATOR UNIT WHEEL LEFT.FRONT SENSOE CONNECTOR GAUGEASSEMBLY
LEFT.FRONT WHEELSENSOB
FUSE/RELAY AOX UNDER.HOOO
IGl I(, AI FUSE
trtrtr
[r D!
D!
ABS INDICATOR UNDER-DASH FUSE/NELAY BOX METER{7.5AI FUSE
HOBN/STOP AI FUSE I15 ABS FUSE/RELAY BOX UNDER.HOOD ABS +B 120Al FUSE PUMPMOTOR('II AI FUSE
MOTORRELAY ABS {7.5AI FUSE MTR CHECK AI 17.5 FUSE
19-27
Anti-lock Brake System (ABS)

Features/Construction
during driving,the wheelscan lock beforethe vehiclecomesto a stop. In suchan event, When the brakepedalis pressed if and the stabilityof the vehicleis reduced the if maneuverability the vehicleis reduced the front wheelsare locked, of the The ABS precisely controlsthe slip rate of the wheelsto unstable condition. creatingan extremely rearwheelsare locked, and maneuverbility stabilityof the vehicle. ensuremaximumgrip forcefrom the tires,and it therebyensures then it controlsthe brake The ABS calculates slip rate of the wheelsbasedon the vehiclespeedand the wheel speed, the pressure attainthe targetslip rate. fluid to
Grip Force of Tire and Road Surlace COEFFICIENT OF FRICTION
TARGET SLIPRATE
RADIAL OIRECTION OF THE ROTATIONAL DIRECTION SLIPRATE
19-24
ABS Control the then it calculates vehicle the The ABS control unit detects wheel speedbasedon the wheel sensorsignalit received, basedon the wheel speed.The control unit detectsthe vehiclespeed during deceleration speed basedon the detected rateof deceleration. the slip rate of each wheel, and it transmitsthe control signal to the modulator unit The ABS control unit calculates valvewhen the slip rateis high solenoid modes. intensi{ying pressure retaining, and pressure reducing, controlhasthree modes:pressure reduction The pressure
I-INIT ABS CONTROL
Self-diagnosisFunction with a main cPU and a sub cPU, that checkeachotherfor problems. The ABS controlunit is equipped checkthe circuitof the system. The CPUs "systemdown mode" or the "controlinhibitionmode". they shiftto the detectfailure, Whenthe CPUS MODE SYSTEM DOWN CONTROL INHIBITION LIGHT ABSINDICATOR ON ON MAIN RELAY No operatron No operaton SOLENOID VALVE Drive inhibition Drive inhibition Restan condition DTC
lgnition Operation*r switch OFF oN (ll) Memory Operation Automatic
lVemory
*1: Except CPUfailure into thesefour categories: can The self-diagnosis be classitied l O : I n i t i ad i a g n o s i s ABS control O: Except O; DuringABS control w @: During arning On-boardDiagnosisFunction with the HondaPGMTester. The ABS systemcan be diagnosed wheel sensorsignals,use the Honda and checking The ALB Checker cannot be used with this system.For air bleeding. instructions. for operating PGIM Tester. Seethe HondaPGMTesteruser'smanuals specific
(cont'd)
19-29
Anti-lockBrakeSystem(ABS)
(cont'd) Features/Gonstruction
ABS Modulator The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and the dampjng hamber. c The modulator reduces caliper the fluid pressure directly. is a circulating-type lt modulator because brakefluid circulates the throughthe caliper, reservoir the master and cylinder. The hydraulic controlhasthree modes:pressure pressure reduction, retaining and pressure intensifying modes. The hydraulic circuitis the independent four channel-type, channel eachwheel. one for
SOLENOID VALVE
PUMP MOTOR
t-
Pressure intensifying mode:Inletvalveopen,outletvalveclosed, Mastercylinder fluid is pumpedout to the caliper. Pressure retaining mode: Inletvalveclosed, outletvalveclosed. Caliper fluid is retained the inletvalveand outletvalve. by Pressure reduction mode: Inletvalveclosed, outletvalveooen Caliper fluid flows throughthe outletvalveto the reservoir. Motor operation mode: Whenstartingthe pressure reduction mode.the pump motor is ON. WhenstoppingABS operation, pump motor is OFF. the The reservoir fluid is pumpedout by the pump,throughthe dampingchamber, the master to cylinder.
19-30
Wheel Sensor type. As the gear pulserteeth rotatepast the wheel sensor'smagnetic The wheel sensorsare the magneticcontactless The ABS controlunit detects with the wheel speed. in changes accordance The coil,AC currentis generated. AC frequency the wheel speed and therebydetects the wheelsensorsignalfrequency
GEARPULSER at LOW SPEED

F
wheel Spod and Modulatot Control
VEHICLSPEED E VEHICLE SPEED
WHEELSPEED
PRESSU
OUTLET VALVE ON OFF INLET VALVE ON OFF MOTOR ON OFF to When the wheel speeddrops sharplybelow the vehiclespeed,the outlet valve opens momentarily reducethe caliper to the fluid pressure. The pump motor startsat this time. As the wheel speedis restored. inlet valve opens momentarily the fluid oressure. increase caliDer
19-31
CircuitDiagram
UNDFS I]OOD FISAFELAY 8OX Cbsod: &rrc ped. deprelled
-tjF wHT/GrN
GFrlrr'vril
GNITION
*oJG\'*" \F*,-
UNDER-HOOD FUSE/FELAY A8S BOX (O 3P CONNECTOR number)

t_--t l-| l l ' " 1
UNDER,DASH FUSFJRELAY BOX (O 20PCONNECTOR number)
M-OD LATORUNIT CONNECTOR U
UNDER.HOOO FUSE/RELAY A8S BOX 2P CONNECTOF(! numbor)
3 5 6 1 0 1 1 12 1 3 ,/ 115 ,/
8 9 19
UNDER-DASH FUSE/RELAY BOX (E 18PCONNECTOR number) 3 4 5 6 '12 1 3 | i 4 9 10 /

1 2
{tT6TsF} !]q:]j_1, (tr
ll3 2ir I
PUMP MOTORCONNECTOR number) 7 18
EFIAKE SWITCH CONNECTOR l-4 | 1t x l 2 |
ASSEMBLY CONNECTOR 5P
ATi)
Terminal oJlemale side terminals
f s a'l Lr--'--.----1
----.4Wiresideol femalelerminals
l1)/l3l/l5l
19-32
Gil
I.]NII ABS CONTROL {NBK) STOP
-[rf$-n*'"
r a
t
G2
[m;]t
SEFVCE CHEC(
,BFN+BsN-,|
. 8 Y WIT/BLIJ ,r-,,..J
,ln
l'? g,l
: G101cr02
Br( --o-
|;
A ^ l 0 l T AL M 8LK
'r6P) i trr cor'hrEcroF
c1013,402
tG2,
rlr*r"t_._*h -----r;c, r"-!cc

-
Lffi_--.^ PMR,
t!94
.,._ PCOM,
Pf:
-tL
t=
#
,,-:g
t
9
GRN/8I(
J*
t-
x
pliirn
Ilcrom.
:C, IRE^R
LT
GFNmL---l
4iq!A
,-ry
5
5
-l BLr( eli -.1 BtK-L
ABs coNTRoL 26pcoNNEcroR -- uNrr (o;fib;;;

e
)E 9E-FY!!CHECK (2P) coNNF :CTOR

-r
lr z :ltl,/ a ,18 e tol/ 12li3l p91 5 | | 4 1 16)17 I1s l2'VIIU)4 V V ffi ABS coNTRoL 22p -- uNrr coNNEcroR i-;;i,;;)
I'
, f
HEEL SENSOR CONNECTOR '98-99 '97 model models RIG-HT-REAR FRO NT/ REAR FRONTI
iTtl\
Termnal sideol mate terminals
/Jr lz !\
Terminal sideol maleterminals LEFT.REAR
t,*---;T- r I
l,'2 -14
, i7
=l------5o ril| , /
19
INK QAIA.L (16P) coNNE croR
- ) 1. 2 2 1
mtTl #
| |
,z
T?'--"r""""./ 6 ,/ 8\
F{ c7
terminals Wire sideof lemale
V L:J Terminal ol side lemaleterminals
/nf'\ 1./ 1F r .4-;1
19-33
ABSControlUnit Terminal Arrangement

ABS CONTROL UNIT26PCONNECTOR
Teiminal numbel
Wiie color
Terminal3ign Teiminalnamgl
Voltrge Description
tdminals Power sourcefor the solenoid valve and pump motor. Condhions (lgnition Switch ON llll)
Output voltago OV AC:3-6V Approx.3 V BatteryVoltage

53mVor above on
PCOM GRNn/VHT (Primary common)
1-GND
ON
ON
6
OFF
SCOM Power sourcefor the solenoid BLI(WHT (Secondary 2-GND common) Detects ignitionswitch2 BLVBLU (lgnition (System 2) signal. activate signal) 3-GND
RRO BLUA/EL (Rear-right 0) Detocts right-rear wheel sensorsrgnat.
OFF the seNice] lConnect SCS connector \ I
GRY
8 GRN
RLO (Rear-left 0)
FRO (Fronr-right 0)
Detects left-rear wheelsensor srgnat.

Detects right-front wheel sensorsignal.
6-19
(AC digitaltester Whenthe wheelis range) {Beference) turnedat 1 turn/second. 150 mvtrp or above on oscilloscope
8-21
STOP {Stop)
Detects bfake switch signal. (Prevents unnecessary operation) 9-GND ABS
Stops pedal pressed. Brake

BrakeDedalreleased. When the wheel is turned at 1 turn/ second.
Approx.2.5 V Battery Voltage OV 53mV above or on digitaltester lAC (Reference) range) 150 mvpporabove onoscilloscope
ADprox. 2.5 V
Detects left-frontwheelsensor srgnal. 10 FLO BRN^/VHT(Front-left 0) 10-23
Stops YEL left-rear outlet solenoid RL-oUT Drives 12.GND (Rearleft outlet) Drives right-rear solenoid inlet
13.GND
ON
ON
OFF
OV AC:3-6V Approx.3 V
13
14
16 't7
19
RR.IN RED^/vHT (Rear-right inlet) B1 WHT/GRN (Baftery 1) 82 (Battery 2) GND2 BLK (Ground 2) RR1 GRN/YEL(Rear-right 1) RL1 LT BLU (Rearieft 1)
FR1 GRN/BLK (Front-right 1) FL1 GBN/ORN 1} {Front-left
OFF theSCS service\ lConnect connector I \ Everytime
Power source the solenoid for valveandpumpmotor.

Power sourcefor the solenoid valve and pump motor.
14.GND
BatteryVoltage
15-GND 16-GND
Ground the ABScontrol for unit. Detects right-rear wheel sensor signal. Detects left-rear wheelsensor signal.
Detects right-front wheel sensorsrgnat.
Below V 0.3
53 mV or above on digitaltester (AC range) (Reference)150 mVp-p or above on oscilloscope
't7-4
19-6 When the wheel is turned at l turn/second,
21-8 23-10 Stops
23
Detects left-frontwheelsensor sagnal.

Drives left-rearinlet solenoid
Approx. V 2.5
=
ON
-9
ON
OV AC:3-6V Approx. V 3 Below V 0.3
RED
RLIN (Rear-left inlet)
25,GND
OFF the service] /Connect SCS conneclor \ I
26
BLK
GND3 (Gtound 3)
Ground the ABScontrol tor untI.
26-GND
19-34
UNIT 22PCONNECIOR ABS CONTROL
Wire side ol lemale terminals Voltage Terminal numDer
Wire color
Terminal 3i9n Terminal name
Description tominals Drivesright-frontinlet solenoidvalve.
Conditions (lgnition Switch ON (ll)l ON
Output voltage OV
AC:3-6V
ON
1-GND
FR-IN 1
RED/BLU (Front-right
inlet)
.9
ot
OFF
ur
OFF the servicel lconnect SCS connedor l \
V Approx.3 OV S Approx. V Approx.2 V Battery Voltage
BRN
Detects service check signal (Diagnostic trouble code (Service check indication) signal) DrivesABS indicator{The indicator goes off when ABS control unit outputs battery voltage). Drives left-front outlet solenoidvalve. Drivesleft-frontinlet solenoid
4.GND
SCSserviceconnector connected. SCS service connector disconnected. lndicatorON
BLU/RED (Warning ramp) YEUBLK FL-OUT (Frontieft outlet)
7.GND
lndicatorOFF 1O-GND
=
ON
I
10
ON
OFF
OV
AC:3-6V
l'l
FL-IN RED/BLK (Front-left inlet)
11-GND
Drivesright-frontoutlet FR-OUT YEUBLU (Front-right solenoidvalve. outlet) 14
12-GND
OFF the servicq lconnect SCS connector l \
V Approx.3
LT BLU
(Datalink connectod
with Honda Communicates PGM Tester.
14-GND
Approx.5 V Pump ON
OFF ON
6 I
17
Detects PumPmotor drive MCK signal. BRN/YEL(Motor check)

Drivespump motor relay.
Battery Vollage
1 7 - G N D motor
relay
OV ON
OFF
OV
AC:3-6V
19
PMR motor YEURED (Pump reray, right-rear outlet Drives valve. solenoid
19.GND
cl)
OFF ponnecl SCS the service] connector I \ ON Pump ON moror rcray OFF
V Approx.3 OV AC:3 6V V Approx.3 Below V 0.3
BLU
RR-OUT (Rear-right outlet) GND2 (Ground 2)
21.GND
'a)
OFF service] the lconnect SCS connector l \
BLK
Ground for the ABS control unit.
22.GND
19-35
Troubleshooting Precautions
ABS lndicalor 1 lf the systemis oK, the ABS indicatorgoes off two seconds after turning the ignitionswitch oN 1l) wathout staning the engine,and then comes on again and goes off after two seconds. This occursbecause the ABS control unit is turnedon by the lG2 powersource. 2. The ABS indicator comeson when the ABS control unit detectsa problemin the system.However, even thouoh the systemis operating properly, ABs indicator the will come on too, underthe followingconditions: . Signaldisturbance . W h e e ls p i n . Only drivewheelsrotate . Battery voltagefluctuates To determine actualcauseof the problem,question customeraboutthe problem,takingtheseconditions the the into consideration: 3 When a problem is detected and the ABS indicatorcomes on, the indicatorcan stay on until the ignition switch is turnedOFF,or it can automatically off, depending the mode. go on . Indicator stayson untilthe ignitionswitchis turnedoff: Whenthe systemis in the systemdown mode. . Indicator automatically goesoff: Whenthe systemis in the controlinhibitionmode. 4 The ABS indicatorstayson when the systemis reactivated without erasingthe DTC,but it goes off after startingthe vehicle. When the wheel sensorsystem is faulty and the ABS indicatorcomeson. the algorithmof the systemautomatically turns off the ABS indicator afterthe wheelspeedsignalreturns the normalspeed. to Also,when the DTc is erased, cpu is the reset andthe ABS indicator goesoff whenthe system checked normalby the initialdiagnosis. out Therefore, test-drive vehicleafterservicing wheel sensorsystem.and be surethat the ABS indicator the the does not c o m eo n . 5 When the ABS controlunit outputsbatteryvoltageto the gaugeassembly, ABS indicator the ooesoff. DiagnosticTrouble Code (DTCI 1. The diagnostic troublecode (DTc)is memorized when a problemis detected and the ABS indicator does not go off, or when the ABS indicator comeson. The DTc is not memorized when the ABS indicator comeson unress cpu is activated, the 2 The memorycan hold any numberof DTCs.However, when the same DTc is detected twice or more,the taterone is writtenover the old one. Therefore, when the same problemis detected repeatedly, is recorded one DTC. it as 3. The DTCs indicated the orderof ascending are in number,not in the orderthey occur. 4. The DTCS memorized the EEPROM are (non-volatile in memorv). Therefore, memorized the DTcscannotbe canceled disconnecting battery. performthe specified by the procedures to erasethe DTCS. Self-diagnosis 1. Self-diagnosis be classified can into thesefour categories: ' Initialdiagnosis: Performed right afterthe engine startsand untirtheABS indicator goesoff. . Except ABS control:Performed when the ABS is not functioning. . DuringABS control:Performed when the ABS is functioning. . Duringwarning: Performed when the ABS indicator ON. is 2. The systemperforms fo|owing contrors the when a probremis detected the serf-diagnosis: by . ABS indicator ON . Memorvof DTC . Mode changetothe "systemdown mode,,or the ,,control inhibitionmode,,. MODE SYSTEM DOWN CONTROL INHIBITION ABS INDICATOR ON ON MAIN RELAY
No operation
SOLENOID VALVE Drive inhibition Drive inhibition
CPU Operation*r Operation
Restart condition
lgnition switch
DTC
oFF- ON l) Memory lMemory
No operal|on
Automatic
*1: Except CPUfailure
19-36
Kickback '1. The motor operates is and the fluid in the reservoir forcedout to the mastercylinder, when the ABS is functioning. pedal. at causingkickback the brake 2. afterthe initialdiagnosisYou may valvewhen the brakepedalis released the The ABS controlunit operates solenoid valveoperateat this time, but it is normal hearthe solenoid
PumoMotol when the ABS is functioning 1. The pump motor operates 2. You may hearthe motor operateat this The ABS control unit checksthe pump motor operationduring acceleration. time, but it is normal.
Bleeding BrakeFluidReplacement/Ail start without ABS To easebleeding, are and fluid replacement air bleedingprocedures the sameas for vehicles L Brake with the front wheels. Troubleshooting and the ABS indicator assume that the causeof the problemis still present flowchartprocedures 1. The troubleshooting diagnosis. resultin incorrect does not come on can the is still on. Following flowchartwhen the ABS indicator 2. the and try to reproduce same conditions when the problemoccurred, the customerabout the conditions Ouestion for troubleshooting. exceptABS control,during ABS control,during is Self-diagnosis made at varioustimes such as the initialdiagnosis, the symptom canngt be checkedunlessthe check vehiclespeed,etc. Therefore, during the specified acceleration, problemconditjons matchwith the conditions is but does not come on duringthe test-drive. troubleshooting performedbasedon the DTC, When the ABS jndicator poor contactof the terminals, etc.,beforeyou starttroubleshooting. checklor looseconnectors, does not come on. Be the erasethe DTCand test-drive vehicle. surethe ABS indicator Aftertroubleshooting, with a doubleoutshow the femaleterminalswith a singleoutlineand the maleterminals illustratjons The connector l ne.
3.
4. 5.
ABS Function Test valvesand pump, usethe HondaPGMTester. the and activate solenoid To simulate ABS operation (DLC). selectthe ABS Whenthe SystemSelectmenu is displayed, the Connect PGMTesterto the 16PDataLinkConnector prompts. TestMode menu,and follow the tester's
19-37
Diagnostic TroubleCode(DTC)
Diagnostic TroubleGodeIDTCIIndication
NOTE:This operation can also be donewith the HondapGM Tester. 1. Connectthe SCS service connector to the service check connector (2P) located on the passenger'sside of the center consote. Turn the ignitionswitchON (ll). NOTE; Do not pressthe brakepedalwhenturningthe ignitionswitch. Record blinkingfrequency the ABS indicator. the of The brinking frequency indicates DTc. the Turn the ignition switch OFF.and remove the SCSserviceconnector. NOTE:The MalfunctionIndicatorLamp (MlL) will stay on after the engine is startsdif the SCSseryicaconnecror rs connected. Erase the DTC.
2.
3 4.
5.
Conditions for DTCindication . The vehicleis stopped. . The SCSserviceconnector is connectedbefore the ignition switch is turned ON flt). . The brakepedalis released. . The SCSservice connector remainsconnected duringthis procedure. The DTC indication stops and the ABS control unit axecutostha softwaro lunction if at least one of tho following conditions i3 satisfiod: . The vehicleis not stoooed. . The ABS controlunit receives normalsignal(whichis for the ABS controlunit)from a HondapGM Tesrer. the . The SCSservice connector disconnectod is duringthis procedure. NQTE:The illustration gaugeassembly of showsthe '97 - 98 models. The '99 - oo modelsare similar.
SEFVICE CHECK CONNESTORI2P} GAUGEASSEMBLY
u.s.A.
@
CANADA
A8S II{DEATOR
19-38
DTCErasure
can also be done with the HondaPGMTester. NOTE:This operation 1. side of the center connector the servicecheckconnector(2P)locatedon the passenger's to Connect the SCSservice console. Press brakeoedal. the goes off aftertwo seconds. The ABS indicator the Turnthe ignitionswitchON (ll)while keeping brakepedalpressed. goes off, release brakepedal. The indicator comeson afterfour seconds. the Afterthe indicator After the indicatorcomeson, pressthe brakepedalagain.The indicatorgoes off againafterfour seconds (the brake oedalis still Dressed.) goesoff, release brakepedalagain. the Afterthe indicator blinkstwice for 0.3secondand the DTCis erased. the Afterfour seconds. indicator and checkthat the DTCwas erased. Confirmthe DTCindication,
2. 3. 4. 5.
6. 7. 8.
the NOTE:Always maintainthese steps.lf you disconnect SCSserviceconnectorand/orfail to operatethe brakepedal indication, DTCwill not be erased. the according the indicator to Conditions for DTCerasure . The vehicleis stopped. . The SCSservice is beforethe ignitionswitchis turnedON (ll) connector connected . The brakepedalis pressed ignitionswitchis turnedON (ll). beforethe . The SCSservice remainsconnected duringthis procedure. connector The DTCerasurestops and the ABS control unit executesthe software funqtion it at least one of the following conditions b satisfied: . The vehicleis not stopped. . The SCSservice is duringthis service. connector disconnected . TheABScontrolunit receives normalsignal(whichis for the ABS controlunit)from a HondaPGMTester. the indication . The brakepedalis not operated according the indicator to . The DTCerasure finished. is
0.3sec.
ON ABSINDICATOR OFF within 3sc. I DEPRESSED BRAKE PEDAL within sc. 3 within3 sec. 0.3sec.
RELEASED
dN (r)
lonition switch
19-39
Diagnostic TroubleCode(DTC)
Troubleshooting Index
This operation can also be done with the HondapGM Teste.. DETECTION TIMING
DTC
3 YR <
ct
DIAGNOSIS/SYMPTOM
z
No DTC
Ed 9 X z
gl
< = E E2E 2 = 3 e 28 ET B 63
(J
8i <
4,, to < J
PROBLEM LOCATION
REFER TO PAGE
OFF ON
ABS indicator does not come on. ABS indicator does not go off. (No DTC) FR Wheelsensor{open/short body ground/short to to power)
19,4'l 19-43
't1
13
't5
17
oN*
o o o o
o o o
FL RR RL
19-45
12 't4
FR
oN*
18 31 32 34
(chipped Wheelsensor/Pulser pulsergearlelectrical notse,
FL RR RL FR-IN
19-45
FR-OUT
FL.IN ON Solenoid(open/short body ground/short to to power/stuck)
o o o
FL-OUT RB-IN
19-47
36
37 38 ON ON Motor lock Motor stuckOFF Motor stuckON Main relaystuckOFF lgnitionvoltage(low voltage/high voltage)
RR-OUT
RL-IN
RL.OUT
53
54 6l 81
ON
ON
ON
ON
19-55 *: lf DTcs 11-18 {wheelsensorcodes)were detected the last time the vehiclewas driven,the ABs indicatorwi stav on untilthe ignitionswitchis turnedON (ll),and the controlunit confirmsthat the wheelsensors OK, are
o o o o o o o o o o o o o o o o
19-49 19-49 19-49

ia_at
'19-54
19-4 0
Troubleshooting
ABS lndicator Does Not Come On
The ABS indicator does not come on when ignition switch is turnodON lll).
checkthe METER {7.5A} fuse in the underCash use/relay ox, f b fuse if it is OK. and reinstaltthe
Reolace the tuse and recheck.
Checkfor an open in the lcl chcuil: 1. Disconnect gaugeassemthe bly 5P connector. 2. Turnthe ignition switch (ll). ON 3. Measure voltagebetween the the gauge assembly5P conn e c t o rt e r m i n a lN o . 5 a n d body ground. . Repairopen in the wire between lhe METER{7.5 A) luse and tho gaugeassembly. . Reolecethe under-dashfuse/ relay box. (Oponcircuit inside the box.)
5P GAUGEASSEMBLY CONNECTOR
Checkthe ABS indicatorbulb in the gaugeassembly.
the ABS indicator bulb. Replace
Checkfor a short to power in the WALPcircuit: the Measure voltagebetween the g a u g e a s s e m b l y5 P c o n n e c t o r terminalNo. 1 and bodyground. Sepair short to power in the wite btweenthe gaugassembly and the ABS control unil.
ls there batteryvoltageT
(To page 19 42)
(cont'd)
19-41
Troubleshooting
ABS IndicatorDoesNot ComeOn (cont'd)
(Frompage19'41)
Checkthe gruge essembly: 1. Turnthe ignitionswitchOFF. 2. Connect the gauge assembly 5Pconnector, 3. Connect terminalNo. 3 to the b o d y g r o u n dw i t h a j u m p e r 4. Turnthe ignition switch (ll). ON
GAUG ASSEMBLY CONNECTOR 5P
l1 t/l3_l/ |5| JUMPER IBLK} I GND
---g-
wrBE
L
Reolacethe ABS indicator drive circuit in the gaug assmbly.
Wireside female of terminals
Doesthe ABSindicator comeon?
.Repair open in the wire between the gauge assembly and body ground. . Repair poor ground {G401, c102l-
19-42
ABS IndicatorDoesNot Go Off (No DTGI

With engine running, the ABS indicsior is ON. With the SCS serviceconnector conncted (s page 19381, no DTCis indicated.
the Check ABS {7.5A) fuse in the undeFdashfuse/relaybox, and reinstall fuse if it is OK. the
ReDlace tuse and recheck. lhe
Checkthe ABS +B (20 A) fuse in t h e u n d e r h o o dA B S f u s e / r e l a y the fuse if it is box, and reinstall
oK.
Replace fuse and rocheck. the A8S CONTROL UNIT 26PCONNECTOR
IG2IBLK/BLU)
Checkfor sn open in the lG2 circuit: 1. Turnthe ignition switch {ll). ON 2. Measurethe voltage between the ABS controlunit 26Pconn e c t o rt e r m i n a lN o . 3 a n d body ground. Repairopen in tho wire between the ABS {7.5A} fu3e .nd the ABS control unit, ABS CONTROLU N 26P CONf{ECTOR Check for an open in the 81 and 82 circuit: M e a s u r et h e v o l t a g e b e t w e e n No. bodygroundandterminals 14 and No. 15individually.
{WHT/GRNI
is there battery voltage?
Ropairopen in tho wi.e between rhe ABS +B {20 A) fuse and the ABS control unit.
(Topage19 44)
(cont'd)
19-43
Troubleshooting
ABS IndicatorDoesNot Go Off (No DTC)(cont'dl
(Frompage19,43)
Check tor a short to body ground in the WALPcircuil: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ABS control unit 22Pand gaugeassembly 5P connectors. 3. Checklor continuity between the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d body ground.
ABS CONTROL UNIT 22PCONNECTOR WALP{BLU/REDI
Repair short to body ground in the wire between the ABS cont.ol unh and the gaugeassembly.
Checkthe ABS control unit: 1. Connect the ABS control unit 22Pconnector. 2. Turnthe ignition switch (ll). ON 3. Measurethe voltage between the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d body ground.
Check tor an open in the GND2 circuit: 1. Connect the ABS controlunit 26Pconnecto. terminalNo. 16 to body groundwith a jumper 2. Measurethe voltage between the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d body ground.
ABS CONTROL UNIT 26PCONNECTOR
JUMPCR GND2IBLKI WIRE Wiresade female of terminals
. Repeir op6n in th6 wire ttetween the ABS control unit and body ground. . Rep.ir poor ground {G401, G4021.
Check tor an open in the WALP circuit: Measure voltagebetween the the g a u g e a s s e m b l y5 P c o n n e c t o r terminalNo. 1 and body ground.
Check lor loose ABS control unh connectors. lf necesssry,substituie e lnown-good ABS control unit and recheck. GAUGEASSEMBLY CONNECTOF 5P
WALPIBLU/FEDI Repairop6n in the wi.e botwen the ABS control unit and th gau9e assmbly.
Replacothe ABS indicator drive circuit in the gauge assembly.
19-44
DTC11- 18:WheelSensor
NOTE:The ABS indicatorcomeson only when the drive wheelsare turning and signaldisturbance detected, is Therefore, testdrive the car at a speedof 12 mph (20 km/h)or more afterturning the ignition switchfrom OFFto ON l), and if the ABS indicator does not come on, the svstemis OK.
With ths ignition switch ON llll, the ABS indicatol does not go ott. Atte. driving, the ABS indicalot comason. With the SCS serviceconnector connocted (s page 19.381, DTGr 11 - 18 sre indbated. Appropriate Terminal {0}srDE ( 1 ) S | D E
ABS CONTNOL UNIT 26PCONNECTOR RRO IBLU/YEL}
Checkthe whcol sensorcircuit: 1. Disconnectthe ABS control unit 26Pconnector. 2, Nleasure the resistance betweenthe appropriate wheel sensorl0) and 1'l)circuitterminals{seetable).
DTC
FLO (BRN/WHTI
1 1 ,l 2 l R i g h t - f r o n t ) No.8: Fno N o . 2 1 F R 1 : 13, 14 (Left-front) No.10rFLo No. 23: FLl 15, 16 (Rightread No.4: RRo N o . 1 7 : R 1 R
17,l8 (Lsft-rear)
No.6: RLo N o . 1 9R L 1 :
RRTIGRN/YELI RLl (LT BLUI
ls the resistance OK? /Fronr:750 r,050o (20"C,68"F\ 68'F, \Rear:950-'1,450O (20"C,
. Ropairopn in th. {01o. lll circuit wire, oa short to the (01circuit wire in the lll circuit wiro betweon the ABS control unit and th. appropriatewhasl sensot. . Roplacethe rpp.opriatc whe6l Sensor.
FLl IGFN/ORN} FRl IGRN/BLKI
Chocklor a short 10 power in the wheel sensoa ciacuil: 1. Reconnect ABScontrolunit the 26Pconnector. 2. Startthe engine. 3. Measurethe voltage betlveen the ABS controlunit 26Pconnector appropriatewheel sens o r ( 0 ) c i r c u i t t e r m i n a la n d body ground(seetable). ls there4 V or more?
NOTE:Judgement value for short
NO NOTE: . Normalvoltage: Approx.2 V .0 V: Replace ABScontrolunit. the . 4 V or more indicatesa shon to power. Checkfor a short to body ground in the whoal s.n3or cilcuit: 1. Disconnectthe ABS control unit 26Pconnector. 2. Checklor cont;nuitybetween the ABS controlunit 26Pconnector appropriatewheel sens o r { 0 ) c i r c u i t t e r m i n a la n d body ground{se6table).
Ropair lhort to pow.r in the l0l ot 11)circuit wiro between the ABS control unit and the appropriate whool sen6or.
NO (To page 19-46)
. Ropairshort to body g.ound in th6 {01 or {1} circuit wire botweon th6 ABS cont.ol unit and tho appropriatowheol sonaot. . Roplacetho appropriate wheel sensot.
(cont'dl
19-45
Troubleshooting
(cont'd) DTC11- 18:WheelSensor
C h e c kf o r c h i p p e d p u l s e r g e a r .
Rcplacs thc drive3haft or hub unh. (Chippedpulsor goar.l
DTC 11, 13, 15. 17: Replaco the ABS control unit. OfC 12, 11, 16, 18: Th6 ABS control unit may have dstected dgn.l disturbsnc.
19-46
DTC31 - 38:Solenoid
With the ignition switch ON {lD, tho ABS indicator does not go off, or the ABS indic.lor comes on whil6 ABS is tunctioning. With th SCS service connoctor connoctcd {sce page 1$381, DTCa31 - 38 ars indicatsd. ABS CONTROL UNIT 22PCONNECTOR FL.OUTIYEL/8LKI
DTC 31:FR'lN
32:FROUT
3 3 :F L l N
Checkfor a 3hori to power in th solenoidci.cuit: 1 . D i s c o n n e ctth e A B S c o n t r o l untrtlr ano zbr connectors_ 2. Startthe engine. 3. Measurethe voltage between the appropriateABS control unit connector solenoid circuit terminal and body ground (see table).
34:FLOUT 35:RR-lN 36:RR-OUT

37: RLIN
Appropraate Connector Terminal 22P No. 1 22P No. 12 22P N o .1 1 22P No.10 26P No.13 22P No.21
26P 26P No.25 No. 12
Wiresideof femaleterminals ABS CONTROL UNIT 26PCONNECTOR
38:RL-OUT
RL.OUT {YELI
R p a i rs h o r t t o p o w e r i n t h e approp.iato solenoid circuit wire betwen the ABS control unit and the modulator unh.
ls there baReryvoltage?
Chockfor a short to body ground in the solnoid circuit: Checkfor continuity betweenthe appropriatesolenoidcircuit terminalandbodyground(see table). . Ropair short to body ground in the appropriatosolenoid circuit wire betwoon the ABS control unit and the modulator unit. . Replace the modulator unit.
Wire sade femaleterminals of FL.OUTIYEL/BLKI
ls therecontinuity?
DTC Checkthe ABS control unit: 1. Turnthe ignitionswitchOFF. 2. Connect the ABS controlunit 22Pand 26Pconnectors. 3. Connect SCSservice the connector. 4. Turnthe ignitionswitchON (ll). 5, Measurethe voltage between the appropriateABS control unit 26PconnectorCOMcircuit terminaland body ground (see table).
3 1 :F R l N
Appropriate Terminal No. 2i SCOM No. 2: SCOM No.1:PCOM No. 1:PCOM No. 1: PCON4 No. 1: PCON4 No. 2: SCOM No. 2: SCOM
32:FR-OUT
33: FLIN
RL.OUT{YELI
34:FL-OUT
35:RRIN
36: RR-OUT
37rRL-lN
3a:RL-OUT
ls thereapprox. V7 3
Checktor loose ABS control unit connectors. ll nece$ary, substitut a known-good ABS control unit and recheck. PCOM {GRN/WHTI
(To page l9-48)
19-47
Troubleshooting
DTC31 - 38: Solenoid(cont'dl
UNIT 22PCONNECTOR A8S CONTROL
FL.OUT IYEL/BLK}
DTC
3 1 :F R I N Connector
32:FR-OUT
33: FL-IN
Checkfor an open in the solenoid circuit: Measurethe voltage betweenthe ABS controlunit con appropriate nector solenoidcircuit terminal and bodyground{seetable).
34:FL OUT 35:RRIN 36:RR-OUT

37:RLIN
22P 22P 22P 22P

26P
No. 1 No.12 No.11 No.10 No.13 No.21 N o .2 5 No. 12
22P
26P
38:RL-OUT
3 ls thereapprox. V?
. Repair open in the appropriate COM circuit wire botween the ABS control unit and th modulator unit. . Repair open in the appropriate solenoid circuit wire betwon lhe ABS control unit and the modulator unit. . Replace ih modulator unit.
ABS CONTROL UNIT 26PCONNECTOR RI-.OUT {YEL)
Checkfor loos ABS control unil connctors. lf nece$ary, substitute a known-good ABS control unit and rechock. Wire sideof femaletermanals
19-4 8
DTC51 - 53:ABS PumpMotor

Wilh the ignition switch ON {ll), the ABS indicator does not go ott. With the SCS seruicoconnector connoctod {sce page 19381, DTCa51 - 53 .re indicated.
c h e c k t h e M T R c H E c K ( 7 . 5A i luse in the under-hoodABS tuse/relaybox, and reinstallthe luse if it is OK.
ABS CONTROL UNIT 22PCONNECTOR Rsplacethe fuse and rech6ck. N O T E : S h o r t t h e P M R t e r m i n a lt o b o d y groundfor a moment,and rochock tuse. the lf the fuse is blown,check a shon to body lor groundin the MCKcircuit. check the PUMP MOTOR(40 A) fuse in the under-hoodABS fuse/ relay box, and reinstallthe fuse if it is oK.
Roolace tusg and rocheck. lhe N O T E : S h o r t t h e P M R t e r m i n a lt o b o d y groundfor a moment,and recheck fuse, the lf the tuse is blown, checktor a short to body ground in the wire betweenthe underhood ABSfuse/relay 6nd the pump motor. box
Feplacethe pump motor r6ley.
Check the pump motor powel sourccircuit: Turn the ignitionswitchON (ll).
Doesthe pump motoroperate?
Ch6ckfo. a short to oowd in th6 pump motor power sourca circuit: Remove pump motor relay. the Repairrhort to power in the wire bclweon the under-hood ABS fuse/.6lay box and ihe ABS pump motor.
Doesthe pump motor operateT
Ch6cktor loos6 ABS control unit connectors. lf necotsary, 3ubstitute . known-good ABS control unit and rocheck.
(cont'di
(To page19 50)
19-49
Troubleshooting
DTC51 - 53:ABS PumpMotor (cont'dl
(Frompage19 49) UNDR-HOOO ABS FUSE/REI-AY BOX JUMPER WIRE Chockthe pump motor ci.cuit: 1. Remove pump motor relay. the 2. Turn the ignitionswitchON {ll). 3. Connectthe pump motor relay connector+B and MOTORterminalswith a jumporwire for a moment,
Check for an open in the pump motor +B circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnect the pump motor switch (ll). ON 3. Turnthe ignition 4. Connect pump motorrelay the +B ter connector and MOTOR minals with a iumperwire. 5. Measurethe voltage beaveen the pump motor connector terminal No. l and body ground.
TERMINAL
TERMINAL
Doesthe pump motor operate?
PUMPMOTORCONNECTOB MOTOR+B {WHTI Fr 12 lF-
(v)
v I
Terminal sideof femaleterminals Bepair opon in the wire botween the under-hoodABS fuse/relav bor and the pump motor.
MOTOR+B IREDI Check the pump motor operation: Connectthe battery(+)terminalto the pump motor connectorterminal No. 1, and the (-) terminalto the terminalNo. 2 for a moment.
MOTOR GNDIBLKI
Terminal sideof male terminals
Doesthe pump motoroperate?
Reolace the modulator unit. lFaulty pump moto.l
Ch6ckfor a short to body ground in the PMRcircuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ABS control unit 22Pconnector. 3. Checktor continuity between t e r m i n a lN o . 1 9 a n d b o d y ground.
Repairopen in the wire bstween the pump motor and body ground, or poo. ground {G3511.
ABS CONTROL UNIT 22PCONNECTOR
Repairshort to body ground in the wir6 botweenthe underhood ABS tuse/rclay box and th ABS contlol unit.
{Topage19-51)
(Frompage19-50)
Chcck for .n opsn in the PCOM circuit: 1. Turnthe ignitionswitchOFF. 2 . R e c o n n e ct h e A B S c o n t r o l unit 22Pconnector. 3. Connectthe SCS serviceconnector. 4. Turn the ignitionswitchON {ll). 5. Measurethe voltage between t h e p u m p m o t o r r e l a yc o n n e c t o r P C O Mt e r m i n a l a n d body ground. Repairopon in the wire betwoen the under-hoodABS fuse/relay box and tho ABS conlrol unh.
) l--l
tr
r"r
ls thereapprox.3V?
ABS CONTROL UNIT 22PCO NECTOR Checkfor an open in tho PMRcircuh: Measurethe voltage betweenthe ABS control unit 22P connector terminalNo. 19and bodyground. Ropairopen in tho wir6 botwagn tho undcr-hood ABS fuse/rolay box .nd the ABS control unit.
Ch.ck tor an opon in the MCK ci.cuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe SCS service connector. 3. Turn the ignitionswitchON (ll). 4. Measurethe voltage between the ABS controlunit 22Pcon n e c t o rt e r m i n a l N o . 1 7 a n d body ground while connecting the pump motor relay connector+B and MOTORterminal with a jumper wire tor moment,
t0 1 1
MCK IBRN,/YEL}
Repairopen in the wiro bdtween the under-hood ABS fus6/telay box .nd the ABS control unit.
Chockfor loose ABS control unit connectoas,It necsssary,substitule a known-good ABS control unit and aocheck.
Troubleshooting
DTG MainRelay 54:
With the ignition switch ON (lll, the ABS indicator does not go off. With the SCS serviceconnector connected {see page 19-381, DTC54 is indicatod.
Checkthe ABS +B 120A) fuse in the under-hoodABS luse/relay box, and reinstall fuse if it is the
oK.
FeDlace tu3e and recheck. the AAS CONTROL UNIT 26PCONNECTON
Chck tor an open in the 81, 82 circuit: M e a s u r et h e v o l t a g e b e t w e e n body groundand the ABS control unit26Pconnector terminal No. 14 and No. 15individually. ls there batteryvoltage? Repairopen in the wiro bstweon th6 ABS conirol unit and the under-hoodABS fuse/rolay box,
IWHT/GRNI
Checkfor a short to body ground in the PMRcircuit: L Turnthe ignitionswitchOFF. 2. Remove pump motor relay. the 3 . D i s c o n n e ctth e A B S c o n t r o l unit 22Pconnector. 4. Checklor continuitybetween t e r m i n a lN o . 1 9 a n d b o d y grouno. Repair short to body ground in the wire betweon the underhood ABS lGe/r.lay box and the ABS control unit. Checkfor a short to body ground in the PCOM,SCOMcilcuit: 1 . D i s c o n n e ctth e A B S c o n t r o l unit 26Pconnector. 2. Checktor continuitybetween body ground and the ABS cont r o l u n i t 2 6 Pt e r m i n a l s o - 1 N and No.2 individually. ls therecontinuity?
ABS COf{TROLUN]T 22PCONNECTOR
PCOM scoM IGRN/WHTI {BLK/WHTI
. Rpair short to body ground in th P1COM circuit wire between the ABS control unit and the und6r-hoodABS tuse/r6lay oox. . R6p.ir short to body ground in the PCOMor SCOMcircuit wire betweon th6 ABS control unit and lhe mod!lator unit. . R . D l e c et h o m o d u l r t o r u n i t . (Short circuit inside the unitl
(To page19-53)
ABS CONTROL UNIT 26PCONNECTOR PCOM (GRN/WHTI Checkfo. a short to power in tha PCOM,SCOMcircuhi 1. Startthe engine. 2. Measurethe voltage between body ground and ABS control unit 26P connector terminals No. I and No.2 individually. ls there8 V or more? SCOM
Tu.n tho ignhion switch OFFand connect thc SCS 3orviceconnector. Then turn thc ignition switch ON (lll and measuretha voltago botween the PCOM .nd SCOM tsrminal3 and body gJound. It ther6 is 0 V, .eplecotho ABS control unit.
'Repair short to powor in ths FCOM circuit wiro botwoon th ABS control unit and the underhood ABS tuse/r.lay box. . Repeir 3hort to power in tho PCOM or SCOM circuit wire betwegn tho ABS control unii and ths modulator unh, . R.placo tha modulatoi unit. (Shon to power in.ido th6 unitl NOTE:8 V or more indicates shortto a
Wiresideof temaleterminals
Troubleshooting
DTC61:lgnitionVoltage
Whh the .ngine running. the ABS indicator b ON, With the SCS servicc connae tor connoctod {sao prgo 1998}, DTC61 b indi)atod.
Problom vorification: 1. Erasethe DTC. 2. Start the engine.
Doesthe ABS indicatorcome on and is DTC61 indicated?
Tho ryrtom i. OK rt thb timo.
Ch.ck the lG2 circuit: Measurethe voltage betweonthe ABS control unit 26P connector terminalNo.3 and body ground. Wiresideof temaletermioals ls there18V or above?
lf the volt gc b 0 V, ch6d( to. an oDn in lhe lG2 circuh. I thole ir 12 - 17 V, subatilui. ! known-good ABS control unit .nd rd|eck.
DTC81:CentralProcessing Unit (CPUI

with the ignition 3witch ON {ll}. the ABS indicator does not go off. Whh the SCS sewice connector connectod {see page 1938), DTC81 b indicatod.
Problemvorific.tion: L Erase u t L. rne 2. Test-drive vehicle. the
Doesthe ABS indicator come on and is DTC81 indicated?
Rplace th. ABS control unit.
The system is OK at this time.
19-55
ModulatorUnit
NOTE: . Do not spill brakefluid on the vehicle;it may damagethe painu if brakefluid does contactthe paint,wash it off immediatelywith water. a Takecarenot to damageor deformthe brakelinesduring removaland installation. . To preventthe brakefluidfromflowing,plug and coverthe hoseends and jointswith a shop towel or equivalent material, Romoval 1. 2. the Disconnect modulatorunit and Dumpmotor connectors. Disconnect brakelines,then removethe modulatorunit. the
lnstallation 1. 2. 3. 4. 5. Install the modulatoru nit.then connectthe brakelines.Tightenthe flare nutsto 15 N.m (1.5kgf.m,11 lbf.ft). Connect modulatorunit and oumo motor connectors. the Bleedthe brakesystem, staningwith the front wheels. goesoff. Startthe engine,and checkthat the ABS indicator Test-drive vehicle, the and checkthat the ABS indicator does not come on, showsthe '97 - 98 models.The'99 - 00 modelsare similar. NOTE:This illustration
PUMPMOTOR CONNECTOR
\ * \
MODULATON UNIT
,@
TORX EOLT kgf.m.7.2lbf 9.8N,m(1.0 ftl
19-56
ABS ControlUnit
Replacement
L
Pulsers/Wheel Sensors
Inspection
1 . Checkthe front and rear pulserfor chippedor damagedteeth. Measure the air gap betweenthe wheel sensorand pulserall the way aroundwhile rotatingthe pulser. lf the gap exceeds mm (0.04in),checkfor a bent 1.0 susDension arm. Standard:o.il - 1.0 mm 10.02 0.04 inl Front/Rear Removethe rear brakedrum to insDect the rear wheol sensorair gap,
Remove passenger's the side kickpanel. Disconnect ABS controlunit connectors. the
ABS CONTROL UNIT
0.4- 1.0mm (0.02- 0.04 inl
CONNECTORS
Remove ABS controlunit. the Installthe ABS control unit in the reverseorder of removat.
19-57
Sensors Pulsers/Wheel
WheelSensorReplacement
NOTE; . Be carefulwheninstalling sensors avoidtwistingthe wires. the to . The torquevalueof the boltsis 9.8 N.m ( 1.0kgf.m,7 Ibf.ft). Front
\all
6 mm BOLT 9.8 N.m {1.0kgtm. ?.2lbf'ft)
WHEELSENSOR
Rgar 1. Remove hub bearingunit (seesection18). the platebolts. the 2. Remove tour backing to the 3, Pullthe backingplateaway from the trailingarm, then removethe wheel sensor.lt is not necessary disconnect brakeline. The '99 - 00 modelsare similar. showsthe '97 - 98 models, NOTE:This illustration
6 mm BOLT 9,8 N.m 11.0kgf.m, 7.2lbf.ft)
WHEELSENSOR
19-58
Body
Bumpers Front Bumper Removaland fnstaflation RearBumper Removaland fnstaflation 'Dashboard RearWheelwellProtectol .....20-90 Replacement ... .........20-72 FuelPipeProtectorReplacement 20-90 .......... 20-91 RearAir Outlet Replacement .........20-74 *FrameRepair 20-106 Chart .............................. Front Grille lnstrument PanelRemovaland .........20-77 Repf acement .........20-47 lnstallation Glass Driver'sDashboard Lower Coverand 20-29 ComponentLocationIndex ............ KneeBolsterRemovaland Hood Installation .........20-48 ......,,,20-75 Replacement Glove Box Removaland ............20-76 Adjustment lnstallation .........20-49 *lnterior Trim CenterPocketRemovaland .........20-49 lnstallation 20-40 ComponentLocationIndex ............ Center Dashboard Lower Cover Mirrors 20-50 Removaland lnstallation ............ 20-26 ComponentLocationIndex .........,,, CenterPanelRemovaland Moldings .........20-50 lnstallation 20-84 Roof Molding Replacement............ Power Window Switch Removaland 20-85 Door MoldingsReplacement.......... lnstallation .........20-51 Openers CenterAir Vent Removaland 20-92 ComponentLocationIndex ............ lnstallation .........20-51 RearHatchGlass Side Air Vent Removaland .........20-52 fnstallation .........20-74 Replacement Side DefoggerTrim Removaland 20-79 Disassembly and Reassembly........ fnstallation .........20-52 ............20-81 Adiustment Removaland Dashboard RearWeatherstripReplacement....20-83 .........20-53 lnstallation Seats Dashboard FrameReplacement.....20-55 20-56 ComponentLocationIndex ............ Doors Side Sill Panel Component Location Index .........20-87 Repfacement FrontDoor ,,...,,,,20-2 SpareTire Cover ...........20-4 RearDoor 20-88 ........................ EmblemInstallation Tailgate Door ................................ 20-6 ..................20-104 Sub-frame Fenderwell Wiper/Washer Front Wheelwell Protector 20-97 ComponentLocationlndex ,,,,,....... Replacement .....20-89 Inner FenderReplacement .,.....,.,.... 20-89
Doors
Component Location Index
Front Door: NOTE:Refertothe 1997SeriesHondaCR-V Body RepairManual(P/N61S1030) forfrontdoor removat.
OOOR CHANNEL TAPE

INNER WATHERSTRIP
OUTER MOLDING
v
PLASTIC COVER MIRROR MOUNT COVER
----s -re
,.r=R ::r \//

*Y
l
t\q
ffi
fl
"\-,-.*
HINGE FRONT DOOR PositionAdjustment, page 20-22
POWER DOORLOCK CONTROL UNIT
efl-Nr2
ARMREST
/ *-8
FRONT DOORPANEL Removal and lnstallation, page20,7
20-2
GLASSRUN CHANNEL
REAR LOWER CHANNEL
\ f \i \ \ \ \
t\\\ \\II
za\\l
@'-ua$
REGULATOR page20-10 Replacement,
WINDOW POWER MOTOR
CYLINDEB PROTECTOR
k'"""'
OUTERHANOLE page20-8 Replacement, INNERHANOLE
@,
LATCH PROTECTOR
,;@ I
POWEN
POWEF ACTUATOB
wtNDow swtTcH
(cont'd)
20-3
Doors
LocationIndex(cont'dl Gomponent
Rear Door: NOTE: Refertothe 1997 Series Honda CR-V Bodv RepairManual (P/N 6151030)for rear door removal. DOORCHANNEL TAPE INNERWEATHERSTRIP OUTERMOLOING
DOORPROTECTION
D \FR,
\a )Ei
ARMREST ARMREST BRACKET
tu4
HINGE
Position Adiustment, page 20-22
REARDOORPANEL 1'99 00 models) Removal and Installation, page20 '11
dP
@
REARDOOR ('97-98 models) Bemoval and Installation, page20-11 (Left side only, '97 - 98 models)
('99- 00 models)
20-4
OUARTER SEAL
OUARTER GLASS Replacement, page20-13 RUN GLASS CHANNEL
REAR CHANNEL-\ -.-----_----_-"" UPPERCOLLAR
trw -flHiili^'i--_Fffi
WINDOW POWER MOTOR
,6S FRONTLOWER CHANNEL
REGULATOR page20'13 Replacement,
STRIKER page20 2L Adjustment,
l I W*
LATCH Replacement, page20'13 LOCKROD PROTECTOR LATCH PROTECTOB
INNRHANDLE
eowea wrruoow
s /*
sYtfcH
/
g
M-q/ -\<SU
s
fl
CItr'
6,1-
iI
POWEBDOOR LOCKACTUATOB
LOCK CRANK
(cont'd)
20-5
Doors
Component Location Index (cont'dl
Tailgate Door: NOTE: Refer the 1997SeriesHondaCR-VBody RepairManual{P/N61S1030) tailgatedoor removal. to for
LICENSE PLATE TRIM page20-16 Replacement,
OOOR TAILGATE page20-23 Adjustment, Position HINGE
TAILGATE DOOR WEATHERSTRIP
HINGE COVER \
illt
REARHATCHGLASSLATCH page20 18 Replacement,
N
SUPPORT STRUT
lVr
d d+-BA^cKEr
LATCHSTOP page20-17 Replacement,
REARHATCHGLASS ACTUATOR page20-19 Replacement,
REARHATCHGLASS
\A
Replacement, page20'19 TAILGATE DOORLATCH page20-17 Replacement, TAILGATE DOOR STRIKER page20-25 Adjustment,
TAILGATE DOOR HANDLE page20-16 Replacement,
k @ /
-6
%
\
TAILGATE DOORWEDGE Adiustment,page 20-25
d\
FLEXIBLE CARGO HOOK TAILGATE DOORPANEL page20-15 and Installation, Removal
20-6
Front Door PanelRemovaland Installation

the NOTE:Takecarenot to scratch door paneland other pans. L 2. Remove the innerhandle(seepage20-3). cover,then removethe screws. Remove speaker the 3 >: Scrwlocations,
>: Screw location3,3
eF** I
>:Clip locttions g>,3 A>, 1
f fw l.$ ; ^ r * l - i
ttv
il F:I
FRONT OOORPANEL
SPEAKER COVER
the Removethe screwsfrom the armrest.Release then removethe door clipsthat hold the door panel, the panel by pulling it upward.Disconnect speaker connector. NOTE:Removethe door panel with as little bendit. or ing as possible avoidcreasing breaking to
TRIM PAD REMOVER (Commercially avaalable) Snap-on *4177,ol equivalent in.) r {0.04
of is lnstallation the reverse the removalprocedure.

'..4'
,mm+,----ZY" -i F
45 mm I
is NOTE:Makesurethe connector pluggedin propefly.
in.} {1.77
20-7
Doors
FrontDoorOuterHandle Replacement
CAUTION: Put on gloves to protect your hands. NOTE;Raise glassfully. the 1 . Removel . Door panel(seepage20-7) . Plastic cover{seepage2O-2) 4. Pull out the outer handle,Pry the outer handlerod out of its joint usingdiagonal cutters. NOTE: . To easereassembly, note location ofthe outer @ handlerod on the joint beforedisconnecting it. . Takecare not to bendthe outer handlerod. . Use a shop towel to protectthe opening in the door.
2.
Disconnect the cylinder rod. Removethe retainer clip,then removethe lockcylinder.
LOCK CYLINDER
RETAINEB CLIP
5.
Removethe bolts securingthe o u t e r h a n d l e , t h e n remove the cylinder protector.
>: Eolt locations,2 6 x'1.0 m m I N.m {0.9kgt.m, 7 rbf.ftl
OUTEB HANDLE
5.
Installation the reverse the removalprocedure. is of NOTE: . Makesureeachrod is connected securely. . Makesurethe door locksand opensproperly.
HANDLE
20-8
FrontDoor LatchReplacement
CAUTION: Put on gloves to protect your hands, NOTErRaise glassfully. the '1. Remove: . Door panel(seepage20-7) . Plasticcover (see page 20-21 . O u t e rh a n d l e 2. Remove the bolt,then move the rear lower channel forward.
>: Bolt location, 1
3.
Disconnect the connector,and detachthe harness the screws, and remove clip from the door. Remove t h e l a t c h h r o u g h h e h o l ei n t h e d o o r . t t NOTE:Takecarenot to bendany of the rods.
>: Screw locations,3
6x1.0mm 6 N.m 10.6kgt m, 4 tbf.ft) CYLINDER ROD
6xl.0mm 8 N.m (0.8kgf m, 6 tbf ft) LOCKROD PROTECTOR
OUTER HANDLE ROD
CONNECTOR
HARNESS
CLIP
of Installation the reverse the removalprocedure. is NOTE: . Make sure the connectoris pluggedin properly, securely. and eachrod is connected a Makesurethe door locksand opensproperly.
20-9
Doors
FrontDoorGlassand Regulator Replacement
CAUTION: Put on gloves to protect your hands, 1. Remove; . Door panel(seepage20-7) . Plasticcover (see page 20-21 Carefully move the glassuntil you can seethe bolts, then loosenthem. Slidethe guide to the front, then pull the removethe glassfrom the guide.Carefully glassout throughthe window slot. NOTE:Takecare not to drop the glassinsidethe door. 3. Disconnect connector,and detachthe harness the clip,then removethe regulatorthrough the hole in the door. NOTE: . Scribea line aroundthe rear roller guide bolt to show the originaladjustment. . When installingthe regulator,align the hole of the rollerguidetowardth rear.
2.
>: Bolt locations,6 6x1.0mm 8 N.m {0.8kgt.m, 6 rbtft)
>: Bolt locations,2 6xl.0mm 9.8Nm(1.0kgt.m. 7.2 tbt.ftl
Roaru/ard
GLASS
Loosen, REGULATOR
20-10
RearDoor PanelRemovaland lnstallation

4. where of all Grease the slidingsurfaces the regulator shown. to NOTE:lf it is necessary removethe power wrnscribea line across dow motor from the regulator, gear and regulator beforeyou removethe the sector power window motor. the NOTE:Takecarenot to scratch door paneland other parts. 1. 2. Remove the innerhandle(seepage20-5). '99 - 00 Removethe screwsfrom the armrest.On models,removethe screwfrom the beverageporthen the tion. Release clipsthat hold the door panel, removethe door panelby pullingit upward. NOTE:Removethe door panel with as little bendor it. ing as possible avoidcreasing breaking to
RGULATOF
TBIM PAD REMOVER (Commercially available) Snap-on t_ #4177,or lmm equivalent in.) {0.04 >: Boh locations,3 6x1.0mm 7 N.m lo.t kgf.m, 5 tbf.ftl
T r-----
/t5 mm I in.) 11.77
>: Screw locelions '97 - 98 models.3 '99 - 00 modols,4
>i Clip locations,6
WINOOWMOTOR POWER REGULATOR
DOOBPANEL ARMREST
4
m î
A A
is of Installation the reverse the removalprocedure. NOTEi Rollthe glassup and down to see if it moves freelywithout binding.Also make sure that there is the glassand glassrun chan no clearance betlveen glassis closed. Adjust the positionof nel when the (seepage20-20). the glassas necessary
EEVERAGE HOLDEN ('99 00modelsi
'99 - 00 models:
\
(,1
3.
of is Installation the reverse the removalprocedure.
20-11
Doors
RearDoorOuter HandleReplacement
CAUTION: Put on gloves to protect your hands. NOTE:Raise glassfully. the 1. Remove: . Door panel(seepage20-11) . Plastic cover(seepage20-4) Remove the lock crank. then remove the screws
securing the latch. >: Screw locations A>.3 6x1.0mm 6 N.m 10.6 kgf.m. 4 tbf.ft) B>,'l HANDLE OUTER ROD
4,
Pull out the outer handle.Pry the outer handlerod out of its joint usingdiagonalcutters. NOTE; o To easereassembly, note location of the outer @ handlerod on the joint beforedisconnecting it. . Takecarenot to bendthe outer handlerod. . Use a shop towel to protectthe opening in the door.
2.
PC tlTn-i
LOCKROD PROTECTOR
Move the latch down, and remove the bolts securing the outer handle, >: Bolt locations. 2
6x1.0mm 9.8 N.m {1.0 kgf.m, 7.2 rbf.ft)
SHOPTOWEL
5.
Installation the reverse is ofthe removalprocedure. NOTE: a Makesurethe door locksand opensproperly. . M a k e s u r e t h e o u t e . h a n d l er o d i s c o n n e c t e d properly.
20-12
.
Rear Door Latch Replacement

CAUTION: Put on gloves to protect your hands,
RearDoorGlass, OuarterGlassand Regulator Replacement

CAUTION: Put on gloves to protect your hands. 1. Remove: o Door panel(seepage20-1 1) . Plastic cover(seepage20-4) Carefully move the glassuntil you can seethe bolts, then loosenthem. Slide the guide to the rear,then removethe glassfrom the guide. NOTE:Takecarenotto dropthe glassinside door. the
NOTE:Raise glassfully. the 1. Removel . Door panel(seepage20-11) . Plastic cover(seepage20-4) . Outerhandle(seepage20-121 D i s c o n n e ctth e c o n n e c t o r n d h a r n e s s l i p , t h e n a c removethe latchthroughthe hole in the door. NOTE: Takecare not to bend any of the rods.
>: Boll locations,2
2.
2.
6x1.0mm 9.8N.m (1.0kgtm, 7.2 tb{ft)
GLASS
3.
Installation is the reverse of the removal procedure.
NOTE: . Make suretheouterhandle andinnerhandle rod properly. rodareconnected . Make properly. sure doorlocks opens the and
(cont'd)
20-13
Doors
(cont'd) RearDoorGlass, OuarterGlassand Regulator Replacement
3. C a r e f u l l y o w e r t h e g l a s s .R e m o v et h e b o l t s a n d l s c r e w f r o m t h e r e a r c h a n n e l ,t h e n p u l l t h e r e a r channelup as shown. Removethe glass from the p r e a r c h a n n e l C a r e f u l l y u l l t h e g l a s so u t t h r o u g h . the window slot. NOTE:Takecare not to drop the glassinsidethe door. >: Bolt,screwlocations A>, t B>,1
-4 rTmtl-larR f\ '^S\\\-.6 x 1.0 mm -
4.
Remove quarterglass. the
WPU
c>,1
W)+
I N m i o . 8 k sm , f
6 tbf.ftt
CLIP
Disconnect the connector.and detachthe harness clip, then removethe regulator through the hole in the door. 4 >: Bolt localions,
6x1.0mm 8 N.m 10,8kgf.m, 6 tbtftl
REGULATOR
20-14
''
and TailgateDoor PanelRemoval

lnstallation
6. where of all Grease the slidingsurfaces the regulator shown. to NOTE:lf it is necessary removethe power winscribea line across dow motor from the regulator, beforeyou removethe the sectorgear and regulator powerwindow motor.
REGULATOR GEAB SECTOR
N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d other parts. 1. R e m o v e h e c o v e r ,and remove the flexible cargo t hook and base. locations.2 >: Screw
CARGO FLEXIBLE HOOKBASE
@t"
COVER
POWER
wtNDow
MOTOR >: Bolt locations.3 6x1.0mm 7 N.m 10.7 kgf.m, 5 rbnftl WINDOWMOTOR POWER FLEXIBLE CARGOHOOK
2.
the door lid,then remove screws. Remove tailgate the

>: Screwlocations.2 >: CliP locations.
?11 |
,4| |
HPI
REGULATOR
7.
of is lnstallation the reverse the removalprocedure. NOTErRollthe glassup and down to seeif it moves freelywithout binding.Also make sure that there is no clearance between the glassand glassrun chanAdjustthe positionof nel when the glassis closed. the glassas necessary {seepage20 20).
TAILGATE LIO DOOR 3. the Release clips that hold the tailgatedoor panel, then removethe tailgatedoor panel. of is Installation the reverse the removalprocedure. clips. replace any damaged NOTE:lf necessary,
20-15
Doors
License PlateTrim Removal and Installation
CAUTION: Put on gloves to prolest your hands. NOTE:Takecarenot to scratch tailgate the door. NOTE: Take care not to scratchthe licenseplate trim and tailgatedoor. '1. Remove the license olate. 2. 3. Remove tailgatedoor panel(seepage20-15). the 2. Removethe nuts, detachthe clip, then removethe license olatetrim. NOTE: Take care not to drop the nuts inside the tailgatedoor.
a: Nut loc.lions.4 5x0.8mm 1.8Nm(0.18kgt.m. 1.3 rbf.ft)
Tailgate DoorHandle Replacement

CAUTION; Put on gloves to protecl your hands,
1.
Remove: . Tailgate door panel(seepage20,15) . License plate . License platetrim Disconnect handlerod. Remove the the nuts securing the tailgatedoor handle,then removethe tailgatedoor handleby pullingit out. NOTE:Takecarenot to bendthe handlerod.
a: Nut locations,2 6x1.0mm 9.8 N.m {1.0kgtm, 7.2 rbtft)
TAILGATE DOOR
,Is
TAILGATE DOOR HANDLE Installation the reverse the removalprocedure. is of NOTE: . Makesurethe handlerod is connected properly. . Makesurethe tailgate door openspropedy.
4.
Installation the reverse the removalprocedure. is of NOTE:lf the clip is damaged, replace it.
20-16
TailgateDoor Latchand LatchStop Replacement

CAUTION: Put on gloves to protect your hands. NOTE:Takecarenotto scratch tailgate the door. '1. 2. Remove tailgatedoor panel(seepage20-15). the Disconnect handlerod. Remove the the bolts securing the latchstop and screwssecuring the latch. >: Bolt,screwlocations A>,3
6x1.0mm
3.
Move the latch stop and latch down, then pry the latchstop rod out of its joint usingdiagonalcutters. Remove the latchstop and latchthroughthe hole in the tailgatedoor. NOTE: . To easereassembly, note location of the latch @ stop rod on the joint beforedisconnecting it. . Takecare not to bend the latch stop rod.
B>,3
''-t.-N
-\S/r
gta
BUSHING
(cont'd)
20-17
Doors
TailgateDoor Latchand LatchStop (cont'd) Replacement
4. lnstallation the reverse the removalorocedure. is of NOTE: . Makesure the handlerod and latchstop rod are properly. connected a Make sure the tailgatedoor locks and opens propenv. . After installingthe latch stop and tailgate door latch,makesure that there is about 1 mm {0.039 in.l between linkA and link B of the latchstop. the Adjust the joint position of the latch stop rod as (Pull needed, then checkthe latchstop operation. the tailgatedoor handlewhile you push on the l a t c h s t o p k n o b ; t h e t a i l g a t ed o o r s h o u l d n o t oDen.)
LATCHSTOP KNOE
RearHatchGlassLatch Replacement
NOTE: Takecare not to scratchthe tailgatedoor. ' 1 . R e m o v eh e t a i l g a t e o o r p a n e ( s e e p a g e 2 0 - 1 5 ) . l t d 2. Disconnect connector. the Removethe bolts securing the latch,then removethe latch.
>: Boh locations,3 6x1.0mm 9.8N.m {1.0kgI.m, 7.2 tbl.Itl REARHATCH GLASSLATCH
3.
is of Installation the reverse the removalprocedure. N O T E : M a k e s u r e t h e r e a r h a t c h g l a s s l o c k sa n d opensproperly.
20-18
RearHatchGlassLockCylinder Replacement
NOTE:Takecarenot to scratch tailgate the door. 1. 2. Remove tailgatedoor panel(seepage20-15). the Removethe bolt securingthe lock cylinder. Turn and pull out the lock cylinder,and disconnect the cylinderrod, NOTE:Takecarenot to bendthe cylinder rod. >: Boltlocation. 1
6x1.0mm 9.8N.m {1.0kg .m, 7.2 tbt.lll
RearHatchGlassActuator Replacement
CAUTION: Put on gloves to protsct your hands. NOTE:Takecarenot to scratch tailgate the door. 1. Remove; o Tailgate door panel(seepage20-'15) . Rearhatchglasslockcylinder Disconnect the connectorand the connectorclip. R e m o v et h e b o l t s s e c u r i n gt h e a c t u a t o r , h e n t removethe actuator. NOTE: Take care not to bend the cylinder rod or damage joint. the >: Boltlocations, 3
6x1.0mm 9.8N.m 11.0 kgt.m, 7.2 tbt.ft)
2.
REARHATCHGLASS
CONNECTOR CONNECTOR
J.
Installation the reverse the removalprocedure. is of NOTE: . Makesurethe cylinderrod is connected properly. . Makesurethe rearhatchglassopensproperly.
REARHATCH GLASS ACTUATOR
JOINT
-6{
Installation the reverse the removalprocedure. is of NOTE: . M a k e s u r e t h e c y l i n d e rr o d a n d c o n n e c t o r r e a properly. connected . Grease joint of the cylinder the rod. . Makesurethe rearhatchglassopensproperly.
20-19
Doors
TailgateDoorWeatherstrip Replacement
as Install tailgate the doorweatherstrip shown. NOTE; . Clean tailgate with the doorbonding surface a sponge in dampened alcohol.
a Makesurethereare no wrinklesin the weatherstrip. a Check water leaks. for > : Clip locations,2
Frontand RearDoorGlass Adjustment

