vnx.su акураинтегра 94 PDF

ACUrj|A
INTEGFIF|
Service Manual 1994
vnx.su
INTRODUCTION
How to Use This Manual
This manualis dividedinto 23 sections.The first pageof each section is markedwith a blacktab that linesup with its corresponding
thumb indextab on this page and the back cover. You can quickly
tind the tirst pageof each sectionwithout lookingthrougha full table of contents.The svmbolsprintedat the top cornerof each page
can also be used as a quick referencesystem.
Each section includes:
1. A table of contents.or an explodedview index showing:
a Partsdisassemblvsequence.
a Bolt toroues and thread sizes.
a Pagereferencesto descriptionsin text.
proceduresand tools.
2. Disassemblv/assembly
3. InsDection.
4. Testing/troubleshooting.
5. Repair.
6. Adiustments.
Specifications
trtl:{lt'
Ma i n te n a n c e
4Pi
Engine
I-""
SpecialInformation
lnai""tes a strong possibility of sevor pelsonal iniury
@
01 loss of life it instructions al not tollowed.
CAUTION: Indicates a possibility ot personal inlury or oquipmont
damage if instructions ale not followed.
NOTE: Gives helpful information.
CAUTfON: Detaifeddoscriptionsot standad workshop procedures,
salety principlosand servicaopelationsare not included Pleasonote
that this manual conlains warnings and cautions against somo spocific sgrvice methods which could cause PERSONALINJURY, damage
a vehicle or make it unsafe. Pleasounderstandthat those warnings
cannot cover all conceivablcwaYs in which service, whetheaor not
recommended bv HONDA, might be done, or of the possibla
hazardous consequences of svery conceivable way, nor could
HONDA investigateall such ways. Anyone using seryice plocedures
or toofa, whethor 01 not recomondedby HONDA, ,nust sttisfY himsett thoroughly that neither personal safty nor vhicle safety will
be jaopaldized.
All informationcontainedin this manualis basedon the latest product
informationavailableat the time of printing.We reservethe right
to makechangesat any time without notice.No part of this publication mav be reproduced,storedin retrievalsystem, or transmitted,
in any Jorm by any means,electronic,mechanical,photocopying,
recording,or otherwise,without the priorwritten permissionof the
publisher.This includestest. figures and tables.
Fueland Emissions
Za
*Transaxle
* S te e ri n g
r-\
* Brakes
(lncludins
!TEg)
l D l
\.t/
HONDA MOTORCO.,LTD,
1448 pages
First Edition7/93
Service Publication ottice
All Rights Reserved
and
Canada
Apply
to
U.S.A.
Specifications
*Electrical
As sections with r includ SRS components.
special precautions are lequiled when servicing.
vnx.su
(lncludins
ISBE)
J--*
, ,
SUPPLEMENTAL
RESTRAINT
SYSTEM(SRS}
The IntegraSRSincludesa driver's airbag,locatedin the steeringwheel hub. ln addition,all modlsexcepi
tna
Rs modelfor canada have a front passenger'sairbsglocatedin the dashboardabovethe glove box, InformaUon
necessaryto safely servicethe SRSis includedin this servica Manual.ltems markedwith an sstorisk(r)
on thr
contents page include,or are locatednear, SRScomponents.Servicing.disassemblingor roplacingthea6
ltems
will requirespecialprecautionsand tools, and shouldthoreiore be done by an authorhed Acura dealer.
' To avoid ronderingths sRS inoporativo,which could lard to porronll Injury or darth In thc
cvant ot. r.yr.
trontal collision, all sRs sorvico work must be pcrformcd by !n ruthorizcd Acu.! daerrr,
' lmpTopor3orvica proceduroa,including inco.roct r.movd r d Installation of tha SRS,could
Lld to pc[onc Inlury caussd by unintsntionalactivationot tho airbags.
' All sRs oloctrical wiring harnoa$! aro coverod with yallow In3ulatlon, Rcbtcd componcnts
arc bcrtad In tha
stoeringGolumn,front console,dsrhboa.d,and darhboardlowor plnol, lnd in thc d$hbolrd abovc tha gaov!
bor. Do not uas oloctdcalte$ oquipmonton thaaa citcuhs.
NoTE: The originalradiohas a codedthett protectioncircuit. Be sureto get the customer'scode numb6r
blore
* disconnecting
the battery.
- removingthe No. 32 (7.S A) fuse Jromthe undsr-hood
fuse/relaybox.
- removingthe radio.
After service,reconnectpowerto the radioandturn it on. Whenthe word ,,CODE,,is displayed,
enterthe cus_
tomer's 5-digit code to restoreradio oDerauon.
vnx.su
GeneralInformation
Chassisand PaintCodes
ldentificationNumberLocations
Warning/CautionLabelLocations
Lift and SupportPoints
Lift
FloorJack
Safety Stands
Towing
vnx.su
1-2
1-4
1-5
1-9
1-10
1 - 11
1-12
Chassisand PaintCodes
U.S.Model
VehicleldentificationNumber
EngineNumber
JH4DB754*RSOOOOO
1
8 l 8 B r ------T----r300@l
Manutactulol, Make and

Typ of Vshicle
J H 4 : H O N D AM O T O RC O . ,L T D .
ACURAPsssenger
car
Line, Body and EnginoType
Engine Typ6
DB7:INTEGRA
4-door/B1
881
DB8:INTEGRA
4-door/81
8Cl
DC2:INTEGRA
3-door/B18C
1
DC4:INTEGRA
3-door/B1
8Bj
BodyType and Trsnsmission
Type
3: 2-doorHatchbackS-speedManual
4: 2-doot Hatchback4-speed
Automatic
5; 4-doorSedans-speedManual
6: 4-doorSedan4-speedAutomatic
Se al Numbel
81881: 1.8 f DOHCSequentiat

Muhi-pori
Fuel-injectedengine
B l8Cl : 1.8 | DOHCVTECSequnrial
Multi-port Ful-iniectedngin
Transmission
Numbsr
Y80- 1000@ I
Transmission
Type
Y80: Manual
MPTA:Automatic
Vehicle Glado (Seriesl

4: RS
5: LS
8; GS-R
Serial Numbel
Check Digit
Model Yaal
R: 1994
Factory Code
S: SuzukaFactoryin Japan
Paint Code
COLOR
BG.33P
Serial Numbl
Vehicleldntification
Numberand
FederalMotor VehicleSafety StandardCertification
3DOOR
4DOOR
1-2
vnx.su
PaintCode
PaintCode
BG.33P
G-71P
NH-5O3P
NH-538
NH-575M
R-72P
R-81
RP.24P
YR.5O3M
Color
ParadiseBlue-g.enPeErl
LausanneGr6enPead
GrsnadaBlack Pea.l
Frost White
ThunderGrav Metallic
Torino Red Pearl
MilanoRed
Stealth Gray Pearl
RosewoodBrown Mtallic
CanadaModel
EngineNumber
VehicleldentificationNumbel
8 1 8 8 1 - 17 0 0 0 0 1
JH4DB753.RS800001
EnginType
Multi-port
81881: 1.8 I DOHCSequential
Fuel-injectedengine
B 1 8 C 1 :1 . 8 I D O H CV T E CS e q u e n t i a l
engrne
Multi-DortFuel-iniected
Manutacturer,Makeand
Type of vhicle
JH4: HONDAMOTORCO., LTD.
car
ACURAPassenger
Lino. Body and EngineTYPo
4-doot/Bl881
D87: INTEGRA
DC2:INTEGRA3-dootBl 8C1
3-dooriB18B1
DC4:INTEGRA
Body Type and TransmissionTYPo
3: 2-doorHatchback5-speedManual
4'. 2-doorHatchback4-speed
Automatic
5: 4-doorSedans-speedManual
6: 4-doorSedan4-speedAutomatic
VehicleGrade{Sedes}
SRSairbag
3: RS without passenger
4: RS with passengetSRSaitbag
SerialNumber
Number
Transmission
Y80-1000001
Type
Transmission
Y80: Manual
MPTA:Automatic
SerialNumbel
8: GS-R
Check Digit
Model Yeat
R: 1994
FactoryCode
S: SuzukaFactoryin Japan
Paint Code
COLOR
BG.33P
Serial Numbel
Numberand
Vehicleldentification
CanadianMotor Vehicle Safety Standard Certification
3DOOR
4DOOR
Paint Code
PaintCode
BG.33P
G-71P
NH-5O3P
NH-538
NH-575M
R-72P
R-81
RP-24P
YR-503M
Color
Pearl
ParadiseBlue-green
LausanneGreenPearl
GranadaElackPearl
Frost White
ThunderGrayMetallic
TorinoRedPearl
MilanoRed
StealthGrayPearl
RosewoodBrown Metallic
1-3
vnx.su
II
I
ldentificationNumberLocations
Vehicle ldontification
NumberlvlNl
v.hiclo ldontificalion
NumbrlVlNl
Transmbsion Numbor
lAuromatic)
Transmissioh l\lumbor
lManuall
1-4
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LabelLocations
Warning/Caution
MODULEDANGR
E: DRIVER
A: CABLEREALCAUTIONA
MANUALFORDETAII'fDINSTRUCTION
SERVICE
BEFERTO-
B: CABLEBEALCAUTIONB
REFERTOSERVICEMAI{UAL FOROETAILEDINSTRUCTION
WHEEL OTICE
C: STEERII{G
]{OT|CE
ORINSTALLATION
WIIEELREMOVAL
STEERII{G
IMPROPEB
DAMAGESRSCOMPONENT.
CAREFULLY.
MANUALINSTRUCTION
FOLLOWSERVICE
D: DRIVERINFLATORWAR[{|NGTAG
WARNII{G
AND POSSIBLE
DPLOYMENT
TO PflEVE T ACCIDE]TTAL
INJURY:
SHORTCOI{NECTOR
ALWAYSII{STALLTHEPNOTECTIVE
IS
WHENTHEHARNESS
COI{I{ECTOR
O THEINFLATOR
DISCONNECTED.
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITHACID,WATERORHEAVYMETALSSUCH
HARM.
MAY PRODUCE
LEADOR MERCURY
AS COPPER,
FUL AND IRFITATINGGASES OR EXPLOSIVECOM.
POUNDS.
MUST NOT EXCEED2OOOF
STORAGETMPERATURES
(1OOOCI.
HANDLING.STORAGEAND DISFORPROPER
TO THE SERVICEMANUAL,
REFER
POSALPROCEDURES
SRSSUPPLEMEf{T.
POTSON
SODIUMAZIDEANDPOTASSIUM
POISONOUS
CONTAINS
I{ITRATE.
FIRSTAID
IF CONTENTSARESWALLOWED,INDUCEVOMITING.
FOR EYE CONTACT, FLUSH EYES WITH U'ATER 15
MINUTES.IF GASESIFROMACIDORWATERCONTACT}
ARE INHALED.SEEKFRESHAIR. IN EVERYCASE, GET
PROMPTMEDICALATTENTION.
KEEPOUT OF REACHOF CHILDREN
F: DRIVERMODULEWARNING
A, WABNING
AND' IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE
I{URTOR KILLYOU.
TALLYDEPIOYED,CAN SERIOUSLY
ORPROBTESTEOUIPMEI'IT
. DO NOTUSEELECTRICAL
ING DEVICES.
OEPLOYMENT.
THEYCAN CAUSEACCIOENTAL
PARTS INSIOE,DO NOT DISAS.
. NO SERVICEABLE
SEMALE.
. PLACEAIRBAGUPRIGXTWHENREMOVED'
. FOLLOW SERVICEMANUAL II{STRUCTIONS
CAREFULLY.
(cont'd)
1-5
vnx.su
Warning/CautionLabel Locations
(cont'd)
G: DBIVEBTNFORMATTON
{SUNV|SORt
G: DBIVEBINFORMATTON
{SUNvtSORt.
ALWAYS WEARYOUNSCIT EELT
C.Ai IS EOUIPPEDWITH A DRIVERAIRBAG ANO
A_FRo_NTSEAT pASSENGERnrnslc nNo e raoNi
SEATPASSENGER
AIRBAGAS A SUPPIEMENTALBES.
TRAINT SYSTEM {SBSI
ro suppLEMENr
rHEsEArBEt-r.
:. BEFoRE
Lr_ll^gls_lglls
oRrvrNG,
ReeoL.qsetmsiDrrxE GLovEBox.
rThis vo.3ion
ot tho lsbl i! us6d in csrs wtth a,ront soat
paasngor'sairbag.
1-6
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M: AIRBAGLABEL
AIRBAG
J: GLOVEBOX INFORMATIOf{
AIBBAGINFORMANO
RESTiAINTSYSTEM(SRS)
SUPPLEMENTAL
TEN YEARSAFTERIT
. THE SRSMUST BE INSPECTED
IS SHOWN
TI{EDATEOFINSTALLATION
IS INSTALLED.
PLATE,LOCATEDON THE
ON THE CERTTFICATION
DOORJAMB.
DRIVER'S
OF SNS
. DIAGNOSTICCHECKSAND REPLACEMENT
MUST BE DONEBY AN AUTHORIZED
COMPONENTS
DEALER
. SEEYOUROWNER'SMANUALFORAODITIONALSRS
INFORMATION.
INFLATORWARNINGTAG
K: FRONTSEATPASSENGER
A WARNING
CAN SERIOUSLY
ACCIDENTALAIRBAG DEPLOYMENT
HURTOR KILLYOU.
WHENTHE INCONNECTOR
INSTALLTHE REDSERVICE
FLATORHARNESSIS DISCONNECTED
MODULEDANGER
L: FRONTSEATPASSENGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITHACID,WATERORHEAVYMETALSSUCH
HARM'
MAY PRODUCE
LEADOR MERCURY
AS COPPER.
FUL AND IRRITATINGGASES OR EXPLOSIVECOM.
POUNDS.
MUST NOT EXCEED2OOOF
STORGETEMPERATURES
AND DISSTORAG
HANDLIING,
tlOO"CI.FOBPROPER
MANUAL,
REFBTO THESERVICE
POSALPROCEDURES
SBS SUPPLEMENT.
POTSON
SODIUMAZIOEAND POTASSIUM
CONTAI'\'SPOISONOUS
NITRATE.
FIRSTAID
INDUCEVOMITING.
IF CONTENTSARESWALLOWED,
FOREYECONTACT,FLUSHEYESWITH WATERFOR15
MINUTES.
IF GASES(FROMACID OR WATERCONTACT)ARE IN.
HALED,SEEKFRESHAIR. IN EVERYCASE.GETPROMPT
ATTENTION.
MEDICAL
KEEPOUT OF REACI.IOF CHILDREN.
HOODI
N: SRSWARNINGIENGINE
SYSTEM(SBSI
RESTRAINT
SUPPLEMENTAL
WITH DRIVERSIDEAIRBAG.
THISVEHICLEIS EOUIPPED
ARE
WIRINGAND CONNECTORS
ALL SRS ELECTRICAL
YELLOW.
COLORED
ORUSINGELECTRIWITH,DISCONNECTING
TAMPERING
ON TI{E SRSWIRINGCAN MAKE
CAL TESTEOUIPMENT
FIR'
OB CAUSEACCIOENTAL
THESYSTEMINOPERATIVE
ING OF THE INFLATOR.
A. WANING
AND, IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE
HURTYOU'
CAf{ SERIOUSLY
TALLY DEPLOYED,
CAREFULLY.
MANUALINSTRUCTIONS
FOLLOWSERVICE
HOODIi
N: SRSWARNINGIENGINE
SYSTEM{SRSI
RESTRAINT
SUPPLEMENTAL
WITH DRIVERANO FRONT
THIS VEI{ICLEIS EOUIPPED
AIRBAGS.
SEATPASSENGER
ARE
WIRINGAND CONNECTORS
ALL SRS ELECTRICAL
YELLOW.
COLORED
ORUSI G ELECTRI'
WITI{, DISCONNECTING
TAMPENING
ON THESRSWIRINGCAN MAKE
CAL TESTEOUIPMENT
FIB'
ORCAUSEACCIDENTAL
THESYSTEMINOPERATIVE
ING OF THE INFLATOB.
A WABNING
AI{O, IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE
HURTYOU'
CAN SEBIOUSLY
TALI-YDEPLOYED,
CAREFULLY.
MANUALINSTRUCTIONS
FOLLOWSERVTCE
'This vorsionol tho labolis u36din cs.t with a front soat
passonger'sairbag.
A' WARNING
AND. IF ACCIDENIS EXPLOSIVE
THEAIRBAGINFLATOR
HURTOR KILLYOU.
CAN SERIOUSLY
TALLYDEPLOYEO,
ORPROB.
TESTEOUIPMENT
. DO NOTUSEELECTRICAL
INGDEVICES.
DEPLOYMENT.
THEYCAN CAUSEACCIOENTAL
. NO SERVICEAALE
PABTS INSIDE.OO NOT OISASSEMBLE.
. PLACEAIRBAGUPFIGHTWHENREMOVED.
. F O L L O W S E R V I C EM A N U A L I N S T R U C T I O N S
CAREFULLY.
{cont'd)
1-7
fi{lHfiFe*%
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Warning/Caution
LabelLocations
(cont'd)
SERVICEINFORMATION
C)
SPARKPtUG
II{FORMATION
BATTERY
CAUTION
AIR CLEAI{R,
RECOMMENDEO
OILand
FILTER
SERVICE
RADIATORCAP
CAUTIOI{
TIREINFORMATION
{300()R)
1-8
vnx.su
TIREINFORMATIOII
t4DOOR)
Lift and SupportPoints

Lift
plac6
Whn heavy16arcomponntssuch aa susponsion,luel tank, spale tile and hatch ale to b removod,
in the tuggageareabsforehoisting.Whensubstantialwoightis lemovedfrom ths lar ol th car, ths
il]iii6iliieigltt
cantor of gravity may chango and can cause the cal to tip folward on the hoist'
can assist
NOTE: Sinceeachtire/wheelassemblyweighsapproximately14 kg (30 lbs),placingthe front wheelsin trunk
with the weight distribution.
1. Placethe lift blocksas shown

and rock the car to be sure it is firmly supported.
2. Raisethe hoista lew inches(centimeters)
3. Raisethe hoistto full heightand inspectlift pointsfor solidsupport.
POINT
FRONTSUPPORT
LIFTBLOCKS
POINT
BEARSUPPORT
1-9
vnx.su
Lift and Support Points

FIoor Jack
1 . Set the parkingbrakeandblockthe wheelsthat are
not beinglifted.
2 . When
when tritrng
lifting the rear o
off the car, put the gearshift
lever in reverse(Automatictransmissionin
sition).
@ po-
3 . Raisethe car highenoughto insenthe safetystands.

4 . Adjustandplacethe safetystandsas shownon page
1-11 so the car will be approximately
level,then lower the car onto them.
Front
Centerthe jsck
bracketin the middle
ot the jack lift platform.
JACK LIFTPLATFORM
Rear
JACK LIFTPLATFORM
Centerthe jack
bracketin the middle
of the jack Iift platform.
1-10
vnx.su
Always uss satety standswhen working oo 01under any vehiclethat is supponedby only a jack.
Naverattompt to use a bumporiack fo. lifting or supporting tho car,
Safety Stands
ATTACHMENTS
RUBBER
t$
\F
FROI{TSUPFORTPOII{T
SAFETYSTANDS
POINT
REARSUPPORT
1-11
vnx.su
Towing
It the car needsto be towed, call a professionaltowing
service.Nevertow the car behindanothercar with just
a rope or chain. lt is very dange.ous.
Front:
Emergency Towing
There are three popularmethodsof towing a car:
Flat-bedEquipmont-The operatorloadsthe car on the
back of a truck. This is the best way of transportingthe
car.
Whsol Lift Equipment-The tow truck uses two oivoting arms that go under the tires (front or rear)and lifts
them otf the ground. The other two wheels remainon
the ground.
rl
Sling-type Equipmont-The tow truck uses metal cables

with hooks on the ends. These hooks go around parts
of the frame or suspensionand the cableslift that end
of the car off the ground.The car's suspensionand bodv
can be seriouslydamagedif this methodof towing is attempted.
It the car cannotbe transponedby flat-bed,it shouldbe
towed with the tfont wheels oft the ground. lf due to
damage.the car must be towed with the front wheels
on the ground, do the tollowing:
ManualTransmission
a Releasethe parkingbrake,
a Shift the transmissionto Neutral.
Automatic Transmission
a Releasethe parkingbrake.
a Start the engine.
a Shift to @ oosition,then to S position.
a Turn off the engine.
TOWING HOOKS
Real:
NOTICE:lmpropertowing preparationwill damagethe

transmission.
Followthe aboveprocedureexactly.lf you
cannot shift the transmissionor stan the engine(automatic transmission),
your car must be transDortedon a
flat-bed.
a lt is best to tow the car no tartherthan SOmileslgo
km). and keep the speedbelow 3b mph (bE km/h).
NOTICE:Trying to litt or tow your car by the bumpers
will causeseriousdamage.The bumpersare not designed
to supportthe car's weight.
vnx.su
SpecialTools
lndividual tool lists are located at the front of each section
vnx.su
Specifications
3-2
Standardsand ServiceLimits .'-.'.'."-'-'
3-17
....'.'.'...."....."......
DesignSpecifications
3-20
'.....'.'.
BodySpecifications
vnx.su
Standardsand ServiceLimits
CylinderHead/Valve
Train(B188tenginel- Secti
Declron 6
Compression
Cylinderh.ad
Camshaft
MEASUREMENT
STANDARD
{NEWI
250rpmandwideopenth.ottl Nominal
1,370(14.0,199)
(kgflcm?,
psi)
kPa
Minimum
930(9.5,140)
Maximumvariation 200t2.0,2a)
W6rpage
Height
r 3 1 . 9 5 -1 3 2 . 0(55 . 1 9-5 5 . 1 9 9 )
Endplay
Camshaft-to-holder
oil clearance
Totalrunout
Camlobeheight
tN
EX
lN
EX
tN
EX
lN
EX
(Cold)*
Valveclearance
ValvestemO.D.
Stem-to-guide
clearance
width
tN
EX
tN
EX
Steminstslled
height
Valvespring
Valv6guide
Freelength{Reference}
lN
EX
NH
CH
Lu.
lN
Installed
height
EX
lN
*: Measuredbetweenthe camshaftand rockerarm.

NH:NIHONHATSUJO
manufacturd
valvespring
CH:CHUOHATSUJO
manufacturod
valvesDrino
3-2
vnx.su
- 0.0061
0.05- 0.15(0.002
- 0.0027)
0.030- 0.06910.0012
0.03(0.001)
max.
33.71611.327
1l
(1.3200)
33.528
- 0.005)
0.08- 0.12{0.003
0.'r6 - 0.20(0.006- 0.008)
- 0.2594)
6.580- 6.590(0.2591
- 0.2583)
6.550- 6.s60(0.2579
0.02- 0.0s(0.001- 0.002)
0.05- 0.08(0.002- 0.003)
- 0.061)
r.25- 1.55(0.049
- 0.061)
1.25- 1.55{0.049
- 41.235
- 1.6234)
(1.6049
40.765
- 1.7022)
12.763- 43.235t1,6a37
42.36(1.668)
47.09{1.854}
47.08(1.854)
- 0.261)
6.61- 6.63(0.260
6.61- 6.6s(0.260-0.261)
- 14.25
- 0.561}
13.75
{0.541
- 0.640)
r5.75- 16.2510.620
'
SERVICE
LIMIT
0.05(0.002)
0.5(0.02)
0.1s{0.006)
0.04(0.002)
6.s5(0.258)
6.52(0.257)
0.0810.003)
0.11(0.004)
2.0t0.08)
2.0(0.08)
(1.6333)
41.485
(1.7120)
43.485
41.s6{1.636)
46.27tl.A22l
46.21l1.a22l
6.65(0.262)
6.6510.2621
Unitof length:mm {in}
s cti 7
k (81881
EngineBlock
{Bl6E1 englnel- sectlon
(NEWI
STANDARD
0.0710.003)max.
- 3.190)
81.00- 81.02{3.189
MEASUNEMENT
Cylinderblock
Piston
Warpageot decksLrrface
Borediameter
BoretaPer
Reboringlimit
SkirtO.D.at 15 mm (0.6in)Irom bottom of skirt
in cylinder
Clearance
Top
Groovewidth (Forring)
Second
--
Pistonring
clearance
Ringto-groove
oil
top
Second
'....=-
Ringendgap
lop
rod
Connecting
Crankshaft
Bearing
Second
oit
rrstonrln
R
T
R
T
o.D.
clearance
Pin-to-piston
Pin-to-rodinterference
Smallendborediameter
Nominal
Largeendborediameter
on crankshatt
Endplayinstalled
Mainjournaldiameter
N o .1 ,2 , 4 a n d5 j o u r n a l s
No.3 iournal
Rodiournaldiameter
Taper
Out-ofround
Endplay
Runout
oil clearance
Mainbearing-to-iournal
No.1,2, 4 and5 journals
No.3 journal
oil clearance
Rodbearingto-iournal
- 3.189)
80.98- 80.99(3.188
- 0.0016)
0.01- 0.04(0.0004
- r.010(0.04060.0409)
1.030
- 0.0488)
- 1.210(0.0484
1.230
2 . 8 0 -5 2 . 8 2 (00 . 1 1 0 40 . 1 1 1 0 )
- 0.0028}
0.045- 0.070{0.0018
- 0.0026)
0.040- 0.065(0.0016
- 0.0028)
0.045- 0.070(0.0018
- 0.014)
0.20- 0.35(0.008
- 0.012)
0.20 0.30(0.008
0.40- 0.5s(0.0r6 - 0.022)
- 0.020)
0.20- 0.s0(0.008
- 0.0181
0.20- 0.45(0.008
- 0.8268)
- 21.000
(0.8265
20.994
- 0.0009)
0.0r0- 0.022(0.0004
- 0.0013)
0.013- 0.032(0.0005
20.968- 20.981(0.825s- 0.8260)
48.0(1.89)
- 0.012)
0.1s- 0.30(0.006
LIMIT
SERVICE
0.10(0.004)
81.07(3.192)
0.05(0.002)
0.25(0.010)
80.9713.188)
0.05(0.002)
1.0610.042)
1.26(0.050)
2.8410.112\
0.13{0.00s)
0.13(0.00s)
0.13(0.005)
0.60{0.024)
0.6010.024)
0.70(0.028)
0.70(0.028)
0.70(0.028)
- 2.1654)
54.976- 55.000(2.1644
- 2.1651)
54.970- 54.994(2.1642
- 1.7717}
- 45.000{1.7707
44.S76
max.
0.00510.0002)
max.
0.005(0.0002)
0.10- 0.35(0.004- 0.014)
max.
0.03(0.001)
0.010(0.0004)
0.010(0.0004)
0.45(0.018)
0.04{0.002)
- 0.0017)
0.024 0.042{0.0009
- 0.0019}
0.030 0.048{0.0012
- 0.0015)
0.020 0.038(0.0008
0.05010.0020)
0.060(0.0024)
0.050(0.0020)
Ri RIKENmanutacture
Pistonring
pistonring
RINGmanufacture
PISTON
T:TEIKOKU
3-3
vnx.su
Cylander
Head/Valve
Train(B18Clenginel Section6
MEASUBEMENT
Compr6sion
Cylind6rhoad
C.mshsft
250rpm and wideopnthrottle Nomin6l

kPalkgl/cmr,psi)
Minimum
Maximumvariation
Warpage
H6ight
Endplay
Camshaft-to-holdsr
oil clearance
Totalrunout
Camloboheight
lN
Primery
Mid
EX
Socondary
Primary
Mid
Secondary
Valvoclorrancelcoldl*
lN
EX
lN
EX
lN
EX
tN
EX
lN
EX
ValvestemO.D.
Stom-to-guid6
clerrsnco
Valvoseat
Width
Sr6minstalledhight
ValvBpring
Fre6length(Roferenca)
lN
Outer
Inner
EX
Valveguido
l.D.
NH
CH
NH
CH
tN
EX
lN
EX
Instslledhoight
Rockrerm
STA]TDARD
INEWI
Arm-to-shaft
clearance
lN
EX
': Masuredbetwoonthe camshattand rcc(ersrm.

NH:NIHONHATSUJOmanufacture
v6lvespring
CH:CHUOHATSUJO
manufscturo
v6lvespring
3-4
vnx.su
SERV|C
UM|T
(19.0,
1,860
270)
930(9.s,140)
200t2.o,2a)
'r41.95
- 1C2.05
(5.s89
- 5.593)
0.05- 0.1s(0.002- 0.006)
- 0.0035)
0.050- 0.089(0.0020
0.015(0.0006)
max.
33.411{1.3154)
36.377tl.13221
(1.3601)
34.547
33.1110.3036)
35.72011.4063)
34.381
{1.3536)
0.15- 0.19{0.006- 0.007}
0.17- 0.21(0.007- 0.008)
- 0.21591
5.475- 5.48s(0.2156
- 0.21s0'
5.450- 5.460(0.2146
- 0.0022}
0.025- 0.055{0.00'10
- 0.0031)
0.050- 0.080(0.0020
- 0.06't)
1.25- 't.5s(0.049
'1.25
- 1.s5{0.049
- 0.061)
- 1.4935)
37.465- 37.935('1.4750
- 1.4817)
37.16s- 37.635t1.4632
41.05(r.6161
36.'16
{1.4241
36.19t1.425)
41.96(1.652)
4 1 . 9 {41 . 6 5 1 )
- 0.218)
5.51- 5.53(0.217
5.5r- 5.53{0.2r7- 0.218)
- r3.0s(0.494
- 0.514)
12.55
- 13.05(0.494
- 0.s14t
12.55
- 0.0020)
0.025- 0.0s2{0.0010
- 0.0020)
0.025- 0.0s2(0.0010
0.05{0.002)
0.5(0.02)
0.15{0.006)
0.03(0.001)
5.11510.21441
s.420{0.2134)
0.0810.003)
0.11{0.(x)4)
2.0(0.08)
2.0(0.08)
(1.5033)
38.185
(1.491s)
37.885
40.26(1.585)
35.30(1.390)
35.30(1.390)
40.95(1.612)
40.95(1.612)
5.55(0.219)
5.5s{0.219}
0.08(0.003)
0.08(0.003)
Unit of length:mm (in)
(818C1englnel- Section7
BI k (ltluur
Engrne]'ocK
Cyiinderblock
Piston
MEASUREMENT
warpageof decksurlace
Borediameter
BoretaPer
limit
Reboring
SkinO.D.ar 15mm (0.6in) {rom bottomot skirt
in cylinder
Clearance
ToP
Groovewidth (Forring)
Socond
oil
Pistonring
Ring-to-pistongrooveclearance Top
Second
I oP
Ringendgap
Socond
oil
rrstonrtn
rod
Connecting
crankshatt
Eearing
o.D.
clearance
Pin-to-piston
Pinto-rodintrference
Smallendborediameter
Nominal
Largeendborediameter
Endplay installedon crankshaft
Msinjournaldiameter
N o .1 , 2 , 4a n d5 i o u r n a l s
No.3 journal
Rodiournaldiameter
Taper
Out'olround
Endplay
Runout
oil clearance
Mainbsaring-to-journal
No.1,2, 4 and5 journals
No 3 journal
oil clearanc
Rodbearing-to-journal
(NEWI
STANDARD
0.05(0.002)max.
- 3.190)
81.00- 81.02{3.189
LIMIT
SERVIC
0.08(0.003)
81.0713.192)
0.05(0.002)
0.25(0.010)
- 3.189)
80.98- 80.9913.188
- 0.0016}
0.0r- 0.04{0.0004
- 0.0409)
1.030- 1.0,r0{0.0406
- 0.0488)
1.230- 1.240(0.0484
- 0.11101
2.805- 2.820(0.1104
- 0.0028}
0.045- 0.070{0.0018
- 0.0026)
0.010- 0.065(0.0016
0.20- 0.35{0.008- 0.014)
- 0.022)
0.40- 0,55(0.016
0.20- 0.s0{0.008- 0.020}
- 0.8268)
20.994- 21.000(0.8265
- 0.0009)
0.010- 0.022{0.0004
- 0.0014)
0.017- 0.035(0.0007
20.964- 20.997(0.8254- 0.8267)
.0 (1.89)
- 0.012)
0.15- 0.30(0.006
80.97(3.188)
0.05(0.002)
1.060(0.0417)
1.260(0.0496)
2 . 8 4 0( 0 . 1 1 1 8 )
0.13(0.005)
0.13(0.005)
0.60(0.024)
0.70(0.028)
0.7010.0281
- 2.16541
- 55.000
(2.1644
54.976
54.974- 54.998(2.'|643- 2.1553)
-' I.7717)
- 45.000
44.976
{1.7707
max.
0.005{0.0002}
max.
0.004{0.0002)
0.10- 0.35{0.00{- 0.014)
max.
0.020(0.0008)
-t-oou
lo.ooort
- 0.0017)
0.024- 0.042(0.0009
- 0.0019)
0.030- 0.048(0.0012
- 0.0020)
0.032- 0.050(0.0013
0.050(0.0020)
0.060{0.0024)
0.060(0.0024)
3-5
vnx.su
- Section
EngineLubrication
eclton g
u _
MEASUREMENT
Engineoil
Capacity
f (USqt, lmp qt)
STANDARD
INEW}
etaet engine 4.6{4.9,4.0}torengineoverhaul

818C1
engine
O i lp u m p
Reliefvalve
SERVICELIMTT
3.8(4.0,3.3)for oil change,inctudin

g talter
3.513.7,
3.11for oil change,withouttiher
4.8{5.1,4.2)for engineoverhaul
4.0(4.2,3.5)lor oit change,includin
g filter
3.7 i3.9 3 3l fdr îl .hi
Inner-to-outer
rotorclearance
Pumphorising-to-outer
rotorclearance
Pumphousing-to,rotor
axialclearance
rressuresettingat engineoil temp.176.F{gO.Ct
kPalkgtcm,,psi)
At idte
At 3,000rpm
0.04- 0.16(0.002- 0.006)

0.10- 0.19(0.004_ 0.007)
0.02- 0.07(0.001, 0.003)
0.20(0.008)
0.21(0.008)
0.1s(0.006)
70 (0.7,10)min.
3{0 {3.5,50)min.
Cooling- Sectiont0
Radialor
MEASUBEMENT
Coolant
capacity I {USqt, lmpq 0
8 1 8 8 1e n g i n e
engine,heater,I
I Including
I coolinglineandreservoir
I
Reservoircapacity:
0.61(0.63USqt,0.53tmpqt)
818C1engine
Radiatorcap
Thermostst
Openingpressure kPa(kgf/cm?,psi)
start to open oF(.C)
Fullyopen .F (.C)
Valvelift at fully open
Coolingfan
lhermoswitch"ON" temperature .F {oC)
"OFF"
Thermoswitch
temporature "F (.C)
ng the coolantin the reservoirandthat remainingin the engine.
3-6
vnx.su
STANDARD
INEWI
M/T:6.4(6.8,5.6)toroverhaul
4.4(4.6.3.9)
f6r s66lsn1gh66q.*
A,rf:6.7{7.1,5.9)for overhaul
4.7{5.0,4.1)for coolantchanoe*
M/T:6.7 {7.1,5.9}for overhaul
4.7{5.0,4.1)for coolantchanoe*
,3 - 113toss- trs, r3=Jt&
1 6 9- 1 7 6{76 80}
194(90,
8.0(0.31)
196- 203(91- 95)
Subtract5 - 14 (3 - 8) from actuat-ON', temperature
Unit ot length: mm {in)
Section 11
Fuel and Emissions
sTAt{ItAno(Newl
MEASUREMENT
SERVICEUMIT
| 12011.1'1'21
I too (:.1, g.st
F aa3urorggulator
81881engine
in l2 V, 10seconds
Disolacoment
818C1engins
m, (fl oz,lmp oz)
Pressurewith regulatorvacuum hose disconnected
Bl8Bl engine
kPa (kgflcm',psi)
Bl8Cl engin
22217.5,7 -81min.
364(12.3,12.8)min.
tualt6nk
Caprcity , {US gal,lmp gal)
11.01
50(13.2,
En9in6
ldle sDeed with headlight and cooling fan ofi rpm
7501 50 (M/T:neut..ll
750I 50 {A/T:E or E position}
Fast idle rpm
1,600i 2(x'lM/T:nsurr6l)
l,eooI 200(A/T:E or E po6itioo)
ldl6 CO
0.1 max.
.u.l pump
Clutch
Section 12
STAM'Ad' IiEWI
MEASUREMENT
clutch padsl
clutch disc
Pr6sur6 plat
275- 32a 12.8 -3.9,39.6 - 46.9)

329 - 378 (3.35- 3.85,47.6- 5.47)
P6d6lheight
Siroke
Pedalplay
Disengagementheight
to lloor
to floor
max,
0.0510.002)
Clutchsudace runout
Rivt had depth
Thickness
Warpage
Oiaphragmspringlingeralignment
SERVICEUMIT
164(6.46)
130- 140(5.12- 5.51)
12 - 21 (0.47- 0.83)
83 (3.27)min.
1.3(0.05)min.
8.4- 9.1 (0.3 - 0.36)
mrx.
0.03(0.001)
0-6(0.02)ma*
0.'15(0.006t
0.2(0.011
6.0(0.24)
0.15(0.006)
0.8(0.03)
3-7
{n+
vnx.su
ll
ManualTransmission Section 13
MEASUREMENT
Transmission
oil
Capacityf {US qt, lmp q0
Mainshaft
End play
Diameterot ball bearingcontactarea
(clutchhousingside)
Diameterof 3rd gear contactarea
Diameterof ball besring contactarea
(transmission
housingside)
Runo!t
STANDARD{NEWI
SERVICEUMIT
2.2{2.3,1.9}loroilchange
2.3(2.4,2.0)lor assembly
Mainshafi
3rd and
4lh gears
t.D.
Endplay
Thickness
Mainshaft
5th gear
t.D.
Endplay
Thickness
Countershaft
Diameterof needlebearingconlact area

Diameterof ball boaringcontactarea
Diameterof 1st gear contactarea
Countershaft
lst gear
t.D.
Endplay
Countershaft
2nd gear
LD.
Endplay
Thickness
3rd
4th
Bunout
Spacercollar
(Countershaft
2nd gear)
t.D.
o.D.
Spacercollar
{l'rainshaft
4th and
sth gears)
t.D.
o.D.
81881engino
818C16ngine
Length
3 -8
Length
vnx.su
0.11- 0.18{0,004- 0.007)

27.977- 27s90 l.1.101- 1.1021
Adjust
2 7 . 9 3( 1 . 1 0 )
37.984- 38.000{1.495- 1.495}

27.987- 28.000{r.1018- 1.1024}
37.93{1.493)
21.94 /.1.10!'
0.02 (0.0008)max.
0.05 (0.002)
, 1.6939)
43.009- 43.02511.6933
0.06- 0.21(0.0024 0.0083)
- 1.3768)
- 31.97
(1.3748
34.92
- 1.23SOl
31.12- 31.1711.2370
43.08t 1.696)
0.3(0.012)
34.8(1.370)
31.3 (1.2321
43.08{1.696)
0.3 (0.012)
3 1 . 3( 1 . 2 3 2 )
- 1.6939)
43.009- 43.025(1.6933
0.06- 0.21 (0.0024- 0.0083)
31.42- 31.47t1.237-1.2391
33.000- 33.015(1.299- 1.300)
24.980- 24.993{0.9835- 0.9840)
- 1.4567)
36.984- 37.000(1.4561
max.
0.02 10.0008)
- 1.6545)
42.009- 42.02511.6539
- 0.0047)
0.04- 0.12(0.0016
- 1.85r4)
47.009- {7.02511.8507
- 0.0047)
0.05- 0.12(0.0020
- 1.3650)
34.62- 34.67(1.3630
- 1.1405)
28.92- 28.97(1.1386
- 1.4366)
36.48- 36.49(1.4352
- 1.6535)
41.989- 42.00011.6531
29.02- 29.04(1.r42s- 1.1433)
- 1.1453)
29.07- 29.09(1.1444
- '1.2209)
31.002 31.012(1.2205
- 1.4951)
37.989- 38.000(1.4956
- 2.22641
56.45- 56.5512.2224
- 1.0268)
26.03- 26.08(1.0248
32.95\1.297)
24.94(0.982)
36.93{1.454)
0.05 t0.002)
42.08(1.657)
Adjust
47.0811.854)
Adjust
3{.5 (1.358)
28.8(1.134)
36.5(1.437)
4 1 . 9 4( 1 . 6 5 1 )
31.06('1.223)
37.94(1.494)
ManualTransmission
Unit of length:mm (in)
Section 13
MEASUREMENI
Reverseidler
gear'1
Synchroring
LD.
gear shaft clearance
Gear-to-reverse
(ringpushedagainst99ar)
Ring-to-gear
clearance
O o u b l ec o n e
synchro ring *2
Clearance
{rin9pushedagainstgear)
Outersynchroring-to-gear
lnnersynchroring-to-gear
Outer synchro ring-to-synchrocone
Shitt fork
Shifttork fingerthickness
Fork-tosynchro sleeveclearance
Shift fork pawl groove width
Fork-to-reverseidler gear clearance
"1" groovewidth
at sth gearside
at reversegear side
shift piece pin clearance
Fork-to-5th/reverse
at 5th gear side
at reversegear side
piece
area
contact
Groovewidth of change
arm clearance
Changepiece-to-shift
qeverseshift
Shift arm
Shift piece
Selector
Groovewidth of shift arm contactarea

Shift piece'to-shiftarm clearance
LD.
Shift piece-to-shaftclearance
Diameterof shift Iork cont6ctarea
Shift piece-to-shiftfork shaft clearance
Diameterof changepiececontactarea
Arm-to-changepiececlearance
Groovewidlh of interlockcontactarea
clearance
Arm-to-interlock
STANDARDINEW)
- 0.7891)
20.016- 20.043(0.7880
0.036- 0.084(0.0014- 0.0033)
0.85- 1.10(0.033- 0.043)
SERVICELIMIT
20.09(0.7909)
0.16(0.006)
0.4(0.0't6)
0.95r 1.68(0.037- 0.066)

0.5- 1.0(0.02- 0.04)
0.5- 1.0{0.02-0.04)
7.4,7.6 (0.291- 0.299)
0.35- 0.65(0.014- 0.026)
0.6(0.024)
0 . 3( 0 . 0 1 )
0.3 (0.01)
- 0.524)
13.0- 13.3(0.512
- 0.043)
0.5- 1.110.020
-0.303)
7.40- 7.70(0.291
- 0.28s)
7.05- 7.25(0.278
1.0(0.039)
13907)
- 0.03s)
0.4- 0.9{0.016
- 0.018)
0.05- 0.45(0.0020
11.8- 12.0(0.4646-0.4724)
0.05- 0.35(0.002- 0.014)
7.9- 8.0 (0.311-0.315)
0.10- 0.30(0.004- 0.012)
14.000- 14.068{0.551- 0.554)
- 0.0036,
0.011-0.092(0.0004
- 12.00(0.469- 0.472)
1'1.90
0.20- 0.50 (0.008- 0.020i
11.90- ' t2.00(0.469- 0.472)
0.05- 0.35{0.002- 0.014)
- 0.3996}
10.05- 10.15{0.3957
0.05- 0.2s(0.002- 0.010)
0.8010.031)
0.60(0.024)
0.150(0.0059)
osoto.oart
0.50(0.020)
0.50(0.020)
' 1 : 8 1 8 8 1e n g i n e
'2 818C1engine
- Automatic Transmission- Section

rr
14
oEutrlrrl
Transmission
lluid
Hydraulic
pressure
I kPalkgflcm', psi)
Capacity
I (USqt, lmp qt)
Line pressureat 2,000rpm

(E or E position)
2nd clutch pressureat 2,000rpm
(DJ position)
3rd clutch pressureat 2,000rpm
(lqr posirion)
4th clutch pressureat 2,000rPm
{E position)
2nd clutchpressureat 2,000rPm
(Elposition)
1st clutch pressureat 2,000rpm
([O or E position)
'lst'holdclutchpressureat 2,000rpm
(Elposition)
Throttle pressureB
SERVICELIMIT
STANDARD{NEWI
MEASUREMENT
Throttle fully closed

Throtlle Iully opened
Stallspeedrpm (Checkwith car on levelground)
5.916.2,5.2)foroverhaul
2.7 (2.9,2.4)for lluid change
830 - 880 (8.5- 9.0, 120- 130)
780{8.0,110)
460 - 14.7,67)
throttleIully closed
4 1 0{ 4 . 2 . 6 0 )
throttle fully closed
II
830- 880(8.5- 9.0,120- 130)

throttlemorethan3/16opened
780{8.0,110)
throttle more than
3/16opened
830- 880{8.s- 9.0.120 130)
780(8.0,110)
830- 880(8.5- 9.0,120- 130)
780(8.0,110)
830- 880{8.5- 9.0,120- 130}
780(8.0,110)
0 - 1 s{ 0 - 0 . 1 5 , 02-1 )
830- 880(8.5- 9.0,120- 130)
2,200- 2,600
78018.0,110)
Below 2,200,
above 2,600
(cont'd)
3-9
vnx.su
AutomaticTransmis3ion(cont'dl- Sostion14
MEASUFEME'YT
Clutch
Clutch initialcl6aranco
Clutch rdtu.n spring troe length
Clutchdisc thicknosg
Clulch plale thickn$3
Clutchond platothictnoss
('l8t)
Clutch ond plato thickn$s

(2nd,3rd,ath)
Clutchond pl.t6 thicknoss

(lst-hold)
STANDARD
{NEWI
lst, 2nd
3rd, 4th
lst-hold
lst, 3rd, 4th
2nd
lst-hold
MARK 1
MARK 2
MARK3
MARK4
MARK5
MARK6
MABK7
MABK8
MARK9
MARK10
MAFK 1,I
MARK12
MARK13
MAEK14
MARK 1
MARK2
MARK3
MARK 4
MARK 5
MARK6
MARK7
MARK8
MARK9
MARK10
MARK 1
MARK2
MARK3
MARK 4
NO MARK
MARK6
MARK7
vnx.su
0.65- 0.85 (0.026- 0.0331