NOTE: . Place vehicleon a firm, levelsurface when adjustthe ing the glass. . Checkthe weatherstrips and glassrun channelfor damthem if necessary, age or deterioration, and replace 1. Remove: p . D o o rp a n e l( s e e a g e s 2 0 - 7 l,l l . Plastic cover(seepages2O-2,41 Adjustthe glass.
i-t] /[L
lE
lll
ll 1T
| I oouere-rrceo
rAPE I aDHEsrvE
I Thickness:
2.
r.2mmlo.o5 in.)
Front: and hold Raisethe glassas far up as possible. it against glassrun channel. the Loosenthe roller guide bolts, and adjust the glassso it is parallel with the glassrun channel.
GLASSRUN CHANNEL
g\
lM /L)
BUTYL SEALANT Sealant area,
DOUBLE.FACED ADHESIVE TAPE Thickne$: 1.2mm 10.05 in.)
BOLTS ROLLER GUIDE 6x1.0mm kgf.m, 8 N.m{0.8 5 tbffi) Tightenthe rollerguide bolts. Loosen front channelbolt. the
e. l.
Lowerthe glass. Pushthe front channelagainstthe glass,then tightenthe tront channelbolt.
20-20
Loosen the rearchannelmountingbolts,

f.
Lowerthe glass. Push the rear channelagainstthe glass,then tightenthe mountingbolts. >: Bohlocationt2 5x1.0mm 8 N.m(0.8kgtm.6lbtft)
GLASS
6x1.0mm 8 N'm10 kg{m' 8 6 tbf.ftl

a, o. c. o.
Raise glassfully. the mountingbolts. Loosenthe regulator Pushthe glassforward. Tightenthe regulator mountingbolts. il >: Bohlocations, 6x1.0mm 8 N.m(0.8 kgf.m, lbf.ft) 6
GLASS
3. 4. 5.
Check that the glassmovessmoothly. Raise glassfully and checkfor gaps. the Check glassoperation. the NOTE:Checkthat the glass contacts the glass run evenly. channel
20-21
Doors
Frontand RearDoorGlass Adiustment(cont'dl
6. for Check water leaks. Spray water over the roof and on the sealingarea as snown. NOTE: . Adjustthe water pressure shown. as . Do not soueeze tio of the hose. the
Frontand RearDoorPosition Adjustment

NOTE: Placethe vehicleon a firm, level surfacewhen adiusting doors. the After instailingthe door, checkfor a flush fit with the body,then checklor equal gaps betweenthe front, rear. a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d Adjustat the hinges body edgesshouldalso be parallel. as shown. CAUTION:Placaa shop towel on the iack to prevent damageto the door when loosening the door and hinge mounting bolts lor adiustment.
in.l 12 mm {0.47
,'r)"f
-"'*r"i
(r\ "1
HOSE 300mm 111.8 in.)
tl
0.5 m (1.6ftl
DOOR MOUNTING BOLTS I x 1.25 mm kgtr.m, lbI.ftl 21 28 N.m12.9 Loosen doormounting the bolrsslighrly doorlN or OUTuntil to movethe it'sflushwith the bodv.lf necessary, youcaninstalla one shimbehind hinge make dooredges to the
PARALLEL with the bodv.
HINGEMOUNTINGBOLTS 8 x 1.25mm kgt.m. 21 lbl.ftl 28 N,m 12.9 Remove innerfender, the loosen the hingemounting bolts,and movethe door BACKWARD FORWARD, or UP or DOWNas necessary to equalize gaps. the
Lowerthe glass.
7.
Attachthe plasticcover,then installthe door panel (seepages20-7,'l 1),
20-22
..-
TailgateDoor PositionAdjustment
The door and body edges should be parallel.lf necessary,adjustthe door cushion. NOTE: Placethe vehicleon a firm, level surfacewhen adjusting tailgatedoor. the A f t e r i n s t a l l i n g h e t a i l g a t ed o o r . c h e c kf o r a f l u s h f i t t with the body, then checkfor equal gaps betweenthe tailgatedoor edgesand the body.The tailgatedoor and body edgesshouldalso be parallel. Adjust at the hinges assnown. CAUTION:Placea shop towel on the iack lo prevent damage to the tailgale door when loosningthe tailgate door and hinge mounting bolts for adiustment.
DOOR CUSHION Check water leaks. for
ry.
oooR cusHroNs
TAILGATE DOOR MOUNTINGsOLTS 8 x 1.25mm 25 N.m {2.6 kgf.m, 19 tbf.ft) HINGEMOUNYING BOLTS 8 x 1.25mm 25 N.m 12.6 m, kgt 19 rbf.ftl
NOTE:Do not squeeze tip ofthe hose. the
8x1.0mm 22 N'rrl 12.2kgl.m, 16 tbt.ftl
6xl.0mm 9.8N.m {1.0kgt m, 1.2 tbl.ltl
(cont'd)
20-23
Doors
TailgateDoor PositionAdiustment
(cont'd)
The door and body edgesshouldbe parallel.
Frontand RearDoorStriker Adjustment

Make sure the door latchessecurelywithout slamming adjust the striker:The striker nuts are it, lf necessary, fixed. The strikercan be adjustedslightly up or down, a n di n o r o u t . 1. Loosenthe screws,then insert a shop towel between the body and striker.
STRIKER Insert shoptowel a between body and the
for Check water leaks. Spray water over the tailgatedoor and on the sealing areaas shown. NOTE: . Adjustthe water pressure shown. as . Do not squeeze tip ofthe hose. the
scREws
8 x 1.25 mm 18 N.m (1.8kgt.m, 13 rbf.ft)
in.) l2 mm (0.47
.*1:]*
d3 "1
,'r)"C
-*4
II
0.5m {1.6ft}
2.
J.
Lightlytightenthe screws. Wrap the strikerwith a shop towel, then adjustthe strikerby tappingit with a plastichammer. CAUTION: Do not tap the striksr loo hard.
HOSE
in.l 300 mm {11.8
4.
5.
Loosenthe screws.and removethe shop towel. Lightlytightenthe screws. out, and pushthe door against Holdthe outer handle the strikerallows a flush fit, lf the the body to be sure door latchesproperly.tightenthe screwsand recheck.
6.
20-24
TailgateDoorStrikerAdjustment
Make sure the door latches securely without slamming it. lf necessary, adjust the striker:The striker nuts are fixed. The strikercan be adjustedslightly up or down, a n di n o r o u t . 1. 2. Remove tailgate the door wedge. L o o s e nt h e s c r e w s ,t h e n i n s e r t a s h o p t o w e l between body and striker. the
TailgateDoorWedgeAdjustment
1. Loosen the bolts,and move the tailgatedoor wedge UP or DOWNto align it with the tailgatedoor wedge striker.Move the tailgatedoor wedge lN or OUT to centerit. Then lightlytightenthe bolts.
STRIKER
Insen a shoptowel between the body and
Forward
TAILGATE OOOR 8 x 1.25mm 18 N.m (1.8kgf.m, r 3 tbf.ft)
Lightlytightenthe screws.
4.
Holdthe tailgatedoor handleout, and push the tailgate door againstthe body to be sure the tailgate door wedge allows a flush fit. lf the tailgate door properly, latches tightenthe boltsand recheck.
Wrap the strikerwith a shop towel, then adjustthe strikerby tappingit with a plastichammer. CAUTION: Do not tap the striker too hard. Loosen screws, lhe and removethe shoptowel. Lightlytightenthe screws.
1.
Hold the tailgatedoor outer handle out, and push t h e t a i l g a t ed o o r a g a i n s t h e b o d y t o b e s u r e t h e strikerallows a flush fit. lf the tailgatedoor latches properly, tightenthe screwsand recheck. Install tailgate the door wedge,and adjustit.
20-25
Mirrors
MOUNT MIRROR COVEB
POWER MIRBOR page20 27 Replacement,
,//
MIRROR HOLDER page20-27 Beplacement,
@
DAMPER
w
REARVIEW MIRROR page20-28 Replacement,
q
COVER
20-26
PowerMirror Replacement
NOTE:Takocarenot to scratch mirror,mirror mount the cover and door. 1. 2. Lowerthe door glassfully.
PowerMirror HolderReplacement
CAUTION: Put on glovss to protest you. hands. NOTE:Takecarenot to scratch mirror. the 1, p Carefully ull out the bottomedgeof the mirror holderbv hand.
ADHESIVE
pry Carefully out the mirror mount coverby hand,

HOOK
Disconnect connector. the then remove the mirror mountingboltswhile supponing mirror, the >: Bohlocations, 3
MIRROR
Separatethe mirror holder from the actuator bv slowly pullingthem apart. Reattachthe hooks of the mirror holder to the actuator, then Dosition the mirror holder on the actuator. Carefullypush the clip portions of the mirror holderuntilthe mirror holderlocksinto place. Check actuator the ooeration.
Installation the reverse the removalprocedure, is of NOTE:Make sure the connector connected propis efly.
20-27
Mirrors
Rearview Mirror Replacement
CAUTION: When prying with a flat-tip screwdrivor, wrap it whh a shop towel to prevent damage. NOTE: Take care not to scratchthe cover or tear the headliner. 1. Removethe cover usingthe end of a flat-tipscrewdrtver.
HOOKS
Remove rubberdamper. the >: Screw locations,3
Remove the screws, then remove the rearview mirror. Installation the reverse the removalprocedure. is of
20-28
Glass
NOTE:The numbersafterthe part namesshow the quantities the pans used. of Windshield:
MOLOING U P P E RS E A L , 2
UPPER RUBBER DAM model) 1'00
UPPER FASTENER ('97- 99 models, and required for replacement reinstallation or '00 model) on FASTENER,2 (Self'adhesive type,glassside) ('97- 99 models, for and required replacement reinstallation or o n ' 0 0m o d e l )
WINDSHIELD page20-30 Replacement, FASTENER,2 (Self-adhesive-type, body side) ('97- 99 models, and required replacement lor or reinstallation on '00 model) SIDERUBBER DAM, 2 and {'97-99 models, required replacement for or reinstallation on '00 model)
*@
LOWER RUBBER DAM ('00model) LOWER RUBBER DAM and required reDlacement for l'97 99 models, or reinstallation on'00 modeli
tE-r
Ouarter Glass:
OUABTER GLASS page20-35 Replacement, FASTENER, 1 (Clip-type, body side)
\,o,,.,.*,,,
( S e l f a d h e s i v e - t y p e ,g l a s s s i d e )
Glass
Replacement Windshield
CAUTION: . Put on gloves to protect your hands. . Use seat coversto avoid damaging any surfaces. 1. first removethe: To removethe windshield, . Rearview mirror (seepage20-28) . Sunvisors and holders(seepage20-44l' . Ceilinglight (seesection23) . Grabhandle(seepage20-44) . Frontdoor trim (seepage20-41) . F r o n tp i l l a r r i m ( s e ep a g e2 0 - 4 1 ) t . Windshield wiper arms and cowl cover (seepage 20-98) Remove moldingand glassbrackets. the NOTE:lf removingthe molding is difficult,cut the moldlngwith a utility knife.
PIANO
4.
Apply protective tape along the edge ot the dashboard and body as shown. Using an awl, make a hole through the rubber dam and adhesivefrom inside the vehicle. Push a piece of piano wire through the hole, and wrap each end around a piece of wood.
PIANO WIRE
PROTECTIVE TAPE
RUBBER UPPER
WINDSHIELD
2.
ADHESIVE PROTECTIVE TAPE WINDSHIELO
MOLDING
PROTECTIVE TAPE WINDSHIELD ADHESIVE
DASHBOARD LOWER RUBBER DAM
CAUTION: Hold the piano wire as closeto the windshield as possibleto prevent damageto the body and dashboard. 5. p W i t h a h e l p e ro n t h e o u t s i d e , u l l t h e p i a n o w i r e cut backand fo(h in a sawingmotion,and carefully through the rubber dams and adhesivearoundthe w entire indshield.
3.
( P u l l d o w n t h e f r o n t D o r t i o no f t h e h e a d l i n e r s e e page20-44). CAUTION: Take care not to bend the headliner excessivsly,or you may break it.
6.
t C a r e f u l lr e m o v e h e w i n d s h i e l d . y
20-30
7.
Using a knife,scrapethe old adhesive smooth to a thicknessof about 2 mm (0.08in.) on the bonding surface aroundthe entirewindshield opening flange. NOTE: a Do not scrape down to the paintedsurface the of body; damaged paint will interferewith proper bonding. . Remove the rubberdams and fasteners from the oooy, . Maskoff surrounding surfaces beforepainting.
10. Glue the rubber dams and fastenersto the inside faceof the windshield shown as N O T E : B e c a r e f u ln o t t o t o u c h t h e w i n d s h i e l d where adhesive will be applied,
>r Fastenerlocrtions. 2 FASTENEB
w,{,. '>Yl
14mm 0.55in.l -'\l ALIGNMENT MARKS
\,@,--
8.
Clean body bondingsurface the with a sponge dampenedin alcohol. NOTE: After cleaning,keep oil, grease and water from gettingon the surface.
--r-r
1 3m m (0.51 in.)
9.
lf the old windshieldis to be reinstalled, a putty use knjfeto scrapeoff all tracesof old adhesive and the r u b b e r d a m s , t h e n c l e a nt h e w i n d s h i e l ds u r f a c e with alcoholwhere new adhesive to be applied. is NOTE:Make sure the bonding surfaceis kept free of water,oil and grease. CAUTION:Avoid setting tho windshieldon its edges; small chips m8y later devolopinto cracks. NOTE:Cleanthe shadowed area.
ALIGNMENT MARKS
1 3m m (0.51 in.l 1 3m m in.) 10.51
*ffi
ALIGNMENT MARKS
1 2m m (0.47 in.l
WINDSHIELD
(cont'd)
20-31
Glass
(cont'dl WindshieldReplacement
s 1 1 . G l u et h e m o l d i n g i d es e a la n d m o l d i n gu p p e rs e a l to the moldingon eachside. t 1 2 . A l i g na n d g l u et h e m o l d i n g o t h e e d g eo f t h e w i n d shield. N O T E : B e c a r e f u ln o t t o t o u c h t h e w i n d s h i e l d w h e r ea d h e s i v w i l l b e a p p l i e d . e a. With a brush,apply a light coat of primer (3lvlN200,or equivalent) the edge ot the windshield to as shown, b. Gluethe adhesive tapes l3M 4212, equivalent) or to both bottomedgesof the windshield. t c . A l i g nt h e a l i g n m e nm a r ko n t h e m o l d i n g o t h e t alignmentmarkof the windshield. d. Gluethe moldingto the edgeof the windshield.
>: Alignment mark locations ALIGNMENT Applyprimer MARK here. \ ln3ide , /
100mm {3.9in.l
100mm {3.9in.}
ADHESIVE TAPE Thic*ness: mm (0.05 1.2 in.) W i d t h 4 m m ( 0 . 1 6n . ) r i
r0 mm (1.6in.l
20-32
'13. Installthe glass brackets to and fasteners the body as shown. 2 >: Fastener locations,
16. With a sponge, apply a light coat of glass primer around the edge of the windshieldas shown, then lightlywipe it off with gauzeor cheesecloth. NOTE: Do not apply body primerto the windshield, and do not get body and glassprimerspongesmixed up. N e v e r t o u c h t h e p r i m e d s u r f a c e sw i t h y o u r hands.lf you do, the adhesive may not bond to the windshieldproperly,causinga leakafter the windshieldis installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface. //fu : Applyglassptimar hea.
R-
then cen 14. Set the windshieldon the glassbrackets. ter it in the opening.Make alignmentmarks across the windshieldand body with a greasepencilat the four pointsshown. NOTE|Be carefulnot to touch the windshield where adhesive will be applied.
ALIGNMENT MABK
Applyglassprimer WINDSHIELD
Applyglassprimer to the molding. WINDSHIELD WINDSHIELD GLASS BRACKETS NOTE: Adjust the glass bracketsto center windshield the in the opening, then tightenthe
DAM 1 0 m m RUBBER {0.4in.}
MOLDING
12 mm 10.5 in.)
15. Remove windshield. the
(cont'd)
20-33
Glass
(cont'dl Windshield Replacement
17. With a sponge,apply a light coat of body primerto t h e o r i g i n a la d h e s i v e e m a i n i n g r o u n dt h e w i n d r a shield openingflange,Let the body primer dry for at least10 minutes. NOTE: . Do not apply glassprimerto the body, and be careful not to mix up glassand bodyprjmersponges. . Nevertouch the primed surfaces with your hands. . Maskoff the dashboardbeforepaintingthe flange. ///////l , apptvaoav primorhere.
7.8mm 10.30 in.) 8mm 16 mm in.) 10.fi in.) (0.31 FASTENER
20, Packadhesive into the cartridge without air pockets to ensurecontinuous delivery. the cartridge a Put in g c a u l k i n g u n , a n d r u n a b e a do f a d h e s i v e r o u n d a the edgeof the windshield shown. as NOTE:Apply the adhesive within 30 minutesafter applyingthe glassprimer. 12mm (0.47 in.)
Ff oo*tt'u'
in.l 8 mm {0.31
Makea slightly thicker beadat eachcorner.
16 mm {0.63 in.l
14.6mm (0.57 in.l 16 mm in.) {0.63
WINOSHIELD
't8, Thoroughly mix the
adhesive and hardener together on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mixing. . Followthe instructions that come with the adhesive.
'19. Beforefilling a as shown.
cartridge, the end of the nozzle cut

WINDSHIELO
Cut nozzle end in.) 10 mm {0.39
RUBBER DAM
3mm {0.1in.l
7 mm {0.27 in,}
20-34
OuarterGlassReplacement
2 1 . U s e s u c t i o nc u p s t o h o l d t h e w i n d s h i e l d v e r t h e o opening,align it with the alignmentmarksmade in . s t e p 1 4 , a n d s e t i t d o w n o n t h e a d h e s i v eL j g h t l y push on the windshielduntil its edge is fully seated on the adhesive the way around. all NOTErDo not open or closethe doors until adhesive is dry.
SUCTTON ALIGNMENT MARK
CAUTION: . Put on gloves to protct your hands. . Use seat covers to avoid damaging any surfaces. 1. To removethe quarterglass,first removethe: . Rearseat(seepage20-63) . Cargofloor lid and cargo storagebin (seepage 20 431 . R e a rt r i m p a n e l a n d r e a r s i d e t r i m p a n e l ( s e e page 20-421 . Rearhatchglasssupportstrut (seepage20-78) . Ouarterpillartrim panel(seepage20-421 . Taillight(seesection 23) NOTE:With the rear hatch glass support strut removed,you will need to support the rear hatch glassby hand. 2. From insidethe vehicle,use a knife to cut through all the quarterglassadhesive the way around. NOTE: . lf the quaner glassis to be reinstalled, take care not to damagethe molding. . lf the molding is damaged.replacethe quarter glass,molding,and clipsas an assembly. . The quarter glasscan be reinstalled using butyl tape.
22. Scrapeor wipe the excess adhesive with a putty off knifeor towel. NOTE:To removeadhesive from a paintedsurface o r t h e w i n d s h i e l d ,w i p e w i t h a s o f t s h o p t o w e l dampened with alcohol. L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n s p r a y w a t e r o v e r t h e w i n d s h i e l da n d c h e c k f o r l e a k s .m a r k l e a k i n ga r e a s ,a n d l e t t h e w i n d s h i e l d dry, then sealwith sealant. NOTE: . Let the vehiclestandfor at leastfour hours after w i n d s h i e l dn s t a l l a t i o n f t h e v e h i c l eh a s t o b e i l. usedwithin the first four hours,it must be driven . . Keep the windshielddry for the first hour after installation. Checkthat the ends of the side molding are set underthe cowl cover.
2 4 . Reinstall remaining all removedparts. NOTE: . Installthe rearviewmirror rubber damper after t h e a d h e s i v h a sd r i e dt h o r o u g h l , . e . A d v i s e t h e c u s t o m e rn o t t o d o t h e f o l l o w i n g thingsfor two to threedays: - S l a m t h e d o o r sw i t h a l l t h e w i n d o w sr o l l e d up. - Twist the body excess,vely{such as when going in and out of drivewaysat an angle or drivingover rough.unevenroads).
(cont'd)
20-35
Glass
Ouarter Glass Replacement(cont'd)
lnside: Using a knife,scrapethe old adhesive smooth to a thickness about 2 mm (0.08in.) on the bonding of s u r f a c ea r o u n dt h e e n t i r e q u a r t e rg l a s s o p e n i n g flange. NOTE: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper b o n dn g . i . lf any of the clips are broken.removelhem trom the body. . Mask off surroundingsurfacesbefore applying pnmer. Clean body bondingsurface the with a spongedampenedin alcohol. NOTE:After cleaning,keep oil, grease and water from gettingon the surface. l f t h e o l d q u a r t e rg l a s si s t o b e r e i n s t a l l e d , s e a u putty knife to scrapeoff all tracesof old adhesive, t h e n c l e a nt h e q u a r t e rg l a s ss u r f a c e i t h a l c o h o l w where adhesive to be applied. is NOTE:Make sure the bonding surfaceis kept free of water,oil and grease. CAUTION: Avoid setting the quarter glass on its edges;the molding can be permanently detormed. NOTE:Cleanthe shadowed area.
/6\ /l
v\//,
ADHESIVE
3.
removethe quarterglass. Carefully NOTEj Checkthe molding for damage,replacethe qua.terglassif necessary.
20-36
7.
to Gluethe fastener the insideface of quarterglass as shown.lf the old quarterglassis to be reinstalled, or applya lightcoatof primer(3M C-100, equivalent), then applybutyltapeto the quanerglassas shown. NOTE: . Be carefulnot to touch the quarterglasswhere adhesive will be aDplied. . Do not peelthe separator the butyl tape. off
9. lf the old quarterglassis to be reinstalled, sealthe body holewith pieceof urethane tape,Set the quar ter glassuprightin the openingand makealignment m a r k s a c r o s st h e q u a r t e rg l a s s a n d b o d y w i t h a grease pencilat the threepointsshown.
/'/.////
| Bttryl taee locationsl3M 8628,or equivalent) Thickness:3.2 10.13 mm in.l
Width: mm 10.25 5.4 in.)
I wmr > t \
GLASS
TAPE BUTYL
>: Fastenoa location, I MOLDING FASTENER
MOLDING
1l mm (0.43in.) GLASS
ALIGNMENT MANK
in.) 400 mm (15.75
8.
lnstallthe fastener the bodv as shown. to

>: Fastenerlocation, 1
r 1 0 . R e m o v eh e q u a r t e g l a s s . t
(cont'd)
20-37
Glass
(cont'd) OuarterGlassReplacement
11. With a sponge,apply a light coat of glassprimer to the insideface of the quaner glass,as shown,then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primer to the quarter glass, a n d d o n o t g e t b o d y a n d g l a s sp r i m e rs p o n g e s m r x e du p . . Nevertouchthe primedsurfaces with your hands. It you do, the adhesive may not bondto the quarter glass properly.causinga leak after the quar ter glassis installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface. With a sponge,apply a light coat of body primerto the originaladhesive remainingaroundthe quaner glassopeningflange.Let the body primer dry for at least10 minutes. NOTE: . Do not apply glass primer to the body, and be c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r sponges. . Nevertouchthe primedsurfaces with your hands. '/fu, : Applybody primerhere.
7///f
' aeery here. sra$primer

1 0m m in.) {0.39
BUTYL TAPE
'13.
Thoroughly mix the adhesive and hardener together on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mi x i n g . . Followthe instructions that came with the adheslve.
BUTYLTAPE 1 4 . Beforefilling a cartridge, cut the end of the nozzle

MOLOING
23 mm in.) in.) 10 mm 10.39 10.90
as snown.
Cutnozzle end in.) 10 mm {0.39
GLASS 7 mm {0.27 in.)
20-38
without air pockets into the cartridge 15. Packadhesive Put delivery, the canridgein a to ensurecontinuous g a c a u l k i n g u n , a n d r u n a b e a do f a d h e s i v e r o u n d the edgeof the quarterglassas shown. NOTE: peel . lf the old quarterglass is to be reinstalled, the off the separator the butyltape afterapplying adhesive. . Apply the adhesive within 30 minutesafterapplying the glassprimer.
16. Use suctioncups to hold the quarterglassover the marksmade opening, alignthe clipsor the alignment Lightly in step 9, and set it down on the adhesive. push on the quaner glass until its edges are fully on all seated the adhesive the way around. N O T E :D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e is adhesive drv. AUGNMENT
i:.8T".,1,/:AoHEsrvE
I rnm (0.31 in.)
BUTYL TAPE
SUCTION CUPS
adhesive with a putty off 1 1 . Scrapeor wipe the excess knifeor towel, from a paintedsurface NOTE:To removeadhesive or the quarter glass,wipe with a soft shop towel with alcohol. dampened 1 8 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r . t h e n spray water over the quarter glass and check for leaks.Mark the leakingareas,let the quarterglass dry, then sealwith sealant. NOTE:Let the vehiclestand for at leastfour hours lf after quarterglass installation. the vehiclehas to be usedwithin the first four hours,it must be driven slowly.
GLASS
removedparts. 1 9 . Reinstall remaining all NOTE:Advisethe customernot to do the following thingsfor two to threedays: . . Slamthe doorswith all the windows rolledup. (suchas when going Twist the body excessively a i n a n d o u t o f d r i v e w a y s t a n a n g l eo r d r i v i n g over rough,unevenroads).
20-39
lnteriorTrim
Location Component Index
(*). precautions, SRScomponents locatedin the areasmarkedwith an asterisk Reviewthe SRScomponentlocations, are in and procedures the SRSsection(24)beforeperformingrepairsor service.
CENTER PILLAR FRONT PILLAR UPPER TRIM TRIM (seepage20 41) (seepage20-41) CENTER PILLAR FRONT SIDE LOWER TRIM PANEL TRIM (seepage20 41) (seepage20-41) BEAR SIDE TEIM (seepage20'41) PILLAR OUARTER TRIM PANEL (seepage20 42) HEADLINER Removal and lnstallation, page 20-44
*CARPET Replacement, page20 45
CENTER CONSOLE IM/T} Replacement, page20-47 CENTEN TABLE (seepage20-45)
PARKING BRAKE COVER (seepage 20-45) TRUNKFLOOR EXTENSION (seepage20 43)
CARGO FRONT SPACER (seepage20 43)
TRIM
20-40
and Removal Installation

CAUTION: . Put on gloves to protect your hands, . When prying with a tlat-tip screwdrivel, wrap it with protective tape to prevent damage. . When removing the support strut of the rear hatch glass,you will need to open or closethe rear hatch glass by hand. the NOTE:Takecarenot to bendor scratch trim and panels. >: Cliolocations a>,5 B> , 8 c>,1 o>.2 e>,2
sl elElw"lel
I l_lss-l
SEATBELT FRONT UPPER BOLT 7/16- 20 UNF 32 N.m {3.3 kgf.m, 24 rbt.ft) Apply liquidthread REARDOOR TRIM
'rrl
PILLAR CENTER TRIM PANEL LOWER REAR SIDE LOWER ANCHOB COVER ('98 00 models) FRONT SEATBEL LOWER ANCHOR BOLT 7/15- 20 UNF 32Nm(3.3kgf.m, 24 tbt.ftl
REARSIDETRIM tlemovethe rearseat (seepage20 63).
ANCHOR CAP ('97model)
{cont'd)
20-41
InteriorTrim
(cont'd) Removal and Installation
>i Clip loc.tions
a>,21
@wt we@M
REANSEATBELT UPPER ANCHORBOLT 7/16-20UNF 32 N.m {3.3kgt.m, 24 rbt.ft) REARSIOE TRIM PANEL Removethe reat seat (seepage20-63). REAR
B>,4
c>,1
D > ,1
E>.!
F> , 3
OUARTER PILLAR TNIM PANEL Removethe rear hatch glass supportstrut (seepage 20-741.
REARDOOR
Disconnect accessory the socketconnectors, F CONNECTOR
5x1.0mm 9.8N.m (1.0kgf.m, 1.2lbt-lrl
6x1.0mm 9.8 N.m (1.0kgtm, 7.2 tbf ftl
ffi
STRIKER REARTRIM PANEL Removethe cargo areafloor and cargoslorage bin.
TIEDOWN HOOK
TIE oowN
HOOK
O\A D
6x1.0mm 9.8N.m (1.0kgt m, 7.2 tbf.ft)
REARSEATBELT LOWER ANCHOREOLT 7/16- 20 UNF 32 N.m {3.3kgt.m, 24 tbl.frl
20-42
>: Bolt, screw locations a>,3 B>,4 /\ rr. 6xl.Omm I
o: Nut locations,2 >: Clip locations
c>,2
I
0>,2
At
A>,8
B>,r
|
m)b -</
r1.o D lbe.8 Nm ksnm.l GlrrIIITTpl -<_/ 0pE 7.2

tbr.rrl I
| I
l w |
tl1|r' t
.\
| I
rl'---llH-
-E
l--Tr@HP I v
| v
TRUNK MAT
BUSHING
LOCKASSEMBLY
> '%L i l v
"ro"*i*
TRUNKFLOOR EXTENSIONS
l V^
CARGOAREAFLOOR
FLOOR SrO LID
CARGO STORAGE BIN
l*,hl
CARGO FRONT TRIM
FLOOR SIDEFRAME
is Insta,lation the reverse the removalprocedure. of NOTE: . lf necessary, replace any damagedclips. r Beforeinstalling anchorbolts,makesurethereare no twistsor kinksin the seatbelts. the
20-43
lnteriorTrim
Headliner Removal Installation and
CAUTION: When prying with a tlat-tip screwdriver, wrap it with protective tape to prevent damage. NOTE: . Takecarenot to bendand scratch headliner. the o Be careful not to damagethe dashboardand other interiortrim. 1. Remove: . Frontand reardoor sidetrim (seepage20-41) ( . F r o n tp i l l a r t r i m s e ep a g e2 0 - 4 1 ) . Centerpillarlowertrim panel(seepage20-41) . Centerpillaruppertrim (seepage20 41) . Rearseat(oneside,seepage20-63) . Cargoareafloor and cargostoragebin {seepage20-43) . Reartrim panel (see page 20-421 . Rearsidetrim panel(oneside,see page20-42l, . R e a rh a t c hg l a s ss u p p o r ts t r u t ( o n e s i d e , s e e page20-78) . Ouanerpillar trim panel {one side, see page 2042) . Ceilinglight,interiorlight and trunk light (seesection23) . Rearview mirror (seepage20-28) Remove sunvisorand holderfrom eachside. the
HEADLINER
>: Scaew location3, 4
3.
R e m o v e h e g r a b h a n d l e s r o m the front and rear t f passenger's sides.

>r Screw locations,6
ry_l
COVER
4.
Remove clips,then removethe headliner. the NOTE:An assistantis helpful when removing the headliner.
>: Clip locations,9
2.
A\"rYr*
I | | |
Pullout. OUARTER TRIM PANEL
suNvtsoR
5. Removethe headliner through the rear hatch glass openrng. Installation the reverse the removalprocedure. is of NOTE: . W h e n r e i n s t a l l i ntg e h e a d l i n etr r o u g ht h e r e a r h h h a t c h g l a s so p e n i n g ,b e c a r e f u ln o t t o f o l d o r bend it, Also, be carefulnot to scratch body. the . C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e securely attached the trim. to
6.
20-44
Carpet Replacement
in the are SRScomDonents located this area.Review SRS precautions, procedures the in and locations, component repairs service. or {24)beforeperforming SRSsection CAUTION: Put on glovesto protect your hands. ' 1 . Remove: . Frontseat(seepage20-571 . Rearseat(seepage20 63) . Kickpanel(seepage20-41) ( . C e n t e p i l l a rl o w e rt r i m p a n e l s e ep a g e2 0 4 1 ) r . Frontsidetrim {seepage20-41) . Lowerconsole cover1A,/T model,see page20-49) . Center model,see page2o-47) console(lM/T 2. Remove footrest. the >: Eoltlocaiions,2
6x1.0mm 9.8N.m {1.0kgf.m, 7.2 tbt.ttt Forwaad
4.
Remove centertable and tableframe bracket. the

>: Bolt locations,4 8 x 1.25mm 22N.m l2.2kgl.n, 16 tbt ft) >: Clip locations,4 a: Nut locations,4 8 x 1.25mm 22 N.m 12.2 kgf.m, 16 tbtfrl
i l l
, l
CENTERTABLE
FOOTREST
3.
Remove the parkingbrakecover.

>: Screwlocations,2 COVER
6bo" I
"
TABLEFRAME BRACKET
{cont'd)
20-45
lnteriorTrim
(cont'dl CarpetReplacement
5. Remove centerlowercover(M/Tmodel). the >: Clip locations,2 8. Removethe clips, and releasethe fasteners. then removethe carpet. NOTE:Takecarenot to damage, wrinkleor twist the carpet. >: Cliplocations.3
-ffi]
lN'
FASTENER
COVER
lnstallation the reverse the removalprocedure. is of NOTE: . Take care not to damage. wrinkle or twist the carper. . Makesurethe seatharness routedcorrectly. is . lf necessary, replace any damaged clips. . Reaftach cut areas@ and @ ('97 model)or the cut area @ ('98 - OOmodels)in the carpetwith wire ties.
6.
Remove SRSunit covers. the

>: Clip locations,2
.dL I tEu( |
- qf I
SNSUNIT
FASTENER ('98- 00 models)
cARPET
COVER
7.
'97 model: Cut areas and @ @ in the carpet,then pullthe carpetback. '98 - 00 models:Release fastenerand cut area the then pull the carpetback. @ in the carpet,
20-46
Dashboard
Replacement Console Genter
M/T model: NOTE;Takecare not to scratchthe dashboardand related parts, 1, Removethe shift lever knob.screwsand clips.then removethe centerconsole.
>: Screw location3,4 >: Clip locations.2
Removal and Panel lnstrument Installation

CAUTION: . When prying with a flat-tip screwdriver.wrap it with protestive tape, and apply prolestive tape around the related parts, to provont damago, a Put on glovss to protect your hands. NOTE: Takecare not to scratchthe dashboardand related pans. 1. Tilt the steering columndown. 2. and detachthe clips,then careRemove the screws, fullv removethe instrument oanel.
>: Screw locations,2 >: Clip locations,2
*K/ 6-Emmmn> | #\
arl l
r#sr\
= -, l
|
]
Remove the screws, then removethe centerupper pocket.

>: Screw locations,4 PANEL
3.
is of Installation the reverse the removalprocedure.
3.
Installation the reverse the removalprocedure. is of any damaged clips. NOTE:lf necessary, replace
20-47
Dashboard
Driver'sDashboard LowerCoverand KneeBolsterRemoval and Installation
SRScomponents located this area.Review SRS are in the precautions, procedures the componentlocations, and in (24)beforeperforming SRSsection repairs service. or GAUTION: . When prying with a tlat-tip screwdriver,wrap h with proteqtive tape, and apply protective tape around the relatd parts, to prevent damage, . Put on glovgsto protect your hands. NOTE:Takecare not to scratchthe dashboardand related pans. 1. R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n removethe driver'sdashboard lower cover.Disconnectthe rearhatchglassopenerswitchconnector.
>: Screw locations,2
2.
Remove bolts.then removethe kneebolster. the

>: Boh locations,3 6x1.0mm 9.8N.m ('1.0 kgtm. 7.2 tbtftl
I GlTtrrrb I . - l
@,' "| {l' l r |

1
>: Cliplocations A>,3 B > ,1 rr.- | lr, l
REARHATCHGLASS OPENER SWITCH CONNECTOR
KNEE BOLSTEF
3.
Installation the reverse the removalprocedure. is of propNOTE:Make surethe connectoris connected erly.
20-48
Glove Box Removaland
Installation
CAUTION: . When prying with a flat-tip 3crewdriver,wrap it with protective tape, and apply protoqtivetape around ths related parts, to prgveni damage. . Put on glovegto protect your hands. NOTE: Takecare not to scratchthe dashboardand related oarts. 1. Remove glove box stopsfrom eachside. the
GLOVEBOX STOPS
CenterPocketRemoval and Installation

A/T model: CAUTION: When prying with a tlat-tip screwdriver, wrap it with protestive tape, and apply protective tape around the related parts to prevent damage. NOTE:Takecare not to scratchthe dashboardand related oans.
1. Remove the lower console cover. >: Scrgw locations,6 >: Clip locations A>,2 B>,2
6F@''I l
elsl
GLOVE BOX
Remove the bolts,then removethe glove box. >i Boltlocations,2

COVER
Removethe screws,then carefullyinsert a flat-tip screwdriver and push down on the top of the hook. Remove centerpocketwith the beverage the holder, Separatethe center pocket, beverageholder and beverage holderbracket.
3.
Installation the reverse the removalprocedure. is of 4. Installation the reverse the removal is of orocedure.
20-49
Dashboard
LowerGover CenterDashboard and Removal Installation
the in are SRScomponents located this area.Review SRS in precautions, procedures the and locations, component repairs service or {24)beforeperforming SRSsection CAUTION: . Whn prying with a flat-tip screwdrivet,wrap it with protective tap, and apply proteclive tape around the rslated parts to prevenl damage. . Put on glovgsto protect your hands. NOTE:Takecare not to scratchthe dashboardand related oarts. 1. Remove: . Driver's lowercover(seepage20-48) dashboard . Glovebox (seepage20-49) . Centerpocket(AVT model.seepage20-49) . Centerconsole (M/f model, see page 20-41l, . Centerupperpocket(M/Tmodel,see page2O-47J 2. 2. R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s . t h e n r e m o v e t h e c e n t e r d a s h b o a r dl o w e r c o v e r . the Disconnect connectors.
>: Screw locationa,.a >: Clip loc.tion6,3
and CenterPanelRemoval lnstallation

the in are SRScomponents located this area.Review SRS precautions, procedures the in and locations, comDonent (24)beforeperforming repairs servace. or SRSsection CAUTION: . When prying with a flat-tip screwdriver,wrap it with protective tape, and apply protectivetape around the relatgd parts to prevent damage. . Put on glovesto protect your hands. NOTE:Takecare not to scratchthe dashboardand related parts. 1. Remove: lowercover(seepage20-48) . Driver's dashboard . Glovebox (seepage20-49) . Centerpocket(A,/T model,seepage20-49) . Center console(M/Tmodel,see page20-47) . Centerupperpocket{M/Tmodel,see page20-47) . Center lowercover dashboard Removethe bolts, and releasethe clips. then pull and the out the centerpanel.Disconnect connectors antennalead.then removethe centerpanel.
>: Bolt locations,2
>: Cliplocation3 A> , 4 B>,2

.t !^
\lJS>,,
6br" Il -
I5
\"P
I AccEssoRy
I socKET
(8NED l L
PANEL CENTER
t t
u .
\>ry
I is
I r-,/'
AUOIOUNIT
3.
CLIMATE CONTBOL UNIT CONNECTORS is of Installation the reverse the removalprocedure. and antennalead NOTE:Make sure the connectors proPerly. are connected
3.
is of Installation the reverse the removalprocedurea N O T E : M a k es u r e t h e c o n n e c t o r s r e c o n n e c t e d properly.
20-5 0
Power Window Switch Removal and Installation

CAUTION: . When prying with a flat.tip screwdriver,wrap it with protective tape, and apply protective tape around th related parts to ptavgnt damage. . Put on glovesto protect your hands. NOTE:Takecare not to scratchthe dashboardand related parts. 'L Removethe driver's dashboard lower cover (see page20-48). Gentlypush out the powerwindow switchfrom the dashboard lower cover opening by hand. Disconnect connectors. the >: Cliplocations, 4
CenterAir Vent Removal and

Installation
CAUTION: . When prying with a flat.tip screwdriver,wrap h with protective tape, and apply proteqtivetape around the rolated parts to prevont damage. . Put on gloves to protect your hands. NOTE:Takecare not to scratchthe dashboardand related pans. 1. R e m o v et h e c e n t e ra i r v e n t . t h e n d i s c o n n e c t h e connector. NOTE:Carefullvinsen a flat-tio screwdriverunder the clips,then pull out the centerair vent while prying up the clips.
>:Cliplocations.,l
2.
ffil
AIB CENTER VENT
POWER WTNOOW SWITCH Installation the reverse the removalprocedure. is of Installation the reverse the removalprocedure, is of propNOTE;Make surethe connectoris connected N O T E :M a k e s u r e t h e c o n n e c t o r s r e c o n n e c t e d a properly.
20-51
Dashboard
Side Air Vent Removaland lnstallation
CAUTION: . When prying with a flat-tip screwdriver,wrap it with protec'tivetape, and apply protcctive tape around the related parts to provent damage. . Put on glovsto protect your hands. NOTE:Takecare not to scratchthe dashboardand related parts. 1. 2. Driver's side:Remove the Dowerwindow switch. side:Closethe vent, and gentlypushout the Driver's c l i p s f r o m t h e p o w e r w i n d o w s w i t c h o p e n i n gb y the hand,then pull out the side air vent. Disconnect connector. Passenger's side:Carefullyinsert a flat-tip screwdriver underthe clips.then pull out the side air vent while pryingup the clips. >: Cliplocations B > ,1 A>,2
Side DefoggerTrim Removal and lnstallation

CAUTION: . when prying whh a flat-tip sctewdriver, wrap it with protective tape, and apply protectiv tape around the relatgd parts to prevent damagg. . Put on gloves to protect your hands. NOTE:Takecare not to scratchthe dashboardand related oarts. 1. 2. Driver'sside:Remove sideair vent. the Driver'sside:Gentlypush out the clipsfrom side air vent openingby hand,then pull out the side defogger trim. Disconnect connector. the Passenger's side: Carefullyinsert a flat-tip screwdriver underthe clips,then pull out the side defogger trim while prying up the clips.
>: Clip locations,2
sl4
f f- it l
POWER MIRROR SWITCH CONNECTOR
TRIM SIDEAIB VENT
3. 3. procedure. Installation the reverse is ofthe removal
Installation the reverse the removalprocedure. is of
20-52
Dashboard Removal and Installation

SRScomponents located this area.Review SRS are in the precautions, procedures the component locations, and in SRSsection repairs service. {24)beforepreforming or CAUTION: . When prying with a flat-tip screwdriver,wrap h with protective tap, and apply protective tape around the related parts to prevgnt damage. . Put on glovesto protct your hands. NOTE: . An assistant helpfulwhen removingand installing is the dashboard. . T a k ec a r e n o t t o s c r a t c h h e d a s h b o a r db o d v a n d t , other relatedparts. 1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e radio,then write down the frequencies or the f radio'spresetbuttons. 2. Disconnect the negativebatterycable.and wait at leastthree minutesbeforebeginning work. Removei a Driver'sdashboard lower cover and knee bolster (seepage20-48) . Glovebox (seepage20-49) . L o w e r c o n s o l ec o v e r a n d c e n t e r p o c k e t ( A / T model,seepage20-49) . C e n t e rc o n s o l ea n d c e n t e ru p p e r p o c k e t( M / T model,see page20-47) . Center dashboard lower cover(seepage20-50) . Powerwindow switch(seepage20-51) . Driver's side air vent (seepage20-52) . Driver's side defogger trim (seepage20-52) Disconnect driver'sairbagconnector, the and lower the steeringcolumn(seesection17) NOTE:To preventdamageto the steeringcolumn, wrap it with a shop towel. 6.
OASHBOARD SIDECOVER UNDER.DASH FUSE/RELAY
5.
Removethe dashboardside cover. Disconnect the dashboard wire harness connectors, remove the nuts, then move the under-dash fuse/relaybox. Disconnect t h e a n t e n n al e a d , a n d d e t a c ht h e h a r n e s sc l i p s . Removethe connectorholder from the dashboard frame. Unbolt the control unit/relay bracketfrom behind middleof the dashboard. the
>: Clip locations.
sl l l l
r t t l
l
ANTENNA LEAD HARNESS SRSMAIN HARNESS
BOX
6x1.0mm DASHBOARD9 . 8 N m 1 1 . 0 k g f . m , FFAME 7.2tbt.ftl CONNECTOR HOLDER
Remove passenger's the dashboard lowercover.

>: Scrw location, 1 D: Clip locations,
I SF:oo l I -
-$t- I ssj
PASSENGER'S DASHBOARD LOWER COVER
I
{cont'd)
Dashboard
Removaland Installation(cont'd) Dashboard
7. cliDS. Disconnect connectors the and harness >: Boli loc.lions B>,1 a>,5
c>,1
^5\h'.'_. 4fl\',r,' r$\'rmTrr':j,1.ff,ry-r,.,". \fl)Prtu' tltbt.ttl

W/* W)-
OASHBOARD GUIDEPIN
c)-
CONNECIORS
CONNECTOR
Remove bolts.then lift and removethe dashboard. the CAUTION: Use protective iape on the botlom of ths tront pillar trim. is of lnstallation the reverse the removalprocedure. NOTE: . Makesurethe dashboard onto the guide pinscorrectly. fits . Before wire harnesses not pinched. are tightening the bolts,makesurethe dashboard properly. . Makesurethe connectors and antennalead are connected
20-54
Dashboard FrameReplacement
CAUTION: Put on gloves to prolect your hands. parts. NOTE:Takecarenot to scratch dashboard the and related
a: Nut locations,3 6x1.0mm 9.8 N.rn 11.0 kgf.m, 7.2 tbt.ftl INSTRUMENT PANEL (seepage20 47)
GAUGE
CENTER PANEL {seepage20 50)
>i Screwlocations A>,16
lu
\,.\ / ,.-------f,\
/A
\,r*
B>,2 ^
S@t' -
1 l
I
c >,2
0 @ ll "
D>.a
0Fl l
Ihll'rifi|
DASHBOARD wlRE HARNESS DASHBOARD FRAME
>: Clip localions.2
.drr I -w
i
FRONT PASSENGER'S
Installation the reverse the removalorocedure. is oI NOTE: . Makesurethe dashboard wire harnesses not Dinched. are . Makesurethe connectors properly. and antennaleadare connected
Seats
REARSEAIS page20 63 Removal and lnstallation, page20 65 Disassembly Reassembly, and page20-67 Disassembly Reassembly, and SeatLinkage page20-69 ArmrestReplacement, page20-69 SeatCoverReplacement,
Removal page20 57 and Installation, Disassembly Reassembly, page2O-58 and SeatLinkage Disassembly Reassembly, page20-60 and ArmrestFleplacement, 20 61 page SeatCoverReplacernent, 20 61 page
20 -5 6
Front Seat Removaland Installation

CAUTION: When prying whh a tlat-tip screwdrivor,wrap it with proteqtivetape to prevent damage. NOTE:Takecare not to scratch bodv or tear the seat the covers. 1. Removethe seat track end cover, and removethe bolts.
>: Bolt loc.tions A>.3 I x 1.25mm 22 N.m i'2.2 kgl.m, 16 rbf.ftl
2.
Lift up the driver's front seat,then disconnect the seatbeltswitchconnector and harness clips. >: Hrrnoss loc.lions clip
B > ,1
10x 1.25mm 37 N.m kgt.m, 13.8 27 tbt.ftl
SEAT BELT SW]TCH CONNECTOR Carefullyremove the front seat through the door opening. NOTE:An assistantis helpful when removingthe front seat. Installation the reverse the removalprocedure. is of NOTE:Make sure the seat belt switch connectoris properly(driver's front seat). connected
20-57
Seats
and FrontSeatDisassembly Reassembly
CAUTION: When prying with a flat-tip screwdriver,wrap it with protsqtive tape to prevent damage. the NOTE:Takecarenot to scratch bodv or tear the seatcovers. Driver's seat lmanually adiustablewith manual height adiustmentl: >: Cliolocations
bar Torsion barremoval: Torsion removal:
HOOK
SEATCUSHION
10x 1.25mm ,17N.m (,1.8 m, kgt 35 tbt.ft)
PIVOTNUT 8 x 1.25mm 22 N.n 12.2kgl.m, 16 rbI.ft) 10 x 1.25mm 47 N.m (4.8 kgf.m, 35 tbtfr) HOOKS 10 x 1.25mm 47 N.m {,1.8 kgl.m. 35 rbt.ft)
20-5 8
Passenger's seat (manually adiustablel:

>: Clip locations HOOK
HEADREST
SEAT.BACK
PIVOTWASHER PIVOTNUT 8 x 1.25mm 22 N.m 12.2kgl..n, 16 tbt.ftl
SEATCUSHION
COVER CENTER
BUSHING m 1 0x 1 . 2 5 m ,U N.m 14.8 35 rbt.ft) '10 1.25mm x 47 N.m {4.8 kgf m, 35 rbl.ft)
UNDER-SEAT TRAYGUIDE
1 0x 1 . 2 5 m m 17 N.m {4.8kgl.m, HOOKS 35 tbf.ft)
COVER
Reassembly the reverse in orderof disassembly. NOTE: . Makesurethe bushingand pivotwasherare installed properly. . To prevent wrinkleswhen installing seat-back the cover,makesurethe materialis stretched evenlyover the pad. . Grease movingportion. the
Seats
and FrontSeatLinkageDisassembly Reassembly
CAUTION: Put on gloves to protect your hands.
RECUNE ADJUSTER 8 x 1.25 mm 22 N.m 12.2kgl.m, 16 tbf.fi)
8 x 1.25mm 22 N.m 12.2 kd-m, 16 tbtf0 CROSSBRACE
8 x 1.25mm 22 N.m 12.2 kgl.m, 16 tbf.f0
INNERSLIDE ADJUSTER
cRoss
BRACE
CONNECTING WIRE To connect,twist 180". OUTERSLIDE AOJUSTER
8 x 1.25mm 22 N.rn l.2.2kgl-m, 16 rbr.ft)
in orderof disassembly. Reassembly the reverse NOTE:Grease moving portions. the
20-6 0
FrontSeatArmrestReplacement
NOTE:Takecare not to tear the seamsor damagethe seatcoverS. >: Boltlocations.2
6r1.0mm 9.8N,m ll.0 kgl.m, 7,2 tbf.ft)
FrontSeatCoverReplacement
CAUTION: Put on gloves to protect your hands. NOTE:Take care not to tear the seamsor damagethe seatcovers. Seat-backcover: '1. Slide the front seatforward,and fold the seat-back forward. 2. 3. Remove armrestfrom the driver'sseat. the Release hook,and fold backthe seat-back the cover.
SEAT-BACK
1 0x 1 . 2 5 m m kgf,m, 47 N.m 1,1.8 35 tbt{t)
4.
Release insidesprings,then fold backthe seatall backcover.and removethe clios.

WIRE {Padsidei
(Seatback frame sjde)
cover on
'00
model)
(cont'd)
20-61
Seats
(cont'dl FrontSeatCoverReplacement
guide,then removethe seatRemovethe headrest Dacx cover. 3. Pull backthe edge of the seat cushioncover all the the way around,then release clips.and removethe seatcushioncover.
COVER
(padside)
6.
is of Installation the reverse the removalprocedure. NOTE: To preventwrinkleswhen installinga seatbackcover,makesure the materialis stretchedevenly over the pad before securingthe hook and inside springs.
is of lnstallation the reverse the removalprocedure. NOTE: . To preventwrinkleswhen installing seatcusha ion cover. make sure the material is stretched the evenlyoverthe pad beforesecuring clips. . Replace released the clipswith new ones.
Seat cushion cover:

1.
59). Remove seatcushion(seepages20-58, the then Remove the clipsfrom underthe seatcushion. loosenthe seatcushioncover.
CLIP
RING UPHOLSTERY PLIERS available) lCommercially
NEWCUP
SEAT FRAME
SEAT CUSHION COVER
20-62
RearSeat Removal and lnstallation

CAUTION: When prying with a llat-tip screwdrivsr, wrap it with protectivetape to prevent damage. NOTE: Takecare not to scratchthe seatcoversand bodv. l Removethe lower hinge covers,then remove the bolts. with tilt: NOTE:Beforeremovingthe rearseat,tilt it.
>: Boh locations.2 8 r 1.25mm 2 N.m 12.2kgl,n, 16 tbf ttl
LOWER HINGE
covERs
HINGE LOWER COVER
(cont'd)
20-63
Seats
(cont'dl RearSeat Removaland Installation
2. Foldthe seatcushionforward,and removethe base framecover,then removethe boltsand nut. NOTE:The rear seat without tilt is shown,the rear seatwith tilt is the same manner.
>i Boh screw locetions
5.
removethe striker. With tilt: lf necessary,
A>, 1
8 x 1.25mm 22 N.m {2.2 kgf.rn, 16 rbtft) a: Nut loc.iion, 'l
B>, 4
@ t
8 x 1.25mm 22 N<n 12.2kglrn, 16 rbtftl BASEFRAME
is of lnstallation the reverse the removalprocedure. N O T E :M a k e s u r e t h e r e a r s e a t b e l t b u c k l e sa n d centerbelttongueare routedproperly(withouttilt).
SEATBELTBUCKTES (CENTER BELTTONGUEI SEATCUSHION
Remove the headrest. Carefullyremovethe rear seatthrough the door opening. is NOTE:An assistant helptulwhen removingthe rear seaI.
4.
20-64
and RearSeat Disassembly Reassembly

CAUTION: When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage. the NOTE:Takecarenot to scratch body or tearthe seatcovers. Without till:
SEAT-BACK
SEAT.AACK RECLINE ROD
PIVOT COVER
PIVOTNUT 8 x 1.25mm 20 N.m 12.0 kg{.m. 14 tbf.ftl
WASHER HOOKS
SEATCUSHION LATCH
SEAT CUSHION 5x1.0mm 9.8 N'm (1.0kgf.m, 7.2 tbl.ltl SEATLINKAGE
SEATCUSHION STRAP
(cont'd)
20-65
Seats
(cont'd) RearSeat Disassembly Reassembly and
with tilr:
SEAT-BACK
SEAT.BACK RECLINE ROO
PIVOTNUT x 1.25mm 20 N{n (2.0kgt.m, 14 tbt-fr)
10 x 1.25mm 47 N.m {4.8kgfn, 35 tbtft)
I-ATCH COVER SEATCUSHION LATCH
SEAT CUSHION
SEATLINKAGE
T;LT KNOB
CLIP
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbf.ftl
SEATCUSHION STRAP
Reassemble the reverse in orderof disassembly. NOTE: . Makesurethe bushingand pivot washerare installed properly. . Grease moving portion. the
20-66
and RearSeat LinkageDisassembly Reassembly

CAUTION: Put on glovesto protect your hands' Without tilt:
REABSEAT FOOT
CENTER COVER
N
HINGE PIN
6x1.0mm 9.8 N{n 11.0kgt'm, 7.2 tbt ftl
BASEFRAME
E-CLIPS Replace.
I
b
I
HINGEBRACKET
(cont'd)
20-67
Seats
(cont'd) RearSeat LinkageDisassembly and Reassembly
with tilt: NOTE:Refer section24 for the rearseatbelt buckles to and centerbelttongue removal
TILTCONTFOL CABLE 1 0x 1 . 2 5 m m 47 N.m {i1.8 kgt.m, 35 tbf.ft)
CENTEB ARM COVER 6x1.0mm 9.8 N.m n.0 kgt.m, 7.2 tbt.tll 8 r 1.25mm 16 N.m (1.6kgf.m, 12 tbt.ftl
//-)
n
/
ASE FRAME DAMPER
6x1.0mm 9.8 N.m 11.0 kgtm, 7.2 tbttr) ROD TILTCONTROL
A @
TILT CONTROL CABLE
SPRING UPPER HINGE
Replace.
BUSHING
H I N G EP I N
E.CLIP Reptace. Reassemble the reverse in orderof disassembly. NOTE: . Grease moving ponion. the . lf necessary, adjustthe tilt controlcable.
20-64
RearSeatArmrestReplacement
NOTE:Take care not to tear the seamsor damagethe seat covers.
SEAT.BACK
RearSeatCoverReplacement
CAUTION: Put on gloves to protect your hands. NOTE:Takecare not to tear the seamsor damagethe sealcovers. Seal-backcover:
L
Remove seat-back the {seepage20-65). Remove: a Armrest . Headrest . Seat-back reclinerod (seepage20-65) Removethe seat cushionstrap bolt and strap bolt mat. trim, then removethe seat-back
COLLAR
2.
COLLAR 6x1.0mm 9.8 N.m {1.0kgf.m,
7.2rbr.ft)
WASHER
NYLON WASHER VE WASHER ARMREST PIVOTBOLT 6x1.0mm 9.8 N.m (1.0kgt.m, 7.2lbllll
ARMREST
"'---.' t.-r"t-- i,': ""
'
4. is of lnstallation the reverse the removalprocedure.
all Remove the clips.
(cont'd)
20-69
Seats
RearSeatCoverReplacement (cont'dl
Removethe headrestguide and latch knob collar, then removethe seat-back frame. SEAT.BACK FRAME i Soat cushion cover: '1. 2. Remove seatcushion(seepage20-65). the R e m o v e h e s e a t c u s h i o nl a t c h a n d s e a t c u s h i o n t strap(seepage20-66). P u l l b a c kt h e e d g e o f t h e s e a tc u s h i o nm a t , t h e n release of the clips. all SEAT CUSHION MAT
3.
--t)c/
pio
t-t t l
L]
l@
I
GUroE
HEADREST
LATCHKNOB COLLAR
Pull backthe edgeof the seat-back coverall the way around.release clips,and removethe seat-back the cover. CUSHION COVER Pull backthe edge of the seat cushioncover all the way around,release clips,and removethe seat the cushtoncover.
CLIPS
cover '00model) on 1.
CLIPS ( L e a t h e rs e a t - b a c k
WIRE (Padside,leather seat,back
cover ,00model) on
Installation the reverse the removalprocedure. is of NOTE: o To preventwrinkleswhen installinga seat_back cover,makesure the materialis stretched evenly over the pad beforesecuring hook and clips. the . Replace released the clipswith new ones.
COVER
20-70
5.
of is Installation the reverse the removalprocedure. NOTE: o To preventwrinkleswhen installinga seatcushi o n c o v e r ,m a k e s u r e t h e m a t e r i a li s s t r e t c h e d the evenlyover the pad beforesecuring clips. clipswith new ones. . Replace released the
FING PUERS UPHOLSTERY (ComE|erciallY available)
PAD
WIRE (Pad side)
20-71
Bumpers
Removal Installation FrontBumper and
CAUTION: Put on gloves to protec,tyour hands. NOTE: . An assistant helpfulwhen removingthe front bumper. is . Takecarenot to scratch front grille,lront bumperand body. the o Firstremovethe front grille (seepage20-77). . lf necessary, platebaseand front license platelower bracket. removethe front license
>: Boli screw locations A>,3 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt t0 FRONT GRILLE (seepage20-77) >: Cliplocations,5
B > ,4
C>,4
S))PF| ffi)m>l v Y./

I
FRONT GRILLE EMBLEMCOVER (seepage20-77)
<
wl w
.r.,
FENDER
tx\ \{_:
I
B FRONT BUMPER
20-72
removethe front bumperbeam,front bumperupperbeamand guard bar. lf necessary, >: Bohlocations

A>,5 V.2
c>.6
D>,2
E>,6
10 x 1.25mm 38 N.rn {3.9 kgf.m, 28 rbl.ftl
Gfu @p;i,li',ll-"-'
>: Clip locations B>.3 A>, 5 @,,2
dE6 I #\Er+W l | = . = r |:;lHl= t
n l n - n l z n I r
TIE DOWN HOOK
Ylr
{to/
BEAM
TIE.DOWN HOOK
v1
Installation the reverse the removalprocedure. is ot NOTE: . M a k e s u r e t h e f r o n t b u m p e re n g a g e s h e f r o n t t bumperupperbeamsecurely. . It necessary, adjust the front bumper upper beam gap. to obtain proper the . lf necessary, any damaged clips. replace
BUMPEB FRONT
20-73
Bumpers
RearBumper Removal Installation and
CAUTION: Put on gloves to proteqt your hands. NOTE: . An assistant helpfulwhen removingthe rearbumper. is . Takecarenot to scratch rearbumDerand bodv. the >: Boli,screwlocations
a>,2
B>,4
c>, 10
>: Clip locelions, 7
rgfi\\* ffi\\-. 3il;l-'lln*n,.., t.2tbtftl

WJ/* Y)f
0f'"I trl
l . K
-
.f-.'
I
l
l
BEARBUMPER STEP
SIOEMARKER LIGHTCONNECTOF REARSPLASH Disconnect. GUARD
To body
To body
SIDE MARKER LIGHT
To body To body
REARBUMPER LIGHT
Installation the reverse the removalprocedure. is of NOTE: . lf necessary, replace any damaged clips. . Makesurethe side markerlight connectors pluggedin properly. are . Makesurethe rearbumperengages sideclipson eachsidesecurely. the
20-74
Hood
Replacement
NOTE: the . An assistant helpfulwhen removingand installing hood. is the hood and body a Takecarenot to damage . When removingthe clips,usea clip remover.
>: Bolt locations,4 6x1.0mm 9.8N.m {1.0kgt.m, 7.2tbtfr) HOOD WINDSHIELD NOZZLES WASHER (seepage20-100)
G
{
\
WINDSHIELD WASHER TUBE (see page 20-100)
HOOD HINGE
of is Installation the reverse the removalprocedure NOTE: . Makesurethe hood opensproperlyand lockssecurely. . Adjustthe hood alignment. (seepage20-102) washernozzles . Adjustthe aim of the windshield
20-75
Hood
Adjustment
the NOTE: Beforeadjusting hood,looseneachbolt slightly. to Turnthe hood edgecushions, necessary, make as the hood fit flushwith the bodv at front and sideedges. Adjustthe hood right and left,as well as fore and aft, holeson the hood hinge by usingthe elongated
f
sz 14--+ik-
HOOD EDGE CUSHION
HOODHINGE
6x1.0mm 9.8N.m (1.0kgtm, 7.2 tbt.ttl
HOODHINGE
Adiustthe hood latchto obtainthe properheightat the forwardedge' in Move the hood latchrightor left untilthe strikeris centered the hood latchas shown
HOOD LATCH
?-9.8N.m (1.0kgf m, 7.2 rbf.ftl
HOODLATCH
20-76
Front Grille
Replacement
CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts to prevent damage. NOTE:Takecare not to scratch front orille and front the oumper. 1. Removethe front grille emblem cover. Loosenand removethe grille mountingscrews.and removethe front grille by pullingit forward. >: Screwlocations a>,5 s>,2
@,"l @-l
N O T E : I n s e r t a P h i l l i p ss c r e w d r i v e rt h r o u g h t h e holes in the front grille,then loosen the screws.
2.
20-77
RearHatchGlass
Replacement
CAUTION: . Put on glovesto protecl your hands. . Use seal coversto avoid damaging any surfaces. . Do not damage the rear window delogger grid lines and terminals. NOTE:An assistantis helpful when removingthe rear hatchglass. a: Nul locations Aa.4 Ba.4
Harnosswiring locations:
REARWINDOWWIPER MOTORCONNECTOR Remove rearwiper lower the cover(seepage20-99i.
HARNESS ' TRIM
@i!iff*-"REARSPOILER
.;=-
8 x 1.25mm 22 N-m l'2.2kgl.m, '16tbt fr) 8 x 1.25mm 22N.m l.2.2*ql.m, 16 tbf.ft| Installation is the reverse of the removal orocedure.
NOTE: . Adjustthe rearhatchglassalignment. . Makesurethe connector, properly. terminalsand washertube are connected . Adjustthe aim of the rearwindow washernozzle (seepage20-103).
20-78
Disassembly Reassembly and

NOTE: . Takecarenot to scratch rearhatchglass. the . lf necessary, spacers and seals. replace any damaged . Refer page20-99fortherearwindowwiper motor removaland section23 for the high mount brakelight removal. to
HINGESPACEN ('97- 99 models) HINGESPACERS
HINGEPLATE ('00model)
REARSPOILEB SPACER {'99 00 models)
HARNESS TRIM
HARNESS TRIM
6x1.0mm 9.8 N.m {1.0kgl.m, 7.2 tbt.ft) WASHER
STBIKER
REARSPOILER SPACER ('97- 98 models)
s
SEAL RAFWINDOW WIPER MOTOR BASEPLATE REARWINDOW WIPERUPPER COVER MOTORBASE PLATESEAL
CAUTION LABEL
FEAR TIME 4WD EMBLEM GLASSPROTECTOR
/=
PIVOTNUT
{cont'd)
20-79
RearHatchGlass
(cont'dl Disassembly Reassembly and
NOTE:Beforeinstalling the rear spoilerspacer,harness trim. cautionlabel,real time 4WD emblem and glass protector, cleanthe rearhatchglassbondingsurface with a spongedampened alcohol. in
>: Alignment mark locatioos
A>
ALIGNMENT HARNESS MARK TRIM
w\ l : f
_\
l |
, r\
ALIGNMENT MARK
lnside:
Center line
SPACER REARSPOILER
Outside: o o o
REARSPOILER SPACER {'97 98 models)
Centorline
REAR SPACERS {'99 00 models)
SPOILER SPACEBS ('99 00 models)
20- 8 0
Adjustment
NOTE: . After adjusting tailgatedoor,adjustthe rearhatchglass. the . Loosen strikermountingboltsslightly. the . Remove rearspoiler,and removethe supportstrutfrom body side. the 1. Loosen the rearhatchglassmountingnuts. and the tailgatedoor. the rearhatchglass, the taillights, 2. Adjustthe rearhatchglassso thereare equalgaps between or NOTE:lf necessary, loosenthe rear hatchglasshinge mountingnuts and move the rear hatchglassbackward forward to fit the rearweatherstrip tailgatedoor weatherstrip. and
REARHATCI{ GLASSHINGES
REARHATCHGLASSHINGE MOUNTINGNUT 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt f Remove rearedge the otthe headliner (seepage20-44). Taillight side:
MOUNTINGNUT 6x1.0mm 9.8N.m 11.0 kgtm, 7.2 rbf.ftt
Tailgate door side:
NOTE:Adjustfor equalgaps between right and left. the
REARH ATCHGLASS
About 7mm in.l 1o.27
(cont'd)
20-81
RearHatchGlass
Adjustment(cont'dl
tightenthe rear hatchglassmountingnuts,and installthesupportstrut. the 3 . After adjusting rearhatchglass, 4 . Adjustthe strikeralignment. NOTE: . Move the strikerfore or aft to makethe rearhatchglassfit flush with the tailgatedoor' in . Move the strikerright or left until it's centered the rearhatchglasslatchas shown.
REARHATCH GLASS LATCH REARHATCHGLASS
STRIKER
6x1.0mm 9.8 N.m (1.0kgt'm, 7.2tbl.ftl NOTE:When equalizing gap between the the tailgatedoor and rear hatch glass,do not dglorm the rear hatch glass. DOOR TAILGATE
5. Tightenthe strikermountingbolts. and lockssecurely. and makesurethe glassopensproperly, the 6. Recheck rearhatchglassalignment. 7. Installtherearspoiler.and adjustit.
NOTE:Adjustthe rearspoiler so thereare four equalgaps and between rearspoiler the the body.
REARSPOILER
REARHATCHGLASS
8. Check water leaks. for the NOTE: Do not squeeze tip of the hose.
20-82
RearWeatherstrip Replacement
W h e n i n s t a l l i n gh e r e a rw e a t h e r s t r i p ,l i g n t h e a l i g n t a ment mark of the rear weatherstrip the body flange to notch. NOTE: . Makesurethereare no wrinklesin the weatherstrio. . T h e s t e e lc o r e i n t h e r e a r w e a t h e r s t r i p a n n o tb e c restored it originalshapeonce it is bend. Replace to the rearweatherstrip when the steelcore is bent. . Apply sealant the areasindicated arrows. to by . Check water leaks. for Sealant: CemedineP/N 08712- 000i1, equivalont or '98 - 00 modols:
SEALANT WEATHERSTRIP
'97 model: area. Sealing
Sealing area. BODY FLANGE
REAR WEATHERSTRIP
WEATHERSTRIP
Moldings
RoofMoldingReplacement
CAUTION: . Put on glovgsto protect your hands. . Whn prying with a {lat-tip screwdriver,wrap it whh protective tape to prevent damage NOTE: . Takecarenot to scratch body. the the . The steelcore in the roof moldingcannotbe restored it originalshapeonce it is bend.Replace roof moldingwhen to the steelcoreis bent. pry . Starting the front, carefully off the roof molding. at
>: Clip locations A>,2
B>,3
Installation the reverse the removalprocedure. is of NOTE: . Takecarenot to damagethe windshieldmolding. . Makesurethe roof moldingis installed securely.
ROOFMOLDING STEEL CORE
20-84
DoorMoldings Replacement
CAUTION: . Put on gloves to protect your hands. . When prying with a flat-tip scrowdriver,wrap it with protstive tape to provent damag. NOTE: . Takecarenot to scratch body. the . Be careful to damage front and reardoor moldings. not the
t
Adhesive aleas,
DOOR Adhesive area. FRONT MOLDING
REARDOOB MOLDING
>: Clip locations, 14
a: Plasticnut location, 1
(cont'd)
20-85
Moldings
(cont'd) Door MoldingsReplacement
It the old molding is to be reinstalled: and tools are requiredto repair The following materials t h em o l d i n g . instructions. NOTE:Followthemanufacturer's (Reference) Materials: . Striperemover 3M 08907 . Stripeadhesive remover 3M 08908 . Adhesive tape Tape Attachment 3M SuperAutomotive Tools: . Protectivetape . Knifeor Cutter . Spongeor Shoptowel . Infrared dryer 7 . G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g sa s snown, N : Adlesivetapelocations
Forwerd L
8 2 0 m m 1 3 2 . 3i n . )
in.l 25 mm {0.98
45 mm (1.8n.l i FRONT MOLDING 125mm 30 mm i in.) { 1 . 2 n . } {4.92 G l u eo n t h e r i b area, 26 mm (1.0in.) 440mm 117.3 in.l 200 mm (7.87 in.)
. . .
Film putty knife Plastic Alcohol
CAUTION: Put on gloves to protect your hands, 1. clipson the moldreplace any damaged lf necessary, ang. Apply the striperemoverevenlyto the bondingsurfaceof the body and molding. of Coverthe bondingsurface the body and molding (40 with a film, then heatto 104- 122"F - 50'C)for 5 - 10 minuteswith an infrareddryer. NOTE: Use care when heatingto preventdeformation of the body and molding. 4. Carefullyscrape the adhesivetape with a plastic putty knife. follow-upwith For removalof adhesive tape residue, stripe adhesiveremover,then scrapethe adhesive tape with a plastic putty knife. the protective tape,then cleanthe bonding Remove in surface with a spongedampened alcohol. is NOTE:Makesurethe bondingsurface keptfree or water,oil and grease.
35 mm 125mm in.) {1.4in.) {4.92
REARDOOR MOLDING (Front/rear end)
2.
Width:5 mm
3.
t'.
Heatthe bonding surfaceof the door and molding with an infrared dryer. Door: 104- 140'F(40- 60'C) Molding:68 - 86'F (20- 30'C) NOTE:Use carewhen heatingto preventdeformation of the molding. , A l i g n t h e m o l d i n gw i t h t h e c l i p l o c a t i o n sa n d s e t the molding. Lightly push on the molding until its tape. on edgeis fully seated the adhesive NOTE: Oo not spray water on the molding within the first 24 hoursafterinstallation.
all 1 0 . Reassemble removedparts.
Side Sill Panel

Replacement
NOTE:Takecarenot to scratch body. the >: Cliplocations
A>.7 >: Screwlocations, 4
NOTE: Loosenthe screw, then removethe lowerclip usinga clip remover,
Remove the side clips from the body by turning them 45'
SIDE CLIP
NOTE:When removing side the sill panel, sideclipswill the stay in the body.
S I O ES I L L P A N E L Remove the lower clips, then remove the side sill panel by sliding it forwatd.
To installthe side sill panel,removethe sideclipsfrom the body,installthem on the side sill panel, then installthe sidesill Danel the vehicle. on NOTE: . Takecarenot to twist the sidesill panel. . lf necessary, replace any damaged clips.
20-47
SpareTire Gover
Installation Emblem
Hard spare tire cover {for some models}: Apply the emblemwhere shown. NOTE: in . Beforeapplying, with a spongedampened alcohol. cleanthe sparetire coversurface . After cleaning, and water from gettingon the surface keepoil, grease Attachment Point lRferencel: U n i t :m m ( i n . ) Honda/CR-vemblem:
APPLICATION TAPE
HONDAEMBLEM
CR.VEMBLEM
SPARE TIRECOVEB
20-88
Fenderwell
FrontWheelwellProtector
Replacement
NOTE: a Take care not to scratchthe front wheelwell protector and body. . Use a T30 Torx bit to remove the Torx screw. >: Screw locations a >,3 B > ,1
InnerFender Replacement
NOTE: Takecare not to scratchthe body. Removethe front wheelwell protector,
>: Screw locations,4 >: Clip locations,
s))pp> Y]
6x1.0mm 9.8Nm(1.0kgf.m, 7.2 tbf.ft)
A\
)fl(
ffi
:rl
6'thp I s ) D Y/ v.l/
>: Clip locations,
,,-C\
l#
wt I a l
4t
A I
I
NOTE: Beforetemoving the remove frontwheelwell Protector, the screwfrom the front bumperand lowerthe front bumper.
INNER FENDER
Installation the reverse the removalprocedure. is of NOTE;lf necessary, replace any damaged clips.
Installation the reverse the removalDrocedure. is of NOTE:lf necessary, replace any damaged clips.
20-89
Fenderwell
RearWheelwellProtector
Replacement
NOTE: Take care not to scratchthe body. NOTE: . Take care not to scratch the rear wheelwell protector and body. . Use a T30 Torx bit to remove the Torx screw.
>: Screw locations B>,I a>,3
FuelPipeProtectorReplacement
the Remove rearwheel (seesection18). >: Clip locations,3
I ,.{\ 6x1.0mm 6him"l F ),@ 9.8N.m {1.0kgl.m. 7.2 rbtft) Y-./ Y/

>: Clip locations
qK
1l
/ll
A> , 5
YnTn |
B > ,1
|
/'d)Ul | +['Tl+l \=lHl | -_H_l

tlrflJ | |
removinsthe INoTE:Before the lclip.remove screw

from the rearbumperand lowerthe rearbumper,
is of lnstallation the reverse the removalDrocedure. replace any damaged clips. NOTE:lf necessary.
is of lnstallation the reverse the removalprocedure. NOTE:lf necessary, replace any damagedclips.
20-90
RearAir Outlet Replacement

NOTE:Takecarenot to scratch body. the Remove rearbumper(seepage20-74). the
>: Cliplocations, 4
A\
-T[-r
Tt-
Installation the reverse the removalDrocedure. is of
20-91
Openers
FUELFILLOOORLATCH page20'96 Replacement, HANDLE HOODRELEASE page20'95 Replacement,
HOODLATCH page20'95 Replacement,
DOOROPENER FUEL CABLE Replacement, Page20 94 CABLE HOODOPENER page20'93 Replacement, OPENER FUELFILLOOOR Replacement, Page20_96
20-92
HoodOpener Cable Replacement

NOTE: . When removingthe clips,usea clip remover. . Takecarenot to bendthe openercable. Remove: . Frontwheelwellprotector and innerfender{leftside,seepage20 89} . Frontgrille(seepage20-77) . Kickpanel(leftside.seepage20-411
>: Clip locations,3
'.--)r
@l
HOODLATCH (seepage20-95)
t"
HOODRELEASE HANDLE (seepage20 95) the opener Route cablethroughthe hole in the body.
Installation the reverse the removalprocedure. is of NOTE: . lf necessary. replace any damaged clips. . Makesurethe hood openercableis routedand connected properly. . Makesurethe hood opensproperly.
Openers
Cable Replacement FuelFillDoorOpener
NOTE: . When removingthe clips,usea clip remover. . Takecare not to bendthe openercable. (seepage20-45), the Remove followingparts,then pull the carpetback,as necessary
a Kickpanel(leftside.see page20-41)
Centerpillar lower trim panel (left side,see page 2041) Frontsidetrim (leftside,seepage20-41) Rearseat(leftside,seepage20-63)
>: Clip locations B>,1 A>,6
Cargoareafloor and cargostoragebin (seepage 2043) a Reartrim panel{seepage20-42) Rearsidetrim panel(leftside,see page20-421 a Rearsidetrim (leftside,see page20-41)
c>,1
@lRlg
FUELFILLOOORLATCH (seepage20-96) FUELFILLDOOROPENER {seepage 20-96)
is of Installation the reverse the removalprocedure. NOTE: . lf necessary, replace any damagedclips. properly. r Makesurefuel fill door openercableis routedand connected . Makesurethe fuel fill dooropens properly.
Hood Release HandleReplacement

NOTE:Takecarenot to bendthe openercable. Remove left kickpanel(seepages20-41). the >: Eoltlocations.2
6x1.0mm 9.8 N.m {1.0kgl.m, 7.2 tbl.tll
HoodLatchReplacement
NOTE:Takecarenot to bendthe openercable. Remove front grille (seepage20-77). the >: Boltlocations,3
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ftl
HOODOPENER CABLE {seepage20-93)
HOOOLATCH
Installation the reverse the removalprocedure. is of NOTE; . Grease eachlocation ofthe hoodlatchas indicated by the arrows. . Makesurethe openercableis connectedproperly. . Makesurethe hood locksproperly. . Adjust the hood latchalignment(seepage20-76).
Installation the reverse the removalprocedure. is of NOTE:Makesurethe hood opensproperly.
20-95
Openers
FuelFillDoorOpener Replacement
NOTE:Takecarenot to bendthe openercable. Remove the leftfront sidetrim (seepage20-41). >: Boltlocstions.2
5x1.0mm 9.8N.m (1.0kgf.m, 7.2 tbt.ftl >: Boh locdions, 2 6x1.0mm 9.8 N.m (1.0 kgf.m, 7.2 tbf.ft) FUELFILLDOORLATCH
Fuel Fill Door Latch Reolacement

NOTE:Takecarenot to bendthe openercable. Removethe rear speakercover and rear speakerfrom the left rearsidetrim panel(seepage20-42).
FUELFILLDOOR OPENER CABLE (seepage 20-94) FUELFILLDOOR After installing, check for a flushfit with the body.
DOOROPENER FUEL CAELE (seePage20,94) LATCH Remove fuel fill door latch the by turningit 90'
FUEL FILL
Installation the reverse the removalprocedure. is of NOTE: . Makesurethe openercableis connectedproperly. . Makesurethe fuel fill door opensproperly,
Installation the reverse the removalprocedure. is of NOTE:Make sure the fuel fill door opens properly and lockssecurely.
20-9 6
Wiper/Washer
WIPER ARMS WINOSHIELD and LINKAGE page20-98 Replacement, Adiustment, Page20-103
REARWINDOWWIPER ARM and MOTOR page20 99 Replacement, page20 103 Adiustment,
RESERVOIN WASHER page20 99 Replacement,
TUBE WASHER page Replacement, 20-100
20-97
Wiper/Washer
Windshield WiperArmsand Linkage Replacement
CAUTION: Put on gloves to protoct your hands. NOTE:Takecarenot to scratch hood and body. the 1. 2. Remove windshield the wiper arms. Remove clips,then removethe cowl cover. the >: Cliplocations A>.9
a. Pryout the anner clip. INNERCLIP b. Remove clip. the
3.
Disconnect the connector,remove the bolts, then removethe windshield wiper linkage assembly. >: Bohlocations,3
6x1.0mm 9.8 N.m (1.0kglm, 7.2 tbt.fr)
/G
SHOP TOWEL (Cowlcoverside)
"rr/ &
4. S e p a r a t eh e w i n d s h i e l d i p e r l i n k a g e n d w i n d t w a shieldwiper motor. NOTE:Scribea line acrossthe link and windshield wiper linkage show the originaladjustment. to >: Bohlocations, 3
6x1.0mm kgf.m, 8 N.m 10.8 5.8 lbf.ftl NUT 10 x 1.25mm kgf.m, 18 N.m 11.8 13 tbf.ftl SPRING WASHER
B>.8
ql
WINDSHIELD WIPER ARMS
NUTS '10 1.25mm x kgf.m. 18 N.m 11.8 13 tbf.ftl
' L|NK / WINDSHIELD WIPER LIN(AGE
s}@ 1ffi, /Y{
WIPERMOTOR
5.
Installation the reverse the removalprocedure. is of NOTE: . Makesurethe connectoris connected properly. . lf necessary. replace any damaged clips. . Install he windshield iperarmsas described t w on page20-103. . Check windshield the wiper motor operation. . Grease moving parts. the
COVER
2 0- 9 8
WindowWiperArm and Rear Motor Replacement

CAUTION:Put on gloves to protect your hands. NOTE;Takecarenot to damagethe rear hatchglass. 1. Remove the rearwindow wiper arm.
a: Nut loc.tion!, 3 6x1.0mm kgt'm, 9.8 N.m 11.0 7.2 tbf.ftl REARWIPER >: Scaowlocationa,2
Replacement WasherReservoir
GAUTION: Put on glovesto protect your hands. 1. Remove: . Frontgrille (seepage20-771 . Front bumper (see page 20-721 . Frontwheel{leftside,seesection18) . Frontwheelwellprotector(leftside,see page2089) . Innerfender(leftside,see page20-89) (leftside,seesection23) . Headlight D i s c o n n e ctth e w a s h e rt u b e s a n d w a s h e r m o t o r connectors. >: Boltlocations, 3
6x1.0mm kgt.m, 9,8 N.m 11.0 7.2 tbt.ftl
@rrc
2.
REARWINDOW MOIOR WIPER
COVER
SPECIAL NUT 18 x 1.0mm 9 N.m 10.9 m, kgt 5.r tbt.ftl
tubes the Route washer to the washerteservoir
WASHER RESERVOIR WINOSHIELO MOTON WASHER CONNECTORS REAR WIPERARM NUT 6x 1.0mm 9.8 N.m {1.0 kgt.m, ?.2 tbfftl HARNESS
cLrP
/ t
Remove the rearwiper lowercover. D i s c o n n e ctth e c o n n e c t o r t h e n r e m o v et h e r e a r , window wiper motor. of Installation the reverse the removalprocedure. is NOTE: properly. . Makesurethe connector connected is . Installthe rea. window wiper arm as described on page20-103. . Check the rearwindow wiper motor operation. . Grease movingparts. the 3.
\ - S(ilq l' wrsHER

s{J
Removethe bolts, then remove the washer reservotr, is of Installation the reverse the removalprocedure. NOTE: a a Makesure the washermotor connectors nd properly. washertubes are connected . Check washermotor operation. the 4.
C-(fu
20-99
Wiper/Washer
Windshield Washer TubeReplacement
NOTE: . Takecarenot to scratch relatedpartsand body. the . When removingthe clips,use a clip remover. Remove followingparts. the (seepage20-89) . Leftfront wheelwellprotector . Left innerfender(seepage20-89)
>: Clip locations A >,2 '97 model:
'fr{------63
ax--\J
,.&--
\7
B>,1
c>,1
D>,1
WINDSHIELO WASHER NOZZLES
Y-JOINT
\
Boutethe w6shertubes to the washerreservoir
lnstallation the reverse the removalprocedure. is of NOTE: . Takecare not to pinchthe washertubes. . lf necessary, replace damaged any clips. . Afterinstalling, (seepage20-103). adjustthe aim ofthe washernozzles
20-100
RearWindow WasherTubeReplacement
NOTE: . Takecarenot to scratch relatedpartsand body. the . When removingthe clips,usea clip remover. (seepage20-45) then pull the carpetbackas necessary the Remove followingpartsfrom the left side of the vehicle, . . . . . . a (seepage20-89) Frontwheelwellprotector Innertender(seepage20-89) Kickpanel(seepage20-4't) Centerpillarlowertrim panel(seepage20-41) Frontsidetrim (seepage20-41) Rearseat(seepage20-63) Cargoareafloor and cargostoragebin (seepage2043) Reartrim paneland rearsidetrim panel(seepage2042J . Rearsidetrim (seepage20-41) . Rear hatch glass support strut (body side, see page 20-7Al . Ouarterpillartrim panel(seepage20-421 23) o Cargoarealight (seesection (rearedge,seepage20-44) . Headliner .
el @s_l 4
GROMMET WINDSHIELD TUBE WASHEB tubes the Route washer to the washerreservoir
location3 cu3hion >: Clip,harness c>,3 A > ,1 B > ,1
D>,12
GROMMET
t!be the Route washer underthe wire harness
wasnerno2zre.
WASHEB RESERVOIR
TUBE WASHER
wrNoow
WINDOW REAR MOTOR WASHER
(cont'd)
20-101
Wiper/Washer
(cont'dl RearWindow Washer TubeReplacement
WINDOW REAR NOZZLE WASHER
GSOMMET
"'..--a
i;r. B
REAR WINDOW WASHER TUBE
Route washer the tube undorthe wire harness,
Installation the reverse the removalDrocedure. is of NOTE; . Takecarenot to pinchthe washertubes. . lf necessary, replace any damaged clips. . After installing, (seepage20-103). adjustthe aim of the washernozzle
20-102
Adiustmenl WiperArms and WasherNozzles

Wind3hieldWipor/Washer: 1, Adiust the wiper arms so that their park positions matchthe illustration. RearWindow wipor/Washer: \ Distance from center '_\ ltne ru"rrr."i. i 2 7 m m ( 1 . 1n . ) from black ceramic edge 88 mm (3.5 in.)
Viow from flont io roar

GLASS
Vi6w trom roar to lront

REAR
sPo[.-ER
C.nlar lino L
2.
Insert a tack into the washer nozzles.and adjust them so that they aim at positionsA, A', B, and B' shown in the illustration. Distance from center line from black ceramicedge
Alignto the rearwindow grid line. defogger
^,J;-ll\
A and A' B and B'
in.) 3,$ mm (13.5 in.) 287mm (11.3 in.) 122mm (4.80 in.) 352mm (13.9
20-103
Sub-frame
Sub-frameTo.que Sequence: CAUTION: After loo3eningthe sub-framemounting bolts, be sure to replacethem with now ones.
REANCROSS BEAM
10 r 1.25mm 49 N.m 15.0 kg{.m, 12 x 1.25mm 36 tbt.ftl 74 N.m (7.5kgtm. 54 tbf.ft)
SNFFENER
BOLTS 1 l x 1 . 5m m 89 N.m 19,1 m, kgt 66 tbt ftl Replace.
20-104
FrameRepairChart
Top view: U n i t :m m ( i n . ) 0: Innerdiameter
{4.021 t1.19} lm 302
tr.rr!9$I
POtt{T
POINT'
POINT hl
SECTION DD
20-106
2&2 t111.11
I POINTn
258,1{10r.7}
32A7 1129.11
(cont'd)
20-107
FrameRepair Chart
(cont'd)
Sideview: U n i t :m m ( i n . ) 0: Innerdiamete.
POINTd3 o15 {0.591 TrensmissionMount For
d15 10.591 Trrnsmi3don For Mount POINTd1 t13 10.5'llFor Transmb3ion Mount POINTel 613 10.51) Transmirsion For Mouni t13 {0,511 Engin6 Mount For M10 x Pl.25 t13 10.51) Uppcr Arm For
130
POINTh1
.25 POINT
,1710.67) Fof Re.r Beam
o16 10.631 LocateHole o12 (0.,171 Right Front Stop For POINTc1 612 {0.47}For Left Front Stoo b2 t12 {0.47}For Right Front Stop POINTc2 r12 {0.47)For Left Front StoD For o11 (0.{31 EngineMount Damper Lower Bushing Point
t5011.97| Locrt. Hol. POINT
t17 10.671 R..r Fo.
r'17 10.671 Rcar Bo.m For
20-108
POlNTx.y /
'sad
POINTm3, m4 FuelTank Strap Poinr (106.32) 2700.5 RearDamoer Center Upper Arm BB SECTION
M12 x P1.25 POINTn

I
FOINT
\ql ol
.df
o2010.8|Locate Hole
rg (0.3)Fuel T Strap Center For RearCros3Beam LocateHole 271,1(10,6.9)

POINT 3, s1
For ReerCross Beam POINTw
Aim For o14 {0.551 Trailing

POINT v
Bear Damper Lower Bushing Point
20-109
Heaterand Air Conditioning

Heater ...........21
22. in is 21 NOTE:Section ("Heater") included section
......'..'.. Air Conditioning

SYSTEM(SRS} RESTRAINT SUPPLEMENTAL
'.'22'1
airbagin the dashboard wheel hub, a passenger's a This model has an SRSwhich includes driver'sairbagin the steering ('98- 00 models).Information in abovethe glove box ('97,00 models).and seat belt tensioners the seat belt retractors (*) the SRSis includedin this ServiceManual.ltems markedwith an asterisk on the contents necessary safelyservice to or replacing theseitemswill requirespecial Servicing, disassembling pageinclude. are locatednear,SRScomponents. or Hondadealer. precautions tools,and shouldonly be done by an authorized and
@ avoid rendering the SRS inoperative,which could lead to personal iniury or death in the event of 8 severefrontal . To
collision, all SRSservicework must be performed by an authotized Honda dealer. lmproper service procedures, including incorrect removal and installation of the SRS, could lead to personal iniury causedby unintentional deployment of the airbags ('97 - 00 models),and seat belt tensioners 138 - 00 models). Do not bump the SRS unit. Otherwise, the system may fail in case of a collision, or the airbags may deploy when the ignitionswitch is ON {lll. SRS eleqtricalwiring harnessesare identified by yellow color coding. Relatedcomponents are located in the steering column, front console,dashboard,dashboardlower panel, and in the dashboard above the glove box. Do not use electricaltest equipment on thes cilcuils.
Air Conditioning
Heater Control Panel Reofacement ,.,...,,.,..,.,.,,22-46 Blower Unit Replacement .................. 22-46 Overhaul...........,,,., .......-.22-17 Evaporalor ReDlacement ...,.,.,..,......,22-4A Overhaul................ .........22-19 A/C Filter Replacement ..................22-50 *HeaterUnit ReDfacement ..................22-50 Overhaul..,.,..,.,...,.. .........22-52 TemperatureControl Adiustment ....................22-53 A/C Service Tips and Precauiions............-....-.... 22-54 A/C SystemTorqueSpecifications .................... 22-55 A/C System Service Performance Test ......,...22-56 Pressure TestChart .-.....22-5a Recovery ..............,. ...-.-...22-59 Evacuation -...........-........22-60 Charging................ .......-.22-61 LeakTest ........................22-61 Compressor Repfacement ..........-.......22-62 Index flfustrated .....,.......22-64 Cfutchfnspection .........,.22-65 CfutchOverhaul ............22-66 ThermafProtector Rep|acement ................... 22-68 Refief ValveReplacement .............................. 22-68 A/C ComoressorBelt Adiustment .................... 22-69 Condenser Repfacement .,.....,,.,..,.,..22-70 'Read SRSprecautionsbetore working in this area.
SpecialTools
Rel. No.
Tool Number 07JGG 001010A 07sAz - 001000A 07947 6340300 07965 6920500
Description
Oty 1 2 1 1
PageRelerence 22-69 22-33,36,37 22-66 22-61
BeltTensionGauge Backprobe Set DriverAttachment @ Hub Assembly GuideAttachment @ * Included the BeltTensionGaugeSet,T/N 07TGG 001000A in
6,
.o
22-2
ComponentLocation
lndex
EVAPORATOR page 22-48 Replacement, page22-49 Overhaul,
SERVICE VALVE ILOW-PRESSURE SIDE}
A/C PRESSURE SWTTCH When the refrigorantpressureis below 200 kPa12.0kglc.r|r, 28 psi) or abov 3,200kPa(32 kgflcmr,455 psi),the AJCpressure switch opensthe circuit to the Ay'C switch and stops the air conditioningto protectthe compressor.
, [\,
CONDENSER page 22-70 Replacement,
-il
SERVICE VALVE IHIGH-PRESSURE SIDEI page 22-62 Replacement, page 22-65 Clutch Inspection, pago22-66 ClutchOverhaul, page 22-68 Thermal ProtectorReplacement, page 22-68 ReliefValve Replacemnt.
(cont'd)
ComponentLocation
lndex (cont'dl
precautions, in and procedures the SRS are locatedin this area.Reviewthe SRScomponentlocations, SRScomponents or section(24)beforeperformingrepairs service.
ruoronl /alowen page

\Test, EVAPORATOR Feplacement, page22-48 Overhaul, page22,49 22-16 /
BLOWER UNIT page22-46 Replacement, Ovethaul,page22 47 RECIRCULATION CONTROL MOTOR page22 42 Replacement,
lest, pag.e22 42
HEATER UNIT page Replacement, 2250 page Overhaul, 2252
VALVECABLE Adjustment,page 22-53
A/C FILIER page 22-50 Replacement. RECIRCULATION CONTROL SWITCH
a/c swtTcH
REAR WINDOW DEFOGGER SwlTCH See section23 MODECONTROL DIAL HEATER CONTROL PANEL page 22 46 Replacement, CONTROL
MODE
MOTOR page22-41 Replacement, Test,page 22-41
swtTcH
22-4
SLOWER MOTORRELAY, RADIATORFAN RELAY. CONDENSER FAN REI-AY, COMPRESSOR CLUTCH RELAY (Located the undeFhood in fuse/relay box) Test. page 22-45 CONDENSER FAN 2P CONNECTOB RADIATORFAN 2P CONNECTOR A/C PRESSURE SWITCH 2P CONNECTOR
COMPARTMENT WIREHARNESS
1PCONNECTOR
{cont'd)
22-5
Component Location
Index(cont'dl
precautions, in and procedures the SRS are locatedin this area.Reviewthe SRScomponentlocations, SRScomponents or section(24)beforeperformingrepairs service.
MOTOR BECIRCULATION CONTROL 4P CONNECTOR TEMPERATURE SENSOR EVAPORATOR Tesl, page 22-44 MOTOR AIR MIX CONTROL page22-43 Replacement, lest, page 22-13
POWER TRANSISTOR 3P CONNECTOR
BLOWER MOTOB 2P CONNECTOR
BLOWER MOTORHIGHRELAY Test, page 22-45 HEATER SUB.HARNESS
7P CONNECTOR
DASHBOARD WIREHARNESS PANEL HEATER CONTROL 8P AND 2OP CONNECYORS
22-6
Description
The air conditioner systemremovesheatfrom the passenger compartment circulating by refrigerant throughthe system as shown below. High'temperature/ h i g h - p r e s s u rg a s e Suction and compression
High-temperature/ h i g h - p r e s s u r le q u i d i
Radiationof heat
r r a p so e o n s , and removes motsture
High-temperature/ h i g h - p r e s sru l i qu i d e
IlcoMpREssoR
Lessmoisturized low-pressure vapor
coruoerusenl*
More liquidified row-pressure vapor Absorption of heat
necetve
EVAPoRAToR (-l
EVAPORAYOR
EXPANSToN vAL
SUCTIONLINE tLow-PRESSURE S|OEt
LIOUIDLINE
CONDENSER DISCHARGE LINE IHIGH.PRESSURE SIDEI
(R-l34a)refrigerant This vehicleusesHFC-I34a which does not containchlorofluorocarbons. attentionto the followPay ing service items: . . . . . . (R-12) (R-134a). Do not mix refrigerants CFC-12 and HFC-l34a They are not compatible. (PAG)refrigerantoil (SP-10) Use only the recommendedpolyalkyleneglycol designedfor the R-134a compressor. (PAG)refrigerant with any other refrigerant will resultin compressor Intermixing recommended the oil oil failure. Afl Ay'C systemparts(compressor, discharge line.suctionline,evaporator, condenser. receiver/dryer, expansion valve, O-rings joints)haveto be properfor refrigerant for R-134a. not confuse Do with R-12parts. Usea halogengas leakdetector designed refrigerant for R-134a. R-12and R-134a refrigerant servicing equipment not interchangeable. only a recovery/recycling/charging are Use station that is U.L.iisted and is certified meetthe requirements SAEJ2210 service to of to R-134a conditioning air system. Always recover the refrigerant R-134awith an approved recovery/recycling/charging station before disconnectingany lVC fitting.
22-7
CircuitDiagram
BOX FUSE/RELAY HOOD UNDEB
IGNIT SWITCH ON
UNDER.DASH FUSEiRELAY BOX
+ wHTBLK
**f
/6'^'\
\_-./
,o+trrffl-
F;t"î I
eLK/YEI f
COMPRESSOF CLUTCH RELAY
I, m
LIl
RED
BLK
BLU'ryVHT
I d I CoMPRESSOR I I I CLUTCH
G401 G402
BLK/RED
T*.'1l Y l l
BLK BLK BLK
I I,^,^,", I L^"^,Y**t,|
CONDENSER MOTOR G201
GRN
WHT
,JC PRESSURE SWITCN 1 2 /:\ -{.-!}Btu/yvHT Btu/RED
\,-/
l l l
G101 G202
r t l
22-8
POWER TRANSISTOR
ORNMHT
EVAPONATOR TEMPERATURE SENSOR
cnNj@_snN
Fg"{
"'"fi3'.Hfi|$l#i9D>
DASH LTGHTS _/4 EE|GHTNESS l_ < -! CONTROLLER REAR RED
GRY
s5v
AMD P
s coM
A I RM I X CONTROL MOTOB
PNK/BLK NED/8LU REO/YEL BRN

YEL/RED
HOT
VENT B/L H
H/D DEF
GRN/YEL 8LU/8LK YEL
I/lODE CONT8OL l\r10T0R

M
YEL/BLU 8RN/WHT
(l fllf$!S,* RELAY
aLurrL
GRNI/VHT GRN/RED 8LK
O:8P coNNEcToR c0NNCToR n :20P

HEATER CONTROL PANEI-
c401 c402
22-9
Troubleshooting
SymptomGhart
function (see next system,reterto selt-diagnosjs which are indicatedby the self-diagnostic malfunctions For electrical page). a Notetheseitemsbeforetroubleshooting symptom. . Check enginecoolantlevel,and allow the engineto warm up beforetroubleshooting. the beforecontinuing test. the . Anv abnormality must be corrected needed,use a digital multimeterwith an output of 1 mA or less at the 20 kO . Because the precisemeasurements of rangewhen testing. procedures check: . Beforeperforming any troubleshooting - Fuses fuse/relay box, and No. 17 {7.5A) in AJ, No. 47 17.5 No. 55 (40A), No. 56 (20A), No. 57 (20A) in the under-hood fuse/relay box. the under-dash ._ GroundsNo. G101, G4O2 G201, G202,G401, - Cleanliness tightness all connectors of and Symptom Mode controlmotor does not run, or one or more modesare inoperative. controldoor doesnot changebetweenFreshand Recirculate. Recirculation on). fan Radiator does not run at all (but condenser runswith the AVC fan on). fan runswith the Ay'C fan Condenser does not run at all {but radiator do and condenser) not run for enginecooling.but they both run with the A,/C Bothfans (radiator on. on Both fans do not run with the Ay'C clutchdoes not engage. Compressor AJCsvstemdoes not come on (bothfans and compressor). Both heaterand A/Cdo not work, 22-24 22-29 Sse pags
22-33
22-34 22-37 22-39
22-10
Self-diagnosis Function
The heatercontrolpanelhasa self-diagnosis function. Runningthe Self-diagnosis Function '97 modl: Turn the ignitionswitchON {ll),then set the mode controldial to the Vent position, and the recirculation controtswitchto Recirculate indicator {recirculation lightcomeson).Press and holdthe recirculation controlswitchto Fresh(recirculation indicatorlight goes off).Continue hold the switch;the recirculation to indicator light will come on for two seconds. then it will blink the Diagnostic TroubleCode(DTC) indicate iaulty component. no DTC'S found,the indicator to a lf are liqht will not blinkatterthe initialtwo secondlight. '98 - 00 models: Set the mode controldial to the Vent position, and turn the ignitionswitchON (ll).Withinsix seconds afterturningthe ignition switchon, pressthe recirculation controlswitchthe required numberof times depending the recirculation on indicator lightstatus: . l f t h e i n d i c a t o r l i g h t i s O N , p r e s s t h e r e c i r c u l a t i o n c os wrioc h i v et i m e s . nt t l f . l f t h e i n d i c a t o r l i g h t i s O F F , p r e s s t h e r e c i r c u l a t i o n c o n t irto lh i xI | m e s . sw c s The recirculation indicatorlight will come on for two seconds, then blinkthe Diagnostic TroubleCode(DTC) indicate to a faultycomponent. no DTC'S found,the indicator lf are lightwill not blinkafterthe initialtwo second liqht. DTCIndicaiion Pattern{SeeDTC3}:
Rocirculation indicator light on Recirculrtion indicator lighi off '97 model: P.essand hold th6 recircul.tion control switch '98 - 00 modek: Within six second3 atter the ignition switch b turned ON (lll. Prassthe rocirculation control switch the required number ol times dependingon the r6circulation indicator light striu3
,r* /
1.5 aaa 0.3 aac RECIRCULANON INDICATOR LIGHT
MODECONTROL OIAL Diagnostic trouble code {DTCI

'l
R6circulation indicator light
Component with problsm
Possiblo causc
See page
O n eb l i n k Two blinks Three blinks
Air mix control molor Elower motor
Openor shortcircuit, obstructed door, faultymotor

Open or short circuit,faultv motor Opon or short circuit,faulty sensor
22-12 22-14,16 22-20
Evaporator temperature sensor
In caseof multipleproblems, recirculation the indicator light indicate only one DTCthat is the leastnumberof blinks. Resetiing the Solf.diagnosisFunqtion Turningthe ignitionswitchOFFwill cancelthe self-diagnosis function.After service work, run the self-diaqnosis function onceagainto checkthat there is no other Droblem.
Troubleshooting
Air Mix ControlMotor
1: light indicates Diagnostic TroubleCode(DTC) A problemin the air mix controlmotor circuit. Recirculation indicator to the The air mix controlmotor regulates mixtureof cool/hotair according outputsfrom the heatercontrolpanel.
Selt-diagnosiscircuit check indicates a Droblem in the air mix control motor circuil.
Chockthe air mix control moior: 1. Disconnect air mix control the motor 5P connector, 2, Testthe air mix controlmotor (seepage22-43). Checkthe air mix control linkago and doors: 1. Remove he air mix control t motor (seepage22'43). 2. Check air mix controllink the age and doors for smooth
ls the air mix controlmotorOK?
Do the air mix controllinkage and doorsmovesmoothly?
Reolacelheair mix conlrol motor.
HEATER PANEL2OP CONNECTOR CONTROL
PNK/BLK
CheckIor a short in the wires: 1 - R e m o v et h e h e a t e rc o n t r o l panel(seepage22-46). 2. Checktor continuitybetween body ground and the heater control panel 20P connector terminalsNo. 1, 6, 9, 17 and 18 individually.
RED/BLU
Wiresideof femaleterminals Ropairany short in the wire(s) betwoon th. heater co.rtrol panel and the air mix conlrol motor.
To page22-13
Ftom page 22.12
HEATER CONTROL PANEL2OPCONNECTOR
Checktor a short to poweri C h e c kt h e s a m e t e r m i n a l s f o r voltage. REO/8LU RED/YEL
Repairshon lo power in the wi.e between the heater control panel and the air mix control motor, (Thisdamagesthe heater control Danel.l
Checktor an open in the wires: Checkfor continuity between foll o w i n g t e r m i n a l so f t h e h e a t e r control panel20P connector and the air mix controlmotor 5P connector, zOPi 5P: N o .1 No.3 No.6 _ N o .4 No.g _ No.2 N o .1 7 _ No.5 N o .1 8 _ N o .1
RED/YEL
Repair any open in the wire{s) betweon the heatercontrol panel and air mix control motor. Check toa loos wir63 or poor connectionsrl the heater control panel 20P connector and st the air mix control motor 5P connsctor. lJ the connections aro good, substitute a known-good hoater control panel, and rechock.I the symptom/indication goes away, ..pl.ce the original heater control panel.
AIR MIX CONTROL MOTOR 5P CONNECTOR Wire sideof femaleterminals
Troubleshooting
BlowerMotor Speed
2: Diagnostic TroubleCode(DTC) A problemin the blowermotor circuit indicator light indicates Recirculation by The speedof the blowermotor is controlled signalssentfrom the heatercontrolpanel
Blower motol only runs on high spood position; h does not run in any othe. speodpositions. NOTE: lf the blower motor does run at all,referto page22-16.
3P POWER TRANSISTOR CONNECTOR Self-diagnosis circuitcheck indic a t e sa p r o b l e mi n t h e b l o w e r motor circuit, 1 2 ) 3 BLK Chacklor.n open in the wire: 1. Disconnectthe power transistor 3P connector. 2. Checkfor continuitybetween the No.3 terminaand body l gro(1nd. Chock for.n op.n in thc wiro botween ihe powa. transistor rnd body ground, It tho wir. is OK, check for poor ground at G,O1 .nd G4o2.
ls therecontinuity?
Chsckfor an opon in the wire: '1. Connect the No. 1 and No. 3 trminals of the power trans i s t o r 3 P c o n n e c t o rw i t h a jumperware. 2. Turn the ignitionswitch ON {ll).
JUMPER WIRE
Repairop6n in the wiro betwoon tho Dower transi3tol and the blowor motor. HEATER CONNECTOR CONIROLPANEL2OP Wire sideoI fgmaletrminals Checktor an open in tho wire: 1. Turnthe ignitionswitchOFF. 2. Disconnect iumperwire. the 3 . R e m o v et h e h e a t e rc o n t r o l panel (seepage 22-46). 4. Check for continuity botween the No. 20 terminal of the heatercontrolpanel20Pconnectorand the No.2 terminal o f t h e p o w e r t r a n s i s t o r3 P connectof,
't1 12 1 3
,/1,/
1ia
10
't5 1 6 1 1 1 8 1 9 20
LI GRN/BLK
o
LT GBN/BLK Rpairopon in tho wire betwoen th6 oowor ttan3i3tor and th6 hoatar control oanel.
10 page22-15
22-14
From page22-14
Chockfor a short in the wire: Checktor continuity between the No. 20 terminal of the heatercon' trol panel20Pconnectorand body ground,
HEATER CONTROL PANEL2OP CONNECTOR
2
11
,/1,/l/
10
12 1 3 1 a 1 5 1 6 1 7 1 8 1 9 20
LT GRN/BLK
o
R.p.ir short in the wire betwoen th. herter control Denel snd the oowor tranSastor. Checkto. an open in the wire: 1. Turnthe ignition swilchON (ll). 2. Measurethe voltage between t h e N o . I t e r m i n a lo f t h e heatercontrol panel 8P connectorand body ground. Wire sideof female terminals
HEATER CONTROL PANEL8P CONNECTOR 1

4
8 BLU/8LK
Wire sideof female terminals Repairopan in the wire betwaen tho heatsr cont.ol o.nel and the blower motor.
Chockth6 power iransistor: 1. Turnthe ignitionswitchOFF. 2. Reconnect heatercontrol the panel8P and 20Pconnectors. 3. Test the power transistor (see page 22 44).
ls the power transistorOK?
Chec* for loo3e wires or Door oonneclions at the heater control panel 8P and 20P connoctorsand at lhe power tran3istor 3P connector. lf lhe connectiorc are good, substituta , known-good hoater contrcl pan6l, and rcheck.ll the symptom/indication goes away. replecg originalheater control th6 oanel.
22-15
Troubleshooting
BlowerMotor
2: Recirculation indicator light indicates Diagnostic TroubleCode(DTC) A problemin the blowermotor circuit. by The speedof the blowermotor is controlled signalssentfrom the heatercontrolpanel,
Blower motor do.3 not run at all.
circuitcheck indiSelt-diagnosis c a t e sa p r o b l e m i n t h e b l o w e r motor circuit,
check rhe No. 55 (40 A) {use in the under-hoodfuse/relaybox, and the No. 17 (7.5A) fuse in the under-dashfuse/relaybox.
Replace th6 fuse(s),and rechalck.
BLOWERMOTOR 2P CONNECTOR Check tho blowe. motor input and output cilcuh: 1. Connect No. 2 terminalof the the blower motor 2P connector to body ground with a jumperwrre. 2. Turnthe ignition switch (ll). ON
JUMPEF w|RE fo page 22-11 Wire side of lemale terminals
Doesthe blowermotor run?
Chockthe blower moto.: 1 . D i s c o n n e ctth e j u m p e r w i r e and the blowermotor 2P connector. 2. Measurethe voltage between the No. l terminal and body ground.
Checktho blower motor rolay: 1. Turnthe ignitionswitchOFF. 2 . R o m o v et h e b l o w e r m o t o r relayfrom the under-hood fuse/relaybox, and test it (see page 22 45l'.
fo page 22-19
22-16
Frompage22-16
Check lhe blower motor high telay: 1. Turn the ignitionswitchOFF, and disconnecthe jumper 2 . R e m o v et h e b l o w e r m o t o r h i g h r e l a y ,a n d t e s t i t { s e e page22-45).
MOTORHIGHBELAYitP CONNECTOR BLOWER Checkfor rn opon in the wire: l. Connect No. 1 terminalof the the blower motor high relay 4P connector body ground to with a iumperwire. 2. Turn the ignitionswitchON (ll). R6pairopcn in the wire botwoen the blower motor and the blower motoi high relry.
. r u u e e l"3 1 i I wrRE I
BLU/BLK rF r .--1 1 2 ) l | _ #
Wire side of female terminals Doesthe blowermotor run?
Checktor an opon in the wire: '1. Turn the ignitionswitch OFF, and disconnect he iumper 2. Turn the ignitionswitchON {ll). 3. Meas0rethe voltage between t h e N o . 2 t e r m i n a lo f t h e blower motor high relay 4P connector and body ground. Repairopon in the wiro betweon the No. 17 fuse and tho blowel motor high relay.
Checktor an open in the wire: '1. Turnthe ignitionswitchOFF. 2. Checklor continuity between t h e N o . 3 t e r m i n a lo t t h e b l o w e r m o t o r h i g h r e l a y4 P connector and body ground. Check for an open in the wire between the blowar motor high rel.y and body ground.lf the wiro i3 OK, check fo. poor ground at G{Ol .nd Gt|()2,
To page22-18
(cont'd)
Troubleshooting
BlowerMotor (cont'd)
Ftom page 22-17
MOTORI{IGHRELAY4P CONNECTOR BI-OWER Wire sideof femaleterminals Checkfor an open in the wiro: 1 . F e m o v e t h e h e a t e rc o n t r o l panel(seepage22-46). 2. Checklor continuitybetween t h e N o . 8 t e r m i n a lo I t h e heatercontrol panel 8P connectorand the No. 1 terminal of the blower motor high relay4P connector.
Ropairop6n in th wira between tho heater control panol and tho blowgr motor high relay.
HEATER CONTROL PANEL8P CONNECTOR Wiresideof female terminsls
Checklor an op6n in the wire: Checklor continuity between the No. 8 terminaloI the heatercon trol panel20Pconnector and the N o . 4 t e r m i n a lo f t h e b l o w e r motor high relay4Pconnector.
I{EATER CONTROL PANEL2OP CONNECTOR Wirc sideot femaleterminals
ls therecontinuhy?
Repairopen in the wire botweon the heater control Daneland the blowel motor high r6lay.
Check fo. looso wiles or oool connoctionsat the haateacontrol Danel8P .nd 20Pconnectorsand at the blower motor high relay 4P connoctor. ll the connctions are good, substitutg a knowngood h.at.r control panol, and r.check. lf the symptom/indicetion goes away, replacethg original heater contrcl panel.
Frcm page 22-16
Rcpbcc tho blower motor rolay. MOTORRELAY4P SOCKET BLOWER Ch.ck th. under-hoodtu.o/rolay box: Measur6the voltage betweenthe No. 3 terminalofthe blowermotor relay4P socketand body ground.
Chacktor an open in the wilo: 1. Turnthe ignition switch (ll). ON 2. Measurethe voltage between the No. 4 terminal of the blower motor relav ,[P socket and body ground. Ropairopon in the wirs botwoon th. No. 17 fu3o and th. blow6r motol lolay.
ls thore batteryvoltage?
Chacktor an opon in tho wilo: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuity between the No. 2 terminal ot the blower motor relay 4P socket and body ground. Chock tor !n opan in the wile bstween tha blowar motor ralaY .nd body ground. It tho wilc is OK, chock fol poor ground at G/Ol and G402. Ropair opon in th. BLU/WHT wira batwaan lho blowor motol rohy and tho blowe. motor.
22-19
Troubleshooting
Evaporator Temperature Sensor
Recirculation indicatorlight indicates Diagnostic Troublecode (OTC) A problemin the evaporator 3: temperature sensorcircuit. The evaporator temperaturesensor is a temperaturedependentresistor{thermistor}. The resistance the thermistor of decreases the evaporator as outletair temperature increases.
Self-diagnosiscircuit check indi cates a problem in the avaporator tempeleture ssnsor circuit,
EVAPORATOR TEMPEMTURESENSOR
Terminal sideof malterminals
Chck the ev.porato. temperature sensor: 1. Disconnecthe evaporator temperaturesensor 2P con2. Measure the resistance betweenthe No. 1 and No. 2 t o r m i n a l so f t h e e v a p o r a t o r temperature sensor. RESISTANCE ko
86'F
30"c
ls the resistance withinthe speci, fications shownon the 9raph.
Checklor a short in the wire: l R e m o v et h e h e a t e r c o n t r o l panel(seepage22-46). 2. Checktor continuitybetween the No.2 terminaol the l heatercontrolpanel20Pcon, nectorand body ground.
Wiresideof fema16 terminals
Repai. short in the wir6 betwan lhe hoater control Danoland the evaporatoa tampereturc senSoa.
fo page22.21
From page22-20 HEATER CONTROL PANEL2OP CONNECTOR Wire sideol femaleterminals Chocktor an oDenin th wire: Checkfor continuity betlveenthe No. 2 terminalof the heatercontrol oanel 20P connector and the No.2 terminaloI the evaporator temperaturesensor2P connoctor.
10
11 1 2 1 3 1 a 1 5 1 6 't7 1 8 1 9 20
GIIN Fopair open in the wiro between tho heato. control penel and the evaporatortempetatule sensor.
TEMPERATURE EVAPORATOB SENSOR 2P CONNECTOR Wire sideoI temaleterminals
'tl
2 8 9 t0 6 1 2 1 3 l a t 1 5 1 6 '17 1 8 't9 20
,/ l,/
Checkfor rn opsn in tha wiJe: Checkfor continuity between the No. 9 terminalof the heatercon trol oanel 20P connector and the No. 'l terminalot the evaporator temperaturesensor2P connector,
o
+
li-L:t
Ropairopen in tho wire betwegn the heater control oanel and the evaporatortgmpcrature sen3or.
Chgck fol loose wiros or pool connectrons the hoator control at oan6l 20P connector and at the eveporator temperatura Sensol 2P connector. It the connections are good, substitute a knowngood he.tel contlol panel, and rechck. ll thg symptom/indication 90o3rwey, roplscethe original heatercontrol oanel.
Troubleshooting
Mode ControlMotor
Mode control motol does not run. or ono or more modesare inoDaa-
Checkthe No. 17 {7.5A) Iuse in the under-dash fuse/relaybox.
Replace the tus, snd iecheck. MODECONTROL MOTOR7P CONNECTOR Chocktor an open in th wi.6: 1. Disconnect mode control the motor 7P connector. 2. Turn the ignitionswitch ON (ll). 3. Measure the voltagebetween the No. l terminal and body ground.
3
BLK/YEL
Repairopon in the wire betwoon tho No. 17 luse and tho mode control motor. Checkthe mode control motor: 1. Turnthe ignitionswitchOFF. 2. Test the mode control motor . Gee page 22 41') Chock th mode cont.ol link.ge and doors: 1 . R e m o v et h e m o d e c o n t r o l motor (seepage22-41). 2. Check modecontrollinkage the and doors for smooth movement,
ls lhe modecontrolmotor OK?
Do the mode control linkage and doors move smoothly?
Replece the inod6 control motor.
Chockfor s shon in the wirs: 1 . R e m o v et h e h e a t e rc o n t r o l panel(seepage22'46). 2. Checkfor continuitybetween the No. 12,13,14,15,16and 19 terminalsol the heater control panel20Pconnector and body groundindividuaily.
2
1 1 12
l,/1,/
[E!r!
YEL/RED BLU
10
1 3 t a 1 5 1 6 1 7 r 8 1 3 20 BRN/WHT
ls therecontinuity? NO To page22-23
Repairany short in the wire(sl between the mode control rnotoa and the h6ater control Danel.
Ii
From page22-22 PANEL2OP HEATER CONTROL CONNECTOR
Chgckfor a short to power: Checkth6 same wires lor voltage.
' V VL g l
10 BRN/WHT
't1 1 2
r s l r r l r s l 1 7e1 8 r
:L/B LU
1 9 20
Ropairlhort to powor in the wiio betw6an tho mode comrol motor end thc hoat.r cont.ol pan.l. (ThisdamagF tha hator Gontrol pancl.l
8LU/BLX
Chackfor an opon in tha wiles: Checklor continuity between the followingterminalsoI the mode control motor 7P connectorand controlpanol20Pconthe heater nector. 7P. 20Pt N o .1 2- N o .3 No. '13 No. 4 N o .1 4 - N o . 5 N o .1 5- N o .6 No. t6 - No. 2 N o .1 9- N o .7
,/1,/l/
10 BRN/WHT
1 1 1 2 1 3 t 1 4 t 1 5 5 1 1 1 8 1 9 20 1
YEL/BLU BLU/BL t I K I GRi |/YELI I I YEL/REDI

t
YEL/ BLUI
q
BRN/WHT
;f;T;T;
YEL BLU/BLK tE GRN/I L YI:L/FED
MODECONTROIMOTOR7P CONNECTOR Wire sideol temaleterminals R.pair any opon in tho wilols) betwaen th6 modg cortrol motor and th. heatar control p.nsl.
Chock fo. loose wiret or pool connections at the heat6r control pancl 20P connector and tt the modo control motor 7P connoctor. lf tho connactions sre good, substitute a known-good hortcr control pan6l, and tech.ck. lf the symptom/indication goes awayt roplacotho original hcater @nttol p3nel.
22-23
Troubleshooting
Recirculation GontrolMotor
Rocirculation control door do6s noi chango botwen Fresh and Reci.culate.
Check No. 17{7.5A)tuse in the the under-dashuse/relay f box.
Roplace the fu36,and rechock.
REORCULATION CONTROL MOTOR ,rPCONNESTOR

Checkfor .n open in the wire: 1. Disconnect the recirculation control motor 4P connector. 2. Turn the ignitionswitchON (ll). 3. Measurethe voltage betlveen the No. l terminal and body ground.
q?
T--V-l
l 1 l, r l / l 1 l
(v)
I BI.IUYEL
Repairop6n in the wire bdtween the No. 17 fuse and thc recirculetion control motor.
Check the rocirculation control moior: 1. Turnthe ignitionswitchOFF. 2. Test the recirculation control motor (seepage22-42). Chock ths r.circulation control linkag. end doori 1. Remove recirculation the control motor (see page 22,42). 2. Checkthe recirculation control linkageand door for smooth
YES
To page22-25
Do the recirculation controllink age and door move smoothly?
Boprir the recirculrtion control linkag. or dooJ,
Ftom page22-24 PANEL8P CONNECTOR CONTROL HEATER
Checktol a short in the wit6: 1 . R e m o v et h e h e a t e rc o n t r o l panel{seepage22-46) 2. Checkfor continuitybetween of the No.2 andNo.3terminals con the heatercontrolpanel8P nectorand body ground individually. terminals Wire sideof female Reoaii short in tfte wir{s) birvn the redrc{lstion conttol motor and ihe hedter control panel.
Checkfor a shon to power: Check samewireslor voltage. the
ls thereany voltage?
Repairshort to power in the wite between the rocirculationcontrol motor and lh heator control panel. (This demsges the heater conlrolpanel.l
Chcktor an open in the wires: Checkfor continuity betweenthe ol following terminals the recircu' lation control motor 4P connector and the heatercontrol panel 8P 4P: 8P: N o . 2- N o . 4 No.3- No.2
GRN/REO ---1 T
' l F I2 1 3 i r l 5 1 6 I ;T;
Ropairopen in the wile(sl between the recirculalioncontrol motor and the heeter cortrol Pan|.
ffi
I V I 4 I
GRN/WHT MOTOR CONTROL RECIRCULATION ,lP CONNECTOR wire sideot femaleterminals
Check for loose wires or pool connections at the heatr control Danel8P connoctor and .t the rocirculation control motor 4P connector.lf lhe connec{ionsare good, substitule a known-good hester control oanel, and rochock. lI the symptom/indication goes away, .eplace the otiginal heater control pan|.
22-25
Troubleshooting
Radiator Fan
Radiator tan doos not run at sll (but condonserfsn runs with the A/C onl.
Check No.57 (20Alfuse in the rhe underhood fuse/relaybox, and t h e N o . 1 7 1 7 . 5A ) l u s e i n t h e 0nder-dash fuserelay box.
R.pl.c. th. fur|.l, .nd r.chack.
Remove the radiator fan r6lay, and test it {seepage22-45).
R.pllco tha r.diator frn rehy.
MDIATOR FAN RELAY SOCKET 4P Check the und.r-hood fus./r.l.y box: Measurethe voltage betweenthe No. 2 terminalol the .adiatortan relay 4P socketand body ground.
Chockthe radiatortan: Connect the No. 1 and No.2 tr minals of the radiatorfan relay 4P socket with a iumperwire.
Doesth6 radiator run? fan
fo page22-21
fo page22-28
Ftom page22-26
FAN REI-AY SOCKET 4P RADIATOR Ch6ckfor an open in the wire: 1. Disconnect jumperwire. the fan the 2. Disconnect radiator 2P 3. Checkfor continuitybeNveen o{the radiathe No. l terminal tor fan relay 4P socketand the N o . 2 t e r m i n a lo f t h e r a d i a ' tor fan 2P connector-
BLK/RED
FAN 2P CONNECTOR RADIATOR Wire sideof lemaleterminals
Repai. open in the wira between the radiatorfan .olay ,nd the radi' atorfan.
Checklor an open in the wi.e: Checkfor continuity betweenthe fan No. 1 terminaloI the radiator 2P connector and body ground.
ls therecontinuity?
Check lor an open in the wir. bturosn the radi.tor fan and body ground. lf ihe wire b OK, check fol poor ground .t G2()l.
Replace the radiator tan motor.
(cont'd)
Troubleshooting
Radiator Fan (cont'dl
From page 22-26
RADIATOR FAN RELAY SOCKET 4P Chockfor an open in the wire: '1. Disconnect jurnper the wire. 2. Turn the ignitionswitchON (ll). 3. lleasure the voltage between the No.4terrninal the radiaof t o r f a n r e l a y 4 P s o c k e ta n d bodyground. 1 2
a BLK/YEL
Rpairopen in th6 wire botwoon the No. 17 fuso and the radiatol fan .elsy.
Rep.ir open in the GRN wire botwen lhe radiator tan relay and the PCM/ECM.
22-28
Fan Condenser
lan Condenser does not run at all lbut radiator fan runs with the A/C on).
Check the No. 56 (20A) fuse in the box, and the under hoodfuse/relay No. 17 {7.5A) fuse in the underdashfuse/relay box.
Replace the luse(s),and .echeck.
fan Remove the condenser relay, and test it (seepage22-45).
Replace the condenserfan rlay.
FAN RELAY4P SOCKET CONDENSER
Checkthe under-hoodluso/relay box: Measurethe voltage betweenthe No.2terminal the condenserfan of relay4Psocketand body ground.
Checkthe condensff fan: Connectthe No. 1 and No. 2 ter minals of the condenserlan rclay with a jumperwire. 4Psocket
fan Doesthe condenser run?
page22-30
To page22 31
(cont'd)
22-29
Troubleshooting
Condenser {cont'd) Fan
Chockfor an open in the wire: '1. Disconnect the iumperwire. 2. Disconnect condenser the fan 2P connector. 3. Checkfor continuitybetween the No. 1 terminalof the con, denserfan relay 4P socketand the No. 2 terminalof the condenser 2P connector. fan
CONDENSER FAN RELAY4P SOCKET
r---------t wHT
lr_f__l
1
fT;.]
Ropairopen in the wire betwoen th condenserfan rslay and the condensertan.
2 |
/Or \j/
| I
I
ls therecontinuity?
CONDENSER FAN 2P CONNECTOR Wire sideol temaletorminals Chechtor an open in the wire: Check continuity for between the No. I terminal of the condenser fan 2P connector and body ground.
-r+-,. 1 2
TBtK
Check for an open in thg wire between the condenser fan and body ground. lf the wiro is OK. checktor poor ground .t G202.
@ !
Replace condenser motor. tho tan
22-30
Ftorn page 22-29 FAN RELAY4P SOCKET CONDENSER
Chockfor an open in the wiro: 1. Disconnect iumperwire. the 2. Turn the ignitionswitchON (ll). 3. Measurethe voltage between the No. 4 terminaloI the condenserfan relay 4P socketand body ground.
Repairopcn in tho wire betwoon the No. 17 tuse and the condensea relay, fan
R e p a i ro p e n i n t h e G R N w i r o b6tw6en the cond.nser lan relay and rhe PcM/EcM,
22-31
Radiator Fan Switch

Both tans (radiator and condenser) do not run fo. enginecooling,but they both run with the A/C on.
Checklor rn open in the wire: 1 . D i s c o n n e ctth e r a d i a t o rf a n switch2P connector. 2. Turnthe ignition switch lll). ON 3, Measurethe voltage betlveen the No.2 terminaand body l ground.
RADIATOB FAN SWITCH CONNECTOR 2P
'.r
GRN
Repairopen in the wire between the radiator tan relay, the condensei lan .elay and the radiaior tan swhch.
Chockfor an open in the wire: 1. Turn the ignitionswitchOFF. 2. Checkfor continuitybetween the No. 1 terminalof the radiator fan switch 2P connector and body ground.
ls therecontinuity?
Check for an open in the wire between the .adialor fan switch and body glound. I ths wire is OF; choc*tor poor g.ound at G'101.
ls the coolingsystemOK?
Replscethe radialor fan switch.
Both Fans
Checkthe No. 17 (7.5 A) tuse in the under-dash fuse/relay box.
Reolace tuse. and recheck. the
RADIATOR FAN RELAY SOCKET 'P
Checkfor an opn in the wire: 1. Remove radiatorfan relay. the 2. TLrrn ignition the switch (ll). ON 3. Measure the voltagebetween the No.4 terminaloftheradia t o r f a n r e l a y 4 P s o c k e ta n d bodyground.
2 1
BLK/YEL
Repairopen in the wire between lhe No. 17 luse and the radiator tan relay. '9? model: Checkfor an open in the wire: 1. Make sure the A/C switch is OFF. 2. Using a *Backprobe Set {T/N 0 7 S A Z- 0 0 1 0 0 0 A )m e a s u r e , the voltagebetweenthe No. 27 I20l terminalol the PCM/ECM connectorA (32P)and body groundwith the PCM/ECM connectors connected. '98- 00 models [ ]:
1
PCMCONNECTOR I32PI A 2
4 6
10 22
12
t5 t6 17 18 r9 GRN
23
11 21
Wire sideoI female terminals
PCM/ECMCONNECTOR (32PI A '98 - 0Omod6ls:
Repairopen in the wire btween the.adiator fan ralav, the condenser tan rolay and the PCM/ ECM.
Checktor loosewires or poor connodions at the PCM/ECM connoctor A (32P1. the connections lf arc good, substitute a known-good PCM/ECM,and recheck. It the symptom/indicalion goes away, r.plrce the originalPCM/ECM.
* How to use the Backprobe Sets patchcords, Connect backprobe the adapters the stacking to and connect cordsto a multi the meter.Usingthe wire insulation a guide for the contoured of the backprobe as tip adapter, gentlyslidethe tip into the connector from the wire side until it comesin contact with the ter minalend ofthe ware {seesectionl1).
22-33
Troubleshooting
Checkthe No. 56 (20 A) fuse in the box, and the underhood fuse/relay No. 17 (7.5A) fuse in the under box. dashluso/rglay
Replace the fuso(sl,and r6check.
R e m o v e h e c o m p r e s s oc l u t c h t r relay,and test it (seepage 22 45).
Checkthe under-hoodfuse/relay
DOX:
Measurethe voltage betweenthe No. 2 terminalof the compressor clutch relay 4P socketand body ground,
Chacklhe complessorclutch: the Connect No. 1 and No. 2 terminalsofthe comoressor clutchrelav 4Psocketwith a jumper wire.
Doesthe comprossor clutchclick?
To page22-35
To page22-36
22-34
Ftom page 22-34 COMPRESSOR CLUTCHRELAY ilP SOCKET Checkfor an open in the wire: 1. Disconnect jumperwire. the 2 . D i s c o n n e ctth e c o m p r e s s o r clutch 1Pconnoctor. 3. Checkfor continuity between the No. 1 terminalof the compressorclutch relay 4P socket and the terminalol the compressor clutch1Pconnector.
-_-l
RED I
tr-=--l
I.TT
@
i
I
I
$"f
1
I
\
__---.1
1___J.RED
COMPRESSOR CLUYCH CONNECTOR lP Wire sideof lemaleterminals Repairopen in the wire between the comp.e3sor clutch relay and the comprsssorclutch.
Inspect tha compreslor clutch clearanco, the thormal protector, and ths comDrg$or clutch tiold coil lsee page 22-65).
.l-
(cont'd)
Troubleshooting
(cont'dl Compressor
Frcm page22-34
Ch6ckfor an open in the wire: 1. Disconnect jumperwire. the switch (ll). ON 2. Turnthe ignition 3, Measurethe voltage between the No. 4 terminalot the com' pressor clutchrelay4P socket and body ground.
COMPRESSOR CLUTCH RELAY 4P SOCKET
2
4
3 BLK/YEL
Repairop.n in the wire between the No. l7 fu3e and the compressor clutch ielay.
Checkfor an opon in the wire: 1. Turn the ignitionswitch OFF, then reinstall the compressor clutchrelay. switch is 2. Make sure the A"/C O F F ,t h e n t u r n t h e i g n i t i o n switchON (ll). Set (T/N 3. Using a *Backprobe measure 07SAZ - 001000A), the voltage betweenthe No. 17 terminal ol the PCM/ECM connectorA (32P)and body g r o u n d w i t h t h e P CM / E C M connected, connectors
A PCMCONNECTOB I32P)
'97 model:
2 15 1 6 1 7
12
6 '18 1 S
10
22
23
11 21
BLK/RED
A PCM/ECMCONNECTOR {32P} 38 - 00 models:
terminals Wire sideof {em6le Repairopen in lhe wire betwoon the compressor clutch r6lay and the PCM/ECM.
Check tor loose wires or Door connections at the PCM,/ECM lf connecto. A {32P1. the connections are good, sub3titute a k n o w n - g o o d P C M / E C M ,a n d rocheck. lf the symptom/indication goas away, replacthe original PCM/ECM.
* How to use the BackDrobe Sets patchcords,and connect cordsto a multithe adapters the stacking to Connect backprobe the tip adapter, meter.Usingthe wire insulation a guide for the contoured ot the backprobe as gentlyslidethe tip into the connector with the teF trom the wire sideuntil it comesin contact minalendo{the wire {seesectionl1).
22-36
A/C System
A/C aystem does not come on {both fans and comDrossor). A/C PRESSURE SWITCH2P CONNECTOR Ch6cklor .n open in the wire: 1. Disconnect the A,/Cpressure switch2P connector. 2. Turnthe ignition switch (ll). ON 3. Measure the voltagebetween t h e N o . 2 t e r m i n a la n d b o d y ground.
ls thereapprox. volts? 5
fo page 22-38 C PCMCONNECTOR (31PI
check tho PcM/EcM: U s i n g a * B a c k p r o b eS e t ( T / N 07SAZ 0010004). measurethe v o l t a g eb e t w e e n h e N o . 5 t 2 7 l t terminal the PCM/ECM of connec, t o r C ( 3 1 P )[ A 1 3 2 P )a n d b o d y l ground with the PCM/ECM connectorsconnected, '98 - 00 models I l:
'97 modol:
PCM/ECMCONNECTOR I32P' A 38 - 00 modeb:
Wire sideof femaleterminals Rop.ir open in th6 wire botweon the A/C Dr*sure switch and the PCM/ECM.
ls thereapprox.5volts?
Check tor loo3e wires or Door connections at the PCM/ECM connoctorC l3lPl lA (32Pll.It the connections arg good, 3ubdtitut a known-good PCM/ECM,and recheck. ll the 3ymptom/indication go.. eway, rplaco thG original PCM/ECM, '98 -00 models [ ]:
* How to use the Backprobe Sets patchcords,and connect cordsto a multiConnect backprobe the adapters the stacking to the meter.Usingthe wire insulation a guide for the contoured ol the backprobe as tip adapter, gentlyslidethe tip into the connector from the wire side until it comesin contact with the ter. minalondolthe wire (seesection11).
(cont'd)
22-37
Troubleshooting
A/G System {cont'd)
Frompage22-37
Checkth A/C pressureswitch: 1. Turnthe ignitionswitchOFF. 2. Checklor continuitybgtween t h e N o .1 a n dN o . 2 t e r m i n a l s ofthe A,/Cpressureswitch.
SWITCH A/C PRESSURE
Check properAy'C for systempressure.
Roplece A/C prssureswitch. tha
PANEL2OP CONNECTOR HEATER CONTROL Chocklor an opgn in thg wire: 1. Feconnectthe A/C pressure switch 2P connector, 2 . R e m o v et h e h e a t e rc o n t r o l panel(seepage22-46). 3. Turn the ignitionswitch ON llli. 4. Measurethe voltage between t h e N o . 1 0 t e r m i n a lo f t h e heatercontrolpanel20P connectorand body ground. Repairopen in the wir. botwcen the A/C pres3urswitch and the heater control oanel.
ls there approx. 5 volts?
Check lor loos6 wiras or pool connectionsat the heater control Danel 20P connoctor and at the A/C pr.ssule switch 2P connsctor. lf the connectionsere good, substitute a known-good heatar co trol pangl, end recheck.lf the symptom/indication goes away, replacethe original heaterconlrol panel.
22-38'
Both heater and A/C do not work.
Check No. 17(7.5 the A)fusein the under-dash fuse/relay box, and the No. 47 (7.5A) fuse in the underhoodluse/relay box.
nophcc ih. fur.l.l, .nd r.check.
HEATER CONTROL PANEL8P CONNECTOR
Checktor rn open in the wiro: 1 . R e m o v et h e h e a t e rc o n t r o l panellseepage22 46). 2. Turnthe ignition switch (ll). ON 3. Measurethe voltage between the No. 1 terminal of the heatercontrol panel 8P connectorand body ground.
Wiresideot femaleterminals
ls thero batteryvoltage?
R.pair opan in lha wlra batw.cn the No. 1? fuaa and tha h.ltcr control panal.
PANEL2OP CONNECTOR HEATER CONTROL
Chgckfor an opan in th wirg: 1. Turnthe ignitionswitchOFF. 2. Measurethe voltage between t h e N o . l l t e r m i n a lo f t h o heatercontrolpanel20Pconnoctorand body ground.
A,/1,/
10
1 t 1 2 1 3 1 a 1 5 1 5 1 7 1 8 1 9 20 WHT/BLU
Repsil opon in tha wi.a batwcan th. No. 47 tur. and tho hoitor contlol panol.
ls there battery voltags?
Checkfor an opon in the wire: Ch6cklor continuity betwoen the No. 7 terminalof the heatercontrol panel8P connector and body ground. Check for an opon in tho wira b6{woon tho hoatar control p.nol and body ground. It the wir. i3 OK, chsck for poor ground rt GlOl lnd Glo2. Check for loose wire3 or oooa connection3at the haater control prnol 8P and 20P connoctors. It thc conncction3are good, substituta a known-good hater control prnol, and rechecft.lf the symptom/indic.lion go.3 ewry, repl.cg the original ha.ter contlol oancl.
3
8
BLK
Troubleshooting
HeaterControl PanelInput/OutputSignals
HEATER CONTROL PANELCONNECTORS 2OP CONNECTOR
8P CONNECTOR
8P CONNECTOR Cavity
'l
lrvire colol L BLK/TE
Signal
Cavity INPUT
Wire colol
Signal
I G 2( P O W E R )
RED
RED/BLK 1 8 BLK
ERIGHTDASHLIGHTS NESS CONTROLLER LIGHT COMBINATION (ViaNo. 30 (7.5A) SWITCH fuse) GROUND
CUTPUT
INPUT
GRN/RED RECIRCULATE GRN/VVHT F R E S H
INPUT INPUT
OUTPUT
INPUT
BLUI/EL
20PCONNECTOR Cavity
1
WINDOW REAR RELAY DEFOGGER
CUTPUT
FEEDBACK BLU/BLK BLOWER
Wire color GRY GRN
Signal +5V AIR MIX POTENTIAL OUTPUT
Cavity
'll
Wire color
Signal INPUT INPUT INPUT INPUT INPUT INPUT OUTPUI OUTPUI INPUT
WHT/BLU BACKPU (POWER)
TEMPERA. EVAPORATOR OUTPUT TURE ENSOR S
12 13 14
I C
YEL
MODEHEAT/DEF
BLU/BLK MODEHEAT GRN/YEL MODEHEAT/VENT V YEURED M O D E E N T
6 7 8
PNI(BLK
AIR MIX POTENTIAL MOTOR HIGH BLOWER
INPUT
to
YEUBLU MODEDEF RED/BLU A I RM I X C O O L L RE D/VE