0.40- 0.60(0.016- 0.024)
0.5- 0.8(0.020- 0.031)
3 1 . 0{ r . 2 2 }
33.2{1.31)
34.6 ('t.36)
'1.8- 2.0
{0.071- 0.079)
1.95- 2.05(0.077- 0.08r)
2.05- 2.10 (0.08'1- 0.083)
2.1s- 2.20{0.085- 0.087)
2.25- 2.30(0.089- 0.091)
2.3s- 2.40{0.093- 0.091)
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- 2.80(0.108- 0.110)
2.85- 2.90(0.112- 0.111)
2.95- 3.00(0.116- 0.118)
3.05- 3.'r0{0.120- 0.122}
3.15- 3.20(0.124- 0.126)
3.25- 3.30(0.128- 0.130)
3.35- 3.40(0.132- 0.1341
2.05- 2.10(0.081- 0.083)
2.15- 2.20{0.085- 0.087)
2.25- 2.30(0.089- 0.091)
2.35- 2.40{0.093- 0.094)
2.45- 2.50{0.096- 0.098}
2.55- 2.60{0.100- 0.102}
2.65- 2.70(0.104- 0.106)
2.75- 2.80{0.108- 0.r10)
2.85- 2.90{0.112- 0.1r4)
- 0.1r8)
2.95- 3.0010.116
2.052.152.252.352.452.552.65-
- 0.083)
2.10{0.081
2.20(0.085- 0.087)
- 0.091}
2.30{0.089
2.40(0.093- 0.0941
2.50(0.096- 0.098)
- 0.102)
2.6010.100
2.70(0.101-0.106)
SEBVICE
UM]T
29.0(1.14)
31.211.231
32.6(1.28)
Untilgroov6wornout
Discoloration
Discoloration
Discoloration
Oiscoloration
II
I
Discoloration
Discoloration
tI
I
Oiscolor6tion
Unitol length:mm (in)
r.t
a t c u a r r u r r 14
AutomaticTransmission- Section
SIANDARD {NEW}
MEASUREMENT
iransmission
Diameterof needlebearingcontactarea
On mainshattand stator shaft
On mainshaft2nd gear
On mainshaft4th gearcollar
On mainshaftlst gesrcollar
(leftside)
On countershaft
3rd gear
On countershatt
4th gear
On countershaft
On countershaftreversegear collar
lst gearcollar
On countershaft
on sub'shaft(leftside)
On sub-shaft4th gearcollar
On reverseidler gear shaft
Insidediameterof needlebearingconlactarea
On mainshaftlst gear
On mainshaft2nd gear
On mainshalt 4th gear
On countershaftlst gear
On countershaft3rd gear
On countershaft4th gear
On countershaftreversegear
On sub-shatt4th gear
On reverseidlergear
On statorshaft(rightside)
On stator shaft {statorside)
Reverseidlergearshaftholderl.D.
Endplay
Mainshaft1stgear
Mainshaft2nd gear
Mainshatt4th gear
1stgear
Countershaft
3rd gear
Countershaft
4th gear
Countershaft
Sub-shaft4th gear
Reverseidler gear
Countershaftreversegear
Selectorhub O.D.
Mainshaft4th gearcollarlength
Mainshatt'lstgearcollarlength
Ist garcollarflangethickness
lvlainshaft
C o u n t e r s h a f td i s t a n c e c o l l a r l e n g t h
reversegearcollarlength
Countershaft
reversegearcollarflange
Countershaft
thickness
1stgearcollarlength
Countershaft
'1st
Countershaft gearcollarflangethickness
Sub-shaft4th gearcollarlength
Sub-shaft4th gearcollarflangethickness
- 0.9052)
22.980- 22.993(0.9047
35.975- 35.9910.4163- 1.4169)
- 1.2595)
31.975- 31.99r(1.2589
30.975- 30.991t1.2195- 1.22011
36.004- 36.017{r.4r7s- 1.4' l80)
- 1.4172)
35.980- 35.996(1.4165
2 7 . 9 8-0 2 7 . 9 9 {31 . 1 0 1-61 . 1 0 2 1 )
3 1 . 9 7 5 - 3 1 . 9 9( 1 . 2 5 8-91 . 2 5 9 5 )
- 1.2595)
31.975-31.991(1.2589
25.991- 26.000(1.0233 1.0236)
2 7 . 9 8 -0 2 7 . 9 9 (31 . 1 0 1-61 . 1 0 2 1 )
- 0.5512)
13.990 11.000(0.5508
- 1.3786)
35.000- 35.016(1.3780
4 1 . 0 0-0 4 1 . 0 1 {61 . 6 1 4-2r . 6 1 4 8 }
- 1.49671
38.000- 38.016(1.4961
- 1.4967)
38.000- 38.0161' ].4961
4 1 . 0 0 -0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 )
- 1.2998)
33.000- 33.016(1.2992
38.000- 38.0160.4961- 1.4967)
32.000- 32.016fl.2598 1.2605)
18.007,18.020{0.7089 0.7094)
2 9 . 0 0-0 2 9 . 0 1 (31 . 1 4 r -7 1 . 1 4 2 2 )
- ' j.1638)
27.000- 21.021(1.0630
- 0.5683)
14.416- 14.43410.5676
0.08- 0.24(0.003- 0.009)
0.05- 0.13(0.002- 0.005)
0.045- 0.140(0.002- 0.006)
0.1- 0.5 (0.004 0.020)
0.04- 0.15(0.002- 0.006)
0.05- 0.13(0.002- 0.005)
0.05- 0.17(0.002- 0.007)
0.05- 0.r8 (0.002- 0.007)
- 0.010)
0.10- 0.2510.004
51.87- 51.90(2.042- 2.043)
49.00- 49.05(1.929- 1.931)
' |.069)
27.00- 27.15(1.0632.5 - 2.6 \2.098- 2.102)
38.97- 39.00 1.534 1.535)
39.02- 39.05 'r.536- 1.537)
39.07- 39.10 1.538- 1.539)
39.12- 39.r5 1 . 5 4 -0 1 . 5 4 1 )
39.17- 39.20 r.542- 1.543)
39.22- 39.25 1.544 1.545)
39.27- 39.30 1.546- 1.547)
- 1.53r)
38.87- 38.90 1 . 5 3 0
'1.532
- 1.533)
38.92- 38.95
14.5- 14.610.57r 0.575)
2.4- 2.6(0.094- 0.102)
'14.5
- 14.6(0.57'-l 0.575)
2.4- 2.6(0.094 0.102)
24.0, 24.1{0.945- 0.949}
3 . 0 0- 3 . 1 5{ 0 . 1 1 8 0 . r 2 4 )
SERVICELIMIT
Wearor damage
Wearor damage
Wearor damage
*rd"-"g"
Wearor damage
Wearor damage
Wearor damage
Wearor damage
Wearor damage
(cont'd)
3-11
vnx.su
Automatic Transmission (cont'dl - Section 14
MEASUREMENT
Transmission
(contdl
STANDARD{NEW}
Mainshaft2nd gear thrust washer thickngss
Thrust washerthickness
Mainshaftball bearing left side
Mainshaft 1st gear left side
Mainshatt1stgearrightside
Sub-shaft4th gearthrustwasherthickness
One-wayclutch contactarea l.D.
Countershaftlst gear
Parkinggear
MainshaftfeedpipA, O.D.{at 15mm trom end}
Mainshaftleed piDeB, O.O.{at30 mm from end)
Countershaft
leed pipeO.D.(at l5 mm from end)
Sub-shaftfeed pip O.D.(at 15 mm trom end)
Mainshaftsealingringthickness
{29mm and 35 mm)
MainshaftbushingLO.
MainshaftbushingLD.
Countershaft
bushingLD.
Sub-shaftbushingl.D.
Mainshattsealingring goovewidlh
Regulator
Sealing ring contact area LD.
Shiftingdeviceand
parking brakecontrol
Reverseshift fork tinger thickness

Parkingbrako ratchetpawl
Parkinggoar
Throftlo cam slopper heighl
Shift fork shaft bore Lo.
Shift fork shaft v6lve bore LO.
Oil pump gearsideclearanc
Oil pump gear-to-bodycl6rance
Servo body
Oil pump
4.00{0.1564.05(0.1584.10(0.r604.'15(0.1624.20(0.1644.25(0.1664.30{0.1681.35{0.1704.40(0.172-
0.'t57}
0.159)
0.1611
0.163)
0.' t65)
0.167)
0.169)
0.17r)
0.173)
3.451.453.432.93-
3.55(0.1361.50(0.0573.50(0.1353.00(0.115-
0.140)
0.059)
0.138)
0.1181
Drive
Drivn
vnx.su
SERVICE
t_tMtT
Wear or damage
II
I
Wearor damage
Wearlordamase
Woaror damage
- 3.2821)
83.339- 83.365(3.2810
66.685- 66.69812.6254- 2.6259)
8.97- 8.98 {0.353- 0.354)
5.97- 5.98(0.23s0- 0.2354f
- 0.3142)
7.97- 7.98(0.3138
- 0.3142)
7.97- 7.98{0.3138
1.980- 1.995(0.0780- 0.07851
t
Wearor damage
6,0189.0008.0008.0002.025-
6.045(0.2380)
9.03(0.356)
8.03(0.3r6)
8.03(0.3161
2.08(0.0821
- 0.2374)
6.030(0.2359
9.015(0.3s43- 0.3549)
- 0.3156)
8.01s(0.31s0
- 0.3156)
8.015(0.3150
- 0.0811)
2.060(0.0797
35.000 35.025{1.3780- 1.3782)
5.90- 6.00 {0.232- 0.236)
Oil pump driveng6arI.D.

Oil pump shaftO.D.
3-12
3.974.024.074.124.174.224.274.324.37-
27.0- 27.r (1.063-1.067)

- 0.5516)
14.000- 14.010(0.5512
37.000- 37.039(1.{567- 1.4582)
0.03- 0.05 (0.001- 0.002)
- 0.0104)
0.210- 0.265{0.0083
0.070- 0.125(0.0028- 0.0049)
- 0.5525)
14.016- 1{.034(0.5518
13.980- r3.990{0.5504- 0.5508)
8.95{0.352t
5.95(0.2341
7.95(0.313)
7.9s(0.313)
1.80{0.071)
35.050(1.3799)
5 . 4 O{ 0 . 2 1 3 )
lWear or other
t_'--'
37.045{1:4585}
0.07 (0.003)
W6aror damage
Wearor damage
tt [t!'tttltttt
MEASUREMENT
Springs
Unit of length: mm (in)
Section 14
Regulatorvalve spring A
Regulatorvalve spring I
Stator ractionspring
Modulator valv body
Torque convortercheckvalve
Cooierchckvalve sprang
Reliefv6lvospring
2-3 orifice control valvo spring
Throttle valve B adiustingsPring
Throttle valve B spring
Throttlevalvo B 6pring
Throttle valve I spring
1-2 shift valve sprang
2-3 shift valve spring
'lst-holdaccumulator
spring
1st accumulatorsprang
2nd accumulalorspdng
3rd accumulatorspring
4th accumulatorsPrang
Lock-upshift valve spring
Lock-uptiming B valve spring
Lock-upcontrol valve spring
CPCvalve spring
Kick-downvalvo spring
3-2 kick-downvalvo spring
Servo control valve spring
4th exhaustv6lve spring
Servo orifice controlvalve spring
STANDAND
INEWI
Wir. Di..
1.8{0.071}
1.8(0.071)
5.5(0.217)
1.3{0.0s1)
1.1{0.043}
1.1{0.043)
1.r (0.043)
0.9(0.035)
0.7(0.0281
1.4(0.055)
1.4(0.055)
1.1(0.055)
0.9(0.0351
0.9(0.0351
0.9{0.035)
4.0{0.157)
2.5(0.098)
3.6(0.142)
2.8(0.1r0)
2.6(0.102)
0.9(0.035t
0.8(0.0311
0.8(0.031)
1.3(0.051)
1.0(0.039t
1.3(0.051)
0.9{0.035)
1.0(0.039)
0.8(0.031)
o.D.
14.7(0.579)
9.6 (0.378)
26.4(1.039)
9.4 {0.370}
8.4 (0.331)
8.4(0.3:]t)
8.6 (0.3l9)
6.6 (0.2601
6.2 (0.244)
8.5 (0.335)
8.5 (0.335)
8.5 (0.335)
8.6 (0.339)
7.6 (0.299)
7.6 (0.2991
21.5(0.846t
16.3(0.642)
22.0 (0.866)
17.5(0.689)
16.3(0.642)
7.6 {0.299)
6.6 {0.260}
6.6 (0.260)
9.4 (0.370)
6.6 (0.260)
8.6 (0.339)
6.4 (0.252)
7.1(0.280)
6.6 (0.260)
Fr.. L.ngth
88.6 (3.488)
11.011.7321
30.3(1.193)
37.3{1.469)
33.8(1.331)
33.8(1.331)
37.1(1.461t
33.0(1.299)
34.0 fi.339)
41.5(1.634)
41.5(1.63i1)
41.6{1.638}
40.4(1.591)
57,0 12.2111
52.0(2.047)
71.1Q.A23l
't05.4(4.150)
108.9(4.287)
105.2(4.'142)
103.3{4.067)
73.7 12.9021
60.8 (2.394)
39.5(1.5s5)
35.3(1.390)
2a.5(.1221
45.6(1.795t
34.1{1.343)
60.3(2.374)
48.2{1.898}
t{o. of Colh
16.5
2.1
12.1
't2,5
12.5
13.4
14.9
10.5
11.2
12.1
14.5
26.8
E.3
16 + 8.6
15.2
19.'l
21.2
32.0
22.1
25.O
12.1
11.7
17.0
11.5
18.5
33.0
3-13
vnx.su
Differential(Manualtransmissionl
Section 15
MASUREMENT
STANDARDINEW)
- 0.7093)
81881engine 18.000- 18.016(0.7087
- 0.7094)
8 1 8 C 1e n g i n e 18.000 18.018(0.7087
- 0.0018)
Carrier'to-pinion
clearance
81881engine 0.0r3 0.045(0.0005
- 0.047(0.0005 0.0019)
B18Ct engine 0.0'13
Driveshafvintermediate
shaft contactarea LD.
8 1 8 8 1e n g i n e 28.000- 28.021\1.1024-1.10321
818C1engine 28.005- 28.025(1.1026 1.'1033)
Carrierto driveshaftclearance
81881engine 0.020- 0.062(0.0008 0.0024)
- 0.0034)
BlSC'lengine 0.045, 0.086{0.0018
Carrier-to-intermediate
shatt clearance
B188l engine 0.050- 0.087(0.0020 0.0034)
- 0.0044)
818C1engine 0.075- 0.111(0.0030
(0.002
Differential
Eacklash
0.05 0.15
0.006)
'18.042
- 18.066(0.7103 0.7113)
prnrongear
t .D .
PiniongeaFto-pinion
0.055- 0.095(0.0022 0.0037)
shaftclearance
Sel ring-to-bearing
outerraceclearance
81881engin 0 - 0.10(0 0.004)
Differentialtaper roller bearing preload
- 3 r.0,13.0-18.7)
StartingtorqueN.m {kgfcm,lbf.in)
Bl8Cl engine 2.1r- 3.04{21.5
Differential
Differential (Automatic transmissionl
Differential
prnrongear
o.t aron,
0.1{0.006}
Adjust
0.15{0.006)
Adjust
Adjust
Section 15
MEASUREMENT
Difterential
carflr
SERVICELIMIT
PinionshaftcontactareaLD.
Pinionshatt contactarea l.D.

Carrier-to-oinion
clearance
Driveshafvintermediate
shaft contactare l.D.
Carrier-to-driveshatt
clearance
Backlash
t.D.
Piniongear-to-pinion
shaftclearance
STANDAROINEWI
- 0.7094)
18.000- 18.018{0.7087
- 0.0020)
0.016- 0.052{0.0006
- 1.1033)
28.00s 28.025{1.1026
- 0.0026)
0.025- 0.066(0.0010
0.05- 0.15(0.002- 0.006)
18.042- 18.066(0.7r03- 0.7113)
- 0.0037)
0.059- 0.095(0.0023
0 - 0.r5(0- 0.006)
Set ring-to-bearing
outerraceclearance
SERVICELIM]T
0.1{0.004)
0.12(0.005)
Adjust
0.15(0.006)
Adjust
Steering - Section 17
Steeringwheel
Gearbox
Purnp
Powersteering
tluid
Power steering
belt*
MEASUREMENT
play at steeringwheelcircumference
Rotational
Staninglosd at steeringwheelcircumference
N {kgf,lbfl
Enginerunning
Angle of rack-guide-screwloosenedfrom locked
position
Pumppressurewith shut-offvalveclosed
kPa(kgtlcm,,psi)
fluid
Recommended
Fluidcapacity
f (USqt, lmp q0
For overhaul
Forfluid change
Deflection
with 98 N (1okgt,22lhfl
betweenpulleys
BelttensionN lkgf,lbl)
Measuredwith belttensiongauge
STANDARDINEWI
0 - 10 {0 - 0.39)
3 4\ 3 . 5 , 7 . 7 1
20" i 5'
6,400 7.400165 75.920- 1.r00)
Hondapowersteeringfluid V
1 . 0 6( 1 . 1 2 , 0 . 9 8 )
0.79(0.83,0.70)
11.5- 13.5(0.45 0.53)withusedbelt
8.0- 10.010.310.39)withnew belt
390 - 540 (40- 55, 88 - 120)with used belt
740 880175 90. 170 200)with new belt
' When usinga new belt,adjustdetlectionor tensionto new values.Runthe enginelor 5 minutesthen turn it off.
Readiustdetlectionor tensionto usedbeltvalues.
vnx.su
Suspension
Unitof length:mm {in)
Sestion 18
STANDARD
I]{EWI
MEASUFEMENT
Camber
a gnment
Caster
Totaltoe
Frontwhelturningangle
Endplay
A1lclbearing
Rim runout(Aluminumwheel)
Rim runoutisteelwhgel)
Brake
Front
Rgar
Front
Front
Rear
Inwardwhel
Outwsrd whel
Front
Roaa
Axial
Radial
Axial
Radisl
-0. 10'1 1.
-0' 15' l$igl
1 . 1 0 ' rt "
0i2(010.081
rN3:i(0.121ff)
36'0o'r 2'
30. 30'
0 - 0.05(0- 0.002)
0 - 0.05{0- 0.002}
STANDARD
INEWI
0 - 0.7{0- 0.03)
0 - 0.7(0- 0.03)
0 - 1.0{0- 0.0{)
0 - 1.0(0- 0.04)
Section 19
STANDARD
{NEWI
MEASUREMENT
trrling brake
; oot brake
,adal
Play in strokat 200 N {20 kgf, 44 lbt)

lever lorce
Pedalheighl lwith floor mat removod)
To b lockodwhen pulled 6 -10

nolchsa
M/T
Freeplay
Vastercylinder
Piston-to-oushrodclearance
f,,s4brake
Oiscthickness
Disc runout
Disc parallolism
Padlhickness
Air Conditioning
Ar conditioning
Compressor
UMIT
SEBVICE
2.0(0.08)
1.5(0.06)
2.0(0.081
r.5(0.061
Front
Re6r
Front
R6ar
Front and rear
Front
Roar
160(6.30)
155(6.50)
1-5(0.04-0.20)
0 - 0.4(0- 0.2)
STANDARD
INEWI
20.9- 21.1t0.82- 0.83t
8.9- 9.1{0.35- 0.36)
9.5- 10.5{0.37- 0.41}

7.0- 8.0{0.27- 0.31)
SERVICELIM]T
19.0(0.75)
8.0 (0.31)
0.10 (0.004)
0.r0(0.00a)
0.015(0.0006t
r.6(0.06)
1.6(0.06)
Scction22
STANDABOIT{EWI
MEASUREMENT
Lubricantcapacitymf (ll oz)
Condnser
Evaporator
Lineor hose
Receiver
Lubricanttype: NO-OlL8{P/N38899- PR7- A0l)
Lubricantcapacitym{ (ll oz}
Lubricanttvge: ND-O|L8(P/N38899- PR7- A01)
Stator coil resistanceat 68'F (20'C)0
plate clearance
Pulley-to-pressure
25(5/6)
40t1 1/3)
1 0( l B t
10(1/31
140';u(4-23';")
3.4-3.8
0.5r 0.15{0.02r 0.006)
7.5- 9.5 {0.30- 0.37)with used blt*'
Compressor
Detlectionwith 98 N (10 kgf, 22 lbf)
8.5- 10.5{0.33- 0.41}witht/sodbelt'3
bh'r
betlveenpulleys
5.0 - 7.0 {0.20- 0.28)with new belt
Belt tnsion N (kgf, lbl)
390 - 540 {r0 - 55, 88 - 120}with used beh*'
Measuredwith beltlensiongauge
340- 490 {35 - 50, 77 - 110}with used belt*3
740 - 880 {75 - 90, 170- 200)with new belt
.1: Whenusinga new bek,adjustdellectionor tensionto new values.Runthe enginetor 5 minulesihen turn it ott.
Readiustdetlectionor tension to lsed beh values.
'2: 81881engine
'3: 818C1engine
3-15
vnx.su
Electrical
Section23
MEASUREMENT
lgnilioncoil
lgnition wire
ll
il
Sparkplug
Tvpe
Gap
lgnition timing
At idling
" BTDC(Red)- rpm
Deflecrionwilh 98 N {10 kgf,22lbll
betweenpulleys
Alternatorblt'2
Alternator
STANDARD
{NEWI
Ratdvoltago V
Primarywinding resistanceat 58'F (20'C)O
Secondarywinding resistance6t 68'F (20"C)kO
Resistancear 68"F(20'C)k0
0.6- 0.8
12.4- 19.2
25 max.
STANDARDINEW}
See Section23
B18Blengine 1.0- 1.1{0.039- 0.043}
B18Clengine
M/T
SEN$CE UM]T
1.3{0.051)rl
16"r 2. -750r 50(Neurra0

16"t 2"-750r 50|!]or L?.lposition)
Eelt tnsion N (kgf, lbf)

Measured with belt tension gsuge
9.0- 11.0(0.35- 0.43)with us6db6li

6.0 - 8.0 {0.24- 0.31}with new b6lt
340 - 490 {35 - 50, 77 - 110)with used bolt
690 - 880 {70 - 90, 154- 198}with now boh
Ourput l3.5 V at hot A

Coil resistance(rotor)at 68"F{20"C}0
Slip ring O.D.
Brush length
Erushspring tonsion N (kgt, lbf)
STANDARD
INEWI
90
2.9
14.4t0.57)
r0.5(0.41)
3.210.33,
0.73)
Output
Mica depth
0.5- 0.8(0.02- 0.03)
Commulatot runout
0 - 0.02(0- 0.0008)
- 1.r81)
CommutatorO.D.
29.9- 30.0(1.177
Brushlength
15.0- 15.5(0.s9- 0.61)
- 5.3)
Brush spring tension (new) N lkgt, lbf)
17.7- 23.5fi.8- 2.4,4.0
*1: Do not adiust the gap, replacespark plug it it is out of spec.
*2r When using a new belt, adjust dtlctionor tension to new valus.Run tho enginelor 5 minutesthon turn it off.
Readiustde{lection
or tensionto usodbeltvalues.
SENUCEUMTT
tnnro.rrr
1.5(0.06t
Staner
vnx.su
0.2(0.0081
0.05t0.@2)
29.0(1.142)
10.0(0.39)
]TEM
:' vENSTONS
3 DOOR
4 DOOR
Overalllength
OvrallWidth
OverallHeight
3 DOOR
4 DOOR
3 DOOR
4 DOOR
Wheelbase
,rerght(usA)
'le,ght {CANADA)
:\GINE
TrackF/R
GroundClearance
SeatingCapacity
WeightRating{GVWR)
crossVhicle
GrossVehiclsWeightRating{GVWR)
8 1 8 8 1e n g i n e
Type
818C1engine
CylinderArrangement
BoreandStroke
Displacement
Ratio
Compression
L!bricationSystom
OilPumpDisplacement
WsterPumpDisplacement
FuelRequired
8 1 8 8 1engrne
818C1engane
8 1 8 8 1engrne
B18CI engine
8 1 8 8 1engine
B18C1engine
8 1 8 8 1engine
8 1 8 C 1engine
8 1 8 8 1engrne
B18C1 engrne
8 1 8 8 1engine
B18C1engine
9 1 8 8 1engine
818C1engine
CLUTCH
Typo
NormalOutput
NominalVoltage
HourRating
Directionof Rotation
Weight
ClutchType
M/T
TRANSMISSION
Area
ClutchFacing
Transmission
Type
M/T
STARTER
PrimaryReduction
ENGLISH
METRIC
172.1in
4.380mm
178.1
in
4.525mm
'1,710
mm
67.3in
1,335mm
52.6in
1,370mm
101.2
in
2,570mm
in
103.1
2,620mm
't,475/1,470
mm 5|8.1/57.9
in
150mm
Four(3 DOOR)Five (4 DOOR)
3,680lbs
NOIES
1,670kg
4-strokeDOHC
Water-cooled,
gasoline
engine
Watercooled,4-strokeDOHC
VTECgasoline
engine
Inline4-cylinder,
transverse
3.19x 3.50in
81.0x 89.0mm
3.19x 3.43in
81.0x 87.2mm
112cu-in
1,834
cm3(mf)
110cu-in
1,797
cm3(m{)
9.2:1
10.0: 1
4 valvepercylinder
Eeltdriven,OOHC
Beltdriven,DOHCVTEC
4 valvepercylinder
Forcedandwet sump,trochoidpump
50, {53USqt, 44lmpqt)/minute'l
71 f {75USqt, 62 lmp qt)/minute"
140f (148USqt, 123lmpqt)/minute*!
140f (148USqt. 123lmpqt)/minute*'
gasoline
with86 Pump
UNLEADED
OctaneNumbror higher
gasoline
wilh
Premium
UNLEADED
91 PumpOctaneNumberor higher
Gearreduction
1 . 4k W
12V
30 seconds
Clockwiseasviewedlrom g6arend
3.7k9
8.3lbs
|
spring
Singleplatedry,diaphragm
Torq!e converter
31 sq-in
203cm'
I
5-speedforward,1 reverse
Synchronized
Electronically
controlled
4-speedautomatic.1 rcverse
Diract1 : 1
(cont'd)
'1: At 6,000enginerpm
'2: At 7,600enginerpm
3-17
vnx.su
{cont'd}
lTEM
TRANSMISSION
M E T R I C I i I G L I S H I N O T E S
Type
Enginetypo
1st
2nd
3rd
4th
5th
Rovrs
G6arRatio
Fin6l Reduction
Geartype
Gear ratio
Type
Manual transmission
81881
818C1
|
3.230
r.9(X)
1.360
1.034
0.'t87
3.000
3.230
1.900
1.269
0.966
o.711
3.000
Singlehelicalge.r
4.266
4.400
Automatictransmission
'l6t
GearRatio
2.722
1.464
0.97s
0.638
1.954
znd
3rd
4th
Revelse
FinalRduction
AIR
CONDITIONING
CoolingCapacity
Compr6ssor
Cond6nsr
Evaporator
Blower
TemperatureControl
CompressorClutch
Refrigerant
STEERING
SYSTEM
SUSPENSION
Goartypo
Gear ratio
Type
OverallRatio
Turns, Lock-to-Lock
SreeringWheel Dia.
Type
14,166BTU/I
swash-plare/NIPPoNDENSO
10
150ml /rcv
|
9.15cu-in/rv
7,600rpm
140mf
1-2Blloz
|
I
l.;3 tmpoz
(P/N38899- PR7- A01)
ND-O|L8
3,570Kcal/h
Type/Make
No. ol Cylinder
CaPtcity
Max. Spsed
LubricantC6pacity
Lubricrnt Type
Type
Type
Type
Motor Input
SpeedContro
Max. Capachy
Type
PoworConsumption
Type
Ou.ntity
Front
Roar
ShockAbsorbr,Front and Rear
3-18
Singlehelic6lgoar
4.357
vnx.su
Corrugatedfin
Corrugatodtin
Siroccotan
200w12 v
4-speed
450 m3/h
15,900cu lvh
|
Airmix type
Dry, singlo plate, poly-V-bltdriv6
40 W max./12V at 68"F{20'C)
(R-134a)
HFC-134a
zoo-Ss
24.7-l.aoe
I
Power assisted,rackand pinion
16.1
2.98
15.0in
380 mm
|
Independentdouble wishbono,
coil spring with st6bilizer
Independontdouble wishbong.
coil spring with stabilizer
Telescopic,hydraulic nitrogen gas-tilled
ITEM
WHEEL
ALIGNMENT
M E T R I C I E N G L I S H I M ) T E S
Camber
Front
Rear
Front
Front
Rear
Caster
TotalToe
BRAKESYSTEM
Type
PadSurfaceArea
ParkingBrake
TIRE
Size
Front
Rear
Front
Rear
Type
Front and rar
SpareTire
ELECTRICAL
8attery
Starter
Alternator
Fuses
In Under-dashFuse/RelayBox
In Under-hoodFuse/RelayBox
In Under-hoodABS Fuso/RolayBox
Headlights
High
FrontSideMarkerLights
FrontTurn SignauParkingLights
RearTurn SignalLighls
Stop/Taillights
High Mount BrakeLight'5
FearSideMarkerLights
Back-upLights
LiconsePlateLights
CeilingLights
CargoArea Lights (3 DOOR)
TrunkLightsl4 DOOR)
Spotlights
GloveBox Light
GaugeLights
IndicatorLights
llluminationand PilotLights
HeaterllluminationLights
omm
In 2 mm
-0.10'
-0.45'
1'1o'
oin
|
ln 0.08in
I
Power-assistedselt-adiusting
ventilateddisc
PoweFassistedself-adjustingsolid disc
io.u cm. x z
|
/,/5 so tn x z
21.0cm, x2
|
3.26sq in x 2
Mechanicalactuating,reartwo wheel brakes
P195/60R14
858*1
P195/55R15
84V*2
T115t0D14*3
T135/70O15.4
I2V-36AH6HR
'12V -'1.4 kW
12V-90A
7.5A, 10A, 15A, 20 A, 30 A
7.5 A, 10 A. 15 A, 20 A, 30 A, 40 A
50 A, 100A
1 0 A ,1 5 A , 2 0 A , 4 0 A
12V-6sW{HB3}
12V-55W(HB4)
12V-3CP
12V -32n CP
12V -32 CP
12V -32n CP
12V-21W
12V-3CP
12V -32 CP
12V-8W
12V-5W
12v-3.4W
12V-3.4W
12V-5W
12V-3.4W
12V-3.4W
v - 0.84w, 0.91w, 1.12W, 1.r W, 3 W
12 V - 0.84W. 0.91W, 1.4W. LEO
12V-1.4W
sAE 168
sAE1157
sAE 1't55
sAE1157
sAE7440
sAE 168
sA 1156
*1: RS,LS
*2: GS-R
*3: RS
*1: LS,GS-R
*5: Excepthigh mount brakelight installedin rcar spoiler.
vnx.su
3-19
Il
I
Body Specifications
Unit:mm (in)
3 DOOf,:
il
vnx.su
Unit mm {inl
. DOOR:
vnx.su
3-21
Maintenance
Points
Lubrication
MaintenanceSchedule
vnx.su
.........4-2
." 4'4
LubricationPoints
For the detailsol lubricationpoints and type of lubricantsto be spplied,reter to the illustratedindex and variouswork
procedure(such as Assembly/Reassembly,
Replacement,Overhaul,Instatlation,etc.) containedin each section.
No.
I
LUBRICATIONPOII\ITS
LUBRICAI\IT
API ServiceGrade:Use SG or SH "Energy Conserving
II" grade oil.
The oil containermay also displaythe API Certification
sal shown below. Make sure it says'For Gasoline
Engines.'
SAE Viscosity;See chan below.
Engine
Transmission
Manual
Automatic
API Service Grades: SF or SG

SAE Viscosity: 1O W-3O or 1O W-4O
Honda Premium Formula or DEXRON@II
Automatic transmissionfluid
Brakeline (lncludesAnti-lockbrake linel
Brakefluid DOT3 or DOT4
Clutch line
Bfake tluid DOT3 or DOT4
Power steeringgearbox
SteoringgreaseP/N 08733-BO7OE
Releasefork (Manualtransmission)
Supe. High Temp Urea Grease(P/N O8798*9OO2)
Throttle wire end {Dashboardlower Danelholel

C.uisecont.ol actuatot wire end
{Dashboardlower Danelholel
Siliconegrease
I Throttle cable end (Throttlelinkl

1 0 Cruisecontrol actuatorcable end lActuator link)
'I 'l
17
18
BrakemastercvlinderDushrod
Clutch mastercylinderpushrod
Enginehood hingesand enginehood latch
Batte.v terminals
Fuel fill lid
Hatch hingesor trunk hinges
Door hinges.upper and lowet
Door oDendetent
19
Rear brakecalioers
Rust-p,eventive
agant
20
Power steering system
Honda power steering tluid-V
21
Air conditioningcompressor
Retrigerantoit ND-otL8 |PlN 38899-pR7-A01)

(For Relrigerant:HFC-134a(R-134a))
12
13
14
15
to
.Multi-purposegrease
-20
-30
API CERTIFICATIONSEAL
0
-20
20
-'to
r}()
o
60
10
ao
20
Recolnmendodengine oil
Engine oil viscosity tor
ambient tgmpelalure rangos
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30
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40"c
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Engine
E n g i n eR e m o v a l / l n s t a l l a t i o. .n. ' ' . . . . . . . .5 - 1
C y l i n d e rH e a d / V a l v eT r a i n . . ' . . . . . . . . . . . .6 - 1
......7-1
EngineBlock....
.........8-1
EngineLubrication
System ...... 9-1
IntakeManifold/Exhaust
.......1O-1
Cooling
vnx.su
EngineRemoval/lnstallation
.".....5-2
S p e c i aTl o o l s . . . . . . . .
..."........ 5-3
..' 5-16
Mount/BracketTorque
vnx.su
SpecialTools
ru
il
Rst. No.
Tool Numbor
07MAC-SLOO200
Dascription
Ball Joint Remover,28 mm
vnx.su
Oty
Pag Rterenco
2.
@
a
Removethe strut brace
Make surejacks and safety stands aro placed ploperly and hoisl brackots arg attachod to the correct positions on tho engine (se ssction 1).
a Mak sure tho car willnot roll off stands and tallwhile
you are wotking under it'
8 x 1.25mm
24 N.m (2.4 kgf.m,
17 rbt.ft)
CAUTION:
a Use fendet covals to avoid damaging painted
sudaces.
r Unspecified itsms alo common
a Unplug tho widng connectots carefully while holding
the couplor and tha connector portion to avoid
oamage.
a Mark all wiring and hoses to avoid misconnection.
Also, be sulo that thsy do not contact other wiring
or hoses, or interfere with othl parts.
NOTE: Anti-theft radioshave a coded theft ptotection
circuit. Be sure to get the customer'scode numberbeJore
- Disconnectingthe batterY.
- Removingthe No. 32 (7.5 A) fuse from the underhood tuse/relaybox.
- Removingthe radio
Atter service,reconnectpower to the radio and turn it
"CODE" is displayed,enterthe cuson. Whenthe word
tomer's 5-digit code to restoreradio operataon.
1.
Removethe hood (seesection 2O).
STRUTERACE
Disconnectthe batterynegativeterminallirst. then

the positiveterminal.
Disconnectthe batterycablesfrom the undel-hood
fuse/relaybox and under-hoodABS fuse/relaybox.
BATTERYCABLES
6 x l.O mm
9.8 N.m (1 .O kgf'm,
7.2 rbl.ftl
{cont'd)
5-3
vnx.su
(cont'd)
Removethe intakeair duct, air cleanerhousingassemblv and the bracket.
7.
Removethe enginewire harnessconnectoEon the

right side of enginecompartment.
6 x 1 . Om m
9.4 N.m {l.O ksf.m, 7.2 tbf,ftl
6 x'l.Omm
9.8 N-m ll.0 kgt.m.
8.
Relievefuel pressureby looseningthe servicebolt

on the tuel filter about one turn {see section 1 1).
oo not amoke whito working on tho
@
fuel system. Keepopen flame away trom wo.k arsa.
Drain fuel only into an approved container.
CAUTION:
a Beforedisconnoctingany ful line. reliovothe tuol
pressule as doscribed above.
a Placea shop towel ov61the fu6l filter to prevont
prossurizedtuel from spraying ovel tho aogine.
Removethe evaporativeemission(EVAp) control

canisterhose and vacuum hose.
VACUUM HOSE
9.
Removethe fuel feed hose.
SERVICE
BOLT
15 N.m (1.5 kgt.m,11 tbt.ftl
BAITJO EOLT
33 N.m 13.4 kgt.m,
25 tbt.ftt
THROTTI.EBODY
vnx.su
1O. Removethe brake boostervacuum hose and fuel

return hose.
6 x 1 . Om m
11 N.m {1.1kgl'm,
8.O rbt.ltl
BRAKEBOOSTER
VACUUMHOSE
' t 2 . Removethe enginewire harnessconnectors,terminal and clamps on the left side ot engine comoartment.
6 x 1.0 mm
9.8 N.m {1 .O kgf.m,
7.2 tbt.ftl
ENGINEWIRE
HABNESS
BETURNHOSE
' t1 . Removethe throttlecableby looseningthe locknut.

linkage.
then slipthe cableendout of the accelerator
NOTE:
a Take care not to bendthe cablewhen removing
it. Always replaceany kinkedcable with a new
one,
a Adjust the throttle cable when installing(seesect i o n 11 ) .
13. Removethe cruisecontrol actualor.
8 x 1.25mm
24 N.m (2,4 kgl.m,
17 lbf.Irl
CRUISECONTROL
ACTUATOR
LOCKNUT
AOJUSTINGNUT
5-5
vnx.su
(cont'd)
1 4 . Removethe engineground cable at the body end.
Removethe adiustingbolt and mountingbolt, then
remove the power steering (P/Sl belt and pump.
a Do not disconnect the P/S hoses.
17. (Manusl transmission)Remove the clutch slave

cylinder and pipe/hose assembly.
a Do not disconnectthe pipe/hoseassembly.
6 x 1.Orl|m
ll
N.m { 1.1 kgt.m,
SLAVE CYLINDER
8.0
8 r 1 . 2 5m m
24 N.m (2.4 kgf.m. 17 lbl.ftl
8 x 1.25mm
24 N.m {2.4 kgl.m,

17 lbt.ftl
6. Loosenthe idlerpulleybolt and adjustingbolt, then

removethe air conditioning(A/C)compresso.belt.
18. Removethe transmissionground cable and hose

cramp.
6 x 1 . Om m
1l N.m 11,1 kgt.m,
I tbt.ftl
IDLERPULLEYBOLT
10 x 1.25mm
44 N.m 14.5 kgt.m, 33 lbl.ftl
5-6
A/C COMPRESSORBELT
vnx.su
25. Removethe upperand lower radiatorhosesand the

heater hoses.
19. Removethe radiatorcap.

u"" care whan removing the ladiatol
@@
cap to avoid scaldingby hot enginecoolant ol ateam.
UPPERRADIATOR
20. Raisethe hoist to full height.

21. Removethe front tires/wheelsandthe splashshield.
LOWERRADIATOR
HOSE
6 x 1 . Om m
9.8 N.m (1.0 kgf'm'
7.2 tbf.ft)
26. (Automatictransmission)Removethe ATF cooler

hoses.
2 2 . Drainthe enginecoolant (see page 1O-5).

a Loosenthe drain plug in the radaator.
Drainthe transmissionoil or fluid. Reinstallthe dtain
plug using a new washer.
2 4 . Drainthe engineoil. Reinstallthe drain plug using

a new wasner.
CAUTION: Do not overtighten tho drain plug.
HOSE
{cont'd)
5-7
vnx.su
*l
(cont'dl
27. Removethe radiatorassembly{see page 1O-4),
8188l engine:
28. Removethe A/C compressor.

a Do not disconnectA/C hoses.
8 x 1.25mm
24 N.m 12.4 kgf.m,
17 tbt.trl
GASKET
Replace.
GASKET
Replace.
SELF.LOCKINGNUT
I x 1.25mm
16 N.m (1.6kgt.m,
12 tbf.ft)
Replace.
8 x '1.25mm
24 N.m t2.4 kgf.m,17 lbl.ftl
29. Disconnectthe heatedoxygensensor(HO2Slconnector, then removeexhaust pipe A.

B'l8Cl engine:
I x 1.25mm
22 N-m 12.2 kgf.m, '16 lbf.ftl
I x 1.25mm
24 N.m (2.4 kgf.m,
17 rbt.ftt
Replace.
5-8
30. Removethe shift rod and extensionrod {M/T).
Ho2s
CONNECTOR
SELF-LOCKING
NUT
8 x 1.25mm
1 6 N . m 1 1 . 6k g f . m ,
12 tbl.ftl
Replace.
10 x 1.25mm
54 N.m (5.5 kgl.m,
40 tbt.ttl
Replace.
EXHAUST
PIPEA
SELF
1 0 x 1 . 2 5m m
54 N.m (5.5 ksf.m.4O lbf'ltl
Replace.
vnx.su
SHIFTROD
34. Removethe driveshatls.
31. Remove the shift cable ( A / T ) .
I x 1.25mm
22 f.m 12.2 kgl'rn'
16 tbl.ftl
CAUTION:
a Do not pull on tho ddv$halt, tho CV ioint mav
como apan.
a Uso caro whsn prying out tho assombly.
Pult it slraight to avoid damaging th6 differantial
oil soal or intormodiato shaft dust seal.
SHIFT CABLE
NOTE: Coat all precisiontinished surfaces with

cleanengineoil or grease.Tie plasticbags over the
driveshaftends.
CONTROL
LEVER
SHIFT CAALE
covER
locx usiea
Replace.
6 x 1.0 mm
14 N.m t1.4 kgf.m, 10 lbl'ftl
32. Removethe dampertork.

3 3 . Disconnectthe suspensionlower arm balljointsusing the specialtool. Referto section 18 tor the proper
procedure.
NOTE: Adjust the tool so the iaws are parallelto
each other.
12 x 1.25mm
REMOVER28 mm
oTMAC-S100200
vnx.su
(cont'd)
5-9
(cont'd)
35. Lower the hoist.
36. Attach the chain hoist to the engine.
I
I
I
vnx.su
37, Removethe left and right front mounts and brackets.
39. Removethe side enginemounr.

1 0 r 1 . 2 5m m
Replace.
WASHERS
Replace.
SIDE ENGIITE
MOUNTBOLT
LEFT FRONT
MOUNT
12 t 1.25nn
59 N.m {6.0 kgt.m,
43 lbf.trl
Replace.
40. Removethe transmissionmount

TRA SM|SS|OI{
MOUNT
MOUNT/BRACKET
38. Removethe rear mount bracket,
1 2 r 1 . 2 5m m
59 N.m (6.0
Replace.
43 rbf.ftl
REARMOUNT
12 r 1.25m|n
59 N.m {6.0 kgt.m,
43 tbt.frl
Replace.
41. Checkthat the engineis completelyfree of vacuum

hoses, fuel and engine coolant hoses, and electrical
wi.ing.
42. Slowly raisethe engineapproximately150 mm (6
in), Check once againthat all hosesand wires are
disconnected from the engine
43. Raisethe engineall the w8y and removeit trom the
car.
14 x 1.5 mm
118 t{.m (12.O kgt.m,86.8 lbl.ft}
R6place.
(cont'dl
5-11
vnx.su
SIDE ENGITIE
MOUNT
5-12
vnx.su
Install the engine side mount, then tighten the

bolt/nutson the engineside. Leavethe mount bolt
loose.
Engine Installation
Installthe enginein the reverseorder of removal.
Reinstall
the mountbolts/nutsin the followingsequence.
Failureto tollow theseproceduresmay causeexcessive
noise and vibration,and reducebushinglife.
1.
10 x 1.25mm
52 N.m {5.3 kgf.m,
38 rbf.Itl
Replace.
Install the transmissionmount, then tighten the

side.Leavethe mount
bolt/nutson the transmission
bolt loose.
A/T:
12 x 1.25mm
64 N.m (6.5 kgt.m,
47 rbf.ft)
3.
Tightenthe mount bolt on the transmissionmount.
A/T:
M/T:
1 2 x 1 . 2 5m m
64 N.m 16.5 kgl.m,
47 tbt.frl
1 2 x 1. 2 5 n n
74 N.m (7.5 kgl.m,
54 rbf'ftt
M/T:
1 2 x 1 . 2 5m m
74 N.m (7.5 kgt.m,
54 tbt.ftl
{cont'd)
5-13
vnx.su
(cont'dl
4.
Tightenthe mount bolt on the side enginemount.
6.
Installthe right front mount/bracket,then tighten the

bolts in the numberedsequenceas shown (O-@).
' 1 . 2 5m m
@ 10 x
44 N.m (4.5 kgt'm,
33 tbt.fr)
A/T:
m'
.tE
12 x 1.25mm
74 N.m (7.5 kgf.m,
54 lbt.ttl
O 12 x 1.25mm
64 N.m 16.5 kgt.m,47 lbf.ftl
Replace.
5.
Installthe rearmount bracket,then tightenthe bolts

in the numberedsequenceas shown {@ @).
M/T:
@
' 1 0x 1 . 2 5 m m
44 N-m (4.5 kgf.m,
@ 12 x 1.25mm
59 N.m {6.0 kgf'm, 43 lbl'It)
Replace.
12 r 1.25mm
59 .m 16.0 kgl.m,
vnx.su
O 1 2 x 1 . 2 5m m
83 N'm (8.5 kgf.m,61 lbt.frl
Insrallthe left front mount,then tightenthe bolts in

the numberedsequenceas shown (O-@),
a Check that the sp.ing clip on the end of each

driveshaftclicks into place.
GAUTION: Uso oow spring clips.
O 12 x 1.25 ]n]n
83 N.m 18.5kst.m,61 lbt.ftl
Replace.
@ 1 2 r 1 . 2 5m m
59 N.m {6.0 kgl.n,
43 tb{.ftl
Replace.
a Bleedair trom the coolingsystem at the bleedbolt

with the heatervalve open (see page 10-5).
a Adjust the th.ottle cable (see section 1 1).
a Check the clutch pedaltree play lsee section 12).
a Check that the transmission shifts into gear
smoothlv,
a Adiust the tension of the following drive belts.
Alternatorbelt {se section 23).
P/S pump belt {see section 17).
A/C comoressorbelt (seesection 22).
a Inspecttor fuel leakage(see section 1 1).
. After assemblingfuel line parts, turn on the ignition switch (do not operate th starter) so
that the Juelpump operatesfor approximatlV two secondsand the tuel line pressurizes.
Repeatthis operation two or three times and
check for fuel leakageat any point in the fuel
line.
@ 1 0 r 1 . 2 5m m
44 N.m (4.5 kgf.m, 33 lbt.ftl
(cont'd)
5-15
k-
vnx.su
Mount/BracketTorque
Mount and BracketEolts/NutsTorque Valve Specification:
il
TRANSMISSION
MOUNT:
I
I
vnx.su
SIDEENGINE
MOUNT:
Torqus Spocifications:
A : 1 0 x 1 . 2 5m m
59 N.m (6.O kgf.m, 43 lbf.ft)
B: 12 x 1.25 mm
59 N.m {6.0 kgt.m. 43 lbt.ft}
Reolace.
C: 14 x 1.5mm
1 1 8 N . m { 1 2 . Ok g t . m , 8 6 . 8 l b t . t t }
Replace.
D: 12 x 1.25 mm
74 N.m {7.5 kgf.m, 54 lbf.tt}
E : 1 2 x 1 . 2 5m m
64 N.m (6.5 kgf.m, 47 lbf.ftl
F: 10 x 1.25 mm
52 N.m {5.3 kgl.m, 38 lbt.ft}
Replace.
G : 1 0 x 1 . 2 5m m
rt4 N.m (4.5 kgf.m, 33 lbf.ft)
H : 1 2 x 1 . 2 5m m
83 N.m (8.5 kgt.m. 61 lbl.ft)
l r 1 2 x 1 . 2 5m m
64 N.m (6.5 kgf.m, 38 lbf.tt)
Reolace.
LEFTFRONTMOUNT:
/>
{cont'd)
5-17
vnx.su
Mount/BracketTorque
(cont'd)
ALTERNATORBRACKET
REARSTIFFENER
10 x 1.25mm
'1.25mm
M/T: 12 x
57 N.m 15.8 kgf'm,
42 rbf.ft)
A/T: 10 x 1.25mm
/14 N.m {4.5 kgf.m,
32 tbt.ftl
8x1.25mm
24 N.m 12.4 kgf'm,
17 tbt.ftt
SIDEENGINEMOUNT
BRACKET
lO r 1.25mm
54 N'm (5.5 kgl.m,
40 tbf.ft)
P/S PUMP BRACKET

1 0 x 1 . 2 5m m
44 N.m (4.5 kgf'm, 33 lbf'ft|
FRONTSTIFFENER
(B18Cl enginonlyl
t-*i;
f--^,c*;"*".*l q
I
-4M
5-18
Ghinein"onvt
ddv
' 1 1N . m ( 1 . 1 k g l ' m , 8 O l b f ' t t )
'12 x 1 .25 mm
57 N.m 15.8 kgt.m,
42 tbf.fr)
8 x 1.25mm
24 N.m (2.4 kgf.m,
17 tbf.ft)
HEAT
INSULATOR
(818C1
10 x 1.25mm
44 N.m {4.5 kgf.m,
33 rbr.ftt
10 x 1.25mnl
44 N.m (4.5 kgf.m,
33 rbr.tt)
vnx.su
CylinderHead/ValveTrain
8 1 8 8 1engine
.............6-2
SpeciafTools
Valve Clearance
............6-3
Adiustment
ValveSeals
Replacement(cylinderhead
removalnot required) .....................
6-5
......6-27
Reconditioning
gelt
Timing
6-7
lllustratedIndex ...............................
..............
6-9
Inspection
6-9
TensionAdiustment ........................
.................6-10
Removal
.............6-12
Installation
CrankshaftPulleyBolt
.........6-8
Replacement
vnx.su
SpecialTools
-
t
Ref.No.
o
o
07GAD- PH70100
07JAB- 001020A
OTMAB_ PY3O1OA
07757- PJ10toA
07947- 6570100
07984- 657010C
@
@
Oty
Ocacription
Tool Numbrr
ValveGuidelnstaller
HolderHandle
PulleyHolderAttachment,HEX50 mm,
Offset
ValveSpringCompressorAttachment
ValveGuideDriver,6.6 mm
ValveGuideReamer,6,6 mm
I
o
e:=-4-b4altltgt
r-l-:ff:-b
vnx.su
Prgc R.terencc
1
1
6-8
1
1
1
1
6-8
6-22
6-25,26
6-26
ValveClearance
Adjustment
Set the No. 1 piston at top dead center(TDC)(see
p a g e6 - 1 2 ) ." U P " m a r k o n t h e p u l l e ys h o u l db e a t
the top, and the TDC grooveson the pulley should
align with the TDC groove on timing belt back
cover.TDC mark (paintedwhite) on the crankshaft
pulley should align with pointeron the timing belt
towercover.
NOTE:
. Valves should be adjustedcold; at a cylinder head
temperatureof lessthan 100'F(38"C).
Adjustmentis the same for both intakeand exhaust
valves.
. After adjusting,retorquethe crankshaftpulleybolt to
177N.m (18.0kgim, 130lbf.ft).
2.
1.
Number 1 Diston at TDC:
Removecylinderheadcover.
ADJUSTINGSCREWLOCATIONS:
"UP" MARKS
INTAKE
TDCGROOVES
EXHAUST
TDCMARKS
lPeintedwhitel
CRANKSHAFT
PULLEY
6-3
vnx.su
ValveClearance
Adjustmentlcont'dl
a
Adjustvalveclearances
on No. 1 cylinder.
7.
lntlkc: 0.08- o.l2 mm (o.(Xxl- 0.qr5 in)

Exhru3t 0.16- 0.20 mm {0.0,05- 0.008in}
4.
Loosen lhe locknut and turn the adjusting screw

until feelergaugeslidesbackand fonh with a slight
amountof drag.
R o t a t et h e c r a n k s h a f t1 8 0 ' c o u n t e r c l o c k w i s t o
bring No. 4 piston to TDC.The'UP" mark should
be pointing straight down. Adjust valves on No. 4
cylinder.
Numbr il piston at TDC:
LOCKNUT9x0.?5mm
25 N.m 12,5kgf.m, 18lbt'ft|
"UP'MARKS
Tightenthe locknutand recheckclearanceagain.

Repeatadjustment if necessary.
6.
Rotate ths crankshaft 180" counte.clockwise

(camshaftpulleyturns 90'). The "UP" mark should
be on the exhaustside.Adjustvalveson No. 3 cylinder.
I{umbcr 3 pidon !t TDC:
8.
Rotate the crankshaft 180' cou nie rclockwise to

bring No. 2 piston to TDC.The "UP" mark should
be on the intakeside.Adjust valveson No. 2 cylinoer.
Numbor 2 pirton !t TDC:
-UP" MARKS
.UP' MANKS
EXHAUST CAITISHAFT
PULI,IY
INTAKECAMSHAFT
PULLEY
vnx.su
NOTE:Referto page6-31when installingcylindorhEEd

cover.
ValveSeals
(cylinderheadremovalnot requiredl
Replacement
NOTE: Cylinder head removal is not required in this
procedure.
The procodureshown below applieswhen usingthe inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h
Y AAA$-2A 718"attachment).
whcn u3ing this tool, a: with any tool,
@@
always u! agproved cyr Protcction. Using th.
right tool for cach iob hclps incraa3. produstivity
whilo 3ltrgu8rding tool!, cquipmcnt lnd the u3c1'
1. Turn the crankshaftso that the No. I and the No' 4
pistons are at top dad center (TDC).
Positionthe pistonat TDCand insertan air adaptor

into th spark plug hole. Pump air into the cylinder
to keepthe valvclosedwhile cgmpressingsprings
and removing the valve keepers.
Position the lever arm under the cross shaft so the
lever is psrpendicularto the shEft and ths compressor attachment rests on toD of the rstainer for th
spring being compressed.Use the rear position slot
on the leveras shown.
NOTE: Put shop towels over the oil passagsto
preventthe valve keepersfrom falling into the cylinder had.
2.
Removethe cylinderheadcover.
3.
Removethe distributor.
4.
Loosen and disconnectthe timing belt from the

c8mshaft pulleys.
5.
Select the 7E in. diameter long compressor attachment and fasten the attachmentto the No. 4 hole of
the leverarm with the speedpin supplied.
OIL PASSAGE
Removethe camshaft holde, bolts, then rmove the

camshaft holder,the camshaftand rocksr arms.
lntakc V!lv6 Sclls

6. Usingthe 6 mm bolts suppliedwith the tool, mount
the two up.ights to the cylinder head 8t the end
camshaftholde.s.The uprightsfit as shown.
7.
Insortthe cross shaft through the bottom hole ot

the two up.ights.
OIL PASSAGES
(cont'd)
6-5
vnx.su
ValveSeals
Replacement(cylinderhead removal not required) (cont'dl
'11.
Using a downward motion on the lever arm. compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring.
21. Positionthe lever arm unde. the crossshaft so the

lever is perpendicular
to the shaftand the compressor attachmentrests on top of the retainerfor the
spring beingcompressed.Usethe rear positionslot
on the leveras shown.
Repeatstep l1 for the othervalvein that cylinder.

N O T E :P u t s h o p t o w e l s o v e r t h e o i l p a s s a g e st o
preventthe valvekeepersfrom fallinginto the cylinder head.
Removethe valveseals(seepage6-22).
'14. Installthevalve
seals(seepage6-23).
OIL PASSAGE
Installthe springs,the retainersand the keepersin

reverseorder of removal.
16. Repeatsteps9 to l5 for the otherthreecylinders.
ExhaGt Valvs Soals
17. Usingthe 6 mm bolts suppliedwith the tool, mount
t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
camshaftholders.The uprightsfit as shown.
18. Insert the cross shaft through the bottom hole of
the two uprights.
Using a downward motion on the lever arm, compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring.
1 9 . Selectthe 7/8 in. diameter short compressorattachment and fastenthe attachmentto the No. 4 hole of
the leverarm with the speedpin supplied.
20. Positionthe pistonat TDCand insertan air adaptor
into the spark plug hole. Pump air into the cylinder
to keepthe valveclosedwhile compressingsprings
and removingthe valvekeepers.
Repeatstep22 for the othervalvein that cylinder.

Removethe valveseals(seepage6-22).
Installthe valveseals(seepage6-23).
Installthe springs,the retainersand the keepersin
reverseorderof removal.
27. Repeatsteps20 to 26 on the otherthreecylinders.
NOTE:Relerto page 6-31when installingcylinder
neaocover.
vnx.su
Timing Belt
lllustratedIndex
NOTE:
. Referto page6-12for positioningcrankshaftand pulleybeforeinstallingbelt.
. Mark the direction of rotation on the belt before removing.
. Replacethe rubbersealstor oil leakagbetweenthe cylinderheadand cover.
a Do not uss the middle cover and lower cover for storing itsms disassembled.
. Cleanthe middlecoverand lowercover beforeinstallation.
CAPNUT
6xl.0mm
9.8N'm (1.0kgf.m,7.2lbtft) WASHER
\o
Replacowhen damaged
or deteriorated.
CYLINDERHEADCOVER
Referto pago6-31when
installing.
RUBBERSEALS
Replacewhen damaged
or deleriorsled.
8 x 1.25mm
37 N.m 13.8kgl.m,27 lbf'ft)
BACK OOVER
AD.'USTINGBOLT
10x t.25mm
5/rN.m15.5kgl.m,,o lbtft)
Foradjustrnent
only,
do not rmove,
COVER
6x1.0mm
9.8 N'm (1.0kg{.m.t.2 lbf.tt}
6x1.0mm
9.8 N,m 11.0kg{.m,
7.2 lbl.frl
TIMIMi BELT
Inspection,page 6-9
Adlustment,pago 6-9
page6"10
Replacement,
ALTERNATOR
BELT
Adjustm6nt,
Soction23
lnstallwithconcave
surfacefacing in.
Clean.
TIMINGBELT
DBIVEPULLEY
Removeany oil
and clean,
LOWEn
COVER
lnstall with concave
surfacefacing out,
Removeany oil
ano ctean.
NOTE:When installinga new crankshaftand/ornew bolt:

O tightenthe crankshaftpulleybolt to 196N'm (20.0kgf'm,145lbf'ft),
O loosenbolt,
O retightenit to 177N.m (18.0kgt.m,130lbf'ftl.
CRANKSHAFT
PULI"EY
Romov6any oil
and clgaaon thg
timing bolt guide
plato side.
BOLT
'14x 1,25mm
lt7 t{.m 118.0kgl.m, 130lbtftl
Replacsmenl,page 6-8
6-7
vnx.su
CrankshaftPulleyBolt
It
Replacement
NOTE:
. Crankshaftpulleybolt sizeand torquevalue:
1 4x 1 . 2 5m m
177N.m (18.0kgt.m.130lbf.ft)
. When installinga new crankshaftand/or new pulley
bolt:
When installingthe bolt, lubricatethe threads and

flangwith enginoil, but don't lubricatethe washe.
and pulley.
Q tiglten the pulleybolt to 196 N.m (20.0kgf.m,145

tbnft).
O loosenthe bolt,
O retightenit to 177N.m (18.0kgf'm.130lbf.ft).
Don't lubricatwasher.
HOI-DERHANDII
o'JAB -oo1020A
PULI.TY HOI.I'R ATTACHi'ENT,

HEX50 mm. OFFSET
- PY3010A
19 mm
SOCrETWRENCH,
AVAILABI.I
COMMERCI,ALLY
vnx.su
Timing Belt
TensionAdjustment
Inspection
CAUTION: Always Ediust timing belt tonsion with tho

cngin. cold.
.
Relerto page6-3'lwhen installing.
Inspectthe timing belt for cracksand oil or coolant

soaking.
NOTE:
. Replacethe belt if oil or coolantsoaked.
. Rsmove any oil or solvent that gets on the belt.
NOTE:
. The tensionetis spring-loadedto apply proper tension to the belt automaticallvaftermakingthe following adjustment.
. Always rotate the crankshaftcounterclockwisewhen
viewed trom the pulley side Rotating it clockwise
may result in improper adjustmentot the belt tension.
R e m o v et h e c y l i n d e rh e a d c o v e r . ( R e f e rt o p a g e
6-31when installing.)
Setthe No. 1 pistonat TDC(seepage6-12).
3. Rotatethe c.ankshaft5 - 6 revolutionsto set the

bslt.
4.
Setthe No. I pistonat TDC.
ADJUSNNGBOLT
54 N.m (5.5kqf.m,
a0 rbr.ftl
Foradiustmentonly,
do not remove,
Rotatepulley
and inspscrbell.
ol
Direction
rolatlon.
After inspecting,retorque the crankshaftpulley bolt

to 177N'm ('18.0kgf'm,130lbt'ft).
5.
Loosenthe adiustingbolt 1/2turn (180')onlv
6.
3-teethon
Rotatethe crankshaftcounterclockwise
the camshaftpulley.
7.
Tightenthe adjustingbolt to the specifiedtorque.
8.
After adjusting,retorquethe crankshaftpulley bolt

to 177N.m (18.0kgl.m.130lbf.ft).
6-9
vnx.su
Timing Belt
Removal
NOTE:
. Turn the crankshaftpulley so the No. 1 piston is at
top d6ad center (TDC)before removing the belt (see
page&12).
a Inspectthe water pump when removed the timing
bolt {see page 10-9}.
1.
Removethawhelwellsplashshield(seepage6-18).
2.
Loosen ths adjusting bolt and mounting bolts, then

remove the power steering {P/S)pump belt.
4,
Loosenthe adjusting nut and mounting nut, then

removethe altrnatorbelt.
ADJUSNNGNUT
8 x 1.25mrr
2a N.m l2.a lef.m,
17 rbl.ftl
AA,USNNG
MOUNTINGNUT
10x 1.25mm
a,lN.m{4.5kgl.m,33lbfftl
MOUivNNGBOLTS
8 x 1.25mm
2aN.m12.4kgf.m,17 lbtfrl
Removethe cruisecontrolactuator(seepage6-18).
Loosenthe adjustingbolt and idler pulley bracket

bolt, then remove the air conditioning(A,/C)comoressorbelt.
EELT
Removethe sid6snginemount.
10x 1.25mm
52N.m{5.3kgr'm,38lbtft}
Replace.
ADJUSTING
IDLERPUI.IEYBRACKET
BOLT
l0 r 1.25mm
a/aN.m{1.5kgf.m.33lbf'ft}
12 x 1.25mm
74 N.m 17.5kgt m,
s4 tb{.ftl
vnx.su
1.
8.
10. Loosenthe adjustingbolt 180'.

1'1. Pushthe tensionerto removetensionfrom the timing belt,then retightenthe bolt.
12. Removethe timing beltfrom the pulleys.
. Referto page6-31when installing.
Removethe Dulleybolt and crankshaftpulley (see
page6-8).
Removethe middlecoverand the lower cover.
NOTE:
. Do not usethe middlecover and lower coverfor
storingitemsdisassembled.
. Cleanthe middle cover and lower cover before
installation.
CAPNUT 6 x 1.0 mm
7.2rbl.ftl
9.8N.m 11.0
WASHER
when damaged
Replace
or
NOTE:Pushthe tensionerpulleyto
loosenthe belt.
CYLINDEFHEAD
COVER
Reterto page 6-31when
installing.
ADJUSTINGBOLT
10 x 1.25mm
54 N.m 15.5kg{.m,
/r0 lbf.ftl
For adjustmentonly,
TIMINGBELT
Adiustment,Page6I
MIDOLECOVER
6x1.0mm
9.8 N.m 11.0kgJm, 7.2 lblftl
KE
6x1.0mm
9.8 N.m ('1.0kgt.m,7.2 lbl fr)
RemoveanYoiland clean
LOWEB@VER
NMING BELT
GUIOEPLATE
lnstallwithconcave
surfacefacingout.
and clean.
6x1.0mm
9.8N.m (1.0kgtm,7.2lbt'ftl
PULLEY
CRANKSHAFT
Removeany oil
and cleanon ihe
timing beltguide
platesido.
6-11
vnx.su
Timing Belt
Installation
Installthe timing belt in the revorceorderof removal;
Only key points are describedhere,
NOTE:Clanthe middle cover and lower cover before
installation.
L
Position the crankshaftand th camshaft pulleys as

shownbeforeinstallingthe timing belt.
A. Set the crankshaftso that the No. 1 oiston is at
top dead center (TDC).Align the g.oovo on the
teth side of the timing belt d.ive pulleyto the O
pointeron the oil pump.
L Align the TDC marks on intakeand exhaustpultevs,
2.
NOTE: To set the camshafts at TDC position for

No. 1 piston, align the holes in the camshafts
with the holes in No. l camshaft holders and
insert5,0 mm pin punchesin the holes.
PIN PUNCHES,5.0 mm
TDCmark align6d with the

pointer on backcover,
TDC MARK
6-12
vnx.su
lnstall the timing belt tightly in the sequence

snown.
O t i m i n g b e l t d r i v e p u l l e y { c r a n k s h a f t )+ @
A d j u s t i n gp u l l e y * @ W a t e r p u m p p u l l e y - @
Exhaustcamshaftpulley+ @ Intakecamshaftpullev.
CylinderHead
lllustratedlndex
CAUTION: To avoid damaging the cylind6r hoad, waii until ongin coolant temporature drop3 below lOO"F(38"C)bfore
rsmoving it.
NOTE:Use new O ringsand gasketswhen reassembling.
CAPNUT 6 x 1.0mtn
9.8 N.m 11.0kgtm,7.2lbtftl
et
CYLINDERHEAD
COVER
Referto page6-31when
installang.
I x 1.25mm
22 N.m 12.2kgt.m,
16 rbf.ft)
RUBBER
SEAL
Replace
whendamaged
or doteriorated.
INTAKECAMSHAFTHOI.DER
I x 1.25mm
24 N.m12.4kgf.m,-.\
--_r,_
17rbt.tr)
Seesection
__.|._
O-RING
Roplace.
EXHAUSTCAMSHAFT
HOI.DER
RUBBERCAP
Replacefor oil
leakage.
EXHAUST
CAMSHAFT
LOCKNUT
25 N.m {2.5kgf.m,
18 tbtfiJ
6x1.0mm
9.8 N.m {1.0kgl.m,7.2lbf.ft)
INTAKECAMSHAFT
Inspection,page5-21
6tal
SEAL
page6-30
Installation,
Replace.
--,
ffi;r
KEY
/
"
'@
SEAL
Replace.
@6
I x 1.25mm
37 N.m (3.8kgt.m,
27 rbtftt
ROCKERARM
CAMSHAFTPULLEYS
Removal,page6 19
page6,30
Installation,
8 x 1.25mm
37 N.m 13.8kg{.m,27 lbfftl
vnx.su
CAUTION: In h.ndling r m.t!l gr3kct, trko clrc not to fold it or dlmaga tho contact surfacr ol thr gaskat.
CYUNDEBHEAD
BOLT
&t N.m 18,5kgl'm,
61 tbf.ftl
Applyengineoilto
the threads.
VAIVE XEEPERS
SPRING
\n
\.\...i6
RETAINER
r*#:-3
STEMSEAL
--------ig
VALVEKEEPERS
I
JI
--../
ENDPIVOTBOLT
6:tN.ml6.akst'm,
,16lbl.ftl
ED..$---S---.----
VALVE SPRING
SEAT
SPf,ING RETAINEB
nrAxE vaLvESPRING
twtAKEvALvESTEMSEAL
sEAT
valvE SPRING
INTAKE VAI-VE GUIT'E
Inspction,pago S24
R6placom6nt,pago 6-25
Reaming,pag6-26
EXHAUSTVALVE
GUII'E
CYUNDERHEAD
Warpage,page6-28
DOWELPIN
TX)WELPIN
CYLINDERHEAD GASKET
{3 LAYERSOF METALI
Reolac6.
EXHAUSTVALVE
INTAKE VALVE
Replacement,Page6_22
O.RING
Replac.
OIL CONTROL
ORIFICE
Clean.
6-15
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GylinderHead
Removal
Engineremovalis not requiredfor this procedure.
5,
Removethe intakeair duct.
CAUTION: To avoid damaging tho cylinder head, wait

until tho ongino coolant temporature drops bolow 100"F
{38"C)beforo loo36ningthe rotainin0 bolts.
NOTE:
. Inspectthe timing belt before removingthe cylinder
neao.
. Turn the crankshaftpulleyso that the No. 1 piston is
at top deadcenter(TDCI(page6-12).
. Markall emissionshosesbeforedisconnecting
them.
. Anti-theftradioshavea codedtheft protectioncircuit.
Be sureto get the customer'scode numberbefore.
- Disconnectingthe battery.
- Removingthe No. 32 (7.5A) fuse irom the underhood fuse/relaybox.
- Removingthe radio.
After service,reconnectoowerto the radioand turn it
on.
When the word "CODE"is displayed,enter the customer's5-digitcodeto restoreradiooperation.
1.
Disconnect
the negativeterminalfromthe battery.
2.
Drainthe enginecoolant(seepage 10-5).

.
3.
Removethe radiatorcapto speeddraining.
Relievefuel pressure(seeSection11).
Do not smoke whils working on tusl
@
systom, keep opon flame or spark away trom work
area.Drain fuol only inlo an approvod containsr.
4.
Disconnect
the fuel feed hose.
SERVIC
BOLT
WASHERS
Replace.
vnx.su
Removethe breatherhose,water bypasshose and

evaporativeemission(EVAP)controlcanisterhose.
Removethe fuel returnhoseand positivecrankcase

ventilation(PCV)hose.
9 . Removethe throttlecable.
1 0 . Removethe throttlecontrolcable (automatictransmissiononly).
NOTE:
. Takecare not to bend the cablewhen removing
one.
. Adjust the throttlecableand throttlecontrol
cablewhen installing(seesection11 and 14).
CONTROL
THROTTLE
CABLE
HOSE
R e m o v et h e b r a k e b o o s t e rv a c u u m h o s e , w a t e r
bypasshoseand vacuumhose.
ERAKEBOOSTER
VACUUM HOSE
VACUUM HOSE
ATI'USTING
1 1 . R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r sa n d
wire harnessclampstrom the cylinderheadand the
intakemanifold.
a Fourfuel injectorconnectors
a Intakeair temperature(lAT)sensorconnector
a Engine coolant temperature(ECT)sensor con-
a
a
a
a
a
a
necror
sensor connector
TDC/CKP/CYP
lgnitioncoil connector
ECTgaugesendingunit connector
Throttleposition(TP)sensorconnector
Manifold absolute Dressure(MAP) sensor connector
ldle air control(lAC)valveconnector
EVAPpurgecontrolsolenoidvalveconnector
HOSE
(cont'dl
6-17
vnx.su
CylinderHead
Removal(cont'dl
12. Rmovethe spark plug caps and distributorfrom
the cvlinderhead.
Removethe upper radiatorhose, heaterhose and
water bypass hose.
15. Removethe enginegroundcable.

Removethe adjustingbolt and mountingbolts,then
remove the power steering (P/S)pump belt 8nd P/S
pump.
.
Do not disconnectthe P/Shoses.

ADJUSTING
BOLT
WATER BYPASS
6x1.0mm
9.8 N.m 11.0tgfm,
7.2 tbf.ftl
UPPERRAI'IAYOR
8 x 1.25mm
24 .m (2.akstm, 17lbf.ftl
P/S PUMP
Remov the air conditioning (Ay'Clcompressor belt

(seepags 6-10).
14. Removeth6 solashshield.
1 7 . Rmovethe alternatorbelt (seepage6-10).
t 8 Ramovethe cruisecontrolactuator.
8 x 1.25mm
2a N.m 12.4kgt m,
9.8 N.m {1.0 kgt m.

t.2 tbr.frt
sHtEut
ACTUATOR
vnx.su
Removethe timing belt (seepage6-10).
19. Removethe sideenginemount.

10 x 1.25mm
52 N.m (5.3 kgt'm, 38 lbf'ft)
WASHERS
Removethe camshaftpulleysand backcover.

SIDEENGINE
MOUNT
12 x 1.25mm
74 N.m {7.5kgf.m,
5{ rbtftl
BACKCOVER
20. Removethe cylinderheadcover.

23. Removethe exhaustmanifold.
CYLINDEBHEAD
NUT
SELF.LOOKING
8 x 1.25mm
BRACKET
(cont'd)
6-19
vnx.su
CylinderHead
Removal(cont'dl
2,0. Removethe intakemsnifold.
Removethe camshaft holder bolts, then remove the

camshaftholde.s.camshaftsand rockerarms.
GASXET
IMTAXEMANIFOLD
25. Loosenthe locknutsand adiusting screws.
27. Removethe cylinder head bolts. then remove the

cvlindsrhead.
CAUTION: To preyant warpago. unlcr.w thc bolt3
in laquoncc 1/3 turn at I tim6; .apeat the $qurnca
until sll boltr arc loosrncd.
ADJUSNNG SCNEWLOCATN)NS:
CYLINOER
HEADBOLTSLOOSENINGSEOUENCE
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Camshafts
Inspection
1 0 . Removethe camshaftholders.Measurethe widest

ponion of plastigageon eachjourna..
1.
Loosenthe adjustingscrews.
2.
Removethe camshaftholdersand the rockerarms

NOTE: Mark the rockerarms before removing
them.
Camshaft-toHolder Oil Clearance:

Standard lNewl: 0.039- 0.069mm
(0.0015- 0.0027in)
0.15 mm {0.006inl
SarvicoLimit
R e i n s t a ltl h e c a m s h a f ta n d h o l d e r s .T i g h t e nt h e
camshaftholderbolts in a crisscrosspattern,beginningwith the innerbolts.
9.8 N.m (1.0kgf.m,7.2lbf.ft)
PLASTIGAGE
Seatthe camshaftsby pushingthem towardthe distributorend of the headwith a screwdriver.

Z e r o t h e d i a l i n d i c a t o ra g a i n s tt h e e n d o f t h e
camshaft. push the camshaft back and forth and
readthe end play.
Camshalt End Play:
St.ndard lNow):0.05- 0.15mm
(0.002- 0.006inl
Seivice Limit: 0.5 mm {0,02in)
11. lf camshaft-to-holderoil clearanceis out of toler
ance:
. And the camshaft has already been replaced,
vou must replacethe cylinderhead.
. lf the camshafthas not beenreplaced,first check
total runout with the camshaftsupportedon Vblocks.
Clmshaft Total Runout:
StEndard{New): 0.03 mm (0.001inl max'
ServicoLimit: o.Oilmm {0.002inl
Removethe camshaftholderboltsfrom the cylinder

head.
N O T E : U n s c r e wt h e c a m s h a f th o l d e r b o l t s t w o
turns at a time, in a crisscrosspattern.
Lift the camshaftsout ot the cylinder head. wipe
them clean,then inspectthe lift ramps.Replacethe
camshaftif any lobes are pitted, scored,or excessrvelyworm
Cleanthe camshaftjournal surfacesin the cylinder
head,then set the camshaftback in place.Inserta
plastigagestrip acrosseachiournal.
Installthe camshaftholdersand torquethe boltsto
the valuesand in the sequenceshownon page6-30.
NOTE:Do not rotatecamshaftsduring inspection.
lf the total runout of the camshaftsis within tolerance,replacethe cylinderhead.
lf the total runout is out of tolerance,replacethe

camshaftsand recheck.lf the oil clearanceis still
out of tolerance.replacethe cylinderhead.
6-21
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Valves,Valve Springs and Valve Seals

Removal
N O T E : l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e
removedso that eachitem can be reinstalledin its oriqinal Dosition.
1.
Tap eachvalve stem with a plasticmalletto loosen

valve keepersbeforeinstallingthe spring compressor.
2. lnstallthe springcompressor.Compressspring and

removevatveKeeper.
VALVESPRINGCOMPRESSOR
xo No.3tB. whh r35 JAW o.
07757- PJ10r0A
Installthe special tool as shown.
Remove the valve seal.
COMMERCIALLY
AVAILABLE
VALVEGUIDESEALREMOVER
LISLEP/N 5t9d) or KO3350
SEAL
REMOVER
lntaks Valvo Dimonsions

A Standard(New): 30.90- 31.10mm
- 1.221inl
|.1.217
(Nowl:
I Standard
103.80- 10'1.10mm
{4.087- 4.098inl
C Standard lNow):
6.580- 6.590mm
{0.2591- 0.259/rin}
C ServicoLimit
6.55 mm (0.258inl
D Standlrd (Nw): 1.35- 1.65mm
10.053- 0.065inl
D SsrviceLimit:
1.15mm (0.045in)
Exhau3tValve Dim6nsions
A Standard {New): 27.90- 28.10mm
- 1.106inl
11.098
(Newl:
B Standard
104.00- 104.30mm
(4.094- 4.106inl
C St.ndard (New): 6.550- 6.500mm
10.2579- 0.2583inl
C ServicoLimit
6.52 mm (0.257in)
D Standard{New): 1.65- 1.95mm
- 0.077inl
10.065
D ServiceLimit:
1.,[5mm (0.057in)
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InstallationSequence
NOTE:Exhaustand intakevalvesealsate NOTinterchangeable.
@/.-uo.**.r..",
NOTE: Placeth 6nd oI valve
springwith closelYwoundcoils
towrrd th cylinder head.
SPRNG NETAINER
EXHAUSTVALVESEAL
{8LACKSPRING}
Replace.
@*_-.tt*
NOTE:Installthv6lvospringsats
beforo instsllingthe valv6 sesls.
PLASTICMALIIT
6-23
.tIF"F-
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Valves,ValveSpringsand
ValveSeals
ValveGuides
ValveMovement
Valvelnstallation
W h e n i n s t a l i i n gv a l v e s i n t h e c y l i n d e r h e a d ,c o a t
valve stemswith oil beforeinseningthem into valve
guides, and make sure valves move up and down
smoothlv.
When valvesand springsare in place,lightlytap the
end of each valve stem two or three times to snsure
properseatingof valvesand valve keepsrs(use plastic mallet).
NOTE:Tap the valvestem only along its axis so you
do not bendthe stem.
Measurethe guide-to-stem
clearancewith a dial indicator while rocking the stem in the direction of normal
thrust (wobblemethod).
lntake Valve Stsm-to-GuideClearance:
Strndlrd (Newl:0.0i1-0.10mm
(0.002- 0.004in)
Ssrvicc Limit: 0.16 mm {0.006in)
Exhsust Valye Stom-to-GuideClearance:
Standard{Nw):0.10- 0.16mm
{0.0O'l- 0.006in)
Slrvica Limit: 0.22 mm {0.000in)
Valveextended10 mm out from seat
PLASNC MALI.IT
lf measurementexceedsthe service limit, recheck

usinga new valve.
l f m e a s u r e m e n ti s n o w w i t h i n t h e s e r v i c e l i m i t ,
reassembleusinga nw valve.
l f m e a s u r e m e n st t i l l e x c e e d sl i m i t , r e c h e c ku s i n g
a l t e r n a t em e t h o d b e l o w . t h e n r e p l a c ev a l v e a n d
guide, if necessary.
?ur
NOTE:An alternatemethod of checkingguide to stem

clearanceis to subtractthe O.D.of the valvestem, meas u r e d w i t h a m i c r o m e t e r .f r o m t h e l . D . o f t h e v a l v e
g u i d e , m e a s u r e dw i t h a n i n s i d e m i c r o m e t e ro r b a l l
gauge.
Takethe measurementsin three placesalong the valve
stem and three placesinsidethe valveguide.
The diiferencebetweenthe largestguide measurement
and the smalleststem measurementshould not exceed
the servicelimit
lntake Valve Stom-to-GuideClearance:
Standard (Newl: 0.02- 0.05 mm
(0.001-0.002in)
0.08 mm (0.003in)
ServiceLimit
ExhaustValve Stom.to.Guid Clearanco:
Standard (Newl: 0.05- 0.08 mm
(0.002- 0.003inl
Srrvico Limit
0.ll mm 10.00'tinl
6-24
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Replacement
1. As illustrated in the removal steps of this proceair-impactdrivdure, use a commercially-available
er attachmentmodified to fit the diameter of the
valve guides. In most cases.tho same procedure
c a n b e d o n e u s i n g t h e V a l v e G u i d e D r i v e ra n d a
conventionalhammer.
-----T_|
sz-12.21i^l
Working from the camshaft side. use the driver and

an air hammerto drive the guide about 2 mm {0.1
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
knock oft some of the carbon and make removal
eaSrer.
GAUTIOiI:
o Alwrys woar safety goggles or a face shiold
wh6n using tho Eir hammer.
. Hold ths air hammsr directly in lins with the
vrlvr guidc to prsvont damaging tho drivor.
COMMERCIALLYAVAILABI,I
VALVEGUIDEDRIVER
4.
l r l
11.3mm
lo.il,l in)
Turn the head over and drive the guide out towatd
the camshaftside of head.
lf a valveguide still won't move,drill it out with a 8
mm (5/16in) bit,then try again.
CAUTION: Drill guid$ only in oxtremo cases:You
could drmrgo tho cylinder hosd if ths guido br"akr.
RGmov.lrnd In3tlllation
6.6mm
VALVEGUIDEDRIVER,
0?942- 6570100
S e l e c tt h e p r o p e r r e p l a c e m e n tg u i d e s a n d c h i l l
t h e m i n t h e f r e e z e rs e c t i o no f a r e f r i g e r a t o rf o r
aboutan hour.
Use a hot plate or oven to evenly heat the cylinder
headto 300'F(150'Cl.Monitorthe temperaturewith
a cookingthermometer.
VALVEGUIDEDRIVER,6.6mm
07942 - 65701q)
CAUTION:
. Do not use a torch; it may warP the hgad.
. Do not get ths head hottq than 3OO'F1150"C);
excessivehgat may loosn thGvalvs soat3.
. To avoid burns, usa hoavy glov93whon handling
the heated cylinder hoad.
OO
",
O (V /rl
-1-- ) o
one
Removethe new guide{s}from the refrigerator,
at a time, as you needthem.
{cont'd)
6-25
vnx.su
Valve Guides
Reaming
Replacement
{cont'd}
7.
SliDa 6.5 mm {0.25in) stselwashorand the correct

driver attachmentover the end of the driver {The
washer will absorb some of the impact and extend
the life of the driver).
.,F-q-re
t
t
T
It
DRVEn
8,
6,5mm t0.25in)
WASHER
NOTE:For new valveguidesonly.

Coatboth reamerand valveguidewith cuttingoil.
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 t c l o c k w i s ew h i l e
removingit from the bore.
ATTACHMENT
Installthe new guide(s)from the camshaftside of

the head; drive each one in until the attachment
bottomson the head.lf you have 8ll sixteenguides
to do, vou may have to reheat the head one or two
moreI|mes.
Thoroughlywash the guide in detergentand water

to removeany cuttingresidue.
Checkclearancewith a valve(seepage6-24).
.
V e r i f y t h a t t h e v a l v e s l i d e s i n t h e i n t a k e8 n d
exhaustvalveguideswithout exrtingpressure.
REAMERHANDLE
VALVEGUII'E REAMER,6.6 MM
079E4- 667ot0c
Valv6 Guida Instsllod Hcight:

13.75- 14.25mm
lntaks:
(o.sal - 0.561inl
15.75- 16.25mm
Exhru3t:
{0.620- 0.640in}
vnx.su
Valve Seats
Reconditioning
1.
2.
Renewthe valve seatsin the cylinderhead using a

valveseatcutter.
The actualvalve seatingsurface,as shown by the

bluecompound,shouldbe centeredon the seat.
NOTE: lf guides are worn (see page 6-24),replace

them (seepage6-251beforecuttingthe valveseats,
C a r e f u l l yc u t a 4 5 ' s e a t , r e m o v i n go n l y e n o u g h
materialto ensurea smoothand concentricseat.
3.
Bevelthe upper edge of the seatwith the 30ocutter

and the lower edgeof the seatwith the 60' cutter.
Checkwidth of seatand adjustaccordingly.
4.
Makeone more very light passwith the 45"cutterto

removeany possibleburrs causedby the other cutters.
7.
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'
cutterto restoreseatwidth.
l f i t i s t o o l o w ( c l o s e rt o t h e v a l v e e d g e l ,y o u
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 shouldalwaysbe madewith
the 45' cutter.
Insert intake and exhaust valves in the head and

measurevalvestem installedheight
Intako Valve Stem Installd Height:
Standard (New): /$.765 - '11.235mm
- 1.6234in}
{1.604It
inl
ServiceLimit: ill.il85 mm (1.6:133
ExhaustValvo Stem lnstalled Height:
Standard {Newl: ,12.765- i|:|.235mm
11.6a37- 1.1022in1
/B.il85 mm (1.7120inl
ServiceLimit
Valvo Seat Width llntake and Exhaustl:

Standard: 1.25- 1.55mm {0.049- 0.061inl
Servics Limit:2.0 mm 10.08inl
SEAT
WIDTH
After resurfacingthe seat, inspect for even valve

seating:Apply PrussianBluecompoundto the valve
f a c e , a n d i n s e r t v a l v e i n o r i g i n a l l o c a t i o ni n t h e
head,then lift it and snap it closedagainstthe seat
severaltimes.
8.
lf valve stem installed height is over the service

limit, reDlacevalveand recheck.lf still over the service limit, replacecylinder head;the valve seat in
the headis too deeo.
ACTUAL
SEATING
SUBFACE
VALVE
SEAT
PRUSSIAN
6-27
vnx.su
GylinderHead
Installation
oil clearances(seepage 6NOTE:lf camshaft-to-holder

2 1 ) a r e n o t w i t h i n s p e c i t i c a t i o nt,h e h e a d c a n n o t b e
resurfaced.
lf camshaft'to-holder
oil clearancesare within specifications,checkthe headfor warpage.
lf warpage is less than 0.05 mm (0.002in) cylinder
headresurtacingis not required.
lf warpageis between0.05mm (0.002in) and 0.2 mm
(0.008in), resurfacecylinderhead.
Maximum resurfacelimit is 0.2 mm (0.008in) based
on a heightof 132.0mm (5.20in).
PRECISION
STRAIGHTEOGE
Installthecylinderheadin the reverseorderof removal:

NOTE:
. Always use a new head gasket.
. C y l i n d e rh e a d a n d c y l i n d e rb l o c ks u r f a c em u s t b e
ctean.
. "UP" markon the timing belt pulleysshouldbe at the
top.
. Do not usethe middlecoverand lowercoverfor storing itemsdisassembled.
. Cleanthe middlecoverand lower coverbeforeinstallation.
. Replacethe washerwhen damagedor deteriorated.
'1. Cylinderhead dowel pins and the oil control orifice
must be aligned,
NOTE:
. When handling a metal gasket,care should be
takennot to told it or damagethe contactsurface
of the gasket.
. Cleanthe oil controlorificewhen installing.
CYLINDERHEADGASKET
{3 LAYERSOF METALI
Replace.
orl coNtnol
OOWELPINS
ORIFICE
Clean.
O.RING
Replace.
Measurealongedges,and 3 ways acrosscenter.

Tightenthe cylinderhead bolts in two steps.In the
Jirststep tighten all bolts,in sequence,to about 29
N.m {3.0kgf.m,22 lbl.ltJ;in the final step,tighten in
the samesequenceto 83 N.m (8.5kgf.m,61 lbf'ft).
NOTE:
. Apply engine oil to the cylinder head bolts and
the washers.
. Usethe longerbolts at positionsNo. 1 and No. 2
as shown.
CYLINDERHEADBOLTSTOROUESEOUENCE
Cylinder Hoad Height:

Standard(New):131.95- 132.05mm
in}
{5.195- 5.191t
Put longer bolts here.
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Installthe intakemanifoldand tightenthe nuls in a

c.isscrosspatternin 2 or 3 steps,beginningwith the
inner nuts.
CAUTION: Check to. fold3 or 3cratchc! on ihc aurtaco ol tho ga3kot. Roplscs with a nlw gaeket if
damagod.
4.
CAUTION:
. Mlka 3uro thrt thc k.ywlyr on tho c.mthlttr lrc
facing up .nd No. I pi3ton i3 8t top d.rd clnt.r
(TDCt.
. Rcphct th! rocksr armr in thsir o.iginal potltlom.
6,
Placethe rocker arms on the oivot bolts and ths

valve stems.
7.
lnstallthscamshafts,then installthcamshaftsosls
with ths open side (spring)facingin.
8.
A p p l y l i q u i d g a s k e ta r o u n dt h e r u b b e rc a p , t h e n
installtherubbercao.
Tightenthe intakemanifoldbracketbolts.
GASXET
Replace.
E x 1.25mm
2irN.ml2.itkg{.m,
17tbf.ftl
5.
8 x 1,25mm
23 N.m12.3kgf.m.
17tbl.frt
Install the exhaust manifold and tighten the new

self-lockingnuts in a crisscrosspattern in 2 or 3
steps,beginningwith the inner nuts.
. Use new self-lockiflgnuts.
8 x 1.25mm
24 N.m (2,akgf.m, EXHAUST
11
SELF.LOCKING
NUT
8 x 1.25mm
31 N.m (3.2 kgt m,23lbfftl
Replace.
GASKEI
Replace.
m
l0 x 1.25mm
8 x 1.25mm
a,t N.m 14.5kgf.m, 2il N.m 12.4kg{.m,
33 tbt.ft)
17 rbtftl
(cont'd)
6-29
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CylinderHead
Installation(cont'dl
9. Apply liquid gasketto the head mating surtacesof
the No. 1 and No. 6 camshaftholders,then install
t h e m ,a l o n gw i t h N o .2 , 3 , 4 , a n d5 .
NOTE:
o "1" or "E" marks are stamoedon the camshaft
holders.
. Do not apply oil to the holder mating surfaceof
camshaftseals.
. Apply liquidgasketto the shadedareas.
. T h e a r r o w s m a r k e do n t h e c a m s h a t th o l d e r s
shouldpoint to the timing belt.
11. Tighten each bolt in two steps to ensure that the

rockers do not bind on the valves.
6r1.0mm
9.8 N.m 11.0kgf.m,7.2lbtft)
INTAKECAMSHAFTHOLDERS
Installkeysinto camshaftgrooves.
No.6
No.5
No.2
N o .1
NOTE:To set the camshaftsat TDCpositionfor No.

1 piston,align the holes in the camshaftswith the
holes in No. 1 camshaftholdersand insert5.0 mm
pin punchesin the holes.
KEYS
10. Tightenthe camshaftholderstemporarily.

.
M a k e s u r e t h a t t h e r o c k e ra r m s a r e p r o p e r l y
positionedon the valvestems.
I r 1.25mm
37 N.m {3.8 kgf.m,27 lbf.ttl
6x1.0mm
9.8N.m(1.0kgf.m,
7.2tbtft)
1 3 . Pushcamshaftpulleysonto camshafts,then tighten

the retainingboltsto the torquespecified.
vnx.su
1 7 . Apply liquid gaskt to the rubber seal at the eight

corners of the recesses.
1 4 . Installthetiming belt {seepage6-12).
Adjustthe valveclea.ance(seepage6-31.
1 6 . Installthe rubberseal in the grooveof the cylinder
head cover. Seat the seal in the recessesfor thg
camshaftfirst, thn work it into the groove around
the outside edges,
NOTE:
. B e f o r ei n s t a l l i n gt h e r u b b e r s e a l , t h o r o u g h l y
cleanthe sealand the groove.
. When installing, make sure the seal is seated
securelyin the cornersof the recassswith no
gap.
NOTE:
. Use liquidgaskst,PartNo. 08718- 0001.
. Checkthat the mating surfacesare clan and dry
beforeapplyingliquidgasket.
. Do not install the parts if 20 minutes or mor6
h a v s e l a p s o ds i n c o a p p l y i n g l i q u i d g a s k e t .
Instead,reapply liquid gasket after removing old
reaidue.
. After assembly, wait at lsast 20 minutes before
fillingthe enginewith oil.
RUBAER
SEAL
Apply liquid g.sket to

the shadedareas.
CYUNDERHEAD
COVER
(cont'd)
6-31
vnx.su
GylinderHead
lnstallation(cont'dl
18. When installingthe cylinder head cover, hold the
rubbersealin the grooveby placingyour fingerson
the camshaftcontactingsurfaces(top of the semicircles).
O n c e t h e c v 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,slidethe cover slightlybackand forth to seat
the rubberseal.
Tightenthe nuts in 2 or 3 steps.In the final step,

tighten all nuts, in sequence,to 9.8 N'm (1 0 kgf'm,
7.2 tbf.ft).
NOTE:
. Beforeinstallingthe cylinder head cover, clean
the cylinder head contacting surfacesusing a
shoptowel.
. Do not touch the pans where liquid gasketwas
aDplied.
6x1.0mm
9.8 N.m 11.0kgt'm,
7.2 tbf.trl
20. After installing,checkthat all tubes,hosesand connectorsare installedcorrectlY.
6-32
vnx.su
'lllllllllmlmti'""
CylinderHead/ValveTrain
818C1engine
SpecialTools
.............
6-34
Rocker Arms
wEc
Removal
.................
6-60
Troubleshooting Flowchart
Location
.................
6-61
WEC SolenoidValve...................
lnspection
..............
6-36
6-62
VTECPressureSwitch .................
Arm-to-ShaftG|earance..................
6-38
6-63
Installation
VTECSolenoidValve Inspection....6-41
.............
5-64
RockerArms
Camshafts
ManualInspection.....,.................
6-42
Inspection
..............
6-65
InspectionUsingSpecial
Valve Guides
Tools ....................................,.....,..
6-/|i|
ValveMovement..............................
6-70
ValveGlearance
Replacement
.........6-71
Adiustment
............
6-44
Reaming
.................
6-72
Timing Belt
Valve Seals
lllustrated1ndex...............................
6-46
Reconditioning
......6-73
..............
Inspection
6-48
Valves. Valve Springs and Valve Seals
TensionAdiustment........................
6-48
.................
Removal
6-67
.................
Removal
6-4{l
lnstallationSequence..........,.......,...
6-69
.............
lnstallation
6-51
Valvelnstallation.............................
6-70
Pulley
Bolt
Crankshaft
Replacement
.........6-47
CylinderHead
lllustratedIndex ...............................
6-53
.................6-55
Removal
Warpage
................6-74
.............
lnstallation
6-75
vnx.su
SpecialTools
o
@
@
@
/.\
o
o
ToolNumbar
or
07HAH- PJ7010A
_ PJTOIOB
OTHAH
07JAB- 001020A
07LAA- PR30100
OTLAJ_ PR3O2OA
07MAB. PY3OlOA
OTMAF_ PRgO'IOA
07742- 0010100
07757- PJ1010A
ValveGuideReamer,5.5 mm
6-72
HolderHandle
6-17
&45
6-43
TappetAdiusterWrench
Air Stoppet
HEX50 mm,
PulleyHolderAttachment,
Offset
ValvSpringCompressorAttachment
Extension
ValveGuideDriver,5.5mm
ValveSpringCompressorAttachment
6-11
6-67
6-71,72
6-67
6-34
Plea Rctllanca
Dctcription
vnx.su
VTEC
Refrto page11-32thru I l-39 beforotroubleshooting.
-g:
-mi
\,__-:-/
\.---l-l
Iel-
(MlL)
indicates
Disenostic
rrouble
code(Drc)2r:Aproblem
inthewEc
!5*3ij'i:,*o:",,XTl.Lamp
-l 2,1l-
MIL h.. b..n Fport d on.