AIR MIX HOT
17
ORNrur'HT RELAY
BRN
INPUT INPUT INPUT
18 '19 20
SENSOR ROUND G
MOTOR GROUND BRNA/VHT IVIODE
10
PRESSURE SWITCH BLU,ryVHTA"/C
TRANSISTOR BASE CUTPUT T GRN/BLKPOWER
22-40
Mode ControlMotor
Replacement
1. Disconnect 7P connector the from the mode control motor. Removethe rod from the arm of the mode control motor, Remove the self-tapping screws and the mode controlmotor.
7P CONNECTOR
Test
1 . Disconnect 7P connector the from the mode control motor. Connectbattery power to the No. 1 terminal, and ground the No. 7 terminal.To avoid damagingthe mode control motor, do not reverse power and grouno.
MODECONTROL MOTOR
MOTOR MODECONTROL
2.
Installin the reveGeorderof removal. After installation, make sure the mode control motor runs smoothlv.
U s i n g a j u m p e r w i r e . c o n n e c tt h e N o . 7 t e r m i n a l i n d i v i d u a l lty t h e N o , 2 , 3 , 4 , 5 a n d 6 t e r m i n a l sn o i that order. Eachtime the connectionis made. the mode controlmotor shouldrun smoothlyand stop. lf the mode control motor does not run when jumping the first terminal,jump that terminalagain after j u m p i n g t h e o t h e r t e r m i n a l s .T h e m o d e c o n t r o l motor is OK it it runs when jumping the first terminal again. lf the mode control motor does not run in step 3, removeit, then checkthe mode control linkageand doorsfor smoothmovement. they move smoothly, lf reDlace mode control motor. the
RecirculationControl Motor
Replacement
1. Oisconnect 4P connectorand the wire harness the clio from the recirculation control motor. Remove the self-tapping screwsand the recirculation control motor,
Test
the from the recirculation 1 . Disconnect 4P connector controlmotor. Connectbattery power to the No. 1 terminal, and groundthe No. 2 and No. 4 terminals; the recirculation control motor should run smoothly.To avoid damaging the recirculationcontrol motor. do not power and ground. reverse
{P CONNECTOR
MOTOR RECIRCULANON CONTROL
lnstall in the reverseorder of removal.After installacontrolmotor runs tion, make sure the recirculation smoothlv.
from ground; Disconnect No. 2 or No. 4 terminals the control motor shouldstop at Fresh the recirculation Don't cvcle the recirculation control or Recirculate. motor for a long time.
4.
lf the recirculationcontrol motor does not run in step 2, remove it, then checkthe recirculationcontrol linkage and door for smooth movement.lf they move control motor. smoothly, replacethe recirculation
22-42
Air Mix GontrolMotor

Replacement
1. Disconnect 5P connectorfrom the air mix conthe trol motor. Remove the self-tapping screws, the air mix controlmotor and the flangecollar.
5P CONNECTOR
Test
1.
Disconnect 5P connectorfrom the air mix conthe trol motor. Connect battery power to the No. I terminal of the air mix control moto., and ground the No, 5 terminal; the air mix control moto. should run, and stop at MAX HOT. lf it doesn't, reversethe connections; the air mix control motor should run, and stoo at MAX COOL. lf the air mix controlmotor does not run, remove i t , t h e n c h e c kt h e a i r m i x c o n t r o l l i n k a g ea n d doors for smooth movement. lf they move smoothly,replacethe air mix control motor.
AIR MIX CONTROL MOTOR
6
AIR MIX CONTROL MOTOR
A
Measure resistance the betweenthe No. 2 and No. 3 terminals. shouldbe approximately kOt 20%. lt 6
4.
Installin the reverse orderof removal. After installation. makesure the air mix control motor runs smoothlv.
Measure resistance the between the No. 2 and No, 4 terminals, shouldbe approximately kO:t 20%at lt 4.8 MAX HOT and approximately '1.2kO t 20% at lilAx
cooL.
22-43
Evaporator Temperature Sensor

Test
Dip the sensorin ice water, and measure the resistance with a digital multimeter.Then pour hot water on the sensor, and check changein resistance. lor Compare the resistancereading between the No. | 8nd No. 2 terminals of the evaporatortemperaturesensor with the specifications shown in the following graph; resistance shouldbe within the specifications.
Power Transistor
Test
1 . Disconnect 3P connectorfrom the oower tranthe st$or. release locktab on the No. 2 terminalin the Carefully the 3P connector,then removethe terminal and insulate it from body ground.
1 2 V1 . 2 - 3 . 1 W EVAPOBATOR TEMPERATURE SENSOB

No. 2 ILT GRN/BLK)
Terminal sideol maleterminals
RESISTANCE
ko
t0
50 10
68 20
86.F 30'c
No.I IBLU/BLK)
Connecta 1.2- 3.4 W bulb betweenthe No, 1 and the No,2 cavityon the 3P connectol Reconnect 3Pconnector the powertransistor. the to Turn the ignitionswitch ON (ll). and checkthat the blowermotor runs. a lf the blower motor runs at half soeed the oower transistor OK, replace heatercontrolpanel. is the . lf ths blower motor does not run at half soeed, reDlaca the Dowertransistor.
22-44
Relays
Test
Thereshouldbe continuitybetween the No. 1 and No.3 terminalswhen power and ground are connected the to No. 2 and No. 4 terminals, and thereshouldbe no continuity when power is disconnected. Thereshould be continuitybetween the No. 1 and No. 2 terminalswhen power and ground are connected the to No. 3 and No. 4 terminals, and there shouldbe no continuitv when oower is disconnected.
,I
In
t) P
.I
3 o Blowermotor relay
tI r I
a Rsdiator fan relay
fan Condenser relay

a Compressor clutchrelay
Blowermotor high relay
,2-4.._.
F)'"
22-45
HeaterControlPanel
Replacement
'1. Removethe center panel togetherwith the heater 20). controlpaneland the audio unit (seesection Remove the self-tapping screwsand the heatercontrol panelfrom the centerpanel.
Blower Unit
Replacement
1 . Bemovethe evaporator (see page 22-48), Disconnectthe connectors from the blower motor, the blower motor high relay, the power transistor and the recirculationcontrol motor. Remove the c w i r e h a r n e s sc l i o f r o m t h e r e c i r c u l a t i o n o n t r o l from the clamp the motor,and release wire harness the mountingbolts,the on the blower unit. Remove mountingnut and the blower unit.
6x1.0mm 9.8 N.m (r,0 kgf.m, 7.2 lbl.ftl
6x1.0mm kgf.m,7.2lbtftl 9.EN.m 11.0 PANEL CENTER
lnstall in the reverseorder of removal. Make sure that there is no air leakage. 3. lnstallin the reverse orderof removal.
22-46
Overhaul
Notetheseitemswhen overhauling blower unit. the . The recirculation contfol motor. the power transistor,the blower motor high relay, and the blower motor can be replaced without removingthe blowerunit. . Betorereassembly, makesurethattherecirculation controldoorand linkage move smoothlywithout binding. o After reassembly, makesurethe recirculation controlmotor runs smoothly(sepage22-42). o Makesurethat there is no air leakage.
RECIBCULATION CONTBOL MOTOR page22-42 Replacement.
m
POWEBTMNSISTOR Test. page 22'44
BLOWER
Tost, page 22-45
22-47
Evaporator
Replacement
1 . Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage22-59). Removethe battery. the Removeeach bolt, then disconnect suctionand Plug or cap the receiverlinesfrom the evaporator. after disconnecting them to avoid linesimmediately moistureand dust contamination, 6. Disconnect connector the from the evaoorator temfrom oerature sensor.and removethe wire harness the evaporator.Removethe self-tappingscrews,the mounting bolt and the mounting nut. Disconnect the drain hose,then removethe evaporator.
5xl,0mm 9.8 N.m {1.0kgf.m, 7.2 lbf.ftl
I I
LINE RECEIVER
-l: "
.. \
EVAPORATOR
6x1.0mm 9.8N'm(1.0kgfm, 7.2 tbl.ttl glove box (seesection20). Remove the Remove the self-tapping screwand the passenger's dashboardlower cover,then removethe bolts and the glove box frametogetherwith the kneebolster. KNEE
6x1.0mm 9.8 N.m (1.0kgtm,7.2lbf.ftl
7.
Installin the reverseorder of removal,and note of theseitems. lf you're installinga new evaporator, add refrig(seepage22-541. erantoil (SP.10) Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l before installingthem. Be su.e to use the right (R-134alto avoid leakage. O-ringsfor HFC-134a a Apply sealant the grommets. to a Makesurethat there is no air Ieakage. a Charge the system (see page 22-6'll, and test its performance(see page 22-56]-, .
GLOVEBOX FRAME
22-44
} -
Overhaul
1. Remove the filter lid. then pull out the A/C filter assembly. Pull out the evaporatortemperaturesensor from fins. the evaporator s R e m o v et h e s e l f - t a p p i n g c r e w sa n d t h e c l a m p s from the housings.
4.
6.
in the Reassemble evaporator the reverseorder of Makenoteof theseitems. disassembly. . with new onesat eachfitting, the Replace O-rings and apply a thin coat of refrigerantoil before them. Be sure to use the right O-rings installing (R-134a) avoid leakage. to for HFC-'134a . Installthe expansionvalve capillary tube with the capillarytube in contactwith the outlet line and wrap it with electricaltape. directly, . Reinstallthe evaporatortemperaturesensor to its originallocation. . Makesurethat there is no air leakage.
Carefullyseparatethe housings,then remove the evaporator. lf necessary,remove the expansion valve When valve,use a secloosening nuts of the expansion the ond wrench to hold the expansionvalve or the evapothey can be damaged. rator line.Otherwise,
TAPE ELECTRICAL Replace. Makesure there is no foreign matter stuck between tube and outletline. the capillary
CAPILLARY TUAE
;
EXPANSION VALVE
TEMPERATURE SENSOR lest, page 22-41
,m
FILTER LID
\!{
HOUSING I-OWER ASSEMBLY A/C FILTER
22-49
A/C Filter
Replacement
1.
HeaterUnit
Replacement
SRS componentsare located in this area. Reviewthe precautions, SRS componentlocations, and procedures in the SRSsection{24)beforeperforming repairsor ser-
Remove glove box (seesection20). the Removethe glove box frame {see page 22-4A). Release the wire harnessfrom the clamps on the evaporator. Removethe filter lid, then pull out the ,VCfilter assembly from the evaporator housing.
1. 2.
Disconnect negative the cablefrom the battery. Fromunderthe hood,openthe cableclamp, then disconnectthe heatervalve cable from the heatervalve arm. Turn the heatervalve arm to the fullv ooened oosition shown. as
ASSEMELY A/C FILTER
HEATERVALVE ARM
R e m o v et h e A / C f i l t e r f r o m t h e f i l t e r h o u s i n g . Replace Ay'C the filter according the maintenance to schedule the owner'smanual. in HEATER VALVE CABLE
When the engine is cool, drain the engine coolant from the radiator(seesection10). Do not remove the rldiator cap when @ the engine is hot; the engine coolant is under pressure and could sevo.ely scald you.
Installin the reverseorder of removal.Make sure that there is no air leakage.
22-50
4.
Disconnect the heater hosesfrom the heater unit. Enginecoolantwill run out when the hosesare disconnected; drain in into a cleandrip pan. CAUTION:Enginocoolantwill damagep8int. Ouickly rinse any spilld engine coolant Itom painted surfaces.
(seesection20). the Remove dashboard 7.

ll.
(seepage22-48). the Remove evaporator from the mode control the connectors Disconnect mix control motor, and removethe motor and the air from the heater clips and wire harness wire harness unit. Remove the clip from the heater duct, then unit the mountingnutsand the heater remove
6x1.0mm 9,8N.m (1.0kgt m,7.2lblft)
HOSE HEATER IOUTLET SIDE)
CLAMPS
HEATER UNIT
Remove the mounting nut from the heater unit. Takecare not to damageor bend the fuel lines,the brake lines.etc.
q
orderof removal.Make note of Installin the reverse the followingitems.

a Apply sealant the grommets. to a Do not interchange the inlet and outlet heater
Makesurethat the clampsare secure. hoses. Refill the cooling system with engine coolant {seesection10). a Adiustthe heater valvecable(seepage22-53). a Makesurethat there is no air leakage.
lbtftl 13 N.m 11.3 kg{.m,9.4
22-51
HeaterUnit
Overhaul
1. Removethe self-tappingscrews and the heater core cover. Pullout the grommetfrom the heatercore pipes. Remove self-tapping the screwand the pipe clamp. Pull out the heate.core. Be carefulnot to bend the inletand outlet pipesduring heatercore removal. Reassemble heaterunit in the reverseorder of the disassemblv.
HEATER CORECOVER
HEATERCORE
22-52
Control Temperature
Adjustment
l. From under the hood, open the cable clamp, then disconnect the heatervalve cable from the heater vatvearm.
HEATERVALVE ARM
5.
From underthe hood.turn the heatervalve arm to t h e f u l l v c l o s e d p o s i t i o na s s h o w n , a n d h o l d i t . Attach the heater valve cable to the heater valve arm, and gently pull on the heatervalvecablehousthen installthe heate.valve ing to takeup any slack, cablehousinginto the cableclamp.
HEATERVALVE ARM
VALVECABLE HEATER
the heatervalve From under the dash, disconnect cableclamp.and disconnect cablehousingfrom the the heatervalvecablefrom the air mix contlol arm
VALVECABLE HEATER
controldial on MAX COOLwith Setthe temperature the ignitionswitchON (ll). Attachthe heatervalve cableto the air mix control arm as shown above. Hold the end of the heater valvecablehousingagainstthe stop,then snap the heater valvecablehousinginto the cableclamp.
22-53
Tips and Precautions A/C Service
(R-134a) refrigerant oil*, which are not The air conditioner systemusesHFC-'134a and polyalkyleneglycol {PAG)refrigerant (R-12) refrigerant or compatible with CFC-12 and mineraloil. Do not use R-12refrigerant mineraloil in this system,and do not attempt to use R-12servicingequipmenudamageto the air conditionersystem or your servicingequipmentwill resutr. *KEIHIN SP-10: . P/N 38897 Pl3 - A01AH:120m{ (4 fl.oz,il.2 lmp.oz) . P/N 38899 Pl3 - A01:40 mf 11113tl.oz,1.4 lmp.oz) Use only serviceequipmentthat is U.L.-listed and is certified meet the requirements SAE J2210to removeR-134a to of from the air conditioner system, CAUTION: Exposureto air conditioner refrigerant and lubricant vapor or misl can irritats eyes, nose and throat. Avoid breathing the air conditioner refrigerant and lubricantvaporor mist, lf accidental systemdischarge occurs, ventilate work areabeforeresumingservice. R 134aservice equipment vehicleair conditioner or systems shouldnot be pressure testedor leaktestedwith compressed air. Some mixtures of air and R-13,1a have been shown to be combustible at elevatd pressuresand can result E@ in fire or explosion causing iniury or property damage. Never use complessed air to pressuretest R-l3,[a service equipment or vehicle air conditioner systems. Additionalhealthand safetyinformation may be obtainedfrom the refrigerant and lubricant manufacturers. 1. 2. 3. 4. 5. 6. parts. Alwaysdisconnect negative the cablefrom the battery wheneverreplacing conditioning air When disconnecting lines,plug or cap the fittings immediately; Keepmoistureand dust out of the system. any don't removethe capsor plugs untiljust beforeyou reconnect eachline. Beforeconnecting any hoseor line.applya few dropsof refrigerant oilto the O-ring, Whentightening loosening fitting,usea secondwrenchto supportthe matching or a fitting. When discharging system,use a R l34a refrigerant the recovery/recycling/charging station;don't releaserefrigerant into the atmosphere. Add refrigerant afterreplacing followingparts. oil the Notetheseitemswhen handlingrefrigerant oil: o To avoidcontamination, not returnthe oil to the container do oncedispensed, and nevermix it with other refrigera n to i l s . . lmmediately after usingthe oil, replace cap on the container, the and sealit to avoid moistureabsorption. . Do not spill the refrigerant on the vehicle; may damagethe painu if the refrigerant contacts paint,wash oil it oil the it off immediately. Condenser . 25 ml (5/6 tl.oz, 0.9 lmp.oz) Evaporator.,................................40 m/ 11113ll.oz,l.4lmp.ozl Lineor hose........... 10 ml (1/3fl.oz,0.4 lmp.oz) Receiver/Dryer....... 10 ml (1/3fl.oz,0.4 lmp.oz) Leakage repair............................ (5/6ll.oz,0.9 lmp.oz) 25 m/ Compressor.......,..., For compressor replacement,subtract the volumg ol oil drained from the removed compressorfrom 130 m{ (4 113tl.oz, 1,6lmp.ozl, and drain the calculatsd volume of oif from the now comprossor:130 ml (,1113tl,oz, 1.6lmp'ozl - Volume of removed compressor= Volume to drain from new compressor. NOTE:Evenif no oil is drainedtrom the removedcompressor, don't drain more than 5 0 m t 1 12 1 3 l l , o z , 1 . m p . o zf)r o m t h e n e w c o m p r e s s o r . l8
r.s rso r rr:0.o., r-o.o.t m
22-54
A/C SystemTorqueSpecifications
EVAPORATOR
LINE SUCTION
HOSE SUCTION
LINE A RECEIVER LINE B RECEIVEN
RECEIVER/ORYER
O Dischargehos to the compressor{6 x 1.0 mml
kgrf.m.7.2lbtftl ....9.8 N.m 11.0
@ Condenserline to the condenser(6 x 1.0 mm) 9.8 N.m {1.0 kgf.m, 7.2 lbt.ft) @ Condensorline to the receiver/dryer{6 x 1.0 mm) ........ 9.8 (6 x 1.0 mm) .......... ................... N.m {1.0kgf.m.7.2lbf.ft} O Receiverline A to the receivor/dryer Receiverline B to th receive. line A @ O Rceivertine C to the receivorline B 9.8 N'm (1.0kgf.m,7.2lbtftl @ Recoiverline C to the evaporator (6 x 1'0 mml O Sustion line to the evaporatot 16x 1.0 mml ......31 N.m (3.2kgl.m, 23 lbf.ft) @ Sustion line to the suction hose .....'...'9 8 N'm (1 0 kgt'm, 7'2 lbf'ftI @ Sucion hose to the qompressor(6 x 1.0 mm) .. 24 N.m l2.il kgf'm, 17 lbf'ft} @ Compressorto the compressorbracket {8 x 1.25mm) . il,t ......... N'm (4.5kgt'm, 33 lbf'ft) (10 x 1.25mm) ................ @ Compressorbracket to the cylindsr block ,14N.m (/r.5 kgf'm,33 lbf'ft) ..................... pulley bracket to the compressorbracket (10 x 1.25mm) @ ldler 24 ......................... N'm (2./tkgt'm, 17 lbf'ft) Lock nut of the sdiusting boh to the compressorbracket @ @|d|erpu||eytotheid|orpu||eybracket.....'..........................'.....'.....'........'....44N.m(4.5kg' 59 N'm bracketto the left front mount (12x 1.25mml ................... ............................ (6.0kgt'm,/l:| lbf'ft1 @ compressor
22-55
A/G System Service

Performance Test
The performance test will helDdetermineif the air conditionersystemis operating within specifications. Useonly serviceequipment that is U.L.-listed is cerand tified to meet the requirements SAEJ2210to remove of (R-134a) HFC-134a from the air conditioner svstem. CAUTION: Exposure to air condiiioner rtrigerant and lubricant vapor or mist can irritate yes, nose and throat. Avoid bre8thing the air conditioner retrige.ant and lubricant vapor or mist, lf accidentalsystem dischargeoccurs.ventilate work areabeforeresumingservice. R-134a serviceequipmento. vehicleair conditioner systems should not be pressure tested or leak tested with comDressed air. some mixturs ol air and R-134ahave becn @ shown to be combuslible at olsvated pressuresand can result in lire or explosion causing iniury or property damage. Never use compressed air to prgssure test R13i[a service equipment or vehicle air conditioner sys. tems. Additional health and safety information may be obtained from the refrigerant lubricant and manufacturers. 1 . C o n n e c ta R - 1 3 4 ar e f r i g e r a n tr e c o v e r / r e c y c l i n g / chargingstationto the vehicle, shown.following as instructions, the equipmentmanufacturer's 2. Insen a thermometerin the centerair vent. Determine the relative humidity and airtemperature. Testconditions: . Avoid directsunlight. o Openhood. . open front doors. . Set the temperature control dial on MAX COOL, the mode controldial on VENTand the reci.culation controlswitchon RECIRCULATE. . Turn the A,/Cswitch on and the fan switch on MAX. . Runthe engineat 1,500 rpm. . No driveror passengers vehicle in After running the air conditioningfor 10 minutes under the above test conditions,read the deliverv temperature from the thermometer the dashvent in and the high and low systempressure from the Ay'C gauges. Recovory/Recycling/charging station
LOW.PRESSURE SIDE
22-56
5.
the To comDlete charts: alongthe verticalline' temperature . Markthe delivery alongthe bottom line' . Markthe intaketemperature {ambientair temperature) to the humidity' . Drawa line straightup from the air temperature . Marka point 10%aboveand 10%belowthe humiditylevel' temperature' the line across delivery a Fromeachpoint,draw a horizontal the shouldfall between two lines' temperature . The deliverv pressure test in the sameway' test and high-side . Complete low-sidepressure the the the line may indicate needfor furtherinspection outside . Anv measurements
kPa {kst/cm') Ipsil 29r,0 t30t l,a0l 2500 (251 t3601 2000 l l20l I t28ol | I 1s00'l {15} |
HUMIDITY LEVEI-
DELIVERY r21or I PRESSURE
kp. {ksf/cmz}"F lcsil Pcl ,l0oI 85 -l (4} | (301
80v.
80vo
980 j rlol
t57lI
r14ol r13l I -lL

200 t2) | 100
3oo-.J {31 I
I
"r1 I l25lI
l
I
HUMIOITY LEVEL
I
68 J (2otI
HUMIDITY LEVEL
r28r I
I -.1
I
ss l
lli' TNTAKE I
PRESSURE ]
(15r I
| 50 -l
DELIVERY TEMPEBATURE .t
,to, I
rsl -ll
I :.] _
fl
6g t2o)
j7 l25l
* (30)
95 (351
104 (ro)
fct
INTAKETEMPERATURE
22-57
A/C System Service

Pressure TestChart
NOTE: PerformanceTest is on page 22-56.
Test results (high) Discharge pressure 6bnormally hagh Relatadsymptoms After stoppingcompressor, pressure dropsto about200 kPa12.0 kgtlcm,, 28 psi)quickly,and then lalls gradualty. No bubbles sightglasswhen in condenser cooledby water is Reduced no air flow through or condenser Prcbablecaus Air in system Remody Discharge, evacuate, recharge and with specifiedamount. Evacuation: page22-60 see Charging: page22-61 see Discharge, evacuate, recharge and with speciliedamount. Clean Check voltage and fan rpm. Check direction. fan Festrictedlines Check leak. for Charge system. Replace comprossor. the
Excessive refrigerantin system . Clogged condenser radiaor tor fins . Condenser radiator or fan not wo.king properly Restricted flow of relrigerantin sy$em Insufficientretrigerantin . Faulty compressor discharge . Faulty compressor seal ' Faulty expansion valve . Moisture in system Insufficiontrelrigerantin
Line to condensoris excossivelv hot. Dischargepressure abnormally low Excessive bubbles sightglass; in condenser not hot. is Highand low pressures balanced are soon after stopping compressor.Low sideis higherthan normal. Outlet ot expansionvalve is not frosted, low-pressuregauge indicates Excessive bubbles sightglass; in condenser not hot. is
Suction {low) pros, sureabnormally
Expansionvalve is not frosted, and low-pressure is not cold.Lowline pressure gaugeindicates vacuum. Discharge temperatureis low, and the air llow trom vents is restricted. Expansionvalve is frosted. Feceiver/dryer outlet is cool, and inlot rsw6rm (should warm during be operation). Suction pressure abnormally high Low-pressure hose and checkjoint are coolerthan tho temperature around evaporator. Suction pressureis loworedwhen condenser cooledby water. is Highand low-pressure equalized are as soonas tho compressor stopped, is and both gauges tluctuate while running. Reduced flow throughcondensr, air
' Frozenexpansionvalve lMoisture in system) . Faultyexpansionvalve Frozenevaporator
Cloggedexpansionvalve Cloggedreceiver/dryer
. Replace . Discharge, evacuate,and recharge with specified amount. Repair leaks. the Discharge, evacuate, and recharge with specified amount. Charge rquired. as . Discharge, evacuate,and recharge with specitied amount. . Replace expansionvalve. th Run the fan with compressoroff, then checkevaporatortempera, ture sensor. Cleanor replace. Replace
. Expansion valveopentoo long . Loose expansion capillary tube Excessive refrigerantin system gasket Faulty Faulty high-pressure valve panicle Foreign stuckin high. Clogged condenser or radiatortins . Condenser radiator or fan not workingproperly Excessive refrigerantjn system Clogged kinkedlowor pressurehose pans Clogged high-pressure line
Repair roplace. or
Discharge, evacuate, recharge and wathspecified amount. Replace compressor. the
Slction and dis, charge pressutes abnormally high
Clean Check voltage and fan rpm. Check direction. Ian Discharge, evacuate, recharge and with specifiedamount. Repairor replace. Repair replace. or
Suction and dischargepressure abnormally low
No bubbles sightglasswhen in condenser cooledby waler is Low-pressure hoseand motalend areasare cooterlhan evaporator. Temperature aroundexpansion valve rstoo low compared with that around Compressor clutchis diny. Compressor boltls)are dirty. gasket wet with oil. Compressor is
Refrigerant leaks
Compressor shaftsealleaking Leaking aroundbolt(s) Gasket leaking
Replace compressor. the Tighton bolt{s)or replace compressor. Replace compressor, the
Recovery
and that is U.L.-listed is cerequipment Useonly service of tifiedto meetthe requirements SAEJ2210to remove (R-134a) system. from the air conditioner HFC-134a CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irritate eyes, nose and throat. Avoid brqathing the air conditioner retrigerant and lubricant vapor or mist. work area ventilate occurs, systemdischarge lf accidental service. beforeresuming sysserviceequipmentor vehicleair conditioner R-134a tested or leak testedwith tems should not be pressure arr. compressed some mixtures of air and R-134ahave been @@ shown to be combustible at elevated plessures and can result in fire or explosioncausinginiury or property damage. Never use compressed air to pressure tect R-134a serviceequipment or vehicleair conditionersystems. may be obtained Additional healthand safetyintormation manufacturers. and from the refrigerant lubricant ' 1 . C o n n e c ta R - 1 3 4 a e f r i g e r a n r e c o v e y l r e c y c l i n g / r r t as chargingstationto the vehicle, shown,following instructions manufacturer's the equipment 2. trom oil Measure amountof refrigerant removed the the A,/Csystem after the recoveryprocessis comoleted.Be sure to installthe same amount of new systembeforechargoil refrigerant backinto the AVC inq.
Station Recovery/Recycling/Charging
22-59
A/C System Service

Evacuation
Use only service equipmentthat is U.L.-listed is cerand tified to meet the requirements SAE J2210to remove of HFC-134a {R-134a)from air conditioner the system. CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irrhate eyes,noso and throat. Avoid breathing the air condhioner retrigerant and lubricant vapor or mist. lf accidentalsystem dischargeoccu.s. ventilate work areabeforeresumingservice. R 134aserviceequipmentor vehicleair conditioner systems should not be pressure tested or leaktested with compressed arr. some mixtures of air and R-134ahsvo been !@ shown to be combustible at elevatedpressuresand can result in tire or explosion causing iniury ot property damage. Never use compressed air to pressure test R134a service equipment or vehicle air conditioner svstems. Additional healthand safetyinformation may be obtained from the refrigerant lubricant and manufacturers. 1, When an A,/C Systemhas beenopenedto the atmosphere,such as during installation repair,it must or be evacuatedusing a R-l34a refrigerantrecovery/ recycling/charging station.{lf the system has been open for severaldays,the receiver/dryer should be replaced, and the system should be evacuated for severalhours.) Connect a R-134arefrigerant recovery/recyclin g/ chargingstationto the vehicle, shown,following as t h e e q u i p m e n t m a n u f a c t u r e r ' si n s t r u c t i o n s . Evacuate system, the lf the low-pressure does not reach more than 93.3 kPa (700 mmHg,27.6 in.Hg)in 15 minutes,there is probablya leak in the system.partiallychargethe system,and checkfor leaks(seeLeakTest). Recovery/Recycling/Charging Station
22-60
Charging
equipment that is U.L.-listed is cerand Useonly service of tified to meetthe requirements SAEJ2210to remove (R-134a) HFC-134a from the air conditioner system. CAUTION:Exposureto air conditionerrefrigerantand lubricant vapor or mist can irritate eyes, nose and throat. Avoid breathingth air conditionerrefrigerant and lubricant vapor or mist. lf accidentalsystem dischargeoccurs,ventilate work A a r e a b e f o r er e s u m i n gs e r v i c e . d d i t i o n a lh e a l t ha n d safetyinformationmay be obtainedfrom the relrigerant and lubricant manufacturers. recovery/recycling/charging Connect R-'134a a refrigerant stationto the vehicle, shown.followingthe equipment as instructions. manufacturer's Station Rcovery/Recycling/Charging
LeakTest
equipment that is U.L.-listed is cerand Use only service of tified to meetthe requirements SAE J2210to remove (R-134a) HFC-134a from the air conditioner system. CAUTION: Exposure to air conditionor refrigerant and lubricantvapor or mist can irritate eyes,nose and throat. Avoid breathing the air conditioner retrigerantand lubricant vapor or mist. lf accidentalsystem dischargeoccurs,ventilate work areabeforeresumingservice. R-134a serviceequipmentor vehicleajr conditioner systested or leak testedwith tems should not be pressure compressed arr. some mixturos of air and R-1348 have !@ been shown to be combustible at olovatod pres3uras and can result in fire or explosion causing iniury or property damage.Never use comprelisedair to pressure test R-13ilaservice equipment or vehicle air conditioner systems. healthand safetyinformation may be obtained Additional from the refrigerantand lubricantmanufacturers. 1 . Connect a R-134arefrigerant recove rylrecycling/ chargingstationto the vehicle, shown in the preas vious column,followingthe equipmentmanufacturer's instructions. 2. Open the high-pressure valve to chargethe system t o t h e s p e c i f i e dc a p a c i t y , h e n c l o s e t h e s u p p l y t valve,and removethe chargingsystemcouplers. S e l e c tt h e a p p r o p r i a t e n i t o f m e a s u r ef o r y o u r u chargingstation. Refrigerantcapacity:700 to 750 g 0.70to 0.75kg 1.5to 1.6lbs. 21.7 to 26.5 oz. refrigerCheckthe systemfor leaksusing a R-134a of ant leak detectorwith an accuracy 14 g (0.5 ozl per year or better. lf you find leaks that require systemto be opened the (to repair or replacehoses,fittings, etc.), recoverthe system accordingto the RecoveryProcedure page on 22-59. 5. After checkingand repairing leaks,the system must (seeSystemEvacuation page22-601. on be evacuated
HIGH-PRESSURE SIDE Add the same amount of new refrigerant to system oil t h a t w a s r e m o v e d d u r i n g r e c o v e r y .U s e o n l y S P - ' 1 0 refrigerant oil. C h a r g et h e s y s t e m w i t h R e q u i r e d m o u n t o f R - 1 3 4 a a refrigerant. not overcharge system; Do the the compressor will be damaged. S e l e c tt h e a p p r o p r i a t eu n i t o f m e a s u r ef o r y o u r chargingstation.
ll-
Refrigerantcapacity:700 to 750 g 0.70to 0.?5k9 1.5to 1.6lbs. 21.7 to 26.5 oz.
22-61
Compressor
Replacement
'L
lf the compressoris marginally operable.run the e n g i n e a t i d i e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r work for a few minutes. then shut the engineoff. Disconnect negative the cablefrom the battery. Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage22-59). Disconnect the condenserfan connector.Remove the compressor clutch connectorand the wire harness clip from the condenser fan shroud,then disconnectthe compressor clutch connector.Remove the mountingbolts and the condenser shroud, fan
6x1.0mm 7 N.m 10.7 kg{.m,5 lbl.ftl
5.
Removeeach bolt, then disconnect suctionand the dischargelines from the compressor.Plug or cap the lines immediatelyafter disconnecting them to avoid moistureand dust contamination,
6x1.0mm 9.8 N.m 11.0 kgf.m,7.2 lbf.ft)
2.
CONDENSER FAN CONNECTOR
LINE
LINE DISCHARGE
6.
Removethe power steeringpump belt (seesection 17t. Loosenthe pivot bolt of the idler pulleybracket and the adiusting bolt, then remove the Ay'C compressor b e l t f r o m t h e p u l l e y s .l f n e c e s s a r y r e m o v e t h e , mountingbolts from the left front mount,then remove the A,/Ccompressorbelt through the gap betweenthe bodv and the left front mount.
PIVOTBOLT 10 x 1.25mm AIUUSTING 4,t N.m (4.5 kgf.m, 33 tbf.ftl
7.
tFT FRONT MOUltlT
10x 1.25mm /t4 N.m (4.5kgl.m,33 lbtftl
COMPRESSOR BELI
8.
the mountingboltsand the compressor. Remove
1 0 . C h e c kt h e i d l e r p u l l e yb e a r i n gf o r p l a y a n d d r a g , and replaceit with a new one if it's noisy or has play or drag. excessive
PULLEY IDLER
kgt +r N.m14.5 m,33lbfftl mm E x 1.25 l7 2aN.m(2.,1kgf.m, lbl.ft) BBACKET

q
BOLT PIVOT mm 10x 1.25 ir4 N.m{4.5kgt m, 33 lbl'ft}
lf necessary,remove the compressor bracket as follows. . Remove the nut and the washer from the left front mount. When tighteningthe nut to the left front mount,makesurethe washeris set properly on the leftfront mount as shown. Removethe mountingbolts and the compressor 12 x 1.25mm bracket.
59 N.m (6.0 kgt'm,
orderof removal.Make note of 1 1 . lnstallin the reverse items, the following . drainall the a lf you'reinstalling new compressor, reJrigerant from the removed compressor,and oil m e a s u r ei t s v o l u m e . S u b t r a c tt h e v o l u m e o f drainedoil trom 130 m/ 14 U3 fl'o2,4.6lmp'oz); the result is the amount of oil you should drain (through suction fitthe lrom the new compressor trngl. Replace the O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o { r e f r i g e r a n to i l before installingthem. Be sure to use the right (R-134a) avoid leakage. to for O-rings HFC-134a (SP-10) R-134a KEIHIN spifor oil Use refrigerant compressorsonly. ral type do To avoid contamination, not returnthe oil to and never mix it the containeronce dispensed, oils. with other refrigerant lmmediatelyafter using the oil, replacethe cap on the container.and seal it to avoid moisture aDsorprlon. oil Do not spill the refrigerant on the vehicle;it oil may damagethe paint; if the retrigerant conwash it off immediately. tacts the Daint, compr'essorblt (see psge 22-69) Adjust the Ay'C and the power steeringpump belt {see section 17t. and Chargethe system (seepage 22-611, test its performance(seepage 22-56]-.
. .
.
10x 1,25mm art N.m (4.5 kgf'm, 33 lbfftl
Gompressor
lllustratedIndex
CENTER NUT
Replace. ARMATURE PLATE page 22-65 Inspection,
sHtM{s)
Replace. SNAPRINGB Replace.
ROTORPULLEY Inspection.page 22-65
SNAPRINGA Replace.
FIELD COIL Inspection, page 22-65
THERMAL PROTECTOR Replace. page 22-55 Inspection, Replacement, page22-68
---------------coMPRESSOR (Donotdisassemble.)
O.RING Roplace. RELIEF VALVE page 22-68 Replacement, RELIEF VALVECOVER ('97modelonly.)
22-64
ClutchInspection
Checkthe plated parts of the armature plate for color changes,peelingor other damage.lf there is damage,replace clutchset. the Checkthe rotor pulley bearing play and drag by rotating the rotor pulley by hand. Replace the clutch set play/drag. with a new one if it is noisy or has excessive . from the holder,then Release field coil connector the it. disconnect Checkthe thermal protectorfor continuity, lf there is no continuity, replacethe thermal prorecror.
ROTOR
Measure the clearance betweenthe rotor pulley and the armature plate all the way around. lf the clearlimits,the armatureplate anceis not within specified must be removed and shims added or removed as required,following the procedureon page 22-66. Cloarance: t 0.15 mm {0.020t 0.q)6 in) 0.5 NOTE:The shims are availablein four thicknesses: 0.1 mm. 0.2 mm. 0.4 mm and 0.5 mm ABMATUBE
NOTE:The thermal protector will have no continuity above 251.6to 262.4"F1122 128"C). to When the temperature (116to 104'C), drops below 240.8to 219.8"F will havecontinuity. the thermalprotector Checkresistance the field coil. of Field Coil Resistance: i 0.15 ohms at 68"F {20'C) 3.2 lf resistance not within specifications, is replacethe field coil.
22-65
Compressor
GlutchOverhaul
1. Removethe centernut while holdingthe armature platewith the tool.
CENTER NUT 17.6N.m ('1.8 kgf.m, 13lbfft) HOLOER A,/CCLUTCH Reolace. \ .vailable) lCommerciallY Robinair:P/N 1020,0 Ked-Mooro: P/N J37872 i
3.
Removethe snap ring B with snap ring pliers. Be careful not to d8mage the rotor pulley and compressor.
SNAPRINGB R6place.
2.
Remove armatureplateby pullingit up by hand. the

PLATE ARMATURE
Remove the rotor pulley from the shaft with the tools.Be surethe clawsot the pullerare on the back of the rotor pulley,not on the belt area;otherwise the rotor pulleycan be damaged.
sHtMls)
Replace.
za:s (i@,
22-66
l5. Remove the bolt and holder,and screw and clamp. then disconnectthe field coil connector.Remove the snap ring A with snap ring pliers,then remove the field coil. Be carefulnot to damagethe field coil and comoressor. 6. Position the rotor pulleysquarelyover the field coil. Pressthe rotor pulley onto the compressor boss with the specialtool. lf the rotor pulley does not press on straight, remove it, and check the rotor pulleyand compressor bossfor burrsor damage. CAUTION: Maximum pre3s load: 39,200 kPa (400kgf/cm,, 5,690psi)
FIELD COIL CLAMP
+
Press 7.
HUB ASSEMBLY GUIDEATTACHMENT 07966 - 6920500 ROTOR PULLEY
HOLDER
GROUND TERMINAL 7,a N.m kgt'm, 10.75 5 tbt ftl
Reassemble comDressor the clutch in the reverse Make note of the following order of disassembly. rrems. Installthe field coil with the wire side facing down, and alignthe bosson the tield coilwith the holein the compressor. C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o s l i d i n g r surfaces with non-oetroleum solvent. a lnstallnew snap ringsA and B. a Make sure the snap rings are fully seatedin the groove. Make sure that the rotor pulley turns smoothly afterit's reassembled. Routeand clamp the wires properlyor they can be damagedby the rotor pulley.
Compressor
ThermalProtectorReplacement
1. Removethe bolt,the groundterminaland the holdthe then remove er. Disconnect field coil connector. the thermalDrotector.
ftl kgrf.m,5lbf 7.4 N.m (0.75 GROUND TERMINAL
ReliefValveReplacement
l.
Recoverthe refrigerant with a Recovery/Recycling/ Charging System(seepage22-59). Remove the reliefvalvecover ('97 model),the relief valve and the O-ring.Plug the openingto keepforeign matterfrom enteringthe systemand the compressor from runningout. oil
O.RING Replace.
RELIEF VALVE 9.8 N.m {1.0hgf.m, 7.2 rbr.ftl
the matingsurfaces. Clean ReDlace thermal protectorwith a new one, and the apply siliconesealantto the bottom of the thermal orotector, Replace O-ringwith a new one at the reliefvalve, the a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l b e f o r e installing it. Removethe plug. and installand tighten the relief valve. Put the cover on the relief valve so that the arrow d i r e c t sd o w n w a r d s a s s h o w n i n t h e i l l u s t r a t i o n above('97 model). 7. Chargethe system (see page 22-61),and test its performance(seepage 22-561r.
SEALANT SILICONE
3.
orderof removal. lnstallin the reverse
22-68
A/C Compressor Belt

Adjustment
Detlection Method 1. Apply a force of 98 N (10 kgf, 22 lbfl, and measure the deflectionbetweenthe A,/C comDressor and the pulley. crankshaft A/C CompressorEelt UsedBeh:7.5- 10.5mm (0.30 0.41inl New Belt: 5.0 - 7.0 mm (0.20- 0.28 in) Notetheseitemswhen adjusting belttension: . lf there are cracks any damageevidenton the or belt,replace with a new one. it . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used for lessthan five minutes. Tension Gauge Method 1. Attachthe special tool to the Ay'C compressor belt as shown below,and measure tensionof the belt. the A/C ComoressorBelt Used Belt; 390 - 540 N (40 - 55 kgf, 88 - 120 lbtl New Belt: 740 - 880 N (75 - 90 kgf, 170- 200 lbt) Notetheseitemswhen adjusting belttension: . F o l l o wt h e m a n u f a c t u r e r 'is s t r u c t i o n f o r t h e n s belttensiongauge. . lf there are cracksor any damageevidenton the belt,replaceit with a new one. . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used for lessthan five minutes.
Loosenthe pivot bolt of the idler pulleybracket and the locknut ofthe adjusting bolt. Turn the adjusting bolt to get properbelttension, Retighten pivot bolt of the idler pulley bracketand the the locknut ofthe adiusting bolt. Recheck deflection the A,/C the of compressor belt,
BELTTENSION GAUGE 07JGG- 00't010A
Loosenthe pivot bolt of the idler pulley bracketand the locknut ofthe adjusting bolt. Turn the adjusting bolt to get properbelttension. Retighten pivot bolt of the idler pulley bracketand the the locknut ofthe adjusting bolt. Recheck tensionof the A,/C the compressor belt.
22-69
Gondenser
Replacement
't. Recoverthe refrigerantwith a recovery/recycling/
chargingststion(seepage22-59) Remove front grille (seesection20). the Removethe coolant reservoii,but do not disconnect the reservoirhose Jrom the coolant reservoir and the radiator. Removethe bolts and the suction line bracketas s h o w n . R e m o v et h e b o l t s a n d t h e u p p e r m o u n t brscketsfrom the radiator.
6xl.0mm kgf'm' 7.2lbf'ft) 9,8 N.m 11.0
6.
Removethe mounting bolts,then removethe condenserby lifting it up as shown. Be carefulnot to d a m a g e t h e r a d i a t o r a n d c o n d e n s e rf i n s w h e n removingthe condenser.
MOUNT UPPER BRACKETS Remove each bolt, then disconnectthe discharge and condenserlines from the condenser,Plug or them after disconnecting cap the lines immediately to avoid moistureand dust contamination.
6x1.0mm 9.8 N.m 11,0kgf.m,7.2 lbfttl
1,0mm
7.
orderof removal.Make note of Installin the reverse the followingitems. . o add refrigera lf you'reinstalling new condenser, ant oil (sP-10)(see page 22-54].. Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l before installingthem. Be sure to use the right (R-134a) avoid leakage. to for O-rings HFC-134a Be careful not to damagethe radiatorand conthe denserfins when installing condenser. Be sure to install the lower mount cushionsof securely into the holes, condenser and test its Chargethe system(seepage 22-61), (seepage22-56). performance
t\,
l/
6x1.0mm
a -: iti..
. . .
LINE DISCHARGE
CONDENSR LINE
22-70
Body Electrical
Toofs Speciaf ,...,..,.............-.23-2 Troubleshooting Tips and Precautions ......,.,..........,.................. 23-3 Five-step Troubleshooting ........,.,.,...,,.,......... 23-5 Wire ColorCodes ...,....,.. 23-5 Relay and Control Unit Locations EngineCompartment..,.,......,......................... 23-6 Dashboard ,.,.,..............-.23-7 Door....................... .........23-10 Index to Cilcuits and Sysiems Accessory Socket.. ,....,.,..,.,. 23-95 *Airbags................ .,....,. Sestion24 Air Conditioning ,.,.,.... Section22 Alternator ................... Section4 Anti-lockBrakeSystem{ABSI ................... Section19 'A/T GearPositionIndicator....................... Section1,1 AutomaticTransmission System ...........,.. Section14 B a t t e r y. . . . . . . . . . . . . . . . . . . ..............23-50 BlowerControls .,...,.,, Section22 il Charging System ....... Seqtion Clock-'98 Model ................ 23-98 Connectorldentification and Wire Harness Routing ................. . . . . . . . .2 . . 1 1 .3 Cruise Control ............ Ssction4 DashLightsBrightness Contlo||er..................... 23-90 FanConlrols ...,......,.... Section10 FuelPump ,..,.,...,....,.... Section11 Fuses...................... .,,.,.,.,.,,.,23-40 *Gauges CircuitDiagram ......-....-..23-58 FuelGauge .....,.,..... Section11 Speedometer ..,..........,... 23-56 GroundDistribution ,....,.,...23-46 HatchGlsssODenor .........................,.,.,.,.,..,.,.,.,,. 23-121 HeaterControls .-........ Soction21 *Horns.,...,..,.,.,....... ................23"104 *fgnitionSwitch ,,.,.,..,.,.,,.,.,.,23-51 lgnitionKey Light System-'97 Mod6l .............. 23.88
+ BODY
SpecialTools
Ret. No.
Tool Numbel OTLAJ PT3O2OA TestHarness
Description
Oty
PageReference 23-62,63
23-2
Troubleshooting
Tips and Precautions
g Before Troubleshootin . Checkapplicable fuses in the appropriate fuse/relay box. . Checkthe batteryfor damage,state of charge,and clean.and tight connections. . Check alternator the belttension. CAUTION: . Do not quick-chargea battery unless the battery ground cable has been disconnected,otherwise you will damage the alternator diodes. . Do not attempt to crank thc engins wilh the battery ground cable loosely connected or you will severely damagethe wiring. Handling Connestors . Makesurethe connectors cleanand haveno loose are wire terminals, . N4ake sure multiplecavityconnectors packed with are grease(except water-tight connectors). . All connectors havepush-down release type locks. Beforeconnectingconnectors, make sure the terminalsare in placeand not bent. N e v e rt r y t o d i s c o n n e c c o n n e c t o r s y p u l l i n g o n t b their wires;pull on the connector halvesinstead. Alwavsreinstall olasticcovers.
LOCKING TAB
. S o m e c o n n e c t o r s a v ea c l i p o n t h e i r s i d e u s e dt o h attach them to a mount bracketon the body or on anothercomponent. This clip hasa pull type lock. Some mounted connectors cannot be disconnected unlessyou first release lock and removethe conthe nectorfrom its mount bracket.
for Check looseretainers and rubberseals.
RETAINER
T h e b a c k s o f s o m e c o n n e c t o r sa r e o a c k e d w i t h grease. Add greaseif necessary. the greaseis con lf taminated. reolace it.
LOCKING PAWLON OTHER Pullto HALFOF disengage CONNECTOR
BRACKET
{cont'd}
23-3
Troubleshooting
(cont'dl Tips and Precautions
Insen the connectorall the way and make sure it is Iocked. securely wires so that the open end of the coverfaces Position down. . Seatgrommetsin their groovesproperly.
NOT GOOD
Handling Wires and Harnesges . Securewires and wire harnesses the frame with to locations. wire ties at the designated their respective . Remove don't damagetheir locks. clipscarefully;
Face openend
lr
-M/
lr*
Tsting and Repairs . Do not usewires or harnesses with brokeninsulation. Replace them or repairthem by wrappingthe break with electricaltape. . A f t e r i n s t a l l i n g a r t s ,m a k e s u r e t h a t n o w i r e s a r e p pinchedunderthem. . W h e n u s i n g e l e c t r i c a tl e s t e q u i p m e n t ,f o l l o w t h e instructionsand those describedin manufacturer's t h i sm a n u a l . . lf possible,insert the probe of the tester from the wire side (except waterproof connector).
Slip pliers under the clip base and through the hole at the tabs to release the an angle,then squeeze expansion clrD.
Usea probewith a taperedtip.
After installingharnessclips, make sure the harness with any moving pans. doesn'tinterfere Keep wire harnesses away from exhaustpipes and other hot parts, trom sharp edges of bracketsand holes.and from exoosdscrewsand bolts.
in Refer the instructions the HondaTerminalKit for to t t i d e n t i f i c a t i o a n d r e p l a c e m e no f c o n n e c t o r e r m i n nals.
Five-step Troubleshooting
1.
Wire ColorCodes
T h e f o l l o w i n ga b b r e v i a t i o na r e u s e d t o i d e n t i f yw i r e s colorsin the circuitschematics: W H T . . . . . . . . . . . . . . . . . . . .W.h i t e. . .. .... Y E L , . . . . . . . . . . . . . . . . . . . .Y.e . . o.w. . . . ll . . B L K . . . . . . . . . . , . . . . . . . . . .B.l.a . .k . . . .c . B L U . . . . . . . . . . . . . . . . . . . . .B.l.u . . . . . . .e GRN.............................Green R E D. . . . . . . . . . . . . . . . . . . . .R.e .d . . . . . . . ORN.............................Oran9e P N K . . . . . , . . . . . . . . . . . . . . . . . n.k . . . . Pi . . B R N. . . . . . . . . . . . . . . . . . . . .B.r.o .w.n . . . . . G R Y. . . . . . . . . . . . . . . . . . . . .G.r. a.y . . . . . . P U R. . . . . . . . . , . . . . . . . . . . .P.u . .p l. e. . .r . . L T B L U. . . . . . . . . . . . . . . . . . , i.g.h .B l u e L . . t. L T G R N . . . . . . . . . . . . . . . . .L . . .h.tG r e e n . ig . . T h e w i r e i n s u l a t i o nh a s o n e c o l o r o r o n e c o l o r w i t h anothercolor stripe. The secondcolor is the stripe.
VerifyThe Complaint Turn on all the components the problemcircuitto in verify the customercomplaint.Note the symptoms. Do not begin disassembly testinguntil you have or narrowed down the problemarea. Analyze The Schematic L o o k u p t h e s c h e m a t i f o r t h e p r o b l e mc i r c u i t . c Determinehow the circuit is supposedto work by t r a c i n gt h e c u r r e n tp a t h sf r o m t h e p o w e r f e e d throughthe circuitcomponents ground.lf several to circuitsfail at the sametime, the fuse or ground is a likelycause, Basedon the symptomsand your understanding of the circuitoperation, identifyone or more possible causes the problem. of
3.
lsolate The ProblemBy TestingThe Circuit Make circuitteststo checkthe diagnosis you made in step 2. Keepjn mind that a logical,simple procedure is the key to efficient troubleshooting. Test for the most likely cause of failure first. Try to make testsat pointsthat are easilyaccessible, FixThe Problem Once the specificproblem is identified,make the repair.Be sure to use propertools and safe procedures. MakeSureThe CircuitWorks Turn on all components the repaired in circuitin all modes to make sure you've fixed the entire problem. lf the problem was a blown fuse, be sure to test all of the circuitson the fuse.lvlake sure no new problems turn up and the originalproblemdoes nol recur.
WHT/BLK
4.
Relayand ControlUnit Locations

Compartment Engine
ELECTRICAL LOADDETECTOR IELDI
UNIT
t:
tr tr ; tr BLOWER MOTOR RELAY
A/C COMPRESSOR CLUTCH RELAY
RADIATOR FAN EELAY
UNDER.HOOD ABS FUSE/RELAY BOX
''r@
l--\ r rr r
23-6
Dashboard
PGM.FIMAIN RELAY
RELAY MOTOR HIGH BLOWER BLK/YEL, lwir. colorc: I BLKI ORN/WHT,.nd LBLU/BLK,
23-7
Relayand GontrolUnit Locations

(cont'd) Dashboard
PANEL CONTROL HEATER
RELAY REAR WINDOWDEFOGGER
-rj,r1 Iu
/-\,r1 lJ-JlJ
r*t
WINDOWRELAY
CONTROL UNIT INTEGRATEO
RELAY TURNSIGNAL/HAZARD
23-8
DAYTIMEBUNNINGLIGHTS UNIT (Canrda){'98 - (X)modok) CONTROL KEYLIGHT IGNITION UNIT l7 model) CONTROL
RUNNINGLIGHTS OAYTIME CONTROL UNIT lcanad!l l'97 modell
UNIT CRUISE CONTNOL
HORNBELAY137 modell CUT RELAY{'98 - 00 modelsl STARTER IWir6 color3:BLK/WHT,BLK^ UHT,I CUTRELAYl7 modll STARTEn I lGRY,.nd BLx/nED lwire colors:BLK/WHT,BLK/WHY,l I IGRY,and BLK/RED HORNFELAYl'98 - 00 modcb) lwire coloF: WHT/GRN, l GRY,and BLU/REDI LWHT/GRN,
WHT/GRN, Iwiro color3: I GRY, BLU/REDI and IWHT/GBN,
{cont'd)
23-9
Relayand ControlUnit Locations

(cont'd)and Door Dashboard
REAR ACCESSORY SOCKET RELAY I Wire colors:YEL/GRN, J BLK,.nd YEL/BLU IWHT/BLK. l
REAR WINDOWWIPER CONTROL UNIT 137 mod.ll INTERLOCX CONTROL UNIT
REVERSE RELAY {A/TI I WirecolonrYEI-/RED, I YEL,.nd GRN/BLK IYEL/RED, I
KEYIISS/POWER DOOR L(rcK CONTROL UNIT
23-10
Routing and Wire Harness ldentification Gonnector
How to ldentity Connectors: "C" for connectors. by The to numbershavebeenassigned all connectors, numberis preceded the letter ldentification "G" for groundterminals "T" for non-ground terminals. or Location Harness cable Starter groundcable Battery Enginegroundcable groundcable Transmission Enginewire harness EngineCompartmsnt T 1 ,T 2 a n d@ G 1 a n dO Dashboard Others lFloor, Door, 8oof, Tailgate)
T3 T4 G3
C t C 1 0 1h r o u g h 1 3 7 T 1 0 1a n dT 1 0 2 G101 C201 throughC218 G201and G202
t5ano9
wareharness Enginecompartment box ABS fuse/relay Under-hood wire harness Main wire harness
C301throughC309 C351throughC361
C401throughC447 G401and G402 (C525) C501 throughC524 G501 C551throughC581 G552and G553 G551, C601throughC605 C701throughC703 C641throughC643 C731 throughC740 C721through C722 C751throughC760 throughC667 C661 C6Tl throughC676 C681throughC684 C69'lthroughC694 C611throughC520 C631throughC634 G631 C801 throughC808 G801 C651throughC653 C645throughC647
wire harness Dashboard Leftsidewire harness Rightsidewire harness lnteriorwire harness Rearbumperwire harness Heater sub-harness heatedoxygensensor Secondary sub-harness switchsub-harness Combination door wire harness Driver's door wire harness Frontpassenger's Left reardoor wire harness Rightreardoor wire harness Rearwire harness wire harness Tailgate SRSmain harness High mount brakelight sub-harness sub-harness sensor Fueltank oressure
Connector ldentification and Wire Harness Routing
Starter Cables Connoctoror Terminal Number of Cavities Location Rightside of enginecompartment Rightside of enginecompartment Battery Connectsto Under-hood fuse/relay box Starter motor Batterypositive terminal
Notes
T1
r2
o
Battery Ground Cable Connoctoror Terminal GI Numberof Cavities
Location Rightfront shocktower Battery
Conneqtslo Bodyground,via batteryground cable Battery negative terminal
Notes
EngineGroundCable Connectoror Terminal Numb6r ol Cavities Location Leftsideof engine Leftside of enginecompartment Connectsto Powersteeringpump bracket Bodyground.via engineground caote Notes
T3
TransmissionGround Cable Connsstor o. Terminal Number of Cavities Location Rightside of enginecompartment Rightside of front frame Connectsto Transmission Body ground,via transmission groundcable Notes
T4
Under-hoodABS Fuse/RelayBox Wire Harnsss Conn6storor Terminal

tc
Numberof Cavities
Location Rightside of enginecompartment
Connoctsto Under-hood ABS tuse/relav box 88tterypositive terminal
Notos
Battery
23-12
STARTER CABLE ABS FUSE/RELAY UNDER-HOOD BOX WIREHARNESS @
EATTERY GROUND
CABLE
ENGINE GROUND CABLE TRANSMISSION GROUND CABLE
23-13
EnginoWire Harness Connecto; or Terminal Number of Cavities

10 6
Location Leftside of enginecompartment Leftside of enginecompartment Middleof engine Middleof engine Leftsideof enginecompartment Leftsideof enginecompartment Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middle f engine o Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Rightsideof engine Middleof engine Behindright kickpanel Underright side of dash Underright side of dash Underright side of dash Underright sideof dash Underright sideof dash Rightsideof engine Rightsideof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine
Conneqtsto (C304) Main wire harness (C305):'9798 models Mainwire harness No. 1 fuel injector Crankshaft speedfluctuation(CKF) sensor Alternator Alternator Engineoil pressure switch No.2 fuel injector purge Evaporative emission(EVAP) controlsolenoid valve No. 3 fuel injector No. 4 fuel injector Primaryheatedoxygensensor (Primary (sensor HO2S) 1) Radiator switch fan Coolant temperature sendingunit (ECT) Enginecoolanttemperature sensor Mainshaftspeedsensor Lock-up controlsolenoidvalve Back-up light switch Shift controlsolenoidvalve Linearsolenoidvalve Countershaft speedsesnsor Startersolenoid Distributor Junctionconnector PCM ECIWPCM ECM/PCM ECM/PCM (C,|:}1) Main wire harness IVT gear positionswitch Vehiclespeedsensor(VSS) Throttleposition(TP)sensor MAP sensor (lAC)valve ldleair control (lAT)sensor lntakeair temperature Junctionconnector Junctionconnector
Notos
c101 c102 c103 c104 c105 c105 c106 c 107 c 108 c 109 c]10 c1l'l c112 c113 c ' t1 4 cl16 cl16 c117 c118 c119 c120 c121 c't22 c't23 c't25 cl26 cl27 cr28 cl29 c130 c131 c132 c 133 c134 c134 c135 c 136
A/r
USA Canada
Alr
AlT
M/'r
Afi
1 10 20
'97 mooel
31 16 22 l0
l0 '14
'97 model '98 - 00 mooets
14 1
Leftsideof enginecompartment Powersteeringpressure (PSP) switch Middleof engine Junctionconnector Middleof engine Knocksensor(KS) Leftsideof en0inecompanment Alternator Rightsideof engine compartment Under-hood fuse/relay box
Middle of engine
'99 - 00 models
T101 r102 G101
ground,via engine Engine wire harness
23-14
c1733 clsl gra,
c103 c137 T101
c104
c112
ENGINEWIREHARNESS cl13 cl' l1
23-15
lrffiltEfinl,
Gonnectorldentificationand Wire HarnessRouting
EngineCompartment Wire Harness Connectorol Terminal Number of Cavities 14 2 2 Location Connectsto Notes
c20'l c202 c203 c204 c205 c206 c207 c208 c209 c210 c212 c213 c2't4 c215 c216 c217 c21A c218
G201 G202
1 'l
(C307) Leftside of enginecompartment Main wire harness Leftside of enginecompartment Cruise actuator Behindfront bumper Rearwindow washermotor Behindright headlight Leftfront turn signal/side markerlights Behindfront bumper Windshield washermotor Behindright headlight Leftfront parkinglight Leftsideof enginecompartment Condenser motor fan Leftsideof enginecompartment Frontfog lights Leftsideof enginecompartment IVC compressorclutch Behindleft headlight Left headlight Leftsideof enginecompartment IVC pressureswitch Behindfront bumper Left horn Behindfront bumper Righthorn Rightside of enginecompartment Radiator motor fan Behindright headlight Rightheadlight Behindright headlight Rightfront turn signal/side marker lights B e h i n d i g h th e a d l i g h t r Rightfront parkinglight Right sideof engine compartment Main wire harness 1C357) (C357) Right sideof engine compadment Main wire harness Rightsideof engine companment Bodyground,via enginecompartment wire harness Leftside of enginecompartment Bodyground,via enginecompartment wire harness
Optional
10
'97 - 98 models '99 - 00 mooets
23-16
ENGINE COMPARTMENT WIREHARNESS
c212
c211
23-17
Gonnector ldentification and Wire Harness Routing

Main Wire HarnesslEngine compartmont left and right branches) Connectot ol Terminal Number ot Cavities 5 2 10 Location Leftside of enginecompartment Leftsideof enginecompartment Leftside of enginecompartment Leftside of enginecompanment Leftside of enginecompartment Leftside of enginecompartment Leftside of enginecompartment Leftsideof enginecompartment Leftside of enginecompartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightside of enginecompartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightsideof engine compartment Rightside of enginecompartment Conneqtsto Windshield wiper motor Daytimerunninglightsresistor Test techometerconnector (C10]) Enginewire harness '97 (C102): - 98 Enginewire harness models Left front ABS wheel sensor Enginecompartment (C201) wire harness Brakefluid level switch {-) Brake fluid levelswitch(+) Under-hoodfuse/relaybox (C908) Under-hood fuse/relay box (C906) Under-hood fuse/relay box (C905) Under-hood fuse/relay box (C907) ABS modulatorunit ABS pump motor Enginecompartment wire harness(C218) Nots
c301 c303 c304 c305

c306 c307 c308 c309 c352 c354 c356 c357
Canada
'14 1 1 t1
ABS
3 10 8 10
c358 c359 c360