Wrth aaavica chack connac,tot
iomp.d, Codc 2l i. indic.t.d.
O o t h o o n g i n oc o n t r o lm o d u l e
(ECM)Rg3otProcgduro.
w6rrn up engine to normal oprating tsmporature (the cooling

fan comogon).
Do th RoadTest.'
ls MIL on and does it indicatocod21?
' RoadTest:
Acceleratein 1st gear to 6n engino spoodovor 6000rpm.
Hold thst engine spedtor at leasttwo seconds.
lflhe MIL do6s not coms on during th first road tost,
reoeatthis test two more tim95.
lmormitt.m t ilur., .yrtom i. OK
!t thi.tim..
Chacl tor poor connactiont ot
loo.. wircr !l VTEC .ol.noid
v.lv. lnd ECM.
Turn tho ignition switch OFF.
O i s c o n n e c tt h o 1 P c o n n s c t o r
lrom the VTECsolenoidvalvo.
Chockfor continuity betw66n 1P

c o n n 6 c l o rt e r m i n a l a n d b o d y
9rcUnO.
ls there '14- 30 07
R.pl.c. th. VTEC rolonoid v.lvr,
YES
(To pago G37l
6-36
vnx.su
{From pag6 636}
ooooooooooo
ooooooooooo
ooooooooooooo
ooooooooooooo
'lP
Ch6ckfor continuity botw6en
and
A4
termiconnectortrminal
nal.
B.9.lr op.n in th. GRI{/YELwirc

b.tw..n ECM{Aa} .od vTEc
aolanoidvalvaconnac'tor.
Ch6ckfor continuity botwoon 1P

connectorterminal (harnessside)
and body ground.
ContinuityT
Ro.ir .hon i|r th. GRN/VELwirc

b.iw..n ECM (A4l .nd VTEC
aoldroid valv. Gonnac'tor.
Sub.titut! . krown-good ECM

|r|d r.ch!ck. lt .ytnptom/indic!tion gor3 away rrplact tha origin.l Ecttl,
6-37
vnx.su
wEc
TroubleshootingFlowchart- VTECPressureSwitch
Referto page11-32thru11-39beJoretroubleshooting'
-.+- l{{?l-
(DTC)22:A problemin the VTEC

-r";-rIndicatorLamp (MlL)indicatesOiagnosticTroublesCode
zizr: Malfunction
pressurSwitchcircuit.
;l
- l r @ l - | 2 21 -
MIL har bagn.oportcd on.

With t.rvic. chack connactor
iump.d, cod 22 it indic.t.d.
D o t h e e n g i n ec o n t r o lm o d u l e
(ECM)Reset
Procedure.
Warm !p engineto normaloperating temperstur (cooling fan

comeson).
Do the Boad Tst.'
ls MIL on and doesit indi'

cate code 22?
* RoadTest:
Accoleratoin lst gear to an engine speedover 6000rpm
Hold that engine speedfor at leasttwo seconos'
lf the MIL does not come on during the first road test'
reoeatthis test two more limes.
Intc.mift.nt failu.o, ry3tom ia OK
at thi. tim..
Chack for pool connaction3ol
loo!. rvirat at VTEC Ptasturo
3whch and ECM.
Turn lhe ignition switch OFF
D i s c o n n e c tt h e 2 P c o n n e c t o r
lrom the VTECPressureswitch.
C h e c kI o r c o n t i n u i t y b e t w e e n
BLKterminaland body ground.
Rcpair opcn in BLKwit. botwcon
2P connectorrnd body ground
tG101l.
C h e c kf o r c o n t i n u i t y b e t w e e n
8LU/8LKterminaland D6 termi'
nal.
(To page6 39)
6-38
vnx.su
(Frompage6-38)
Ropairopn in BLU/BLK$,iro be
tween ECM lD6) and 2P conn.ctor,
Checkfor continuity between D6
terminaland body ground.
o oooooo ooo ooo I oooooooo trt!*Hffi

o oooo ooooo ooo I oo oooo oo
Oooooo ooooo
o o o o o oo o o o o
D6
R6pri. short in BLU/BLKwir. bctweon ECM (D6l .nd 2P connectoa,
Remove10 mm sealingbolt and

connectorl pressuregauge.
GAUGEJOINT ADAPTER
SNAPON MT2&17
10 x 1.0mm
. lJse new washerwhen
installingthe sealingbolt.
Coitlnuity?
Y AVAILAEII
GAUGE
OILPRESSURE
Connecta tachometer{soe sect i o n1 1 ) .
\n
Startthe engineand warm it up

to normal operatrngtemperature.
C h e c ko i l p r e s s u r ea t e n g i n e
speeds of 1,000,3,000 and 5,000
rpm,
ls pressurebolow 50 kPa
(0.5kgflcm', 7 psi)?
\-
]L
NOTE:
Keep mgasuringtime as short as possiblebocausengine is
runningwith no load(lessthan one minute).
Inrpoct tho VTEC aolanoid v.lv..
vtEc sot-NotD
Turn off the engine.

Checklor continuity betweenthe
2 terminals on the VTECpressure
switch.
YES
(To page 6-40)
Conlinuity?
(cont'd)
6-39
vnx.su
VTEC
Flowchart VTECPressureSwitch (cont'dl
u
Troubleshooting
lFrom pag6 6-39)
OOMMERCIALLYAVAILABII
OIL PRESSURE
GAUGE
D i s c o n n s c tl h e 1 P c o n n e c t o r
trom the VTECsol6noidvalve.
Attach the battery positivo tormi

nal to the GRN/WHTterminal.
Startthe engineand chgckoil

pressureat 5,000rpm (lor VTEC
test).
oil prssure
NOTE:
Keep moasuringtim6 as shon 6s possible becauseenginei5 runningwith no
load lless than ono minuto).
ls pressureabove 400 kPa

(4kgt/cm,,60 psi)?
In.p.ct th. VIEC .olrnoid v.lv..
Checktor continuity betwe6n the

2 terminsls on th VTECprsssure
switch !nder above condition.
Sub.titut. . klown-eood ECM

and rachack.|f aymplom/indication goaa away rrplaca th. o?igin.l ECM.
vnx.su
GAUGE JOIMf ADAPIOR

SNAPON MT2S1'
1 0 x 1 . 0m m
. Use new washer when
installingth6 soalingbolt.
WEC SolenoidValveInspection
Disconnectthe 1P connector trom the VTEC
solenoidvalve.
Masurs resistancebetween th terminal 8nd body
grouno.
4.
lf th6 filter is not clogged, push the VTEC solenoid

valv with your finger and check its movement.
.
l f V T E Cs o l s n o i d v a l v e i s n o r m a l , c h e c k t h e
enginsoil prssure.
R.3bt!nc!: 1l - 30 O
6x1.0mm
lf the resistanceis within specificstions,romove the

WEC solnoid valve from the cvlindor hsad, and
checkthe VTECsolenoidvalvefilterfor clogging.
.
lf there is clogging,replacsthe engin oil filter

and the engineoil.
VTECSOT.CNOTD
12 tTln 11.2kg[.m,8.7 lbttt]
6-41
vnx.su
VTEC
Arms Rockerrtrrrri'
nlrungf
rYrorrtrcr
rrrDPEUtrl,rl
1.
Set rh6 No. I Distonat TDC.
2.
Removethe ignitionwire coverand the wires.
3.
Removethe ignitionclampswhile pulling up on the

lock.
4.
Pushthe mid rockerarm on the No. 1 cylindermanually.
Checkthat the mid rockerarm moves independently of the primaryand secondaryrockerarms.
6 x 1.0.nm
9.8 N.m 11.0lgfm, 7.2 lbf.ftl
SECONDARY
ROCKERARM
w
7.
Checkthe mid rockerarm of eachcvlinderat TDC.

.
lf the mid rockerarm does not move,removethe

mid, primary and secondaryrockerarms as an
assemblyand checkthat the pistonsin the mid
and primaryrockerarms move smoothly.
lf any rocker arm needs replacing,replacethe
primary,mid, and secondaryrockerarms as an
assemblv.
NOTE:Referto page6-78when installingcylinderhead

cover.
vnx.su
RockerArms - InspectionUsingSpecialTools
Apply specified air pressure to the rocker arm pistons after looseningthe regulatorvalveon the valve
inspectiontool.
CAUTION:
. Boforo using tho valvo inspoctiontool. make 3uro
that th6 air prsssure gaugs on th6 air comprossol
indicatG over 250 kPa {2.5 kgf/cm',36 psi}
. Inspectthe valvs clearancobefors rockel lrm insPoction.
. Covor the timing belt with a shop towsl to plvent
qotting oil on lhe b6lt.
. Checkths mid rocker srm of oach cylindor at TDC.
1.
2.
P l u g t h e r e l i e f h o l e w i i h t h e s p e c i a lt o o l ( A i r
Stopper).
SpecifiedAir Presrure:
250 kPa (2.5 kgt/cm',36 psi)
- 500 kPa 15.0kgf/cm'. 71 Psi)
Make sure that the primary and secondaryrocker
a r m s a r e m e c h a n i c a l l cy o n n e c t e db y t h e p i s t o n s
and that the mid rocker arms do not move when
pushedmanuallv.
RELIEFHOLE
LOST MOTION
ASSEMALY
3.
o lf any mid rockerarm moves independentlyof

tho primaryand secondaryrockerarms, replace
the rocker arms as a set.
Removethe bolt and washer from the inspection

holeand connectthe valveinspectiontool
AIR STOPPEB
OTLA' - PR3O2OA
VALVE
REGULATOR
. Pullthsleverand
turn to adjust.
6.
Removethe tools.
7.
Checkthe oDerationof the lost motion assembly by

p u s h i n go n t h e m i d r o c k e ra r m . T h e l o s t m o t i o n
a s s e m b l vs h o u l d c o m p r e s sf u l l y a n d o p e r a t e
smoothlythrough its full stroke.Replacethe assembly if it does not work smoothlY.
8.
A f t e r i n s o e c t i o n ,c h e c k t h a t t h e M a l f u n c t i o n
IndicatorLamD(MlL)does not come on
INSPECTION
HOtt
WASHER
Replace.
PfiIMARY
ROCKERARM
NOTE:Referto page6-78when installingcylinderhead

cover.
10 x 1.0mm
20 N.m 12.0kgf.m,
1a tbt'ft|
TOOL
AVAILABLE}
ICOMMERCIALLY
6-43
vnx.su
ValveClearance
Adiustment
NOTE:
. Valves should be adjustedcold; at a cylinder head
temperatureof lessthan 100"F(38'C).
. Adjustmsnt is the same for intakeand exhaust
vatves.
o After adjusting, retorque the crankshaftpulloy bolt to
177 N.m ( 18.0kgf.m, 130 lbf.ft).
1.
FOI{IER Ot{
LOWEFCOVER
TDCMANK
lP.int d whit.t
Removecylinderheadcove..
BOLTLOCANONS:
ADJUSTING
IMTAKE
No.3 No. 2
No. 4
No. 1
Diroctionof
aotation.
3. Adjust valv6 clearanc6on No. 1 cylinder.
No.4
No.3
No.2
EXHAUST
Intlkc: 0.15- 0.19 mm (0.006- 0.0,07inl

Exh.u3t 0.17- 0.21 mm (0.007- 0.m8 inl
N o .1
4.
Set No. 1 piston at TDC. "UP" mark on the pulley

should be at top, and TDC grooves on the pulley
should align with the pointer on back cover. TDC
g r o o v e s ( w h i t e p a i n t ) o n t h e c r a n k s h a t tp u l l e y
should align with pointer on the timing belt lower
cover.
Looson lh6 locknut and turn the adjusting screw

until feeler gaugo slides back and fonh with a slight
amountof drag.
FEEENGAUGE
TAPPETAI\,USTEN WREI{CI{
O'LAA - PRIOIq'
Numbr. 1 pirton .t TDC:
7 x 0.75 mrn
20 f+|n (2.0kgf'm.14lbtftl
6-44
vnx.su
Tightsn the locknut and recheckclearanceagain.

Rep6atsdjustm6nt if necossary.
7.
Rotatocrankshaft180' countsrclockwiseto bring

"UP" mark shouldbo
N o . 4 p i s t o n t o T D C .T h e
pointing straight down. Adjust valves on No. 4
cylinder.
Numb.r 4 pidon .t Tt C:
FEEI.IRGAUGE
Rotsts tha crankshaft 180' counterclockwiss

(c8mshaftpulleyturns 90'). The "UP" mark should
be on th sxhaust 8id6, Adiust vslves on No. 3 cylinoer,
8,
Rotatecrankshaft180" counterclockwisto bring

"UP" marks should be on
No. 2 piston to TDC.The
the intaks sid6. Adjust valves on No. 2 cylinder.
Nonb.r 2 pirton .l TltC:
Nurrb.r3tittondTDC:
.UP' MANKS
NOTE: Referto page 6-78 when installing cylinder head

cover.
6-45
vnx.su
TimingBelt
lllustrated lndex
NOTE:
.
.
.
.
.
ReJertopage6-51for positioningcrankshaftand pulleybeforeinstallingbelt.

Markthe directionof rotationon the belt beforeremoving.
Replacethe rubbersealsfor oil leakagebetweenthe cylinderheadand cover.
Do not usethe middlecoverand lower coverfor storingitemsdisassembled.
Cleanthe middlecoverand lowercoverbeforeinstallation.
WASHER
Replacewhen
CAP NUT
x 1,0mm
9.8 N.m 11.0kgf.m,7,2lbttrl
or deteriorated.
CYLINDER
HEAOCOVER
Reterto page 6'78
when installing.
RUBBER
SEALS
Replace
whendamaged
3-E
or deteriorated,
TIMINGBELT
page 6-48
Inspctaon,
Adjustment.page 6-48
Rplacement.page 6'49
MIDDLECOVER
5xl,0mm
9.8 N.m (1.0kgt m,
7.2 rbtftt
8 x 1.25mm
56 N.m 15.7kgt m,
41 tbtftl
6x1.0mm
9.8 N.m {1.0 kgl.m,
7.2lbf.ftl
6x1.0mm
9.8N.m (1.0kgt.m,7.2lbfftl
10 x 1.25mm
5a N.m 15.5kgl.m.
(} tbf.ftl
Foradiustmentonly
do not remove.
TIMINGSEL
Installwithconcave
DRIVEPULLEY
surfacetacing out.
COVER
R e m o v e a n y o i l a n d c l e a n . Removeany oiland clesn.
Installwithconcave
surfacelacingin.
Clean.
NOTE:When installinga new crankshaftand/ornew bolt:

O tightenthe crankshaftpulleybolrto 196N.m (20.0kgf.m.145lbf.ft),
@ loosenbolt,
@ retightenit to 177N.m fl8.0 kgf.m,130lbnft).
6-46
vnx.su
PULLEY
Removeany oil and clean
on the timing beltguide
plateside.
BOLT
1il x 1.25mm
177N.m 118,0kgtm, 130lbtft)
Replacement,page 6-47
GrankshaftPulleyBolt
Replacement
NOTE:
. Crankshaftpully bolt size and torqus value:
1,0x 1.25mm
177 N.m (18.0kgt.m, 130 lbf'ft)
. When instslling a new crankshaft 8nd/or now pulley
bolt:
. When reinstallingthe bolt, lubricatethe thresds8nd

flangewith engineoil, but don't lubricatethe washer
and pulley.
Lubricetowith engine oil hers.
O tight6nthe pulleybolt to 196N'm (20.0kgf'm, 145

tbf.ft).
@ loosonthe bolt,
@ r6tighten it to 177 N.m (18.0kgf'm, 130 lbf'ft).
ATTACHMEUT,
PULITYHOLDEB
HEXslt mm, OFFSET
- PY3O1OA
OTMAB
SOCKETWRENCH,19 mm
COi'MEBCI,ALLYAVAILABT.E
6-47
vnx.su
TimingBelt
TensionAdjustment
lnspection
.
CAUTION: Always adlust timing bslt tsnsion with th6

engine cold.
Referto page6-78when installing.
Inspectthe timing belt for cracksand oil or coolant

soaking.
NOTE:
. Replacethe belt if oil or coolantsoaked.
. Removeany oil or solventthat gets onthe blt.
NOTE:
. The tensioneris spring-loadedto apply proper tension to the belt automaticallyaftermakingthe following adjustment.
a Alwavs rotate the crankshaftcounterclockwisewhen
viewed trom the pulley side. Rotating it clockwise
may result in improper adjustmentof the belt tension.
Removethe cylinderhead cover. (Referto page 678 when installing.)
Setthe No. 1 pistonat TDC(seepage6-51).
Rotatethe crankshaft5-6 revolutionsto setthe belt.
4.
Set the No. 1 pistonat TDC.
AINUSTINGAOLT
5/aN.m 15.5kg{.m,to lbtftl
For adjustmentonly,
\v-/
.//
Direction
rotat|on,
Rotatepulley
and inspectb6lt.
5.
Loosenthe adjustingbolt 1/2turn (180')only.

Rotatethe crankshaftcounterclockwise
3 teeth on
the camshaftpulley.
After inspecting.retorquethe crankshaftpulleybolt

to 177N.m (18.0kgf.m,130lbf.ft).
6-48
vnx.su
7.
Tightenthe adjustingbolr.
8.
After adjusting,retorquethe crankshaftpulley bolt

to 177N.m (18.0kgf.m,130lbf'ft).
Removal
NOTE:
. Turn the crankshaftpulley so the No. 1 piston is at
top dead center {TDC)before removing the belt (see
page6-51).
. Inspectthe water pump when removed the timing
belt {seepage10-9).
4.
Loosenthe adiusting nut and mounting nut, then

removethe alternatorbelt.
NUT
I x 1.25mm
24 N.m {2.algf.rn,
17 tbf.ftl
Removethe wheel well splashshield (see page 657).

Loosenthe adiustingbolt and mountingbolts,then
remove the power steering (P/S)pump belt.
AOJUSTING
MOUNTINGNUT
10 x 1.25mm
4,t N.m lia.5 kgl.m,
33 tbt ftl
Removethe cruisecontrolactuator(seepageG58).
I x 1.25mm
2aN.ml2.akgt.m,17lbt ttl
Bemovethe side enginemount.
Loosenthe adjustingbolt and idler pulley bracket

combolt, then remove the air conditioning(Ay'C)
oresso. belt.
10x 1.25mm
52N.m15.3kgtm, 38lbtftl
ADJUSNNG
CNGINC
MOUNT
D1IN
BOLT
10 x 1.25mm
ira N.m (4.5 kgf.m, 33 lbf'ttl
BELT
12 x 1.25mm
74 N.m (7.5kgt m,
s4 lbf.trl
(cont'd)
6-49
vnx.su
Timing Belt
Removal lcont'd)
1.
8.
1 0 . Loosenthe adjustingboh 180'.
1 1 . Pushthe tensionerto rmovetensionfrom the timing belt,then retightenthe bolt.
Referto page6-78when installing.
Removethe pulley bolt and crankshaftpulley (see

page6-47).
Removethe middlecoverand the lowercover.
NOTE:
. Do not uss the middlecover and lower coverfor
a Cleanthe middle cover and lower cover before
installation.
WASHER
Replacewhen
or deteriorated.
1 2 . Removethe timing beltfrom the pulleys.
6x1.0mm
9.8 N.m 11,0kgf'm, 7.2 lbl'ftl
CYLINDER
OOVER
Relrto pago 6-78
when inslalling.
NMING BELT
Adjustment,page 6-48
MIDDLE
COVER
@^R
RUABERSEALS
v@
R e p l a c 6w h e n
or deteriorated.
6x1.0mm
9.8 N.m {1.0 kgf.m,
7.2 rbnftl
LOWERCOVER
6r1.0mm
9.8N.m 11.0kgf.m,7.2lbtftl
CRANKSHAFT
PULl"EY
Removeany oil and
cleanon the timing belt
guideplat6side.
BELT
TENSIONER
TIMINGBELT
GUIDEPLATE
lnstallwithconcave
surfacefacing out.
Removeany oil
and clean.
ADJUSNI{G BOLT
10 x 1,25mm
5,t N.m 15.5kgf.m,
.(l rbf.ftt
For adjustmntonly,
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PULI.TYBOLT
17?N m {18.0kgf.m,130lbtftl
TimingBelt
lnstallation
Installthe timing belt in the feverseorderof removal;
Only key pointsare describedthere.
NOTE:Cleanthe middle cover and lower cover before
installation.
1.
Positionthe crankshaftand the camshaftpulleysas

shown betoreinstallingthe timing belt.
A. Set the crankshaftso that the No. 1 piston is at
top dead center {TDC).Align the groove on the
teethside of the timing belt drive pulleyto the V
pointeron the oil pump.
B. Align the TDC marks on intakeand exhaustpulleys.
2.
I n s t a l lt h e t i m i n g b e l t t i g h t l y i n t h e s e q u e n c e
shown.
O T i m i n g b e l t d r i v e p u l l e y ( c r a n k s h a t t*) @
A d j u s t i n gp u l l e y * @ w a t e r p u m p p u l l e y * @
Exhaustcamshaftpulley* @ Intakecamshaftpullev,
(cont'd)
6-51
vnx.su
Timing Belt
1
Loosen and retighten the adjusting bolt to tsnsion

thB belt.
4.
Rotatethe crankshaftabout 4 or 6 turns countsrclockwiseso that the belt positions on the pulleys.
5.
Adjust ths timing bolt tension (see pags &48).
1.
l f a c a m s h a f t p u l l e y i s n o t p o s i t i o n e da t T D C .
.emove the timing belt and adiust the positioning
following the procedureon page 6-51,th6n r6install
rhe riming belt.
NOTE: Refsrto page 6,19 for timing blt removal.
b.
Chckths crankshaftpullsy and the camshaftpullsys at TDC.

CRANKSHAFTPULLEY:
CAMSHAFT PULI..EY:
"UP- MANKS
6-52
vnx.su
Aftr installation,adiust the tension of each blt.

o See section 23 for alternator belt tension adiustmenr.
. See section 22 tot NC comprssor b6lt tension
adjustmnt.
. See section 17 for P/S pump b6lt tnsion adiustmenL
Cylinder Head
lllustratedIndex
CAUTION: To svoid dsmaging the cylindor h.ad, wsit until tho engino coollnt tomper.turo drop3 bolow 100'F (38'C)
bofore romoving it.
NOTE:
r Use new O-ringsand gasketswhen reassembling.
. Use liquidgasket,Pan No. 08718- 0001.
. Replacethe rubbersealsfor oil leakagebetweenthe cylinderheadandcover.
fterw
to anycontactparts.
drythem,andapplylubricant
cleanallthe partsin solvent,
,o reassembling,
8 x 1.25mm
27 N.m 12.8kgt m,
20 rbt ft)
6x1.0mm
9.8 N.m (1.0 kgt'm,
7.2tblftl
f,
6xl.0mm
9.8 N.m {1.0 kgl m, 7.2 lbf.ftl
4qi
CYLINDERHEAD
COVER
Referto psge 6-78
when instglling.
CAMSHAFT
INTAKE
CAMSHAFT
6 x 1.25mm
2it t*m 12.4kg[.m,
17 rbf.ftl
SEAL
Replace.
liquidgasket
to thos points.
Replacewhen damaged
or detriorated,
r 1.25mm
56 N.m 15.7kg{.m,
ial lbf.ft)
Replace.
6-53
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NOTE:Cleanthe headoil controlorificeand the rockershaftorificeswhen installino.
ROCKEBARM ASSEMBLY
CYLINDERHEAD
BOLTS
1 1x 1 . 5m m
81 N m (8.3ks{ m, 60
INTAKEVALVESPRINGINNER
Apply clean engine oil

to threads and washer
contact surface.
SPRINGRETAINER
INTAKEVALVESPRINGOUTER
VALVE
SPRINGSEAT
VALVESEAL
Replace.
SPRINGSEAT
VALVEGUIDE
SPRINGRETAINER
MOTION
ASSEMBLY
EXI{AUSTVAL
SPRING
INTAKEVALVE
VALVESEAL
Replace.
INTAKE ROCKER
ORIFICE
Clean.
VALVE
LOSTMOTION
ASSEMBLY
ROCKERSHAFT
DOWEL
PIN -,
EXHAUSTVAL
OOWEL
PIN
ROCKER
SHAFTORIFICE
CYLINDERHEAO
GASKET
13LAYEBSOF MET
Replace.
SEALINGBOLTS,20 mm
64 N.m 16.5kgf.m,47 lbtftl
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Cylinder Head
Removal
Engineremovalis not requiredor this procedure.
CAUTION: To avoid damaging tho cylinder head, wail
u[tilths.nginc coolant tsmperaturo drops bolow 100"F
(38'Cl bafore loos6ningtho retaining bolts.
5. Removeth strut brace,
8 x 1.25mm
24 N.m (2.1kg[.m, 17 lbtftl
NOTE;
. Inspectthe timing belt before removingthe cylinder
head.
Turn the crankshaftpulleyso that the No. 1 piston is
at top deadcenter(TDc){page6-51).
a Markall emissionshosesbetoredisconnecting
them.
a Anti-theft radios have a coded theft protection circuit.
Be sure to get the customer's code number before
- Disconnectingthe battery.
- Removingthe No.32 (7.5A) fuse trom the underhood fuse/relaybox.
- Removingthe radio.
After service,reconnectpower to the radio 8nd turn it
on.
When the word "CODE"is displaved.enter the customer's5-digitcodeto restoreradiooperation,
'1. Disconnect
the negativeterminalfrom the battery.
Drainthe enginecoolant(seepage10-5).
.
Removethe radiatorcapto speeddraining.
6. Removethe intakeair duct.
Relievefuel pressure(seesection111.
Do not 3moke whilo working on fuel
l@
systgm. ko6p opon tlamo ot Sparkaway trom work
aroa. Drain fugl only into an approved containsr,
4.
INTAKE AIR
Disconnectthe fuel feed hose.
SERVICBOLT
15 N.m (1.5 kgtm, rl bf.tt)
WASHERS
Replace.
BANJOBOLT
(cont'd)
6-55
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CylinderHead
Removal (cont'd)
7.
Removethe vacuum hose and vaoorativsemission (EVAP)controlcanisterhose.
9. Removeths brake boostervacuum hose and ful

return hose,
BRAKEBOOSTER
VACUUMHOSE
6x1.0mm
12N.m11.2kgf.n,8.t lbf.trl
EVAPCONTROL
CANISTERHOSE
10. Rmov6tho thronlo cable.
Remove the water bypass hose and positive

crankcase
ventilation{PCV)hose.
PCV HOSE
NOTE:
o Taks care not to bsnd the cabl6 when removing
on6.
o Adiust the th.ottle cable when installing (sees6ction1l).
WATERBYPAss
HOS
AD.'USTING THROTTI,"E
NUT
CABI.T
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l l . Removethe engine wire harnessconnectorsand
14. Removethe sDlashshield.
wi.e ha.nessclampsfrom the cylinderheadand the

intakemanitold.
a Four fuel injector connectors
o Intakeair tempe.ature {lAT) sensor connector
a Engine coolant temperature(ECT)sensor connector
o TDC/CKP/CYP
sensor connector
a lgnition coil connctor
a ECTgaugesendingunit connector
a Throttle position (TP)sensor connector
a VTECsolenoidvalveconnector
a VTECDressureswitch connector
a Manifold absolute pressure(MAP) sensor connector
a ldle air control{lAC)sensorconnector
a EVAPpurgecontrolsolnoidvalvoconnector
a Intake air bypass {lABl control solenoid valve
conneclor
6r1.0mm
9.8 N.m (1.0kgt m,
1.2 tbtftl
12. Removethe spsrk plug caps and distributorfrom

the cylinderhead.
1 3 . Removethe upper radiatorhose, heatrhose and
water bypass hose.
1 5 . Removethe enginegroundcable.
Romovothe adjustingbolt and mountingbolts,then
remove the power steering (P/S)pump belt and P/S
pump.
. Do not disconnectthe P/S hoses.
WATER BYPASS
6x1.0mm
9.8 N.m 11.0kgl.m,
7.2 tbt.ttl
HOSE
(cont'dl
6-57
vnx.su
, l
Cylinder Head
Removal(cont'dl
1 6 . Removethe heat shield from the P/S bracket(see
p a g e5 - 1 8 ) .
21. Removethe cylinderheadcover.

22. Removethe timing belt (seepage6-49).
1 7 . Removethe air conditioning(Ay'Clcompressorbelt

(seepage6-49).
23. Removethe camshaftpulleysand backcover.
'18. Remove
the alternatorbelt {sepage6-49).
'19.
Removethe cruise control actuato..

8 x 1.25mm
N.m 12.4kgf.m, 17 lbtftl
ACTUATOR
24. Removethe exhaustmanifold.
20. Removethe sideenginemount.

10x 1.25mm
SELF.LOCKING
NUT
8 x 1.25 mm
31 N.m {3.2 kgt m, 23 lbf.ftl
Replace.
SIDEENGINE
12 x 1.25mrn
7a N.m 17.5kgl.m,
5a rbtftl
6 -5 8
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'ilffi{
21. Remove the camshaft holder plates, camshaft hold-
25. Removethe intakemanifold.
ers, and camshafts.

GASKET
CAMSHAFT
28. Removethe cylinder head bolts, then removethe

cylinderhead.
26. Loosenthe adjustingscrews.
CAUTION: To prsvent warpage, unscrew th bolts
in sequencel/3 turn at a time; repeat until all bolts
aro loosoned.
CYLINDERHEADBOLTLOOSENINGSEOUENCE
No.4
No. 4
INTAKE
No.3 No.2
No.3
N o .2
EXHAUST
No. 1
No. 1
6-59
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RockerArms
Removal
Holdthe rockerarmstogetherwith a rubberbandto
oreventthem from seParating.
3.
Screw 12 mm bolts into the rockerarm shafts.

Removeeach rocker arm set while slowly pulling
out intakeand exhaustrockerarm shafts.
BAND
RUBBER
Removethe intake and exhaust rocker shaft orifices,

then removethe VTECsolenoidvalve and the sealing bolts.
NOTE:The shapesof the rockershaftorificesof the
intakeand exhaustare different.ldentify the parts
as they are removedto ensurereinstallationin the
originallocations.
EXHAUSTROCKER
SHAFTORIFICE
Clean.
O.RING
Replace.
INTAKE ROCKER
SHAFTOBIFICE
Clean.
O-RING
Replace.
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ROCKERSHAFTS
Locations
tho orifice ls corrccdY
GAUTION: Aftcr in3tlllino th! roCk.r shrft o.ifice, trY to tum ihc tock r .hatt to makr luta thlt
not
turn'
in3artcd in the holc of tho lockor shrft. It the oritice b in placc' it should
NOTE:
in originallocdtions'
o ldentifypartsastheyareremovedto ensurereinstallation
. lnsoect rockershafts and rockerarms (see pages 6-62and 63)'
o Rocke.arms must be installed in the same position it reused'
. Cleanthe rockershaft orifices when installing.
I
erio, to ,einstalling,clesn all the parts in solvent, dry them and spply lubricantto any contact surfacos'
ARII,IASSEi/IBUES
NTAKEBOCXER
BA D
RUBBER
INTAKEROCXER
sEALlMi BoLTS,20 m|tr

64 N.m 16.5ksf.]n,4.7lbf.ftl
SHAFT
Cl6an.
&
tu
ry
o-nrM;s
R6placo.
ry
-%
HOII
TROCIGRSHAFT
oRrFrcEsl
EXHAUSTROC(ER
BOCXER
SHAFT
RUASERBA'{D
EXHAUSTB(rcKERARMASSEMBLIES
6-61
vnx.su
RockerArms
lnspection
N O T E :W h e n r e a s s e m b l i n gt h e) p r i m a r y r o c k e ra r m ,
oil passageof the
c a r e f u l l ya p p l y a i r p r e s s u r et o the
t
rockerarm.
ROCKERARM
Push
SECONDARY
PISTONS
Inspectthe rockerarm piston.

ciston.Pushit manually.
- lf it does not move smoothly,
replacethe rocker
smoot
arm assembly.
\ xva
V/\'
Checkpistonmovement
.
.
Removethe lost motion assemblyfrom the cylinder

head and inspectit. Test it by pushjngthe plunger
with your finger.
- l f t h e l o s t m o t i o n a s s e m b l yd o e s n o t m o v e
smoothlv,reDlaceit.
Apply oilto the pistonswhen

whe reassembling.
B u n d l et h e r o c k e ra r mss with
w i a rubber band to
keepthem togetheras a set.
6-62
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LOSTMOTIONASSEMBLY
Arm-to-Shaft Clearance
Measureboth the intake rocker shaft and exhaust rocker
shaft.
Measureinside diameterof rockerarm and chgck

for out-of-roundcondition.
1.
Rock6rA.m-iq.Shaft Clearance:
lntak. and Exhaust
Standald (Now): 0.025- 0.052mm
(0.0010- 0.0020in)
S.rvicc Limit:
0.08 mm {0.003in}
Measurediameterof shaftat first rockerlocation,
Surfacoshouldbe smooth.
2.
Zerogaugeto shaftdiameter.
Inspectrockerarm
facetor wear.
Repestfor all rockers.

- lf over limit. replace rocker shaft and all over
tolerancerockerarms.
MICROMETER
N O T E : l f a n y r o c k e ra r m n e e d s r e p l a c e m e n t ,
replaceall three rocker arms in that set (primary,
mid, and secondary).
6,63
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RockerArms
Installation
1.
I n s t a l l t h e r o c k e r a r m s i n t h e r e v e r s eo r d e r o f
removal:
. Valveadjustinglocknutsshould be loosenedand
adjusting screw backedoff before installation.
. The componentparts must be reinstaltedin the
originallocations.
2.
Installthelost motionassemblies.
3.
Install the rocker arms while insening the rocker

arm shaft into the cvlinderhead
4.
Clean and install the rocker shaft orifices with new

O - r i n g s .l f t h e h o l e s i n t h e r o c k e ra r m s h a f t a n d
cylinderhead are not in line with each other,screw
a 12 mm bolt into the rocker arm shaft and rotate
the shaft.
NOTE:The shapesof the rockershaft orificesfor
the intake and xhaust are different.The orifices
must be installedin the originallocations.
NOTE:Removethe rubber band after installingthe

rocKerarms.
EXHAUSTROCKER
SHAFTORIFICE
INTAKEROCKER
SHAFTORIFICE
Clean.
Cl6an.
O.RING
Beplace.
Beplace.
'/'/
12 mm EOLT
6-64
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Camshafts
Inspection
NOTE:
. Do not rotatethe camshaftduringinspection.
. Removethe rockerarms and rockershafts.
1.
P u t t h e c a m s h a f t sa n d c a m s h a f th o l d e r so n t h e
c y l i n d e rh e a d ,a n d t h e n t i g h t e n t h e b o l t s t o t h e
soecifiedtorque.
SpecifiedTorque:
O - @: 8 mm bolts 26 N.m {2.7 kgl.m,20 lbt'ftl
(D -(D:6 mm bolts 9.8 N.m {1.0kgt.m,7.2 lbf'ftl
4,
Removethe bolts,then removethe camshaftholders from the cvlinderhead.

N O T E : U n s c r e wt h e c a m s h a f th o l d e r b o l t s t w o
turns at a time, in a crisscrosspattern.
5.
Lift camshaftout of cylinderhead.wipe clean,then

inspectlift ramps.Replacecamshaftif lobesare pitted, scored,or excessivelyworn.
Cleanthe camshaftbearingsurfacesin the cylinder
head.then set camshaftbackin place.
1.
Placea plastigagestrip acrosseachjournal.

Installthe camshaft holders,and then tighten the
bolts to the specifiedtorque as shown in the left
columnon this page.
Seateachcamshaftby pushingit toward distributor

end of the cylinderhead.
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 te n d o f d i s t r i b u t o r
drive, then push the camshaftback and forth and
readthe end play.
Camshaft End Play:
Standard (New): 0.05- 0.15 mm
10.002- 0.006inl
Sawics Limit: 0.5 mm (0.02inl
NOTE:Do not rotatecamshaftsduring inspection.

9.
Removethe camshaftholders.Measurewidest Dortion of plastigagestrip on eachjournal.

Camshaft-to-HolderOil Clearance:
Standard {New): 0.050- 0.089mm
{0.002- o.Ooilin)
Sswice Limit: 0.15mm (0.006in)
(cont'dl
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Gamshafts
Inspection(cont'd)
10, lf camshaft-to-holderoil clearanceis out of lolerance:
11. Checkcam lobewear.

Clm Lobs Hcight Standard (N.w):
And camshaft has already been replaced,you

must replacethe cylinderhead.
lf camshaft has not been replaced,first check
total runout with the camshaftsupportedon Vblocks.
CamehaftTotal Runout:
Sisndard (New): 0.015mm (0.0006inl
ServiceLimit:
0.03 mm (0.0012in)
IiITAKE
EXHAUST
PRIMARY
33.i{'l1 mm
( 1 . 3 1 5 4i n l
3 3 . 1 1 1m m
(1.3036in)
MID
36.377mm
l't.4322inl
35.720mm
(1.4063inl
SECONDARY
34.547mm
( 1 . 3 6 0 i1n )
34.381mm
(1.3536in)
Rotatcamshsft
while measuring
Checkthis are6tor wsar.
Crm Porition
lf the total runout of the camshaftis within tolerance,replacethe cylinderhead.

lf the total runout is out of tolerance,rDlacethe
camshaftand recheck.lf the oil clearanceis still
out of tolerance.replacethe cylinderhead.
INTAKE
Mto
CXHAUST
sEc
SEC MID
PRI
fTt-]--Tt-Tt-l
\ l l i l i l | /
\
t t t t l
LIL__H___}{-}U
ftB
T/B: nMING BELT

PRI: PRIMAFY
MID:MID
SEC:SECONDARY
6-66
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ftB
Valves,Valve Springs and Valve Seals

Removal
N O T E : l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e
removedso that eachitem can be reinstalledin its orioinal position.
1.
Using an appropriate-sized
socketand plasticmallet. lightlytap the valve retainerto loosenthe valve
keepersbeforeinstallingthe valve spring compressor.
I n s t a l ls p r i n g c o m p r e s s o rC
. o m p r e s ss p r i n g a n d
remove valve keeper.
VALVESpRtNG
COMPRESSoR
ATTACHMENT
VALVESPRING
ATTACHMENT
COMPRESSoR
EXTENSION
Snap-onCFrll
(cont'd)
6-67
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Valves,ValveSpringsand ValveSeals
Removal(cont'dl
3.
Installthespecialtoolas shown
Valve Dimensions
COMMERCIALLY
AVAILABLE
VALVEGUIDESEALREMOVER
Lrst"EP/N s79(x'OR KD3350
4.
lntrko ValYo
A Standsrd (N.wl: ilil.go - *t.10 mm
(1.295- 1.303inl
B Standard (Newl: 101.00- 101.30mm
(3.976- 3.988inl
C Standard (N.w): 5.a75- 5.185mm
(0.2156- 0.2159inl
C Sorvicc Limit
5.i!15(0.21.lt in)
D Standard (Ncw): 1.05- 1.35mm
(0.04i - 0.05:tin)
D Sorvicc Limh:
0.85 mm (0.033inl
Removethe valveguide seal.
Exhau3tValve
A Stand.rd (Ncwl 27.90- 28.10mm
- 1.106inl
11.098
B Standard (Ncwl: 1qr.6lt- loo.glt mm
(3.961- 3.972inl
- 5.460mm
C St.nd.rd (Now| 5./L51,
(0.2146- 0.215|,inl
C ServicoLimit:
5.a20(0.2134inl
D Standsrd lNewl: 1.65- 1.95mm
{0.065- 0.077inl
D Sorvicc Limit
1.45mm (0.057inl
6-68
vnx.su
InstallationSequence
NOTE:Exhaustand intakevalvesealsare NOT interchangeable.
VAIVE IGEPGNS
v^LvEsP'ittNG
*nt
/^no,n
/'=\/
INTAKEVALVESPAING
\y
VALVE SPRING
@--'**
9-**
EXHAUSTVALVESEAL
(BLACKSPRINGI
Replace.
NOE: Placethe end ofv.lv

spring with closelywound coilg
loward the cvlinder had.
SPRINGSEAT
NOTE: lnstallthe valvo spring se6t6
bsfore installingthe valv6 so6ls,
VALVE GUIDE SEAL II{STALITR

KD-2EgS
NOTE:UsosmalllD
ond oftool.
P.%
VALVE SEAL
Rplace.
6-69
vnx.su
Valves,Valve Springsand
Valve Guides
ValveSeals
ValveMovement
Valvelnstallation
When installingvalves in cylinder head, coat valve
stemswith oil beforeinsertinginto valveguides,and
makesurevalvesmove up and down smoothly.
clearancewith a dial indicaMeasurethe guide-to-stem

t o r w h i l e r o c k i n gt h e s t e m i n t h e d i r e c t i o no f n o r m a l
thrust(wobblemethod).
When valvesand springsare in place,lightlytap the

end of each valve stem two or three times to ensure
proper seatingof valve and valve keepers(use hamm e rh a n d l e ) .
lntaks Valvr Stom-to-GuideClearance:

Standard(Newl: 0.05- 0.11mm
{0.002- 0.OO'lin)
0.16 mm (0.006in)
Ssrvice Limit:
NOTE:Tap the valve stem only along its axis so you

do not bendthe stem.
ExhaugtVdve Stem-to-GuideClsarancg:
StandaldlNowl: 0.10- 0.16mm
(0.00'l- 0.006in)
Sorvics Limit:
0.22 {0.0m in)
Valveextended10 mm out from seat.
.
.
.
l f m e a s u r e m e n te x c e e d st h e s e r v i c e l i m i t .
recheckusinga new valve.
lf measurementis now within the servicelimit,
reassembleusinga new valve.
lf measurementstill exceedslimit, recheckusing
alternatemethod below,then replacevalve and
guide,if necessary.
NOTE: An alternatemethod ot checkingguide to

stem clearanceis to subtractthe O.D.of the valve
stem. measuredwith a micrometer,from the l.D.ot
the valve guide,measuredwith an insidemicrometer or ball gauge.
Take the measurementsin three placesalong the
valvestem and three placesinsidethe valveguide.
The differencebetweenthe largestguide measure'
ment and the smalleststem measurementshould
not exceedthe servicelimit.
lntafte Valvs Stom-to-GuidaClearance:
Stardard (Nowl: 0.025- 0.055mm
(0.0010- 0.0022inl
0.08 mm (0,003in)
ServiceLimit:
ExhaustValvo Stem-to-GuideClearance:
Standard lNew): 0.050- 0.080mm
10.0020- 0.0031in)
Srvics Limit:
0.11 mm {0.0oilinl
6-70
vnx.su
1 . As illustratedin the removal steps ot this proced u r e . u s e a c o m m e r c i a l l y- a v a i l a b l ea i r - i m p a c t

driverattachmentmodifiedto fit the diameterof the
valve guides. In most cases,the same procedure
c a n b e d o n e u s i n g t h e V a l v eG u i d e D r i v e ra n d a
conventionalhammer,
COMMCRCIALLY.AVAILABLE
VALVEGUIDEDRIVER
5.3mm
(0.21inl
Workingfrom the camshaftside, usethe driverand

an air hammerto drive the guide about 2 mm (0.1
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
knock off some of the carbon and make removal
easier.
CAUTION:
. Always wear ssfcty gogglos 01 a taca rhiold
whcn using thc air hrmmcr,
. Hold tho.ir hammer diroctly in line with tho
v6lvo goido to prov.nt drmaging tho driv6r.
_{l
azmm +-
szmm
{3.43inl
tz.zt in)
Turn the head over and drive the guide out toward
the camshaftsideof head.
tfr
lf a valve guide still won't move, drill it out with a

8.0 mm (5/16in) bit,then try again.
10.8mm
10.42inl
R.mov.l andIn3trll.tion
VALVEGUIDEDRIVER.
5.5mm
07742- q)101tt0
CAUTION; Drill guid6 only in oxtromc cs3os:you

could dlmsgo tho cylinder hoad if tho guidc brcakr.
t uidesand chill
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
them in the freezer section of a refrigerator for
aboutan hour.
Use a hot plate or oven to evenly heatthe cylinder
headto 300'F(150"c).Monitorthe temperaturewith
a cookingthermometer.
VALVEGUIDEDBIVER.
5.5mm
07742- 0010100
-_ -\
lo
CAUTION:
. Do not us9 a iorch; it may warp ths hsad.
. Do not get ths head hottor than 300"F (150"C);
excsssivohgat may loogenthe valvo soaG.
. To avoid burns, use hsaw glovo3whon handling
the heated cylindor had.
vnx.su
6.
oc)
one
Removethe new guide(s)from the refrigerator,
at a time, as vou needthem.
(cont'd)
Valve Guides
(cont'dl
Replacement
7.
Reaming
Slip a 6 mm {0.2 in) steel washer and the correct

driver attachmentover the end of the driver (The
washerwill absorbsome of the imDactand extend
the life of the driver).
:=:-/--P
DRIVER
6 mm 10.2int
WASHER
ATTACHMENT
Installthe new guide(s)from the camshaftside of

t h e h e a d ;d r i v e e a c h o n e i n u n t i l t h e a t t a c h m e n t
bottomson the head.lf you have all sixteenguides
to do, Vou may haveto reheatthe head one or two
more times.
NOTE:For new valveguidesonly.

1.
Coatboth reamerand valveguidewith cuttingoil.
2,
Rotatethe reamer clockwisethe full length of the

valveguide bore.
3.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit from the bore.
4.
Thoroughlywash the guide in detergentand water

to removeany cuttingresidue.
5.
Checkclearancewith a valve(seepage6-70).
.
Verifythat the valve slidesin the intakeand exhaustvalveguideswithout exertingpressure.
REAMERHANDLE
Turn reamerin
clockwisedirection
onry.
C'
a
-'{
)
Valve Guide Installed Height:

Intake: 12.55- 13.05mm {0.49it- 0.51itinl
Exhaust 12.55- 13.05mm {0.494- 0.514inl
VALVEGUIDE
6-72
vnx.su
ValveSeats
Reconditioning
After resurfacingthe seat, inspect for even valve
s e a t i n g :A p p l y P r u s s i a nB l u e C o m p o u n dt o t h e
valve face, and insen valve in original location in
thc hea.l.then lift it and snap it closedagainstthe
seat severaltimes.
Renewthe valve seats in the cylinder head using

valve seat cutters.
NOTE: lf guides are worn, replacethem before cutting the valveseats.
ACTUALSEATING
SURFACE
VALVE
SEAT
PRUSSIANBLUE
The actualvalve seatingsurface,as shown by the

bluecompound,shouldbe centeredon the seat.
. lf it is too high (closerto the valve steml, you
must make a second cut with the 60' cutter to
move it down, then one more cut with the 45'
cutter to restoreseat width.
. lf it is too low (closer to the valve edge), you
must make a secondcut with the 30'cutter to
move it up, then one more cut with the 45" cutter
to restoreseat width.
NOTE; The final cut should alwavs be made with
the 45'cuttef.
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 go n l y e n o u g h
materialtoensurea smoothand concentricseat.
1.
Bevelthe upperedge of the seatwith the 30' cutter
and the lower edge of the seat with the 60'cutter'
Checkwidth of seatand adjustaccordingly.
lnsert intake and exhaust valves in the head and

measurevalvestem installedheight.
Intake Vllve Stm ln3tslled Hsighl:
Stsndard (Now): 37.'155- 37.935mm
(1.4750- f .il935in)
38.185mm 11.5033in)
SorvicoLimit:
ExhaustValvo Stom In3talledHoight:
Standard (Now): 37.165- 37.6:15mm
- 1.,1817
inr
11.4{X}2
(1.i1915
in)
Limit:
37.885
Sewico
Make one more very light pass with the 45ocutter to

removeanv possibleburrs causedby the other cutters.
Valve Seat Width:
1.25- 1.55mm {0.0,19- 0.061in)
Stlndard:
Ssrvico Limit 2.0 mm 10.08in)
SEAI wlDTH
VALVE STEM
INSTALLEDHEIGHT
8.
lJ valve stem installed height is over the service

limit, replacevalve and recheck.lf still over the service limit. replacecylinder head;the valve seat in
the headis too deeD.
6-73
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GylinderHead
Warpage
NOTE: lf camshaft-to-holderoil clearances(see page
6-65)are not within specification.the head cannot be
.esurfaced.
Measurealongedges.and 3 ways acrosscenter.
lf camshaft-to-holder
oil clearancesare within sDecifications,checkthe headfor warpage.
lf warpage is less than 0.05 mm {0.002in) cylinder
headresurfacingis not required.
lf warpageis between0.05mm {0,002in) and 0.2 mm
{0.008in), resurfacecvlinderhead.
Maximum resurfacelimit is 0.2 mm {0.008in) based
on a heightof 142mm (5.59in).
PRECISION
STRAIGHTEDGE
Cylindsr Hssd Height:

Standard lNsw): 1i11.95- 1,f2.05mm
15.s89- 5.593inl
6-74
vnx.su
lnstallation
Installthecylinderheadin the reverseorderof removal:
NOTE:
. Alwaysusea new headand manifoldgasket.
. The cylinderheadgasketis a metal gasket Takecare
not to bend it.
. Rotatethe crankshaft,set the No. 1 piston at TDC
(page6-51).
. D o n o t u s e t h e m i d d l ec o v e r a n d l o w e r c o v e rf o r
. Cleanthe middlecoverand lowercover beforeinstallation.
a Replacethe washerwhen damagedor deteriorated
1.
2.
Tightencylinderhead bolts in two steps.In the first

step, tighten all bolts in sequenceto about 29 N'm
( 3 . 0 k g f . m . 2 2 l b f ' f t ) .I n t h e f i n a l s t e p ,t i g h t e n i n
samesequenceto 81 N.m (8.3kgnm.60lbf'ft).
NOTE: Apply clean engine oil to the bolt threads
and underthe bolt head.
CYLINDERHEADBOLTTOROUESEOUENCE
1 1x 1 . 5m m
81 N.m{8.3kgf.m,60lbfft)
tnstallthe cylinderhead gasket.dowel pins and the

headoil controlorificeon the cylinderhead
NOTE:Cleanthe oil controlorificewhen installing.
O.RING
Replace.
HEAD
OIL CONTROL
ORIFICE
Cloan.
Installthe intakemanifoldand tightenthe nuts in a

crisscrosspatternin two or three steps,beginning
with the inner nuts.
GASKET
RePlace
8 x 1.25mm
23 N.m 12.3kgl.m.
17 tbf.ftt
8 x 1.25mm
kgf m,
24 N,m 12.,4
17 tbf.ft)
(cont'd)
6-75
vnx.su
CylinderHead
Installation{cont'd)
4.
Install the exhaust manifold and tighten the new

selJ-lockingnuts in a crisscrosspattern in two or
threesteps,beginningwith the inner nuts.
.
5.
NOTE:
. Installthe camshaftswith keyway facing up.
o Installtheoil sealwith the springsidefacingin.
. The oil sealhousingsurfaceshouldbe dry,
. Set the O-ringand dowel pin in the oil passage
of th No. 3 camshaftholder
Usenew self-lockingnuts.
SELF.LOCKING
NUT
8 x 1.25mm
31 N.m 13.2kgf'm, 23 lbtltl
Replace.
8 r 1.25mm
2aN..n12.4lgtm,
r 7 tbf.ftl
EXHAUST
O-RING{ReDlace.)
GASKET
Replsco.
&,x
a.l N.m 14.5kgt m,
33 tbr.trl
Installthe camshafts,camshaftoil sealsand rubber

cap.
Kgywayis lacingup.
A p p l y l i q u i d g a s k e ta r o u n dt h e r u b b e rc a p , t h e n
installthe rubbercap.
8 x 1.25mm
24 N.m (2.4 kgt m,
rt tbfft)
6-76
vnx.su
7.
Apply liquid gasket to the hesd mating surface of

th No. 1 and No. 5 camshaft holders on both the
intako and exhaust side. Confirm that the camshaft
koywEysface up, then place those holders,together
with th No.2, No. 3 and No.4 camshaftholders,
on th cylind6r head.
9. Tightenthe bolts in the sequenceshown below.
NOTE: The arrows msrked on the camshaft holders

shouldpoint to the timing belt.
INTAKE
CAIISHAFTHOIDERS
lrlo.6
Ho.a
r
t
No.3
l
t
1to.2
t /
l bl
d
ffi
rfl?x
888
ro
I
t
o o o
\trt
EXHAUST
Applyliquidgaskot
to lh6 3haddaroas.
Temporarilytightonthe bolts of tho camshafthold6rs and thE camshaftholderplates,
(D - @: 8 x 1.25mm 27 N.m {2.8 kgf.m,20 lbt ttl

(D - (D: 6 x 1.0 mm 9.8 N.m (1.0 kgrl.m,7.2 lbf'ft}
10. Installthe backcoverand camshaftpulleys.
CAMSHAFT
CAMSHAFT HOI,I'ER
10x 1.25mm
56 N.ln l5.t kgf.m,
4r lbl.trl
6x1.0mm
9.8 N.m 11.0kgtm, t.2lbf'ft)
(cont'd)
6-77
vnx.su
CylinderHead
Installation lcont'd)
1 1 . lnstallthetiming belt lsee page6-51).
14. Apply liquid gasketto the rubbe. seal at the eight

corne.s of the recesses.
12. Adjustthe valveclearance(seepage6-44).

1 3 . Installthe rubberseal in the grooveof the cylinder
head cover. Seat the seal in the recessesfor the
camshaftfirst, then work it into the groove around
the outsideedges.
NOTE:
. B e f o r e i n s t a l l i n gt h e r u b b e r s e a l .t h o r o u g h l y
cleanthe sealand the groove.
. W h e n i n s t a l l i n gm
, a k es u r e t h e s e a l i s s e a t e d
securelyin the cornersof the recesseswith no
gap.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001.
. Checkthat the matingsurfacesare cleanand dry
a Do not install the parts if 20 minutes or 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,.eapplyliquid gasketafter removingold
residue.
r After assembly, wait at least 20 minutes before
filling the enginewith oil.
Apply liquidgasketto
the shadedareas.
COVER
6-78
vnx.su
Tighten the nuts in 2 or 3 steps. In the final step'

tighten all nuts, in sequence,to 9.8 N'm (1.0kgf'm,
7.2 tbf.ft).
When installingthe cylinder head cover. hold the

rubbersealin the grooveby placingyour fingerson
the camshaftcontactingsurfaces(top of the semicircles).
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,slidethe cover slightlybackand forth to seat
the rubberseal.
NOTE:
Before installingthe cylinder head cover, clean
t h e c y l i n d e rh e a d c o n t a c t i n gs u r f a c e su s i n g a
shop towel.
Do not touch the pans where liquid gasketwas
applied.
6x1.0mm
9,8 N.m 11.0kgt'm,
7.2 tffirl
1 7 . After installing,checkthat all tubes,hosesand connectors are installedcorrectly.
6-79
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EngineBlock
PistonRings
.............7'2
SpeciafTools
.........7-16
Replacement
7-3
lllustratedIndex ...................................
.................7-17
EndGap
Flywheel and Drive Plate
7 -17
Ring-To-Groove
C|earance,,,,.,,,......
.........7-7
Repfacement
..............7-18
Alignment
Main Bearings
Piston Pins
7-8
,..............
Clearance
........,........7-18
Removal
7-8
................
Selection
7-19
Installation(818B1engine) .............
Connecting Rod Bearings
(818C1
7-20
enginel .............
fnstaffation
...............
7-9
Clearance
..............7-2O
fnspection
7-9
................
Selection
Rods
Connecting
Crankshaft
.................7-21
.................7-10 End Play
Removal
..........,,,,,,7-22
.................7-12 Sefeetion
EndPlay
........,,,.,,7-12 Oil Seal
lnspection
.............7-25
fnstaffation
.............7'22
fnstallation
Installation
CylinderBlock
(engineremoval not requiredl.........7-26
..............7-13
Inspeetion
.....,.,,.7'14
BoreHoning
Pistons
..............7-15
Inspaction
.............7-16
Installation
vnx.su
SpecialTools
Raf.No.
07GAF- PF60300
07HAF- P120102
_ PR4O1OA
OTLAD
07LAF PR30100
07LAB- PV00100
or
07924- PD20003or
01924 - PD20002
07948- S800101
07749- 0010000
07973- PE00310
07973- PE00320
07973- 5570500
07973- 6570600
@
@
@
Tool Numbcr
Dcacription
Oty
Piston Pin Easelnsert

Piston BaseHead
Seal Oriver
PilotCollar
RingGearHolder
1
I
1
'I
Driver Attachment
Driver
Piston Pin Driver Shaft
Piston Pin Driver Head
Piston Base
PistonBaseSpring
1
1
1
1
1
1
Pago Rotcrenc.
7-14,19,20
1-18,19,20
7-19,20
7-1
7-25,26
7-19,20
1-19.20
1 - 1 8 ,1 9 ,2 0
1-18
Eg
o
,a\
0
@
7-2
vnx.su
lllustrated Index
Lubricateall internalpartswith engineoil during
reassemory.
NOTE:
Apply liquidgasketto the matingsurfacesof the right
s i d e c o v e r a n d o i l p u m p h o u s i n gb e f o r ei n s t a l l i n g
them.
- 0001.
. U s el i q u i dg a s k e tP, a n N o . 0 8 7 1 8
. C l e a nt h e o i l p a n g a s k e t m a t i n g s u r f a c e sb e f o r e
installingit.
.
Bl8Bl engine:
6x1.0mm
12 N.m (1.2kgf.m,I lbf.ftl
OIL PAN
wAsHEF
DRAINPLUG
44 N.m {4.5kgf.m,
33 tbtfr)
6x1.0mm
11 N.m (1.1kgf.m,8lbtft)
GASKET
Replace.
OIL SCREEN
6x1.0mm
1'l N.m {1.1kgt.m, I lbtft)
12 x 1.0mm
103N.m (10.5kgf.m,?6lbf ft)
MANUAL
FLYWHEEL
'12x 1.0mm
74 N.m {7.5kgt m,54lbf.ftl
page7 7
Torquesequence,
GASKET
Replace.
WASHER
BEARINGCAP
AUTOMATICTRANSMISSION
DRIVE PLATE
Checkfor cracks,
Apply liquidgasket
to blockmatingsurface.
11 x 1.25mm
76 N.m
17.8kgl.m, 56 lbf ftl
Applyengineoilto the bolt
threadsand the washers.
NOTE: After torquing
each cap, turn crankshaft
to checklor binding.
CRANKSHAFT
End play,page7-12
Runout,Taper,and
pages7 12,13
Out-of-Round,
page7 22
Instsllation,
MAIN BEARING
page7-8
Radialclearance,
page7-8
Selction,
NOTE:New main bearings
must be selectedby matching
crankand blockidentification
markrngs.
6x1.0mm
11 N.m {1.1kgl.m,
8 tbf.frt
OIL SEAL
page7-25,
Installation,
RIGHT
SIDECOVER
DOWELPINS
THRUSTWASHERS
Groovedsidesfaceoutward.
NOTE:Thrustwasherthickness
is tixedand must not be changed
by grindingor shamming.
OIL PUMP
Overhaul,page 8-9
8 x 1.25 mm
2,1N.m {2.4kgt m,
17 tbt.ft)
O.RING
Applyengrne
orl.
Replace.
OIL SEAL
page8-11
Installation,
6x1.0mm
Apply liquidgasket '11N.m {1.1kgf'm, 8 lbl ft)
to blockmating
(conr'dl
7-3
vnx.su
lllustratedIndex
(cont'd)
NOTE:
. Apply liquidgasketto the matingsurfacesof the right
side cover and oil pump housing before installing
thsm.
. Useliquidgask6t,PartNo. 08718- 0001.
. C l e a nt h e o i l p a n g a s k e t m a t i n g s u r t a c sb e f o r e
innallingit.
Bl8Cl !ngin.:

reassemblv.
DBAINPLUG
4,aN.mla.stgl.m.
33 rbr.ftt
6x1.0mm
11 N.m (1.1kgt m,
E |bfitl
OIL PAN
12x t.0 mln

lo:t N.|n110.510f'm,
tG lbffrl
page7-7
Torquesoquonce.
6x1.0mm
ti l*m 11.lkgf m,
I tbf.ftl
GASKET
Replace.
BAFFLEPLATE
6xl.0mm
ll N.m (1.1kgt m.
8 tbt frl
O|L SCAEEN
6 x 1.0 rim
11 N.m (1.1 kgf.m,
8 tbt ft)
FLWYHEEL
7-4
vnx.su
No. a 3, /aCAP BOLTS

l l x 1 . 5m m
64 N.m {6.5 kgt m,
49 tbf.ftl
Applyengineoilto tho bolt
threads and the washers.
NOTE:Aftertorquing
each cap, turn crankshaft
to checkfor binding.
BEARING
CAPBRIDGE
No. 1,5 CAP BOI-TS

11x 1.5mm
73 N.m {7.4 kgf.m,
56 tbt'ft|
Apply engineoil.
CRANKSHAFT
Endplay,page7-12
Runout,Taper,and
pages7'12.13
Out-of-Round,
page7-22
Installation,
BEARINGCAP
YHRUSTWASHERS
Groovedsideslace outward.
NOTE: Thrust washerthickness
is fixedand must not be chanod
MAIN BEARING
page7 8
Radialclearance.
S6lction,page7-8
NOTE:New main bearings
must be selectedby matching
crank and block identification
marxrngs.
OIL SEAL
Installation,
pages7-25,26
Replace.
OIL JEI BOLY

16 N.m 11.6kg{'m,12lbtftl
Be caretul not to damage.
OIL JET
Inspection,
page 8-8
6r1.0mm
11 N.m 11.1kgt m,
8 lbf ftl
RIGHTSIDE
COVER
Applyliquidgasket
to block mating
surface.
OIL PUMP
Overhaul,page8-9
Apply liquidgasket
to block mating
surface.
6x1.0mm
11 N.m {1.1kSf.ft,
8 rbf.ftl
DOWELPIN
DOWELPIN
O.RING.
Apply engine
orl.
Replace.
OIL SEAL
Instellelion,
page8-11
Replace.
8 x 1.25mm
24 N.m {2.4 kgt m,
17 tbtft)
(cont'd)
7-5
vnx.su
lllustratedIndex
(cont'd)
reassemorv.
NOTE: New rod bearingsmust be selectedby matching

connectingrod and crankshaftidentificationm a r K r n g s
( s e ep a g e s7 - 8 , 9 )
r@
-1@
PISTONINSTALLATIONDIRECTION
PISTONRINGS
page7'16
Replacement,
page7-17
Measurement.
Alignment,page7 18
EXHAUST
PISTONPIN
Removal,page7-18
pages7 19,20
lnstallation,
page7'20
Inspection,
INTAKE
Removal,page7'11
page7 15
Measurement,
CONNECTING
ROO
Endplay,page7-21
page7-22
Selection,
page7-21
Smallend measurement.
Inspecttop of each cylinder bore

for carbonbuild-upor ridgo
betore removing piston.
page7'11
Removeridgeit necessary,
ROD
CONNECTING
EEARINGS
page7-9
Clearance,
Selection,page7-9
RODNUT
CONNECTING
818B1ongine
8 x 0 . 7 5m m
31 N.m {3.2 kgf.m,23 lbf ftl
818C1engine
9 x 0.75mm
a,aN.m (4.5kgt m, 33 lbf.ft|
Aftertorquingeachbearang
cap, rotate crankshaftto
checkfor binding.
BLOCX
page7 13
Cylinderboreinspection,
page7'14
Warpageinspection,
Cylinderborehoning,page7-14
CONNECTING
RODBEARINGCAP
page7'23
Installation,
NOTE:Installcapsso the bearingrecessis
on the samesideas the recessin the rod.
r-(,
vnx.su
Flywheel and Drive Plate

Replacement
ManualTransmission:
AutomaticTransmission:
Removethe eight flywheel bolts,then separatethe llyw h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n ,

tightenthe boltsin the sequenceshown.
Removeth eight drive plate bolts, then separatethe

drive plate from the crankshaftflange, After installation,
tightenthe bolts in the sequenceshown.
RINGGEARHOLOER
o?LAB- PV00100,
07924 - PO2IX)03or
07924 - PD20/m2
.t=?4
/ AK{:{AAo
fut!!-+-r
t=tz-21
I lvaz'Z
- +
rs#*ffi_9
ENGINE
BLOCK
r t.0 mm
t,l N.m
(7.5 kg{.m,54 lbf.ft}
-o.r
/ oo^t,
\..?bi
r10.5kgi.m,76lbt.ftl
7-7
vnx.su
Main Bearings
Selection
Clearance
T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,
removethe main capsand bearinghalves.
C l e a ne a c h m a i n j o u r n a la n d b e a r i n gh a l f w i t h a
cleanshop towel.
Placeone strip of plastigageacrosseach main iournal.
NOTE:lf the engineis still in the car when you bolt
the main caD down to checkclearance,the weight
of the crankshaftand flywheelwill flattenthe plastigage further than just the torque on the cap bolt,
and give you an incorrectreading.Fot an accurate
reading, support the crank with a iack under the
counterweightsand check only one bearing at a
trme.
Reinstallthe bearing caps and cap bridge (818C1
engineonly)then torquethe bolts.
81881engine:77N'm (7.8kgf'm,56lbl'ft)
818C1engine:
73 N'm (7.'lkgt'm,56lbf'ftl
No. 1,5 cap bolts
N'm (6.5 kgf'm, 49 lbf'ftl
6a
4
cap
bolts
No. 2, 3,
NOTE:Do not rotatethe crankshaftduring inspectron,
Removethe cap bridge (818C1engine only), caps
and bearingsagain,and measurethe widest part oJ
the plastigage.
Main Bearing-to-JournalOil Clarance:
Standard (Newl:
No. 1, 2, 4, 5: 0.024- 0.042mm
- 0.0017inl
10.0009
ServiceLimit: 0.050mm {0.0020inl
0.030- 0.0,18mm
No. 3:
- 0.0019inl
(0.0012
Ssrvice Limit: 0.060mm {0.0024inl
CAUTION: lf ths codes are indeciphorable becau3o ot

an lccumulation ol dirt and dust, do not gcrub thgm
with a wirs brush or gcrapsr.Clean them only with 3olvont or doisrggnt.
Crankshaft Bore Code Location

Letters have been stamped on the end of the block as a
codefor the sizeof eachof the 5 main journalbores
U s e t h e m , a n d t h e n u m b e r so r b a r s s t a m p e do n t h e
crank(codesfor main journalsize),to choosethe correct
bearings.
Mlin Joumal CodGLocttion3 (Numborsor
gaBl
STNIP
PLASTIGAGE
lf the plastigagemeasurestoo wide or too narrow,

(removethe engineif it's still in the car),removethe
crankshaft.and removethe upper half of the bearing. Installa new. completebearingwith the same
color code (selectthe color as shown in the right
column),and recheckthe clearance.
CAUTION: Do not file, shim, or scrapoihe bo.rings
or the caps to adiust clearance.
lf the plastigageshows the clearanceis still incorrect,try the next largeror smallerbearing(thecolor
listedaboveor belowthat one),and checkagain.
NOTE: lf the Droperclearancecannot be obtained
by usingthe appropriatelargeror smallerbearings,
reolacethe crankshaftand startover.
7-8
vnx.su
B..ring ld.ntificrtion
Colorcodeis
on the edge ot
the bearang.
Largercrank Dore
-------.r>
smaller bearing(thicker)
tr;;lIl
IlE;tl
t r -I tt l
l H l t
I L o . " " lLiGreen

Smaller
msin
journal
Smaller
bearing
(thicker)
G'een
Gre^
Blacr
Green
Elack
Blue
ConnectingRod Bearings
Selection
Clearance
1.
Removethe connectingrod cap and bearinghalf.
2.
Cleanthe crankshaftrod journal and bea.ing half

with a cleanshootowel.
CAUTION: lf the codss are indeciphsrable bocause of

an accumulation of dirt and dust. do not scrub tham
with a wiro brush or scraper.Clean them only with solvont or dotetgenl.
3.
Placethe plastigageacrossthe rod journal.
Connecting Rod Code Location
4.
Reinstallthe bearing half and cap, and torque the

nuts.
A number has been stampedon the side of each connectingrod as a code for the sizeof the big end. Use it,
and the lettersstampedon the crank(codesfor rod journal size),to choosethe correctbearings.
81881 sngino: 31 N'm 13.2kgf.m,23 lbt'ft)

818C1sngine: 4,1N.m 14.5kgf.m. 33 lbf'ft}
NOTE:Do not rotatethe crankshaftduring inspection.
ConnectingRod Baring-to-JournalOil Clcalancr:
8l88l ongine:
Standard (New): 0.020- 0.038mm
{0.0008- 0.0015in)
ServicaLimit: 0.050mm (0.0020inl
818C1engin:
Standard (New): 0.032- 0.050mm
(0.0013- 0.(XP0inl
ServiceLimit: 0.060mm (0.0024in)
Halfof numberis
stampedon bearing
cap and the other
half is stampedon
rod.
STRIP
PLASTIGAGE
Conn.cting Rod Joumsl Codc LocatioN lLotteE or B.trl
ll the plastigagemeasurestoo wide or too narrow,

removethe upper half of the bearing.installa new,
completebearingwith the same color code (select
t h e c o l o r a s s h o w n i n t h e r i g h t c o l u m n ) ,a n d
recheckthe clearance.
Berring ldcntification
Colorcodeis
on the edgeof
the bearing.
Largerbig end bore

t
CAUTION: Do not file, shim, or scrape lhe bearing

or the capgtq adiust clgaranca.
1.
lf the plastigageshows the clearanceis still incorrect,try the next la.geror smallerbearing{the color
listed above or below that one), and check clearanceagain.
NOTE: lf the proper clearancecannot be obtained
by usingthe appropriatelargeror smallerbearings,
reolacethe crankshaftand stan over.
vnx.su
3
Smallerbearing{thicker)
tF;l
It
l - l f
Grn
Red
l i B o r ' r lI l
lEalllt
I 1 o . , , ,L' l l
Smaller
rod
journal
Smaller
bearing
(thicker|
Elack
Blak
Blue
Crankshaft
Removal
NOTE:End play for th connectingrods and crankshaft
shouldbe inspectedbetoreremovingthe crankshaft.
1.
Removethe oil Dan,oil screenand the oil pump.
5,
Removethe bearingcap bolts,

CAUTION: To prevent warPag, unscrew ths bohr
in 3equoncg1/3 turn at a tim; rspeat ihe sgquanco
until all bolts are loosned.
OIL PAN
R e m o v et h e c a p b r i d g e { 8 1 8 C 1e n g i n eo n l y } a n d
in order.
Keepall caps/bearings
main caps/bearings.
Removethe baffleplate.
Turn the crankshaftso No.2 and 3 crankpinsar at
the bottom.
Removethe right side cover.
7 -1 0
vnx.su
7 . Removethe rod caps/bearings.

Keepall caps/bearings in order.
8 . Lift the crankshaftout of the engine,being careful
not to damagejournals.
12. Use the wooden handleof a hammer to drive the

prslonsouI.
CAUTION:
a Take care not to damage the contact surfaco ot
the metal gasket.
. When removing the piston/connecting rod, taks
caronot to hit the oil iot {818C1snginsonlyl.
. It tho oil iet nozzlo is damag6d or bont, replaco
the oil ist assembly (818C1engine only, page 88).
CRANKSHAFT
9 . Removethe upper bearinghalvesfrom connecting
caDs.
rodsand setthem asidewith their resDective
1 0 . Reinstallmain caps and bearingson the engine in
oroDerorder.
1 1 .l f y o u c a n f e e l a r i d g e o f m e t a l o r h a r d c a r b o n
around the top of each cylinder, remove it with a
ndge reamer.
instructions.
Followthe reamermanufacturer's
CAUTION: It the ridge is not removed, it may damage the pistons as they are pushed oul.
1 3 . Reinstallthe rod bearingsand caps after removing

eachpiston/connecting
rod assembly.
rod assemblywith its
1 4 . Mark each piston/connecting
RIDGEREAMER
cylindernumberto avoid mixup on reassembly.

NOTE:The existingnumber on the connectingrod
does not indicateits positionin the engine,it indicatesthe rod bore size.
7-11
vnx.su
Crankshaft
lnspection
End Play
NOTE;End play should be inspectedbefore removing
crankshaft.
Pushthe crankfirmly awav from the dial indicator,and
zerothe dial againstthe end of the crank.Then pull the
c r a n k 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 r ;d i a l r e a d i n g
shouldnot exceedservicelimit.
.
.
Cleanthe crankshattoil passageswith pipe cleaners

or a suitablebrush.
Checkthe keywayand threads.
Alignment
Measurerunouton all main journalsto makesurethe
crankis not bent.
The differnce between measurementson each journal must not be more than the servicelimit.
Crank3haftTotal lndicatod Runout:
Bl8Bl engins:
Sisndod {Nsw): 0.03 mm {0.001in) max.
SorviceLimit: 0.05 mm {0.002inl
818C1engin:
Standard {Nsw): 0.020mm (0.0008in} mar.
SGrviceLimits: 0.030mm 10.0012in)
OIALINDICATOR
Rotatetlvo complete
revolutions.
CrankshaftEnd Play:
Standard(New):0.10- 0.35mm
(0.04- 0.01i|inl
SrvicLimit
0.i15mm (0.018inl
.
lf end play is excessive,inspectthe thrust washrs

Replacepans as
and thrust surfaceon the crankshaft.
necessary.
NOTE:
Thrust washer thickness is fixed and must not be
changedeitherby grindingor shimming.
Thrustwashersare installedwith groovedsidesfacing outward.
7-12
vnx.su
Support with lathe-
GylinderBlock
Inspection
Out-ot-Roundand Taper
1.
Measureout-of-roundat the middle of each rod and

main journalin two places.
The differencebetween msasurementson each journal must not be more than the se.vicelimit.
Measure wear and taDer in dirsction X and Y at

three levelsin eachcvlindsras shown.
6mm
Journal Oul-of-Round:
Bt8Bi.ngine:
Strndrrd (Now): 0.(x15mm
Scrvicr Limit
0.010mm
Bl8Cl cngins:
Strnd.rd {Nowl: 0.004mm
0.qt6 mm
Sorvicc Limit
(0.0002inl m!x.
(o.fixx inl
Meaauremonl
Second
Moa6urgmont
Thi.d
M063uremgnt
G mm {0.24in}
(0.(XD16inl m!x.
{0.qx!2,1 in}
near edggs.
frrgt
BOREGAUGE
CYUNDER
Cyllndor Borr Siz.:

Standard (Ncwl: 81.q!- 81.02mm
(3.18, - 3.190inl
Scrvicr Limh: 81.07(3.192in)
Ovar3izc:
O.25t81.25- 81.27mm (3.199- 3.200inl
Borc Tlpor:
(Ditfcrcncc bctw!.n firtt tnd third
Scrvice Limit
moasurcm.ntl 0.115
mm (0.002in)
.t +
.
.
Measuretaper at the edges of each rod and main
journal.
The difference between measurementson each journal must not be more than the servicelimit.
Journal Tapor:
8l8Bl angino:
Standard (Newl: 0.q)5 mm l0.0(Xl2inl m.x.
0.010mm (0.0004inl
SorvicoLimit
BlSCl ongino:
Standrrd (Now): 0.005mm (0.0002inl m8x.
Scrvic Limit
l f m o a s u r m e n t si n a n y c y l i n d s r a r e b e y o n d
OversizeBore ServiceLimit, rsglacethe block.
lf the block is to be rebored, refer to Piston
ClearanceInspection(see page 7-151after reboring.
NOTE: Scored or scratchedcylinder bores must be

honed.
Rcboring Limil: 0.25 mm (0.01inl
(cont'd)
7-13
vnx.su
CylinderBlock
Inspection(cont'dl
2. Checkthe top of the blockfor warpage.
Measurealong the edgesand acrossthe centeras
snown.
Measurecylinderboresas shownon page7-13.

lf the block is to be reused,hone the cylindersand
remeasurethe bores.
Honecylinderboreswith honing oil and a fine (400
pattern.
grit) stonein a 60 degreecross-hatch
SURFACES
TO BE MEASURED
NOTE:
. Use only a rigid honewith 400grit or finer stone
suchas Sunnen,Ammco,or equivalent.
a Do not usestonesthat are worn or broken.
Engine Block Warpsgc:

81881ongine:
Standard lNewl: 0.07 mm {0.003inl max.
ServiceLimil: 0.10mm {0.00,1inl
B18Cl engine:
Standard (New): 0.05 mm 10.002inl max.
ServiceLimit
0.08 mm {0.003inl
W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e
cylinderblockof all metal panicles.Wash the cylinder bores with hot soapy water, then dry and oil
immediatelyto preventrusting.
NOTE: Never use solvent, it will only redistribute
the grit on the cylinderwalls.
lf scoring or scralchesare still presentin cylinder
bores after honing to the service limit, reborethe
engineblock.
NOTErSome light venicalscoringand scratchingis
acceptableif it is not deepenoughto catchyour fingernailand does not run the full lengthof the bore.
CYLINDERHONE
.
.
7-14
vnx.su
After honing,cleanthe cylinderthoroughlywith

soapywater.
Only scoredor scratchedcylinderboresmust be
noneo.
Pistons
Inspection
1.
3,
Checkthe oiston for distortion or cracks.

NOTE:lf the cylinderis bored,an oversizedpiston
must be used,
2.
M o a s u r t h e p i s t o n d i a m e t e ra t a p o i n t l 5 m m
(0.6in) from the bottomof the skin.
C a l c u l a t et h e d i f f e r e n c eb e t w o nc v l i n d e r b o r e
diameteron (seepage7-13)and pistondiametsr.
Pbton-io"Cy'indorClea18nco:
Stsndard (Nrwl: 0.010- 0.0/O mm
{o.ofira- 0.0016in}
S.rvic. Limit: 0.05 mm {0.002in)
Pbion Diamat6r:
Standard lNowl: 80.S - 80.99mm
(3.188- 3.189inl
Limit
80.97
mm (3.188in)
Sorvica
rKI
lf the clearanceis near or xcedsthe servicelimit,
inspect the piston and cylinder block for excessive
wear.
Ov.rsizc Pilton Diamcter:
O.25t81,23- 81.21|rnm{3.1980- 3.198'lin)
7-1
vnx.su
Piston
PistonRings
lnstallation
Replacement
Beforeinstallingthe piston,applya coat of

engineoil to the ring groovesand cylinderbores.
1 . Usinga ring expander,removeold pistonrings.
'1. lf the crankshaftis alreadyinstalled:

. Removethe connectingrod caps and slip short
sectionsof rubber hose ove. the threadedends
of the connectingrod bolts.
a Installthe ring compressor,checkthat the bear'
ing is securelyin place,then positionthe piston
i n t h e c y l i n d e ra n d t a p i t i n u s i n gt h e w o o d e n
handleof a hammer.
Stop after the ring compressor pops free and
checkthe connectingrod-to-crankjournal alignment beforetappingpistoninto place.
. Installthe rod caps with bearings,then torque
the nuts,
81881 ongino: 31 N.m {3.2 kgf.m, 23 lbf.ftl
818C1cngino: 44 N'm 1,t.5kgf.m, 33 lbf.ftl
lf the crankshaftis not installed:
o Removethe rod caps and bearings.install the
ring compressor,then positionthe piston in the
cylinderand tap it in usingthe woodenhandleof
a nammer.
. Positionall Distonsat toD deadcenter.
The arrow must face

the timing beltside
of the engine.The
connectingrod oil hole
must lace the intak
manifold{81881ngine).
ROD
CONNECTING
OIL HOI-E(Br8Bl onginel
NOTE:Maintaindownwardforce on the ring compressor to prevent rings from expanding before

enteringthe cylinderbore,
BINGCOMPRESSOR
Usethe woodenhandle
of a hammerto pushor
tap the pistonintothe
cylinderbore.
vnx.su
Cleanall ring g.oovesthoroughly.

NOTE:
. Use a squared-oJfbroken ring or ring groove
cleanerwith bladeto fit pistongrooves.
. Top ring groove is 1.0 mm (0.039in) wide, second groove is 1.2 mm (0.047in) wide. and oil
ring grooveis 2.8 mm (0.110in) wide.
. Filedown bladeif necessary.
CAUTION: Do not use a wire brush to cloan thr
ring lands, or cut ring lands dsopo. with claning
tool.
NOTE: lf the piston is to be separatedfrom the connectingrod, do not installnew ringsyet.
Installnew rings in the prope. sequenceand position (seepage7-18).
NOTE:Do not useold pistonrings.
I
'1.
Using a piston, push a new ring into the cylinder

bore 15- 20 mm (0.6 0.8 in) from the boftom.
After installinga new set of rings, measurethe ring-togfoove clearances:
M e a s u r et h e p i s t o n r i n g e n d - g a pw i t h a f e e l e r
gauge:
Top Ring Clarance:

Standard lNewl: 0.045- 0.070mm
10.0018- 0.0028in)
ServiceLimit: 0.13mm {0.005inl
lf the gap is too small.checkto see if you have

the properringsfor your engine.
lf the gap is too large,recheckthe cylinderbore
diameteragainstthe wear limits on page7-13.
ll the bore is over the servicelimit, the cylinder
blockmust be rebored.
SecondRing Clearance:
Standard {Newl: 0.040- 0.065mm
(0.0015- 0.0026inl'1
0.0i15- 0.070mm
- 0.0028in)',
(0.0018
ServiceLimit: 0.13 mm (0.005inl
Piston Ring End-cap:

Top Ring
(0.008- 0.01'linl'1
0.20- 0.30 mm
- 0.012inl''
10.008
ServicaLimit: 0.60 mm (0.024in)
Second Ring
Standard (Now): 0.40- 0.55 mm
- 0.022in)
10.016
ServiceLimit: 0.70 mm (0.028in)
Oil Ring
(0.008- 0.020in)'1
0.20- 0.,15mm
{0.008- 0.018inl',
ServicaLimit: 0.70 mm 10.028in)
iliiii
.--r.llli.j---.-
PISTONNING
ioi
---'z
ll
ENDGAP-11-RIKENmanufactured
pistonring
T E I K O K UP I S T O NR I N Gm a n u f a c t u r e do i s t o n r i n q
{ 8 1 8 8 1e n g i n eo n l y )
RIKENmanufacturedpistonring
T E I K O K UP I S T O NR I N Gm a n u f a c t u r e dD i s t o nr i n o
( B ' 1 8 8e1n g i n eo n l y )
7-17
vnx.su
PistonRings
PistonPins
Alignment
Removal
1.
1.
Installtheringsas shown.
ldentifytop and secondrings by the chamferon the
edge.Makesurethey are in their propergrooveson
the prston.
Assemblethe PistonPin Toolsas shown.

PISTON BASE HEAD
PISTO]TPIN BASE INSEN|T
--r
otGAF- PH6{t1,0
NOTE: The manufacturingmarks must be facing

upwaro.
TOPBING
--l
PISTON BASE SP '{G
07973 - 65r06{X'
SECONDRING
Rotatethe rings in their grooves to make sure they

do not bind.
MARK
OIL RING
3.
SPACER
Positionthe ring end gapsas shown:

sEcoNo
----'-- R|NG
_- GAp
- {
position ' ring

' gap
DO NOT
-.:': :.-"' : -any
at prston
thrustsurfaces.
App.ox. 90"
OIL RING
ls" GAP
TOP BINGGAP
DO NOTpositionany ring gap
in linewith the pistonpin hole.
SPACERGAP
OIL RINGGAP
7 -1 8 ,
vnx.su
Installation(B18Bl engine)
2.
Adjustthe lengthA of the pistonpin driver.
1.
Usea hvdraulicoressfor installation.

When pressingthe pin in or out, be sureto position the recessedflat on the piston againstthe
lugs on the baseattachment.
A:81881 engine:49.70mm {1.957inl

Bl8Cl ngin:51.70mm {2.035inl
PISTONPIN DRIVERHEAD
07973 - PE00320
PISTONPIN DRIVERSHAFT
07973- PE00310
The arrowmustfacethe
timing beltsideo{ the
engineand the connecting
rod oil hole mustfacethe
rearsideof the engine,
PILOI COLLAR
07LAF- PR30100
Embossedmarkfacingup.
otl Hols
2. AdjustthelengthB of the pistonpindriver.
B:49.70mm (1.957
inl
NOTE:Usea hydraulicpress.
When pressingpin in or out,
makesurethat the recessed
portionof the pistonaligns
with the lipson the collar.
PISTONPIN DRIVERHEAD
07973- PEfl)320
Placethe piston on the piston base and pressthe

pin out with a hydraulicpress.
PISTONPIN DR|VENSHAFT
079?3- PE|X)310
Embossedmark
ffi*.r,"ror","l
PILOTCOLLAN
07LAF- PF301(x)
PISTONPIN BASEINSERT
07GAF- PH603oO
PISTONBASEHEAD
07HAF- PL20t02
PISTONBASE
079?3- 6570500
NOTE: lnstall the assembledpiston and rod with

the oil holefacingthe intakemanifold.
7-19
vnx.su
PistonPins
Inspection
Installation
lB18C1enginel
1.
Measurethe diameter of the piston pin.
Usea hydraulicpressfor installation.

.
When pressingpin in or out, be sure you position the recessedflst on the piston againstthe
lugs on the baseattachment,
Pi3ton Pin Dirmltlr:

Standard lN.wl: 20.994- 21.dlo mm
Ovo.3ize:
Th arrow must tace

timing beltsidof rhe
engino.
(0.8265- 0.8:168inl
20.907- 21.(xxtmm
- 0.&16S
(0.8267
in)
NOTE: All replacementpiston pins are oversize.
Tho mork must tace

the timing belt side
ot the engine.
Adjust the lngth B of piston pin driver.

Br 51.70mm (2.035inl
PISTONPIN
-T-
fl--.l
j
I
ll t
\J ---..''
tl i-
- ,rH ,l l
ilil
Embossedm.rk ll ll-l!-lJ
facins up.
\
t
HEAD
DRr\rER
- PEm32o
07e73
PlsroNPtN
sHAFr
DRtvER
- PEoo3lo
07s73
2.
-4
r
PISTONPIN
PILOTCOLLAR
o?LAF-PR3o1n'
I =)ffi
ri _-r -_t, -l l l'll,llltllrl ll ll li l i l l
L-lt|lllltlll
_-
PrsroNPINBASEINSERT
- PH6O3q)
O?GAF
PISTONBASEHEAD
07HAF- P120102
PISTONBASE
07973 - 65705U)
7-20
vnx.su
Zerothe dial indicatorto the pistonoin diamater.
ConnectingRods
End Play
3.
NOTE:End play should bs inspctedbefore removing

the crankshaft.
Measurothe piston pin-to-pistonclearance.