LJO I
G35l
USA ABS ABS '97 - 98 models Enginecompartment (C218) '99 - 00 wire harness mooets Rightfront ABS wheelsensor ABS Under-hood ABS fuse/retay (C931) ABS box Under-hoodABS fuse/relaybox (C9321 ABS '98 Evaporative emission(EVAP) contro 00 canister vent shutvalve mooets Bodyground,via main wire harness ABS
23-18
UNDEB.HOOD FUSE/RELAY BOX
MAIN WIREHARNESS branch) G351
MAIN WIREHARNESS {left branch}
23-19

Main Wire Harnss(left side of dash and floor branchesl{cont,dl
c401 c402 c403 c404 c404 c405 c406 c407 c408 c409 c410 c410 c411 c412 c413 c413 c414 c415 c416 c416 c417 c418 c419 c420 c420 c421 c422 c423 c424 c425 c42A c426 c437 c438 c438 c439 c440 c441 c442
5 20 20 24 't4 8 5 3
Behindleft kickpanel Behindleft kickpanel Behindleft kickpanel Behindleft kickpanel Behindleft kickpanel Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft sideof dash Underleft side of dash Underleft side of dash Underleft side of dash
Starter relay cut Horn relay (C558) Leftsidewire harness (C559) Leftsidewire harness (C559) Leftsidewire harness Cruise controlunit Daytimerunninglightscontrolunit Daytimerunninglightscontrolunit lgnitionkey light controlunit Interiorwire harness {C701) Cablereel Cablereel
'97 model '98 - 00 mooets Canada Canada '97 model '97 model '98 00 models
12
10 '1 18 20 '18 10 15 1 4 8 5 5
22
lgnitionkey switch lgnitionkey switch '97 Combination switchsub-harness {C753) 98 models Combination (C753) '99 - 00 switchsub-harness moqets (C803) SRSmain harness (C503) Dashboard wire harness (C501) Dashboard wire harness Dashboard wire harness {C501) Under-dash fuse/relay box (C922) Under-dash fuse/relay box (C920) '97 model Under-dash fuse/relay box (C919) '98 - 00 lntegrated controlunit mooets Integrated controlunit Optional Frontfog lightsswitch Brakeswitch Interlock controlunit Reverse relay Rearaccessorysocketrelay Rearaccessorysocketrelay Rearheatedoxygensensorsub(C722) harness Optional Security controlunit Optional Securitystarter cut relay (for security alarmsystem) Junctionconnector(for interlocksystem) Optional Security wire harness Optional '97 model Security wire harness Rearwindow wiper controlunit Combinationswitchsub-harness (C760) '97 - 98 mooels Combinationswitch sub-harness (C760) '99 - 00 models Securltyindicator Optional Securityvalet switch Optional Clutchinterlockswitch Mfi Clutch switch(forcruise control) Mlr Bodyground,via main wire harness
23-20
MAIN WIREHARNESS
c115 cla6 c+to "n,
dn' cntt
I --r F -'L-1al 1l}a]

a -n-rrr---rrr
-:/l
-
UNDER-DASH BOX FUSE/BELAY
Connectorldentificationand Wire HarnessRouting
Main Wire Harness{Right side of dash and floor branchesl{cont,dl Connector or Tsrminal Number ol Cavities 25 6 26 22 7 20 Location Frontpassenger's door Behindright kickpanel Behindright kickpanel Behindright kickpanel Behindright kickpanel Underright side of dash Under.ight side of dash Undermiddleof dash U n d e rm i d d l e f d a s h o Undermiddleof dash Undermiddleof dash Behindright kickpanel Underright side of dash Connectsto Frontpassenger's door wire harness (c671) Rightsidewire harness {C601) ABS controlunit ABS controlunit (C127) Enginewire harness PGM-Fl main relay JUnotron connector Tailgate open relay Headlightslasherrelay f (C731 Heater sub-harness ) (C731) Heater sub-harness ECM/PCM Body ground,via main wire harness Notes
c427 c428 c429 c430 c431 c432 c433 c434 c435 c436 c436 c447
G402
ABS ABS
5 7
Optional Optional '97 model '98 00 models '98 00 mooets
23-22
MAIN WIREHARNESS
23-23

DashboardWire Harness Connectorol Terminal Numbr of Cavities 10 1 20 Location Above under-dash fuse/relaybox Above under-dash fuse/relaybox Above under-dash fusehelaybox Above under-dash fuse/relaybox Behinddashboard lower panel Above under-dash fuse/relaybox Above under-dash fuse/relaybox Left side of steering wheel Left side of steering wheel Underleft side of dash Behindgauges Behindgauges Behindgauges Behindgauges Behindgauges Rightside of gauges Behindmiddleof dash Behindmiddleof dash Behindmiddleof dash Undermiddleof dash Undermiddleof dash Behindmiddleof dash Behindmiddleof dash Behindmiddleof dash Behindmiddleof dash Behindmiddleof dash Behindgauges Uppermiddleof dash Behindmiddleof dash
Conngctsto (C416) Main wire harness (C416) Main wire harness Under-dashfuse/relaybox 1C912) (C415) Main wire harness Hatchglassopenerswitch Left side wire harness(C556) (C556) Leftsidewire harness Dashlightsbrightness cont.oller Cruisemain switch Junctionconnector Gaugeassembly Gaugeassembly Gaugeassembly Gaugeassembly Gaugeassembly Hazard warningswitch Audio unit Heatercontrol panel Heatercontrol panel Datalink connector Servicecheckconnector Front accessorysocketconnector Ashtraylight Heatersub-harness(C733) Heater sub-harness {C740} Heatersub-harness(C740) Gaugeassembly Clock Bodyground,via dashboard wire harness
Notes
c501 c501 c502 c503 c504 c505
Mir
14 16
c506 c507 c508 c509 c510 c511 c512 c514
'97 - 98 models '99 - 00 models
6 20 13 5 t6 14 10
to
A/r
c518 c519 c520 c521
20 16 2 24 2
1
c524
'97model '98- 00 mooets '98- 00 models
G501
23-24
DASHBOARD wlRE HART{ESS
23-25
Routing ldentification and Wire Harness Connector
Left Side Wire Harness ConnectoroI Terminal Number of Cavities 8 16 10 14 'I 14 16 Locaiion Behind under-dash fuse/relay box Behindunder-dash fuse/relay box Left side of steeringwheel Left side of steeringwheel Left side of steeringwheel Above under-dash fuse/relaybox Above under-dash fuse/relaybox Driver's door Behindleftkickpanel Behindleftkickpanel Behindleftkickpanel Left side offloor Leftquanerpanel Fueltank On left half of rearcrossbeam On left half of rearcrossbeam Leftquarter panel Leftquarter panel Leftquarter panel Leftquarter panel Leftquarter panel Leftquarter panel On left half of rearcrossbeam panel Rightquarter panel Rightquarter Leftquarter pillar Leftside of floor Left B-piller Left B-piller Behind kickpanel left Behind kickpanel left Underleftsideof dash LeftB-piller Fueltank Leftside of steeringwheel left Behind kickpanel Left side ot floor piller Leftquarter Connectsto fuse/relay box (C921) Under-dash fuse/relay box (C923) Under-dash Powermirror switch Powerwindow masterswitch Powerwindow masterswitch wire harness Dashboard {C505) Dashboard wire harness 1C505) (C661) Driver's door wire harness (C403) wire harness Main (C404) Main wire harness (C404) Main wire harness Driver's seat belt switch Left rear door switch F u e lu n i t Left rearABS wheelsensor Left rearABS wheelsensor Rearaccessorysocketconnector{+} Rearaccessorysocketconnector (-) Rearbumperwire harness 1C641) Trailerlightingconnector Tailgate door latchswitch Left rear speaker RightrearABS wheelsensor (C611) Rearwire harness Rightrea. door switch Lefttaillight Parking brakeswitch (C681) Leftreardoor wire harness Driver's door switch Selectunlockrelay(for security alarm system) Junctionconnector(for power door locks) (C807) SRSmain harness Driver'sseat belttensioner Fueltank pressure sensor sub-harness (c645) Power window master switch Bodyground,via left sidewire harness Bodyground,via left sidewire harness Body ground,via left sidewire harness Not6s
c551 c552 c554 c556
'97 - 98 mooets '99 - 00 models '97 model '98 - 00 models
c558 c559 c559 c560 c562 c563 c563 c564 c565 c566 c568 c569 c570 c572 c573 c574 c575 c576
20 20 24 ) 1 5
'97 model '98 - 00 models
1 1 6 1 2 14 1 1 6 1
Optional
c578 c579 c580 c581

G551 G553
'98 - 00 mooets '98 - 00 models '98 - 00 mooets '99 - 00 mooets
23-26
c553 c5:6 c5J5
C561 C565 C566 LEFTSIDEWIREHARNESS
23-27
Right Side Wire Harness Connec{oror Tsrminal Numberof Cavities 6 '1 2 2 Location Behindright kickpanel RightB-piller Rightreardoor Undermiddleof dash Right -piller B Conneststo (C428) Main wire harness passenger's door switch Front (C691) Rightreardoor wire harness SRSmain harness {C808) seatbelttensioner Frontpassenger's Notes
c601 c602 c603 c604
'98 - 00 mooets '98 - 00 models
Rear Bumper Wire Harness Connectorol Terminal Number ot Cavities 4 2 2 Location Leftquarterpanel Behindrearbumper Behindrearbumper '98 Model Location Fueltank Leftside of fuel tank Leftside of fuel tank Connectsto (C580) Leftsidewire harness pressure sensor Fueltank bypass emission(EVAP) Evaporative valve solenoid Not63 Connoctsto (C566) Leftsidewire harness Leftrearside markerlight Rightrearside markerlight Notes
c641 c642 c643
FuelTank PressureSensor Sub-harness Connectoror Terminal Number ot Cavities

?
c645 c646 c647
High Mount Brake Light Sub-harnoss Conneslor or Terminal Number of Cavities Location Top of hatchglass Top of hatchglass Top of hatchglass Connec-ts to High mount brakelight (C617) Rearwire harness (C618) Rearwire harness Notes
c651 c652 c653
2
1 1
23-28
HIGHMOUNT BRAKELIGHT SUB-HARNESS
RIGHTSIDEWIBEHARNESS
FULTANK PRESSURE SENSOR SUB.HARNESS
REARBUMPER WIREHANNESS
23-29
RearWiro Harness Connectoror Terminal Number of Cavities 14 2 6 1 1 'I 1 Location q r R i g h t u a r t ep a n e l q r R i g h t u a r t ep a n e l q r R i g h t u a r t ep a n e l q R i g h t u a n e rp i l l e r Rightside of hatchglass Middleof hatchglass Top of hatchglass Top of hatchglass Leftside of hatchglass Roofarea q r R i g h t u a r t ep i l l e r Connects to (C57'l) Leftsidewire harness Rightrearspeaker (C631) wire harness Tailgate Rightaillight Rearwindow defogger(+) Rearwindow wiper motor High mount brakelight sub-harness (c652) Hjgh mount brakelight sub-harness {c653) Rearwindow defogger(-) l R e a r e i l i n gi g h t c Bodyground,via rearwire harness Notes
c61l c612 c613 c614 c617 c618 c619 c620

G611 Tailgate wire Harness Connestoror Terminal
Numberof Cavities
Location Rightquarterpanel Middleof tailgatedoor Leftsideof tailgatedoor Middleof tailgatedoor I/iddle of tailgatedoor
Connectsto (C613) Rearwire harness Hatchglassopenersolenoid platelight License Hatchglasslatchswitch Body ground,via tailgatewire harness
Noles
c633 c634
2 2
1
23-30
TAILGATE WIREHARNESS
23-31
Drivsr's Door Wire Harness Connectoror Terminal Number of Cavities 25 4 Location Driver's door Driver'sdoor Driver's door Driver's door Driver's door Driver's door Driver's door Connoctsto Leftsidewire harness {C557) Left front speaker Driver'spowerwindow motor Driver's door lock actuator Driver's door lock switch Driver's power mirror actuator Keyless/power door lockcontroluni Notes
c664
at
c667
18
Front Pa$enger's Door Wire Harnsss Connectoror T6rminal Number ot Cavities

2^
Location Frontpassenger's door Frontpassenger's door Frontpassenger's door Frontpassenger's door Frontpassenger's door Frontpassenger's door
Connectsto (C4271 Main wire harness Rightfront door speaker power window motor Front passenger's Frontpassenger's door lockactuator power window switch Front passenger's power mirror actuator Front passenger's
Notes
c671 c612 c674 c675
DBIVEB'S DOOR WIRE HARNESS
6tt
inliiioint""
23-32
o,-
Left Rear Door Wile Harness Conneclor or Trminal Numbor of Cavities 2 5 Location Left rear door Leftreardoor Left rear door Left rear door Connectsto Leftsidewire harness {C575) Leftrearoowerwindow motor Left rear door lock actuator Left rear oower window switch Notos
c681 c6a2 c683 c684
Right Real Door Wire Harness Connectoror Terminal Number of Cavitios Locstion Rightreardoor Rightreardoor Rightreardoor Rightreardoor Conneststo (C603) Rightsidewire harness Rightrearpowerwindow motor Rightreardoor lockactuator Rightrearpowerwindow switch Notos
c691 c692 c694
LEFTREARDOOR WIRE HARNESS
lntglior Wire Harness Connectoror Terminal Numbr of Cavities Location Underleft sideof dash Roofarea Roofarea Connoct3lo (C409) Main wire harness light Frontceiling Spotlights Notes
c701 c702 c703
SocondaryHeatedOxygen Sensor Sub-harflss

Connoqto. ol Tarminal
Numbor ot Cavities
Location Undermiddleof dash Undermiddleof dash
Connectsto heated oxygensensor Secondary H02S)(Sensor 2) {Secondary (C426) Main wire harness
Notos
c721 c722
23-34
OXYGENSENSOR
SUE.HARNESS
23-35
Hoat6rSub-harness Connectoror Tgrminal
Numbsrot Cavities
5 7 7 24
Localion Undermiddleof dash Undermiddleof dash Behindmiddleof dash Behindmiddleof dash Behindglove box Behindglove box Behindglove box Behindglove box Behindglove box Behindglove box Behindmiddleof dash Behindmiddleof dash
Connectsto Main wire harness {C436) (C436) Main wire harness Modecontrolmotor (C522) wire harness Dashboard Air mix controlmotor Evaporator temperature sensor Blowermotor high relay Blower motor Powertransistor controlmotor Recirculation (C523) wire harness Dashboard (C523) Dashboard wire harness
Notes '97 model '98 - 00 modsls
c73'] c731 c732 c733 c734 c735 c736 c737 c738 c739 c740 c740
'97 model '98- 00 mooels
Combination Switch Sub-harness

Conneqtor ol Terminal
Number of Cavities 6 7 12 10
Location Above under-dash fuse/relay box Above under-dash fuse/relay box Underleft side of dash Underleft sideof dash Behindsteering column Behindsteering column Behindsteering column Behindsteering column Behindsteering column Behindsteering column Underleft side of dash Underleft side of dash
Conneststo fuse/relay box (C914) Under-dash fuse/relay box {C915) Under-dash (C413) Main wire harness (C413) Main wire harness Shift locksolenoid pin Parking switch light switch Combination Combination light switch Wiper/washerswitch Wiper/washerswitch (C442) Main wire harness (C442) Main wire harness
Notos
c751 c753
'97 - 98 mod6ls '99 - 00 models
c754 c755 c756 c757 c758 c760 c760
7 6 8
'97 - 98 models '99 - 00 models
23-36
Ol-
f-
SRS Main Haln93s
o1 ConnGtor Terminal
Numbor of Cavities
t
Location Leftside of under-dash fuse/relay box Top of under-dashfuse/relay box Underleft sideof dash Underleft sideof dash Behindglove box Middleof floor Underleft sideof dash Undermiddleof dash Middleof floor
Connectsto fuse/relay box (C911) Under-dash Memoryerasesignal{MES)connector Main wire harness {C414) Cablereel Frontpassenger's airbag SRSunit (C578) Leftsidewire harness (C604) Rightsidewire harness Bodyground,via SRSmain harness
Notes
c801 c802 c803 c804 c805 c806 c807 c808

G801
18
'98 - 00 mooets '98 - 00 mooets
23-38
SRSMAINHARNESS
D\
n
ll-
23-39
/
Fuses
Box Under-hoodFuse/Relay
ALTERNATOR lTo engine wire harness{T102)l BATTERY lTo slarter cableslTlll
DE n
r-'l
IJ
11
tr tr tr
cro1
lTo condensrtan .slayl
IJ
r'1 51
LI
r-'l 56
IJ
r-'l
57
LJ
lTo blower motor releyl
c903
.: Not used
lTo radiator ten relavl
fuse/relay box. of NOTE:View from the backside the under-hood
c306
fTo main wiro hamose(C352ll
c305 lTo mainwiie harnes lc353ll
lTo main wirc harness1C354)l
lTo main wire harnesslC351ll
23-40
Under-dashFuse/RelayBox
c912 wire {C502ll lTo dashboard harness
c914 lTo switchsub-harness {C751ll
c911 mainharness {C801)l lToSRS
c915 switchsub-harness lTo combinatioo 1C752)l
r'=G@6
23 21 25 26 21 28 12 13 1a t5 16 | 2 3 1 5 6 7
T"r r-1 T't r't r-l r-r r't r;l Fl T1 r-l r-l
29
G
32 0
rr Ll tJ tJ LJ Ll lJ LJ t-J LJ u Ll
30
31
33
- r-l n rT n Tl r-l ri n Fl r-'l r-l

L-] [J LI LI I.J I.J tJ tJ TJ LI LI IJ - Fn Fl F1 r-'l T1 r;l r-l r-t r;l |-] r-l
a 9 1 r 11 1a 19 20
21 22
c9r6 [Topowe.windowrelay]
a; Canada
LI I.J LI LJ tJ LJ IJ LI I.J IJ IJ tJ
i -': C927loption {ACCll C928lOption (lG2)l 141: NOTEr View from the backside of the under-dash tuse/relay box.
lTo rear window defoggerrelayl
c922 wireharness 1C417)l lTomain
c924 conttolunitl lTo integraled
(css1)l c920
c919 1C419)l lTo mainwire herness
1C418)l lTo main wire harness
Fuses
Under-hoodABS Fuse/RelayBox
lTo under-hoodABS fus6/r6lay box wire harnessl
c931
lTo main wire harness1C359)l
c933
lTo ABS pump moto. relayl
c932
lTo main wire harness(C360)l
23-42
PowerDistribution
sequence) Index(numerical Fuse-to-Gomponent(sl
Under-hood Fuse/RolayBox:
Fuse
41 43
Capacity '100 A 40A 7 . 5A
wiro Color WHT/BLK WHT/RED WHT/BLK WHT/BLU WHT/BLU
Circuit(s)Protcted A lgnitionswitch(BAT) lntegrated controlunit Ceilinglights Spotlights main relay PGM-Fl Not used box fuse/relay No. 7, 8, 10,11fuse in the under-dash A u d i ou n i t Clock{'98- 00 models) ('98- 00 models) Datalinkconnector ECM(VBU){'98- 00 models:M/T) Heater controlpanel PCM (VBU)(A./T) fuse/relay box) light switch(via under-dash Combination fuss/relay box No. 20,33 fuse in the under-dash Not used Rearwindow defogger(viarelay) Door lockcontrolunit Hatchglassopenersolenoid Keyless door lockcontrolunit ('98- 00 models) Horn relay Horns(via relay) via brakeswitch: ABS controlunit Brakelights controlunit Cruise ECM ('98 - 00 models: M/T) Highmount brakeiight PCM(4./T) Trailerlightingconnector relay(viaswitch) Turn signal/hazard (+B) Optionconnector box fuse/relay No. 6 fuse in the under-dash Blowermotor (viarelay) fan Condenser motor (viarelay) Ay'C compressorclutch (via relay) Radiator motor (viarelay) fan
44 46 47
1 5A 40A 7 . 5A
48 49 50
30A
WHT
204 204
WHT/GRN WHT/GRN
52
1 5A
WHT/GRN
53 54
10A 40A 40A 204 20A
WHT/BLK WHT/RED BLU/WHT WHT RED BLK/RED
50
Under-hoodABS Fuss/nehy Box: Fusg 61 Capacity 40A 204 7 . 5A Wire Color Circuitls) Protoct ABS pump motor {via relay} ABS controlunit ABS controlunit
WHT WHT/GRN BRN/YEL
{cont'd)
23-43
PowerDistribution
(cont'dl Fuse-to-Component(sl Index(numerical sequencel
Under-dashFuse/RelayBox:
Fuse
1
Capacity
Wire Color
Circuit{s)Protected Not used Not used Rearwindow washermotor (viaswitch) Rearwindow wiper controlunit ('97 model) Rearwindow wiper motor Daytimerunningrightsresister {Canada) R i g h t e a d l i g h{tH i g hb e a m } h (Canada) Daytimerunningrights resister High beam indjcator light (Highbeam) Left headlight Rearaccessory socket(viarelay) Left rearpowerwindow motor (viaswitch) Rightrear powerwindow motor (viaswitch) (ignition Distributor controlmodule) powerwindow motor (viaswitch) Frontpassenger's Driver'spowerwindow motor {viaswitch) Powerwindow masterswitch(powerwindow controlunit) Turn signal/hazard relay(viaswitch) PGM-FI main relay SRSunit (VA) Cruisecontrolunit (viaswitch) Cruisemain switchindicatorlight Alternator Charging systemlight E L Du n i t( U S A ) EVAPbypasssolenoid valve('98- 00 models) EVAPcontrolcanister vent shutvalve('98- 00 models) EVAPpurgecontrolsolenoidvalve PrimaryHO2S Secondary H02S VSS ABS controlunit (lG2) Optionconnector Ay'C compressorclutch relay Blowermotor high relay Blowermotor relay Condenser relay fan Heater controlpanel (viaswitch) Left power mirroractuators Mode controlmotor Radiator relay fan Recirculation controlmotor (viaswitch) Rightpower mirror actuators Daytimerunninglightscontrolunit (Canada) Back-up lights Reverserelay (A"/T) Daytimerunninglightscontrolunit (Canada) R i g h th e a d l i g h(tL o wb e a m ) (Low beam) Left headlight
1 0A
"^
1 0A 5 1 0A
RED/B LU RED/GRN
6 7 I 9 10 11 12 13 14
1 0A 20A 204 15A 204 204 7 . 5A '15 A 7 . 5A 7 . 5A
WHT/BLK RED/VVHT YEUBLK RED GRN/BLK BLU/BLK YEVBLK YEUGRN RED BLK/YE L BLK/VVHT
17
7 . 5A 7 . 5A
BLVBLU BLKA/EL
18 19 20 22
7.54 7.54
YEUBLK YEVRED BLKAr'YHT RED/VHT RED/YE L
l0A 1 0A
23-44
under-dash Fuse/RelayBox: Fuse Capacity 1 0A 7 . 5A 7 . 5A wir6 Color PNK Circuit(sl Protocted SRSunit (VB) Powerwindow relay Integrated ControlUnit light ABS indicator A/T gear positionindicatorlight Clock('98- 00 models) light Cruiseindicator Gaugeassembly Interlock controlunit (A,/T) Keyless door lockcontrolunit ('98- 00 models) Powerdoor lockcontrolunit Shift locksolenoid(lVT) light SRSindicator Integrated controlunit ('98- 00 models) wiper switch) controlunit (viawindshield Integrated washermotor (viaswitch) Windshield wiper motor Windshield Front accessorysocket Rearaccessorysocket relay (ACC) Optionconnector Audio unit Not used (dashlights) Optionconnector controlunit Integrated Ashtraylight gear positionindicator light A,/T ('97model) Audio univclock Audio unit ('98- 00 models) Clock('98- 00 models) light Cruiseindicator Cruisemain switchlight controlunit Dashlightsbrightness Gaugelights warningswitchlight Hazard Heater controlpanel Powerwindow masterswitchlight ('99- 00 models) Integrated controlunit ECM('98- 00 models:M/T) PCM (4./T) main relay PGM-Fl Leftfront pa.kinglight Leftfront side markerlight Left rearside markerlight Lefttaillight platelight License Rightfront parkinglight Rightfront side markerlight Rightrearside markerlight Rightaillight Trailerlightingconnector lgnitionkey light lgnitionkey light controlunit ('97model) Interlock controlunit (via ignitionswitch) solenoid Key interlock
25
204 GRN/BLK YEUGRN YEURED 29 30

7.5A
10A 28 10A
a, olrL"
7 . 5A
BLU,ryVHT
7 . 5A
RED/GRN
7 . 5A
WHT/GRN
23-45
GroundDistribution
Ground-to-Component(sl Index
Ground Wire Color BLIVRED BRN BLK BLK Component or Circuits Grounded Battery ValveCover Transmission housing A,/Tgear position switch ECM(PG1, PG2)('98- 00 models:M/T) PCM(PG1, PG2l(Avrr) PGM-FI main relay (PSP) Powersteeringpressure switch Radiator switch fan VSS Datalinkconnector ECM(1G1,LG2)('98- 00 models:M/T) PCM(LGI, LG2)(IVT) Shielding: between ECM ('98 - 00 models: M/T) or PCM (Ay'T) CKFsensor and between ECM{'98- 00 modets: M/T}or pCM (Ay'T) CKpsensor and between ECM ('98 - 00 models: M/T) or PCM (rVT)and CYPsensor betweenECM ('98 - 00 models: M/T) or PCM (Ay'T) TDC sensor and between ECM {'98 - 00 models: M/T) or PCM (ly'T)and countershaftspeed sensor (Ay'T) between ECM ('98 - 00 models: M/T) or PCM{A,,/T) mainshaftsped sensor {!VT) and between ECM ('98 - 00 models: M/T) or PCM(A,/T) and primary HO2S between ECM ('98 - 00 models: M/T) or PCM(Ay'T) secondaryHO2S and H o r n( H i g h ) Horn {Low} Radiator motor fan Right eadlight h Rightfront parkinglight Rightfront side markerlight Rightfront turn signallight Condenser motor fan Cruise actuator Leftfront parkinglight Leftfront side markerlight Leftfront turn signallight Leftheadlight Rearwindow washermotor Windshield washermotor ABS pump motor
G2 G3 G1 0 ' l
BRN/BLK
G201
BLK
G202
BLK
G351
BLK
23-46
Ground G401
Wir Color
Component or Circuits Grounded circuit ABS indicator ABS controlunit Ashtraylight dimmingcircuit A/T gear positionindicator Brake fluid levelswitch Clock('98- 00 models) switch(M/T) Clutchinrerlock Clutchswitch(Mff) Cruisemain switch circuit Cruiseindicator controlunit Cruise controller Dashlightsbrightness Dataiink connector Daytimerunningrightscontrolunit (Canada) Front accessarysocket Gaugeand indicators Heater controlpanel lgnitionkey light controlunit ('97model) lgnitionkey switch Integrated controlunit Interlockcontrol unit (Ay'T) pin Parking switch{A,/T) Powerwindow relay socketrelay Rearaccessary Bearwindow defoggerrelay Rearwindow wiper controlunit ('97model) Service checkconnector Spotlights circuit SRSindicator relay Turn signal/hazard wiper motor Windshield switch Windshield wiper/washer - plus everything grounded through G402 ABS controlunit Blowermotor relay Blowermotor high relay E L Du n i t( U S A ) Powertransistor - plus everything groundedthroughG401
BLK
G402
BLK
{cont'd)
23-47
GroundDistribution
Ground-to-Component(sl Index(cont'dl
Ground G501 Wire Color BLK BLK Component or Circuits Grounded Audio unit (doorlockknob switch) Driver'sdoor lockactuator Driver's door lockswitch Driver'spowerwindow motor Keyless door lockcontrolunit ('98- 00 models) Powerdoor lockcontrolunit Powermirror switch Powerwindow masterswitch Driver's seat belt switch F u e lg a u g e e n d i n g n i t s u Fuelpump (FP) Leftrearside markerlight Lefttaillight Rearaccessary socket Rightrearside markerlight Trailerlightingconnector High mount brakelight Rearwindow defogger Rearwindow wiper motor Rjghtaillight - plus eveMhing grounded throughG631 Hatchglassopenersolenoid platelight License - plus eveMhing groundedthroughG6l1 SRSunit
G552
BLK
BLK
BLK
BLK
G801 BLK
23-48
Box Fuse/Relay Under-dash

a S R Sc o m p o n e n t s r e l o c a t e di n t h i s a r e a .R e v i e wt h e precautions, and procedures SRS componentlocations, (241 performingrepairsor serbefore in the SRSsection vice. Installation: 1. f t C o n n e c t h e c o n n e c t o r so t h e u n d e r - d a s hu s e / relay box (seesection24 for the SRSmain harness connector),then install the under-dashlusehelay orderof removal. box in the reverse lnstallthe knee bolsterand the driver'sdashboard lower cover(seesection20). the the batterypositivecable,then connect Connect negative cable. codefor the radio,then enterthe Enterthe anti-theft fearadiostationpresets(with anti-thett customer's ture). work properly Confirmthat all systems
Removal: 1. code for the radio, Makesureyou havethe anti-theft for then write down the frequencies the radio'sprefeature). set buttons(with anti-theft cable,then disconthe Disconnect batterynegative nectthe positivecable,and wait at leastthree minutes. lower cover and the Remove the driver'sdashboard bolster(seesection20). knee 5. 4. Remove two mountingnuts,and pull the underthe box out from underthe dash dashfuse/relay 2.
3. 2.
4.
3.
f D i s c o n n e ctth e c o n n e c t o r s r o m t h e u n d e r - d a s h box (seesection24 for the SRSmain harfuse/relay fuse/ and take out the under-dash nessconnector), relayoox.
23-49
Battery
Test
@M fluid (eleqtrolyte)contains sulturic acid. lt may cousesevore . Battery

. .
burns if it gets on your skin or in your eyes. Wear protective clothing and a fac6 shield. - lf elestrolyte gets on your skin o. clothos, rinse it otf with wator immdiately. - lf leqtrolyte gets in your eyes.tlush it out by splashing water in your syes for at least 15 minutes; call a physician immediately. A battery gives off hydrogon gas. lf ignited, the hydrogen will xplode and could crack the battery case and splattr acid on you. Kgop sparks.flamss, and cigarettesaway from the battry, Overchargingwill raise the tomperatute of the electrolyte.This may torcs electrolyto to spray out of the battEry vents, Follow the charger manutacturer'sinstructions, and chargethe battery at a proper ral,
Use eithera JCI or BearARBST tester,and follow the manufacturer's procedures. you don't have one of tnesecomputlf erized testers, follow this conventional test procedure: To get accurate results, temperature the ofthe electrolyte must be between 70.F(21.c)and loo"F (38"c).
lf the caseis cracked the terminals or are roose. replacethe batterv.
CheckIndicator EYEColor lf the indicator shows low electrolyte, distilled add water if possible. EYEIndicates OK
(#1) Test LoadCapacity . Apply 300amp load for 15 seconds removesurface to charge. . Allow 15 seconds period. recovery . Apply test load (seeTest LoadChart). . Record voltageat the end of 15 seconos. Voltagestaysabove9.6 volts;batteryis OK.
23- 5 0
(},
Chargeon High Setting(40amps) 30 Chargeuntil EYEshowschargeis OK,plus an additional minutesto Jull assure charge. to NOTE:lf the batterychargeis very low, it may be necessary bypass polarityprotection circuitry. the charger's lf the EYEdoes not show chargeis OK within three hours,the batteryis it. no-good; replace Writedown how long the batterywas charged.
Test Load Capacity(#2) . . . . charge. to Apply 300amp load for 15 seconds removesurface period, recovery Allow 15 Seconds Applytest load (seeTest LoadChart). voltageat the end ot 15 seconds. Record Voltagedropsbelow9.6volts; batteryis no-good,
Voltagestaysabove9.6volts; battery is OK.
J-
TESTLOAD CHART printedon amps (CCA) Usethe test load or use 1/2the cold cranking is indicated. the inforuse lf the labelon the top of the battery. neither mationbelow:
BATTERY CODE
55
COLDCRANKING AMPS (CCA) 410
TESTLOAD {amps)
200
BATTERY CODE
i
5582{LtS)-MF
23-51
J
PowerRelays
RelayTest
NOTE:See page23-86for turn signal/hazard relay input
IESI.
. .
Blowermotor relay Rearwindow defoggerrelay type 1:
Normally-opontype: '1. Check continuitybetween terminats. for the . Thereshouldbe continuity between No. I and the No. 3 terminals when power and groundare connected the No. 2 and No. 4 terminals. to . Thereshouldbe no continuitybetweenthe No. 1 and No. 3 terminals when power is disconnected.
Terminal
t"""r f*r
t*i__\
Disconnected Connected
o
type 2i
a Blowermotor high relay a Rearaccessory socketrelay(M/T) a l \
Itrrz-Hl llHrrUll
' , 3
Y:F,
a l
ffi
23-52
Normally-opentype: 1. the for Check continuitybetween terminals. between No. 1 and the . Thereshouldbe continuity when power and groundare con No. 2 terminals nected the No.3 and No. 4 terminals to the No. 1 . Thereshouldbe no continuitvbetween when power is disconnected. and No. 2 terminals
Normally-opentype: 1. the for Check continuitybetween terminals. the . Thereshouldbe continuity between No. 4 and when power and groundare conNo.3 terminals nected the No. 1 and No. 2 terminals. to the No. 4 . Thereshouldbe no continuitybetween when power is disconnected. and No. 3 terminals
Terminal
Terminal
t.*", ^"-
t*f
tl**^-*
-_\
Drsconnected Connected
Disconnected
Connected
o- ---o
a a a a a
Powerwindow relay Radiator relay fan fan Condenser relay clutchrelay A,/C compressor Reverserelay (A/f) Horn relay Rearaccessorysocketrelay {A,/T) a Starter cut relay
ABS pump motor relay
\K,
lgnition Switch
Test
S R Sc o m p o n e n t s r e l o c a t e di n t h i s a r e a .R e v i e wt h e a SRScomponentlocations, precautions, and procedures in the SRSsection{24}beforeperformingrepairsor ser vtce. L l M a k es u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e radio,then write down the frequencies or the f radio'spresetbuttons(wilh anti-theft feature). 2. Disconnect batterynegative the cable. 3. Remove the driver'sdashboard lower coverand the kneebolster{seesection20). 4. Disconnect the 5P connectorfrom the under-dash fuse/relay box and the 3P connector from the main wtre narness,
3P CONNECTOR
ElectricalSwitch Replacement
SRS componentsare located in this area. Review the precautions, SRScomponentlocations, and procedures in the SRSsection{24)beforeperformingrepairsor service. 1. M a k e s u r e y o u h a v e t h e a n t i - t h e t tc o d e f o r t h e radio,then write down the frequencies or the f radio'spresetbuttons(with anti-theft feature). Disconnect batterynegative the cable. Remove the driver'sdashboard lower coverand the kneebolster(seesection20). Disconnect the 5P connectorfrom the under,dash tuse/relay box and the 3P connector f.om the main wire harness {seeleft column). R e m o v e h e s t e e r i n gc o l u m n c o v e r s( s e es e c t i o n t '17 t. Insertthe ignitionkey,and turn it to "0". 7. Removethe two screws and the electricalswitch from the steeringlock,
2. 3.
4.
5P CONNECTOR
Wireside of temale terminals Checktor continuitybetweenthe terminalsin each switchpositionaccording the table. to \ ros[ron rernrnal I \ I3l 5 3 I1l
(ACC) {BAT} flG1) 0G2i
lsrl
swrTcH
LOCKCYLINDER
0 (LocK)
r(Accl
fl (oN) III(START) { I | 3Pconnector
o- -o
G
_o -.o
lnstallin the reverse orderof removal.
9.
o-
7.
lf the continuitychecksdo not agreewith the table, replace electrical the switch. After reconnecting the battery,enter the anti-theft code for the radio,then enter the customer'sradio (with anti-theft stationpresets feature).
After reconnecting the battery,enter the anti-theft code for the radio,then enter the customer'sradio (with antj-theft stationpresets feature).
23-54
GaugeAssembly
precautions, in and procedures the SRS are locatedin this area.Reviewthe SRScomponentlocations, SRScomponents repairsor service. section{24}beforeperforming
I x 1.25mm 24 N.m {2.4 VEHICLE SENSOF{VSS' SPEED page23-62 Troubleshooting,
GAUGEASSEMBLY ge/lndicator/Terminal Gau LocationIndex,page 23-56 page23-57 BulbLocations, page23-61 Removal, FUELGAUGESENDING UNIT Seesection1l
J-
BRAKESWITCH PARKING
GAUGE COOLANT TEMPERATURE SENDING UNIT
BRAKEFLUIDLEVELSWITCH SWITCH OIL PRESSURE ENGINE
GaugeAssembly
Gauge/lndicator/Terminal LocationIndex
"A" CONNECTOR INDICATOR) {A/T GEABPOSITION a1___-__-____>816
cl--------->cl3
JilililIJililil1 JililtHililL
.. , """^
u e
o u
t)1- --->t)5 "DCONNECTOR {ABS INDICATOR)
E1- - -->E5 "E" CONNECTOR INDICATOR' {CBUISE
Fl---->F5
"F" CONNECTOR {SRSINDICATOR}
SPEEDOMETER: Indicates km/hat 637 rpm or 60 60 mph at 1,026 rpm ofthe (VSS). vehicle speedsensor
oo/
\oo
TACHOMETER: lndicates rpm at 100 200pulsesper minute of the ignitioncontrol module(lCM).
23- 5 6
l-
Bulb Locations
TAILGATE INDICATOR (,I.4 (1.4WI LIGHT W) LIGHT CHARGING SYSTEM GAUGE LIGHT {1.4WI BRAKE SYSTEM LTGHT Wl 11.4 HIGHBEAM INDICATOR LIGHT W {1.4 l GAUGE LIGHT I1,4WI LOW ENGINE OIL PRESSURE LIGHT{1./rW} INDICATOR MALFUNCTION INOICATOR LAMP {MIL) BULBI1.4WI LEFTTURN SIGNAL INDICATOR LIGHT{1,4W}
SEATBELT REMINDER LIGHT{1.' W' LOW FUELINOICATOB LIGHT WI 13
RIGHTTURNSIGNAL INDICATOR LIGHTI1.' WI
GAUGELIGHT
1,.
f-=\ F -
t3wl
GAUGELIGHTS13WI A/T GEARPOSITION INDICATOR x {1.12 7} (Onthe printed GAUGELIGHT{3.' W} circuitboard) (1,4 ABSINDICATOR W) lOn the printedcircuitboard)
('1./t SRSINDICATOR W) (Onthe printed circuitboard)
tNDtcAToR w) cRutsE 11.r2

(On the printed circuit board)
23-57
GaugeAssembly
CircuitDiagram
U N O E R . I I O OF U S E / R E L8 O X D AY BATTERY UNOER_DASH FUSEiNELAY BOX
@*"
( ( No.41100A) No.4240A)
YEL E5 ASSEMSLY GAUGE
''' |
RED
8LK BLU/RED
l-I
| 0l
ALTERNATOR
-I
DASH LIGHTS BRIGHTNESS CONTROLLER
CRUISE CONTROL UNIT
ABS CONTROL UNIT
UNIT SRS
G401 G4A2
23-58
(}-.
tI -, I I T
rJr--------11-.----..1'\-J
BLK/YEL BLUMHT I
BLKMHTJ 'i-
l t Y
IGNITION CONTROL I/lODULE IcM)
| g
_ YEL TURN SIGNAU HAZARD WARNING No.s i10A) .--......_ FUSE LEFT
swrTcH
Y Y Y
RIGHT
f7
BLU
I 1.,
MALFUNCTION INDICATOR tA[rP([,{tL) {1.4W1
CRN/ORN
l.,
PCM
COOLANT TEII,4PERATURE SENDING UNIT
T
G401 G402
G552
BLK
(cont'd)
23-59
GaugeAssembly
CircuitDiagram(cont'd)
GAUGE ASSEMBLY PREVIOUS PAGE BRAKE SYSTEM LIGHT l1.4Wl
SEAT BELT REMINDER LIGHT (1.4W) a1 \

\J
TAILGATE INDICATOR LIGHT {1.4W}
\ ./
' \ \
B6
Gnru;neo
I
|
f7
R U I \ N | N0 G H T S G
|
I
'BLU BED I INTEGRATED I coNTRoL I UN|T REAR CEILING LIGHT
I
|
i oo,,#, i
L__c_o!l!g_yI'__l rcanada) t \
I I l
l v
I tI t
-l
IBLU RED
r-
Al I J
ABS CONTROL UNIT
+
G401 G402
FLUIO I SRAKE I LEVET SWITCH . Floal I fCLOSED down) . Floal J up lLoPEN BLK
T
tlsA)G552
BLK
I Glass open I rCLOSED closed toPEN : Glass I
TAILGATE LATCH swtTcH rTailsate I open fCLoSED I0PEN iTailsateclosed.J
23-60
Removal
'1. Remove panel. the two screwsfrom the instrument 2. 3. 4, 5. 6. 7, panelcarefully avoiddamaging clips. Remove instrument the to the Tilt the steering wheeldown with the tilt adjustment lever. Spreada protective cloth over the steering column. Remove four mountingscrewsfrom the gaugeassembly. the Pullthegaugeassembly out, and disconnect connectors all from it. Remove gaugeassembly. the
GAUGEASSEMELY
INSTRUMENT PANEL
23-61
VehicleSpeedSensor(VSSI
Troubleshooting
box. testing,inspect the No. 15 (7.5A) fuse in the underdashfuse/relay Before
T6st tho BLK wirei the 3P connector 1. Disconnect from the vehicle speedsensor {VSS). 2. Connect the test harness only to the {07LAJ- PT3020A) enginewire harness. the 3. Connect FEDtest harness clip to the positiveprobe of an ohmmeter, 4. Checkfor continuitybetween the REDtest harness clip and body ground. TESTHARNESS OTLAJ PT3O2OA REDTESTHARNESS
PROTECTIVE TAPE
Repairopen in the BLK wire betwGonthe vSS .nd G101.
GRNTESTHARNESS CLIP T.st the BLK/YELwire: 1. Connectthe WHT test harness clip to the positive probe of a vohmeter, and connect RED the clip test harness to the negative probe. 2. Turnthe ignition switch (ll). ON
TESTHARNESS OTLAJ PT3O2OA REO CLIP HARNESS
WHT TESTHARNESS CLIP
Rep.ir op.n in th. BLK/YELwire betwaen the VSS rnd the und6rdash fuse/.6lav box.
Test the BLU/WHTwi.s: C o n n e c t h e G R Nt e s t h a r n e s s c l i p t o t h e p o s i l i v ep r o b e o f a voltmeter.and connectthe RED clip to the negative test harness probe.
TAPE
ls thereabout5 V or more?
Repairopen in the BLU/WHTwiro bstweon the VSS and PCM.
(To next page)
23-62
o-.
(Fromprevious page) WHT TESTHARNESS

CLIP
T6st the VSS: 1. Turn the ignition switch OFF. 2 , C o n n e c tt h e o t h e r t e s t h a r nessconnector the VSS, to 3. Raise front and rearof the the v e h i c l e a n d s u p p o r tj t w i t h , safety stands. 4. Put the transmission neuin t r a l w i t h t h e i g n i t i o ns w i t c h
TESTHARNESS OTLAJ_ PT3O2OA BEDTESTHARNESS GRNTESTHARNESS
ct-tP
PROTECTIVE TAPE
oN r).
5. Slowly rotateone wheel with the otherwheelblocked.
Doesvoltage pulse from 0 to approx, V or more? 5
Spoodom6torT6st: 1, Disconnect 16Pconnector the " B " f r o m t h e g a u g ea s s e m 2. Toucha probeto the BLUMHT wire. and connect it to body groundthrougha voltmeter. 3. Slowly rotate one wheel with the otherwheel blocked.
'BGAUGEASSEMBLY 16PCONNECTOR
Wire sideof femaletermin6ls
BLU/WHT
Doesthe meter indicatepulsing voltage?
R.p.ir opon in the BLU/WHTwire betwen the VSS and the 3oeedomgter.
I (v) It
23-63
Integrated Gontrol Unit

CircuitDiagram-'97
BATTEFY ' I No.4{'004)
Model
tGNITtON lCrl SW
\0.d2'40A) |
UNDER.HOOD FUSEi RELAY 8OX
cr*"
w_T+!v_T ELK
l__*l;;T
I
H-uTr.r--i=r-
BLKryEL
WINDSHIELD WIPER/ WASHEF 9WTTCH , OFF/INT INT
G F NB L K i
,,.h\ WINDSHIELD ( il) WASHEB
lo
SWITCH
a
g
t t
t
l l
l
WHTiBLK
YEL
WHT]BLKWINDSHIELD WASHER I MOTOB I
lI
BEMINDEB LIGHT (r 4w)
NTERMITTENT WIPERRELAY CIRCUlT
KEY.IN/SEAT BELT and LIGHTS-ON BEMINDER CIRCUIT
RED/BLU
BLUMHT
BLK
WINDSHIELD WIPER MOTOR (As)
DRIVER'S SEAT BELT r Unbuckled f CLOSED ) (OPEN :Buckled -.1
swtTcH
BL( -tr
-l
G401
G552
23-64
<
ELK/WHT
COMBINATON LIGHT SWITCH
\-/
RED/GRN
S'TARTEB CUT RELAY
A,/rGEAR POSrr SWTTCH 0N (CLOSED :lnpostion N) Eor
1,,,,,"
.lNTEGRATED CONTROL UNIT KEY.IN]SEAT andLIGHTS'ON BELT REMINDER CU CR T
GRN/RED
Yilei'r
. BNAKE FLUIO LEVEL SWITCH . P A R K I NE R A K E G
(usA) swrTcH
A8
BULB BRAKE CHECKCIFCUT
B1o PowER I LOCK BLU/RED DOOR T CONTFOL UN I
POWER DOOR LOCK CONTROL UNIT
RED BLUi
J F r,r'tro
"l\ u/
LTGRN/RED
LTGRN/RED
LT
/rh
v
d[) !s-l
LEFT REAB 00OR SWITCH : Door f CLOSED opel closed \oPEN Doo'
no* llon.
\oPEN | 8LK
155,1'*n s e d e d I a C L O S E DK e y l
Keyrcmoved
I FFONT I I PASSENGEBS I I DOOR | oDen lSwlTcH ) I : ooot dosedJ J f C-OSED ooer ) | ( ooE\ Doot dosed,r | |
_L :
-._ -
l
23-65
G40r
Integrated ControlUnit
CircuitDiagram-'98 - 00 Models
FUSE/BELAY UNOER,HOOD 8OX EATTERY
@*"
(100A) N0.41
(40A) N0.42
-....+ WHT/BLK
WHT/RED
WHT
IJNDER DASH FUSEi BELAY BOX
WINDSH WPER/ ELD
GRN/BLK
gsHERlIrTcH .
OFF/ NT INT
REAS WINDOW /.Fn WINDSHIELD WIPER ( il) WASHEF MOTOR
lo
f7
f7
l
SWITCH
t t
t
l
-9
WHT/BLK
f7
BLU/BLKYEUBLU
WINDSHIELD WASHEF MOTOR
I LTGRN
WHT/BLK
INTEGFATED coNTsoL UNIT I 85
I 83
t,,
NEAFWINDOW INTERMITTENT WIPER RELAY CIRCUIT
INTERIT,IITTENT RELAY WIPER CIRCUIT
8LK
G401 G402
23-6 6
COMBlNATION LIGHT SWIlCH
\-7
REO/GFN
GRY
I rql)
-"'-},,,,,"
YEL
GRN
Y4-orot POSTT1ON
SEAT EELT REM NDER LIGHT (1.4W)
(A/T) SWTTCH I I . (cLosEDInposrlion NI Eor I CLUTCN INTERLOCK I (M,T) I swrTcH :Clulch I /CLOSED Dedal\ \lullydeprsssed I |
' BFAKE FLUID LEVEL SWITCH 'PARKINBRAKE G
g v**JT"
8LK
Y l1eff E
I I
Gl01(A,T)
f;iillrvrr
(usA) swrTcH
A6
INTEGRATED CONTROL UNIT
A8
\-
i
KEY]N/SEAT BELT LIGHTS.ON and REMINDER CLRCUIT
I : *,
RED/BLU RED/BLU /BLU
ltrh::ffIxl,,'.l'" ,,,[:
BLU/ ED B
KEYLESS/POWER DOOB LOCK CONTROL UNlT
FEO/BLU
dF)
Y* lsE
swrTcH 13fr rcLosED

(OPEN
BtK
(3!?i". sl:$P)l Hrtrff"% lHfi.#' ) l l(3

: G40t G402
DRIVER'S SEAT BELT
A Y
T
l*,*,J I
I
GFN/nED+-]
LTGRN/RD
V
t
I cvro\
Y*,u,.,
| Bft_oi|l
A
I
LTGRN/RED
d['\ \s.i
4P'\
EF's l*'n
13fft" ) l39P* ooe.) :Door oper) | fCLOSED. Doo'open| fCLO#D. Door

. Door dosd, \oPE\ . 000'closed, \oPE\
IFFÎ'
|
Door ciosed,
l--
l --
IntegratedGontrol Unit
Input Test -'97 Model
precautions, SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, and procedures the SRS in section{24)beforeperformingrepairs service. or '1. Remove driver'sdashboard the lowercoverand the kneebolster(seesection20). 2. 3. 4. Disconnect 'l0Pconnector the from the inteorated controlunit. Remove the integrated controlunit from the under-dash fuse/relay box. Inspect connector the terminals be surethey are all makinggood contact. and socket to . lf the terminalsare bent,looseor corroded, repairthem as necessary, recheck system. and the .lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket. - lf any test indicates problem,find and correctthe cause, a then recheck system. the - lf all the inputtestsproveOK,the controlunit must be faulty;replace it.
INTEGRATEO CONTROL UNIT
rOPCONNECTOR
femaleterminals
23-6 8
All Systems: Cavity

414
Wire
Test condition Underall conditions

Under all conditions
Test: Desiredrsult for to Check continuity ground: Thereshouldbe continuity. Check voltageto ground: for Thereshouldbe batteryvoltage. Check voltageto ground: for Thereshouldbe batteryvoltage.
Possiblecauseif result is not obtained . P o o rg r o u n d( G 4 0 1G 4 0 2 ) , . An open in the wire . Blown No. 43 (7.5A) fuse in the under-hood fuse/relay box . An open in the wire . Blown No. 25 (7.5A)fuse in the underdashfuse/relay box . An open in the wire
A9 lgnitionswitchON (ll) A6
Intermittent Wipol System: Cavity Wire Tost condition Test: Desiredresult Check voltageto ground: for Thereshouldbe batteryvoltage. Possiblecauss if result is not obtained Elown No. 26 (20A)fuse in the under-dash fuse/relay box Faultywindshield wiper switch Faultywindshield wiper motor An open in the wire Blown No.26 (20A) fuse in the under-dash fuse/relay box Faultywindshield wiper motor
B1
lgnitionswitchON (ll), and windshield wiper BLU/BLK switchat OFF/lNT
lgnitionswitchON (ll)
82
BLUrur'HT
lgnitionswitchON (ll), and windshield wipe. switch at INT
for Check voltageto ground: Thereshouldbe batteryvoltage.
Anopen thewire in
B3 YEVBLU
Check voltageto ground: for Thereshould be battery voltage. Blown No. 26 (20A) tuse in the under-dashfuselrefaybox Faultywindshield wiper switch An open in the wire Blown No. 26 (20A) fuse in the under-dash fuse/relay box Faultywindshield washerswitch An open in the wire
B4
lgnitionswitchON (ll), washer and windshield WHT/BLK switchON
(cont'd)
23-69
lntegratedControlUnit
InputTest-'97 Model(cont'd)
At----------+A7
Key-in/SeatBelt Reminder,Lights-on RemindorSystem: Cavity Wire Test condition C o m b i n a t i olng h t i switchON Test: Desiredrosult for Check voltageto ground: Thereshouldbe batteryvoltage. Possiblecause if re3ult is nol obtainod B l o w nN o . 3 0( 7 . 5 ) f u s ei n t h e A under-dash fuse/relay box Faultycombination light switch An open in the wire Poorground (G552) Faulty seat belt switch Blownseatbelt reminderlight bulb An open in the wire . Faultydriver'sdoor switch . An open in the wire
A8
B7
RED/BLU
lgnitionswitchON {lll. and driver'sseatbelt switchunbuckled lgnitionswitchON (ll), and driver'sseatbelt switchbuckled Driver'sdoor open
for Check voltageto ground: Thereshouldbe 1 V or less. Check voltageto groundl for Thereshouldbe 4 V or more. Check voltageto ground: ior Thereshouldbe 1 V or less. Check voltageto ground: for Thereshouldbe 4 V or more. for Check voltageto ground; Thereshouldbe 1 V or less. Check voltageto ground: for Thereshouldbe 4 V or more.
B9
GRN
Driver's door closed lgnitionkey insened into the ignitionkey switch lgnitionkey removed trom the ignitionkey swrtch
8 1 0 BLU/RED
Poorground(G401, G,[02) Faultyignitionkey switch An open in the wire
Bulb CheckSystem (BrakeSystem Light): Cavity Wire Test condition lgnitionswitchON {ll), brakefluid reservoir full, and parkingbrake teveroown lgnitionswitchat (lll),and START A/T gear position switchE or E
T6st: DGsirgd rosult
Possiblecause if resuh is not obtainod Blown No. 25 (7.5A) iuse in the under-dash fuse/relay box Blown brakesystemlight bulb An open in the wire Blown No.31 (7.5A) fuse in the under-dash fuse/relay box Faultystartercut relay FaultyA/f gear positionswitch P o o rg r o u n d( G 1 0 1 ) An open in the wire
A4
Connect ground:Brakesystem to l i g h ts h o u l d o m eo n . c
Check voltageto ground: for Thereshouldbe batteryvoltage.
A13
23-70
InputTest-'98 - 00 Models
precautions, and procedures the SRS in SRScomponents are locatedin this area.Reviewthe SRScomponentlocations, section(24)beforeperforming repairs service. or L 2. 3. 4. Remove driver'sdashboard the lower coverand the kneebolster(seesection20). Disconnect 'l5Pconnector from the inteqrated the controlunit. Remove the integrated fuse/relay box. controlunit from the under-dash Inspect connector the and socket terminals be surethey are all makinggood contact. to . lf the terminalsare bent,looseor corroded. repairthem as necessary, recheck system. and the .lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket. lf any test indicates problem, a find and correct the cause, then recheck system. the - lf all the input testsproveOK,the controlunit must be faulty;replace it.
UNDER-DASH FUSE/RELAY BOX
A8<------A14 INTEGRATED CONTROL UNIT
YEL/BLU 15PCONNECTOR
LT GRN
WHT/BLK
IntegratedControl Unit
InputTest-'98 - 00 Models(cont'dl
YEL/BLU A 1- - - - - - - - > A7 LT GRN
WHT/BLK
GRN/BLK LT GRN/REO Wiresideof female terminals
A8------->A14
WHT/BLK
BLU/RED
Key-in/Se8t Beft Reminder,Lights-on Remindol System: Cavity Wire Test condition Combination light switch ON Test: Desiredresult Check voltageto ground: for Thereshouldbe battery voltage. Possiblecaus it result is not obtained Blown No. 30 (7.5A) fuse in the under-dash fuse/relay box Faultycombination light switch An open in the wire Poorground{G552) Faulty seat belt switch Blownseatbelt reminderlight b ul b An open in the wire . Faultydriver'sdoor switch . An open in the wire
A8
RED/BLU
lgnitionswitchON (ll), and driver'sseatbelt switchunbuckled lgnitionswitchON (ll), and driver'sseat belt switchbuckled Driver's door open
Check voltageto ground: for Thereshouldbe 1 V or less. Check voltageto ground: for Thereshouldbe 4 V or more. Check continuity ground: for to Thereshouldbe continuity, Check continuity ground: for to Thereshouldbe no continuity. Check voltageto ground: for Thereshouldbe 'l V or less. Check voltageto ground: for Thereshouldbe 4 V or more.
814
GRN
Driver'sdoor closed lgnitionkey inserted into the ignitionkey swrtch lgnitionkey removed from the ignitionkey switch
B8
BLU/RED
Poorground(G401, G402) Faultyignitionkey switch An open in the wire
Bulb CheckSystem lBrake System Lightl: Cavity Wire Test condition lgnitionswitchON (ll), brakefluid reservoir full, and parkingbrake leverdown lgnitionswitchat ( START lll),and gear position A,/T switchE or E Test: Desiredresult Connect ground:Brake to system l i g h ts h o u l d o m eo n . c Possiblecaus if result is not obtained Blown No. 25 (7.5A) fuse in the under-dash fuse/relay box Blown brakesystemlight bulb An open in the wire Blown No. 31 {7.5A) fuse in the under-dash fuse/relay box Faultystarter cut relay gear positionswitch(A,/T) FaultyA,/T Faultyclutchinterlock switch(M/T) Poorground{G101: AfI. G401and G402:M/T) An open in the wire
A4
Check voltageto ground: for Thereshouldbe battery voltage.
A13
23-74
LightingSystem
l-.
I-IGHT I{IGHBEAM INOICATOR
RUNNING LIGHTS DAYNME REslsToi lCan!drl page23-80 Test,
COMBINATION LIGHTSWTCH Test,page 23-78 DAYTIME RUNNINGLIGHTS CONTROL UNIT lCanadal Input Test, page23-79
Replacment, Page23-80 Adjustment,Page23-81
FRONT TURNSIGNALLIGHT/ FRONT SIDEMARKER LIGHT page23-80 Replacemont,
HIGHMOUNT BRAKELIGHT page23-84 Replacement,
LIGHT BRAKE/PARKING page 23-82 Replacement,
LIGHT BACK.UP page 23-82 Replacement,
23-75
LightingSystem
CircuitDiagram(USAI
BATTERY UNOER_HOOD FUSE/RELAY 8OX
@**'
rrf JLo -,.9,;,,
Td
UNDER-DASH FUSEiREIAY BOX
I
No.5 tl0Al
i,"dii
Zt'"olli
No.4 {10A)
N0.30 17.5A)
li':,.î I
RED/ BLU
'BLK RED
l t
HIGHSEAI\4 INDICATOR LIGHT
' DASH , PARKING LIGHTS LIGHTS . DASH . SIDE LIGHTS MARKR LIGHTS BRIGHTNESS,TAILLIGHTS . LICENSE COIVTROLLER PLATE TIGHT
G40l G4a2
BLK
BLK
.& G202
23-76
O,-
CircuitDiagram(Canada)
80X FUSEiRELAY UNDERHOOD BATTEBY
@*"
UGHT c0t\48rNATroN SWITCH
+WHT WHT/BLK
l = o ), : . , o F F
4
RED
U N D E RD A S H U S E / R E L8 O X F AY
BBAXE SYSTEM LIGHT ABS CONTROL UNIT
. DASH LIGHTS LIGHTS ' PARKING , DASH MAHKER LIGHTS LIGHTS ' SIDE T E R I G H T N E S.S A I L L I G H T S .L PL L CONTHOLLER ICENSE ATIGHT
I GRN/RED
NEO/CRN
T,
HIGHBEAM INOICATOR LIGHT 8LK
G401 c402
I I
BLK
G202
G20
BLK
8LK
8LK
-L -::
G40l G402
d -G401 G402
23-77
LightingSystem
Combination Light Switch Test
'1. Remove the driver'sdashboard lower coverand the kneebolster(seesection20). 2. Remove steering the columncovers(seesection'17). 3. Disconnect 4Pand 7P connector the from the switch. 4. Remove screws, the and slidethe switchtowardthe driver,sdoor, 5. Inspect connector the and socket terminals be surethey are all makinggood contact. to
4P CONNECTOR
2 5 6
Terminal
Position
1 OFF
Headlight switch
:m:
=D L0w
HIGH
o_ ----o o-- ----o o_ ----o
o-
----o o- _--_o_----o o_ ---o
Passing switch r : Canada
OFF
ON
23-78
DaytimeRunningLightsControlUnit Input Test (Canadal

1.
Removethe driver's dashboard lower cover and the knee bolstet (seesection 20). the connectorsfrom the daytime runDisconnect ning lightscontrolunit. Inspectthe connectorand socket terminals to be surethey are all makinggood contact. repair are lf the terminals bent,looseor corroded, the and recheck system. them as necessary, l f t h e t e r m i n a l sl o o k O K , m a k e t h e t o l l o w i n g IP CONNECTOR inout testsat the connector' - lf anv test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input tests prove OK, the control unrt must be faulty; replaceit.
DAYTIMERUNNINGLIGHTS UNIT CONTBOL
8P CONNECTOR
YEL/BLK
GRN/RED BLK/WHT
RED/GRN
Cavity B1 BLK
Tst condition Underall conditions Underall conditions
Tost: Desiredresult to for Check continuity ground: Thereshouldbe continuity. tor Check voltageto ground: There should be battery voltage. for Check voltageto ground: Thereshouldbe batteryvoltage.
Possiblecauseii r$uh is not obtained . Poorground(G401, G402) . An open in the wire Blown No. 20 (7.5A) luse in the box fuse/relay under-dash An open in the wire Blown No. 18 (7.5A) fuse in the box tuse/relay under-dash Faultyignitionswitch An open in the wire Blown No.,tg (30A) fuse in the under-hoodfuse/relaybox light switch Faultycombination An open in the wire G401, G202, Poorground (G201. G402) bulbs Blown headlight Faultydaytimerunninglights resrslor An open in the wire Blown No. 25 (7.5A) fuse in the box fuse/relaY under-dash Blown brake system light An open in the wire
. Faulty parking brake switch . An open in the wire
A2
BLK,4iVHT lgnitionswitchoN (ll)
82
YEUBLK
light Combination " " switchin =D Posiuon
A4
RED
for Check voltageto ground: There should be battery voltage.
A1
R'I
light Combination a switchOFF;connect jumperwire between WHT/RED the 82 and 41 terminals,then turn the ignition switchON (ll) lgnitionswitchON (ll), brakefluid reservoir GRN/RED full. and parkingbrake leverdown 8EDlGRN brakeleverup Parking
(highbeam)should Headlights on, (andhigh beam come shouldcome on). indicator
to Connect ground:The brake systemlight shouldcome on.
B6
to for Check continuity ground: Thereshouldbe continuity
LightingSystem
Test (Canada)
Headlights
Replacement
CAUTION: Halogen headlights bGcomevery hot in use; do not touch them or the attaching hardware immediately after they have been turned oft. 1. 2. 3. Remove front bumper(seesection2O). the Remove the mountingbolts. Disconnect each connector, then removethe headlight assembly.
Dafime Running LightsResistor
CAUTION: The d.ytime running lights resistor becomes very hot when the daytime running lights are on; do not touch it or the attaching hardware immediatelyaller the lighls have been turned off. 1. Disconnect 3P connector the from the resistor.
HEADLIGHT ASSEMELY
Measurethe resistance betweenthe resistorterminal No. 1 (or No. 2) and the powerterminalNo. 3. Resistance: - 2.0 O 1.0 Replacethe resistorwith a new one if any of the resistances beyondspecification. are
HEADLIGHT: 60/55 W TURN SIGNAL/SIDE MARKERLIGHT: 2118W {37 model} 2718W ('98 - 00 modelsl PARKING LIGHT:5W l'97 modell 3CP{'98 - 00 modelsl
23-80
Adjustment
Bstore adiusting the headlights: . Parkthe vehicleon levelground . Makesurethe fuel tank is tull . The driver or someonewho weighsthe same should sit in the driver'sseat. . Loadthe trunk with the itemsyou usuallycarry' . Push down on the front and rear bumpers several timesto makesurethe vehicleis sittingnormally' CAUTION: Halogen headlights become very hot in use; do not touch them or the atiaching hardware immediately after they have been turned off. 1. 2. 3. the hood. ODen the left innerfender{seesection20). Remove indicator. adjustment horizontal Checkthe "0" markon the horizontal gear should indicator The with the mark. be aligned HORIZONTAL INDICATOR GEAR 5. "0" mark as lf eitherindicatoris not alignedwith its can be made left column,an adjustment described screwdriver. by usinga Phillips by to Adjustthe headlights localrequirements turnthe adjusters. ing NOTE: . As the outer lensesare made of an acrylicoated, do material, not cover the headpolycarbonated lightswhen they areturnedon slide the . When making horizontaladiustments, gear rearward. indicator horizontal After horizontaladjustment,put back the horigear. zontalindicator
"0" MARK
The bubble indicator. Checkthe verticaladjustment the longest scribe should be centeredunderneath markon the gauge. INDICATOR: VERTICAL
ol23-A1
)
RearSide MarkerLights/ License PlateLight

Replacement
RearSide Marke. Light: 1. Removethe retainingspring, and removethe rear side markerlight from the rearbumper. Disconnect 2P connector the from the light.
Taillights
Replacement
1. 2. 3. Openthe hatchglass. Disconnect 6P connector the from the taillight. Removethe three screws,then pull out the outer taillight.
2.
RETAINING
HOUSING
LicensPlate Light: 1. Remove two screwsfrom the license the plate light, and pull the light out part of the way. Disconnect 2Pconnector the from the light,
Brak/Plrking light 2115W Back-uplight: 21CP(18 W) Turn signll light 21 W Inspect the gasket; replace it if it is distorted or $ays compressed. Installthe taillight, and run water over it to make sure it does not leak.
2.
(8 LIGHT WI
23-A2
Back-upLights
CircuitDiagram
FUSE/RELAY BOX UNDEN-HOOD
_*,,@_ "*" *"_,,. ]__ _..' iu.Er.w
-r-
(M/r) I
I
BACK,UP LIGHT
swtTcH
/0n1he \ I lransmisson J \no!s{ / : In R lolosed posilion l
GRN/BLK
LEFI BACK,UP LIGHT ( 2 1 C P1 8 W )
RIGHT BACK,UP LGHT 21CP 8W) 0
A,/IGEAR Posrl0N swtTcH /Back'up \
\lhl swilch ,/ : In ICLOSED posilion [8ll
BLK
8LK
G101
BrakeLights
Gircuit Diagram
UNDER.HOOD FUSE/RELAY BOX | No.s2 {15A) |
High Mount BrakeLight Replacement

1. P u s ht h e c l i p s , a n d r e m o v e t h e c o v e r f r o m t h e housing.
HOUSING
BATTENY /,i\
\Y*-I=f*-'o*T*'no"l
I
T:,^-,
HORNSYSTEM
*",*"", i.t53l|
GRNA,VHT
-.1 GBNMHT
. ABS CONTFOL UNIT ' ECM/PCM . CRUISE CONTROL UNIT
2.
Disconnect connectors. the Remove two nuts and the housing. the
GRNAVHT
t l A[$^Jlr A (2rw)
LEFI BFAKE LIGHT
GRNWH
Yi,?'il Y
BLK
RIGHT EFAKE LIGHT (21w)
BLK
t
l r
BLK
ll
BLK
G553
d oi,,
23-84
Turn SignallHazardFlasherSystem
O -. Diagram Circuit
BOX FUSE/NELAY HOOD UNDEF BATTEFY
IGNT]ONSWITCH UNDER.OASH FUSE/RELAY BOX
No12(7.sA)
@**'
(7.54) N0.30 FUSE
YEUBLK WHTiELK
V
REO/BLK
l,
t' I
\ l----r-l-----i-F--
--------_
HAZARD WARNING swtTcH _ GRN/ORN
10
GRN/ORN
3
GRNAVHT
FqD
qINDICATOR TFAILER LIGHTING CONNECTOR
.+
DASH LIGHTS BSIGHTNESS CONTROLLER
INDICATOR (1.4W)
BLK
BtK
G553
G401 G402
:i1r'97model *2 :'98-00 models
23-85
Turn SignallHazard Flasher System

Turn Signal/Hazard RelayInput Test
S R Sc o m p o n e n t s r e l o c a t e di n t h i s a r e a .R e v i e wt h e a SRScomponent/ocations, precautions, ano proceoures in the SRSsection(24)beforeperformingrepairsor service.
1.
Remove turn signal/hazard the relayfrom the underdashfuse/relay box. Inspect relay and luselrelay the box socket terminals to be surethey are all makinggood contact. l f t h e t e r m i n a l sa r e b e n t , l o o s e o r c o r r o d e d , reparr them as necessary, recheck system. and the l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g input testsat the fuse/relay box socket. - lf any test indicates problem,find and cora rectthe cause, then recheck system. the - lf all the input tests proveOK, the turn signal/ hazard relaymust be faulty;replace it.
'
/ll
$ o{+ll
IF\_-'l ] -
FUSE/RCLAY BOX SOCKET Cavity 2 Test condition

Underall conditions l g n i t i o ns w i t c h O N ( l l l
Tesl: Desiredresults Check continuity ground: for to Thereshouldbe continuity. Connect voltageto ground: for Thereshouldbe batteryvoltage.
Possiblecause if result is not obtained . P o o rg r o u n d( G 4 0 1G 4 0 2 ) , . An open in the wjre Blown No. 12 (7.5A) fuse in the under-dash fuse/relay box Faultyhazard warningswitch An open in the wire Blown No. 53 (10A) fuse in the underhood fuse/relay box Faultyhazard warningswitch An open in the wire Poorground(G201. c202, c401, G 4 0 2G 5 5 3G 6 1 1c 6 3 1 ) , , , Faultyhazard warningswitch An open in the wire . Faultyturn signalswitch
Hazard warningswitchON
Connect voltageto ground: for Thereshouldbe batteryvoltage.
Hazard warningswitch ON;connect the No. 1 terminalto the No. 3 terminal.