NOTE: Checkthe Distonfor distonion or cracks.
It the piston pin clearanceis greater than 0.022 mm
(0,0009in), remeasureusing an ovorsizepiston pin.
Connrcting Rod End Pl.y:

Stlndrrd (Nrwl: 0.15- o.3o mm
(0.(xt6- 0.012inl
Scrvict Limit
o./tomm (0.016inl
Pbton Pin-to-PLton Cloeranco:

StlndErd (Ncwl: 0.010- 0.022mm
- o.(Xxlg
(0.(xto4
inl
a lf out-of-tolerance,install a new connscting rod.

a lf still out-of-to16rance,
replacethe crankshaft
pages7-10and 7-22)
4.
Check the difference betwsen piston pin diameter

and connectingrod smallend diamter.
Pbton Pin-to4onnocting Rod Inlcdaranca:
Strndlrd {Ncw}:
Bl8Bl ongino:0.013- 0.G12mm
(0.fiX15- 0.0013inl
Bl8Cl cngin.: 0.017- 0.036mm
IO.ON1- O.|,o11int
7-21
vnx.su
Crankshaft
ConnectingRods
Selection
lnstallation
Eachrod falls into one of four toleranceranges(from 0

to + 0.024mm (0 to + 0.0009inl, in 0.006mm {0.0002in)
increments)dependingon the size ot its big end bore.
It's then stampedwith a number(1,2,3, or 4) indicating
the range.
You may find any combinationol 1, 2, 3, or 4 in any
engane.
Before installingthe crankshaft.apply a coat of

engineoil to the main bearingsand rod bearings.
1.
Installthe thrustwashersin the No. 4 iournslof the

cvlinderblock.
Normsl Boro Sizoi ,18.0mm 11.89inl

NOTE:
a Referencenumbersare Jor big end bore sizeand do
NOTindicatethe positionof the rod in the engine.
. Inspectconnectingrod for cracksand heatdamage.
CONNECNNGRODBORE
REFERENCE
NUMBER
HalfoI numberis stampedon
bearingcap.th otherhalfon
connectingrod.
Groovedsidetacing
o!tward
Insertbearinghalvesin the engine block and connectingrods.
Holdthe crankshaftso rod journalsfor cylindersNo.
2 and No.3 are straightup.
Lower the crankshaftinto the block. putting the rod
journalsinto connectingrods No.2 and No.3.
Installthe rod capsand nutsfinger-tight,
CONNECNNGROD
7 -22
vnx.su
Rotatethe crankshaftclockwise,put journals into

connecting rods No. 1 and No. 4, and install the rod
caps and nuts finge.-tight.
8.
13t st.p: 29 N.m (3.0 kgf.m, 22 lbt.ftl

2nd 3tsp:
81881 .ngin.: 76 N.m (7.8 kgt.m,56 lbf,ft)
Bl8Ct engine:
No. 1, 5 cap bol$: 73 N.m (7./rkgf'm, 56 lbf,ftl
No. 2, 3, a clp bolbr 6{ N.m (6.5 kgf'm, /r9 lbf,ftl
NOTE:lnstallcaps so the bearingrecessis on the

samgsideas the .ecessin the rod.
Check rod bearing clsarancewith plastigage(see
page 7-9),then tighten the capnuts in 2 steps.
l3t 3t.p: 20 N.m (2.0 kgf.m, rl btfil
2nd 3tep:
81881 cnginc: 31 N.m (3.2 kgf.m, 23 lbf.ft)
818C1.ngin!: ,14N.m (4.5 kgt.m,33 lbf.ft)
Checkclearsncewith plastigsge(see page 7-8).then

tighten bearingcap bolts in 2 steps.
BEARINGCAP BOLTSTOROUESEOUENCE
Bl88l cngino:
NOTE: Referencenumbers on connectingrod are

for big-endbore toloranceand do NOT indicatethe
positiooof pistonin the engine.
I n s t a l l t h e m a i n b e a r i n g s / c a p sa n d c a p b . i d g e
(818C1engineonlyl.
NOTE:Coatthe bolt threadswith oil.
CAPBRIDGE
lBlSCl .noin. onlyl
Bl8Cl ongino:
EEARIlTG
CAUTION: Whenever any crsnkehaft or connocting rod

b.aring is rlphccd. it i5 ncccrsrry aftor rclssombly to
run tho ongino ai idling 3p6ad until it re.chei normrl
opcrating tcmporature, thon continuo to run it fol
spp.oximltoly f 5 minula3.
(cont'd)
7-23
vnx.su
Grankshaft
Installation(cont'd)
9.
liquidgasketto the blockmatApply non-hardening

ing surfaceof the right side cover,and installit on
the cylinderblock,
liquidgasketto the blockmat10. Apply non-hardening

ing surface of the oil pump, and install it on the
cvlinderblock.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001.
. Checkthat the matingsurfacesare cleanand dry
. Apply liquid gasket as an even bead, centered
betweenthe edges of the mating surface.
. To preventleakageof oil, apply liquid gasketto
the innerthreadsof the bolt holes.
. Do not install the parts if 20 minutes or more
have elapsedsince applying the liquid gasket.
Instead,reapplyliquid gasketafter removingthe
old residue.
. After assembly, wait at least 20 minutes before
fillingthe enginewith oil.
OILPUMP:
RIGHTSIDECOVER:
6x1,0mm
tl N.m {1.1kgr'm.
8 tbf.ftl
RIGHTSIDE
6x1.0mm
11 N.m {1.1tgl.m,
DOWELPIN
O.RING
R6plac.
OIL PUMP
DOWELPINS
7-24
vnx.su
8 x 1.25mm
2il l$m l2.iakg[.m.
1t rbf.ftl
Oil Seal
lnstallation
The sealsurfaceon the blockshouldbe dry.
Apply a light cost of oil to the crankshaftand to
the liDof the seal.
1 1 . lnstalltheoil screen.
Installtheoil pan.
1' I
NOTE:Cleanthe oil pan gasketmatingsurfaces.
Drivein flywheelend sealagainstright sidecover.
Tightenthe boltsas shown below.
NOTE:Drivethe end sealin squarely.
Torque: 12 N.m {1.2 kgf.m, 9 lbf'ft)
DRIVER
07t,49- (xll(xtoo
NOTE: Tighten the bolts and nuts in two steps and

toroue the bolts in a crisscrosspattern
lnstallsealwiththe
part numberside
tacing out.
2.
Confirmthat clearanceis equal all the way around

with a felergauge.
Cler.6nce: 0.5 - 0.8 mm (0.02- 0.03 inl
RIGHTSIDE
COVER
NOTE:Reterto right column and 8-10lor installation of the oil pump side oil seal.
7-25
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Oil Seal
Installation(engineremovalnot
required)
The sealsurfaceon the blockshouldb dry.
Apply a light coat of greaseto the crankshaftand
to the lio of seal.
Using the specialtool, drive in the timing pullsyend seal until the driver bottoms against the oil
pump.
When the seal is in place,clean any excessgrease
off lhe crankshaftand checkthat the oil seal tiD is
not distoned.
SALDRIVEB
07LAD- PRimroA
lnstallse6lwith
tho
Pan number
tacing out.
Usingthe specialtool, drive in the flywheel-endseal

until the driverbottomsagainstblock.
NOTE:Align the hole in the drivsr attachmentwith
the Dinon the crankshaft.
7-26
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EngineLubrication
........8-2
S p e c i aTf o o l s . . . . . . . .
."' 8-3
l l l u s t r a t e dI n d e x . . . . . . . .
EngineOil
. . . . . . . . . . . " ' . . .8' - 5
Inspection
R e p l a c e m e n. t. . . . . . . . . . . . .".". . . . . . . . ' . ' .8 - 5
Oil Filter
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . ." . . . . . . . 8 - 6
Oil Pressure
....' 8-8
Testing
Oil Jet
I n s p e c t i o n{ 8 1 8 C 1 e n g i n eo n l y } . . . . . 8 - 8
Oil Pump
... 8-9
Overhaul
Removal/lnspection/lnstallation. . ' . . . 8- 1O
vnx.su
SpecialTools
Rel. No.
Tool Numbel
OTLAD_ PR4OlOA
o 7 9 12 - 6 1 1 0 0 0 1
Descrlption
Oty
8-11
8-7
Seal Driver
Oil Filter Wrench
8-2
vnx.su
I Pago Roferenco
lllustrated Index
CAUTIOIiI: Do not ovortighten the drain plug.
NOTE;
o Use new O-ringswhen reassembling.
a Apply oil to O-ringsbetore installation,
. Use liquid gasket, Part No. O8718-OOO1.
a Cleanthe oil pan gasket mating surtacesbefore installingit.
6 x'l.omm
12 N.m {1.2 kgt.m,9 lbt.tt)
81881 sngine:
WASHER
Replace.
DRATTPIUG
44 .m (4.5 tgf.m, 33 lbf'ftl\
Do not ovgr tightgn.
\
\
\
-@5
\
OILPAI{
GASKET
R6placs,
6 r l.O mtn
121{.m11.2kol.m,
I lbl.ttl
6 x 1.0 mm
'11 N.m 11.1 kgt'm,8lbt.ftl
OIL SCREEN
O|L BNEATHER
TAIIK
6 x 1 . Om m
ll N.m {1.1kgf'm,
I tbt.ftl
GASKET
Replace.
BAFFLEPTATE
eq
nU2o@
\\
#-'
OIL FIL
Repl.cemont, p6gs 8-6
I x 1.25mm
24 N.m 12.4 kgf..n,
17 rbr.ftl
A
ENGINEOIL PRESSURE
,F
swlTcH
18 .m 11.8 kgl.m, 13lbl.ftl

'l/8 in. BSP lgritish Standard
Pioo Taporl 28 Threads/inch.
Use propgr laquid56alant.
HEAD OIL
CONTROLORIFICE
CIean.
OIL PUMP
Overhaul,page 8-9
lnspectionpage, 8-1O
Apply liquid gasket to
block mating surlace.
6 x 1 . Om m
11 N-m(1.1kgt.m,8lbf.ft)
(cont'dl
8-3
vnx.su
lllustrated Index
(cont'dl
CAUTION: Do not overtighten rhe dlain ptug.
818C1 engine:
DRAINPLUG
44 N.m (4.5 kgf.m, 33 lbt.ftl
Do not overtighten.
NOTE:
a Use new O-ringswhen reassembling.
a Apply oil to O rings before installation.
. U s e l i q u i dg a s k e t .P a r tN o . 0 8 7 1 8 - O O O 1 .
a Cleanthe oil pan gasket mating surfacesbefore installingit.
OIL PAN
6 x 1.0mm
12 N.m 11.2 kgl.m, 9 lbf.ftl
6 x 1.0 mm
1 1 N . m 1 1 . 1k g t . m ,
S lbf.fil
OIL JET BOLT
16 N.m {'1.6kgf.m, '13 lbf.ft}
Replace.
OIL JET
Be careful not to damage.
Inspection,page 8-8
EAFFLEPLATE
O-RING
Replace.
6xl.0mm
11 N.m (1.1 kgt.m, I lbt.ft)
OIL SCREEN
GASKET
Replace.
Il
,--)e
6V
ENGINEOIL COOLER
6 r ' 1 . 0m m
l 1 N . m ( 1 . 1 K9-m,
8 rb-trl
ENGINEOIL FILTER
page 8-6
Replacement,
O-RING
Replace.
OIL COOLER
CE TER BOLT
74 N.m (7,5 kgf.m, 54 lbf.ft) ENGINEOIL PRSSURE
swtTcH
HEAD OIL CONTROL

ORIFICE
Clean.
1A N.m {1.8 kgf.m, 13 lbf.ft)

1/8 in. BSP {BritishStandard
PipeTaperl 28 threads/inch.
Use properliquidgasket.
8-4
vnx.su
8 x 1.25mm
24 N.m (2.4 kg-m, 17 lb-ft)
OIL PUMP
Overhaul,page 8-9
Removal/lnspection/lnstallation,
page 8-10
Apply liquidgasketto mating
surfaceot the engineblock.
EngineOil
Replacement
lnspection
Check engine oil with the engine off and ths cal
parked on level ground,
CAUTION: Remova tho drain plug calfully whilo the

ongine is hot; the hot oil may cause scalding.
Make cenain that the oil levelindicatedon the dipstick is between the upper and lower marks.
1. Warm up the engine.

2,
Drainthe engineoil.
3.
Reinslallthedrainplugwith a new washer,and refill

with the recommendedoil.
3 . lf the lvel has droppedclose to the lower mark, add

oil until it reachesthe upper mark.
CAUTION: Inssrt lho dipstick carotully to avoid
bending it.
CAUTION: Do not ovortighton tho drain plug.
Requirement
Capacity
Change
"Energy
API ServiceGrade:Use
Conservingll" SG or SH grade oil.
SAE 5W-3O Drefered.
B 1 8 B 1e n g i n e :
3.51 (3.7 US qt, 3.1 lmpqtl
at oil change.
3.8 t (4.0 US qt, 3.3 lmp qt)
at change.includingfilter.
4.6 I 14.9US qt. 4.0 lmp qt)
after engineoverhaul.
B18Cl engine:
3.7 f (3.9 US qt, 3.3 lmp qt)
at oil change.
4.O t 14.2US qt, 3.5 lmp qt)
at change,includingfilter.
4.a I (5.1 US qt, 4.2 lmp qt)
after engineoverhaul.
Every 7,5OOmiles (12,OOokm) or
6 months
(cont'd)
8-5
vnx.su
EnglneOil
Oil Filter
Replacement{cont'd)
Replacement
CAUTION: Aftar the ongine has boan run. tho oxhaust
pipos will bo hot; b caretul when wo.king around tho
erhaust manitold,
Removethe oil tilter with the specialoil filter wrench.
Inspectthe threadsand rubbe.sealonthe new lilter.
Wipe off seat on engineblock.then apply a light coat
of oil to the tilter rubberseal,
NOTE: Useonly filrerswith a built-inbypasssystem.
ElrclltEs
Inspectthreadsand
rubbersealsurface-
APICERTIFICATION
SEAL
The numbersin the middleof the API Servicelabeltell

you the oil's SAE viscosityor weight. Selectthe oil for
your car accordingto this chart:
Ambient TomDo?aturo
An oil with a viscosity of 5W-3Ois preferredfor improved

fuel economyand year-roundprotectionin the car.
You may use a l OW-3Ooil it the climatein your areais
limited to the tempe.aturerange shown on the chart.
4.
Fillthe enginewith oil up to the specifiedlevel,.un

the enginefor morethan three minutes.then check
lor oil leakageand oil level.
8-6
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Apply oil to rubber seal

betore anstalling.
ENGINEOIL COOLER
(8'l8Cl ongino onlyl
Eightnumbers{'l to 8) are printedon the surfaceof

rhe filter.
Installthe oil tilter by hand.

4.
After the rubbersesl seats,tighten the oil filter clockwise with the specialtool.
The followingexplainsthe procedurefor tightening

filters using these numbers.
Tighten: 7/8 turn clockwise.

Tightening torque: 22 N.m (2.2 kgf'm, 16 lbf'ft)
1) Makea markon the cvlinderblockunderthe number that shows al the bottom of the filter when
the rubberseal is seated.
CAUTION: Installationother than the abova plocedure could r6suh in serious engine damag due to
oil leakage.
2) Tightenthe tilter by turning it clockwiseseven

numbersfrom the markedpoint. For example,if
a markis madeunderthe number2 when the tubber seal is seated.the filter shouldbe tightened
'l
until the number comes up to the markedpoint.
OILFILTEBWRENCH
07912-6110001
MARK
Number when rubber
seal is seated.
Numberafter tightening.
Numberwhen rubber
seal is seated
Numberafter tightening 8
5.
6
o
After installation,till the enginewith oil up to the

specified level, run the engine for more than 3
minutes,then check for oil leakageand oil level.
8-7
_l-
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.4
Oil Pressure
Oil Jet
Testing
Inspection(B18C1 engineonly|
lf the oil pressurewarninglight stayson with the engine

running, check the engine oil level. lf the oil level is
correct:
Removethe oil jet (seepage 8-4) and inspectit as

follows.
a Make surethat a I .l mm (O.04in) diameterdrill
will go throughthe nozzlehole{1.2 mm {O.OSin)
diameterl.
a Insertthe other end of the same 1.1 mm (O.O4
in) drill into the oil intake {1.2 rnm {0.05 in}
diameter).
Make surethe check ball movessmoothlv and has
a stroke of approximately4.0 mm {O.16 in).
a Checkthe oil jet operationwith an air nozzle.lt
should take at least 2OOkPa (2.O kgf/cmr,28
Dsi)10 unseatthe check ball.
1. Connecta tachometer.
2.
Removethe oil pressureswitch and installan oil pressure gauge.
3.
Stan the engine.Shut it off immediatelyif the gauge

registersno oil pressure.Repairthe problembefore
continuing.
4.
Allow the engineto reachoperatingtemperatu,e{fan

comes on at least twice). The Dressureshouldbe:
NOTE: Replacethe oiljet assemblyif the nozzle

is damagedor bent.
Engine Oil Pressure:

70 kPa (0.7 kgf/cmr, 10 psi)
minimum
At 3,OOOlpm: 340 kPa {3.5 kgf/cmz, 50 psi}
minimum
At ldle:
1 . 2 m m 1 0 . 0 5i n )
a lJ oil pressureis within speciJications,replacethe

engineoil pressureswitch and recheck.
a lf oil pressureis NOT within specifications,inspect the oil pump (see page 8-1O).
OILPRESSURE
GAUGE
COMMERCIALLY
AVAILABI.E
'16 N.m (1.6 kgt.m, l2lbt.ftl
2.
Mountingtorqueis critical.Be very precisewhen installing.

Torque: 16 N.m (1.6 kgt.m, 12lbf.ftl
8-8
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Oil Pump
Overhaul
NOTE:
a Apply oil to O-ringsbefore installation.
. U s e l i q u i dg a s k e t ,P a r tN o . 0 8 7 1 8 - O O 0 1 .
a After reassembly,check that the rotors move without binding.
6 x 1.0 mm
6 N.m 10.6 kgl.m, 4 lbt'ttl
O.RING
Replace.
OUTERROTOR
pagesI 10, 11
Inspection,
DOWEL PIN
6 x 1 . Om m
11 N.m (1.1kgf.m,
8 tbf.frl
PUMPCOVER
Inspection,page 8-10
8 x 1.25mm
24 N.m (2.4 kgf.m,
t7 tbt'ft)
INNERROTOR
Inspect|on,
page 8-1 1
OIL SEAL
Installation,Page8-1 1
Replace.
PUMP HOUSING
lnspection,pages8-10, 11
Apply liquidgasket
to matingsufaceoI
the cylinderblock
when installing.
RELIEFVALVE
Valve must slide treely
in housingbore.
Replacewhen scored.
SPRING
*\
8 x 1.25mm
24 N.m (2.4 kgl.m,
17 lbl.Irl
vnx.su
SEALINGBOLT
39 N'm 14.0 kgf.m,
29 tbt.ttt
Oil Pump
Removal/lnspection/lnstallation
1O. Removethe screws trom the pump housing,thsn
separate the housing and coveJ.
Drainthe engineoil.
Turn the crankshatt and align the white groove on
the crankshaltpulleywith the pointeron the lower
cover.
5.
Remove the cylinder head cover and middle cover.
4.
Removethe power steeringpump belt, air conditioner belt and the alternator belt.
1 1. Check the inner-toouter roto. radialclearanceon the

pumP rotor.
Innor Rotol-to-Outor Rotor Radial Cloaranco
StandErd(Newl: O.O4-O.16 mm
(0.O02-0.006 in)
Service Limit:
O.2O mm (0.008 inl
Removethe crankshaft pulley and remove the lower cover.

6.
Removthe timing belt.
7.
Rmovethe drive pulley.
8.
Removthe oil pan and oil screen.
9.
Remove the oil pump.
OILPUMP
1 2 . Check the housing-to-rotor axial clearance on the

pump rotor.
Housing-to-Botor Axial Claalanc
Standard(Nowl: O.O2-O.O7 mm
-O.OO3 inl
(O.OO1
ServiceLimit: O.15 mm (0.006 in)
HOUSING
OIL PAN
8-10
vnx.su
t5.
rotor radialclearance.
Check the housing-to-outer
Housing-to-Outer Rotol Radial Clearance:
Standard{Newl: O.1O-O.19 mm
(O.oO4-O.OO7in)
ServicLimit: O.2Omm {O,OO8in)
1'l
the oil pump,applyingthreadlockto the

Reassemble
pump housingscrews.
1 8 . Check that the oil pump turns freely.

1 9 . Apply a light coat of oil to the seal lip.
20. Installthe two dowel pinsand new O-ringon the oil
pump.
Apply liquidgasketto the cylinderblockmatingsurface of the oil pump.
NOTE:
. U s e l i q u i dg a s k e t ,P a r tN o . 0 8 7 1 8 - O O O 1 .
a Checkthat the matingsurfacesarecleanand dry
betore applyingliquidgasket.
a Apply liquidgasketevenly,in a narrowbeadcentered on the mating surface.
a To preventleakageof oil, apply liquidgasketto
the innerthreadsot the bolt holes.
1 4 . Inspect both rotors and pump housingfor scoring or

other damage.Replaceparts il necessary.
1 5 . Removethe old oil seal trom the oil pump.
to-
Gentlytap in the new oil seal until the specialtool

bottoms on the PumP.
NOTE: The oil seal alone can be replacedwithout
removingthe oil pump.
Do not installthe parts if 20 minutesor more have

elapsed since applying liquid gasket. Instead.
reapply liquid gasket aftet removing the old
restclue.
After assembly,wait at least 20 minutesbefore
filling the enginewith oil.
OIL PUMP
(cont'd)
8-11
vnx.su
Oil Pump
Removal/lnspection/lnstallation
(cont'd)
22. Installthe oil pump on the cylinderblock.
a Apply greaseto the lip of the oil pump seal.
Then, installthe oil pump onto the crankshaft.
When the pump is in place, clean any excess
greaseoll the crankshaftand checkthat the oil
seal lip is not distorted.
23. Installthe oil screen.
24. Installthe oil pan.
NOTE: Cleanthe oil pan gasket mating surtaces.
8 x 1 . 2 5m m
24 N.m (2.4 kgl.m,
17 tbt.ftl
6 r 1 . Om m
1'l N.m {1.1kgf.m,
8 rbf.fr)
OIL PUMP
Apply liquidgasketto
cylinderblock mating
sudace.
O-RING
Apply engineoil
DOWEL PINS
GASKET
Replace.
OIL SCREEN
6 x 1 . Om m
11 N.m ('l .1 kgf.m,
8 tbf.trl
OIL PAN
6 x 1 . Om m
12 N.m {1.2 kgf.m, 9 lbf.ft}
8-12
vnx.su
System
lntake Manifold/Exhaust
Intake Manifold
..
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 2
Exhaust Manifold
R e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 4
..
Exhaust Pipe and Muffler
. .-. 5. .
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . 9
vnx.su
Intake Manifold
Replacement
NOTE: Use new O-ringsand gasketswhen reassembling.
CAUTION: Check for tolds or scratches on the aurface ot the gasket. Roplacewith a now gasket it damagod,
81881 engine:
5r0.8mm
6 N'm {0.6 kgl.m.
4 rbr.ftl
INTAKEAIR
TEMPERATURE
IIATI SENSOR
'*o*ot'u""'""N
PURGECONTROL
SOLENOIDVALVE
5xO.8mm
6 .m (0.6 kg{.m.
4 tbf.ftl
IiITAKE MANIFOLD
ReplaceiI cracked or
it mating s!rtaces aro
damago.
O-RING
Replace.
8 x 1.25mm
22 N.r 12.2 kgl.m,
'16 tbt.ftt
GASKETS
Replace.
I x 1 . 2 5m m
20 N.m (2.0 kgt.m.
14 rbf.ftl
IDLE AIR
{IACI VALVE
Be careful not
to damage.
O.RING
Replace.
THROTTLE
BODY
O-RINGS
Beplace.
8 x 1.25 mm
23 N.m (2.3 kgl.m,
17 lbf.frl
8 x 1.25mm
24 N.m (2.4 kgf'm,
17 rbf.ft)
"o
aY
c
BRACKET
8 x 1.25mm
24 N.m (2.4 kgl'm.
17 tbr.ftl
THERMO
VALVE
8e careful not to
damage.
8 x 1.25mm
24 N.m (2.4 kgl'm,
1 7 rbf'ft1
9-2
vnx.su
NOTE: Use new O-ringsand gasketswhen reassembling.

CAUTION: Chock for folds 01 scratches on th6 surfac6 of tho gaskot. Replace wilh a new gasket if damaged.
818C1 engino:
5 x O.8 rnm
6 N.m 10.6 kgl.m,
4 tbt.ttl
INTAKE MANIFOLD
Replaceil cracked or
il mating surfaces are
damageo.
l
I
IAT SENSOR
VALVE
? , /
5xO.8mm
6 N.m 10.6 kgf.m,
4 tbf.ftl
EVAP PURGECONTROL
/
GASKETS
Replace.
O.BI G
Replace.
INTAKE AIR
BYPASSVALVE
BODY
INTAKEMANIFOLD
CHAMBER
IAC VALVE
Be carelul not
lo oamage.
8 x 1.25mm
23 N.rn 12.3 kgt'm,
17 tbf.frl
BRACKET
O.RINGS
Replace.
I x 1.25 mm
22 N.m 12.2 kgl.ft,
t6 tbt.tt)
8 x t.25 mfi
24 N.m (2.4 lgf.m.
17 tbt.ft)
8 r 1.25mm
24 N.m {2.4 kgf.h,
t7 rbr.ftl
I r 1.25 lnm
24 N.m 12.4 kgt.m,
17 tbt.ftl
THROTTLE
AODY
8 x 1.25mm
20 .m (2.0 kgt.m,
14 tbf.ftl
HEATERBYPASS
PIPE
o-Rt Gs
Replace.
FAST IDL THERMO VALVE

Be carelul not to damage.
I x 1.25mm
24 N.m (2.4 kgl.m, 17lbf'ft|
9-3
vnx.su
Exhaust Manifold
Replacement
NOTE: Use new gasketsand seltiocking nuts when teassembling.
GASKET
Replace.
XHAUST MAt{IFOLD
I r 1.25 mm
24 N.ln (2.4 kgf.m, l7 lbt.ft)
Ss
Z \
tr l'A
|
i...1%\
/ \\-i
R
A\
1tr.
\
8 x '1.25mm
3l N.m {3.2 kgf.m. 23 lbf.ltl
Replace.
8 x 1.25mm
24 N.m {2.4 kgf.m,
1 7 tbf.ftl
10 x 1.25mm
44 .m {4.5 kgl.rh. 33 lbf.ft}
vnx.su
ExhaustPipe and Muffler

Replacement
NOTE: Use new gasketsand selflocking nuts when reassembling.
Bl88l engine:
HEAT SHIELDS
MUFFLER
6 x 1.0 mm
9.8 N.m l1.O kgf.m, 7.2 lbf.ftl
EXHAUSTPIPE TIP
^1
e
HEAT SHILD
,@\
8 x 1.25mm
22 N.m 12.2 kgt.m, 16 lbf.ftl
Replace.
Tightenthe bolts in steps,
alternatingside-to-side.
SELF-LOCKIIIGNUT
1 0 x 1 . 2 5m m
33 N.m (3.4 kgt.m,
25 tbf.ftt
Replace.
COVER
HEATEOOXYGEN
SENSOR(HO2Sl
44 N.m 14.5 kgt.m,
33 rbf.ftl
I x 1.25mm
24 N.m 12.4 kgf.m,
17 tbl.frl
BRACKET
GASKETS
Replace.
GASKET
Replace.
THREEWAY
CATALYTIC
CONVERTER
COVER
SELF-LOCKINGNUTS
10 x 1,25mm
54 N'm 15.5 kgf'm,
40 tbf.ftl
Replace.
NUT
SELF-LOCKING
8 x 1.25mm
16 N.m {1.6kgf.m,
r2 tbt.frl
Replace.
6 x 1.0 mm
9.8 N.m l1.O kgf.m, 7.2 lbl.ttl
I x 1.25mm
22 N.m (2.2 kgl.m, r6lbt.ftl
Replace.
Tighten the flange nuts in steps,
alternating side-to-side.
vnx.su
(cont'd)
ExhaustPipe and Muffler

Replacement(cont'dl
NOTE: Use new gasketsand selt-lockingnuts when reassembling.
818C1 engine:
MUFFLER
HEAT SHIELOS
EXHAUST PIPETIP
6 x 1.0 mm
9.8 N'm {1.O kgt.m, 7.2 lbf.ft)
HEAT SHIELD
EXHAUSTPIPEB
GASKET
Replace.
8 x 1.25mm
22 N.m 12.2 kgf.m, 16 lbf'ftl
Replace.
Tighten the bolts in steps,
alternating side'to-side.
NUT
SELF,LOCKING
10 x 1.25mm
33 N.m {3.4 kgf.m,
25 tbf.frl
Replace.
COVER
HO25
44 N.m {4.5 kgf.m,
33 tbf.fr)
I r 1.25mm
24 N.m 12.4 kgf.m,
17 lbf.ftl
BRACKET
GASKET
Replace.
GASKETS
Replace.
EXHAUST PIPEA
COVER
SELF.LOCKINGNUTS
10 x 1.25mm
54 N.m 15.5 kgl.m,
40 lbf.frl
Replace.
6 x 1 . Om m
9.8 N.m (1.0 kgf.m, 7.2 lbt'ft|
8 x 1.25mm
22 N.m 12.2 kgf.m, 16 lbl.ftl
Repiace.
Tighlenrhe flangenuts in sreps,
alternatingside-to-side.
SELF-LOCKINGNUT
8 x 1.25mm
1 6 N . m 1 1 . 6k g f . m ,
12lbf.ftl
Replace.
vnx.su
Cooling
10-2
lllustrated Index
Radiator
. .O. .-.4.
R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . 1
Engine Goolant Refilling and
Bleeding
10-5
. . . . . . . . . . . . .1. .0 - 6
.........10-6
C a pT e s t i n g
Testing
Pressure
Thermostat
. .O. .-.7.
R e p | a c e m e.n. t. . . . . . . . . . . . . . . . . . . . . . . 1
.....1O'7
Testing
Water Pump
. 10-8
Index.........
lllustrated
.10-9
Inspection
. .O. .-.9.
R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . 1
vnx.su
lllustrated Index
sy"t". is under high plessurewhen engine
@
is hot. To avoid dsnger of relsssing scalding engine
coolant. remove cap only when engine is cool.
Total Cooling System Capacity (lncluding heater and
rservoirl
Bl8Bl engine:
Mfl: 6.4 | {6.8 US qt, 5.6 lmp qt}
AlTt 6.7 | {7.1 US qt, 5.9 lmp qt}
Bl8Cl engine:
Mfi: 6.7 t {7.1 US qt, 5.9 lmp qt}
CAUTION: lf any engine coolant spills on paintd portions ot the body, rinse it ofl immediately.
NOTE:
a Checkall coolingsystem hosesfor damage.leaksor
deteriorationand replaceif necessary.
a Check all hose clamps and retightenif necessary.
RADIATOR
Enginecoolant refillingand bleeding,
page 10-5
'l0-6
Leaktest, page
Inspectsolderedjoints and
seamsfor leaks.
Elow out dirt from between
core fins with compressedair.
lf insects,etc., are clogging
.adiator,wash them off with
low pressurewater,
CONDENSER
FAN SHROUD
{soe soction 221
\*
S!
*)
ATF COOLER
HOSES
{81881 6ngine)
6 x 1 . Om m
7 N.m (O.7 kgt.m. 5 lbf.ftl
5x0.8mm
4.4 N.m (O.45kgf.m,
3.3 lbl.fr)
FAN SHROUD
M/T: Manual t.anamiaaion

A/T: Automatic t.ansmiasion
ATF: Automatic t.ansmission fluid
10-2
vnx.su
R
U
COOLANT
RESERVOIR
ENGINECOMPARTMENTHOSECONNECTIONS:
Bl88l engine:
FAST IDLE
THERMOVALVE
THERMOSTAT
HOUSIITG
IDLEAIR CONTROL
IIAC} VALVE
BREATHERPIPE
O'RING
Replace.
O-RING
Replace.
HEATERHOSES
818C1 engine:
ENGINEOIL
COOLER
BREATHERPIPE
IAC VALVE
HEATERBYPASS
PIPE
FASTIDLE
THERMOVALVE
THERMOSTAT
HOUSING
HEATEBHOSES
10-3
vnx.su
Radiator
Replacement
1.
5.
Removethe upperand lower radiatorhoses,and ATF

cooternoses.
lnstallthe radiatorin the reverseorder of removal:

NOTE:
a Set the upper and lower cushionssecurely.
a Fill the radiatorand bleed the air.
Disconnectthe fan motor connectors.

4.
Removethe fan shroudassembliesand other parts

from radiato..
Drainthe enginecoolant.
Removethe radiatorupper brackets,then pull up the

radiator.
UPPERBRACKET
AND CUSHTOl{
RADIATOR
CAP 6 x l . O m m
9.8 N.m (1.O kgt.m,
7.2 rbf.ft)
6 x 1.0 mm
9.8 il.m 11.Okgt'm,
7.2 lbr.ftl
FAN MOTOR
CUSHION
O-RING
Replace.
SHROUD
6 x 1.0 mm
9.8 N.m ('l.O kgl.m,
7.2 tbl.ttl
DRAIN PLUG
LOWERRADIATOR
HOSE
vnx.su
EngineCoolantRefillingand Bleeding
ne-oving the radiatorcap while the engine
@
is hot can cause the engine coolant to splay out, seriously scalding you. Always let the engine and radiatol
cool down betore removing the radiator cap.
CAUTION: When poudngenginecoolant,be sure to shut
the relay box lid and not to let coolant spill on the electlical pans or the paint. ll any coolant spills, rinse it otf
immediately.
1.
Slidethe heatertemperaturecontrol leverto maximum heat.

Make sure the engineand radiatorare cool to the
touch.
2.
Removethe radiatorcao.
3.
Loosenthe drainplug on the bottom of the radiator,

and removethe drainbolt from the enoineblock.Let
the coolant drain out.
NOTE:
. Use only HONDA-RECOMMENOED
antifreeze/
coolant.
a For best corrosionprotection,the enginecoolant
concentrationsmust be maintainedyear-roundat
50% MINIMUM.Coolantconcentrations
lessthan
50% may not provide sufficient protection
againstcorrosionor freezing.
CAUTION:
a Do not mix ditterent blands ot anti-freeze/
coolants.
a Do not use additional rust inhibitois or anti-rust
products; they may not bs compatibl with the
recommgndsd engins coolant.
Engin Coolant Retill Capacity: including reservoir
{0.6 t (0.6 US qt, 0.5 lmp qt)).
81881 engine:
MlTt 4.4 | (4.6 US qt, 3.9 lmp qr)
A f f t 4 . 7 [ ( 5 . OU S q t , 4 . 1 l m p q t ]
Bl8Cl engine:
Mnt 4.7 | (5.0 US qt.4.1 lmp qt)
8. Pourcoolantinto the radiatorup to the baseof the
filler neck.
9. Loosenthe bleedbolt on top of the engine.Tighten
it againwhen coolantcomesout in a steadystream
with no bubbles.
ENGINEDRAIN BOLT
78 N.m {8,O kgt.m, 58 lbt.ftl
Apply liquidgaskerto
BLEEDBOLT
9.8 N.m (1.O kgl.m, 7.2 lbf.ftl
bolt thread when installing.
WASHER
Replace.
Removethe reservoirfrom its holder by pullingit

straightup. Drainthe coolant,then put the reservoir
back in its holder.
5 . Whenthe coolantstopsdraining,applyliquidgasket
to the drainbolt threads,then reinstallthebolt with
a new washer. Tighten it securely
1O. Refillthe radiatorto the base of the tiller neck. Put

the cap on the radiator.and tighten it only to the tirst
stop, Stan the engineand let it run until it warms
up (theradiatorcoolingfan comeson at leasttwice).
6.
Tightenthe radiatordrain plug securely.
11. Turn oft the engine.Checkthe levelin the radiator,

and add coolant it needed.Installthe radiatorcaD,
and tighten it fully.
7.
Mix the recommendedantifreeze/coolant

with an
equal amount of water in a clean container.
'12. Fillthereservoirtothe MAX mark. lnstallthereservoir cap.
10-5
vnx.su
Radiator
Cap Testing
1 . Removethe radiatorcap, wet its seal with engine
coolant,then installit on the pressuretester.
2 . Apply a pressureol:
9 3 - 1 2 3k P a
( O . 9 5 - 1 . 2 5 k g J / c m ' ,1 3 . 5 - 1 7 . 8 p s i )
3 . Check for a drop in pressure.

PRESSURE
TESTER
PressureTesting
1 . Wait until the engineis cool, then carefullyremove
the radiatorcap and fill the radiator with engine
coolant to the top of the filler neck.
Attach the pressuretesterto the radiatorand apply
a pressureof:
93- 123 kPa
( O . 9 5 - 1 . 2 5 k g f / c m , .1 3 . 5 - 1 7 . 8 p s i )
Inspect for engine coolant leaks and a dfop in
pressure,
Removethe tester and reinstallthe radiatorcap.
NOTE:
a Checkfor engineoil in the enginecoolantand/or
coolant in the engineoil.
a Check for ATF in the engine coolant and/or
coolant in the ATF (A/T).
10-6
vnx.su
Thermostat
Replacement
NOTE:Use new gaskets and O-rings when reassembling,
6 x 1 . Om m
1 1 N . m 1 1 . 1k g t . m , 8 . Ol b t . f t l
THERMOSTAT
MOUIITINGRUBBER
Replace.
l
ECT SWITCH
22-25 N.m 12.2-2.6 ksl.m, 'l6-'19 lbl.ttl
Testing
Replacethermostatif it is open at room temperature.
To test a closed thrmostat:
SusDendthe thermostatin a containerof water as
shown.
THERMOMETER
Heat the water and check the temperaturewith a

thermometer.Checkthe temperatureat which the
thermostatfirst opens and at full lift.
CAUTION: Do not let the thelmometer touch the
bottom of the hot container.
Measurethe lift heightof the thermostatwhen it's
fullv oDen.
THERMOSTAT
STANDARDTHERMOSTAT
Lift height: above 8.O mm (O.31 inl
Starts opening:169 - 176"F {76-8OoCl
Fully open: 194oF (90oCl
10-7
vnx.su
Water Pump
lllustratedIndex
NOTE:
a Usenew O-ringsandnew specialboltswhenreassembling.
a Useliquidgasket,PartNo. O8718-0OO1.
ENGI E COOLAI{T
3;iil3
TEMPERATURE
IECTI SENSOR
t8 N.m 11.8kot.m,13lbt'ttl
onsino:
B18c1
Bl8Bl cngln :
ECT SEI{SOR
ECTGAUGESEDINGU]{IT
I N.m (0.9 tgf.n, 7 lbf'tt)
Apply liquid gaskot
to tho threads.
6 r 1 . 0m m
11 N.m l1.l kgl.m,8.O lbl.ftl
6r1.Omm
1l t{.m ll.1 tgl.m.
8.O tbt.ftl
KNOCK SEI{SOR
3l N.m {3.2 kgf.m.
23 tbf.ftl
(8l8Cl .ngin onlyl
OUTIET
BLEEDBOLT
9.8 N.m (l.O rg[.m. 7.2 lbt'ft|
WATER OUTLET
COVER
Apply liquid gasket
to mating sudace.
ECTSIY]TCH
WATERPUMP
Inspectaon,
pagelO-9
22-26
.m 12.2-2.C )l{/l'nt.
16-19 tbr.ftl
o-Rtt{G
Roplaco.
o-itltc
Roplrco.
8r1.Orxtr
12 .|n ll.2 lgt.m,
8.7 n{.ftt
6xt.Omm
12 N'ft (1.2 kgf..n.8.7 lbt.ft)
10-8
vnx.su
Replacement
Inspection
J.
Removethe timing belt (81881 engine:see page

6 - 1 O ,B 1 8 C 1e n g i n e :s e e p a g e6 - 4 9 ) .
Removethe timing belt (818B1 engine:see page

6 - 1 0 , 8 1 8 C 1 e n g i n e :s e e p a g e6 - 4 9 ) .
Check that the water pump pulley turns counterclockwise,
2 . Removethe camshaft pulleysand the back cover

( 8 1 8 8 1e n g i n e s: e ep a g e6 - 1 9 . B 1 8 C 1e n g i n e s: e e
page 6-581.
Check for signs ol seal leakage.

NOTE: A small amount ot "weeping" from the
bleed holo is normal,
J.
Removethe water pump by removingfive bolts,

NOTE: Inspect,repairand cleanthe O-ringgroove
and mating su.lace with the cylinderblock.
BLEEDHOLE
DOWELPIN
6 r 1.O rnm
12 N.m {1.2 kgf.m,
4.7 bf.ftl
BI-EEDHOI-E
4.
lnstall the water pump in the reverse order

removat.
NOTE:
a Keepthe O-ring in positionwhen installing.
a Cleanthe spilledenginecoolant.
10-9
vnx.su
Fueland Emissions
Fuel Supply System
. . . . . . . . . . . . . . .1. 1 - 2
S p o c i aTl o o l s
Systam TloubloshootingGuid. ..................1 1-97
Componnt Location
F u o lL i n o s
. . . . . . . . . . . . . . . . . . . .1. '.l- 9 8
. . . . . .1 1 - 3
l n d e x. . . . . . . . . . . . . . . . .
........ 11-100
System Description
System Description
F u o lP r a s s u r e
. . . . . . . . . . . . . . . .1.1 - 1 0 0
V a c u u mC o n n e c t i o n.a. . . . . . , . . . . . . . . . . . . . . . . .1.1. .- 8
. . . . . . . . . . . . . . . .1.1 - 1 0 2
E f e c t r i c aCl o n n e c t i o n.s. . . , . , . , . . . . . . , . . . , , . . . . . , ' 1 1 - 1 2 F u 6 lI n i 6 c t o r s
Fuel PressureRagulato.
.,. 11-106
S y s t mC o n n e c t o r s. . . , . . . , . . . . . . . . . . . . . . . . . -1. -1- -. 2 O
F u e lF i l t e r
. . . . . . . . . . . . . . . . . . . .1. 1
. -108
T.oubloshooting
F u a lP u m p
. . . . . . . . . . . . . . . . . . .1. .1 - 1 0 9
T r o u b l e s h o o t i nGgu i d o . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 3 2
P G M - FM
l a i nF 6 l a y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .1. .".11 1
Self-diagnosticProcedures.,..,...............1 1-34
F u e lT a n k
. . . . . . . . . . . . . . . . . . . .t. 1. - 1 1 4
H o w t o R o a dF l o w c h a r t s. . . . . . . . . . . . . . . . . . . , 1
. .1. - 3 9
PGM-Fl System
Intake Air System
S y s t o mD e s c r i p t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . 1. .l.-.4 O
System TroubloshootingGuido ..................1 1-1 1 5
Troubleshooting Flowcharts
........ 11-116
Systom Dascription
E n g i n eC o n t r o lM o d u l s. . . . . . . . . . . . ...... . . . . . . . .1 1 - 4 2
. . . . . . . . . . . . . . . . . .1. .1 - 1 1 7
Air Cleanr
H e a t e dO x y g o nS e n s o r . . . . . . , . . . . . . . . . . . . . . .1. .1. - 4 6
T h r o t t l sC a b l e
................'11-118
HeatedOxygn Sonsol Heatel .....,......... 1 1-47
T h r o t t l 8B o d y
. . . . . . . . . . . . . . .1. 1 - 1 2 0
F u e lS u p p l yS y s t e m. . . . . . . . . . . . . . - . . . . . . . . . . .1. .1. -. 5 0
lntake Air Bypass Cont.ol Systsm
Manitold Absolute Pressure
. , . . . . . . . . .1 1 - 1 2 3
[B18Cl enginal
....
S s n s o r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1. .- .5. 2
Intake
.................
11-128
Manilold
onginol
[B1881
Top D6ad Cente./Crankshatr
Position/Cylindor
Positionsonsor ........ 1 1-56
Emission Control System
EngineCoolantTempsratureSonsor ....... 11-58
Systsm
TroubleshootingGuido ..................1 1-129
T h r o t t l oP o s i t i o nS o n s o r. . . . . . . . , . . , , . . . . . . . . 1. .1. - 6 0
........ 11-130
Systam Doscription
Intake Air TemperatursSensor...............11-62
........... 11-130
TailpipsEmission
B a r o m e tc P r s s s u r o
S e n s o r. . . . . . , . . . , . . . , . .1, .1 - 6 4
ThraeWay CatalyticConvortor ...,...,.........,11-131
l g n i t i o nO u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .1. 1
. .- 6 6
PositivaCrankcaEoV6ntilationSystcm .,....., 11-134
V e h i c l eS p e dS e n s o r. . . . . . . . . . . . . . . . . . . . . . . .1. 1
. .- 6 8
EvaporativoEmissionContro|,..,..,.,.,,.,,..,..,1 1-135
7
O
E l e c t d c aLl o a dD o t e c t o r. . . . , . . . , . . . . . . . . . . , . 1. .1.
K n o c kS e n s o r[ 8 1 8 C 1e n g i n e ]. . . . . . . . . . . . . .1. 1 - 7 4
A / T F l S i g n a lA / B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.7 6
ldle Contlol System
System TroubleshootingGuide ..................1 1-78

........ 11-79
Systom Description
Troubloshooting Flowchans
l d l A i l C o n t r o V
. .- 8 2
l a l v e . . . . . . . . . . . . . . . . . . . . . . . .1. 1
A i l C o n d i t i o n i nS
g i g n a l . . . . . . . . . . . . . . . . . . . . . .1. .1.- 8 4
A l t e m a t o rF R S i g n a l . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .1. -. 8 6
Automatic Transaxle (A/T) Gear
PositionSignal
......... 11-88
B r a k eS w i t c h S i g n a l . . . . . . . . . . . . . . . . . . . . . . . . . .1.1. -. 9 O
S t a r t e lS w i t c hS i g n a l. . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .- 9 2
Power Steering PressureSwitch Signal ... 11-93
. .1. -. 9 4
F a s tl d l e T h e r m oV a l v e . . . . . . . . . . . . . . . . . . . , . . . . . 1
l d l s S p e e dS t t i n g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .1.-. 9
.5
vnx.su
SpecialTools
Ref. No I
Tool Numbr
Description
I OtV I
A973X_041*XXXXX
Vacuum Pump/Gauge
,l
@
@
@
@
oTJAZ-O010008
OTLAJ_PT3O1OA
oTPAZ-0010100
o7406-OO40001
Vacuum/Pressure
Gauge0-4 in. Hg
Test Harness
SCS Short Connector
Fuel PressureGauge
1
1
'l
\t
1 1 -2
vnx.su
Page Reference.
1't-'t20, 124, ' 1 3 7 ,
140
1 1 - 1 3 91,4 0
't 1-37
I t -J.+
1 1 - t 0 11
, 06
Component Locations
lndex
81881 sngin6:
IOLEAIR CONTROLOACI VALVE

page '11-82
T
ABSOLUTE
MANIFOLD
PRESSURE
{MAP}SENSOR
EVAP
PURGECONTROL
VALVE
SOLENOID
Troubleshooting,
Troubleshooting,
11-137
THROTTLEPOSITIOIII{TP) SENSOR
Troubleshooting, page 1 1-60
THROTTLECABLE
page 1 1-118
Inspection/Adiustment,
Installation,page 11-1 18
TOP DEAD CENTER/CRATIIKSHAFT

POSITION
POSITIOf{/CYLINDER
(TDC/CKP/CYP}SENSOR
page 1 1-56
Troubleshooting,
INTAKE AIR TEMPRATUREIIAT) SEI{SOR

Troublshooting, page 1 1-62
POWERSTEERINGPRESSURE(PSP)
swtTcH
ELECTRICAL
LOAD
OETECTOR
IELD}
page 11-93
Troubleshooting.
Troubleshooting.
page,l l-70
sq
MODULE{ICMI
IGNITION
Troubleshooting, page 1 1-66
IDLETHERMOVALVE
ENGINECOOLANT TEMPERA
page I 1-58
Troubleshooting,
(ECTISENSOR
HEATEO
SENSORlHO2S}
pages 11-46, 47
Troubleshooting.
11-3
vnx.su
Component Locations
lndex
B18Cl ongino:
EVAP
PURGECONTROL
SOLEiIOIDVALVE
Troubleshooting,
p a g e1 1 - 1 3 7
AESOLUTE
MANIFOLD
(MAPISENSOR
PRESSURE
page 11-52
Troubleshooting,
INTAKE AIR TEMPERATURE

IIAT) SENSOR
p a g e1 1 - 6 2
THROTTLE
(TP}
POSITION
SENSOR
THROTTLECABLE
page 'l 1-119
Inspection/Adiustment,
page
1
1-1
19
lnstallation,
Troubleshooting,
page 1 1-6O
IOLE AIF CONTROL(IACI VALVE

Troubleshooting. page 1 1 -82
TOP DEAD CENTER/CRANKSHAFT

POSITION
POSITION/CYLINDER
{TDC/CKP/CYPISEI{SOR
Troublshooting. Page 1 1-56
POWERSTEERINGPRESSURE(PS'I
swtTcH
page 1 1-93
Troubleshooting,
ELECTRICAL
LOAD
DETECTOR
IELD}
Troubleshooting,
page.11-70
IGNITIONCONTNOLMODULE OCMI
Troubleshooting, Psge 1'l-66
sElrlsoRtKsl
Troubfeshooting, page 1 1-7 4
ENGIT{E
COOLANTTEMPERA
{ECT}SEI{SOR
Troubleshooting,
Pag11-58
HEATED OXYGEN SENSOR(HO2S}

pages 11-46, 47
Troubleshooting,
VALVE
FAST IDLE
'l
Inspection, page 1 -94
11-4
vnx.su
AIR CLEAI{ERIACL)
Replacoment,
11-117
BODY(T8I
THROTTLE
page11-120
Inspsction,
page11'122
Disassembfy,
THROTTLE
CABLE
pages1l-'l 18, 119
InsDection/Adjustment,
pages1 1-118, 119
Inslallation,
INTAKE
AIR
BYPASS (IABI
co TROL
OIAPHRAGM
{Bl8C1 ongino onlyl
Troubleshooting,
page 11-124
INTAKE
AIR
EYPASS IIABI
co TnoL
SOLENOID
RESONATOR
POSITIVE
CRA KCASE
vEt{TtLATtOt{(PcVl VALVE
psgo1 l-134
Inspection,
VALVE (B18Cl .ngino onlyl