1
Hazard lightsshouldcome on.
l g n i t i o n w i t c h N ( l l )a n d s O t u r n s i g n a s w i t c hi n r i g h t l or left;connect the No. 'l t e r m i n atlo t h e N o . 3 terminal.
R i g h to r l e f t t u r n s i g n a ll i g h t ss h o u l d come on.
23-86
Turn SignalSwitch Test

lower coverand the 1 . Remove the driver'sdashboard kneebolster(seesection20). Removethe steering column covers {see section 17]-. D i s c o n n e c t h e 4 P a n d 7 P c o n n e c t o r sf r o m t h e switch. 4. and slidethe switchtowardthe Remove the screws, driver'sdoor.
WarningSwitch Test Hazard

1. 2. the Remove centerpanel{seesection20). Removethe two screws,then remove the switch from the centerair vent.
lNol usd)
HAZARD
swtTcH
Checkfor continuitvbetweenthe terminalsin each to switchpositionaccording the table. Checkfor continuitybetweenthe terminalsin each to switchpositionaccording the table. Terminal Position RIGHT
Neutral
Terminal
2 3
7 8 10
t**--\
1 2
OFF
(9 U
(_)
oo- --o
ON
o @o o o
tl-
LEFT
23-87
lgnition Key Light System-'97

CircuitDiagram
IJNDER-HOOD FUSE/HELAY BOX
Model
BATEBY
tF*-'--ff::f-*"-l
l-Noj',roo{ l;;f
.l-----
| ; )"tli|illsx"r
I
WHT/CRN
( P I KEYLGHT
o,u ,k ,0r,,
I
I
{14w)
WHT/BLK
WNT/GRN
OR VER'S 000R
9!rl9rl^ : U O O r O p e n ^ ULU5EU
I I (OPEN :Doordosed J
ControlUnit Input Test

20). lowercoverand the kneebolster(seesection the l. Bemove driver'sdashboard the from the controlunit. 2, Disconnect 5P connector the and socket terminals be surethey are all makinggood contact. to 3. Inspect connector . . and the lf the terminalsare bent,looseorcorroded,repairthemas necessary, recheck system. lf the terminalslook OK, makethe followinginput testsat the connector. - lf any test indicates problem, the find and correct the cause. then recheck system. a - lf all the inputtestsproveOK,the controlunit must be faulty;replace it.
IGNITION KEYLIGHT CONTROL UNIT
5P CONNECTOR
))
Cavity
Wire BLK
Test condition Underall conditions lgnitionswitchON (ll)
Test: Desiredresult Check continuity ground: for to Thereshouldbe continuity. for Check voltageto ground: voltage. Thereshouldbe battery Check voltageto ground: for Thereshouldbe 1 V or less. Check voltageto ground: for Thereshouldbe 4 V or more. Connect ground:lgnitionkey to light shouldcome on.
Possiblecauseif rsult is not obtained . Poorground{G401, G402} . An open in the wire . Blown No. 33 (7.5A) fuse in the fuse/relay under-dash box . An open in the wire . Faultydriver'sdoor switch . An open in the wire
'I
WHT/GRN Driver's door open GRN Driver's door closed Underall conditions WHT/BLK
Blown No. 33 (7.5A) fuse in the under-dash fuse/relay box Blown ignitionkey light bulb An open in the wire
23-89
Controller DashLightsBrightness
CircuitDiagram
G401
23-9 0
Input test Controller

NOTE:The controlunit is built into the dashlightsbrightnesscontroller.
1.
pry Carefully the controller of the dashboard. out trom the controller, Disconnect 3P connector the Inspect the connector terminalsto be sure they are all makinggood contact. . lf the terminals bent,loose,or corroded, are repair them as necessary, recheck system. and the . lf the terminals look OK, makethe followinginput tests at the connector. - lf any test indicates problem,find and cora rect the cause.then recheckthe system. - lf all the input tests prove OK, the controller must be taulty;replace it.
OASHLIGHTS BRIGHTNESS CONTROLLER
Csvity
Wire
Tst condhion Combination light switch ON
Tsst: Desiredresuli Check voltageto ground: for Thereshouldbe batteryvoltage.
Possible cause if result is not obi8inod
RED/BLK
Blown No. 30 (7.5A) fusein the fuse/relay under-dash box Faultycombination light switch An open in the wire . Poorground(G401, G402) . An open in the wire . An open in the wire
BLK
RED
Underall conditions Combination light switchON
for Check continuity ground: to Thereshouldbe continuitv. Connect ground: to Dashlightsshouldcome on full bright.
23-91
InteriorLights
FRONT LIGHT CEILING Test,page 23-94 SPOTLIGHTS Test, page FRONT PASSENGER'S DOORSWITCH LIGI{T REARCCILING Test, page 23-94 RIGHTREAR
swtTcH
DRIVER'S DOORSWITCH
HATCHGLASS LATCHSWITCH LEFTREAR
oooRswtTcH
TAILGATE LATCH SwlTCH
23-92
I J
CircuitDiagram
FUSERELIY UNOER.I]OOO BOX BA--FqY
\:/-*-.........-='_Fn-'.,,
[t..*;;;;l
o-,
INDCATOF !ICH'I
f7
I I I
BLU/EL(
rJ----r I Y l^,,o.orro | | | coNthoL
I F#l*'
FI
t_* "r**I d,*^* r"$$i,,,,,*,,

l J
LTG
/f\ \9/
I
I FRoNT I PASSENGEF'S | 0@R
I l
Iii{il'' t
) | swrlcN D@' J lTcLosED
.-" Iuffi**
-
l!oPEN:D@'
23-93
InteriorLights
Test CeilingLaght
Front and rgar: 1. 2. 3. 4. Turn the light switchOFF. Pry off the lens. Remove two mountingnuts and the housing. the from the housing. Disconnect 3P connector the
SpotlightTest
1. Turn the spotlightswitchOFF. 2. 3. 4. Pry off the lens. Remove two screwsand the housing. the Disconnect 3P connector the from the housing.
1' 3' 2'
aULB(5Wx2l
Checkfor continuitvbetweenthe terminalsin each switchpositionaccording the table, to
Checkfor continuitybetweenthe terminalsin each switchpositionaccording the table. to
\ t"",rr"
Terminal \ ON
2 1
ol
2'
\ Position
trmtnar 1 \
or 1'
2'
3'
3
Pd'l
R
OFF
OFF
ooo-
MIDDLE ON
/=\
/a\
\:/
-o -o -o
ON L
OFF
oo oo-
/-\ \:./
--o o --o --o
@
/a
\:./ (9
23-94
AccessorySocket
o-.
Circuit Diagram
UNDER_HOOO FUSE/RELAY 8OX IGNITION SWITCH txt Fffi^-.rr-.rrl wHT'BrK 6\ +*HT-137F wHr BLK t-'**1*fffiT
-*T]
(
) No.6
REO/GRN
I
I
I
I
i{10A)
i ll%ti
YEL GRN
FUSE/RELAY i l9:,'3 BOX
UNDER-DASH
l-
J-i,_, l ''l '"*'

l ft l333iEi.''
/BLK
YEL/GRN
YEL, YEL/GflN
RED/BLK
,*1. I
ir*?:r"$ |
BLK
t l
8LK
t l
t l
8LK
l J
t t l lt l l l
l
$Ni*" t-*r8LK
-:a
-:
G553
G40t G4A2
G401 G4A2
G40t G4A2
23-95
AccessorySocket
SocketTest/Replacement Accessory
Front AccessorySocket: 1. lower cover (seesecRemove the centerdashboard t i o n2 0 ) . from the front accessory Disconnect 2Pconnector the socket. Inspect the connector terminalsto be sure they are all makinggood contact. repair lf the terminals bent,looseor corroded, are the them as necessary, recheck system. and l f t h et e r m i n a l so o kO K ,g o t o s t e p4 . l 5. If all the tests proveOK, replace front accessory the socket.
2.
PBOTECTOB FACEPANEL
ACCESSORY SOCKET
Turn the ignition switch to ACC (l), and checkfor voltagebetween the No. 1 and No. 2 terminals. . . Thereshouldbe batteryvoltage. checkfor: lf there is no batteryvoltage, - b l o w n N o . 2 7 ( 1 0A ) f u s e i n t h e u n d e r - d a s h fuse/relay box. - p o o rg r o u n d( G 4 0 1G 4 0 2 ) . , - a n o p e ni n t h e w i r e .
23-96
RearAccessorySocket: '1. Removethe left rear side trim panel {see section 20t. 2. 3. Disconnect connectors. the terminalsto be sure they are lnspectthe connector all makinggood contact. l f t h e t e r m i n a l s r e b e n t ,l o o s eo r c o r r o d e d , a repairthem as necessary, and recheckthe sys tem. o l f t h e t e r m i n a l ls o kO K ,g o t o s t e p4 .
5.
Removethe thermofusehousingand thermal pro tector,then removethe socketand cover.
COVER THEEMAL PROTECTOR
ACCESSORY SOCKET
THERMOFUSE HOUSING
T$
SOCKET
A (YEL/8LUI
ry
\ J
4.
I IBLK}
tor Turnthe ignitionswitchto ACC(l),and check volt agebetween A and B terminals. the o Thereshouldbe batteryvoltage. . lf there is no batteryvoltage, checkfor: - b l o w nN o . 6 ( ' 1 0 ) a n d N o . 2 7 ( 1 0A ) f u s e si n A the under dashfuse/relay box. - faulty rear accessory socketrelay (test,page 23-53). - poor ground (G401, G402, G553). - a n o p e ni n t h e w i r e .
23-97
-'98 - 00 Models Glock

CircuitDiagram
UNDEE,HOOD FUSE/RELAY BOX
BATTERY
@-*"
No.41(1004) N0.42140A)
(7.54) N0.47
-l
IGNTIONSWlTCH
8ox
UNOEN.DASH FUSgFELAY
G40t G402
23-9 8
Removal
1. 2, 3. Remove centerair vent (seesection20). the Disconnect 4Pconnector. the Remove two screws. the
Terminals
CLOCK
Connectsto
I
WHT/BLU YEL
RED/BLK
power (time Constant memory) lG1 (mainclockpowersupply) Lights-on signal G r o u n d G 4 0 1G 4 0 2 } { ,
BLK
CENTERAIR VENT
23-99
StereoSoundSystem
AI{TENNA MAST page 23'103 Replacement, SUB ANTENNALEAD
AUDIO UNIT page Replacement. 23-'102 page Terminals, 23-102
FROI'IT SPEAKERS page Replacement, 23-103

REAR pago 23-103 Beplacement,
23-100
E
t J Diagram Circuit
FUSE/FELAY BOX UNDER.HOOO
IGNITION SWITCH
WHT,tsLK
l-^*"-l T'5 1
-T
UNOEB,DASH FIJSE/RELAY BOX
(7.5A) No.30 FUSE
I I I I I
YEURED
a,-,
AUOIO UNIT
o o
1 s 1 6 l |7 [ 6 1 l GHY,ryVHT
o o
s tr4 | 1l7l
BRN/BLK
LEFTREAR SPEAKER
RIGHT BEAR SPEAKER
LEFI FRONT DOOF PEAKER S
RIGHT FBONT DOOB SPEAKER
23-101
StereoSound System
Audio Unit Removal
1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e radio,then write down the frequencies or the f radio's presetbuttons (with anti-theftfeature). Remove centerpanel(seesection201, the Remove four mountingbolts,and pull the audio the unit out. D i s c o n n e c t h e ' l 6 P c o n n e c t o ra n d s u b a n t e n n a lead,then removethe audio unit.
AudioUnit Terminals
AUDIOUNIT
CENTEB PANEL
Cavrty 1{7) Installin the reverse orderof removal. After installingthe audio unit, enter the anti-theft code for the radio. then enter the customer's radio station presets(with anti-theftfeature). 2 {8}
Wire RED/GRN
Connoct3 to Right front door speaker@ Left front door speaker@ Lights-on signal power (tuning Constant memory) ACC (main sterso power supplyl Left rear soeaker@ Rightrearspeaker @ Riqht f.ont door speakerO Left front door soeakerO Dashlightsbrightness controller ( Ground G501) Left rear speakerO Rightresr speaker O
BLU RED/BLK WHT/BLU YEURED BLU/YEL RE D/VEL

BRN/BLK
3 {9)
4 (10) 5 (2) 7 (6)
8 (s)
9 (17) 1 0( 1 8 ) 1 2( 1 9 ) 14 (20) 1 5( 1 6 ) 1 6( 1 5 )
GRY/BLK RED BLK GRYMHT

BRN^ll/HT
T e r m i n aN o . 6 , 1 1 ,a n d 1 3 :N o t u s e d l ( T e r m i n a l o . 1 , 3 ,4 , ' 1 1 , 1 21 3 ,a n d ' 1 4 o t u s 6 d ) N , N { ): '99 - 00 models
23-102
Replacement Speaker
1. 2. 3. cover. Remove speaker the Remove threescrewsfrom the speaker. the
Mast AntennaReplacement
to NOTE:To remove the antennalead, it is necessary (seesection20). removethe dashboard 1. Disconnect antennaleadfrom the audio unit. the Remove two mountingscrews, the then removethe mast antenna.
Disconnect 2P connector, the and removethe door speaker.
2.
Front speaker:
MOUNTINGSCREWS
FRONT SPEAKER
Rearspeaker:
/a--=-
2P CONNECTOR
ll-
SPEAKER COVER
23-103
Horns
precautions, procedures the SRS SRScomponents are locatedin this area,Reviewthe SRScomponentlocations, and in section(24)beforeperformingrepairs service. or HORN page23-105 Test,
HORNSW|TCHES Test,page 23-106
m
HORNRELAY Test. page23-53
/\
CAELEREEL
R e p l a c e m e n t ,s e c t i o n 2 4
23-104
CircuitDiagram
HornTest
1. 2. 3, 20). Remove front bumper(seesection the from the horn the Disconnect 2P connector Remove the horn.
HORN
2P CONNECTOR
} -
BLU/FED
KEYLESSi POWEF DOOR LOCK CONTROL UNIT
fl"'
4.
BLUi EO F
g)iirrN I
BLK
BLU/RED
Test the horn by connectingbatterypower to one terminaland groundingthe other.The horn should sound.
LOW HORN
t
l
I
BLK
BLK
I I
G201
5.
it lf the horn failsto sound,replace
23-105
Horns
Switch Test
1 . Disconnect batterynegativecable,then disconnect the the positivecable,and wait at ieastthreeminutes. Disconnect driver'sairbagand front passenger's the (seesection24). airbagconnectors Remove the drive.'sdashboard lower coverand the kneebolster(seesection 20). Disconnect cablereel sub-harness or 6P conthe 3P nectorfrom the main wire harness. 6. Removethe driver's airbag (see section 241,then disconnectthe horn connectorfrom the steerinq wneet. 7 . Checkfor continuity betweenthe No. 2 or No. 3 terminal of the cable reel sub-harness or 6P con3P nectorand horn Dositive terminal.
MAIN WIRE HARNESS 3P o. 6P CONNECTOR
CABI.I REEL SUB.HARNESS 3P or 6P CONNECTOR
HORNCONNECTOR
37 modol
,98- 0Omodots Terminal of side male terminals
lf there is no continuity,replacethe cable reel (seesection 24). lf there is continuity.repair or replacethe horn switch. 8. lf sll tests prove OK, reinstall the driver's airbag (seesection24), and reconnect the cable reel subharnessconnector. 9 . Reconnect driver'sand front passenger's the airbag connectors,and reinstallthe accesspanel on the steering wheel. 1 0 . Reconnect batterypositivecable,then the negative the cable.
1 1 . After installing the airbags, confirm proper system
Checkfor continuitybetween the No. 2 or No. 3 term i n a l o f t h e c a b l er e e l s u b - h a r n e s a n d b o d y s groundwith the horn switchpressed.
'97 model: '98 - (X)modols:
operatron:
Terminalside of Terminal sideof
. .
lf there is continuity. horn switchis OK. the go lf there is no continuity, to step 6.
Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds and then go off. Makesure both horn buttonswork.
23-106
PowerMirrors
CircuitDiagram
FUSURELAY BOX UNDER.HOOD IGNITION SWITCH +WHT WHT/8LK lBAI \ l
(100A) N0.41 (40A) N0.42
@"*'
^rc2l .Y
YEL
-t----t
BLKIryEL
I lu.'x I
I
UNDER,DASH FUSE/RELAY B0x
POWEN MIRRON SWTCH
3 YEURED
BLUMHT
BLK
vHT GRN +l
l,[ ]: '9&00 rnodels
-:
G551
23-107
PowerMirrors
Function Test
1.
Pry the switch out of the dashboard. carefulnot Be to damagethe mirror switchor the dashboard driver's lowercoverwhen pryingthe switchout. Disconnect 10Pconnector the from the switch. Choose appropriate dasedon the symptom: the test . Both mirrorsdon't work, go to step 4. . Left mirror doesn't work, go to step 6. . Rightmirror doesn'twork,go to step 7.
Left mirror inoperative: 6. Connectthe No. 2 {BLKI/EL)terminal of the ,l0p connectorto the No. 3 (YEUREDI terminal and the N o . 5 ( o r N o . 6 ) t e r m i n a lt o b o d y g r o u n d w i t h jumper wires. The left mirror should tilt down (or swing left) when the ignition switch is turned ON t). lf the mirror doei not tilt down (or does not swing left),removethe left door panel,and checkfor an open in the BLUMHT (or BLU/BLK) wire between the left power mirror and the switch. lf the wire is OK,checkthe left power mirror actuator, lf the mirror neithertilts down nor swings left, repairthe YEURED wire. lf the mirror operatesproperly, checkthe mirror switch. Right mirror inoperaiiva: 7. Connectthe No. 2 {BLVYEL) terminat of the 1Opconnector the No. 3 (YEURED) to terminaland the No. 9 (or No. 8) terminal to body ground with jumper wires. The right mirror should tilt down (or swing left) when the ignition switchis turnedON l). . lf the mirror does not tilt down (or does not swing left), remove the right door panel, and checkfor an open in the GRN,4TVHT yEUBLK) (or w i r e b e t w e e nt h e r i g h t p o w e r m i r r o r a n d t h e switch. lf the wire is OK, checkthe right power mtrror actuator. lf the mirror neithertilts down nor swings left. repairthe YEURED wire. lf the mirror operates properly,checkthe mirror switch.
.
-.t-..------'-
Both inoperative: 4. Checkfor voltage between the No. 2 (BLVYEL)terminal and body groundwith the ignitionswitch ON
flr).
5.
Thereshouldbe bafteryvoltage, . lf there is no voltage,checkfor: - blown No. 17 (7.5 A) fuse in the under-dash fuse/relaybox. - an open in the BLK,/YEL wire. . lf there is battery voltage, go to step 2. Checkfor continuitybetweenthe No. 4 {BLK)terminal and body ground. Thereshouldbe continuity. lf there is no continuity, checkfor; . an open in the BLKwire. . poor ground (c551).
23-108
Switch Test
1. Removethe switch as describedin FunctionTest {seepage23-108). CheckJor continuitybetweenthe terminalsin each to switchpositionaccording the table.
Actuator Test
1. 2. Prv out the mirror mount cover (seesection20). from the power mirror. the Disconnect 8P connector
MIRROR MOUtrlT COVER
2.
Teminal
t*t* UP
DOWN L LEFT RIGHT
UP
DOWN R
o ooo oo oo o .o o o o oo o o oo oo o oo o o oo o o
o o
J-
RIGHT
Checkactuator operation by connecting power and groundaccording the table. to \ ;;,i". Terminal -\ 1 8
@ @
TILTUP
TILTDOWN SWINGLEFT SWINGRIGHT
o
@
MIRROR POWER
swtTcH
23-109
RearWindow Defogger
Gomponent LocationIndex
rr^ja}
aia\
al I
rl
REAB WINDOW DEFOGGER SWTTCH p89e Input Test, 23-113

FUSE/RELAY BOX
REAR WINDOW DEFOGGER page23-112 Function Test. page23-112 DetoggerWre Repair,
23-110
a-
EI
CircuitDiagram
BOX FUSE/REI-AY UNDER-HOOD BATTERY IGNITION SWTCH +WHT WHT/8LK
( N0.42404)
@-*"
N0.41 100A) {
-f
"r?h \_--,' I
I I
l-
DEFOGGER SWITCH REAs WINDOW panel) control B1 {iniheheater
8LK
l"
I J
G401 G402
23-111
RearWindow Defogger
Function Test
1. Check voltagebetween for the positive terminaland body ground with the ignitionswitch and defogger switchON. Thereshouldbe batteryvoltage. . lf there is no voltage.checkfor: - faultydefoggerrelay. - faultydefoggerswitch. - an open ,n the BLK/BLU, WHT/GRN, BLU/YEL, or BLKwire. lf there is batteryvoltage, to step 2. go
DefoggerWire Repair
NOTE:To make an effectiverepair,the brokensection m u s tb e n o l o n g e r h a no n e i n c h . t 1. Lightlyrub the areaaroundthe brokensectionwith fine steelwool, then cleanit with alcohol. Carefully maskaboveand belowthe brokenportion of the defogger wire with cellophane tape.
OPEN
2.
POSITIVE TERMINAL
CELLOPHANE TAPE Mix the conductive paint thoroughly.Using a small brush, apply a heavy coat of the conductivepaint extending about 1/8" on both sides of the break. Allow 30 minutesto dry.
Checkfor continuitybetweenthe negative terminal and body ground. l f t h e r e i s n o c o n t i n u i t yc h e c kf o r a n o p e n i n t h e , defoggergroundwire. Touch the voltmeter positiveprobe to the halfway point of eachdefoggerwire, and the negative probe to the negative terminal.Be carefulnot to scratchor damagethe defogger wireswith the testerprobe. Thereshouldbe approximately V with the ignition 6 switchand the defoggerswitchON. . .
oK.
lf the voltageis as specified, defoggerwire is the
lf the voltageis not as specified, repairthe defogger wire. - lf it is more than 6 V, there is a breakin the negative half of the wire. - l f i t i s l e s st h a n 6 V , t h e r e i s a b r e a ki n t h e positivehalf of the wire. Check continuityin the repaired for wire.
5,
Apply a secondcoat of paint in the sameway. Let it dry three hoursbeforeremovingthe tape.
23-112
Switch Input Test

NOTE:Beforetesting, check for blown No. 17 (7.5 A) box. fuse/relay fuse in the under-dash 1. 20). the Remove centerpanel{seesection
SWITCH REAR WINOOWDEFOGGER controloanel) lin the heater
PANEL CENTER
Checkfor voltagebetweenthe 84 and 87 terminals in each switch positionwhen batterypower is connected the B l terminal. to
OFF
lessthan 0.4V baftery voltage
ON
OlI
23-113
Wipers/Washers
SRScomponents are locatedin this area.Reviewthe SRs componentlocations, precautions, and procedures the s6s in section(24)beforeperforming repairs service. or
REAB WINDOW WIPER MOTOB Tst,page 23-120

WPSR/WASHER SWITCH Test.page 23-l't9
REAR WINDOW WIPER CONTROL 137mod.ll UNlT page Input test. 23-118
WINDSHIELD WIPER MOTOR page Tost, 23-119
n t ff
UNDER.DASH FUSE/RELA BOX INTERMITTENT W|PENRELAY CIBCUIT, REARWINDOWINTERMTNENT wlPER RELAYCIBCUITl'98 - 0Omod.t.l (ln the integratedcontrol unit) Input test, page 23-68
23-114
-
l -
CircuitDiagram{Windshieldl
BOX FUSE/NELAY UNDEB.HOOD
IGNITON SWITCH
UNDEB,DASH BOX FUSENELAY
@*"
(1004) N0.41
N0.42 {40A)
BLUiBLK YEUBLU WHTiBLK INTEGEATED CONTFOL UNIT bui[-in / Has \ I inlermiltenl I relay \ wiper /
l-
BLK
8LK
BLK
_L
G401 G402 G401 G402 G401 G402
I I
23-115
Wipers/Washers
(Rear CircuitDiagram Window)-'97 Model
@**'
N0.41 (100A)
N0.42 (40A)
WHT/BLK +WHT
, 7 ! i s - - - - - - -- - - -
JiJ frT
BLK
d -l
G401 G4A2
G202
8LK
t'
G611 G631
23-116
(Rear Windowl-'98 - 00 Models CircuitDiagram

80X FUSEi UNDER.HOOD RELAY BATTERY
@*,'
N0.4(100A) 1
N 0 . 4( 4 0 A ) 2
+WHT WHT/BLK
ON GNIT SW TCH
UNDEF-DASH FTJSE/RELAY BOX
REAR WINDOW WPER MOTOR
J D L
I
OFF
GRN/BLK
UN INTEGRATED CONTROL T /Has boll-inre wndow\ w perrelay ] t nlermillenl
A n',$s".,,,
vil8t8E
BLK
BLK
I
I
BLK
OtI
.L
G40l G402
nG202
n_ -:
G611 G631
23-117
Wipers/Washers
RearWindow WiperGontrolUnit lnput Test-'97 Model
1 . Removethe driver'sdashboard lower cover and the
kneebolster{seesection20). Disconnect 8P connector the from the controlunit. Inspect connector the and socket terminals be sure to they are all makinggood contact. a lf the terminals are bent,loose,or corroded, repair them as necessary. and recheckthe system. . lf the terminalslook OK, makethe following input tests at the connector. - lf any test indicates problem,find and correct a the cause, then recheck system. the - lf all the input tests are OK, replace the control
UNII.
8P CONNECTOF
LT GRN/BLK T GRN/RED\ LT
1
2 6
GRN/BLK
Cavity 4
Test condhion
Test Desirdr93uh Check continuity ground: for to Thereshouldbe continuity. Check voltageto ground; for There should be battery voltage. Check voltageto ground: for There should be battery voltage.
Possiblecause il rasuh is not obtained . Poorground(G401, c402) . An open in the wire Blown No. 3 (10A) fuse in the under-dashfuse/relaybox An open in the wire Blown No. 3 (10A) fuse in the under-dash fuse/relay box Faultyrearwindow wiper/washer switch An open in the wire Blown No. 3 {10A) fuse in the under-dash fuse/relay box Faultyrearwindow wiper motor An open in the wire B l o w nN o . 3 { 1 0A ) f u s ei n t h e under-dash fuse/relay box Faultyrgarwindow wiper motor An open in the wire B l o w nN o . 3 ( 1 0A ) f u s ei n t h e under-dashfuse/relaybox Faultyrearwindow wiper/washer switch An open in the wire
BLK
GRN
Underall conditions lgnitionswitchON (lll
'l
LT GRN/ RED
lgnitionswitchON (ll), and rearwindow wiper/washerswitch ON lgnitionswitchON (lll
LT GRN/ BLK lgnitionswitchON (ll) LT GRN
Check voltageto ground; for Thereshouldbe batteryvoltage.
lgnitionswitchON lll), and rearwindow GRN/BLK wiper/washerswitch at washerposition
23-118
Switch Test Wiper/Washer

Window Wiper/WasherSwitch: Windshield/ReEr 1. lower coverand the Remove the driver'sdashboard kneebolster(seesection20). columncovers{seesection17) Remove steering the D i s c o n n e c t h e 8 P a n d 6 P c o n n e c t o r sf r o m t h e switch, remove the two screws, and pull out the switch.
\ lind3hi.ld:
WiperMotor Test Windshield

1.
Open the hood, removethe cap nuts, and caretully remove the wiper arms so that they do not touch the hood. Remove cowl cover(seesection201. the the 5P connectortrom the windshield Disconnect wiper motor.
2. 3.
IEZIA
Raar Window: 1 12 3
tilt-rltl
I t-7 al
J-
the termlnalsin each Checkfor continuitybetlveen positionaccording the tables. to switch Windshield Wiper/WasherSwitch: \ P*tOFF
Terminal ---__\ 4
INT LO HI "0N" Mistswhch "0N" switch Washer
oo o o o
1
o o o o
3
o o o o o
Test the motor by connectingbattery power and groundaccording the table. to \ Terminal
;fi;"
LOW SPEED
-l
4
@ @
HIGH PEED S
RearWindow Wipsr/Washer Switch \
ti'"
Teminal ---\
lf the motor does not tun or fails to run smoothly, replaceit. an Connect analogvoltmeterbetweenthe No. 5 (+) and run the motor at low or and No. 3 (-) terminals, high speed. The voltmeter should alternatelyindicate0 V 8nd 4 V or less.
'0N' Washer switch (wiper oFFl switch

OFF
G G G G
-o -o o -o
-o
ll -
ON "ON' Washer switch "0N"1 (Wiper switch
-o 23-11 9
Wipers/Washers
RearWindow WiperMotor Test
1 . Remove tailgate the trim panel(seesection20), Disconnect 4P connector the from the wiper motor assembly.
WasherMotor Test
1.
Remove front bumper(seesection20). the D i s c o n n e c t h e 2 P c o n n e c t o r sf r o m t h e w a s h e r molors,
REARWINDOW WASHER MOTOR
4P CONNECTOR
Push tab to release,
WIPEB LOWER COVEn
Test the motor by connecting battery power to the No. I terminal,and groundto the No. 3 terminal. lf the motor does not run or fails to run smoothly, replaceit.
4.
Test the washer motor by connecting battery power and groundaccording the table. to
L_Iq'.r91
Battery
Disconnected Connected
,l
Reconnect 4P connector the wiper motor. the to Connect analogvoltmeterbetweenthe No. 4 (+) an and No. 2 (-) terminals. Run the motor by turning the wiper/washer switch
5.
a lf the motor fails to run smoothly, replaceit. a lf the motor runs smoothly, but little or no washer
oN.
The voltmeter should alternatelyindicate0 V and 1 1V o r l e s s .
f l u i d i s p u m p e d ,c h e c kf o r a d i s c o n n e c t e d r o blocked washerhose,or a cloggedpump outletin the motor.
23-120
HatchGlassOpener
CircuitDiagram
FUSE/RELAY BOX UNDER.H@D BATTEFY
Switch Test
1. Remove the dashboard lower cover (see section 20). Disconnect 2Pconnector the from the switch. R e m o v et h e s w i t c h f r o m t h e d a s h b o a r d l o w e r cover.
@*"
|-*;rr^!...',r,*;l .......1<\o<\r+l
2.
I
I
WHT/GRN
3.
DASHBOAND LOWER COVER
WHT/GRN
rt
I I
WHT/GBN
KEYLESSi POWEF DOOB LOCK CONTROL UNIT
V
I I
I
YEL HATCH GLASS OPENER SWITCH
Ot-
J T I
BLK
HATCH GLASS OPENER
soLENOr0
Checkfor continuitybetweenthe No. 1 and No. 2 terminals. . . There should be continuity when the switch is pushed. Thereshouldbe no continuity when the switchis released.
out,
G631
23-121
HatchGlassOpener
Solenoid Test
1. Open the tailgateand removethe tailgatetrim (see section20). Disconnect 2Pconnector the from the solenoid.
Replacement Solenoid
't. Remove tailgate the trim (seesection 20). 2.
Disconnect 2P connector. the
2.
SOLENOID
Terminalsade of maletermtnals
Remove the rod from the key cylinder. Connectpowerto the No. 1 terminaland groundto t h e N o . 2 t e r m i n a l s o m e n t a r i l vT h e s o l e n o i d m . shouldooerate.
4.
Remove the three mountingbolts,then removethe solenoid. Install the replacement solenoidin the reverse oader of removal.
23-122
Power Door Locks

Component Locationlndex
TRANSMITTER Test, page23-130 Cod6 Input Procedure, page23-131
DOOR L(rcK SWITCH DRIVER'S page Test, 23-129
LOCK BUTTON
HATCHGLASS BUTTON
RIGT{TREARDOORLOCK ACTUATOR Test,page 23-129 20 Replacement,section FRONT PASSENGER'S DOORLOCKACTUATOR Test, page 23-129 soction20 R6Dlacement,
PA rc AUTTO]II
HATCHGLASSOPENER SOLENOIO fesl, page 23-122 pago 23-122 Replacemnt.
LEFT BEAR DOOR LOCK ACTUATOB page Tesr, 23-129 Beplacement, section 20
. DRIVEB'S DOORLOCK KNOB SW|TCH Tesr,pag623-128 . DRIVER'S DOORLOCK ACTUATOR T6st,psge 23-128
23-123
Power Door Locks

EntrySystem) CircuitDiagram(With Keyless
FUSE/FELAY UNDER.HOOD BOX EATTEFY
GNTIONSWTCH UNDER DASH FUSE/RELAY BOX
@*n'
WHT/GFN YEL
8 UNLOCK
ITEYLES--l
nrrenu@
I TRANSMIT]ER I Lr-------HORN RELAY
f7 I IHATCH OPENER swlTcH

FRONT CEILING LGHT
LOCK
GRY
@
KEYLESS DOOs LOCK CONTROL IT UN
f7
Y_o*,,.,,,0I
. PASSENGENS DOOR SWITCHES . ]NTEGRATED CONTROL UNIT 5
INTEGRATED CoNTROL T UN
YEL
,Y, I F",'*-{
.,ufrro
I I
fIl l B
+
l
HATCH GLASS OPENER SOLENO D
L rthg#,i."J
T
BLK
l
DRIVER'S DOOF LOCK
8!?i"'[:lll',fffi)
swrTcH
BL(
I--
G61l G63l
I
G551
BLK
G401 G402
I
G551
8LK
23-124
CircuitDiagram{WithoutKeyless EntrySystem)
UNDER.HOOD RELAY FUSEi 8OX BATTEBY
IGNTIONSWITCH
@**'
wrr +wqr-t_t3-K
6\
BLKYEL ffr
tr.*;l
UNDER-DASH FUSE/RELAYBOX
vEL
t
HORN RELAY
l-J';
| I
oBtvERs DOOn LOCK ACTUATOR
KNOB
V
(Nol used) LOCK HATCH GLASS OPENER SWTCH
FRONT CEILING TIGHT
f7
V
r-
POWER DOOR LOCK CONTROL UNIT
l_
INTEGRATED CONTROL UNIT
V
YEL BLU/RED
EIGHT REAR 00oR LocK ACTUATOR
I
I
lBLU/RED
8Lr
YEURED GRNORN
t / |Iupl ::iii^
I I
I
-Tq.
s l-lLocx^l
, | -=tGJ--
l,
GRNWHT
tFl
?
G6l1
YAil''"',4,.'{yrcLosED tottt l'

BLK
,#. L?Vno' ( li: ) swrTcH
Locx
I
I
DRIVER'S D00RLOC( SWITCN
BLK
I':
I I
BLK
I:
I I
G()1 G402
G551
'tl
23-125
PowerDoor Locks
GontrolUnit Input Test
1. Remove driver'sdoor panel(seesection the 20). 2. Disconnect 18Pconnector the from the controlunit. the and socket terminals be surethey are all markinggood contact. to 3. lnspect connector . . the lf the terminalsare bent,looseorcorroded,repairthemas necessary, recheck system. and lf the terminalslook OK, makethe followinginput testsat the connector. - lf any test indicates problem, a find and correctthe cause, then recheck system. the - lf all the input testsproveOK,the controlunit must be faulty;replace it.
18PCONNECTON
BLU
GRN/BED GRY YEL WHT/REO WHT/GRN \
2 10
3 1t
,/
1 21 1 3 14 LT
5 16 17
1E
GRN/WHT I
femaleterminals
23-126
Disconnocithe 18Pconnestor from the powr door lock control unit. Cavity
11
Wire
8LK
Test condition
Underall conditions Connectthe No. 7 termi' nalto the No. 8 terminal, to and the No.6 terminal the No. 17terminal momentarily. Underall conditions
Tost: Dcsiredresult
Check continuity ground: for to Thershouldbe continuity. Checkdoor lock operation: Driver's door shouldunlock.
Po$ible csuse il result is not obtainod

. Poorground (G55'l) . An openin the wire Faultyactuator junctionconnector (C577) Faulty An openin the wire BlownNo. 51 (20Al{use in the underhoodfuse/relay box BlownNo.52 (15A)tuso in the underhood fuse/relaybox Faulty horn Faulty horn relay An openin tho wire Faultyactuator An openin the wire BlownNo.51 (20A)fuse in the underhood fuse/relaybox Faulty actuator An openin the wire BlownNo. 51 {20A) fusein ihe underhood fuse/relaybox ' Faultydriver's door lock actualor . An openin the wire
BLU
to Connect ground: Hornshouldsound,
GRY Connectthe No. 'l8 terminalto the No. 8 terminal, and the No.6 terminal to the No. 17terminal momentarily.
Checkdoor lock operation: Passenger's doors should unlock.
YEURED
Connect No.6termithe nalto th6 No.I terminal, WHT/RED and the No. 18terminal to the No. 17terminal momentarily. Connect ohmmeter an between No. 9 termithe nal and the No. l7 terminal.Driver's door lock knobin UNLOCK
Check door lockoperationl All doorsshouldlock.
for Check conlinuity: Thereshouldbe continuity.
BLU/RED
*: With keylessentry system NOTE:To preventdamageto the motor,apply batteryvoltageonly momentarily. Feconnoctthe 18Pconneqtorto the power door lock control unit, Cavity Wir6
WHT/GRN Driver's door lockknob in 10
Test condition
Underall conditions
Tost: Dsirodresult
for Check voltage ground: to There should be batteryvoltage. Check voltage ground: tor to Thereshouldbe 1 V or less. tor Check voltage ground: to Thereshouldb 1 V or less. Checkfor voltage to ground: There should be battery voltage. Checkhatchglass lock operation: Hatchglassshouldunlock. for to Check continuity ground: Thereshouldb continuity. Check voltage ground: tor to There should be battery voltage. lor Check voltage ground: to Thereshouldbe 1V or less.
Possiblecauseif result is not obtaind

BlownNo. 51 (20Alfuse in the underhood tuse/relaybox An openin the wire Faulty driver's door lockactuator Poorground(G551) An openin the wire Faulty ignitionkeyswitch Poorground(G401, G402) An openin the wire BlownNo. 25 (7.5A) fusein the underdashfuse/relay box An openin the wire
. Faulty hatch glass opener solenoid . An opon in the wire . F a ( l l t yd o o r s w i t c h . An open in the wire
BLUAVHT LOCK
lgnitionkeyis in the igni-
13
BLU/RED tion switch

lgnitionswitchON (ll) YEL Connect No. 5 the terminal the No.I terto minalmomentarily
5
14
YEL
LT Passengor's door open GRN,NED

GRN/RD
Front ceiling light "MlDDLE" position
2 12
'
Driver'sdoor lock switch GRNAr'VHT in LOCK Driver'sdoor lock switch GRN/ORN in UNLOCK
Faulty lront ceilinglight An openin the wire Faultydriver's door lock switch Poorground{G551) An openin the wire
23-127
Power Door Locks

Driver'sDoorLockKnobSwitchTest
1. 2. the Remove driver'sdoor panel(seesection20). Disconnectthe 6P connectorfrom the actuator.
Driver'sDoorLockActuatorTest
1, 2. Remove driver'sdoor panel(seesection20). the from the actuator. the Disconnect 6P connector
6P CONNECTOR
6P CONNECTOR
Terminalside ot maleterfiinals
Checkfor continuitybetweenthe terminalsin each switch position accordingto the table. \ Position LOCK UNLOCK rsrmrnal \
?
power and Checkactuatoroperationby connecting ground according the table.To preventdamsge to to the actuator. apply battery voltage only momentarilv, \ Terminal
o- -o o- --o
F*'',1."
__l
@
LOCK UNLOCK
o
@
23-128
DoorLockActuatorTest Passenger's
20). 1 . Remove passenger's the door panel(seesection Disconnect 2P connector the from the actuator. NOTE: The left rear door lock actuator is shown; the front passenger's right reardoor lockactuaand tors are similar.
2P CONNECTOR
Driver'sDoor LockSwitch Test

L
20). Remove innerhandle{seesection the then removethe two Disconnect 3P connector. the mountingscrewsand driver'sdoor lockswitch.
Checkfor continuitvbetweenthe terminalsin each to switchpositionaccording the table. \ Position LOCK OFF Terminal of side male terminals power and Checkactuatoroperationby connecting ground according the table.To preventdamage to to the actuator, apply battery voltage only momenraflry. \ UNLOCK lermlnal \
o- --o o- -_o
;;il;--r
Terminal
,l @ @
LOCK UNLOCK
4.
lf the actuatordoes not work properly, replaceit.
23-129
PowerDoor Locks
Test (With Keyless EntrySysteml Transmitter
NOTE: . The ceilinglight (in middleposition) comeson within 30 seconds when you unlockthe doorswith the transmitter. . The doorsdo not lockor unlockwith the transmitter the ignitionkey is in the ignitionswitch. if . lf any door is open,you cannotlockthe doorswith thetransmitter. o lf you unlockthe doorswith the transmitter, do not open any of the doorswithin 30 seconds, doors relockautobut the matically. . For hatchglassbuttonoperation, hold the buttonfor morethan two seconds. . lf you pressthe PANICbuttonfor more than two seconds, horn soundsfor about 30 seconds, the and the transmitter LEDcomeson. (The panic mode will not be activated the ignition key is in the ignitionswitch.)The panic mode is if cancelled pressing by any of the transmitter buftons. . The horn soundsonly the first time you press a transmitterbutton,(Pressing repeatedly does not activate the horn again.)
Doors cannot bo locked or unlockedwhh lhe transmitter.
BATTERY {cR20251
R e w r i t et h e t r a n s m i t t e rc o d e , then try to locldunlockthe doors {seepage23-131}.
23-130
Programming Transmitter
codes: Storingtransmitter can be read into The codesof up to three transmitters the kevlessreceiverunit memory (lf a fourth code is firstwill be erased.) stored. the codewhich was inDUt N O T E : l t i s i m p o r t a n tt o m a i n t a i nt h e t i m e l i m i t s betweenthe steps. 1 . Turn the ignitionswitchON (ll). Within 1 to 4 sec.,push the transmitterlock or unlock buttonwith the transmitteraimed at the vehicle. Within 1 to 4 sec.,turn the ignitionswitchOFF. Within 1 to 4 sec.,turn the ignitionswitchON (ll). W i t h i n 1 t o 4 s e c . . p u s h t h e t r a n s m i t t e rl o c k o r u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle.
o.
turn the ignitionswitchOFF. Within 1 to 4 sec.,
1 . Within 4 sec.,turn the ignitionswitchON {ll). W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle. turn the ignitionswitchOFF, 9 . Within 1 to 4 sec., 1 0 . Within 4 sec., turn the ignitionswitchON (ll). 1 1 . W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o f u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle. 1 2 . Confirm you can hear the sound of the door lock aduators. ( 1 3 .W i t h i n 8 s e c . ,a i m t h e t r a n s m i t t e r s u p t o t h r e e ) whose codes you want to store at the receiver,and pressthe transmitter lockor unlockbuttons. Confirm that you can hear the sound of the door lock actuatorsafter each transmitter code is stored. and pull out the key. 1 4 . Turn the ignitionswitchOFF, with the new code{sl. 1 5 . Confirmproperoperation
23-131
PowerWindows
t J 1J 15-
- -------------) ------------
L--JIJJ'JJL
t_.1
POWER WINDOWMASTER SWITCH (Hasbuilt in controlunit) Input Test,page 23-'134 Test,page 23-135
FRONT PASSCNGER'S WINDOW MOTOR Test,page23-137 FBOI{TPASSENGER'S WI{DOW SWTTCH page23-138 Test, LEFT REAN WWDOW SwlTCH Test,page23-137 LEFT REAR WINDOW MOTOR page23-'t38 Test,
DRIVER'S WINDOW MOTOR Test, page 23-137 RIGHTREAR WINDOW MOTOB Test. page 23-138
--.-\-.--t
\-
RIGHT wtNDow swTcH page23-137 T6sr,
23-132
Diagram Gircuit
H@O FISETRELAY L]NDEF BOX
@-*'
rblr (r0oA) rlo42t40A)
V
I
PASSENGEAS
FFONT PASSENGEFS
23-133
Power Windows
MasterSwitch Input Test
NOTE:The controlunit is built into the powerwindow masterswitchand only controlsdriver'sdoor window operations. 1. Remove the masterswitch,and disconnect 14P,2?and 1Pconnectors the from the masterswitch. 2. Inspect connector the and socket terminals be surethey are all makinggood contact. to . . lf the terminals are bent, loose or corroded, repair them as necessary, and recheckthe system, lf the terminalslook OK, makethe followinginput testsat the connector. - lf a test indicatesa problem, find and correctthe cause,then recheckthe system. - lf all the input tests prove OK, the power window maser switch must be faulty; replaceit.
lirP CONNECTOR 1P CONNECTOR
BLU/ORN
RED/BLU
YEL/BLK
GRN
GRN/YEL
BLU/YEL \ RED/YEL
WiresideoI female terminals
GRN/BLK aLu/BLK
BLK RED/WHTYEL/GRN YEL
POWER WINDOWMASTEBSWITCH
RED/BLK
23-134
Cavity A11
Wi1
Test condition Underall conditions
Tesi: Dssiredrosult for to Check continuity ground: Thereshouldbe continuity.
Po$ible causeif 183uhis not obtained . Poorground(G551) . An open in the wire
BLK B1
A 1 0 BLU/BLK A9 A6 GRN/BLK lgnitionswitchON (ll)
Blown No. 7, 8, 10 or l1 (20A) fuse/relay fuse in the under-dash box Faultypowerwindow relay An open in the wire
YEUBLK
412 RED/WHT the Connect A10 termiRE D/BLU nalto the 43 terminal, and the A4 terminalto the A11 terminal, then RED/YEL turn the ignitionswitch Check driver'swindow motor: the It shouldrun (thewindow moves down). . Faultydriver'swindow motor . An open in the wire
A4
A3
oN flr).
A1 Connectthe A9 termiBLUI/EL nalto the A2 terminal, and the Al terminalto t h e 4 1 1 t e r m i n a lt,h e n BLU/ORN turn the ignitionswitch Check front Passenger's the window motor: It shouldrun (thewindow moves down). window Faultyfront passenger's motor window Faultyfront passenger's switch An open in the wire Faultyright rearwindow motor Faultyrightwindow switch An open in the wire
A2
oN flr).
A14
Connect 46 termithe nalto the A13terminal, and the 414 terminal to the A11terminal, YEUGRN then turn the ignition switchON (ll). YEL Connect A12 termithe
Check right rearmotor: the It shouldrun (thewindow moves oown).
A8
GBN/YEL nalto the A7 terminat,

and the A8 terminalto the A11terminal.then turn the ignitionswitch
Check leftrearmotor: the ,t shouldrun {thewindowmoves down),
Faulty rearwindowmotor left Faulty rearwindowsrrvitch ,eft An openin thewire
GRN
oN flr).
Connect A10te.mithe nalto the 43 terminal, and the A11 terminal to the 44 terminal. then turn the ignition switchON (ll). light Combination switch ON Checkfor voltage betweenthe A5 and Al l terminals: as ADorox.6V shouldbe indicated the driver'swindow motor runs. Faultypulser Faultydriver'swindow motor An open in the wire
A5
BLU
*cl
RED/BLK
fo. Check voltageto ground: Thereshouldbe batteryvoltage.
Blown No.30 (7.5A) fuse in the fuse/relay box under-dash light switch Faultycombination An open in the wire ' An open in the wire
RED
light Combination switch ON
Connect ground: to Dashlightsshouldcome on full bright.
PowerWindows
MasterSwitch Test
1 . Removethe switch (seesection 20). from the Disconnect 14P,2P and 1P connectors the power window masterswitch. Checkfor continuitybetweenthe terminalsin each to switchpositionaccording the tables.
DRIVER'S
Switch: F.ont Passongsr's \
'**[ffi
OFF
rermrnal
A2
A1
A9
B1
ON
swrTcH
FRONT PASSENGER'S
oo- --o
G-
-_o --o --o --o

C
swncH
UP
ON OFF ON
ooo-
DOWN
OFF
7-.i::,,,
\\'. )),,
B \\N
Right RearSwitch: \ Terminal
'".'*l-$j[\
ON
OFF
A14
413
A6
B1
OFF ON OFF ON
UP
DOWN
OFF
--o oo* --o --o o--o oo-- --o o- --o
Left R.ar Switch:

t - _ _ _ _ _ r - _ _
I F---T-----r-----r----r-----T---------T-----'r I l l a l l A 2l A 3 l A { l A 5l A 6 l A 7l a B l l
I r________r_____J
Terminal
lF#l ae
ll
e*Li*l$[\
ON OFF
OFF
A12
A8
A7
B1
l A 1 0 l l A 1 1 l A 1 2 ll A 1 3 l a l . l l t-t___Jl
I t-------l -ll l 'lr 8 1 l ll l l c 1 | c 2 l lr l l I l
fr---r-l
r---- -------r
UP
ON OFF ON
L--:J
DOWN
OFF
ooo-- --o o- --o oo-
o --o --o -_o --o
Dliver's Switch: The driver'sswitchis combinedwith the control unit so you cannot isolatethe switchto test it. Instad, run th6 masterswitchinputtest procedures page23-134. on lf the tests are normal.the drive/s switch is faulty.
Swhch Light: '99 - 00 modls \ Terminal
ti.*----_\
all Under conditions
o-
-o
ILED)
23-136
Window Switch Test Passenger's

the 1 . Remove inner handle(seesection20). the 5P connectorthen removethe two Disconnect switch. mounting screwsfrom the passenger's
Driver'sWindow Motor Test

Motor Test: 1. all Removethe driver'sdoor panel,and disconnect (seesection201. connectors the Disconnect 4Pconnectorfrom the window motor.
2.
sideof Terminal maleterminals
batTestthe motor in eachdirectionby connecting t e r y p o w e r a n d g r o u n d a c c o r d i n gt o t h e t a b l e . one lead Whenthe motor stopsrunning.disconnect immediately. Checkfor continuitybetweenthe terminalsin each to switchpositionaccording the table \ ;"rLTerminal __\ 1
\ ;;b" Terminal -\
UP
DOWN 4.
o
@
(!r
UP
OFF
oo-
DOWN
-o -o o- -o -o
lf the motor doesnot run at all or doesnot run it. smoothly.rePlace
PulserTest: 5. the Connect test leadsof an analogohmmeterto the No, 3 and No. 4 terminals. power and groundto Run the motor by connecting The ohmmeterneedle the No. 1 and No. 2 terminals. shquldmove backand forth alternately.
6.
23-137
PowerWindows
Passenger's Window Motor Test
Front: l. Removethe passenger'sdoor panel,and disconnect (seesection allthe connectors 20). Disconnect 2Pconnector the from the window motor. Terminal \ .l\ ;."b" 3. Checkwindow motor operation by connectingpower and ground according the table.When the motor to stops running, disconnect ohe lead immediatelv. Front: 2.
UP DOWN
Rar: I Terminal -l\
;*r*
UP DOWN
o
@
lf the motor doesnot run at all or does not run smoothly,replace it.
Rear: 1. Remove the passenger's doo. panel,and disconnect (seesection allthe connectors 20). Disconnectthe connectorfromthe window motor. 2P
2.
23-138
I J
Restraints
.....24-1 SeatBelts SYstem Restraint Supplemental (sRSl......'.'. ""'.""".""""24-13
f,
SeatBelts 24'2 Index.'."..'..'-'.' Location Component 24-3 '......"'.. FrontSeatBeltReplacement '.' ......'.". 24-6 RearSeatBeltReplacement .....""""""""' 24-9 lnspection ChildSeatTetherAnchor -'97 - 99 Models."'."24-10 lnstallation ChildSeatTetherAnchor Removal/lnstallation -'00 Model ....'......'.'....'.'.."-'-'."' 24'11
l -
Seat Belts
SRScomponents locatedin the partsareasmarkedwith an asterisk Reviewthe SRScomponentlocauons, are {*). precautions,and procedures this section (24)beforeperforming in (,98_ 00 models). repairsor service
CHILDSEATTETHEN ANCHOR -'97 lnstallation page24-10 99 models, Removal/lnstallation'00 model,page24-11 CHILDSEATTETHER ('00 modtl ANCHOR COVER REARSEATBELTBUCKLE/ CENTER BELTTONGUE (seepage24-7)
.FRONTSEATBELT page24 3 Replacement, page24-9 Inspection,
BELTEUCKLES (seepage24 5)
24-2
FrontSeat Belt RePlacement

the in are SRScomponents located this area.Review SRS in precautions, procedures this and locations, component (24) before performing repairsor service('98 - 00 section models). CAUTION: Check the front seat bslts for damago. and replacothom if necessary.Be careful not to damage them during removal and in3tallation' Front scat bolt: 1. M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e for radio,then write down the frequencies the preset buttons. the negativebatterycable,and wait at Disconnect work. leastthree minutesbeforebeginning Slidethe front seatforwardfully. 20): Bemove(seesection . Centerpillarlowertrim Pane . Kickoanel . Frontsidetrim '97 model:Remove the upper anchorcover and the lower anchorcaP. '98 - oO models: Removethe upper anchor cover and pull the lower anchorcoverback.
ANCHORBOLT UPPEN 7/1&20UNF 32 N.m (3.3kgt'm. 24 tbf.ft) Applyliquidthread lock. SHOULDER ANCHOR ADJUSTER SHOULDER ANCHOR ADJUSTER SEATBELT TENSIONER {'98 - 0o modols) RETRACTOR MOUNTINGBOLTZ,, ./ Gx1.0mm 9.8N.m (1.0kgt.m, ?.2 tbtft) REARSIDE
o.
Disconnectthe seat belt tensiongr connector. To avoid accidontal deployment and @ possibteinlury, always disconnectthe soat bsh tonsionr connoctor bofore rsmoving th6 retractor l'98 - 00 modsls, se page 21-231 .
7 . R e m o v et h e u D D e ra n d l o w e r a n c h o r b o i t s , t h e retractor bolt, the retractor mounting bolt, and remove the front seat belt and retractor. 20). the 8. Remove centerpillaruppertrim (seesection the 9 . Remove shoulderanchoradjuster.
2. 3. 4.
5.
I x 1.25mm kgt.m, 23 N.m 12.3 1? tbf.ft)
UPPER COVER
of isthe reverse the removalprocedure. 10. lnstallation NOTE: funclockingmechanism that the retractor Check on tions as described Page24-9. collarand bushingon the the Assemble washers, uooerand lower anchorboltsas shown. Eeforeinstallingthe anchor bolts, make sure there are no twists or kinksin the front seat belt. Make sure the seat belt tensionerconnectorls connectedsecurelv. code for the radio,then enter Enterthe anti-theft the customer's radio station presets
ANCHOR COVER l'98- 00models)

BOLT RETRACTOR 7/1&20UNF 32 N.m 13.3kgt m, 24 tbt.ft)
ANCHOR CAP ('97 modell LOWER ANCHORBOLT ?,/1&20 UNF 32 N.m {3.3 kgf.m,2,1lbf.ftl
(cont'd)
24-3
Seat Belts
FrontSeat Belt Replacement {cont'dl
Uppgr anchorboh construqtion:
UPPEB AI{CHOR
Rtractorbolt construqtion:
aolT
Apply liquidthread tock.
T(X)THED WASHCR LOCI(
RETNACTOR BOLT
bwd
RETBACTOR
Lower anchor bolt construction: '97 modol:

LOWER ANCHOR
24-4
Ssat belt buckle: 1. 2. 3. Slidethe front seatforwardfully Remove centercover(seesection20). the Driver's: Disconnectthe seat belt switch connector, clips from the seatcushion and detachthe harness frame. >: Cliplocations
Csntor anchor bolt construstion:
TOOTHED LOCK WASHER
WAVE WASHER
CENTER ANCHOR BOLT
SPRING WASHER
WASHER
CENTER ANCHOR
5.
of is lnstallation the reverse the removalprocedure. the NOTE:Assemble washerson the centeranchor bolt as shown.
To seat belt buckle.
BELT SEAT swlTcH CONNECTOR 4. the Remove centeranchorbolt,then removethe seat belt buckle. Pull out the seat belt switch harness (with seat belt switchl. BELT SEAT BUCKLE
ANCHORBOLT CENTER 7/1&20UNF 32 N.m {3.3kg{ m, 24 lbf ftl
SEATBLT SwlTCH HARNESS
24-5
Seat Belts
RearSeat Belt Replacement
CAUTION:Checkthe rear sat belts for damage,and replacelhem if necessa.y.Be caretul not to damage them during temoval and installation. Rearseat belt: 1, 2. Remove the rearseat{seesection20}. pull on the upper anchorcover and lower Carefully anchorcoverto removethem. 6. Installation the reverse the removalprocedure. is of NOTE: . Check that the retractor lockingmechanism functions as described page24-9. on . Assemble washers, the collarand bushingon the lower anchorbolt as shown. . Beforeinstalling anchorbolt, makesurethere the are no twistsor kinksin the rearseatbelt. Upper anchot bolt construction:
UPPER ANCHORBOLT 7/16-20 UNF 32 N.m 13.3 kg{.m, 24 tbt.ft)
UPPER ANCHOR TOOTHEO LOCKWASHER
REARSEAT BELT
A \tt
ANCHOR COLLAF
UPPER ANCHOR COVER
RETRACTOR
LOWER ANCHOR COVER
Lowel anchor bolt construqtion: LOWERANCHOR BOLT
RETRACTOB MOUNTINGBOLT 6x1.0mm 9.8N.m (1.0kgt.m. 7.2 rbf.ftl RETRACIOR EOLT 7/16-20 UNF 32 N.m {3,3kgf.m, 24 rbr.ft)
SPRING WASHEB
TOOTHED LOCI( WASHER
LOWER ANCHOFBOLT 7/1S20UNF 32 N.m 13.3 kgl.m, 2/r lbf.ftl
BUSHING WASHERS LOWER ANCHOR COLLAR
3. 4.
Remove the lower anchorbolt. (seesection20): Remove . Cargoareafloor and cargostoragebin . Reartrim paneland rearsidetrim panel Removethe upper anchor bolt, the retractorbolt. the retractormounting bolt, and remove the rear seatbelt and retractor.
Rgtractor boll construction:
f/F\-.
/
/\
P \v*\
T(X)THED LOCK WASHER
(t--nnnllH \
\ \
r>--->.
RETRACTOR
RETMCTOR BOLT
24-6
) J
Seat belt buckles/Centerbelt tongue: without tilt: 1. 2. the rearseaton eachslde. Remove removethe cenler Raisethe trunk floor extensions, and anchorbolts,then removethe seat belt buckles tongue. centerbelt
ANCHORBOLTS CENTFR 7/16-20UNF 32 N.m (3.3kgf.m, 2a rbtftt
with tilt: 1. 2. forward.and tilt the rearseatup Foldthe seat-back up, remove While holdingthe trunk floor extension centeranchorbolts the
SEAT.BACK BELTYONGUE CENTER
BOLTS CEiITER AT{CHOR 7/1e20 UNF 32 N.m {3.3kgt m, 2r bf.frl
SEATBELT BUCKLE
and returnthe seatto its origiRaisethe seat-back, position. nal Removethe center anchor bolts, then remove the center belt tongue and seat belt buckle.
SEATBELT BUCKITS
\\
of is lnstallation the reverse the removalprocedure. the NOTE:When reinstalling rear seats.make sure there are no twists or kinksin the centerbelt tongue and seatbelt buckle.
(cont'd)
Seat Belts
RearSeat Belt Replacement(cont'dl
5. Installation the reverse the removalDrocedure. is of NOTE:Makesurethere are no twists or kinksin the centerbelttongueand seatbelt buckle. Cenler anchor bolt construction:
TOOTHED LOCKWASHER ANCHOR
24-8
Inspection
SRS componentsale located in this area. Reviewthe precautions, and procedures SRScomponentlocations, in this section(24)beforepreformingrepairsor service ('98- 00 models). To avoid accidontaldeployment and possi!!!@ 6i6-'rnpry. att"ays aisconnsct th seat beh tensioner connctor belore removing tho retrastor {.98 - 00 modols, seo page2+231. Rgtlastor Insgection 1. that the seatbelt the installing retactor,check Before can be pulledout freely Make sure that the seat belt does not lock when the slowlyup to 15'from the mounted is retractor leaned The seat belt should lock when the retractor Dosition. is leanedover 40". CAUTION: Do not attsmpt to dbassemble ths relrac' tor. Front: '97 modol:
.: Mounted Position
Rear:
40.
/A
*1ix
\| _t-. \ /
L = ls
RETRACTOR Forwerd Forwerd
lnsida
2.
3.
if the Beplace seatbeltwith a new assembly thereis any abnormality.Do not disassembleany part of the seatbeltfor any reason.
In-vehicleS68t Belt InsPestion 1. Chckthat the seat belt is not twistedor caughton anything. After installingthe anchors,checkfor free moveremovethe ment on the anchorbolts lf necessary, anchorbolts,and checkthat the washersand other or partsare not damaged improperlyinstalled. the Check seatbeltsfor damageor discoloration. Cleanwith a shop towel if necessary. CAUTION: Uso only soap and wator to clean. NOTE:Dirt build-upin the metal loopsof the upper anchorscan causethe seat belts to retractslowly Wipe the insideof the loopswith a cleanclothdamP alcohol. enedin isopropyl Checkthat the seat belt does not lock when pulled out slowlv. The seat belt is designedto lock only duringa suddenstop or impact. automatically Makesurethat the seatbeltwill retract when released. seat belt, make sure that the For each passenger's locking mechanism in the seat belt retractorwill engagewhen the seatbelt is pulledall the way out. '1. if the Replace seatbeltwith a new assembly there is any abnormality.Do not disassembleany part of the seatbeltfor any reason.
RETRACTOR Forward '98 - 00 modcls:

lnside
RETRACTOR Forward -
24-9
Seat Belts
ChifdSeat TetherAnchor Installation -,97 - 99 Models
Canadamodel: Attachment pointsare providedfor a rear searmounted childrestraint system which usesa top tether.The attach_ ment pointsare located both rearcorners the head_ on of liner,just behindthe rear seat-back. When using a child seatwith a top tether,installthe child seattetheranchor securelv. NOTE:To installa child seat on the rearseat,selectthe point you want to use,and removethe plug attachment coverfrom the attachment point of the headliner. Install the child seattetheranchorsecurely. NOTE: . Do not removethe toothedwasherfrom the childseat tether anchor.Use the seat anchorwith the toothed washerattached it. to . When installinga child seat on the rear seat,follow the instructions the manufacturer the childseat. of of . Additional anchorsare available.
ATTACHMENT POINTS
PLUGCOVERS
CHILO SEAT TETHER ANCHOR
TOOTHED WASHER
24-10
l r
-'00 Child Seat TetherAnchor Removal/lnstallation
Model
AttachmentDointsare providedfor a rear seat mountedchild restraintsystemwhich usesa top tether'The attachment just behindthe rear seat-back The child seattether anchorsare pointsare locatedon both rear cornersof the headliner, with a childseattetheranchorcover. point.Eachchild seattetheranchoris covered into eachattachment installed NOTE: . Do not removethe toothedwasherfrom the child seattetheranchor.Usethe anchorwith the toothedwasherattached to it. of of . When installing childseaton the rearseat,follow the instructions the manufacturer the childseat. a U n i t im m ( i n . )
HEADLINER
TOOTHEO WASHEB
CHILD SEAT ANCHOR TETHER
mm I x '1.25 22 N.m (2.2kgf m, 16 rbf.ft)
24-11
SupplementalRestraintSystem (SRS)
.."....."" 24-14 Troubleshooting SpecialTools 24-26 Self-diagnosticProcedures............. Component/Wring Location '97 model ..........'.." '....."""24-15 24'26 .....".."' lndexthe Reading DTC .................. Component/WiringLocation Erasingthe DTCMemory ................24-28 24-16 lndex - '98 - 00 models ..............." Troubleshooting lntermittent .'.........."'.24'17 "'...........24'24 Description Faifures .........24'14 CircuitDiagram TroubleGode {DTC} Diagnostic "......24-29 Chart-'97 model ....""....... Precautions/Procedures (DTCI TroubleGode Diagnostic 24-19 ......".."'........... Precautions General 24-31 Chart-'98 - 00 models ............. Airbag/SeatBelt Tensioner SRSIndicatorLight Wire 24-19 and Stolage ....''........... Handling ','," 24'33 Connections 24-20 ...............'...... SRSUnit Precautions ....-........24'34 Ffowcharts lnspeciionAfter Deployment .......'.24'20 Driver's Airbag WiringPrecautions.............'............24-21 ..'......21'87 acement Repf SpringJoadedLockConnector with Built-inShort Contact '...'....24-21 Front Passenger'sAirbag .....'.',24'AS Repfacement Lock Connectors.."' 24-22 Spring-loaded GableReel Lock SPring-loaded BackProbing ,.......24-22 Conneetors .......'.24-91 Replacement and Airbag Connectors the Disconnecting SRSUnit the Seat Beh Tensioner .........24-95 Replacement ....'....24-23 Connectors Airbag/SeatBelt Tensioner .......... 24-25 Precautions Steering-lelated .................24'97 Disposaf
\ )
<D
SpecialTools
Ref. No.
Tool Number
Description Deployment Tool SCSServiceConnector SRSInflatorSimulator SRSSimulatorLeadC Backprobe Adapter,l7 mm
Oty 1 1 '1 I 2
o"'
@-,
/a\
PageReference 24-91 24-21 24-50 24-50 24-43
@ rA*,
07HAz SG00500 07PM- 0010100 07sAz TB40114 07TAZ SZ50114 o7T - OO1O20A AZ
* 1: Included SRSTool Set 07MAZ- SM5000B in *2: Use with the stacking patch cords from T/N 07SAZ0010004,BackprobeSet.
/n
24-14
Index-'97 model Locations Component/Wiring
(ln LIGHT the gaugeassembly) SRSINDICATOR page24-27 Troubleshooting, Gaugeassembly,section23
To CRUISE CONTROL
SET
DASHBOABDw|RE HARNESS LIGHTin to SBS INDICATOR GAUGEASSEMBLY 5P MAIN WIREHABNESS wlRE HARNESS to DASHBOABD 21P
AIBMG DRIVER'S Replacement, page 21-87 Disposal,page 24-97
To DRIVERS AnBAG
AIRBAG FRONTPASSEITGER'S pago 24{9 Replacement, Disposal,page 24-97
sBsitAr[ ] nNEss
to FROI|T PASSEiIGEB.S ANBAG 2P
SRSMAIN HABNESS to UNOEB-DASH FUSE/BELAY BOX 2P CONNECTOR SRSMAIN HARNESS to MAIN WIRE HARNESS 3P OONNECTOR MEMORYERASE SIGNAL IMES) CONNECTOR I2PI [GRY. GRYI or twHT, BLr.l
GOf$ECrOn PPI lBLr( 8R t
sns ut{fT GROUND
tosnsU n
SES MAIN HAR]GSS ItP OOIIITECTOR
24-15
Gomponent/Wiring Locations Index-'98 - 00 models
SRSINDICAIORLIcHT (ln the gauge assembty) page24 27 Troubleshooting, Gaugeassembly.section23
CABLEREEL Replacement, page24-91
To HORNSWITCH
To CRUISE CONTROL SET/RESUME SWTCH To DRIVER'S AIRBAG FRONT PASSENGER'S AIRBAG page24-89 Replacement, page24 97 Disposal, SRSMAIN HARNESS to FROI{TPASSENGER,S AIRBAG 2P CONiIECTOR
DASHBOARD WIREHARNESS to SRS INDICATORLIGHf in GAUGEASSEMBLY 5P CONNECTOR SRSMAIN HARNESS
ORIVER'S AIRBAG Replacement, page 24-87 Disposal,page 24-97
ro CABLE REEL 2PCONNECTOR