Troubl6shooting,
p a g e1 1 - 1 2 4
MODULE{ECM)
ENGI]TE
CONTROL
page11-34
Procedures,
Selt-diagnostic
page11-42
Troubfeshooting,
SERVICECHECX CONNECTOR(2PI
page'l 1-34
56ll.diagnosticProcedures,
MAIN RELAY
RelayTesting,page 1 1-111
pag 1 1-112
Troubleshooting,
11-5
vnx.su
SystemDescription
Index
FUELGAUGESE]IIDINGU]{IT
Tgsting,sction23
FUELFILTER
page 11-l OB
Replacement,
FUEL PUMP
Tsting.page 11-1 10
Roplscamnt.page 11-l 10
FUELFEEDPIPE
FUELFIIL CAP
FUEL II{JECTORS
page 1 1-102
Troubleshooting,
page 1 1-105
Replacemont,
FUELTA K
R6placomont,
p a g el 1 - 1 1 4
EVAFORATIVE
EMISSION
IEVAP}TWO WAY VALVE
Testing,pag11-140
EVAPORATIVE
EMTSStOt{
{EVAP}PURGE
FUL
PNESSURE
REGUIATOR
Testing,page11-106
page11-107
Roplacmnt,
CONTROLDIAPHNAGM
VALVE
page'l 1-137
Troubleshooting,
FUELVAFONAPE
FUEL RAIL
EVAFORATIVCEMISSION
(EVAPI COI{TROLCANISTER
Troubl6shooting. pag6 1 1-'l 37
11-6
vnx.su
System Description
Vacuum Connections
81881 engin:
EVAPORATIVEEMISSIOT{
(EVAPI
PURGECONTROL
SOLENOIDVALVE
EVAPORATIVE
EMISSION
(EVAP}PURGECONTROL
To
DIAPHRAGM
VALVE
EVAPORATIVE
EMtSSTON
{EVAP}
TWO WAY
VALVE
EVAPORATIVEEMISSION
IEVAP) CONTROI-CANISTER
FRONTOF
VEHICLE
11-8
vnx.su
ENGINE
COOLANT
|l
U]
HEATEDOXYGEI{SEI{SOF(HO2S}
(MAP)SEI{SON
PRESSURE
MANIFOI.D
ABSOLUTE
ENGINECOOLANTTEMPERATURE
IECT}SENSOR
INTAKEAIRTEMPERATURE
IIAT} SEI'ISOR
IDLEAIR CONTROL
IIAC)VALVE
FASTIDLETHERMOVALVE
FUELII{JECTOR
FUELFILTER
REGULATON
FUELPRESSURE
FUELPUMPIFP)
FUELTAI{K
(EVAP}VALVE
EMISSION
@ FUELTAI{K EVAPORATIVE
DAMPER
G) FUELPULSATION
@ AIR CLEANER
@)RESONATOR
(TWC)
@ THREEWAY CATALYTICCONVEnTER
VEITITILAT|ON
IPCV)VALVE
CRANKCASE
o POS|TIVE
CANISIER
EMISSION
IEVAP)COI{TROL
@ EVAPOBATIVE
@ EvApoRATrvEEMrssroNIEVAP)PURGEcoNTRoL
VALVE
SOLENOID
(EVAP)PURGE
CONTROL
EMISSION
@ EVAPORATTVE
VALVE
DIAPHRAGM
(iDEVAPORATIVE
(EVAPITWOWAY VALVE
EMISSION
11-9
vnx.su
System Description
Vacuum Connections
818C1 engine:
INTAKEAIR
SYPASSIIAB}
CONTROLDIAPHRAGMVAI-VE
to
EVAPORATIVE
EMISStON
IEVAPI
TWO WAY
VALVE
MANIFOLOABSOLUTE
PRESSURE
{MAP) SENSOR
EVAPORATIVEEMISSION
{EVAP) PURGECONTROL
DIAPHRAGMVALVE
INTAKE
AIR
BYPASS IIAB}
VACUUM
TANK
EVAPORATIVEEMISSION
IEVAPI CONTROLCANISTER
INTAKEAIR
BYPASS IIABI
CONTROLSOLENOIDVALVE
PURGECONTROL
SOLENOIDVALVE
11-10
vnx.su
lHO2Sl
c) HEATEDOXYGENSENSOR
PRESSURE
IMAPISENSOB
) MANIFOLDABSOLUTE
{ECT}SENSOR
O EI{GINECOOLANTTEMPERATURE
{IAT)SENSOR
) INTAKEAIR TEMPERATURE
tKSl
@ KNOCKSENSOR
@ IDLEalR coNTRoL llAcl vALvE
O FASTIDLETHERMOVALVE
@ FUELINJECTOR
@ FUELFILTER
REGULATOR
@ FUELPRESSURE
O) FUELPUMP(FPI
@)FUELTANK
EMISSIONIEVAPIVALVE
@ FUELTANK EVAPORATIVE
DAMPER
G) FUELPUI-SATION
@ AIR CLEANER
(D RESONATOR
6 imrlre arR Bypass (tAB)coNTRoL DIAPHRAGM
VALVE
VALVE
(D)IITITP IIN BYPASS{IAB)COTROLSOLENOID
ds)INTIXT AIR EYPASSTIABIVACUUMTANK
rio'lrnrarg ltn BYPASS(lABl cHEcK vALvE
6 rsnee wav cATALYTtccoNvERTERlrwc)
6 posrnve cRAf{KcAsEvENTILATIoN{Pcv) vALVE
6 evlponlrtve EMtsstot{ tEvAPlcoNTBoL cANlsrER
coNTRoL
EMtssloN{EvAP}PURGE
6 evlponltvE
VALVE
SOLENOID
(EVAPIPURGE
CONTROL
EMISSION
6i EVAPORATIV
VALVE
DIAPHRAGM
Eutsstof{ IEVAPIrwo wAY vALvE
6o ivlpoalrtve
11-11
vnx.su
SystemDescription
ElectricalConnections
PGM.FI MAII{ RELAY
@
fUEL
PUMP
- rc2lL
IllL
i i \|
r--ri l {a/Tl
.i
FUELINJCTORS
DATA
LIIIK
To BAOIATORFAt!
RETAY,CONDENSER
FAI{ RELAY
co t{EcToR
To A/C SWITCH
A/C CLUTCH RELAY
A/T GEAR
FUSES
I1OOAI*
O BATTERY
@ oPTroNt50 alr
o rG {50 A).
@ sroP. HoBN{2OAl*
@ BACKUP(7.5 Al*
LIGHT{7.5 A)
@ No. 3 INTERIOR
O Ecu (EcMt(1s A)'
@)No. 24 ACG (ALTI0Gl
{15 A: 81881sngin6,
2OA:818C16n9ine)
@ No. 15 BAcK-uPLlcHTsllo Al
RELAY
@ No. 13 REARDEFROSTER
HEATERMOTORRELAY
FAN MOTORRELAYI7.5 A}
COOLING
SIGNAL
17.5A)
O No. l8 STARTER
*: UNDER-HOOD
BOX
FUSE/RELAY
11-12
vnx.su
ITIAP
sEl{SOR
TP SEI{SOR
..!L1.99'!.elsrl
VTEC SOLE]{O|O
EVAP
PURGECOT{TROL
SOLEI{OIOVALVE
|AA CO TROL SOLEI{OID

VAI.VE
ECT SEI{SOR
ALT C 416
IUSA or yl
TERMINALLOCATIONS
ooooooooooooo
ooooooooooooo
oooooooo
oooooooo
ooooooooooo
ooooooooooo
(cont'd)
11-13
vnx.su
System Description
ElectricalConnections(cont'd)
rHriRED,
fl--fwl
I
Jftfi:]ff*-,
HO2S
cl13
181881cngr|.l tBl8cl .nerEt Flll--------------YEURED - YEr/wI{ri |

|
- YvHrnEr-l | i|APsEIrsoFI
-cn AvHrr
ll_l
cl11
ECTSEI{SOR
c120
{E
, REDI'EL
GRI{/BLU
IAT SET{SOR
cl15
1E
YEL/BLU
RED/8U(
GR]I/BLU
cl19
wt{T/GRl{
wL?/nEor
WHT/GRT{
WHT/REDr
ALTERI{ATOF
cl to
tclrl
c131
".rro*.fl..Fl
- ll PnEssunE I
- atK'
swrcH
I
1l
(To psge 1 l -15)
11-14
vnx.su
-'-'--''''-''-'
D14 :wHT/nED'
TDC/CYP/CKPSENSOR
811
812
813
814
815
816
'- -----
:j:on 2-"''''-'
:-WHT--------'-''''-''''
:ji oRNi sLU =::::i-:jjjjjjj
:ji WHT/ALU jjji-::-:-:::i:jj
KS
t{o. 1 FUEI
II{JECTOR
c122
t{o. 2 FUEL
II{JECTOR
c123
No. 3 FUEL
NJECTOR
c124
YEL/ALX
YELI
YEL/BLK
- RED2
t{o. 4 FUEL
II{JECTOR
EVAP PURGE
cot{TRoL
soLE{otD
VAIVE
(cont'd)
11-15
vnx.su
System Description
ElectricalConnections (cont'dl
BLI(/YEL
oRI{r
BTKiYEL-JT---l
oR 1 ----l I vss
BLK'
{l
c't 16
v:r-,sr-*-J
l-----]
'o"
uo.u.
".*,".u
{l
lA18a1ongine,
lB18C1 6ngin)
".t t
enn__JlF-----l
r Brx_LlswrcH
il
tl
ll
c423 ! caor
-L
es-ot
c405
eaurvxrJ
r BLK -l
G401 :--
SERVICECHECK
COIIIIECTOR
c40a
BRN/BLKf
DATA LINK
LT BLUI
corrttIEcToR
WHT/RED
{
11-16
vnx.su
lBl lcl
I T
t Il
neonr-x
RED/WXT
GAUGE ASSEMALY
c449 -
C553
F-
{!L rNDrcAToR
GR[{/OR]{
["'
To RADIATORFAt{
RELAY, COI{DI{SER
FAI{ RELAY
To A/C COTT|PfiESSOR
CLUTCH RELAY
To A/C SWITCH
(cont'd)
11-17
vnx.su
System Description
ElectricalConnections(cont'dl
160Al
wnrneo
J
-l
,*rr"a*
fioo Al
c216
wHr/8ru
T
I
YEL/WHT--L
c214
wHvem {
sToP. HORI{t20 Al
auryet{
oR nED-l
-alx {
I "rti'
f_ c218
G20r
I{o. 3 lttTERlOR LIGHT
wxrneo
"a*,"ao {
c44t)
*utwxr
o. la STARTER
stGI{At- t7.5 Al
{
wHriRED--l
or-rrv:r{
c551
-{
nft
C4.
l|5^.llll.n'i'20r!|.c1q*,
No. 15 8ACK-UP LIGHIS

t10 al
Af,:
Ca13 f
-l
8rr(/nED
surwxr -{
el3t
F
w{T/GRr{_-]
cR î|Hrl
{Toptg 11-19,
11 - 1 8
vnx.su
{Frompago 1 1-'l8l
PGM-FI lrtAtt{
REL,AY
G502
11-19
vnx.su
System Description
SystemConnectorsIEngineCompartmentl
ENGINE
WIRE HARNESS
{818C1 onginol
o
t3
c132
c131
UNDER,
HOOO
FUSE/RELAY
aox
MAllrl
WIRE
HARI{ESS
ct 04
c220
c102
c222
11-20
vnx.su
c112
c111
cl10
cl1
r'ft]
r+
lrl2l
trtr
\:-/
lI-FErwHr
l-l l
1olGuNlert
IOTBLF------l
la lsLx/YEL
fo lanlr
c 132
tr
/ r \
\^y
IETYEL/Lh---l
----,,
lohED'
ldlcRr/vEr
ffi
c221
^Jl
r'fr]
c214
---l
c216
c215
I if,l.)
l;TYra-"wrrr.
I
le llel/nEo
I
I TcRNrwHrtl
I ,ITwHr^rJl
I
c 13 t
c117
lB18C1engine)
l]l
E:I
ffi
FFIN
fi'Twtl-rirllrlerrrltlerl-l
- lll
fr-Twrr
I@ LWHTTREO I
ohN/BLK
|/BL!
ALU/YEL
NOTE: a Different wires with the same color have been given a number suffix to distinguishthem (for example,
YEL/BLK1and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSystem.
a - Connectorof male terminals:View from terminalside
(cont'd)
- Connectorof temaleterminals:View from wire side
11-21
vnx.su
System Description
SystemConnectors[EngineCompartment](cont'd)
c 120
{81881sngino}
(B18Cl onginol
11-22
vnx.su
cl16
FI
c117
lBl88l 6nginol
EI
/
\2
|@|iaf,-'6trlaltrlaru----1
toltEUB'.f----
c121
fr
|6-I!EUBLK
lO lhEo'
c122
ffi
ct 20
l8lSBt.nglnrl
ET
c119
RP
--'l
I
(Bl8Cl .ngln l
F,-f.
\?
16lwHiffiN----f
l@lwHrnco' I
| 3 l a L & Y E r --- I
frlwHrEru
l6TciN-6LU----loliEo/YEi----.
c 123
24
ffi
ffi
---------l
l6'lau,-r,
IO IYEL/8LX
cr20
l6-ltR,iEit---l@ IiEp/YcL
cr33
.2
--.-.1I
|o lhEo/8llJ
I-T-
c3t I
ct 34
,8.
\^y
tsF
f6-IPilK/BLu---l
I
IO IYEUBL(
NOTE: a Different wires with the same color have been given a numbe. suffix to distinguish them (for example
O: Related to Fuel and EmissionsSystem.
a - Connector of male terminals: View from terminal sid6
- Connectorof female terminals:Viow from wire side
11-23
vnx.su
System Description
System Connectors [Dash and Floor]
ENGINE
COMPARTMENT
WIRE
PGM-FIMAIN
RELAY
DASHBOAROWIRE
HARNESS
REAR
WIRE
HARNESS
MAIN
WIRE
HARI{ESS
C1I44
UNDEN-OASH
FUSE/REALY
BOX
11-24
vnx.su
c4't9
2 3 4 5
7 8
e nc
t6| -
a ALUfYEL
YEL'
c431
lwlth
cruit
coniroll
c431
(wlthout
crui!a
control)
c423
|' l r l
-t
t t I
5
6
----'l
l6'TwHr/cnN----l
1ol cRN^vHr
BLU/YEL
lslnl
t3
12
13
fitr G-Fil-----lo ln/Hr/68n I

lo lciN,r/vHr I
l-IcRY------l
1a
20
c432
c439
ffi
rfltrrn
c44il
riTLF-I
I'VCT,1
lETWrr;eo---f
-frlwHr.
l3l8rK
I t lBLx,REo
t 5
I 6 G R N / B L X-f?-TFEpcFN
ffi
14l51617l
YEL/BLK'
Ht/alu
I
I
|
I
iEO/YIL
15
16
't7
lO lGRt/8LU
ktlBrKr--
I o lYcL/Gnir
lao laLx./YEL
I "] IYEUBL(
ktlterwirr
a
BL&"/EL
YEL
Titfgruffir-----l
---
I
I
I
20
c444
ffir
trtr]
I6TLK^//Hr
L' l!!g!!r
-l
l
l o l s L k r F E D l]l I
|;TBLU'BLi
NOTE: a Ditterent wires with the same color have been given a number suttix to distinguishthem (fot example
YEL/BLKrand YEL/BLK,are not the samel.
(cont'd)
- Connectorof femaleterminals:View from wire side
11-25
vnx.su
System Description
System Connectors [Dash and Floor] {cont'd}
DASHBOARD
HARNESS
UNDER-DASH
FUSE/RELAY
BOX
MAIN
WIRE
HARNESS
11-26
vnx.su
1 2 3
gL&YEL
BLK/YEL
BLK
GFN,YEL
5
2
GFN
YEL
15
LT GRII/SL(
6 7
REO/6LU
12
r0l1 11121131
114115116
8RN/8LK
3 BLU
9
12 BLUf/L
GRN/BLII
YEL/RED
13
YEL
YEL/6LK
16
BLU
t6
a DiJterentwires with the same color have been given a number sutfix to distinguishthem (for example
YEL/BLK1and YEL/BLK'are not the same).
a - Connectorot male terminals:View from terminalside
- Connectorof female terminals:View from wire side
{cont'd)
11-27
vnx.su
System Description
SystemConnectors[Dashand Floorl (cont'd)
c/ro5
SERVICE
CHECK
CONI{ECTOR
11-28
vnx.su
c405
c406
fr
c410 tEGM-Al
r'tr--Jl
-----l
I6TBRN/B,L(-__-l
l, lwHr/uED l_l
l6TLr BN---
ffi
tt4
YEL'
| (jt
ALK/AED
1a
SLU
ALK
t(9
YEL
| 0o)
GRN/oRr
ALK'
ALK'
YEL/BLK
BLK
l@
c408 {ECM-Bl
3
2 4
9 1 t3tl5
8 1C l 2 4
BLK
2
YEL
I
ALU/REO
ALU/YEL
a Different wires with the same color have been given a number suffix to distinguishthem (for example
Connectorof femaleterminals:View from wire side
11-29
vnx.su
System Description
SystemConnectors[FuelPumpl
REARWIRE
HAFNESS
11-30
vnx.su
c510
NOTE: a Ditferent wiros with tho samo color hava been given a numbr sutfix to distinguish them {for example
YEL/BLKI and YEL/BLK, are not th same).
O: Rlated to Fuel and EmissionsSystom.
a - Connoctor ol malo tarminals: Vi6w from terminal side
- Connector ol f6msl tarminals: Viw from wire sid
11-31
vnx.su
Troubleshooting
TroubleshootingGuide
NOTE: Across each row in the chart. the systems that could be sourcesof a symptom are ranked in the order they should
be inspectedstaning with O. Find the symptom in the left column, read acrossto the most likely source.then refer
to the pagelistedat the top of that column.lf inspectionshows the systemis OK, try the next mosr likelysystemO, etc,
PGM.FI
TOPDEADCINTTR/ ENGINE
INfAKE AIR BARO.
MANIFOLO
ENGINE HEATEO
IGNITION vEHtct-E
CRANKSHAFT COOLANT THROTTTE
TEMPRA. METRIC
AESOLUTE
OUTPUT SPfED
POSTT|ON/ TEMPfRA. POStTtON
CONTROL OXYGEN
TURE PRESSURE
PRESSURE
TURT
CYLINDER
MOOULE S E N S O R
SENSOR sar,rs0RSENSOR SIGNAL SENSOR
SENSOR
POSITION
SENSOR SENSOR
11.42
SYMPTOM
MALFUNCTION
INOICATOR 1 l o r : t : ] :
L A M P( M I U " T U R N O
SN
4 6 ,4 7 , 5 0
lrmr:
-D:o.:@.
MALFUNCTION
INOICATOR
:O. or-8.
L A M P( M I L ) ' ' B L I N K S
o, O'
ENGINEWON'T STAffT
DIFFICULT
TO START
ENGIN
WHENCOLO
WHENCOTD
FASTIDLE
16l-
i;:i'
-tK3t-
l 3 l
/__-\
(9)
RPMTOO
LOW
WHILE
AFTER
FREOUENT
STALLING
MISFIREOR
ROUGH
RUNNING
POOn
PERFOEM. FAITS
EMISSION
ANCE
TEST
Loss0F
-r:+r-
-{"Pr:
\ --l-l
-l
r 0I
| t - /----\
/__-\
7
11-64
1t-66
-o_ -16l-.
z-\
1r-68
r6t
/_-\
\.--r--l
| 1 3|
z_---\
r5 -t
I t - /-]-\1 7t /.---\
o
@
@
@
POWER
-16l
/-----\
11-62
RPMTOO
HIGH
16l
' - \
1l-60
ROUGHIDLE
l1-58
.E-o.:O: or tr]- - i-i-\! l

/
ouT0f sPtc
IRREGULAR
IDLING
11-56
lf codes other then those listedabove are indicated,count the numberof blinksagain.It the MIL is in fact blinking
^ these codes, replacethe ECM.
qy, lf the MIL is on while the engineis running.connectthe SCS shon connectorto the servicecheck connector.It no
code is displayed{MlL stays on steady),the back-upsystem is in operation.
Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM.
USA:
MALFUNCTION
INDICATOR
LAMP {MIL)
CANADA:
CHECK
\ ----l
-ltGl-
ENGTNE
{ -1t-
LTGHT
* * *: 818C1engine
1-32
vnx.su
I O L EC O N T R O L
PGM-FI
VARIAEIEVALVEVARIABLEVALVE
TIMINC& VALVE TIMING& VATVE
ELECTRICALLIFTELECTRONIC
I-IFTILECTRONIC KNOCK
LOAO
stNsoR
cottTR0t
coNTRO|DETECTOR
PffESSURE
SOLENOID
s38
| 1"70
E
\.-r-l
-t l0 t---i-\
r6t-
- ---
t 2 tI
/ --i-\
--\-!-/
l 2j--\2 l
/--
11.74
-16l/-----..
IOLEAIR
OTHER
OTHER
FUEL
FUEL
IOLE
INJECTOR
SUPPTY
CONTROLS
FI
SIGNAL
FI
SIGNAT
c0NTR0r-
r 1-76
t 1-76
11-82
fl
\.--r-z
FUELSUPPLY
11-78
-o_
| 1-102
r 1-97
INTAKE
AIR
t 1 - 11 5
MtsstoN
CONTROLS
l l 129
,.''\
\.---l
30
t 3 rt - /----\
[|t 2 3l - -t
,--T-\ l- /-.--\
/--.i-\
I 1 6t\ -
/ _-i-
@
@
o
o
o
a,
Q)
@
@
o
(JJ
11-3
vnx.su
Troubleshooting
Procedures
Self-diagnostic
When the MalfunctionIndicatorLamp {MlL) has been reportedon, do the following:
'1.
Connect the SCS short connecto. to Service Check Connector as shown. (The 2P Service Check Connector is
locatedunder the dash on the passengerside of the car.) Turn the ignitionswitch on.
DATA LII{K
(3PI
CONNECTOR
NOTE:
Do not attach
jumperwire.
2. Note the DiagnosticTroubleCode (DTC):The MIL indicatesI code by the length8nd numbsrot blinks.The MIL
can indicatemultiplecomponentproblemsby blinkingseparatecodes,one after another.Codes 1 through Igre
indicatedby individualshon blinks.Codes 1Othrough 43 are indicatedby a seriesof long and shon blinks.Th
numberof long blinksequalsthe first digit, the numberot short blinks equalsthe seconddigit. Sometimesthe
firsr blink is difficult to see; always count the blinks at least twice to verify the code.
MALFUNCTIOI{
INDICATOR
LAMP
IMIL}
CANADA:
CHECK
ENGINE
LIGHT
Sgprrate Prcbaomr:
shT
-n-----n-=n+!+1].TL;I!!=-L
'"
,JU
Long .hon
"
"
= s.o DTc1
= s.. Drc 3
= Sce DTC 13
Multiplr Probl.ln.:
= S. DTC 1 lnd 3
J-l_tx-TL-n-ffu-r-J.rrU-L-r]tltlr'l- __-tnrua = Sce DTC 3 and 4
Jll-lrl-t-----Tt/'tnj]_
= S.. DTC 3 lnd 14
11-34
vnx.su
Engine Control Modute {ECM) Reset procedure

1. Turn the ignition switch otJ.
2' Removeth BACK UP (7.5 A) fuse trom the unde.-hoodfuse/relaybox for lo secondsto reset
the EcM.
BACKUP I7.5 AI FUSE
UNDER-HOOO
FUSE/RELAY
BOX
Final Procedurelthis procedure must be done after any troubleshooting)

1. Removethe SCS Short Connector.
NOTE: lf the SCS short connectoris connectedand there are no DTCSsto.ed in the ECM,the MIL will stav on.
2. Do the ECM Reset Procedure.
11-35
vnx.su
Troubleshooting
Self-diagnosticProcedures(cont'dl
DIAGNOSTIC
TROUBLE
CODE(DTCI
SYSTEMINDICATED
Psge
ENGINE
C O N T R O LM O D U L EI E C M )
11-42
,l
H E A T E DO X Y G E NS E N S O RI H O 2 5 )
11 - 4 6
MANIFOLDABSOLUTEPRESSURE
{MAP SENSOR)
CRANKSHAFTPOSITION(CKPSENSOR)
11-52
4
o
(ECTSENSOR)
ENGINE
TEMPERATURE
COOLANT
11-58
11-60
THROTTLEPOSITION(TP SENSOR}
11 - 5 6
11 - 5 6
TOP DEADCENTERPOSITION(TDC SENSORI

No. 1 CYLINDERPOSITION(CYPSENSOR)
10
(IAT SENSOR)
INTAKEAIR TEMPERATURE
11-62
13
(BAROSENSOR}
BAROMETRIC
PRESSURE
1|-64
14
IDLEAIR CONTROL(IAC VALVE}
11-42
t c
IGNITIONOUTPUTSIGNAL
to
FUELINJECTOR
17
VEHICLESPEEDSENSOR{VSSI
20
ELECTRICAT
LOAD DETECTOR(ELD)
21
VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC

CONTROLSOLENOID
VALVE{VTECSOLENOID
VALVE)'
6-36
22
VARIABLEVALVE TIMING& VALVE LIFT ELECTRONIC

CONTROLPRESSURE
SWITCH(VTECPRESSURE
SWITCHI-
6-38
23
K N O C KS E N S O R{ K S } -
1 1 - 74
30
A/T FI SIGNALA
11-76
3'r
A/T FI SIGNALB
11 - 7 6
4'l
HEATEDOXYGENSENSOR(HO25} HEATER
11-47
43
FUELSUPPLY
SYSTEM
11 - 5 6
11-66
1't-102
11-68
't 1-70
11 - 5 0
':818C1 engine
a lf codes other than those listed above are indicated, verifv the code. lf the code indicated is not listed above, replace
rhe ECM.
a The MIL may come on, indicatinga systemproblemwhen, in fact, there is a poor or intermittentelectricalconnection.
First, check the electricalconnections,clean or repairconnectionsit necessary.
o The MIL and @ indicatorlight may light simultaneously
when the DiagnosticTroubleCode (DTC)6, 7 or 17. Check
the PGM-Flsystem according to the PGM-Flsystem troubleshooting, then recheck the l!! indicator light. ll it lights,
s e e p a g e 1 4 - 5 O ,5 1 .
a The MIL does not come on when there is a malfunctionin the A/T Fl signalor ElectricalLoadDetector(ELDIcircuits.
However, it will indicate the codes when the Service Check Connector is shorted.
11-36
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It the inspectionfor a particularcode requiresthe test harness.removethe right door sill moldingand kick panel. Pull
the carpet back to exposethe ECM, Unbottthe ECM cover. Turn the ignitionswitch off and connectthe test harness
Check the system accordingto the proceduredescribedfor the appropriatecode(s)listed on the following pages.
KICK
PANEL
TEST
HARNESS
OTLAJ_PT3OlOA
DIGITAL MULTIMETER
Commarciallyovribbla or
KS-AHM-32-OO3
NOT USED
o oooooooooooo oooooooo
ooooooooooooo oooooooo
TERMINAL LOCATIONS
ooooooooooo
ooooooooooo
(cont'd)
11-37
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Troubleshooting
Self-diagnosticProcedures(cont'dl
a Punctudng th6 inruLtion on r wirc cln cruaa poo? or Int!finltttri
aLctrlcC connac,tlom.
a For tosting at connoctofs othor thsn tho taat hrmara, bdng thc tartar probc Into contact whh tha tarnilnal trom thr
connector ride of wilo hamclr conn.ctora In thc cnglnc comprnrnam. Foi t.|nab connactorr,lurt touch llgl ly whh
tha tostor probo and do not Inlcrt tho prcbc.
TES'EB PNOBE
TERflt]IAI
11-38
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How to ReadFlowcharts
A flowchrrt is dasignedto be usd fiom start to final repair. lt's like a map showing you the shortest distanco. But be"map" anywhere but a "stop" symbol, you can easily get lost
ware: if you go off tho
l6rffil
(bold tyDo)
Desclibas the conditions or situation to start a troubleshooting flowchart.
|TeTiONl
Asks you to do something; pedorm a test, set up a condition etc'
<:6Eei6io-fr\>
Asks you about the result of an action, then sends you in the appropriste troubleshooting direction.
I-SJTFI
(bold typel
The snd of a series ot actions and decisions, describes I tinal repair action and aomotimea diracts
you to 8n garlier part of the tlowchart to confirm your repair'
NOTE:
a Tha tarm ,,lntormittgnt Failure" is used in these chans. lt simply means a system may have had a failur6, but it chocks
out OK !t this time. lf th6 Msltunction Indicator Lamp (MlL) on ihe dash does not come on, check for poor connections
or loose wires at all connectors rolated to the cilcuit that you are troubleshooting (see illustration b6low).
a Most ot tho troublashootingflowchans have you reset the EngineControl Module (ECM)and try to duplicate the Disgnostic Troubls Cod6 (DTC). lf the problem is intermittent and you c8n't duplicat the cod6, do not continus through
the flowchart, To do so will only rosult in confusion and, possibly, a nedlessly replaced ECM
a ,,opon,'and ,,short,, are common electricalterms. An open is a break in a wir6 or at a connction.A short is an
accidontalconnaction ot a wir to ground or to another wire. In simple electronics,this usually means somthingwon't
work at all. In complex electronics (like ECM's), this can sometimes mean something wolks, but not the way it's suppoSadto,
a il th6 olectricsl readingsare not as specified when using the test harness, check the test harnessconnoctions bsfore
procooding.
LOOSE
11-39
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PGM-FISystem
System Description
ENGINECONTROLMODULE(ECMI
TDC/CKP/CYP
Sensor
MAP Senso.
ECT Sensor
IAT Sensor
TP Sensor
HO2S
vss
BAROSensor
ELD
Starter Signal
ALT FR Signal
Air ConditioningSignal
A/T Gear Position Signal
BatteryVoltage{lcN. 1)
BrakeSwitch Signal
PSPSwitch Signal
Knock Sensor'
VTEC PressureSwitchr
lFuettnjectorTimingandDuration]
I Electr..l"ldle Contr;il
Fit'e' contr; Funcrfit
OUTPUTS
Fuel-lnjectors
PGM-FIMain Relay(FuelPump)
MIL
IAC Valve
A/C CompressorClutch Relay
Radiator Fan Relav
CondenserFan Relav
ALT
rcM
EVAP PurgeControlSolenoid
l6tio;
Ttntrlg c..trol
tEcM aack-,rpFunctiorlsl
HO2S Heater
VTEC SolenoidValve'
IAB Control Solenoid Valve*
': 818C 1 ngine
PGM-Fl System
The PGM-Flsystem on this model is a sequentialmultipon fuel injectionsystem,
Fuol Iniector Timing and Duration
The ECM containsmemoriestor the basic dischargedurationsat variousenginespeedsand manifoldpressures.The
basicdischargeduration,after beingreadout from the memory,is turther modiliedby signalssent from vanoussensofs
to obtain the final dischargeduration.
ldle Air Control
ldle Air ControlValve (lAC Vatve)
When the engineis cold, the A/C compressoris on, the transmissionis in gear (A/T only) the brakepedalis depressed,
the P/Sloadis high,or the alternaloris charging,the ECMcontrolscurrentto the IAC Valveto maintaincorrectidlesoeed.
lgnition Timing Control
a The ECMcontainsmamoriesfor basicignitiontiming at variousenginespeedsand manifoldpressures.lgnitiontiming
is also adjustedfor enginecoolanttemperature.
a A KnockControlSystemis alsoused.when detonationis detectedby the knocksensof.the ignitiontiming is retarded
(B18Cl engine).
Other Control Functions
1. StartingControl
When the engineis started.the ECM providesa rich mixture by increasingfuel injectorduration.
2. Fuel Pump Control
a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-Flmain relaythat supplies
currentto the fuel pump tor two secondsto pressurizethe tuel system.
a When the engineis running,the ECMsuppliesgfound to the PGM-Flmain relaythat suppliescurrentto the fuel pump.
a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FImain relavwhich cuts
current to the fuel pump.
11-40
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3.
Fuel Cut-oft Control

a During decelerationwith the throttle valve closed, current to the {uel injectors is cut otJ to improve fuel economy
at speeds over tollowing rpm:
. 8188l engine:91O tpm (Canadamodel: 1,O50 rpm)
. 818C1 engine:95O tpm (Canadamodel: l,O5O rpm)
a Fuelcut-olf actionalsotakes placewhen enginespeedexceeds,7,O0Orpm {818B1 engine),8,1O0 rpm (B18Cl
engine), regardlessoI the position of the throttle valve, to protect the engine from ovet-revving.
4.
A/C CompressorClutch Relay

When the ECM receivesa domand for cooling trom the air conditioning system, it del8ys the compressorfrom being
enetgized,and enriches the mixture to assure smooth transition to the A/C mode.
EvaporativeEmission(EVAP)PurgeControlSolenoidValve
Whenthe enginecoolanttemperstureis below 163oF {73"C), the ECMsuppliesa groundto the EVAPpu.gecontrol
solenoid valve which cuts vacuum to the EVAP purge control diaphragm valve.
6 . Intake Air Bypsss (lAB) Control Solnoid Valve

When the enginerpm is below 5,750 rpm, the IAB control solenoidvalve is activatedby a signalfrom the ECM,
intske air flows through the long intake path, then high torque is delivered. At spaeds highe. than 5,750 rpm, the
solenoid valve is deactivated by the ECM, and intake air flows through the short intake path in order to reduce the
resistancein airflow.
ECM fail-safe/bEck-upFunctions
1. Fail-sateFunction
When an abnormalityoccursin a signalfrom a sensor,the ECM ignoresthat signaland assumesa pre-progtammed
value tor that sensorthat allows the engineto continueto run.
Back-uDFunction
When an abnormalitv occurs in the ECM itself, the fuel iniectors are controlled by a back-up citcuit independentof
the system in order to permit minimaldriving.
2
FunctionIMaltunctionIndicatorLamp {MlL)1
Self-diagnosis
Wh6n an abnormalityoccurs in a signalfrom a sensor,the ECM suppliesground for the MIL and stores the code
in erasablememory.When the ignitionis initiallyturned on, the ECM suppliesgroundtor the MIL tor two seconds
to check the MIL bulb condition.
4.
Two Trio Detection Method

To prevent tals indications, th Two Trip Dstection Method is used for the HO2S and fuel metering-relatedselfdiagnostictunctions.When an abnormslityoccurs,the ECM stores it in its memo.y. Whn the ssme sbnormality
recursalter the ignitionswitch is turned OFF and ON ag8in,the ECM informs the driver by lightingthe MlL.
However, to ease troubleshooting, this function is canclld when you short the service check connector. The MIL
will then blink immedistelvwhen an abnormalityoccurs.
11-41
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PGM-FISystem
EngineControlModule(ECM)
The Malfunction Indicator Lamp
(MlL) n6v6. com6s on lovon fol
lwo socondal aftor ignition is
tumed on.
NOTE: lf this svmptom is intermittent.check for a loosefuse No. 15 (BACK

UP LIGHT,1OA)in the under-dashJuse/relaybox, a poor connectionat ECM
terminalA13, or an intermittentopen in the GRN/ORNwire betweenthe ECM
(A13) and the gauge assembly.
lurn the ignitionswitch ON.

ls the low oil pressurelight on?
InspectNo. 15 {BACK-UP
LIGHT}
l1O A) luse in the underdash
tuse/relay box.
Turn lhe ignition switch OFF.
ls the fuse OK?

Conneclthe test harnessbetween
the ECM and connectors (see
p a g 1 1 - 3 7 ) .
Repairopon in YEL wiio botw6on

No.'15IBACK-UPLIGHTI110 A)
luso and gaug6 assombly.
I
Turn the ignitionswitch ON.
l s t h e M I Lo n ?
- Rplaco No. 'l5

IBACK-UP LIGHT)
llo Al fuso.
- Ropair short in
YEL wiro botwoon
No. 15 (BACK-UP
LIGHT){10 A) fuso
ano gauge 6$omblv.
A13
I| | o o o o o o o o o o o o o I o o o o o o o o I o o o o o o l o o o o o o o o o o o I
- RsDlacotho MIL bulb.
- Ropairopon in GRN/ORNwi.e
betwoen ECM {A13} and
gaug a$6mbly.
lB18B1 onginoonlyl
Measure voltage between body
Oroundand the tollowingterminafs individuallv:423, 424.
ls there less than 1.O V?
Ropah op6n in BLK wirolsl botw6en ECM and GlOl llocatod at

thormostat housing) that had
moro than 1.0 V.
Substituto a known-good ECM

and rochgck, lf symptom/indication gos away, roplacotho original ECM.
11-42
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G 10'l
Th. ll.lfunction Indicltor Lamp

lMlll at!y3 on o. cornaaon alt6l
two aacond!.
Connectthe SCS short connector

to th6 sorvice check connector
(see page 11-34).
Turn the ignition switch ON.
Doesthe MIL indicateanv Oiagnostic Trouble Code (DTC)?
Romoveth SCS shon connector

lrom the service chck connector.
NOTE:
a Whenthere is no code stored,the MIL willstay on if the servicecheckconnector is shorted.
a tf this svmotom is intermittent,check for:
- A loose ECM fuse (15A) in the under-hoodtuse/relaybox
- A looseNo. 24 fuse (ACG)(ALT)( 1 5A: B18B1 engine,2OA: B18C1 engine) in the under-dashfuse/relaybox
- An intermittentshort in the BRN/WHTwire betweenthe ECM (D4) and
the servicecheck connector
- An intermittentoDenin the BLK wire betweenthe servicecheck connector and G4O1
- An intermittentshon in the GRN/ORNwire betweenthe ECM(A 13) and
the gauge assembly.
- An intermittentshort in the YELMHT wire betweenthe ECM (D19)and
the MAP sensor
- An intermittentshort in the YEL/BLUwire betweenthe ECM (D20) and
the TP sensor
Go to iolfdiagnostic Proceduros
(se pago 11-34).
o o o o o o o o o o o o o l o o o o o o o o l i i i : $ A $ . P s ,ol o o o o o o o o o o
oooooooooo
ooooooooooooo I oooooooo
D22 t-l
D 4( + )
Turn the ignition switch OFF.
Try to start the engine.
l"oo,o'.
uu,l
Connectthe test harnessbetween

p a g e1 1 - 3 7 ) .
Measurevoltage botween D4 (+ )
terminaland D22 { - ) terminal.
ls thereapprox.5 V?
Ropair shon to body g.ound in

BRN/WHT wire betwoon th6 ECM
lD4) end sorvlco chock connocto?.
InsDoctECU{ECM)115A) tuse in
th6 undeFhood luse/relav box.
ls the luss OK?
(To page 1 'l -44)
connect the SCS shon

connector to servlce
check connector.
Measure voltage be_

tween D4 {+} terminal
and body ground.
- R6pairopen in BRN/WHTwito
botwoon EcM lD4) and s6rvice chock connactor.
- Repoir opon in BLK wiro botwoon 36rvi@ chock connectoa
and G4Ol.
ls thereapprox.5 V?
- Rsolaco
ECU{ECM}(15 Allus.
- R6pairshon in YEL/WHT wilo
botw6on ECU lEcMl 115 A)
fuso and PGM-FI main rolay.
Removethe scs short

Connector from the
service check connector.
'NOTE: After repair,disconnectthe SCS Short

Connsctor,test drivethe car, and rechecktheMIL
lor a code.
(cont'd)
lTo page 1 1-44)
11-43
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PGM-FISystem
EngineControl Module (ECMI (cont'dl
(Frompage 11-43)
(Frompage 1 1-43)
Inspectthe No. 24ACG {ALT)(lG)

(15 A: 81881 engine, 2OA:
818C1 enginelfuse in the underdash fuse/relav box.
ls the fuse OK?
Disconnect"A" connector from the ECM.
- R.pllr .hon in BLK|rEL wlr6

batr.vqr undariair luro/Fby
box lnd FGM-FI m.in .obv.
- noebco lto. 24 ACG {lG) nLT)
(15 A: 81881 ongin., 2OA:
Bl8Cl onein.l tu!6.
Disconnect the 3P connector ot

each sensor one al a time:
. MAP sensor
. TP sensor
Doesthe MIL remainON?
Subrtltute r knowngood ECM

.nd rochock. ll lymptom/indicstlon g@a rw!y, rephco tho origin.l ECM.
ls the MIL ON?
Ropair short to body

giound in GRN/ORN
wir6 botwoon tho ECM
lA131 6nd MlL.
Rcplaoo thg lgnlor that caur6d
th. llght to Oo out.
Dt9
I
connect the test harness.

Disconnect the "D" connector
from th ECMonly, not the main
wire harness(see page 11-37).
I o o o o o o o o o oo o o I o o o o o o o o I o m o o o l o o o o o o o o o o o |
I o o o o o o o o o o o o o I o o o o o o o o 1 o ( ' o e ( l oI o o o o o o o o o o o |
-
|
|
D2O
\-.J
Continuity?
Check tor continuity between

body ground and D19, O2Oterminals,
- Bapai?rhod ro body g.ound in
YEL/WHT wi.e boiwoon ECM
(Dl9) .nd MAP ..n3or.
- R.p!k shon to body ground in
YEL/BLU wire b.lwo6n ECM
(O2Ol .nd TP 3on!or.
Reconnect all tho sensor connecrors,
Reconnectthe "D" connector to
rhe ECM.
{ T o p a g e1 1 - 4 5 }
11-44
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(Frompage 1l-44)
Measure voltage between 426

{- ) andthe following:B'1(+ } and
A25 {+t.
BATTERY
VOLTAGET
ls there battery voltage?
- Ropsir opon in YEL/BLK wiro

botwoon ECM (425, 81l and
PGM-FIm6in relay.
- Chock PGM-FImain rclay and
wiring connectors at PIGM-FI
main.olay(soepsg6 11-1121.
Measurevoltage between body

ground and the tollowingtermiA23. A24, A26,
nalsindividually:
42.
ls there less then 1.0 V?
- noprir opon in BLK wit. b6twson ECM 1A23, A24l and

G'101 {locatod al th6.mostat
housingl.
Repair opon in BRN/BLKwite
botweon ECM (A26, B2l and
Gl0r.
Substitut6 r known{ood ECM

and r6chock. lf symptom/indication goos away, roplacotho original ECM.
ooooooooooo
ooooooooooo
oooooooo
ooooooo
ooooooooooo
ooooooooooo
Lssthan 1.0 V?
11-45
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PGM-FISystem
HeatedOxygenSensorlHO2Sl
-fi-l:
-t6l--.:
\ /?\
The Malfunction Indicator Lamp (MlL) indicates Diagnostic Troubls Code (DTC) 1: A problsm in
the HeatedOxygen Sonsor(HO2S| circuit.
The Heated Oxygen Sensor IHO2S) detcts th6 oxygon contont in th6 exhaust gas and signals th6 ECM. In operation,
the ECM receivs th6 signals trom the sensor and varis the duration during which tu6l is iniocted. To stabilize thd senaor's output, tho sensor has 8n intarnal heater and the sensor olemant is coatod with a catslyst. The HO2S is installod
in TWC housing(B18Cl engine)or exhaustpipe B (Bl8Bl ngine).
sEl{SOR
TERMII{ALS
sTotcHtoltETnc
ztRcot{lA
VOLTAGE(V}
AIR-FUEL
BANO
ELEiIE'{T
HEATER
- --.'!-
-__-
l r P l _ l! l -
HEATEB
TEBMIT{ALS
- Th! mll h.. bo.n raportad on.

- Wlth thr SCS rhon coon cto.
connoctad lr.. p!9. 1t-341,
cod. t l. Indlcltrd.
Oo th ECM Rest Procodure {soo

pag 11-35).
Stan the 6ngine. Hold th6 engine

A3,qgq rpm with no load {A/T in
Lrylor lll position, M/T in nourrall
until the radiator lan com6s on.
then lot it idle lor ot least on6
minutg beforo road t6tin0.
Connoctths SCSshort connoctor

to th6 sorvic check connector
lsoo p.g6 1 1-34).
Rood tst witlthe

automatic
transmissionin L?l position (M/T:
4th gear).
Stsrting st l,600 rpm, acc6lorate
u6ing wide open throttlo for at
lesgt 5 seconds.Thsn dgcolrste
for at lorst 5 sconds with th
throttlo completoly closed.
Ooes the MIL blink and doos it

indic6t6 cod6 1?
Intarmittd[ t llurc, lyri.m b Of

!l thla tlmc. Ch.ck lor poor connacdona o? loota wlrat |l C223
(loc.trd at right $ock towo.l,
Cr 13 (HO2S| lnd ECM.
Go to plga and partonn tad fot

cod. 43 lr.a p.go l1-501.
1 1 -4 6
vnx.su
- LEAI{
RICH - AN.
FUEL
RATIO
mll
Y-
-.----r-
Diagnostic
TroubleCode(DTCI41: A problemin
Lamp(MlL)indicates
Indicator
TheMalfunction
the HeatedOxygenSensor{HO2S)Heatercircuit.
)ffltl
-:-
\-
l-l
-t
tt(gt- r - - - 7 r tt I
- Th6 MIL has boenroponod on.
- With the SCS rhort connocto. connociod (aoe pago
11-341. codo 41 is indic.tod.
Do the ECM ResetProcedure{see

p a g e1 1 - 3 5 1 .
ls the MIL on and does it indicste code 41?
Intoamittont tdl||.g, ryrt m i3 OK at thi! timo

(tost driv6 lnay bg nscearatYl.
Chock tor poor conn6ctions or looro wires at
C223 llocatod at right
shod( row..l, C3O5 {located 6t loft ahock lowor), C424, C113
(HO2S) and ECM.
trminal side
Measurc tasistance betwgen terminals3 snd 4 on the HO2S.
ls thero 1O-4O 0?
DIGITALMULTIMETEB
Commorciallyavailabloor
KS-AHM-32-OO3
(cont'd)
(To page 1 1-481
vnx.su
PGM-FISystem
HeatedOxygenSensorHeater(cont'd)
11-471
Check for continuity to body

groundon terminals3 and 4of the
HO2S.
YEL/BLK
I+I
Checkfor continuity betweenter

minal4 and terminals1 and 2 individually.
(-I
ORI{/BLK
wire side
At the HO2S harness. measure

voltagebetweenYEL/BLK1f lteF
minal and ORN/BLK l-) termrnal.
HO2S
44 N.m
{4.5 kgt.m, 33 lbf.ft}
YES
Measure voltage between YEL/

BLK l+) terminal and body
ground.
Turn the ignitionswitch OFF.

Disconnectthe "A"
from the ECM.
connector
At HO25 harness,measurevoltage between YEL/8LK(+) terminal and ORN/BLK{-) terminal.
ls there baftery voltage?

Ropai.opon in YEL/BLK
wire botwoan HO2S
.nd PGM-FImain relav.
{ T o p a g e1 1 - 4 9 )
{ T o p a g e1 1 - 4 9 }
11-48
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RoDair short in ORN/

BLK wir6 b6tw6on ECM
(A6l and HO2S.
"A"
Connect the test harness
connector to the main wire har
ness only, not the ECM (seepage
11 - 3 7 1 .
Connectan ammetetbetweenterminalsA6 {+ ) and 426 (- )
* Monitor over a 5 minute Deriodunl6ss

the current drops below O.1A immediatelv.
ls the current less than

0.1A?.
Subrtitulo s known-good ECM

.nd r.ch6ck. lf symptom/indication goes away. roplacotho origin.l ECM.
Connoct the test harnss "A"

connector to the main wire harn6ss only. not th CM {seopage
't't-37).
BATTERY o o o o o o o o o o o o o I o o o o o o o o
VOLTAGE?o o Q o o o o o o o o o o I o o o o o o o o
L-E;
ooooooooooo
ooooooooooo
Measwe vohage bstween A6 {+ }

tg.minaland A23 {-)terminal.
Ropsii op6n in ORN/BLKwiro botw..n ECM {A6l and tho HO2S.
Subrtiluto s known{ood ECM

lnd Echock. ll .ympiom/indic{tirn god !way, '.pLc! f|e origlh.l ECM.
11-49
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PGM-FISystem
Fuel Supply System
rj-t
-
T,-n
- L:!-i -
The MaltunctionIndicatorLamp (MlL) indicaresDiagnosticTroubleCode (DTC)43: A problemin

the HeatedOxygen Sensor(HO2S)circuit. or a probtemin the Fuel Supply System.
-+-
1 3|
l- t @"-t - -- t--i-'
- Tho MIL h.s boenreportodon.