MAIN VYIRE HARNESS to DASHBOARD WIREHARNESS 24PCONNECTOR RIGHTSIDEWIREHARNESS to SEAI BELTTENSIONER 2P CONNECTOR SRSUNIT (lncluding safingsensor and impactsensor) page24-95 Replacement, SRSMAIN HARNESS to RIGHTSIDEWIREHARNESS 2P CONNECTOR
to SRSMAIN HARNESS LEFTSIDEWIREHARNESS 2P CONNECTOR
SRSMAIN HARNESS to MAIN WIREHARNESS 3P CONNECTOB SRSMAIN
SERVICE CHECK CONNECTOR I2PI IBLK BRNI
to UNDER-DASH BOX FUSE/RELAY 2PCONNECTOR

MEMORYERASE SIGNAL (MES)CONNECTOR I2PI IGRN,GRNIor IWHT,BLKI
SEATBELTTENSIONER page24 3 Replacement, Disposal,page 24-97 ORIVER'S SEATBELT page 24-3 Replacement, page24-97 Disposal, LEFTSIDEWIREHARNESS to SEATBELTTENSIONER 2P CONNECTOR
24-16
Description
)
J
to with the seat belt,is designed help protectthe driver and The SRSis a safetydevicewhich,when used in conjunction safingsenof The systemconsists the SRSunit (including a front passenger a frontalimpactexceeding certainset limit. in airbag. reel,the driver'sairbagand front passenger's the sor and impactsensor), cable Seat Bolt Tensioner {'98 - 00 models} of the The seatbelt tensioneris linkedwith the SRSairbagsto further increase effectiveness the seat belt. In a front-end in the firmly to secure occupants their seats retracts belt the collision, tensionerinstantly the
DRIVER'S AIRBAG PASSENGER'S FRONT AIREAG FRONT PASSENGER'S SEATBELTTENSIONER {'98 - 00 modelsl
SRSUNIT
DRIVER'S SEATBELT TENSIONER - 0Omodeb) l'98
Operation lf ignitesthe intlatorcharges. bat and judgesthe forceof impactand, if necessary, The main circuitin the SRSunit senses power is disconnected to the impact,the voltageregulatorand the back-uppower circuit due tery voltageis too low or will respectively keepvoltageat a constantlevel. For the SRSto operate: to (1) The impactsensormust activate, signals the microprocessor. and sendelectric (andseatbelttensioners). (2) The microprocessor and sendthem to the airbaginflators must computethe signals, the (3) The inflatorsmust igniteand deploythe airbags(andactivate tensioners).
---__-l
TENSTO1En I I
_-___J 1 9 8 00 N4odes)
Selt-diagnosis System Iight comes A self-diagnosis circuitis built into the SRSuniUwhen the ignitionswitchis turned ON (ll),the SRSindicator on and goesoff afteraboutsix seconds the systemis operating if normally. an in lf the light does not come on, does not go off aftersix seconds, it comeson while driving,it indicates abnormality or the system. The systemmust be inspected and repaired soon as possible. as and on For batteryserviceability, memorywill storethe causeof the malfunction, the data link circuitpasses the infor the (DLC). mationfrom the memoryto the data link connector This information can be readwith the HondaPGMTesterconnected the DLC{16P). to
24-17
CircuitDiagram
usesall GRY('97model)or GRN('98- 00 models)wires. NOTE:The SRSmain harness

UNDEF,HOOD FUSE/RELAY BOX -'WHT/BLK WHT
IGNITION SWITCH
UNDER.DASH FUSE/RELAY BOX
SFS INDICATOR CIRCUIT (lnlhegauge assembly) SRS NDICATOR LGHT r.4W) { Shillloc*soenoid
YEUGRN
PGM I F mam relay
FRONT PASSENGER'S ALRBAG INFLAlOR
DRIVEB'S AIRBAG NFLATOR
BLK
GRY (GFN)
t l
GFY (GRN) 0 1 12 4
#+
t. /t l
d
BLU
t lI
GRY GRY (GRN) (GRN)
GR\
1 5
1 4
3 11 | 16 17 15 I 18 I
GRN (BLU/PNK)
lcFNt
GFY
(GlN)
GRY
GNY
GRY
FRONT PASSENGERS SEAT BELT TENSIONEF
DRIVER'S EELT SEAT TENSIONER
G401
I LTBLU t
r
r-? BRN t
V
?
?
BRN
DATA LINX PCM/ECMSERVICE MEMORY ERASE (MES) CONNECTOR CHECK S GNAL (Drc) (r6P) CONNECTOB CONNECTOR
(2P) S8S UNT TERMINALS
H
7
('98 00M o d e l s )
3 10 11
I
17 18
14 15
T e r m i n a s i d eo f m a l et e r m i n a l s l
24-18
Precautions/Procedures
)
General Precautions
Carefullyinspectany SRS part beforeyou install it. Do not installany partthat showssignsof beingdropped or improperlyhandled,such as dents,cracksor deformation: Airbags Cablereel SRSunit Seatbelttensioners
Airbag/Seat BeltTensioner Handling Storage and

Do not try to disassemble airbag or a seat belt tenan parts.Once an airbag sioner.They have no serviceable or a seatbelttensioner havebeendeployed. they cannot be repaired reused. or For temporarystorageof an airbag or a seat belt tenpleaseobservethe following presioner during service, cautons: . Store the removed airbag with the pad surface up. passenger's The driver's/front airbagconnectors and seat belt tensionerconnectorshave a built-in short contact (see page 24-211.
r th airb.g is impropcrty stord face down, @ accidental deployment could propel the unit with enough forcto caus6serious iniury,
Use only a digital multimeterto checkthe system,lf it's not a Honda multimeter,make sure its output is 10 mA (0,01A) or lesswhen switchedto the smallest value in the ohmmeterrange.A testerwith a higher outputcould damagethe airbagcircuitor causeaccidentaldeployment and possible injury. Do not install used SRS Dansfrom anothervehicle, When makingSRSrepairs, useonly new pans. E x c e p tw h e n p e r f o r m i n g e l e c t r i c a li n s p e c t i o n s , alwaysdisconnect both the negative cable and positive cable from the batterv.and wait at least three minutesbeforebeginning work. R e p l a c e m e no f t h e c o m b i n a t i o nl i g h t a n d w i p e r / t w a s h e rs w i t c h e sa n d c r u i s ec o n t r o ls w i t c h c a n b e donewithout removingthe steering wheel: Combinationlight and wiper/washerswitch replacement{seesection231. (see Cruise controlsevresume switchreplacement 41. section
AIRBAGCONNECTORS
Wheneverthe ignition switch is ON {ll}, or has been turnedOFFfor lessthan three minutes,be carefulnot to bump the SRSunit; the airbagscould accidentally deployand causedamageor injuries. Whenever the airbaghas been activated, replacethe SRSunit.
Store the removed on a secureflat surfaceawav from a n y h i g h h e a t s o u r c e( e x c e e d i n g 1 2 " F / 1 0 0 ' C )n d 2 a free of any oil, grease. detergent water. or lmproperhandlingor storagecan internallydamage makingthem inopthe airbagand seatbelttensioner. erative. lf you suspect airbagand seatbelt tensioner the have b e e n d a m a g e d ,i n s t a l l n e w u n i t s a n d r e f e r t o t h e Deploymenvoisposal for Procedures disposing the of damaoedunits.
The original radio has a coded theft protectioncircuit. Be sure to get the customer'scode number before disconnectingthe batterycables.
SRSUnit Precautions
Takeextracarewhen paintingor doing body work in the area belowthe dashboard. Avoid directexposure of the SRS unit or wiring to heat guns, welding, or sprayingequipment. passenger's Disconnect driver's/front the airbagconnectors and seat belt tensioner connectorsbefore working belowthe dashboard nearthe SRSunit. After any degreeof frontal body damage,or after a collisionwithout airbagdeployment, inspect the SRS unit for physicaldamage.lf it is dented,cracked, or reolace it, detormed,
Inspection After Deployment

After a collision in which the airbags were deployed. replace SRSunit,and inspect following: the the 1. Inspectall the SRS wire harnesses. Replace, don't repair,any damagedharnesses Inspect cablereelfor heatdamage, thereis any lf the damage. replace cablereel. the After the vehicle is completely repaired,turn the ignitionswitch on. lf the SRS indicatorlight comes on for about six seconds and then goesoff, the SRS systemis OK. lf the indicator light does not function properly, to SRSTroubleshooting. go
2.
3.
Be surethe SRSunit is installed securelv. Do not disassemble SRSunit. the S t o r e t h e S R S u n i t i n a c o o l { l e s st h a n a b o u t 1 0 4 " F / 4 0 " C )n d d r y { l e s st h a n 8 0 o / o u m i d i t y . n o a h moisture)place.Do not spill water or oil on the SRS unit,and keepit awavfrom dust. During installation replacement, carefulnot to or be bump (impactwrench,hammer,etc.)the areaa[ound the SRS unit, The airbagscould accidentally deploy and causedamageor injury.
rD
24-20
Wiring Precautions
. Neverattemptto modify,spliceor repairSRSwiring. yellow by NOTE:SRSwiring can be identified special outercoveflng.
Spring-loadedLock Connestorwith Built-in Short Gontact

The driver's airbag/frontpassenger'sairbag and seat lock have a spring-loaded connector with belttensioners a built-inshort contact.When this connectoris disconnected,the power terminal and the ground terminal in shorted. are the airbagconnector automatically Conngctorhalvcs diSconnested:
GROUND TERMINAL
Be sureto install harness the wiresso that they are pinched interfering or with otherparts.
ACT
SHORTCONTACT
CABIf REELCONNECTOR
Connector halves connected; GROUND TERMINAL
M a k e s u r e a l l S R Sg r o u n d l o c a t i o n s r e c l e a na n d a groundsare securely fastened optimum metal-tofor metalcontact.Poorgroundingcan causeintermittent problems that are difficultto diagnose.
CONTACT
CONTACT
24-21
LockConnectors Spring-loaded
havea spring-loaded lock. SomeSRSsystemconnectors . Disconnecting toward To release lock,pull the spring-loaded the sleeve halt of the connector. the stop while holdingthe opposite halvesapart.Be sure to pull on Then pull the connector half. the sleeve and not on the connector
SPRING-LOADED SLEEVE
BackprobingSpring-loadedLock
Connectors
on When checkingvoltageor resistance this type of to connector first time, it is necessary removethe the retainer insertthe testerprobefrom the wire side. to the removed retainer; It is not necessary reinstall to the terminalswill stay lockedin the connectorhousinq.
Connecting 1. Hold the pawl-sideconnector hall and press on the backof the sleeve-side connectorhalf in the direction shown. As the two connector halves are Dressed together,the sleeve is pushed back by the pawl. Do not touch the sleeve.
RETAINER *Discardafter removal.
To removethe retainer,insert a tlat-tip screwdriver betweenthe connectorbody and the retainer.then Takecare not to break carefullypry out the retainer. the connector.
RETAINEN
When the connec-tor halvesare completelyconnected, the pawl is released. and the spring-loaded sleeve locksthe connector.
SPRING.LOAI'ED
RETAINER
24-22
) 1 ,
Connectors and Disconnecting AirbagGonnectors the SeatBeltTensioner the

(the SRSunit,the cablereeland the seatbelttensioner connector), disdevices Beforeremovingthe airbagor SRSrelated the or from relateddevices,or removingthe dashboard the steeringcolumn, disconnect airbag connecting connectors accidental deployment connectors Drevent to connectors and seatbelttensioner Turn the ignition switch oFF and disconnect ths nogative cable from the battery, and wait at least ihree @ minutes before beginning the tollowing proceduresA and B. lprocedure B follows the procedureA.l both airbags(C,D) and both seatbelttensioners from the SRSunit,disconnect Beforedisconnecting SRSmain harness the (F,H) {'98- 00 models). (C). (B), the the Beforedisconnecting cablereel2P connector disconnect driver'sairbagconnector (E).disconnect driver'sseat belt tensioner2P connector the the Beforedisconnecting left side wire harness2P connector (F)('98- 00 models). (G),disconnect tront passenger's seatbelttensioner 2P 2P the Beforedisconnecting right side wire harness connector the (H)('98- 00 models). connector
SRSMA1N HARNESS
i---
----l
Jl
LEFT SIDE WIREHARNESS
Jl
l*",r*
I I
{cont'd)
24-23
Connectors(cont'd)
1.
Disconneeting AirbagConnectors the Seat BeltTensioner the and

Disconnect batterynegativecable,then disconthe nectthe positivecablefrom the battery. and wait at leastthree minutes. D i s c o n n e ctth e a i r b a g a n d t e n s i o n e rc o n n e c t o r s lsee page 24-22). Driver's Airbag: . R e m o v et h e a c c e s sp a n e l f r o m t h e s t e e r i n g w h e e l , t h e n d i s c o n n e c tt h e 2 P c o n n e c t o r between the driver'sairbagand cablereel.When disconnected, airbag connectoris automatithe callvshorted. Seat Bslt Tensioner(38 - 00 modebl: . Remove the left and (or) right centerpillar lower 20). trim panels(seesection . Disconnectthe seat belt tensioner 2P connectors (driver's side)and from the left sidewire harness (frontpassenger's (or)the right sidewire harness side). When disconnected. seatbelttensioner the is automatically shorted.
CLIPS
ACCESS PANEL
DRIVER'S AIRBAG 2PCONNECTOR Front Passsng/sAirtag: . Disconnect the 2P connectorbetweenthe front passenger's airbagand SRSmain harness. When disconnected. airbagconnectoris automatithe callYshorted.
DRIVER'S SIDE:LEFTSloE WIREHARNESS SIDE:RIGHTSIDEWIRE FRONTPASSENGER'S HARNESS
24-24
Steering-related Precautions
Stooring Whel and Csble Re6lAlignmnt T o a v o i d m i s a l i g n m e n t f t h e s t e e r i n gw h e e l o n o reassembly, make sure the wheels are turned straight aheadbeJore removingthe steering wheel. NOTE: . Whenthe airbagand cabler6elare disconnected, and the batteryis reconnected and the ignition switch is turned ON (ll),the SRSunit will storethis as an open in the driver'sairbag inflator,and the SRS indicator light will come on, In such a case,makesure to confirm the DTC, then clearthe SRSunit memory. . For disconnecting the spring-loadedlock type connector, refer to page24-22.
'97 model: SRSMAIN HARNESS 2P CONNECTOR CABLEREEL 2P CONNECTOR
To centerthe cable reel,rotatethe cable reel clockwise (approxiuntil it stops,Then rotate it counterclockwise matelytwo and a halfturns) until the arrow mark on the cablereel labelpointsstraightup.
'98 - 00 models:
LABEL
Steering Column Bemoval CAUTION: Before removing the stosring column, tirsi disconneqt tha connsctor between tho cabls roel and the SRSmain harness. lf the steering column is going to be removed without dismounting the steering wheel, lock the sieering by turning the ignition key to o-LOCKposition, or remove the key trom the ignition so that the steering wheel will not turn.
UNDER-DASH FUSE/RELAY BOX Do not replace originalsteering wheelwith any other the d e s i g nb e c a u s e t w i l l m a k e i t i m p o s s i b l e o p r o p e r l y i t installthe airbag(use only genuineHondareplacement partsl. After reassemblv,confirm the wheels are still turned straightaheadand that the steeringwheel spokeangle is correct.lf minor spokeangleadjustment necessary, is do so only by adjustingthe tie-rods,not by removing and repositioning steering the whee .
24-25
Troubleshooting
Self-diagnostic Procedures
function of the SRSsystem allows it to locatethe causesof system problems and to store this informaThe self-diagnostic For easier via tion in memory, troubleshooting, datacan be retrieved a data linkcircuit. this the When you turn the ignitionswitchON (ll).the SRSindicator will come on. lf it goes off aftersix seconds, systemis normal. . lf there is 8n abnormality, system locates the and definesthe problem.storesthis informationin memory,and turns the SRSindicator light on. The datawill remainin the memoryevenwhen the ignitionswitchis turned off or if the batterv is disconnected. (2P),and turn the ignitionswitchON (ll), . When you connectthe SCSservice connector the service to checkconnector light will indicate diagnostic the SRSindicator the troublecode (DTC) the numberof blinks. by . After readingand recording DTC,proceed with the troubleshooting forthis code. the . Precsutions . Useonly a digitalmultimeter checkthe system.lf it's not a Hondamultimeter. to makesure its outputis 10 mA (0.01 A) or lesswhen switchedto the smallestvalue in the ohmmeterrange.A testerwith a higheroutput could damagethe airbagcircuitor causeaccidental airbagdeployment and possible injury. . Whenever ignitionswitchisON (ll).or has beenturnedOFFfor lessthan three minutes,be carefulnottobumpthe the SRSunit;the airbagscouldaccidentally deployand causedamageor injuries. (seepage24-23). . Beforeyou removethe SRSmain harness, disconnect airbagand tensioner the connectors . Make sure the battery is sufficiently charged (see section 23). lf the battery is dead or low, measuringvalues won't be correct. . Do not touch a testerprobeto the terminalsin the SRSunit or harness connectors, and do not connectthe terminals with a jumperwire. Use only the backprobe and the SCSservice set connector. For backprobingspring-loadedlock type connectors,.efet to page 24-22.
Reading DTC the

Whenthe SRSindicator light is on, readthe DTCusingone of thesemethods; A. and follow the tester'sprompts.lf the tester the HondaPGM Testerto the 16PData Link Connector Connect {DLC), jumping the servicecheckconnector(2P)and watchingthe indicates DTC,DTC9-1 and DTC9-2,double-check no by light (seenext page). SRSindicator
DATA LINKCONNECIOR {DLCI{16P)
HONDAPGM TESTER
24-26
) B . The SRSindicatorlight can also indicate DTCby the numberoJ blinkswhen the SCSservice the connector connecris
(2P). ed to the service checkconnector 1 . Turn the ignitionswitchOFF,and wait for ten seconds. Then connectthe SCSservice connector the service to check connector lf {2P). you do not wait ten seconds. SRSunit will not be completely the resetand will not outputDTCS.
SEBVICE CHECK CONNECTOR I2PI IALK,BRNI
SEBVICE CONNECTOR 07PAZ- 0010100
2.
3. 4.
Turn the ignitionswitchON (ll).The SRSindicator light comeson for aboutsix seconds and then goesoff. Then it will indicate DTC: the - The DTCconsists a main code and a sub-code. of - Including most recentproblem,up to threedifferentmalfunctions be indicated. the can - In caseof a continuous (seeexample1 below). failure. the DTCwill be indicated repeatedly - In caseof an intermittent failure, SRSindicator the lightwill indicate DTCone time,then it will stayon (seeexarnthe pte2 below). - lf both a continuous and an intermittent failureoccur,both DTCS will be indicated continuous as failures. - In casethe systemis normal {no DTC), SRSindicatorlight will stay on (seeexample3). the Readthe DTC. Turn the ignitionswitchOFF.and wait for ten seconds. Then disconnect SCSservice the connector Jromthe service (2P). checkconnector
Examplesof DTCIndications: 1. Continuous failure,SRSIndicator Light is:

0.3 s 0.3s 0.35 0.3s
, s--l f.-, s--.l
--l fl-!
--1 M.h@de
r-
-r f-
Main code (1)
Sub-code (2)
-l
F
otc I r
--l F
Sub-cod6ltl
M.a^ code (rt .............v_
DTC21 Mo6t r.@nl p.oblem
DTC .2 r
Third.mGr .oconl
2.
Intermittent failure,SRSIndicator Light is:
Light srayson in cas ol
DTC5,1
3.
Normal(no failure), SRSIndicator Light is:
24-27
Troubleshooting
Erasing DTCMemory the
from the SRS unit, use a Honda To erase the DTC{S) P G M T e s t e r( s e et h e H o n d aP G M T e s t e rS R SV e h i c l e or SystemSupplement) the followingprocedure. 1. 2. Makesurethe ignitionswitchis OFF. Connect SCSserviceconnector the MES con, the to nector(2P). not use a jumperwire. Do
Troubleshooting Intermittent Failures

lf there was a malfunction. it doesn'trecur,it will be but storedin the memory as an intermittent failure,and the light comeson. SRSindicator After checkingthe DTC,troubleshoot as follows: 1. Readthe DTC(see"Reading DTC"). the E r a s et h e D T C m e m o r y ( s e e " E r a s i n g t h e D T C Memory").
3.
With the shift leverin neutral, turn the ignitionswitch ON (ll),and let the engineidle.
4 . The SRSindicatorljght comeson for about six seconds and then goesoff.
MEMORYERASE SIGNAL(MES}CONNECTOR I2PI IGRY,GRYIor IGRN,GRNI
SCS SERVICE CONNECTOR 07PAZ 0010100 3. 4. Turn the ignitionswitchON (ll), The SRS indicator light comeson for aboutsix seconds and then goes off. Removethe SCSservjcecon nectorfrom the MES connector {2P)within four seconds afterthe SRSindicatorlight went otf. The SRSindicatorlight comeson again.Reconnect the SCS service connectorto the MES connector (2P)within four seconds afterthe SRSindicator lioht comeson, The SRS indicatorlight goes otf. Removethe SCS s e r v i c ec o n n e c t o rf r o m t h e M E S c o n n e c t o r( 2 P ) within four seconds. The SRSindicatorlight indicates that the memoryis erasedby blinkingtwo times. Turn the ignition switch OFF,and wait for ten sec onos.
ON
t*F
l t
--- _l
5.
6.
Shake wire harness the connector, the and takea test quick braking,cornering), drive (quickacceleration, and turn the steeringwheel fully left and right,and hold it there for five to ten secondsto find the cause of the intermittent failure. lf the problem recurs,the SRS indicatorlight will stayon.
7. L
-+t
6!.c
l.-
,l sec or less Problemrecurs,light stayson. SRSindicator liqtfi OFF MES connac'lol terminals
CONNECTED OISCONNECTEO
6.
lf you can't duplicate intermiftent the tailure, systhe tem is OK at thistime.
:-
24-28
Ghart-'97 model Diagnostic TroubleCode(DTG)

SRS indicator light doesn'tcome on
DTC
none (doesn't come on) none*' (doesn't go off)
Pos3iblscause light circuit FaultySRSindicator
Corroctiveaction Troubleshooting
Slc pago
24-34
light circuit,internal FaultySRSindicator tailureof SRSunit,faultySBS powersupply Openin the driver'sairbaginflator resistance the driver'sairbag in Increased inflator Shortto anotherwire in the driver'sairbag resistance inflatoror decreased Shortto power in the driver'sairbaginflator
Troubleshooting
24-37
24-50
24-50
Troubleshooting 24-52
24-54
doesn't go off
Shortto groundin the driver'sairbaginflator airbaginflator Open in the passenger's airbag Increased resistance the passenger's in inflator Shon to anotherwire in the passenger's airbag inflator or decreasedresistance Troubleshooting
24-56
24-58
24-54
24-60
2-4
2-5
airbag Shortto power in the passenger's inflator airbag Shon to ground in the passengar's inflator
24-62
24-64
(cont'd)
24-29
Troubleshooting
Diagnostic TroubleCode(DTC) Chart-'97 model (cont'dl
SRS indicator light DTC Possiblecause Correstiveaction See page
5-3
5-4 5-5
o-l
Internal failureof the SRSunit
SRSunit replacement
24-96
6-2
6-4
Internal failureof the SRSunit
SRSunit replacement
24-96
doesn'tgo off
7-2
7-3 8-1
lnternal failureof the SRSunit
SRSunit replacement
24-96
a-2
8-5 8-6
Internal failureof the SBS unit
SRSunit replacemenr
24-96
Internal failureof the SRSunit or two failures at a time Internal failureof the SRSunit
Troubleshooting SRSunit replacemenr Troubleshooting SRSunit replacement
24-82 24-96 24-84 24-96
9-2
'101
FaultySRSpowersupply(VBline) SRSairbagsdeployed(SRSunit must be replaced)
l*
*1: In caseof an intermittent failureDTC9-1,it meanstherewas an internalfailureof the SRSunit or a faultv SRSindicator light circuit.Do the troubleshooting intermittent for failures{seepage24-28), *2: DTCcannotbe readwith a HondaPGMTester; checkby jumpingthe SCSservice connector. NOTE: Before troubleshooting DTCS 5-1 through 8-5, check battery/systemvoltage. lf voltage is low. repair the charging systembeforetroubleshooting SRSsystem. the
24-30
Chart-'98 - 00 models Code(DTCI Trouble Diagnostic

SRSindicator light doesnt come on
DTC
none (doesn't come on) none*3 {doesn't go off)
Possiblscause light circuit FaultySRSindicator light circuit.internal FaultySRSindicator failureof SRSunit,faulty SRSpower supply ( V Bl i n e )
Correctivaagtion Troubleshooting
See page 24-34
Troubleshooting
24-42
No DTC (light comes FaultySRSpower supply(VA line) on afterselfdiagnosis) Open in the driver'sairbaginflator 1-1 in resistance the driver'sairbag lncreased inflator
Troubleshooting
24-47
24-50 24-50 Troubleshooting 24-52 24-54 24-56 24-54 24-58 24-60 24-62 24-64 24-66 24-66 24-64 24-10 24-72 24-14 24-74 24-76 24-74 24-AO
1-3
1-4
Shortto anotherwire in the driver'sairbag reslstance inflatoror decreased Shortto power in the driver'sairbaginflator Shortto groundin the driver'sairbaginflator airbaginflator Open in the passenger's airbag in resistance the passenger's Increased inflator Shon to anotherwire in the passenger's resistance airbaginflatoror decreased
1-5 2-1
Troubleshooting
doesn't go off
2,4
airbag Shortto power in the passenger's inflator arrbag Shortto ground in the passenger's inflator
3-1 3-2
Openin the driver'sseatbelttensioner in resistance the driver'sseatbelt lncreased tensroner Troubleshooting Shon to anotherwire in the driver'sseatbelt tensroner Short to power in the driver'sseat belt tensioner Shortto ground in the driver'sseatbelttensloner seatbelttensioner Open in the passenger's seat in resistance the passenger's Increased belttensioner seat Shortto anotherwire in the passenger's belttensioner Short to power in the passenger'sseat belt tensroner seatbelt Shon to groundin the passenger's tensroner
3-4 4-1
4-3
4-4
Troubleshooting
4-5
(cont'd)
24-31
Troubleshooting
Diagnostic TroubleCode(DTC) Chart-'98 - 00 modets(cont,dl
SRSindicator light
l*Sec pag 24-96
DTC
5-l
Po$ibla cause
Corroctivelction SRSunit replacement
Internal failureof the SRSunit 5-4 6-1
6-3
6-4
lnternal failureof the SRSunit
SRSunit replacement
24-96
Internal failureof the SRSunit doesn'tgo off 8-1
SRSunit replacement
24-96
8-2
8-3 8-4 8-6 Internal failureof the SRSunit SRSunit replacement code (SRSunit must not be usedany longer) SRSunit.eplacement SRSunit replacement 24-96 24-96 Internal failureof the SRSunit SRSunit replacement 24-96
9_2*2*3
10-1
1,.-
NOTE: *1: In caseof an intermittent failureDTCg-1,it meanstherewas an internalfailureof the SRSunit or a faulw SRSindicator light circuit.Do the troubleshooting intermittent for failures(seepage2,+_2g), *2: In caseof an intermiuent fairureDTc 9-2, it meansthere was an internar fairureof the power suppry(vB rine).Do the troubleshooting intermittent for failures(seepage24-29). *3: DTCcannotbe readwith a HondaPGM Tester; checkby jumpingthe SCSservic connector. NOTE: Before troubleshooting DTCS through g-6. check battery/systemvoltage. lf voltage is low, repair the charg_ 5-1 ing systembeforetroubleshooting SRSsystem. the
\f
..
24-32
LightWireConnections SRSIndicator
SRS Indicator Light Power Circuit
WIREHARNESS DASHBOARD YEL BLK To UNDER-DASH BOX <_ FUSE/RELAY 20PCONNECTOR + To GAUGE assEMBLy
csog
SRS Indicator Light Control Circuit
SRSMAIN HARNESS
MAIN WIREHARNESS
V A I V B I t To UNDER-DASH BOX FUSE/BELAY 2P CONNECTOR
c414 c415 c502 c503 c509 c801 c803 c806
3P MAIN WIREHARNESS CONNECTOR 24P MAIN wlRE HARNESS CONNECTOR 2OP CONNECTOR WIREHARNESS DASHBOARD 24P WIREHARNESS CONNECTOR OASHBOARD 5P WIREHARNESS CONNECTOR DASHBOABD 2P HARNESS CONNECTOR SRSMAIN 3P SRSMAIN HARNESS CONNECTOR T8PCONNECTOR SRSMAIN HARNESS
Terminalside of msle trminals Terminalaide of male terminals Wire side of lemslo terminsls Wire side of female trminal3 Wire sid ot lemale te.minals wire side ol f.male terminals Wire side ol female terminals Wire side of lomrle terminals
24-33
Troubleshooting
The SRSIndicatorLight Doesn'tComeOn
CAUTION:Wheneverthe ignition switch is ON D, or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamage or iniuries.
Ch6ckthe power supply (fuse): Turnthe ignitionswitchON {ll),and check whetherthe other indicator lightscomeon (brake system, e(c.r. Do the other indicator liglrts com6 on?
lr-
Check No. 25 (7.5A) fuse in the under-dash the tuse/relay

DOX.
ls the tus oK? YES NO
Checkthe bulb: Replace the No.25 (7.5 A) fuse, and checkthat the SRSindicator lightcomeson. Doesthe SRSindicator liqht come on?
YES
END
NO
Checkthe wire h.rnesi kwen fus.nd gauge .3sembly: Checkfor an open in the wire harnessbetween fuse No. 25 (7.5Al and the gaugeassembly, repair. and Check that lhe SRSindicato.lighi Doesthe SRSindic.tor liqht com6 on?
lu
YES
END Checkthe SRSindicator light bulb: 1. Turnthe ignitionswitchOFF. 2. Remove gaugeassembly. the 3. Check blown SRSindicator lor tightbulb. ls the SRSindicator tight bulb OK? YES
NO
NO
Checkthe SRSindicator light circuit: Replace the bulb, and reconnectthe gauge assembly conneclors. Thenturn the ignitionswitchON {ll). Doesthe SRSindicator light come on?
I YEs
:ND
No
(A)To page24-35
(B)To page24 35
24-34
Jt
Frompage24 34 (A) From page 24-34 (8) WIREHARNESS DASHBOARD 5P CONNECTOR
Chockth6 SRSindic.lor light circuit: the dashboardwire harness5P connector 1. Disconnect from the gaugeassembly. 2. Connecta voltmeterbetweenthe No l terminal (+) o{ and grouncl. the 5P connector voltage 3. Turn the ignitionswitchON {ll),and measure 8.5 V or lats for 3ix second! aflsr the ignition ls thero switch ha3 bon turnod ON (ll)7
YES
NO
Fdulty SRS indicator light cilctlit in ths gauge sssomblY; replaco tho SRS printod circuit board in the gauge aasombly,
WIREHARI{ESS DASHBOARD 5P CONI{ECTOR
c509
MAIN WIREHARNESS
Chockth6 wire harn.$ of the SRSindicstor light circuh (11: 1. Turnthe ignitionswitchOFF. the 2. Disconnect main wire harness24Pconnectorfrom wire harnessthe dashboard 3. Connecta voltmeterbetweenthe No 5 terminal (+) of and ground 24P the ma;nwire harness connecior voltage. 4. Turnthe ignitionON {ll),and measure ls there 8,5 V or lr3 tor six scond3efter the ignilion switch has bssn turnod ON llll?
YES
NO WIRE DASHBOARO HARNESS24P CONNECfOR
Short to powor in the BLU wire of tho dashbosrd wire harne3s; Epait the harne3.s.
MAIN WIREHARI{ESS2/tP COI{ ECTOR
sideof maleterminals Terminal To page 24-36
(cont'd)
24-35
Troubleshooting
The SRSIndicatorLight Doesn'tComeOn (cont,dl
From page 24-35 '97 modol:
Checklhe wire harnessotthe SRSindicator light circuit l2l: L Turnthe ignitjonswitchOFF. 2. Disconnect SRSmain harness connector the 3p from the mainwire harness. 3. Connecta voltmeterbetweenthe No. I terminal (+) of the SRSmain harness connector 3P and qround. 4. Turnthe ignitionswitchON (ll),and measure voltaqe. ls there 8.5 V o. less tor six seconds atter the ignition switch has beenturned ON
MAIN WIREHARNESS 3P CONNECTOR
UNDER.DASH FUSE/RELAY BOX '98 00 models:
SRSMAIN HARNSS 3P CONNECTOR
Short to power in th BLU wire of the main wiro halno3s;
MAIN WIREHARNESS 3P CONNECTOR
SRSMAIN HARNESS 3P CONNECTOR SRSMAIN HARNESS 3P COI{NECTOB
FUSE/RELAY BOX
c803
Checkth wire hahess of th6 SRSindicator ci.cuit {31: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe battery negative cable, then the positive cable, and wait threeminutes. 3. Disconnect driver's and front passenger,s the airbag connectors{anddisconnect seatbelt tensionerconnectors} the (seepage24-23). 4. Disconnect SRS main harness18p connectorfrom the 5. Reconnect the battery positive cable, then reconnectthe negative cable. 6. Connecta voltmeterbetweenthe No. 6 terminal (+) of 'l8P the SRSmain harness connector and ground. 7. Turnthe ignitionswitchON (ll),and measurevoltage. There shouldbe 0.5V or less.
SRSMAIN HARNESS 18PCONNECTOR
Short to power in the BLU wire oI the SRS main harngas;
24-36
The SRSIndicatorLight Doesn'tGo Off -'97 model

CAUTION:Wheneverth ignilion switch i3 ON (lll, ol has been turnd OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accideniallydeploy and causedamag or iniuries.
Try to reproducethe sRs indicator light: DTCmemory(seepage24 28) 1. Erasethe 2. Turn the ignitionswitchON {ll),and checkthat the SRS and then indicator light comeson for aboutsix seconds goes off.
Doe3 the SRS indicator light slay on?
YES
NO
Intermiftent ftilure, system is OK at this time. So Troubl_ on shootingIntermittentFailutes p.ge 24_28.
Checkthe No. 13 (15 Al fuse: 'L Turn the ignition switch OFF. 2. Checkfor blown No. 13 (15 A) fuse in the under dash fuse/relaybox. ls lhe tuse OK? YES Replace luse, and err3e the memory the ' 1 . R e p l a cte e N o .1 3 ( 1 5 A ) f u s e h 2. Erase DTc memory(seepage24-28). the 3. Turnthe ignitionswitchON (ll).
ioes the SRS indicatol light go off after 3ix s6conds?
Al No. 13 115 FUSE NO
UNOER.DASH BOX FUSE/RELAY
SRSUNIT
YES ENO
NO
Confirm tho OTC,and continuettouble3hooting.
Checkfor an open in the SRSmain hatnss{VA lins}: negativecable,then disconnect the 1. Disconnect batterY and wait for threeminutes. cable, the positive airbagcon and front passenger's the 2. Disconnect driver's (seepage24-23). nectors the 3. Disconnect SRS main harness18Pconnectorfrom the sRs unit. the battery positive cable, then reconnectthe 4. Reconnect cable. negative 5. Connecta voltmeterbetweenthe No. 7 terminal (+) ot and 9rouncl l8P the SRSmain harness connector 6. Turnthe ignilionswitchON {ll). ls there battory voltage? YES NO
SRSMAIN HARNESS r8P CONNECTOR
SRSMAIN HARNESS18P CONNECTOR
Ooen in the SRS main harness{VA line); replacethe natnoss.
(cont'd)
(A) To page24 38
24-37
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off - '97 model (cont,d)
Frompage24 37 (A)
Checkthe SRSunit: Connect SRSmain harness the 18Pconnector terminals No. 6 and No.7 with a jumperwire and backprobe
Faulty SRSunit or poo. contact at the SRSmain ha.ness 18Pconnectoi; checkthe connector. lfthe conneqtoris OK, replacethe SRSunit.
Oidtuse No. 13 (15Al blow?
JUMPERWIRE
(B) To page 24'39

Check for a short to ground in the SRS indicator tight circutl: 1. Turnthe ignitlonswitchoFF. 2, Disconnect the dashboardwire harness5p connector from the gaugeassembly. 3. Check resistance between No. 1 terminalofthe dash the board wire harness5P connectorand ground. There shouldbe 1 MOor more. Wlresidoot tomale terminsls
)
DASHBOARD WIREHARNESS 5P CONNECTOR
(c)
To page 24-40 Shon to ground in th6 gaugo assembly;replacothe gau96
DASHBOAND WIRE HARI{ESS 5P CONNECTOR
c509
T
243a
Frompage24-38 {B)
WIREHARNESS DASHBOARD 5P CONNECTOR
Checklhe SRSindicalor circuit: 1. Turnthe ignitionswitchOFF t 2 . R e m o v e h e g a u g e a s s e m b l y D o n o t d i s c o n n e ctth e wire harness5P connectorfrom the gauge dashboard assemoly. 3. Turn the ignition switch ON (ll). termi5P wire harness connector tie 4. Connect dashboard nalsNo. I and No 5 with a iumperwire. Doesthe SRSindicator light 90 otn
Faulty SRS indicator light circuit in the 9aug6 a$embly; reolace the SRS printod circuit boa.d in th' gauge
WIREHARNESS DASHBOARD 5P CONI{ECTOR
Y;yfivvcsos
ffi BLU I
Checktor rn open in the SRSindicator light circuit: 1. Turnthe ignitionswitchOFF the dashboardwire harness5P connector 2. Disconnect from the gaugeassemblY. between the No. 6 terminal ol the SRS 3. Checkres]sta-nce and No l terminal ol the main harness18Pconnector there should be wire harness5P connector; dashboard
IYEL
JUMPERWIRE
Wir6.sideof female lormrna|s
SRSMAI HAN ESS t8P CO I{ECTOR
Wire side oI fsmale terminals
{D) To page24-41
1E) To page24-41
WIREHARNESS DASHBOARD 5P COI{NECTOR
(cont'd)
24-39
Troubleshooting
The SRSIndicatorLight Doesnt Go Off -'97 model {cont'dl
Frompage24-38 1C) MAIN WIRE HARNESS 24PCONNECTOR
i,
Checkfor a short to ground in tho main wire ha.n.3s: 1. Disconnect dashboardwire harngss24p connector the from the main wire harness, 2. Checkresistance betweenthe No. 5 terminal of the dash_ board wire harness24P connectorand ground. There shouldbe 1 M0 or more.
Short to ground in tho deshbosrd wire harne.r; raD.ir the dashboardwiro harness. DASHBOARD WIREHAff{ESS 24P COi{NECTOR
OASHBOARD WIRE HARNESS 24PCONNECTOR BLU
Wire side of female t6rminals
MAIN wlRE HARNESS 3P CONNECTOB
Checktor a short to ground in tho SRSmain hfina3!: 1. Disconnectthe SBS main harness3p connectorfrom the maan wire harness. 2. Checkresistancebetween the No. 1 terminal of the SRS main harness connector 3P and ground.Thereshouldbe 1 MO or more.
SRSMAIN HARNESS 3P CONNECTOR UNDER.OASH FUSE/RELAY BOX SRSMAII{ HARI{ESS 3P CONNECTOR
cao3
Short to ground in tho main wire harnesr; ,opair th6 main wire hamoss.
Short to ground in the SRS main hsrn6sa;.oplac. thc SRS main harn6ss.
24-40
)
From page24-39 (D) wlRE hARNESS DASHBOARD 5P CONNECTON
Checkthe SRSindicator circuit input voltage: to the 1. Reconnect SRS main harness18Pconnector the SRSunit 2. Connecta voltmeterbetweenthe No 1 terminal (+) of and ground. 5P the dashboard connector 3. Turn the ignition switch ON (ll), wait for six seconds, voltage then measure fs there 8.5 V or more? NO
YES
The oroblem hts disappoareddue to disconnoctingand connecting the connectors. Be 3ure all terminals make good contact, and rocheckthe system {see Trouble' shooting Intermittent Failur6 on pagg2'l-281'
WIREHARI{ESS DASHBOARO 5P CONI{EC'OR
Pool contacl at the SRS main harness18Pconnector;check the connector. . lf the connoctor is OK. aubstituta a known-good SRS unit, and recheck. . ll the problem is still present, replaco the SRS main h'r-
c509
ness.
Frompage24-39 iE) Checkfor an oPen in the dashboardwire hatn8s: Irom the 1. Disconnect main wire harness24P connector wire harness the dashboard 2. Check resistancebetween the No. 6 terminal of the SRS otthe main and 18P mainhamess connector No 5 terminal thereshouldbe 0- 1 0 O 24Pconnector; wire harness 15 the resistance.s specified? NO sideof malelerminals Terminal
YES
ODen in the BLU wire ot the dashboard wit6 harness; rep.ir the dashboaldwite harness.
Checkfor an open in the main wirc harness: '1. Disconnect SRSmain harness connector from the 3P the mainwire harness, 2. Checkresistancebetweenthe No. 6 terminal of the SRS ofthe SRS and 18P mainharness connector No 1 terminal be should 0 - 1 0 u 3P main harness connector;there as |3 lhe re3istance sPecifiod? YES NO SRSMAIN HABNSS 3P CONNECTOR
Oon in the BLU wire ol the main wire harness; rcpair tha main wire harness
Opn in the SRS main harn4s; replacethe SRS msin har' no3s.
24-41
Troubleshooting
The SRSIndicatorLight Doesnt Go Off - ,99- 00 models
CAUTION:Wheneverthe ignition switch is ON {lll, or has been turnod OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamage or iniuries.
T.y to reproducethe SRSindicator tight: 1. Erase DTCmemory(seepage24-28). the 2. Turn the ignitionswitchON { }, and checkthat the SRS indicator light comeson for aboutsix seconds and then goes off. Doesthe SRSindicator tight stey on? YES NO
tl-
Intermittent failure, system b OK at this time. 56 TroubleshootingInle.mittent Failures page24-2g. on
Check the No. 23 (10Alfuse: 1. Turnthe ignitionswitchOFF. 2. Checkfor blown No. 23 flO A) fuse in the under dash luse/relay box. ls the fuse OK?
YES
Repl.ce the tuse, and erasethe memory 1. Beplace No. 23 (10Ai fuse. the 2. Erase DTCmemory(seepage24-28). the 3. Turnthe ignitionswitchON flt). Doesthe SRSindicator light go ott after six secondt YES
No. 23 110Al FUSE NO
FUSE/RELAY BOX
I
END Conti.m tha DTC,and continue troubl*hooting.
NO
Chockfor an open in the SRS main harness(Vg line): 1. Disconnect batterynegativecable,then disconnect the the positive cable, and wait for threeminutes. 2. Disconnect driver,sand front passenger,s the airbag con_ nectors,and discoonect seat belt tensionerconnectors the (seepage 24-23). 3. Disconnect SRS main harness18p connectorfrom the the sRs unit. 4. Reconnect bafterypositive the cable,then reconnect the negativecable. 5. Connecta voltmeterbetweenthe No. 3 terminal (+) of the SRSmain harness connector 18p and oround. 6. Turnthe ignitionswitchON 0l). ls there battery voltage? YES NO
Open in the SRS main harness(VB line); replacothe natness,
|
(A)
To page24 43
24-42
)
Ftom page 24-42 (A)
SRSUNIT SRSMAIN HARNESS Checkthe SRSunit: terminalsNo. 18Pconnector the Connect SRSmain harness 3 and No.6 with a iumperwire and backprobe Doesthe SRSindicator light go otf?
Faulty SRSunit or poor contact at the SRSmain harness 18Pconnedor; checkthe connector. lf the connoctoris OK, replacethe SRSunit
18PCONNECTOR SRSMAIN HARNESS Did tuseNo. 23 {10A} blow? JUMPERWIRE
1B) fo page24-44
Wiresideof lemalelerminals WIREHARNESS DASHBOAED 5P CONNECTOR
Check for a short to ground in the SRS indicator light circurl: 1. Turnthe ignitionswitchOFF. the dashboardwire harness5P connector 2, Disconnect from the gaugeassembly, the resistance between No l terminalofthedash3. Check 5 r b o a r dw i r e h a r n e s s P c o n n e c t o a n d g r o u n d .T h e r e shouldbe 1 Mo or more.
(c)
To page24-45 Short to ground in the gauge assembly;replacethe gauge WIREHARNESS DASHEOARD 5P CONNECTOR
c509
(cont'd)
24-43
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -'99 - 00 models(cont,d)
Frompage24,43 J
(B)
Checkthe SRSindicator circuit: 1. Turnthe ignitionswitchOFF. 2 . R e m o v e h e g a u g e a s s e m b l y D o n o t d i s c o n n e ctth e t . dashboardwire harness5p connectortrom the gauge assemDty. 3. Turnthe ignitionswitchON 0l). 4. Connect dashboard the wire hamess connector 5p termi nalsNo. 1 and No. 5 with a iumoerwire. Dooslhe SRSindic.tor light go offl YES NO
Fauhy SRS indic.tor light circuit in lho gruge a3samblv; replaco the SRS print6d circuit bo.rd in the g.uge assombly.
DASHBOARD WIREHANNESS 5P CONNECTOR
Checkfor an opeo in the SRSindicaior light circuit: 1. Turnthe ignitionswirchOFF. 2. Disconnect the dashboardwire harness5p connector from the gaugeassembly. 3. Checkresistance between the No. 6 terminalof the SRS main haroess18Pconnector and the No. 1 terminal ot the dashboard wire harness connector; 5P there should be0-1.0O.
|3 the rosbtance a3 sDecified?
liTv;Tv;1c5i0s # lsru lYEr

JUMPERw|RE Wiresade lernale ol rerminats
YES
NO
Wirsideot lemaleieminals
(D) To page 24-46
(E) To page24-46
J
24-44
J
From page 24-43 1C) MAIN WIRE 2,lP CONNECTOR HABNESS
Chockfo. a short to glound in tho main wire harn63: wire harnoss24P connector tho 1. Disconnect dashboard from the mainwire harness. the between No 5terminaloIthedash2. Check resistance board wire harness24P connectorand ground. There shouldbs 1 Mo or more.
Short to ground in tho dashboatd wilo harnots; repair WIREHARI{ESS OASHBOARD 24P CONNECTOR
WIRE OASHBOARD HARNESS 2,rP CONNECTOR BLU
MAIN WIRE 3P CONNECTOR Chcckfor a short to ground in the SRSmain harnoss: the SRS main hart\ess3P connector{rom the 1. Disconnect main wire harness, 2. Checkresistancebetween the No. 1 terminal of the SRS Thereshouldbe and ground. main harness connector 3P 1 MOor more.
cToR
BOX FUSE/RELAY
SRSMAIN HARNESS 3P CONIIECTOR
c803
Short to ground in the mlin wire harnoss; .epair lh mlin wira harness.
Short to ground in thc SRS mtin hemess; replacetho SRS
)
(cont'd)
24-45
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -,99 - 00 models(cont,d)
Frcm page 24-44 {D) DASHBOARD WIREHARNESS J)
Chckthe SRSindicator circuit input voltage: 1. Reconnect SRS main harness18p connector the the to SRSunit. 2. Connecta voltmeterbetweenthe No. 1 terminal {+) of the dashboard connector 5P and ground. 3. Turn the ignition switch ON {ll}, wait for six seconds, then measure voltage. ls there 8.5 V or more?
YES
NO
The problem has disappareddue to disconnectingand connecting tho connectors. Be sure all terminals make good contact, and .echeck the system {seo Troublo_ shooting Intermiftent Failureson page2it-2E). DASHEOARD WFE HARNESS 5P CONNECTOR Poo. contact at the SRS main harn8s 18p connector;check the connector. . lf the connoctor is OK, aubstitute a known-good SRS unit, end recheck. . lf the problem is still present, .6place tho SRS m.in harne33.
Ftom lage24-44
c5ott
Wiresideof lemale terminals
(E)
Checkfor an open in the dashboa.dwire harnessi 1. Disconnect main wire harness24p connectorfrom the the dashboard wire harness. 2. Checkresistancebetween the No. 6 terminal of the SRS main harness18Pconnector and No. S te.minalof the main wire harness connector; 24P thereshouldbe 0 - 1.00. ls th resistancers speciliedT YES NO
Open in the 8LU wi.o ol the dashboard wire hrmess: repair the dashboardwire ha.ness.
Torminal sideol maletermtnal
Checkfo. an open in the m.in wire hamess: 1. Disconnect SRSrnainharness connector the 3p from the main wire harness, 2. Check resistancebetweenthe No. 6 terminal of the SRS rnain harness18Pconnector and No. 1 terminalof the SRS main harness connector;there 3P should 0 1.0O. be
b the rGbtanco as sDecified?
c806
YES
NO
ca03
Open in the BLU wir6 of th6 main wire hernos3;reori. the main wire hamess, Open in the SRS main harness;rplacethe SRS main ha.noss. SRSMAIN HARNESS 3P CONNECTOR
24-46
No DTC
CAUTION:Wheneverthe ignition switch is ON {lll, ol has been tulned OFF for less than three minutes, bs careful not to bump the SRS unit; the airbags could accideniallydeploy and causedamago or iniuries.
Chckthe fuse: 1. Turnthe ignitionswitchOFF. 2. Checkfor blown No. 13 ('15A) fuse in the under-dash Iuse/relay box. b th fuse OK? YEs NO
To 1A) page24 48 Replace fuse.Turn the ignitionswitchON {ll),and check the that the luse doesn'tblow. ls the fuse OK? YES NO
No. 13(r5 Al FUSE
UNDER-DASH BOX FUSE/RELAY
Ted{rive the vhicle and The problm has disappeared. Intermittont Failurea page21-28. on see Troubfeshooting
Check Ior short to ground between tho underdash tuse/ relay box and the SRSunil. 1. Turnthe ignitionswitchOFF. the 2. Disconnect batterynegativecable,then disconnect the positive cable, and wait for threeminutes. airbag conthe 3. Disconnect driver's and front passenger's the nectors,and disconnect seat belt tensionerconnectors (seepage24-23). from the 4. Disconnect SRS main harnessl8P connector the sRs unit. between the No. 7 terminalof the SRS 5. Checkresistance and ground. main harness connector 18P Thereshouldbe 1 M0 or more. ls the .esistancoas soecified? YES NO
SBSMAIN HARNESS 18PCONNECTOR
18PCONNECTOR SRSMAIN HARNESS
Faulty SRSunit; replacelhe SRSunit {seepage 24-951.
(B) 24-48 To page
(cont'd)
24-47
Troubleshooting
No DTC(cont'dl
ltofi page 24-47
1
(B)
Chockfor short to ground in the SRSmain harne3s: 1. Disconnect SRSmain harness connector the 2P lrom the underdashfuse/relay box. 2. Checkresrstance betwoen the No.7 terminalof the SRS main harness18Pconnector and ground.There should be 1.0M0 or more. k the ro3irtancc as specifid?
YES
NO
Short to ground in tho under-da3hlus6/rolay box; replacethe under-dashfuse/relav box, Short to glound in the SRS m.in hernoss;roplacetho SRS main hatnei3.
FUSE/RELAY BOX
J (A)Frompage24-47 Checktor an opn in the SRSmain harness: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegative the cable,then disconnect the positive cable.and wait for threeminutes. 3. Disconnect driver's and front passenge/sairbag con, the nectors,and disconnect seat belt tensionrconnectors the {seepage 24-23}. 4. Disconnect SRS main harness18Pconnectorfrom the the SRSunit. 5. Reconnect the battery positive cable, then reconnectthe negative cable. 6. Connecta voltmeterbetweenthe No. 7 terminaloI the SRSmain harness connector 18P and ground. 7. Turnthe ignitionswitchON (lll , and measure voltage. SRSMAIN HARNESS 18PCONNECTOR
SRSMAIN HARNESS 18PCONNECTOR Poor conlact .t the SRS main harness l8P connesto.: checkth6 connector, . It the connector is OK, substitute a known-good SRS unit, and rgcheck. . It lhe problem ii still p.es6nt, rcplace the SRS mlin hamess.
To page24-49
J 3
24-48
)
Frompage24-48
Checktor an open in the SRSmain harne$: 1. Turnthe ignitionswitchOFF. lrom the 2. Disconnect SRSmain harness connector the 2P undeFdashfuse/relaybox. 3. Checkresistancebetween the No. 1 terminal of the SRS main harness connector 2P and the No. 7 terminalof the SRSmain harness connector. l8P Thereshouldbe 0 - 0.5O. ls the re3istanc soecitiod? as
YES
NO
Poor contact at iho SRS main harnoss2P connoctor; checkthg connocior. . lf the connector is OK. substitute a known-good underda3hfuse/rolav box, and .echeck. 'lf tho problm is still present. replace tho SRS main harne3s.
UNDER-DASH BOX FUSE/RELAY
lEP CONNECTOR SRSMAIN HARNESS Opon in the SRS main ha.ness;replacethe SRS main har ness.
c801
SRSMAIN HARNESS 2P CONNECTOR
24-49
Troubleshooting
DTC1-1and DTC1-2
J DRIVEF'S AIRBAG 2P CONNECTOR
CAUTION:Wheneverthe ignition switch is ON {ll}, or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamage o1 iniuries.
Try to reproducethe SRSindicator light: 1. Erase DTCmemory(seepage24-28). the 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicator light comeson tor about six seconds and then ooes off. Doesthe SRSindicator liqht stav on?
CABLEREEL 2P CONNECTOR
YES
NO
Intermiltent failure, svstem is OK at this time. See Trouble3hootingIntermittent Failureson page 24-28.
Checktor an open in the driver's airbag inflatori 1. Turn the ignitionswitchOFF2. Disconnect batterynegative the cable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnect the driver's airbag 2P connectorfrom the cable reel 2P connector- not disconnect passen Do the ger'sairbagconnector. (2 4. Connect specialtool O)to the cablereel2P connec the tor. 5. Reconnect battervpositive the cable,then reconnect the negative cable, 6. Erase DTCmemory(seepage24-28). the 7. Readthe DTC{see page 24-261. ls DTC 1-1or DTC 1-2 indicsted?
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR t2 0 JACKI 07saz - TB40r1A
'97 modol: CABLEREEL 2P CONNECTOR
'98 - 00 models:
YES
NO SRSMAIN HARNESS 2P CONNECTOR
Open or increased resistance the driver'sairbaginflato.; in replacethed.ive.'s airbag (s6epage24-871.
Checkfoi an ooen in the cable reel: 1. Disconnect batterynegativecable,then disconnect the the positive cable, and waat threeminutes. for 2. Disconnect specialtool (2 Oi from the cable reel 2P the 3. Remove the dashboard lower cover,and disconnect the cablereel2P connector from the SRSmain harness. 4. Connect special the tool (2 0) to the SBSmain harness 2P (cont'd) connector,
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR 120 JACKI 07sAz - TB4011A
To page24'51
24-50
)
Frompage24 50
Checkfor an opon in the cabl rel (cont'd): 5. Reconnect battervpositive the cable,then reconnect the negative cable, 6. Erase DTCmemory(seepage24-28). the 7. Read DTC(seepage24-2d. the ls DTC 1-1or DTC 1-2 indic.ted? YES
NO
Open or increased resistance in the cable reel; replace the cable reel (seepaqe 24-91J.
Checkfor an open in the SRSmain harne$: 1. Disconnect batterynegativecable,then disconnect the the positive cable, and wait lor threeminutes. 2- Disconnect front passenger's the airbagconnector land disconnect both seatbelttensioner connectors), 3, Disconnect the SRS main harness18Pconnectorfrom the SRS unit. Do not disconnect the specialtool 12 O) from the SRSmain harness. 4. Checkresistance between terminals No. 1 and No. 13 of the SRSmain harness connector. 18P Thereshouldbe aoorox.2.0 3.0 0. ls the rcsistancas soecified?
YES
NO
Poor contact at the SRS main harnoss 18P connctor; check the connector. . It the connecior is OK, substitute a lnown-good SRS unit, and recheck. .lf the problem is still present,.eplacethe SRS main harness,
Opon or inc.oasedrc3istancein the SRS main harnoss; roDlace tho ha]nss.3.
24-51
Troubleshooting
DTC1-3
J
CAUTION: Whonovor the ignition switch is ON (ll), or has been turnod OFF for less thsn three minutss. be caroful not to bump the SRS unit; tha ailbags could accidentallydoploy and cau3odamage or iniuries.
Try to r.produce the SRSindicator light: 1. Erase DTCmemory(seepage24-28). the 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicator light comeson for about six saconds and then goes off. Do.s the SRSindic.tor light stay on?
2P CONNECTOR
YES
NO
Intermittenl failuro. sy3tom i3 OK at this time. Soo Trouble3hootingIntormittenl Failure3on prqo 24-28.
Chockfor a short to enother wirG in the driver's sirbag inf,artor: 1. Tlrn tho ignitionswitchOFF. 2. Disconnect battery negative the cable,then disconnect the positivecable,and wait for three minutes. 3. Disconnct the driver's airbag 2P connectorfrom the cablo rel 2P connector, not disconnect oassenDo the ger'sairbagconnctor. (2 4. Connect specialtool Olto the cablereel2P connecthe tor. 5. Reconnect the baftery positive cable, then reconnectthe negative cable. 6. Erasethe DTCmemory (seepage 24-28). 7. Readthe DTC(see page24-261. b DTC1-3 indicatod? YES NO
ffi
'97 model:
SRSSIMULATOR tfAD c 0?TAZ- SZ5olrA and SRSINFLATOR /SIMULATOR / Q a JACKI 07s,A-TB411A /'
,98 - 00 models: CABLE REEL 2PCONNECTOR
Sho.t in the driv6r's airb.g intletor; replacethe d vr's .irb.g l3oo pag6 247).
Ch6cklor a short in the cablc reol: '1. Disconnect the battery negative cable,then disconnect the positive cable, and wait for threeminutes. 2. Disconnect specialtool {2 O) lrom the cable reel 2P the conneclor. 3. Remove the dashboard lower cover,and disconnect the cablereel2P connector from the SRSmain harness. 4. Connect the special tool (2 O) to the SRS main harness 2P connector. {cont'd}
SRSSIMULATOR LEADC 07TAZ- SZ50114 and SnS INFLATOR SIMULATOR {2 0 JACK} 07sAz - TB{011A
To pago 24-53
24-52
Frompage24-52
Chockfor a shon in th6 cablo recl {cont'dl: 5. Reconnect the battery oositive cable,then reconnecttha negativecable. 6. Erssethe DTCmemory (seepage 24-28). 7. Readthe DTC(see page24-26l'. ls DTC'l-3 indic{tod?
YES
NO
SRSUNIT
Short in the csble reel; replacetha cabls rcol lsao paga 24-911.
Chockfor a short in th SRSmain ha.nors: 1. Disconnect batterynegativecable,thn disconnect the the Dositivecable,and wait for three minutes. 2. Disconncttho lront passengor'sairbag connector (and disconnectboth seat belt tensionerconnectors). the 3. Disconnect SRS main harness18Pconnectorfrom the specialtool (2 0) the SRS {rnit.Do not disconnect from the SRSmain harness connector. 2P 4. Checkthe resistance betweenterminals No. 1 and No. 13 of SRSmain harness connector. 18P Thereshouldbe aDorox. - 3.00. 2.0
b th rsciitlnce
a3 sDecifi6d?
SRSMAIN HABNESS 18PCONNECTOR
YES
NO
( . ,L z l3 l l
Faulty SRSunit; rspl.c. th6 SRSunit l.co p.sc 2a-95,,
3 18
c806
15
Wiresideot tormrnats Shori in the SRS m.in h.rn.e!; ropbce the SRS main htrne33.
24-53
Troubleshooting
DTC1-4
ial
CAUTION: Whonover the ignition switch is ON (ll), or has boen turned OFF for less than throe minutos, bs carelul nol to bump tho SRS unit; the airbags could accidentallydeploy and causedamago or iniuri63.
Try to rop.oducotho SRSindicator light: 1. Erase DTCmomory(soepage24-28). the 2. Turn the ignitionswitchON {ll},and checkthat the SRS and then indicator light comeson for aboutsix seconds goes off. Doe3th6 SRSindicltor light 3tay on?
REEL
2P CONNECTOR
YES
NO
Intormittent tailure, rystem is OK rt this timo. See Troubl$hooting Intermittent Failurcson pago 2G28. SIMULATOR LEAD C 07TAZ- SZ5011A .rd SRSINFIATOR /SIMULATOR ./ ea JA0KI
Chacklor a 3hort to powor in ths driyar's airbag inflrtor: 1. Turnthe ignitionswilchOFF. the 2. Disconnect batterynegativecable,thn disconnect cable, and wait for threeminutes. the positive the driver's airbag 2P connector{rom the 3. Disconnect Do the cable reel 2P connector. not disconnect passenger'sairbagconnector. 4. Connect special the tool (2 0) to the cablereel2P conn6ctor, the battery positive cable.then reconnectthe 5. Reconnct negativecable. 6. Erasethe DTCmemory (seepage 24-28). 7. Readthe DTC{see page 24-261. ls DTC 1-4 indicatod? YES NO
ffi
'97 model:
1(
otstz-terore
ltl
'98 - 00 models: CABLE REEL
Short to powe. in the driv.r's rirbrg inflator; replacethe ddver's airbeq (!o D.qa 2447).
Chckfor. short to powe. in tho cabl6.ool: 1. Disconnect batterynegativecable,then disconnect the the oositivecable,and wait lor three minutes. the tool (2 O) from the cable reel 2P 2. Disconnect special connefior, the dashboard lower cover,and disconnect the 3- Remove cablereel2Pconnector lrom the SRSmain harness. 4. Connect the specialtool (2 0) to the SRS ma;n harnss (cont'dl 2P connoctor.
SIMULATOR I-EADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR (2 0 JACKT 07sAz - lB4011A
To page 24-55
!
24-54
Ftom page24-54
Checkfor 6 short power in the cable r6el {cont'd): 5. Reconnect the battery positive cable, then reconnectthe negative cable. 6. Erasethe DTCmemory (seepage 24-28). 7. Readthe DTC(see page 24-261. b DTC1-4 indicarodz
YES
NO
Short to power in lhe cablo roel; replace th cabl ieel {seepago24-91).
Checktor a short to power in th. SRSmain harn$s: 1.Disconnect batterynegativecable,then disconnect the the positivecable, and wait for three minutes. 2. Disconnect front passenger's the airbagconnector {and disconnect both seatbelttensioner connectors). 3. Rernove special the tool (2 O)from the SRSmain harness 2P connector. 4. Disconnect SRS main harness18Pconnectorfrom the the SRSunit. 5. Beconnectthe batterv positive cable, then reconnectthe negative cable. 6. Connecta voltmeterbetweenthe No. 1 {+) terminalol the SRSmain harness connector 18P and body ground. 7. Turn the ignition switch ON (ll), and measurevoltage. Thereshouldbe 0.5V or less. 8. Turnthe ignitionswitchOFF. 9. Connect voitmeterbetween a the No. 13 {+i terminalof the SRSmain harness connector 18P and body ground. 10.Turnthe ignitionswitch ON lll), and measurevoltage. Thereshouldbe 0.5V or less. Are voltagesas specified? YES NO
Faulty SRSunit; replacoth SRSunit lsoo pas6 24-95).
Short to power in th SRS main hamoss; roplecethe SRS main haanass.
24-55
Troubleshooting
DTC l-s
CAUTION: Whenever tho igniiion switch is ON {ll), or has been lurned OFF for loss lhan thrse minules, be caretul not to bump the SRS unit; the airbags could accidentallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicator light: 1. Erase DTCmemory(seepage24-28). the 2. Turn the ignitionswitchON lll), and checkthat the SRS indicator light comeson for aboutsix seconds and then goes off. Doostho SRSindicator liqht stav on? AIRBAG DRIVER'S 2P CONNECTOR
O'-
CAALEREEL 2P CONNECTOR
YES
NO
Inte.mittent tailure,3y3tem is OK at this timo. 506 TroubleshoolingIntermittent Failureson Daq24-28.
Checktor a short to ground in the driver's ai.bag intlator: 1. Turnthe ignitionswitchOFF. 2. Disconnect battery negative the cable,then disconnect the positive cable, and wa:l for threeminutes. 3. Disconnect the driver's airbag 2P connectorfrom the cable reel 2P connector, not disconnect passen, Do the ger'sairbagconnector. 4. Connect special the tool {2 O}to the cablereel2Pconnector. 5. Reconnect the battery positive cable. then reconnectthe negative cable. 6. Erase DTCmemory(seepage24 28). the 7. Readthe DTClsee page 24-261. ls DTC1-5 indicated? YES NO
ar/ h
ffi
'97 model:
SRSSIMULATOR LEADC 07TAZ- SZ50r1A .nd SRSINFLATOR SIMULATOR {2 0 JACK) 07sAz - TBaolrA
'98 - 0Omodels: CABLE REEL 2PCONNECTOR
Short to ground in the driver's airbag inflator;replacethe driver's airbag (s6epage 24-871.
Chockfor a short to ground in the cablo reel: 1. Disconnect battery negative the cable,then disconnect the positive cable, and wait for threeminutes. 2. Disconnect special the tool i2 O) from the cable reel 2P 3. Remove the dashboard lower cover,and disconnect the cablereel2P connector from the SRSmain harness. 4. Connect the special tool {2 O) to the SRS main harness (cont'd) 2P connector. SRSSIMULATOR LEAOC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR t2 0 JACKI 07sAz - TB{01rA
To page24-57
J..
24-56
)
Frompage24 56
Check{or a short to ground in the cable reel (cont'd): 5. Reconnect the batterv positive cable, then reconnectthe negative cable. 6. Eraselhe DTCmemoty lsee page 24-28). 7. Readthe DTClsee page24 26). ls OTC1-5 indicated?
YES
NO
Short lo ground in the cable reel; replacethe cable reel {seeoaoe 2,1-91}.
Checkfor a short to ground in the SRSmain harness: '1. Disconnect batterynegative the cable, disconnect the the positive cable, and wait for threeminutes. 2. Disconnect airbag 2P connector the tront passenger's (6nddisconnect connectors). both seatbelttensioner 3. Remove special the tool 12{))fromthe SRSmain harness 2P connector. 4- Disconnect SRS main harness18Pconnectorfrom the the sRs unit. 5. Checkresistance between the No. l terminalo{theSRS main harness18Pconnector and ground,and between the No. 13terminalof the SRSmain harness 18Pconnector and ground. Thereshouldbe I M0 or more. ls lhe resistanceas soecitiod? YES NO
Faulw SRSunit reDlace SRSunit lsee paqe 24-951. the
Short to ground in the SRS main harness;replacethe SRS main hamss,
24-57
Troubleshooting
DTC2-1 and DTC2-2
CAUTION:Wheneverthe ignition switch is ON lll), or has been turned OFF tor less than throe minutes, be careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicator light: 1. Erase DTCmemory(seepage24-28). the 2. Turn the ignitionswitchON (ll),and checkthat the SRS indacator light comeson for aboutsaxseconds and then Doesthe SRSindicator lioht stav on? SRSMAIN HARNESS !a
Intermittent tailure, svstem is OK ai lhis time. See Troubl*hooting Intermittent Failureson paqe24-28.
Chockfor an open in the passongor's airbag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegative the cable,then disconnect the positive cable, and wait for threeminutes. 3- Disconnect front passenger's the airbagconnector lrom (seepage24-2:,,. the SRSmain harness 4. Connect the special tool (2 0) to the SRS main harness 2P connector. not disconnect driver'sairbagcon, Do the nector. 5. Reconnect the battery positive cable, then reconnectthe negative cable. 6. Erase DTCmemory(seepage24-28). the 7. Readthe DTC(seepage 24 26!'. ls DTC2-1 or DTC2-2 indicated?
ffi
y'
SIMULATOR I-EADC 07TAZ- SZ5tt11A and SRSINFLATOR /StMULATOR / Q A JACKI
07slz-TA411A
Open or incrcased resistance in tho passenger'sairbag
To page 24'59
24-58
)
Frompage24 58
Checkfo. an oD6nin the SRSmain harness: 1. Disconnect batterynegative the cable,then disconnect the positive cable, and wait for threeminutes. 2. Disconnectthe driver'sairbag2P connector land disconnect (see both seatbelttensioner connectors) page24 23). 3. Disconnect SRS main harness18Pconnectorfrom the the SRS unit. Do not disconnect the soecialtool (2 Oi from the SRSmain harness. 4. Check resistance between No. 10terminaland No. 14 the terminalof the SRS main harness 18Pconnector. There shouldbe aoorox.2.0- 3.0g. ls the .osistancas soecified? YES NO
sRs UNIT
Poor contacl ai the SRS main harness 18P conneclori checklhe connector, .lf the conneclor is OK, substitute a known-good SRS unit, and recheck. .lf the problem is still present,replacethe SRS main
hatnesli,
18PCONNECTOR
Open or increasedresistancein the SRS main harness; replacethe harness.
24-59
Troubleshooting
DTC2-3
CAUTION: Whenevor the ignition switch is ON { }, or has been turned OFF for less than three minutes, be careful not to bump the SRS unit; lhe airbags could accidentallydeploy and causodamage or iniuries.
Try to reproducethe SRSindicator light: 1- Erase DTCmemory{seepage24 28). the 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicator light comeson for aboutsix seconds and then goes off. Doesthe SRSindicator light stay on? SRSMAIN HARNESS
{J
YES
NO
Intermittont failur, syslem is OK at this time. 560 T.oubloshootinglntormittent Failur6 on page 24-28.
Checkfor a short to another wiro or decreased resbtanc in the pa$nger's airbag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegativecable,then disconnect the the positive cable, and wait for threeminutes. 3. Disconnect the front passenger's airbag 2P connector (seepage24-23). from the SRSmain harness 4. Connect the special tool (2 O) to the SRS main harness 2P connector. not disconnect driver,s Do the airbagconnector. 5. Reconnectthe battery positive cable, then reconnectthe negative cable. 6. Erase DTCmemory(seepage24 28i. the 7. Readthe DTC(seepage 24-26). ls DTC2-3 indicated? YES NO
ffi
y'
SIMULATOR LEAD C 07TAZ- SZ50I1A and SRSINFLATOR /STMULATOR / I2n JACKI
-fB1011A 07sAz
Short to another wir6 or decaea3draktance in the oassenger's airbag intlatoi; replac the passenger'sairbag {see pago 24-8t1.
To page24 61
24-60
)
Frompage24 60
aGsistance in Ch6cktor a short to another wire or decreasod lh SRSmain harness: 1. Disconnect batterynegativecable,then disconnect the the positive cable, and wait for threeminutes. (anddisconnect 2. Disconnect driver'sairbag2P connector the both seatbelttensioner connectors). '18P connectorfrom 3. Disconnect SRS main harness the the tool (2 O). the SRSunit.Do not disconnect special 4. Check resistance the between No. 10terminaland No. 14 18Pconnector. There terminalof the SRS main harness shouldbe aoorox. - 3.00. 2.0
ls the rosistanc6 as specified?
YES
NO
Faultv SRSunit; replacelhe SRSunit lsee page 24-95). SRSMAIN HARNESS 18PCONNECTOR
Short to anothor wire or decre.sed re3i3t.nce in the SRS main harness;replacthe SRSmain harn*s.
24-61
Troubleshooting
DTC2-4
GAUTION: Whnever tho ignition switch is ON 0t). or has been turned OFF for less than threo minutes, bo careful not to bump the SRS unit; the airbags could accidentallydeploy and causedamaga or iniuriss.
Try to reproducethe SRSindicator light: 1. Erase DTCmemory(seepage24-28i. the 2. Turn the ignitionswitchON (lli, and checkthat the SRS indicator light comeson tor about six seconds and then goes off. Dosthe SRSindicator light stay on? YES NO SRSMAIN HARNESS
Ot-
Inlermittent tailure, system is OK at this tim. Sce Troubleshooting Intermitt.f Failureson page 2+28.
Checkfor a short to power in the passengar,s ai.bag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnect bafterynegativecable,then disconnect the the positive cable, and wait for threeminutes. 3. Disconnect the front passenger's airbag 2P connector Irom the SRSmain harness lseepage24-23). 4. Connect the special tool (2 O) to the SRS main harness 2P connector. not disconnect driver,s Do the airbagcon, nector, 5. Reconnect the battery positive cable, then reconnectthe negative cable. 6. Erase DTCmemory(seepage24-28). the 7. Readthe DTC(see page 24-26|'. ls DTC2-4 indicsted?
ffi
//
07TAZ SZ5011A .nd SRS INFLATOR /stMU|_ATOR / t2 tr JAoKI olsAz-Tsn11A
SIMULAYOR LEAD C
YES
NO
Sho.t power in the passenger's airbag infator; rsplece tho paisonge/i airbag {se pag 2il-89).
To page24-63
24-62
Frcm page24-62 Checklor a short to power in the SRSmain harness: 1. Disconnect batterynegativecable,then disconnect the and wait for threeminutes. the positive cable, (anddisconnect the 2. Disconnect drive/s airbag2P connector both seatbelttensionerconnectors). the 3. Disconnect SRS main harness18Pconnectortrom the SRSunit. (2 4. Remove specialtool 0) from the SRSmain harness the 2P connector, the batterv positive cable,then reconnectthe 5. Reconnect negative cable. the No. 10 (+) terminalof 6. Connect voltmeterbetween a 18P and ground. SRSmain harness connector 7. Turn the ignition switch ON (ll). and measurevoltage Thereshouldbe 0.5V or less. a 8. Connect voltmeterbetweenthe No. 141+)terminalof and ground,and the SRS main harness18Pconnector Thereshouldbe 0.5V or less. voltage. measure Are voltages .3 specifiedT YES NO
sRs
.I8PCONNECTOR
FaultySRSunit; replacethe SRSunit (sce page 24'95).
Short to powor in the SRS main ha.ne3s; replace the SRS main hdrness.
24-63
Troubleshooting
DTC2-5
tl
CAUTION:Wheneverthe igniiion switch is ON {ll}, or has ben turnd OFF for less than three minutes, be careful nol to bump the SRS unit; the sirbags could accidentallydoploy and causo damage or iniuries.
Try to rep.oducethe SRSindicstor tight: 1. Erase DTCmemory(seepage24-28). the 2. Turn the ignitionswitchON 0l), and checkthat the SRS indicator light comeson for aboutsix seconds and then goes off. ooes th6 SRSindicaror light st.y on?
YES
NO
Inte.mitt.nt failure, system is OK at thi3 time. Se Troubl6hooting Intermittem Failur6 on page2+28.
Checkfor a short to gaound in th6 prsenger,i airbag inllator: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynogativecable,then disconnect the the positive cable, and wait for threeminutes. 3. Disconnect the front passenger,s airbag 2p connector from the SRSmain harness {seepage24-23). 4. Connect the special tool (2 0) to the SRS main harness 2P connector. not disconnect driver,s Do the airbagcon, nector. 5. Reconnectthe battery positive cable, then reconnectthe negative cable. 6. Erasethe DTCmemory (seepage 24-28). 7. Readthe DTClsee page2[-261. ls DTC2-5 indicated? YES
ffi
SIMULATOR LEAOC 07TAZ- SZ5011A .nd SRSINFLATOR /StMULATOR / t2 a JACKI 07saz-fB&11^
NO
Short to ground in the pasngert airbeg inflator; ,cplace the passenge/s airbag (se page 2+991.
To page24 65
24-64
J
Frompage24'64 Checkfor a short to ground in the SRSmain harnessl 1. Disconnect batterynegativecable,then disconnect the the posilive cable.and wait for threeminutes. (anddiscon2. Disconnect driver'sairbag2P connector the nectboth seatbelttensioner connectors), 3. Disconnect SBS main harness18Pconnectorfrom the the sRs unit. 4. Remove special the tool (2 O)from the SRSmain harness 2Pconnector, 5. Check resistance between No. 10terminalof the SRS the main harness18Pconnector and ground,and between the No. 14terminalof the SRSmain harness connec 18P tor and ground. Thereshouldbe 1 M0 or more. ls the resistanceas sDcitied?
YES
NO
sRs
Faultv SRSuniu replacethe SRSunit {seepaqe 24-951. 18PCONNECTOF
Short to ground in the SRS main harnss;replacihe SRS main harness.
24-65
Troubleshooting
DTC3-1and DTC3-2
CAUTION:Wheneverthe ignition switch is ON flll, or has been turned OFF for less than three minutes, b careful not to bump th SRS unit; the airbags could accidenlallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicatoi light: 1. Erase DTCmemory(seepage24-29). the 2. Turn the ignitionswitch ON 1 ), and checkthat the SRS indicator light comeson for aboutsix seconds and then goesoff. Doesthe SRSindicaior lighr stay on? YES NO DRIVER'S SEATBELTTENSIONER 2P CONNECTOR LEFTSIOEWIRE HARNESS 2P CONNECTOR
Intermittent failure, system is OK at this time. See Troubleshooting lfiermittent Failu.6s page24-28. on
Checktor an open in the driver's seat b6lt tensioner: 1. Disconnect negative the battery cable,and wait lor three minutes. 2. Disconnect drave/sseat belt tensioner connector the 2p from the left side wire harness connector (see page 2P 24-23). not disconnect lront passenger,s belt Do the seat tensioner connector. 2P 3. Connectthe specialtool {2 O) to the left side wire harness 2P connector, 4. Reconnect negative the baftery cable 5. Erase DTCmemory{seepage24,28). the 6. Readthe DTC(see page 24-26). ls OTC3-1or DTC3-2 indicatedT YES NO
07TAZ SZ501rA andSRS INFLATOR STMULAToR I t2 0JACKI I oTsaz- TB4ot t lA
SRSSIMULA LEADC
Open or increasedresistancein the d.iver's seat belt tensioner; replacethe driver's seat belt {seepage 2il-91).
To page24 67
24-66
)
Frompage24-66
Checkfor an oFn in thc aide wir6 harne$: from 1. Disconnect left sidewire harness connector 2P the the SRSmain harness connector. 2P 2. Connect the special tool (2 o) to the SRS main harness 2Pconnector. 3. Erase DTCmemory. the 4. Read DTC. the ls DTC3-l or DTC3-2 indicated?
LEFTSIDEWIRE HARNESS 2P CONNECTOR
YES
NO
Ooen or incrersd reeidance in the lelt side wire hame3s; rDlacathe hamess.
00
art
Checkfor an open in the SRSmain harness: battery cable,and wait for three 1. Disconnect negative the minutes. airbags, 2. Disconnect the driver'sand front passenger's (see connectors and front passenger's belttensioner seat page24-231. 3. Disconnect SRS main harness18Pconnectorfrom the the specialtool (2 O) the SRS unit. Do not disconnect 2P from the SRSmain harness connector. 4. Check resistance between No. 4 and No. 11terminals the Thereshouldbe 18Pconnector. of the SRSmain harness 2.0- 3.0 0.
13lhe resistance as soecified?
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR {2 0 JACKI 07sAz - T84011A
YES
NO
Faulty SFS unil or poor contad at the SRS main h.mss 18P connector and th SRS unit. check the connection between the SRS main harn$s 18P connector and the SRS unit. lf the connector i3 OK. rDlacoihe SRS unit (s66pas6 24-951.
sRs UNIT
ODen or incaoased resistancein the SRS msin harness; reolacethe SRSmain harnss.
SRSMAIN HARNESS .I8PCONNECTOR
)
terminals
24-67
Troubleshooting
DTC3-3
CAUTION; Whenever the ignition switch is ON llll, or has bon turned OFF for l6ss than three minutes, be carelul not to bump the SRS unit; the airbags could accidontallydeploy and causedamage or iniuries.
Try to rproducethe SRSindicator light: 1. Erase DTCmemory(seepage24-28). the 2. Turn the ignitionswitchON (lll, and checkthat the SRS indicator light comeson for about six seconds and then goes off. Doesthe SRSindicator lighl stay on? ORIVER'S SEATEELTTENSIONER 2P CONNECTOR LEFTSIDEWIRE HARNESS 2P CONNECTOB ra
YES
NO
Intarmittent failure, system is OK at this time. 506 Troublshooting IntormittantFailures paqe24-28. on
Checktor a 3hort to anothr wire or decreased resistancein ihe driver's seat bolt tan3ioneri 1. Disconnect negative the battery cable,and wait for three minutes, 2. Disconnectthe driver's seat belt tensioner 2P connector (see page from the left side wire harness connector 2P 24-23). not disconnect front passenger's Do the seat belt tensioner connector, 2P 3. Connectthe specialtool (2 O) to the left side wire harness 2P connector. 4. Reconnect negativebattery cable the 5. Erasethe DTCmemory (seepage 24-28). 6. Readthe DTC(seepage 24.26l'. ls DTC3-3 indicated?
SRSSIMULATOR LEAOC 07TAZ-525011A and SRSINFLATOR
srMULAroR I t2 0 JACK| t ozsAz ls{orra !
YES
NO
Short to another wire or decreased.esistance the in driver's s6at beh tcnsioner; replacthe diive.'s seat bolt {seprge 24-911. To page 24 69
24-64
\.p
Frompage24-68 reaistancein Checklor a short to another wire or decreased the side wire harnoss: 1. Disconnect left side wire harness connector the 2P trom the SRSmain harness connector. 2P 2. Connect the specialtool (2 0) to the SRS main harness 2P connector. 3. Erase DTCmemory. the 4. Read DTC. the ls OTC3-3 indicated? YES NO
SRSMAIN HANNESS 2P CONNECTOR
Short to another wire or decrcased resbtance in the le-h side wire harness;reglacethe harneas.
0a
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLAToR SIMULATOR {2 0 JACK} 07sAz - TB4011A
I J
Checklor a 3hort to another wire or dec.easedresistancein the SRSmain ha.ne$: 1. Disconnect negative the battery cable,and wait for three minutes, 2. Disconnect driver's and front passenger's the airbags, (see and front passenger's belttensioner seat connectors page24 23l'. 3. Disconnect SRS main harness18Pconnectorfrom the the SRSunit. 4. Disconnect special the tool (2 O)from the SRSmain harness 2P connector. 5. Checkresistance between No. 4 and No. 11terminalsof the the SRS main harness18Pconnector. There should be 1 M0 or more. ls the resistancas soocified?
YES
NO
SRS UNIT
Faulty SRSunit; replacethe SRSunit lso paqe 24-95).
Short to another wire or decrasodrosistanco in the SBS main harness;replacethe SRSmain harness.
I J
lerminals.
24-69
Troubleshooting
DTC3-4
CAUTION: Whenever the ignition switch is ON (lll, ol has been turned OFF for l6ss than thr6e minutes, b careful not to bump the SRS unit; lho airbags could accidentallydeploy and causdamage or iniuries.
Try lo reproducoth6 SRSindicator light: 1. Erasethe DTCmemory(seepage24-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS light comeson for aboutsix seconds indicator and then ooes off, Doe3the SRSindicator liqht stav on?
DRIVER'S SEATBELTTENSIONER 2P CONNECTOR
LEFTSIDEWIRE HARNESS 2P CONNECIOR
YES
NO
Intcrmitt.nt f.ilur., iystem is OK at this time. Soe Troubla3hooting Intermittent Failurca on Dage24-28.
Checklor a shortlo Dowar in the driver'33at beh tonsioncr: 1. Disconnoct the negativebattery cable, and wait for three minutes. 2. Disconnect driver'sseat belt tensioner connector the 2P (see page from the left side wire harness connector 2P 24 23).Do not disconnect front passenger's the seat belt tensioner connector, 2P 3. Connectthe specialtool {2 0) to the left side wire harness 2P connector. 4. Reconnect negativebattery cable. the 5. Erasethe DTCmemory {see page24-28). 6. Readthe DTC(see page 24-26). ls DTC3-4 indicsted?
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR
SIMULATOR I {2 o JACK} I ozsaz- tamrrl i
YES
NO
Short to powar in the d.iver's seat belt tensioner; replacethe d.iver's seat belt tensione. {3eepago 2il-31.
To page24'71
24-70
)
Frompage24-70 Chocktor a short lo power in the sid wi.e harness: 1. Disconnect left sidewire harness connector the 2P from the SRSmain harness connector. 2P 2. Connect the sDecial tool {2 O) to the SRS maanharness 2P connector, 3. Erasothe DTCmemory. 4. Readthe DTC. b DTC3-4 indiclted?
h
(
YES
NO
Short to power in the left side wire ha.n6ss;replecethe narness.
00
Checkfor a short to power in the SRSmein harness: 1. Disconnect negative the battery cable,and wait for three mrnutes. 2. Disconnect driver'sand lront passenger's the airbags, (see and front passenger's belttensioner seat connectors page 24-231. 3. Disconnect SRS main harness18Pconnector the trom the SRSunit. 4. Disconnectthe specialtool(2 0)fromthe SRSmainharness 2Pconnector, then reconnectthe negative batterycable. 5. Turn the ignitionswitchON (lll. 6. Checklor voltage betweenthe No. 4 terminal ol the SFS main harness'18P connectorand body ground. There shouldbe 0.5 V or less.Checkfor voltagebetweenthe No. 11terminalsol the SRSmain harness18Pconnector. There shouldbe 0.5V or less. ls tho voltage as specffied?
SRSSIMULATOR LEAOC 07TAZ- SZ5011A and SRSINFLATOR (2 0 JACKI 07SAZ- TB/t011A
YES
NO
Faulty SRSunit; replacetho SRSunit lsee paqe 24-95).
Short to power in the SRS m.in harness;.eplace the SRS main hame3a.
24-71
Troubleshooting
DTC3-5
CAUTION: Whonover tho ignition switch is ON (ll), or has been turned OFF for less than thres minutes, b careful not to bump the SRS unit; the airbags could accidontallydeploy and causedamsgo or iniurirs.
Try to reproducothe SRSindioto. light: 1. Erasethe DTCmemory (s66 pag624-28). 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicator lightcomoson Ior aboutsix seconds, and then goes off. Do. the SRSindicsto. light 3tav on? DRIVER'S SEATBELTTENSIONER
*r
YES
NO
lnto.mitlont hilure, ryltom is OK at thia timc. Ses T.oubleshootinqIntermittont Failuroson page 2+28.
Chck for a short to ground in the djivoi's soat b6h tonsioner: 1. Disconnect the negativebattery cable, and wait tor three mtnutes. 2. Disconnoctthe driver's seat belt tensioner 2P connector Irom the lft side wire harness 2P connector (see page 24-23).Do not disconnectthe front passenger's seat belt tensioner2P connector. 3. Connectthe specialtool (2 0) to the left side wire harness 2P connector, 4. Rgconnect negativebattery cable. the 5. Erasethe DTCmemory (seepage 24-28). 6. Readthe DTC(see page21-26). ls DTC3-5 indicated?
-teronl t ozsnz
SRSSIMULATOR LEADC 07TAZ-S25011A and SRSINFLATOR SIMULATOR \ (2 0 JACK' I
YES
NO
Short to ground in the driver's soai belt tensioner; repllce the driver'3 seat belt lse Daq624-31.
To page2a-73
24-72
)
Frcm page24-12
Checklor . short to ground in lhe lido wire hrrnassi 1. Disconnect llt sidewiro hamess2P connector the from the SRSmain harness connector. 2P 2. Connect the special tool (2 0) to the SRS main harness 2P connoctor. 3. Erasethe DTCmemory. 4. Readthe DTC.
LEFTSIDEwlRE HARNESS 2P CONNECTOR
\r
(
Short to ground in the lolt side wi.e harno3s;.eplscethe hamer3.
00
Checkfor a short to ground in tho SRSmain harna+t: 1. Disconnect tho negativebattery cable, and wait for three mtnutes. 2. Disconnect drive/s and front passenger's the airbags, and front passenger'sseat bolt tensioner 2P connectors (seepage24-231. 3. Disconnect SRS main harnessl8P connectorfrom the the SRSunit. 4. Removethe spacialtool {2 0) from the SRSmain hamess 2P connector, 5. Checkresistancebetween the No. 4 terminal of the SRS m a i n h a r n e s s1 8 Pc o n n e c t o r n d b o d y g r o u n d ,a n d a betweenthe No. ll terminalsofthe SRS main harness 18Pconnector and body ground.Thereshouldbe 1 M0 or more.
/ I
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR / (2 o JACK) 07sAz - TB4o11A
Short to ground in the SRS m.in hrrnar3; roplacotho SRS mein hamoSs.
24-73
Troubleshooting
DTC4-1and DTC4-2
!|
CAUTION: Whenever tho ignition 3witch is ON (ll), ot has boen turnd OFF for less than thro6 minutos, bo carful not to bump ihe SRS unit; the airbags could accidentallydeploy and causodamage or iniurios,
Try to roproducathe SRSindicator light: 1. Erase DTCmomory(seepage24'28i. the 2. Turn the ignitionswitchON (ll).and checkthat the SRS indicator light comeson for aboutsix seconds. and then ooes off, Doesthe SRSindicator lisht stay on? YES NO
RIGH1SIDEWIRE HARNESS 2P CONNECTOR
FRONT PASSENGER'S
Intermittent failure, syatem i3 OK at this tim6. Soo Trouble3hootingInta.mittent Failuroson page24-28.
Ched( for an open in the front p.ssongo/s 3eat bolt teruiona.: 1. Disconnect negative the cable,and wait for three battery mrnutes. 2. Disconnect front passenger's the seat belt tensioner2P connectorfrom the right side wire harnss2P conneclor (see page 24-23).Do not disconnectthe driver's seat belt 2P tensioner connector. 3. Connect special the tool (2 O)to the right sido wire harness2P connector. 4. Reconnect negativebatterycable. the 5. Erasethe DTCmemory lsee page 24 28). 6. Readthe DTC(seepage 24'26). k DTC4-1 or DTC4-2 indicatodT
SRSSIMULATOR LEADC
/izo.ncri -
07TAZ SZ5n11A andSRsINFLATOR SIMULATOR
ozsAz T8.011A
YES
NO
Open or increaaad resistance in lhe tront pa$enger's seat belt tensioner; roplace the front p.s3engar's 3eat belt lsee p.ge 24-31.
fo page24-75
24-74
)
Ftom page 2!-7a
Checklor .n oo.n in the side wire hsrness: 1. Disconnect rightsidewire harness connector the 2P from the SRSmain harness connector. 2P 2. Connect tool (2 Oi to the SRS main harness the special 2Pconnector. 3. Erase DTCmemory. the 4. Beadthe DTC. ls DTC4-1 or DTC4-2 indicated?
RIGHT SIDEWIRE HARNESS 2P CONNECTOR
YES
Open or inc.oasedresistancein th right side wire harness;replacethe harness.
"r$
Checktor an open in the SRSmain harness: 1. Disconnect negative the battery cable,and wait for three mtnutes. 2. Disconnect the driver'sand front passenger's airbags, (seepage24and driver'sseatbelt tensioner connectors 23\. 3. Disconnect SRS main harness18Pconnectorfrom the the SRS unit. Do not disconnect the specialtool (2 0) from the SRSmain harness connector. 2P 4- Check resistance between No. 5 and No. 12 terminals the of the SRSmain harness connector. 18P Theresho!ld be 2.0- 3.00. ls the resistancaas soecified?
SRSSIMULATOR LEADC 07TAZ- SZ5011A .nd SRSINFLATOR SIMULATOR (2 0 JACK) 07sAz - TB4011A
YES
NO
Faulty SRSunit or poor contact at the SRSmain harne3s 18P conneclor and the SRS unit, check the connestion btween the SRS main harness 18P connctor and th6 SRS unit. lf the connector is OK, reDlacethe SRS unit {seepage 24-951.
Open or increesedresistancoin the SRS main h.rnes3; replacethe SRSmain harness.
)
le.minals.
24-75
Troubleshooting
DTC4-3
CAUTION: Whonev.r ths ignition switch is ON (ll), or has been turned OFF tor less than throe minutes, b careful not to bump tho SRS unit; the airbags could accidentallydeploy and csuse damage or iniuries.
Try lo reproducothc SRSindicator light: '1. Erase the DTCmemory (seepage 2{-28). 2. Turn the ignitionswitchON {ll},and checkthat the SRS indicator light comeson for aboutsix seconds, and then goes off. Doosthe SRSindicstor light stay on? YES NO RIGHTSIDEWIRE HARNESS 2P CONNECTOR FRONT PASSENGER'S
Intermittent failure, rystgm ia OK rt this timo. S6c TroubloshootingIntermittont Failu.oson pago 2+28.
Chock to. a short to .nothor wira or decre8od ro3btance in the froni pa3sengor'3 aoat belt ten3ioner: 1. Disconnect negative the battery cable,and wait for three mrnutes. 2. Disconnect front passenger's the seat belt tensioner2P connectorfrom the right side wire hamess 2P connector (see page 24-23).Do not disconnectthe driver's seat belt tensioner connector. 2P 3. Connect special the tool (2 O)to the right side wire harness2P connoctor. 4. Reconnect negativebattgrycable. the 5. Erasethe DTCmemory (see page 24-28). 6. Readthe DTClsee page 24-261. |3 DTCG3 indicatod?
SRSSIMULATOR LEADC 07TM - SZ5011A and SRSINFLATOR SIMULATOR
/2 o JACKI l07sAz - TB4011A
tna t2s>,-ar'
--\>
YES
NO
Short to .noth6r wire o. dc6e.rd raktanco in the front passenger'3 sat boh teniioner; roplaccthe lront pass6ng6r's aeat belt (sepsge 2a-31.
To page24-77
24-76
Frompage24-76
Chockto. a aho.l to lnothcr wire or dcreslod rosbtanco in th. side wiro harn.$: 1. Disconnoct rightsidewire harness connector the 2P lrom the SRSmain harness connector. 2P 2. Connoct the special tool (2 O) to the SRS main harness 2P connector. 3. Erasethe DTCmemory. 4. Readtho DTC. 13DIC +3 indicated? YES NO
RIGHTSIOEWIRE HARNESS 2P CONNECTOR
Short to .noth6r wiro or doc.oasod r.sistanco in thG dght sida wiro ha]ne3s;rapl.ce the hamcas.
SRSMAIN 2P CONNECTOR
Chackloi a short to anothor wire o. docreasd rGbtancc in tho SRSmain h.]n$: 1. Disconnect the negativebattery cable, and wait for three mtnutes, 2. Disconnect driver's and front passenger's th6 airbags, and driver's seat belt tensionerconnectors(see page 24-
SRSSIMULATOR LEADC 07TAZ- SZ50114 and SRSINFLATOR SIMULATOR {2 0 JACK) 07saz - Ta1ol1A
3. Disconnect SRS main harness18Pconnectorfrom the the SRSunit. 4. Disconnect specialtool (2 0) from the SRS main harthe ness2P connctor. 5. Checkresistance betweenthe No. 5 and No. '12terminals of the SRSmain harness 18Pconnector. Thereshouldbe 1 MO or more. b the raaistanco aa soscifiedT
YES
NO
F.ulty SRSunit; roplactho SRSunit lseo pase 24-951.
Short to enothor wi.o or decree3odr*istance in the SRS main harnoit rophco the SRSmain ha.nsss.
SBSMAIN HARNESS 18PCONNECTOR
c806
15
l;
iid of {6male
terminals,
24-77
I
Troubleshooting
DTC4-4
CAUTION:Wheneverthe ignition switch is ON (ll), or has been turned OFF tor less than thlee minutes. be careful nol to bump the SRS unit; the airbags could accidontallydeploy and causedamage or iniuries.
Try to reproducethe SRSindicator light: 1. Erase DTCmemory{seepage24-28). the 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicator light comeson for aboutsix seconds, and then goes off. Doosthe SRSindicator light 3t.y on? RIGHTSIDEWIRE HARNESS 2P FRONT PASSENGER'S
vEs
NO
Intermittent f!ilure, system is OK at this time. See T.oubleshootingIntermittent F.ilures on page 24-28.
Checktor a 3horl lo power in the frolt passnge.'ssat belt tensaoneri '1. Disconnect negative the battery cable,and wait for three mrnutes. 2. Disconnect front passenger's the seat belt tensioner2P connector from the right sidewire harness connector 2P Do the {seepage24-23}. not disconnect driver'sseatbelt tensioner connector. 2P 3. Connect special the tool (2 O) to the right sidewire harness2P connector. 4. Reconnect negaiivebafterycable. the 5. Erasethe DTCmemory (seepage 24-28). 6. Read the DTClseepage24-261. ls DTC4-,1 indicated?
SRSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR
,StMULATOR /(2 o JACK) 1A t _07SAZTBiro1
YES
NO
Short to power in the front passong6r'3seat belt tensioner; replacethe front passongar'3 sat beh {see page 21-31.
To page24'79
24-78.
)
Ftom page24 78
Checkfor a short to power in the side wire harn6s: from 1. Disconnect rightsidewire harness connector the 2P the SRSmain harness connector, 2P 2- Connect the specialtool (2 0) to the SRS main harness 2Pconnector. 3. Erase DTCmemory. the 4. Read DTC. the ls DTC4-{ indicated? YES NO
RIGHT SIDE WIRE HARNESS 2P CONNECTOR
Short to power in the right side wire harness; replace the harness.
SRSMAIN 2P CONNECTOR
) J
Checktor a short to oow6r in the SRSmain harness: 1. Disconnect negative the batterycable,and wait for three mtnutes, 2. Disconnect airbags, the driver'sand front passenger's (seepage24and driver'sseatbelttensioner connectors 23). 3. Disconnect SRS main harness18Pconnector the from the sRS unit. 4. Disconnect special the tool i2 0) from the SRSmain har ness2P connector, then reconnect negativebattery the caore. 5. Turnthe ignitionswitchON (ll). 6. Check voltagebetween No. 5 terminalof the SRS for the m a i n h a r n e s s 8 Pc o n n e c t o a n d b o d y g r o u n d .T h e r e 1 r should be 0.5 V or less.Checkfor voltagebetweenthe No. 12 terminals the SRSmain harness connector. 18P of Thereshouldbe 0.5V or less. ls the voltage as specified? YES NO
SBSSIMULATOR LEADC 07TAZ- SZ5011A and SRSINFLATOR SIMULATOR \ (2 0 JACK) \ 07sAz-T84011A
Faulty SRSunit; replacethe SRSunit (seepase 24-95).
Short to power in the SRS main harness;replacethe SRS main harness. SRSMAIN HARNESS 18PCONNECTOR
24-79
Troubleshooting
DTC4-5
GAUTION: Whonever the ignition switch is ON fll). ol has be6n turned OFF for less than thrso minuter. be careful not to bump the SRS unit; the airbags could accidontallydeploy and causodamage or iniurias.
Try to roproducoth. SRSindicrtor tighi: 1. Erase DTCmemory(seepage24-28). the 2. Turn the ignitionswitchON (ll),and checkthat the SRS indicator light comeson for aboutsix seconds, and then goes off. Doe3the SRSindicator light stay on? RIGXTSIOEWIRE HARNESS 2P FRONT PASSENGR'S
YES
NO
Intrmittent t.ilurG, syst.m is OK at thi! timo. So TroubleshootingInte.miftnt Failure3on psqa 2+28.
Chcck Ior a shon to ground in the trodt parsnge/s lert beh tensionea: 1. Disconnect negative the battery cable,and wait for three mrnutes. 2. Disconnect front passenger's the seat belt tensioner 2p connector trom the right sidewire harness connector 2p (see page 24-23).Do not disconnectthe driver's seat bek tensioner connector. 2P 3. Connect special the tool (2 0) to the right sidewire harness 2P connector, 4. Reconnect negativebatterycable. the 5. Erasethe DTCmemory lsee page 24-28). 6. Readthe DTC(seopage 24-26!-. k DIC G5 indicated?
1A o?saz Taaol
SRSSIMULATOR LEADC 07lAz - s25011A and SRSINFLATOR SIMULATOR t2 0 JACKT
YES
NO
Short to ground in the Lont passengc.'33rt boh tonsioner; replacetho from p.rlenger's sort beh lsa page 21-3t.
To page24-81
24-80
Frompage24'80
Checklor a short to ground in the sido wir harness: 1. Disconnect rightsidewireharness connector the 2P from the SRSmain harness connector. 2P 2. Connect tool {2 O) to the SRS main harness the special 2P connector. 3. Erase DTCmemorv. the 4. Read DTC. the b DTC4-5 indicrtad?
RIGHTSIDEWIRE HARNESS 2P CONNECTOR
YES
Short to ground in the right side wire harness; replac. the harne3!.
Checktor a short io ground in the SRSmain ha.nessi 1. Disconnect negative the battery cable,and wait for three minotes, 2. Disconnect driver's and front passenger's the airbags, and driver's seat belt tonsionerconnectors(see page 24231. 3. Disconnect SRS main harness18Pconnectorfrom the 4. Disconnect special the tool (2 0) from the SRSmain harness2Pconnector. 5. Checkresistancebetweenthe No. 5 terminal oI the SRS m a i n h a r n e s s1 8 Pc o n n e c t o r n d b o d y g r o u n d ,a n d a between the No. 12 terminalof the SRS main harness 18Pconnector and body ground.Thereshouldbe 1 M0 or more,
b th re3i3tance as specified?
SRSSIMULATOR LEADC 07TAz- SZ5011A and SRSINFLATOR SIMULATOR \ {2 0 JACK} \ 07SAZ-TB,O114
ffi
YES
NO
Faulty SRSunit replacethe SRSunit {seepace 2a-951.
Short to ground in the SRS main harness;replacethe SRS main harnoss. SRSMAIN HANNESS 18PCONNECTOR
24-81
Troubleshooting
DTC8-6 -'97 model
\
CAUTION: Whonever th ignition switch is ON fll). ol has ben turned OFF for les3 than thro minutes, be caretul not to bump the SRS unit; tho airbags could accidentallydeploy and causedamage or iniurios. Besides indicatingan abnormalityin the SRS unit, DTC 8-6 may also indicatethat two problemsequivalentto DTC1-1 and 2-4, 'l-4 and 2-1,or 1-4and 2-4 occurredat the sametime. Proceed the ordershown below. in
Chockthe SBS main harnGs: 1. Disconnect batterynegativecable,then disconnect the the positive cable, and wait for threeminutes. 2. Disconnectthe driver's airbag and front passenger,s afrDagconnectors{see page 24-23). 3. Disconnect SRS main harnesst8p connectorfrom the the sRs unit. 4. Reconnect batteryposative the cable,then reconnect the negative cable. 5. Turnthe ignitionswitchON 0t). 6. Connecta voltmeterand measure voltagebetweenthe No. 10 terminalot the SRSmain harness l8p connector and ground, and between No. 14terminal the and qround. Thereshouldbe aDorox.0-0.5 V. Are voltagesas specitied?
18PCONNECTOR
YES
NO
Shon to power in tho SRSmain harness; reglacethe SRS main harn63.
Chockthe SRSmein harnels and the cable rel: Connect voltmeter a and measure voltage between No. 1 the t e r m i n a l o f t h e S R S m a i n h a r n e s sl 8 p c o o n e c t o ra n d ground,and between No. 13terminaland ground.There the shouldbe approx.0 0.5V. Are voltagesas specifiod? YES NO
Faulty SRSunit; replacethe SRSunit {saepago 24-951.
To page 24-83(A)
24-82
)
Frompage24-82 iA)
Checkthe cable reeli 1. Turnthe ignitionswitchOFF. 2. Disconnect the cable reel 2P connectorfrom the SRS main harness, 3. Turnthe ignitionswitchON lli). 4. Connect a voltmeter and fieasute voltage beNveenthe No. 'l terminaloI the SRS main harness18Pconnector a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d ground. Thereshouldbe approx. - 0.5V. 0 Are voltagcs as specifiod?
YES
NO
Short to powor in the cable reel; replace the cable reel {soooaqa 24-921.
Short to powe. in ths SRS main harn633;replaco tho SRS main harness.
24-83
Troubleshooting
DTC9-2-'97 model
\
CAUTION: Whenever the ignition switch is ON flll, or has been turned OFF tor loss than thrse minute3, bs careful not to bump the SRS unit; lhe airbags could accidentallydoploy and causodamage or iniuriss.
Ch6ckthe tuso: 1. Turnthe ignitionswitchOFF. 2. Checktor blown No. 23 (10 A) fuse in the !nder-dash Iuse/relaybox.
(A)To page24-85 Replace fuse.Turn the ignitionswitchON {ll},and chck the thatthe fusedoesnt blow.
No. 23 110 FUSE Al

FUSE/RELAY BOX Tho problem has dilappeared. T6t-drive the vohid and see Troubl6hogting Intermittedt Failur6 on prgc 2il-2g.
Check for shon to ground botween the undor-darh fu36,/ relay box and tho SRSunit. 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegativecable,then disconnect the the positive cable,and wait for threeminutes. 3. Disconnect driver's the and front passenger,s airbagconnectors{seepage 24,23). 4. Disconnect SRS main harness18p connectorfrom the 5. Checkresistancebetween the No. 3 terminal of the SFS main harness connector 18P and grouncl. Thereshouldbe 1 M0 or more.
sRs
18PCONNECTOR
FauftySRSunit; replacoth6 SRSunit {3epage 2t-951.
To page 24-85
24-84
from page 24'84 (B) Ch6ckfo. short io ground in the SRSmain harnes!: 1. Disconnect SRSmain harness connector lrom the the 2P under-dash fuse/relay box. 2. Checkresistance between the No. 3 terminalof the SRS main harness18Pconnector and ground.There should be 1.0MO or more. ls the resbtancoas soecitied?
YES
NO
Short to ground in the undor-dalh fuse/relay box; rplacoth under-da3h fuse/relav box. Short to ground in the SRS main harneas;replacothe SRS main harneas.
FUSE/RELAY BOX
(A) From page 24-84 Chckfor an open in the SRSmain harnes: 1. Turnthe ignitionswitchOFF. 2. Disconnect batterynegative the cable,then disconnect the positive cable, and wait tor threeminutes. 3. Disconnect driver's the and front passenger's airbagconnectors{see page2il 23). 4. Disconnect SRS main harness18Pconnectorfrom the the sRs unit. 5. Reconnect the baftery positive cabie, then reconnectthe negative cable. 6. Connect voltmeterbetweenthe No. 3 terminalof the a SRSmain harness connector 18P and oround. 7. Turnthe ignitionswitchON (ll), and measure
SRSMAIN HARNESS 18P CONI{ECTOR
SBS MAIN HARNESS 18P COI{l{ECTOR Poor contrct at the SRS main harnss 18P connector; checkthe connectoa. . lf the connsctor is OK, substitute a known-good SRS unit, and rccheck. . lf the problom is still present. replaco the SRS main harness,
To page 24'86
(cont'd)
24-85
Troubleshooting
DTC9-2-'97 model lcont'dl
Frompage24-85
Checkfor an open in the SRSmain harness: 1. Turnthe ignitionswitchOFF. 2. Disconnect SRSmain harness connector the 2p from the under-dashfuse/relaybox. 3. Checkresistance between the No. 2 terminalof the SRS main harness connector 2P and the No. 3 terminalof the SRSmain harness 18Pconnector. Thereshouldbe 0-0.5 0. ls th6 resistanceas soecified? YES NO
Poor contact at the SRS main harness2p connector; checktho connector, . lf the connectori3 OK, substituto a known-good undrdash fuse/relaybox, and recheck. . lf the problem is still present, roplace the SRS main natness,
UNDER.OASH FUSE/RELAY BOX
Open in the SRS main harn$s;.eplace the SRS main harness.
SRSMAII{ HARI{ESS 2P CONNECTOR
24-86
Driver'sAirbag
Replacement
the After a collisionin which the airbagswere deployed, airbags,the seat belt tensioners(if so equipped),and the SRSunit must be replaced. Store a removed airbag with the pad su.@ tacs up, lf th airbag is improperly stored face down. accidental deployment could propal the unit with enough forc io causgseriouginiury. CAUTION: . Always disconnoct the drivor's airbag connector when the SRSmain harnessis disconnactod. . Do not disassembleor tamper with ihe airbag. NOTE: Do not install used SRSparts from anothervehicle, When repairing, only new SRSparts. use Carefullyinspectthe airbag beforeyou install it. Do not install an airbag that shows signs of being suchas dents,cracks droppedor improperlyhandled, or deformation. 1 . Disconnect batterynegativecable,then disconthe nect the positive cable from the battery, and wait at leastthree minutes. Remove the access panel from the steering wheel. then disconnectthe 2P connector between the drivthe er'6 airbag and cable reel.When disconnected. is shorted. airbagconnector automatically 3. Removethe two Torx bolts from the steering whsel, and disconnectthe horn connector. Remove the driver'sairbag,
DRIVER'S
PANEL ACCESS 2P CONNECTON
(cont'd)
24-87
Driver'sAirbag
Replacement lcont'd)
CAUTION: 8. sure to instattthe SRSwiring so that it is not plnched or inlerfsring with other parts. 4. P l a c et h e n e w d r i v e r ' s a i r b a g i n t o t h e s t e e r i n g wheel, and secure it with new Torx bolts. 5. C o n n e c tt h e d r i v e r ' sa i r b s g 2 p c o n n e c t o rt o t h e c a b l e r e e l 2 P c o n n e c t o r , h e n i n s t a l lt h e a c c e s s t panelon the steering wheel.
TORX EOLTS 9.8N,m11.0 kgl.m,7.2tbf,ftl Feplace.
2PCONNECTOR
Connectthe battery positive cable.then connectthe negative cable. 7. After installing airbagassembly, the confirm proper systemoperation: . Turn the ignitionswitch ON llt); the SRS indicator light should come on for about six seconds and then go off. . Mske sure both horn buttons work. o Takea test-drive, and make sure the cruisecontrol switcheswork.
24-88,
Airbag Front Passenger's

Replacement
the After a collisionin which the airbagswere deployed, airbags,the seat belt tensioners(if so equipped),and the SRSunit must be reolaced. store a rsmovod airbag with lhe pad sur@ face up, It the airbag is improporly stor6d face down, accidental doploymnl could propsl ths unit with gnough forco to causeserious iniury. CAUTION: . Always disconnsqt the front pa3s6ng6r'3airbag connoctor when tho SRSmain harnessis disconnocted, . Do not disassambl6or tamper with tho airbag, NOTE: . Do not install us6d SRSparts from anothervehicle. When repairing, only new SRSparts. use . Carefullyinspectthe airbag beforeyou install it. Do not install an airbag that shows signs of being suchas dents,cracks droppedor improperlyhandled, or deformation.
1.
Remove three mountingnuts from the bracket. the 5. Lift the front passsnger'sairbag out of the dashDOaro. NOTE:The airbag lid has pawls on its side which To attach it to the dashboard. remove the airbag, cover the lid and dashboardwith a cloth, and pry with a flat tip screwdriver. carefullv
FRONT PASSENGER'S
Disconnectthe battery negative cable, then disconnect the positive cable from the battery. and wait at leastthree minutes. Removethe glove box (seesection 20). betweenthe front DasDisconnect 2P connector the When dissenger'sairbag and SRS main harness, connected,the airbag connector is automatically shorted. FRONT PASSENGER'S
FRONT PASSENGER'S AIRBAG MOUNNNG NUTS
(cont'd)
24-49
Front Passenger's Airbag

GAUTION: Be sure to installthe SRSwiring so that it is not pinched or interfering with olher parts. 6. P l a c et h e n e w f r o n t p a s s e n g e r ' s i r b a g i n t o t h e a d a s h b o a r dT i g h t e nt h e f r o n t p a s s e n g e r ,a i r b a g . s mountrngnuts.
FRONTPASSENGER'S
7.
Attachthe airbagconnector the connectorhold_ to er, then reinstall glove box. the
FRONT PASSENGER'S
FRONT PASSENGER'S AIRBAGMOUNTINGNUTS 9.8 N.m {1.0kgJ.m,7.2lbf ft) Replace.
Connect b8tterypositivecable,then connect the the negative cable. After installingthe airbag.confirm proper sysrem ooerauon: Turn the ignition switch ON ( ); the SRS indicator l i g h t s h o u l d c o m e o n f o r a b o u t s i x s e c o n d sa n d then go off.
24-90
CableReel
)
Replacement
stors a removed airbag with the pad sur@ tace up. lf th airbag is improperly stored face down, a c c i d e n t a ld 6 p l o y m e n t c o u l d p r o p e l t h e u n i t w i t h gnough force to causeserious iniuty. CAUTION: . Always disconnect the airbag connector whgn the SRS msin harnessis disconnoctod. . Do not disassembloor tamper with the airbag. NOTE:Carefullyinspectthe airbag before installingit. Do not installan airbagthat shows signs of being droppedor improperlyhandled, suchas dents,cracks or deformation, '1. Disconnect batterynegative the cable,then disconnectthe positivecablefrom the battery, and wait at leastthree minutes. Removethe accesspanelfrom the steeringwheel, then disconnect 2P connectorbetweenthe drivthe er's airbagand cablereel. Makesurethe wheelsare alignedstraightahead. Removethe two Torx bolts from the steering wheel, a n d d i s c o n n e ctth e h o r n c o n n e c t o r R e m o v et h e , driver'sairbag,
TORXBOLTS Use a Torx T30 bit.
DRIVER'S
DRIVER'S DASHBOARD LOWER COVER
5.
Removethe driver's dashboard lower cover (and the knee bolster).
*f
(cont'd)
24-91
GableReel
6, Disconnect connectors the from the horn and cruise control sevresumeswitches. 8. Remove columncovers, the
cRursE coNtRoL
SET/RESUME SWITCHCONNECTOR
2P CONNECTOR COVER
1.
Loosenthe steeringwheel bolt, then install a steering wheel puller on the steeringwheel and remove it. Note these items when removing the stee.ingwheel: . Do not tap on the steering wheel or the steering columnshaftwhen removingthe steering wheel, . lf you threadthe puller bolts into the wheel hub more than five threads, boltswill hit the cable the reel and damageit. To preventthis. installa pair of jam nutsfive threadsup on eachpullerbolt.
STEERING WHEEL STEERING WHEELBOLT 39 N.m 14.0kgf.m.29 lbf.ftl
Disconnectthe 3P [6P] connector betweenthe main wire harnessand cable reel sub-harness, and the 2p connectorbetweenthe cable reel and SRS main harness.
STEERING
CAALEREELSU8 HARNESS 3P l6PlCONNECTOR [ ]:,98_00modets 10. Remove the cable reelfrom the cotumn,
24-92
)o
NOTE: . Before installing the steering wheel, the front wheelsshouldbe alignedstraightahead. . Be sure to installthe harness wires so that they are not pinchedor interfering with other parts. . After reassemblv,confirm that the wheels are still turned straightaheadand that the steering wheel spokeangle is correct(roadtest).lf minor is do spokeangleadjustment necessary, so only by adjustingthe tie-rods,not by removing and repositioning steering the wheel, 11. Set the cancel sleeve so that the projectionsare alignedas shown. columncovers. 1 3 . Install steering the 1 4 . lf necessary, center the cable reel. {New replacement cable reels come centered,lDo this by first rotating the csble reel clockwise until it stops, Then rotate it counterclockwise(approximatelytwo and a half turns) until the arrow mark on the cable reel labelpointsstraightup.
VERIC AL
PR(NECNONS
)...0
t5.
Installthe steeringwheel on to the steeringcolumn wheelshaftengages shaft,makingsurethe steering sleve.Do not tap on the cable reel and canceling the steeringwheel or steeringcolumn shaft when wheel. installing steering the
CABLEREEL
I l: 38 - 00 models
't2. Carefullyinstallthe cable reel on the steeringcolumn shaft. Then connectthe 3P t6Pl connectorto and connectthe 2P conthe cablereel sub harness, nectorto the SRSmain harness. (cont'd)
24-93
CableReel
1 6 . T i g h t e nt h e s t e e r i n gw h e e l b o l t t o t h e s p e c i f i e d torque,and connect the horn connector the steer to ing wheel.Then installthe driver'sairbag. TORX BOLTS 9.8N.m(1.0 kgd.m,7.2 lbnftl
Replace. DRIVER'S
Reconnect the driver's airbag 2P connectorto the cable reel 2P connector,and reinstall the access panelon the steering wheel. 1 9 . Reconnect batterypositivecable,then the negathe tive cable.
20. After installingthe cable reel,confirm proper system operation: Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds and then go off. a Makesure both horn buttonswork. . Go for a test drive.and makesurethe cruisecontrol switcheswork. .
STEERING WHEELBOLT 38 N.m (3.9kgl.m,28lbf.ftl Replace.
1 1 . Attach the cable reel 2P connectorto the connector holder. Theninstall(thekneebolster and)thedriver,s dashboardlower cover.
CABLEREEL
BOLSTER l'98 - 00 modalsl DRIVER'S DASHEOARD LOWER COVER
24-94
SRSUnit
).0
Replacement
CAUTION: . Before disconnecting any part of the SRS wire harnesg,disconnectthe airbag connoctors (and soat beh tensioner connectorsl. . During installation or replacament,do not bump (impact wrench, hammer etc.) the area near the SRS unit. Do not damage the SFS unit terminalg or connsclors. Do not disassemblethe SRS unit it has no saryiceable parts, a Store the SRS unit in a clean,dry area. a Do not use any SRS unit which has been subiected to water damage or shows signs ot being dropped or improperly handlgd, such as dents, cracks or deformation.
'1.
3.
Remove right sidecoverfrom the SRSunit. the

SRSUNIT
TORX AOLTS Use a Torx T30 bir.
Disconnect batterynegative the cable,then disconnectthe positivecablefrom the battery, andwaitat leastthree minutes. (andseatbelttenDisconnect airbagconnectors the (Whendisconnected, airbag sionerconnectors). the and seat belt tensionerconnectors automaticalare ly shorted.) Driver's Side: . R e m o v e t h e a c c e s sp a n e l f r o m t h e s t e e r i n g w h e e l , t h e n d i s c o n n e c tt h e 2 P c o n n e c t o r betweenthe driver's airbag and cable reel (see page 24-231. Front Passenger's Side: . Disconnect 2P connectorbetweenthe front the passenger's airbag and SRS main harness(see page 24-231. Soat Beh Tensionor('98 - 00 modelsr: . Remove the left and right centerpillar lowertrim panels(seesection 20). . Disconnect seat belt tensioner connectors the 2P (driver's from the left sidewire harness side)and the right wire harness(front passenger's side) (seepage24'231.
2.
COVER
Remove the left slde cover from the SRSunit. then d i s c o n n e ctth e S R S m a i n h a r n e s s1 8 Pc o n n e c t o r from the SRSunit.
sRs
HARNESS 18PCONNECTOR
TORX BOLTS Us a Torx T30 bir.
stoE
COVER
) o
Remove the four Torx boltsfrom the SRSunit.then oull out the SRSunit from the driver'sside. (cont'd)
24-95
SRSUnit
6. l n s t a l lt h e n e w S R S u n i t . l f t h e T o r x b o l t s y o u r e m o v e di n t h e p r e v i o u ss t e p h a v e r e d t h r e a d s , replace Torx bolts. the 9. Reconnect driver's aibag 2P connectorto the the cable reel 2P connector,then reinstallthe access panelon the steering wheel.
1 0 . Reconnect front passenger's the airbag connector

to the SRSmain harness.
1 ' t . Reconnect left side wire harness2P connector the

to the driver'sseat belt tensionerand the right side wire harness 2P connector to the front passenger's ('98- 00 models). seatbelttensioner 12. Reinstall centerpillar lowertrim panels{'98- 99 the modelsl.
1 3 . Reconnectthe battery positive cable,then the negative cable. 1 4 . After installing the SRS unit, confirm proper system operation: Turn the ignitionswitch ON (ll);the SRS indicator light shouldcome on for aboutsix seconds and then go off,
TORXBOLTS 9.8 N.m {1.0 kgf.m,?.2 Use . Torx T30 bh,
SRSUNIT
TORX BOLTS 9.8N.m11.0 kgf.m,7.2 lbtft) Usoa TorxT30bit.
7.
Connect SRSmain harnessl8P connector the the to SRSuniu push it into positionuntil it clicks. Install the SRS unit covers (right and left). Make surethe coverssnaptogetherin the middle.
8.
24-96
-
Airbag/Seat Belt Tensioner

)
Disposal
Beforescrappingany airbags{and seat belt tansioners) (including the those in a whole vehicleto be scrappedl. must be deployed.lf airbags(and seat belt tensioners) the vehicleis still within the warrantvoeriodthe Honda District ServiceManager must give approval and/or special instructions, beforeyou deploythe airbags(andseat belttensioners). Only afterthe airbags{andseat beltten(as sioners) havebeendeployed the resultof vehiclecollision, example), they be scrapped. for can lf the airbags (and seat belt tensioners)appear intact (not deployed), treatthem with extremecaution. Followthis procedure: Doployingtho Airbags (and Soat B6li Ten3ione6): ln-vehicle lf an SRSvehicleis to be entirelyscrapped, airbags its (and seat belt tensioners) should be deployedwhile still in the vehicle.The airbags (and seat belt tensioners) p s h o u l d n o t b e c o n s i d e r e da s s a l v a g e a b l e a r t s a n d in shouldneverbe installed anothervehicle. confirm that each airbag {and seat belt @ tonsiongr) i3 ggcurely mountod; othgrwise, severe personal iniury could result from d6ploym6nt, 6. connectors. Cut off the airbag(and seatbelt tensioner) Strip the ends of the airbag (and seat belt tensioner) wires. and connectthe deploymenttool alligatorclips to the airbag (and seat belt tensioner).Placethe deploymenttool at least thirty feet (10 meters)away from the airbao(and seatbelttensioner),
DRIVER'S AIBBAG
FRONTPASSENGER'S AIRBAG
AI.IIGATOR
cuPs
lY6llowl
1.
Disconnect batterynegative the cable,then disconnectthe oositive cable. Confirmthat the special tool is functioningproperly by following the checkprocedure the tool label on or on page24-98. Removethe accesspanel,then disconnectthe 2P connector betweenthe driver's airbag and the cable reel(seepage24-23). Remove the glove box, then disconnect 2P conthe nector between the front passenger'sairbag and (seepage24-23). SRSmain harness Remove the centerpillar lower trim panel,then disconnect the 2P connector betweenthe seat belt tensionerand side wire harness('98- 00 models)(see page 24-231.
At lcast thirty feot 110motersl
(cont'd)
24-97
Airbag/SeatBelt Tensioner
(cont'dl Disposal
1. Connect 12 volt batteryto the tool' a It the green light on the tool comes on, the airbag ignitercircuitis defective and cannotdeploy t h e a i r b a g .G o t o D a m a g e dA i r b a g S p e c i a l Procedure. . l f t h e r e d l i g h t o n t h e t o o l o m e s n ,t h ea i r b a gs c o i readyto be deployed. . P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h e a i r b a g should deploy (deploymentis both highly audible and visible;a loud noise and rapid inflationof the bag,followedby slow deflation). . . lf the airbagsdeploy and the green light on the tool comeson, continuewith this procedure. lf an airbag doesn't deploy,yet the green light comes ON, its igniter is defective.Go to DamagedAirbagSpecialProcedure. During deployment, the airbag can become hot enough to burn you, Wait thirty minutes after deployment beforetouchingthe airbag. Deploying tho Airbag: Out-ot.vohicle lf an intact airbag has been removedfrom a scrapped vehicle,or has beenfound defective damagsdduring or transit.storageor seryice, should be deployedas folit lows:
'L
Dispose the completeairbag.No part of it can be of reused.Placeit in a sturdy plasticbag, and seal it securety. CAUTION: . Wear a faco shield and gloves when handling a deployedairbag. . Wash your hands and rinse them well with water after handling a deployed airbag.
2.
3.
Confirmthat the specialtool is functioningproperly by followingthe checkprocedure this pageor on on the tool label. Position airbagface up, outdoorson flat ground the at leastthirty feet (10 m) from any obstacles peoor Dte, Followsteps6, 7, 8. and 9 of the in-vehicle deployment proceoure.
Dlmaged Airbsg {or Seat Beh Ten3ion6r}Sp6cial Procgdure r an airbag {or seat Beh rensioner} cannol !@ be doployod,it should not be treated as normal scrap; it should still be considereda potntially explosive device lhat can causeserious iniury. 1. 2. 3. 4. lf installedin a vehicle.follow the removal procedure on page24-3and 24-87through90. In all cases, makea shortcircuitby twistingtogether the two airbag inflator wires. Package the airbag in exactlythe same packaging that the new reDlacement came in. Dart Mark the outside of the box "DAMAGEDAIRBAG N s { o r T E N S I O N E R ) O T D E P L O Y E D "o i t d o e s n o t get confusedwith your parts stock. Contactyour Honda District Service Manager for how and whereto returnit for disposal.
5.
DeploymentTool: CheckProcedure
l.
Connectthe yellow clips to both switch protector handles the tool; connect tool to a battery. on the Pushthe operationswitch:green meansthe tool is OK: red meansthe tool is faultv. Disconnect bafteryand the yellow clips. the
24-98

Honda CRV 97-00 Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Honda CRV 97-00 Service Manual

Uploaded by

Copyright:

Available Formats

General lnformation

Chassis and PaintCodes

B-84P NH-552M NH-592P R-94

Vehicleldentification Number and FederalMotor Vehicle

EXT. COLOR KA S2BA1 C

Multiport B20B4t 2.01 DOHC Sequential Fuel-injected engine

B-84P G-82P NH-552M NH-592P R-94

VehicleldentificationNumber and CanadianMotor Vehicle

Chassis and PaintCodes

JHL: HONDAMOTOR CO.,LTD HONDA. Multipurpose

B2OZ2:2.0 DOHC | Sequential Multiport Fuel-injected engine

B-84P B-92P G.95P NH-578 NH-552M R,81

Supermarine Blue Pearl Nighthawk BlackPearl CloverGreenPearl TaffetaWhite SebringSilverMetallic MilanoRed

Vehicle ldentification Number and CanadianMotor Vehicle

EXT. COLOR KA S2BA1 C

MultiDort 2.0 Seouential B20Z2t I DOHC Fuel-injected engine

Automatic MDLA; 4-speed Automatic MDMA:4-speed SBXM: s-speedManual

MDLA:3000001MDHA: 2000001SBXM:2000001in CrSaitamaFactory Japan(Sayama)

B-92P B-95P G-95P NH-578 NH-552M R-81

Nighthawk BlackPearl BluePearl Electron CloverGreenPearl Taffeta White SebringSilverMetallic Milano ed R

Safety Standard Certification. lrl ..V

EXT, COLOR KA S2BA1 C

and PaintCodes Chassis

2.0 MultiDort B20g4t | DOHC Seouential Fuel-injected engine

MDMA:4-speed Automatic Automatic SDMA: 4-speed Factory Japan(Sayama) in C: Saitama

B-84P G-82P NH-552M NH-592P R-94

Supermarine BluePearl CypressGreen Pearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed

Multiport Sequential | 8208 4:2.0 DOHC engine Fuel-injected

Automatic M4TA: 4-speed Manual SBXM:5-speed SBXM:1000001M4TA: 3000001* in C: SaitamaFactory Japan(Sayama)

B-84P G-82P NH-552M NH-592P R-94

BIuePearl Supermarine CypressGreen Pearl SebringSilverMetallic Flamenco BlackPearl San MarinoRed

Chassis and PaintCodes

B20Z2i I DOHC 2.0 Sequential Multiport Fuel-injected engine

MDMA:4-speed Automatic SBXM: s-speed Manual

B-84P a-92P G.95P NH.552M R-81

Supermarine BluePearl Nighthawk BlackPearl CloverGreenPearl SebringSilverMetallic MilanoRed

VehicloldentificationNumber and Canadian Motor Vehicle Safety Standard Certification.

EXT. COLOR KCS2BC2 C

Multiport | Sequential 8 2022:2.0 DOHC engine Fuel-injected

Automatic MDMA:4-speed Manual SBXM: s-speed

Vohicle ldentification Number and Canadian Motor Vohicle

COLOR EXT. KCS2BC2 C

Vehiclldentific.tion Number tvtNl

(U.S.A. modelonlyl modolonlyl {U.S.A.

model lU.s.A.'97i '97 00modls I lcanada

VACUUM HOSEROUTING DIAGRAMlUndor-hood EmissionsControl Lrb6ll ENGINE COOLANT INFORMATION

AIR CONDITIONING INFORMATION

ControlLabel Emissions Under-hood

Families and Evaporative Engine

Year Model v:1s97

INFORIMATION VEHICLE Ii/PORTANT

| \6( Zror '.

Under-hood Emissions ControlLabel

Engineand Evaporative Families

Family Typo V: LDV T: LDT

IMPORTANT VEHICLE INFORMATION

Evaporative Fami Family:

Groupldentification Emission (1999 model)

Families Engineand Evaporative

wNrcHEVEn coMEs LEs ffi'"R "Eifil:$o""niii?i,THffi @ M lmo rhl,

Type Family V: LDV T: LDT

INFORMATION VEHICLE IMPORTANT

Ll:.-.-,1 I rFrll \=#_H*

Model Yoal X:1999 ManutacturarSubcode