- With rhe SCS short connoctor connocted (soo paga
1l-34), codo 43 b indlcat.d,
ls the code 43 accompanied by
the MIL and poor driveability?
From codr I troebl.lhoorlng lprgo 1146).
Go to Fuol Supply .y.t.m

pag6 1t-971.
(|ec
Do the ECM Resetftocedure lsee

p a g e1 1 - 3 5 ) .
Connectthe SCSshort connector
to the service check connector
'l1-34).
{see page
Start the engine. Hold the engine
at 3,00O rDm with no load {A/T in
@or@ position,M/T in neutral)
until the radiator Ian comes on,
then let it idle for at least one
manute,
Raisethe enginespeedto 3,000
rpm and hold that throttle position
tor at least one minute.
Do not vary the throttle position
even if the rpm drops.
Intonnitl.nt t llure, tydom lr OK

at thi. tim. lto.t drlv. mly b.
nocaararyr.
Chock lor poo? connactlona ot
loots wiro at C223 lloc.t.d at
rlghl lhock towo.]. Cl13lHO2Sl
and ECM,
Ooesthe MIL blink and does it

indicatecode 43?
Turn the ignitionswilch OFF.

the ECM and conneclors {see
p a g e1 1 - 3 7 1 .
NOTE:
. UseDIGITAL
MULTIMETER.
. U6e2 Volt rang6.
o oooooo oooooo I oo oooooo
ooQooooo ooooo I oooo oooo
426
ooooooooooo
ooooooooooo
JUMPERWIRE
With the ignitionswitch OFF,wait
for at least two minutes.
lnstalla jumper wire on the test
harnessbetween A6 and A26.
o ooooo oooo ooo I oo oooooo Isdtcllodsl ooo oooooooo

o oooo ooo oo ooo I oooo oooo
ooooooooooo
426 t-l
|.-
1Topage 1 1-5'll
11-50
vnx.su
vohrgo rhould rl.n.t

0.4-0.5 V wh.n th.
ignirioo .wilch i! fird
t|rtrod o.r, Itd docr!6a
to b.low O.1 V in L..
th6n two minutaa.
D 1 4{ + l
{Frompage I 1-5O)
Measure voltage between o14

(+ l terminaland A26 (- I terminal as soon as the ignition switch
is turned on.
ls there O.1 V or less when the

igniiion switch is first tu.ned
on?
Msasuro voltage between D14

(+) le.minal snd 426 l-) ter-
ls ther more than O.1 V?
Disconnect the "D" connoctor

from the main wire h6rness.
Turn th ignition switch ON.
Measure volt6ge betwesn D14

l+) terminal and A26 (-) terminal.
Measure voltage al th ongino
wire harnsss sid ol the HO2S
conngctor botween WHT/RED
(- ).
{+)and GRN/BLU
R.pri. rhort in WHT/

REDwire betwon ECM
(Dl41 rnd lho HO2S.
ls there more than O.1 V?
Subdlht.
. known{ood ECM
.nd r..firck. ll rymptom/indic!tion goaa !w!y, .aphca rha otiglnll ECM.
ls thero moro than O.1 V?
Ch.ck for oDcn in WHT/RED wir.

brrworn ECM (D141 .nd lh.
HO2S. It wl]o l. OK, .oprir opn
iD GRil/8LU rvlr. b.tw..n ECM
lD22l lnd thc HO2S.
(+)
WHT/RED
(-I
GRI{/BLU
wire side
DIGITALMULIIMETER
avallabloo.
Commarcially
KS-AHM-32-OO3
HO25
44 N.m (4.5 kgl.m, 33 lbf.ftl
11 - 5 1
vnx.su
PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor
fxai
-:-
- lfil1
-?-
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 3: An electrical

problemin the ManifoldAbsolutePressure(MAPI Sensorcircuit.
The MAP sbnsorconvertsmanitoldabsolutepressureinto electricalsignalsand inputs the ECM.

SENSOR
OUTPUT
VOLTAGE
1.5
600 700
(in. Hsl GAUGE

READIIIO
{mft Hg)
- Tho MIL has boon roportod on.

- Wirh tho SCS rhort connoctor
connectod lsoo pags 11-34),
codo 3 b indicatsd.
Do the ECM ResetProcedure{soe

p a g e1 1 - 3 5 ) .
ls the MIL on and does it indicate code 3?
Intormittont tailuro, lystom ir Ol(

at thls timo {tort drivo may bs
nocessary).
Chack to? Door connocllon oi
loosa wiroa 6t C223 {locltod at
right shock tow6rl, C'l 14 (MAP
sonaorl and ECM.
YEL/REDlBlSBl onginc)
YEL^YHTlBlaCl .ngin.l | + I
{+l
Disconnectthe 3P connectortrom
the MAP sensor,
{ T o p a g e1 1 - 5 3 )
1 1 -5 2
vnx.su
11,52)
Measurevoltage between YEL/

WHT {818C1 engine),YEL/RED
(B188'1engine){+ ) terminaland
bodv ground.
ls there approx. 5 V?
Measure voltage between YEL/

WHT (818C1 engine),YEL/RED
{B1881engine)(+ } terminaland
GRN/WHT(- ) terminal.
Turn the ionitionswitch OFF.

ls there approi. 5 V?
Connect the test harness "D"
connectorto the ECMonly, notto
the main wire harness {see page
11,37).
Repair opon in GRN/

WHT wir6 botweon
ECM lD2l l and tho
MAP sonsor,
Measurevoltage between D19

{+} terminaland D21 {-}
termrnat,
Measurevoltage betweon wHT/

YEL (+ ) terminaland GRN/WHT
{- } terminal.
Bepairopen in YEL/WHTwi.e betw6n ECM lD19) and tho MAP

aon30t.
Substitule s known-good ECM
and rechock. ll symptom/indica'
tion goes away, replactho oiigi'
nal ECM.
Reconnecl the 3P connector to

the MAP sensor.

the ECMand connector(seepage
11 - 3 7 1 .
(cont'd)
{ T o p a g e1 1 - 5 4 }
lTo page I l-54)
vnx.su
PGM-FISystem
ManifoldAbsolutePressure{MAPISensor(cont'd)
l F r o mp a g e1 1 - 5 3 )
(Frompaqe 1 1-53)
M6asure voltage between D17

{+) terminaland 021 (-}
terminal.
Connect the test harness "D"

connectorto the ECMonly. not to
the main wire harness lsee page
11-37).
ls there approx.3 V?
Substituto 6 known{ood ECM

.nd rach.ck. It symptom/indication gooa away, Eplaco tho orlginrl CM.
approx.3 v?
D 1 7t i l D 2 1( - l
Measurevoltage botwson Dl7

( + ) t e r m i n a la n d D 2 1 { - }
terminal.
ooooooooooooo
I oooooooo l
o oooooooooooo ! oooooooo
l 5 o i E t d lo o o o o o o
ooooooooooo
R.p.lr opon or ahort in WHT|rEL

wi?obotw.on ECM {O17) and tho
MAP senso..
NO
Substitute a known{ood ECM
and rochsck. It prdcribed voltrgo
b now availablo, rophce trie original ECM.
11-54
vnx.su
'
'
PGM-FISystem
TDC/CKP/CYP
Sensor
_f'=l_
t:l'6]-i-flG]l, -
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)4: A problemin

the CrankshaftPosition(CKP)Sensorcircuir.
fi_l
ftl
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 8: A problemin

the ToD Dead Center ITDC) Sensorcircuit.
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)9: A problemin

the CvlinderPositionICYP)Sensorcircuit.
ft-]
The CKP Sensordeterminestiming tor fuel injectionand ignitionof each cylinderand also detects enginespeed.The
TDC Sensordeterminesignitiontiming at start-up(cranking)and when crank angleis abnormal.The CYPSensordetects
the positionof No. 1 cylindertor sequentialfudl injectionto each cylinder.
\.--r-l
-__l_-
tPJ:;LlJ:lEl--;?
l ,:
- Tho MIL hos beonroponod on.
- With rho SCS short connoctor
conneclod lsso pago I l-341,
code 4, 8 and/or 9 ar6 indicated.
Do the ECM Resetprocedure(see

p a g e1 1 - 3 5 ) .
ls the MiL on and does it indicate code 4, 8 and/or 9?
Intohittent failuro, systm is OK

at thia tima {t6st drivo may be
noceaSaayr.
Chock for poo. connections or
looss wires at C222 (located at
right shock towerl, C110
(TOC/CKP/CYP
Sonsorland ECM.
Disconnectthe 8P connectorfrom
the TDC/CKP/CYP
sensor.
{To page 1 1-57)
11-56
vnx.su
{ F r o mp a g e 1 1 - 5 6 )
SEIiSOF
Measureresistancebetween terminalsof the indicatedsensor.

'see table
TDC
ls there 35O-7O0 0?
R.olac6 th. distributor

housing (8oo aoction
231.
DTC
SENSOR
ECM
TENMINAI
COLOR
815
ATU/GFN
816
BTUTVEI
813
ORN/BTU
a
9
814
B1t
ORN
s12

ground on both terminalsot the
indicatedsensor,
Rgplace tho di.tributor
housing llo loction
23t.
Connect the test harness to the

main wire harnessonly, notto the
ECM (see page 1 1-371.
Measureresistancebetween terminalsof the indicatedsensoron

test harness.
'see table
o oooooo oo ooo o I oooooooo l6coocl

o oo ooo ooooo
o oooo ooooo ooo I oooo oooo lo{nofioo't oooooooo ooo
350-7000?
ls there 350
70O 0?
812
Roprir opon in tho indicated senaoawirea.

*soo tablo

groundon 815. 813 and/orB'l 1
terminals.
ls there continuity?
NO
Repair short to body

ground in tho indicrl.d
tnaor wiroa.
i se tabla

and rechock. lf symptom/indication goes away. roplacotho origin.l ECM.
11-57
vnx.su
PGM-FISystem
Engine Coolant Temperature(ECT) Sensor
- ,-!-t@l-
\ ---1- -l 6
| - The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)6: A problemin
the EngineCoolantTemperature(ECT)Sensorcircuit.
The ECT Sensoris a temperaturedependantresistor(thermistor).The resistanceoI the thermistordecreasesas th engine coolant tempe.atureincreasesas shown below.
RESISTANCE
{k0l
JrsG-11
\
- -\.--r-l
t 5|
/--i\
j 3 2 6 8 l O r rl a 0 t 7 6 2 t 2 2 a 8( . F l
-2tt 0 20 rto ao D r@ t20 (,cl
ENGII{ECOOLAI{TTCMPERATURE
- Th MIL has boon roDortodon.
- Wlth tho SCS shon connoctor
connoctod {s66 pag6 '11-34},
code 6 is indicatod.
Do the ECM ResetProcedu.elsee

page 1 1-35).
ls the MIL on and does it indicate code 6?
Intoimittont failur6. ryatom is OK

el this lime ltosl d.ive may bo
nocassaryl.
Chock for poor connsctiona or
looso wiros al C223 {locatod at
tight shock lowor, C111 (ECT
sonsorl,C419 {TCMI and ECM.

at 3,O0Orom with no load {Afi in
N or lF]position,M/T in neutral)
until the radiatorlan comes on,
then lot it idle.
Turn the ignitionswirch OFF.
Disconnectthe 2P conneclorlrom
the ECT sensor.
Measure resistancebetween the

2 terminalson the ECT sensor.
ls there 2OO-4OOO?
(To page 1 1-59)
11-58
vnx.su
--
ECT SENSOR
Measure voltage betweon RED/

WHT and body ground.
Measure voltage between RED/

WHT {+}terminal and GRN/8LU
(- ) terminal.
GRN/BLU
{-}
Ropai. opon in GRN/

BLU wiro botwoon ECM
(D221 and tho ECT
36n3('r.
A/T only
Sub3tituto a known-good CM
and rochock. lf 3ymptom/indication go6s away, roplacothe odginal ECM.
Oisconnectthe 22P connector

trom the Transmission Control
Module (TCM).
ls there approx. 5 V7
Turn the ignitionswitch OFFand

reconnect the connector to the
TCM.
_i
Connect the test harnss "D"
connectorto the ECMonly. not to
the main wire harness {see page
11-37).
Measurevoltage between D13

(+) terminal and D22 (-l termlnal.
ls the.e approx. 5 V?
Repair opoa or shon in

REO/WHTwiro botwoen ECM
lDl3l and th6 ECT sonsor.
R6pairshon in REO/WHTYYi..
b6tw66n ECM{D131andTCM.
Substiluto a known-good ECM

and rochock. ll lymptom/indication goea6wsy, replacotho o.igin6l ECM,
11-59
vnx.su
PGM-FISystem
ThrottlePosition(TPl Sensor
.:-\.----ll@l--l
The MalfunctionIndicatorLamp(MtL)indicateeDiagnosticTroubleCod(DTC)7: A problcmin

rhe ThronlePosition(TPl Sonsorcircuit.
TheTPSensoris a potsntiometer,lt is connectedto the throttlevalveshaft.A8 the throttlopositionchan96, the throttlo
positaonsensorvariesthe voltagesignalto the ECM.
t l-
BBUSH
HOLDER
OUTPUTVOLTAGEIV)
BNUSH
I
a
t
RESISTOF
t
I
o.|
o
IXNOTTII
;0rr- of no
TERMIIIAL
THNOTTIE
)ran1 )ril
-Y-
-?..
- Th. MIL h.. baln rlport d on.

- With th. SCS thort conn.ciol
conn.c-ted (rco pngc 11-341.
codo 7 i. indlc.t d.
Do the ECM Resethocedure (se

page l 'l-35).
ls the MIL on and dos it

indicats codo 7?
l. ..mrtt nt fClur., lyrt m la OX

.t thb dm. ll.at drlv. rn.y br
ncoaataryl.
Chack lor poo? connactlo|ra ot
loora wlr.r !t C223 lloc.t d !t
dgtn drod( tow..t, Cl15 ITP ...trorl, C419 (TCMI .nd ECM.
Turn th ignition switch OFF.
RED/BLK
{-I
Disconnecttho 3P connectorlrom
th TP sensor.
YEL/aLUl+l
cnn/BLuI - l
Meosu.o voltage betwoon YEL/

BLU (i ) terminaland GRN/BLU
I -, torminal.
Measurs voltagG betw66n YEU

BLU (+l terminal and body
giound.
(To page 1 1-6'l)

(To page 1 1-611
11-60
vnx.su
,,,----
TP SEITSOR
(From
{From page 1 1-60)
1 1-60)
ls there approx. 5 V ?
Repsir op.n in GRN/

8LU wii6 botwoon ECM
lD22l snd tho TP
aenaot.

page 11-37l-.
Connectthe test hamessbetween

the ECMand connector{seepage
11-37).
Turn the ignilion switch ON.

Measure voltage between D2O
{ + ) t e r m i n sal n d D 2 2 { - }
termtnal,
ls there approx. 5 V 7
Measure
voltagebetweenD11 {+ )
terminaland 022 (- I terminal.
Ropoi. open in YEL/BLU

wire bgtween ECM
{D20} and rho TP
30naot.
-ReDai. ahort in YEL/BLU wiro

borwoonECM (D2Oland tho TP
son30t.
-Sub3tituto a known-good ECM
6nd rochock. It prcacribodvolt6go is now availablo, roplaco
th6 original ECM.
Fr.
o.5 v n tua .b
drdn
A/T only
ls voltageapprox.O.5 V at lull
close throtlle. and approx. 4 v
at full open throttle?
NOTE:Thereshouldbe a
smooth transition as the throttle is depressed.
Disconnect the 22P connector

from the Transmission Control
Module (TCM).
lurn the ignitionswitch ON.

Substitute a known-good ECM
and roch6ck. ll symptom/indication 9063 away, roplacoth6 original ECM.
ls voltageapprox.0.5 V ar full
close throttle, and approx. 4 V
at tull open throttle?
NOTE:There shouldbe a
smooth transition as the throt'
tle is deprossod.
Replaco tho TP
aonsoa,
Repai. opon or ahon
in RED/BLKwir. btwoon ECM lDl1l,
TCM 6nd TP sonsor.
11-61
vnx.su
PGM-FISystem
IntakeAir Temperature(lAT) Sensor
\ ----:--
\ ---L
-h6lI- t0 l-\ The MalfunctionIndicatorLamp (MlL) indicstesDiagnosticTroubleCod6 (DTC) 1O: A problemin

/
| \ /
the Intake Air TemDerature(lAT) Sensorcircuit,
The IAT Sensor is a temperature dependant resistor (the.mistor). The resistanc of the thermistor d6creases8s the
intake air temDeratura incroases as shown below.
RESTSTAXCE
tmt
THERMISTOR
-a a2 aa roa .t7a 212 a t |l

-20 o 20 rto ao I t6 rro t.cl
I TAKE AIR TEiiIPTFATURE
)1611:till
---l---i-\
/
Th! *llL hs b!!n Egortad on.

\|\rrdrdra SCS rhon connrcto.
conn.ct.d lt . psg. 1l-341.
cod. 10 l. hdlclt.d.
Bl8Bl onglnc:
Do the ECM Resot kocoduro {se

pago 11-35).
ls the MIL on and doos it

indicate code 10 ?
Turn the ignition swiich OFF.
wi.a sido
Into.n{tlont failuro. rysr.m ir OK .t thi. iim.

(toat drlvc m6y b6
arooa!!1ryt.
Ched( tor poor clnncclioiE or loote wlrar 6t
C223 lloc.tod right
lhock toworl, C12O
(lAT renrcrl and ECM.
Oisconnoct tho 2P connector from

the IAT sensor.
818C1 .nglnc:
Meosu.eresistonc
betweenthe
2 torminalson the IAT aengor.
ls thero 0.4-4.0 k0?
Rlobco tho IAT aonsor.
(To pago 1'l-63)

RED/YELI+ )
11-62
vnx.su
IAT SEI{SOR
{Frompag6 l1-62}
Messuro voltage btw6n RED/

YEL (+) terminal and body
ground.
ls thore approx. 5 V ?
Masurs voltage between RED/

YEL {+) rerminaland GRN/BLU
{ - I terminal,

ls thero a99rox. 5 V ?
Connsct lhg tst hamess "D"
connoctorto the ECMonly. not to
th6 main wire harness lsse page
11-371.
Rsp.lr op.n in GBt{/

8LU wir bctwo.r ECM
lD22l snd tho IAT
aanaor.
ECM
Sub.lhul. a tnown{ood
lnd rachack. It rymptom/lndlc!don gort arv.y, t pl.c. dr! oilgln.l ECM.
Turn tho ignition switch ON.
Mgasur voltag bstwgon D15

(+) terminal and D22 l-l
tgrminal.
ls thre spprox. 5 V ?
Rap.lr opon or rhon In REDfYEL

wh. b.tw..n ECM lDl5l rnd th.
lAf tcrrao.-
ECM
S0brlitrrt. . lnown{ood
'|d '.<hoc-l, tl p.slcribad voltlec
ta now lvarlblc, rlplaca tha original ECM.
11 - 6 3
vnx.su
PGM-FISystem
BarometricPressure(BAROISensor
fAl-
f;ff:
L--:g
The MaltuncrionIndicatorLamp (MtL) indicatesDiagnosticTroubteCode (DTCI 13: A probtemin

the BarometricPressure{BARO)Sensor.
The BARO Sensoris built into the ECM.
-.+.-- \--r- /
t ( g t - t 1 3t '
Tho MIL has booo reponod on.

with th6 scs Short COnnOCtO.
connoctod (aeo psgo 11-34),
cod 13 is indicatod.
Do the ECM ResetProcedurc(see

p a g e1 ' l - 3 5 ) .
ls the MIL on and doesit indicate

c o d e1 3 ?
Intormittnt trluro, system is OK !l this timo

{le!t driv6 msy bo
necoSaaiy).
Substituto . knorvn-good ECM

and reck6ck. lt symptom/indicrtion goes away, roplacoth6 original ECM.
11 -6 4
vnx.su
PGM-FISystem
lgnition Output Signal
i16;11
'--=--
:ffi1
. -r-
The MalfunctionIndicatorLamp(MlLl indic8tesDiagnosticTroubleCode(DTC)15: A problmin

the lgnitionOutput Signslcircuir.
Th. MIL hsr b..n roport.d od.

Widr ths SCS .hon cohnecto.
connoctd {..o plgo 11-341,
codg |5 i! indicatrd.
Do the ECM Reset ftocedure (see

page 'l'l-351.
NOTE| ll the onoine won't stan. it

may take 20 seconds ot cranking to
5t th COde.
ls th MIL on and dos it indicate

code 15 ?
Intarmltt nt hllur.. ryltam i. OK

!t drlr dm. (t |l drlva mly bo
naoaaalry).
Chack tor Door cmnactiona or
loo|. rYlrar !t C223 llocltld !t
rlghr .hoct tow.rl, Cl10 (lCMl
.nd ECM.
Turn the ignition swirch OFF.
D|STNIBUTOB
wir6 sido
Measure voltage betwoon BLK/

YEL (+) terminal snd body
grouno.
ls the.e battory voltage ?
R.p.ir op.n In BLK/YELwlr. boftvarn th. 2P conn.cior lnd ionition rwitch.
(To page 11-67)
11-66
vnx.su
Turn tho ignition 3witch OFF.
TTERYVOLTAGE4
421 (+l
Connoct th toat hamess bgtwe,sn
the ECM and connctors {see
pago 11-371.
ooooooooooooo
oooooooooooo
Turn th6 ignition switch ON.
Measurc voltags betwen A21

{+) te.minaland A26 {-}
t6rminal.
-
R.pl.c.
th! lC
(trr..ctlo[
23t.
ls th6re bottory vollsge 7
- napllr op.n or .ho?t In

YEL/GB'{wlrc b.tw.cn ICM
..d Eciil lA21l.
NoTEr lf rhe YEL/GRNwke was shortsd,
tho ICM may bo damaged.
Sub.thut. ! known{ood ECM

.nd r.ck ck. ]t .ymptom/lndlc.don go.. !w!y, ..pbc. lha odgln.l ECM.
11-67
vnx.su
PGM-FISystem
Vehicle Speed Sensor (VSS)
- _-_f_-.,
It6l-
\-=1_
IndicatorLamp(MtL)indicateE Diagnostic Trouble Code IDTC) 17: A problem in

-l tl' l- The Maltuncrion
ths VehicloSD6sd(VSS)circuit.
The VSS generates a pulsing signal when the front wheels turn.
Tha mll hs b..n ltgortld o.r.

Yvlrh th. Sc]S $o.r coi[cto.
connast.d l... ploa I l -341,
cod! 17 i. Indlc.i.d.
Do the ECM Basot Procodur6 16

pag I I -351.
Roadrosr whh A/T in13 positaon

{M/T: in 2nd O6ar),accol6rat6to
4,OOO rpm, thon d6c6l6,ate to
1,5OO .pm with th.ottlo fully
closod tor at loast 5 s6conds.
ls th6 MIL on and doos it indic.t6

'l7
code
?
Block roar whe19 and 5st th6

parking brsko. Jsck up th f.ont
of the c6. and support with safiy standa.
Int rmltllrt t llur., .yrtam b O|(

.t drlr drr.
Chcct lor poor conicctlon! oa
lootc wl... !t C3O50ocrtad rt
Ltt rhod. torr.l, eA24. C112
IVSA).nd ECil.
@4""r
r.r whadr b.lor.

l.d.lnC up tront ol
cat,
Turn the ignition Bwitch OFF.
Connect tho tst hamos3 btwn

tho ECM ond connoctora {as
p a g 61 1 - 3 7 ) .
Tu.n th ignitioh switch ON.

Block the .ight lront whoel and
alowly rctato loft tront wh6ol and
m6asur6 voltago btwoon BlO
{+) torminal and A26 l-}
terminal.
Doss voltago puleo O V and

10 v?
Sub|tllul. ! knosn{ood
ECM
lnd r!ch.ck. lt .Vmgiom/lndlc.tlon g@.. .w.y, r.pLca di. orlgln.l ECM.
a 2 5{ - t
atol+l
0- 10V ?
NOTE:Transmission
in llj positionlA/Tl.
Tu.n th ignition switch OFF.
lTo p6ge 1 1-691
11-68
vnx.su
(Frompage 1 1-68)
Disconnect the "B" connector

from the ECM only, not the main
wile hatness.
Block tho right front whol and

slowlv rotate l6ft front wheel and
masure voltage between 8'l O
l+) terminaland A26 (-)
terminal.
Doos voltage pulso O V and
'tov?
SubrtituL . known-good ECil lnd

Ech.ck. fi lynptom/ndcltbn gp..
rw!y, .rpleco lh. originalECM.
Roo.ir lhort in ORt{

wire belween ECM
18101tnd rhs VSS
or cruia6 control
unit.
ncp.i. opn in ORI{
wira botwoan ECM
(8101and the vSS.
It wir. i! OK, tott
tho vSS. lsoc aection 231
11 - 6 9
vnx.su
PGM-FISystem
ElectricalLoad Detector (ELDI
tft;-]/
-Li!-
The Maltunction Indicaror Lamp (MlL) indicatss Diagnostic Trouble Code IDTC) 20: A probtem in
tne ElectricalLoad Detecror{ELD}circuit.
With lho SCS lhon connectol

connoctod {ree pago 11-34}, cod.
20 is indicatod.
Do the ECM B6setProcedurs{see

page 1 'l-35).
Start engine and keep engin

speed at idle.
Turn on headlights.
Ooes the MIL indicato code 20?
lntennlna
tlllure, lyrtom lt Ol(
!t irl. dm. (lgtt driv. mly bo
na@raaryl.
Chrck for Door connactlona oa
loota wiro. rt C218 IELD, lnd
Ectrt.
View trom
wire side
B L K( - )
Romove the undgr-hood fusg/
relay box and remove the tus6/
relav box lowet cover.
GRn/iEDI - |
BLK/YELI + I
Turn lhe ignition switch ON.
Measure voltage betwon BLK/

YEL (+l terminal and BLK (-)
terminal.
ls there bartory voltagel
Msasuro voltag btweon BLK/

YL {+) terminal snd bodv
ground.
Rcpir oo.n in BLK wir.
batwaan lha 3P connrctor lnd G2Ol {loc.t.d
troit ot angh|. comprnm.r dghl .ld.l,
B.p.lr op.n in BLKrYEL wlrr b.tw..n o.24ACG (ALn flcl115
A: Bl88l .ngln!, 20 A:818C1
cnginol fu!. In thr und.r{..h
tu.o/r.lly bor lnd tho 3P conrcclo?.
( T o p a g e1 1 - 7 ' l )
11-7 0
vnx.su
(Frompog6 1 1-7Ol
Meaauro voltage betweon GBN/

RED ierminal and body ground.
13the.e approx, 5 V?
Boplir opon 01lhort in GR /RED

wir. batworn ECM (DlOl and tho
3P connoctor.
1l wir. i! OK, .ubrtituta. knowngood ECM .nd rochock.
wire side
B L K{ _ I
GR /NEDI-I
Turn tho ignition switch OFF.
BLKIEL { + }
connect tho loat hamasa botweon

tho ECM and connectors (soa
pag 11-37),
(To page 11-72)
11-71
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PGM-FISystem
ElectricalLoad Detector (ELD) (cont'd)
While measuringvoltagebetween
D l O 1 + ) t e r m i n a al n d 4 2 6 l - )
terminal,turn the headlighrswitch
to the secondposition(a) {low).
425t-t
,
Does the voltage drop when

the headlightsare turned on?
Subrtitute . known-good ECM

and rochock. lt 3ymptom/indiction goos away, ioplaco th6 original ECM.
11-7 2
vnx.su
D 1 0l + )
DoosVolrago Orop?----------------J
PGM-FISystem
Knock Sensor(KS) tB18C1 enginel
ml-
nl:
The Malfunction
IndicatorLamp(MlL)indicatesDiagnostic
TroubteCode(DTC)23: A probtemin
the KnockSensor(KS)circuit.
a6l--fzt
.i--1/.---r+\
The MIL h6s boon r6port6d

on.
With th6 SCS ahort connector connoctod (soe pago
11-341,codo 23 is indicrtod.
Oo the ECM ResetProceduro(see

p a g e1 1 - 3 5 ) .
Startthe engine.Holdthe engine

g!-3,Opqrpm with no load {A/T in
LrylorlPlposirion,M/T in neurra
until the radiatorfan comes on,
then let it idle.
Holdthe engineat 3,0O0-4,000

rpm for 10 seconds.
Intomittor failure, ay5t.m is OK at this tim6

(teat drivo mav bo
necsaary,.
Chock tor Door connection3 or loo3o wlaos et
C222 {locatod 6r ghr
shock tow6r), Cl33
(KSl and ECM.
Connect the test harness to the

main wire harnessonly, not to the
ECM (seepage 1 1-37).
ware sido
oooooo ooo ooo o loooooooo
o oooo ooo oo ooo I oooo oooo
Check for continuity between D3

terminaland body ground.
Ropdr short in RED/BLU

wiro btweon ECM {D3l
and ths Ks.
( T op a g e1 1 - 7 5 )
11-7 4
vnx.su
(Frompage 1 1-74)
Chock tor continuitv on REO/8LU

wirs botween D3 tormin6l8nd 2P
conn6ctor.
Rop.ir op.n in RED/BLUwir. b.twcen ECM (D3l and th. KS.
Stsrt the engine. Hold th engine

st 3,000 rDmwith no load (A/T in
@ or@ position,(lvt/t in neutratl
until the r6diator l6n comoa on,
then l6t it idl.
Holdthe enginat 3,000-4,OOo

rDmlor 10 seconds.
Subrtitutr r known{ood ECM

.nd 6ch.ck. lt tymptoh/indic!liarn goar away. raplaca lha otigind ECM.
KS
32 N.m (3.2
wire side
11-75
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PGM-FISystem
A/T Fl Signal A/B (A/T only)
\[l0l-L=\
tItil-Li!-
\.__r_/
The MaltunctionIndicarorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) 30: A problemIn

the A/T Fl SignatA circuit between TransmissionControlModule (TCMI and ECM.
The MalfuncrionIndicarorLamp {MlL) indicatesDiagnosticTroubleCode {DTCI 31: A problemIn
the A/T Fl SignalB circuit between TransmissionControtModule (TCM) and ECM.
\.__r_/
-l 30 o'-l 3tl-----\ l /----\

Wlth tho SCS ahon connocrol
coni|ocd {!o. p.g. 'l 1-341, codo
3O and/or 31 ars indicltod.
Oo ths ECMResotProceduro{see
pag 'l 1-35).
Test drive necessary.

Drive the car lor severalmiles so
that the transmissionuDshiftsand
downshilts several times.
Doesthe MIL indicarecode

30 and/or 31?
Intormittant tsilu.o, sy3tem iB OK

at thir tima,
Chack lor poor connactions ot
l.ro! wiror at C419 (TCM] and
ECM.
Connect the test harness to th

main harnessonly, not to the ECM
(see p8go l'l-37).

from the TCM.
84'
Check lor continuity between B3

andlor 84' terminal and body
grouno.
ulty?
Continuity?
r: code 31 1A/TFl signal Bl

Ropairlhon in GRN/8LUor GRY'
wiro b6twoon ECM (83 or 84'l
and tho TCM.
( T op a g e1 1 - 7 7 )
11-7 6
vnx.su
(Frompage 1 'l-76)
Check for continuity on GRN/BLU

or GRY'wire between83 or 84'
and 22P connectorof the TCM.
Ropairopen in GRN/BLUor GRY'
wiro botwoon ECM lB3 or B4'l
and the TCM,
Substituts a known-good ECM
and rochock. ll symptom/indication goos 6way, roplacatho original ECM.
11-77
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ldle Gontrol System

Guide
SystemTroubleshooting
NOTE:
a Acrosa each row in the chan, the sub-systemsthat could be sourcesof a symptom are ranked in the order they should
be inspected, starting with O. Find the symptom in the left column, read across to the most likely source, then reler
to the page listsd at ths top ot that column. It inspection showa the system is OK, try the next system @, etc.
a lf the idle speed is out of spcification and th Malfunction Indicator Lamp {MlL) does not blink Diagnostic Trouble
Code (DTC) 14, 9o to inspectiondescribdon pags 1 1-81.
POWER
AUTOMATIC
HOSES
AIR
STEERII'IGFASTIOLE
ALTER. IRAI{SA(LE ERAK STARTER
IDTI
IDLEAIR coN0f
ANO
THERMO
swrTcH swtTcH PffESSURE
FN
GtAR
OJUSTIi c0NTROtCONNEC.
TtoNtitc NAION
SIGNAL P0sm0 SIGNAL SIGNAT swncH
SCREW
TIONS
SIGNAL
SIGNAL
stGIAt
PAGE
11-95
SYMPTOM
11-42
11-84
11 - 8 6
11-88
DIFFICULTTO START
ENGINEWHEN COLD
WHEN COLD FAST IDLE OUT OF
SPECl1,0OO- 2,0OO rpm|
11-90
11-92
I 1-93
ROUGH IDLE
ldl6 3p6od b blow

specitisd rpm (no loadl
ldla 5p66d doos nol

incraasalter initial
TOOLOW
WHEN WARM RPM TOO HIGH
WHEN
On mod6l3 with automatic transmBsion,ths

idlo sped drops in 963r
ldl6 speds drops when

8ir condilioner in ON
ldls spo6d drops when

6ts6iing wh66l i6 turninC
o
o
o
WHILE WARMING UP
AFTERWARMING UP
FREOUENT
STALLING
ldla spoed lluctust63

with alactrical load
FAILS EMISSIONTEST
1 1 -7 8
11-94
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SystemDescription
The idle speed ot lhe engineis controlledby the ldle Air Control {lAC) Valve.
The valve changes the amount ot air bypassing into the intake manifold in responseto electric current controlled by the
ECM. When the IAC Valve is activated,the valve opens to maintainthe proper idle speed.
#l' ----r
To FGM-FI
MAIN
RELAY
VARIOUS
SENSORS
FAST
IDLE
THERMO
VALVE
IAC VALVE
BLK
INTAKE MAI{IFOLD
(cont'd)
11-79
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ldle Control System

System Description (cont'd)
1.
Atter the engineslarts.the IAC valveopensfor a censin time, The amountot air is increasedto raisethe idle soeed
about 15O-3OO rom.
2.
When the coolanttemperatureis low, the IAC valve is openedto obtain the properfast idle speed.The amount of
bypassedair is thus controlledin relationto the enginecoolanttemperature.
IDI-ESPEED
lrpm)
176
80
11-80
vnx.su
ENGINE
COOLANTTEMPERATURE
t"Fl
(oct
1. when the idls speedis out of specificationand the MalfunctionIndicatorLamp(MlLldoesnot blink DiagnosticTrouble Code (DTC) 14, check the tollowing items:
. Adiust the idle speed {see page I1-95)
. Air conditioningsignal (see page l1-84)
. ALT FR signal (seepage '11-86)
A/T gea, positionsignal(see page 11-88)
Erakeswitch signal (see page 1 1-90)
Starter switch signal(see page 1l-921
PSPswitch signal(see page 1 1-93)
Fast idl6 thormo valve (see page l1-94)
Hoses and connsctions
IAC valve and its mountingO-rings
2.
lf the above items are normal,substitutea known-goodIAC vslv and readjustthe idle speed (see page 11-95)'
. It the idle speed srill cannot be adjusted to speciJication(and the MIL does not blink code 14) after IAC valve
roplacement, substitute a known-good ECM and recheck. It symptom goes away, replsce the original ECM.
11 - 8 1
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ldle Control System

ldle Air Control(lACl Valve
-l lf l- The MaltunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode {DTC} 14: A problemin
lt6l''
the ldle Air Control llAC) Valve circuit.
The IAC Valve changes the amount of air bypasEingthe throttle body in respons to a current signal from the ECM in
order to maintainthe properidle speed.
ffi:| \ r;611
/--T-\
-
The MIL h.3 beenreport don,

With tho SCS shon connoctol
connoctod (soo pago 'l 'l -341,
cod6 14 is indicatod.
Do the ECMResetProcedure(see
p a g e1 1 - 3 5 ) .
ls the MIL on and does it indicate

code 14?
With the engine running snd the

accelerator pedal releasd, disconnct th 2P connector frort
tho IAC valvo.
the IAC valve.
Sub.iituto . known{ood
vdva lnd iotolt.
{ T o p a g e1 1 - 8 3 }
11-82
vnx.su
IAC
htarmitlaot frlu]., ayat.m i. OK !t thir tlft.

ll.rl drlv. mly ba nacaaaaryl.
Chack tor Doo. connctlonr oi loora wirca at
C3O5 (loc.t.d .t |.ft
lhock tow.tl, C424,
Cl tB (lAC v.lvol .nd
ECM.
(From page 'l 1-82)
Measure voltago between the

YEL/BLKwire and bodv ground.
ls thrs battery voltage?
Turn th ignition swirch ott and

reconnectthg 2P cohnectorto the
IAC valve.
R.pair op.n In YEL/8LK who b.twoon IAC vCvc dd PGM-FImdn

relay.
IAC VALVE
BLK/BLU{ _ }
Connct the test hs.ness "A"

connector to the main wirs hrrn6ss only, not the ECM lsee page
t 1-37).
Tu.n tho ignition switch ON.
Momentarilyconnect Ag torminal
to 423 terminol seveaaltims.
Does th6 IAC valve click?
Raplir op.n or rhort in 8LK/BLU

wl]. b.tw.cn IAC v!lv..nd ECM
(A91, It th. wlro L OK, r.Dhc.lhe
IAC v.lv..
Sub.titutr ! known{ood ECM

.nd ral..t. lt .ymptom/hdlcatioo
goa! awsy. rophca tia origlnal
ECM.
JUMPERWIRE
A9 l+)
A23{-l
1 1-83
vnx.su
ldle Gontrol System

Air ConditioningSignal
This signals the ECM when there is a demand for cooling from the air conditioning system.
Connectthe tst harnessbetween

the ECM and connectors.Disconnect "B" connectorfrom the main
wire harnessonlv, not the ECM
{see page 11-37}.
.pprox. 5 V?
426 (- )
Measurevoltagebetween851+ )
lerminaland A26 l- I terrninal.
Sub.litut ! known{ood CM
rnd r6<tEck. ll p.lrcib.d vottrgo
i! now avalhbla, iaplaco tho o,igin.l ECM.
Turn th ignition switch OFF.
Reconnect"8" connector to the

main wire harness.
Cllcklng?
ooooooooooooo oooooooo
oooooooooooo oooooooo
ooooooooooo
ooooooooooo
Turn the ignilionswitch ON.
MomentarilvconnectA15 terminalto A26 terminsl severaltimes.
ls there a clicking noise from

the A/C comDressorclutch?
Momsntarilv connect the 8LK/

REDtrminal of the 4P connector
on the A/C clutch rel6v to body
ground sevsral times.
ls there a clicking nois lrom

th A/C comoressor clutch?
lTo page
Rop.ir opon in BLK/BEDwiro betwo.n ECM {A15} and A/C clurch

rally.
11-84
vnx.su
3o6 rlr condhlohar inrDactlon llaa lac{ion

221.
(Frompage 11-84)
than 1.0 V?-----------.1

r-Less
85{+l
I
|----------------
I|
| ooooooooooooe loooooooo 1t)6i}66i)l ooooooooooo

l-_---_-------l426t_t
I
Does A/C operate?
Measurevoltage between 85 {+ )
terminaland A26 (-) terminal.
ls voltagelessthan 1.O V?
Aii coiditiodlng slgnal i! OK.
Rpairopoi in BLU/RED
wiro btrYaen ECM lBSl
and A/C awilch.

and rochock, lf 3ymptom/indication goos 6way, rplacoth6 original ECM.
11-85
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ldle Control System

Alternator (ALTI FR Signal
This signalsthe ECM when the Alternator(ALT) ascharging.
Inspection ot ALT FR Sign.l.
Connectthe tost harnessbetween

the ECM and connectors.Disconnect "D" connector from the
main wire harnoss only, not the
ECM lsee page 11-37).
ooo oo oooooo
ooooooooooo
Measurevoltage between D9 (+ )
terminaland A26 {-}terminal.
Sub{inno s known-good ECM

and redrack. It pro.ctibod volt go
la now availablg, ropllco tha orlginal ECM.
Reconnect"D" connectorto the

main wire harness,
Start tho engino. Hold the engine

!L3,099 rpm with no load (A/T in
LN]or El position, M/T in neutral)
until the radiator tan comes on,
rhen let it idle.
Voh.go?
D 9l + )
ooooooooooo
Measurovoltage between Dg (fl

terminaland 426 (- I terminal.
Does the voltage decrease

when headlightsand .ear
delogger are turned on?
ooooooooooo
Turn ths ignitionswitch OFF.
ALT FR rignal is OK.
(To page 1 1-87)
11 - 8 6
vnx.su
(Frompage 1 1-86)
Disconnect "D" connector lrom

ECM only, not the main wire
harnesa,
Disconnect tho nsgstive baftery

cable from the baftery.
Check for continuity betwen D9

terminal and body ground.
Continuity?
Check for continuity betwoan D9

te.minal and body ground.
soe AIT Inrpactlon

(... r.ctlon 231.
Check lor continuity between D9

trminsl snd body ground.
Rop.lt C|on in WHT/RED wi.. b.tw.on ECM lDgl rnd ALT.
Ropair opo in WHT/RED wito b6tween ECM {D9} .nd .ltomrtor.

Sao ALT inapaction
lres .lctlon 231.
11-87
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ldle Control System

Automatic Transaxle {A/Tl Gear Position Signal {A/T onlyl
This signalsthe ECM when the transmissionis in @ or @ position.
obsorve the A/T shift indicator

a n d se i e c l e a c h p o s i t i o n
separately.
Soo A/T goa. position indicator inspoqtion ls6o lection 141.
Connectthe test hamessbetween

the ECM and connectors.Disconnect "B" connoclorlrom the main
wire harnessonly, not the ECM
(seepage 11-37).
appror. 5 V?
87l+)
ooooooooooooo
oooooooooooo
A26 {-}
Measurevoltage between 87 (+ I
terminaland 426 1- ) terminal.
Subslituto . known-good ECM

6nd .ech6ck. lf pr63cribod voltage
ia now availablo,rcplacoths o.iginel ECM.
Reconnect"8" connectorlo lhe

maanwire harness.
( T op a g e1 1 - 8 9 )
1 1 -8 8
vnx.su
-.
{Frompage 11-88)
L63r than 1,0 V? 87 l+)
ooooooooooooo
oooooooooooo
426 (- )
Measurevoltagebetween87l+)
terminal and A26 (-) teJqrinal
with the transmission in Lryl posataon.
ls there lessthan 1.0 V?
Measurevoltage between 87 (+ I
terminal and A26 (-) reJqrinal
with the transmissionin lPl position.
ls there less than 1.0 V?
Ropair open in LT GRN/BLK

wir. botwoon ECM lB7) and
gaugo as!mbly.
- Rspalr opon in GR wito b.twoon tho gaug6 a$ombly lnd
A/T goar position .witch.
Lo.s rhln 1.0 v? --ii
t+t
o o o o o o o o o o o o o I o o o o o o o o I O O n P s O lo o o o o o o o o o o
ooooo ooooo ooo I oooooooo lQcosito I ooooooooooo
A26 (- )
Reprir open in GRNMHT wi.r bgtwoon gaugo ssrombly and A/T
goar poritlon 3witch.
BATTERYVOLTAGE? --;;
MeasurevoltagebetweenB7l+)
terminal and A26 l-) terminal
with the transmission in gear.
ls there battery voltage ?
{+ I
A26 t- )
R6oai. short in LT Git{/BLK wire
botwo6n ECM (B7l and gaugoaraombly.
A/T goat position signal b OK.
11-89
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ldle Control System

Brake Switch Signal
This signalsthe ECM when the brake pedal is depressed.
Inlp.ction ot Brd(. Switcfi Siignal.
Are the brake lights on without

depressinOthe brake pedal?
ltuoacl ths braka .wilch {!.a !acdon 191,
Oo the brake lights come on?
InspectSTOP,HORN(20 Alluse
in the undeFhoodfuse/relavbox.
ls the luse OK.?
Connect tho tst harness to the

main wire hamessonly, not to the
ECM {seepage 11-37).
- Ropalropon In WHT/GRNwiro
batwoan b'lka lwltch and
STOP, HORTI{20 Al lu!o.
- InlDect tho braka awitch la6a
.6cdon 19).
( T o p a g e' l 1 - 9 1 )
11-90
vnx.su
R.pl!c.
S T OP ,
HOR {2O A) tu...
R.pdr dbrt In WtlT/
GBI wlrr batu..n
b?!ka .wltch a.rd
sToP, HOR[{ (20 A}
lura.
(Frompage 11-9Ol
426 {-)
I-Measurcvohage between D2 (+ l
terminal and A25 (-) terminal
with the brake oedal deoressed.
BATTERY
VOLTAGE?
D 2( + l
Repair opon in GRI{/WHT wiro botwoen th6 b..ko rwitch .nd ECM
{D2}.
Brako lwitch signal ir OK,
11 - 9 1
vnx.su
ldle Gontrol System

Startel Switch Signal
This signalsthe ECM when the engineis cranking.
BATTERY
VOLTAGE?
Connectthe lest harnessbotween

the ECMand connector(seepage
11,37).
Measurevoltage between 89 (+)

terminal and 426 (-) terminal
with the ignition switch in the
start position.
ls there batterv voltage?
ooooooooooooo
oooooooooooo
A 2 6{ - }
NOTE:
a M/T: Clutch pedal must be
oeprgsseo.
a A/T: Trsnsmission in lll or LIJ position.
InspectNo. 18 STARTERSIGNAL
{7.5 A) fuse in the under-dash
fuse/relav box.
- Roplac. No. 18
STARTER SIG AL
(7.5 A) lurc,
- Rrpsir lhort In BLU/
WHT wir. batwccn
ECM (89) .nd No.
18 STARTER SIG.
t{AL {7.5 Al 1u..,
PiGM-Fl fi.ln rol.y.
R.palr opon in BLU/WHT wir6 b6tw.n ECM lB9l and t{o, 18
STARTERSIGNAL 17.5 Al lu.o.
Startor .witch .ign.l is OK.
11-92
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Power Steering Pressure(PSP)Switch Signal

This signalsthe ECM when the power steeringload i s h i g h .
-;"nection.*."------'.ill]
-
;;;;;;;l
;:"r"tffa;i'
(see
connecrors
o ooooo oooo ooo I oo ooo oo o l.Dod(iltl ooooooooooo

o oooo ooo ooooQ I oooQ oo oo $aG$ast.l oooooooo oo
A 2 6l - ) B gl + l
L6s! thsn l.O V?
Measurevoltagebetween88 {+ )
terminaland A26 {-) terminal.
the PSPswitch.
ls there lessthan 1.0 V?
Tu.n the ignitionswitch ON.
Turn steeringwheel slowly.
Measurevoltage between B8 (+)

terminal and 426 (-) termanal
while steeringwheel is turning.
PSP switch signal is OK.
ls there less than 1.O V?
Ropair opon in GRN wire betwssn

ECM {88} and PSPsrYilch ot BLK
wi.o botw6cn PSP switch and
G301 (locatodat loft ongin6compartm6ntr.
Disconnectthe 2P connectorlrom
the PSPswitch.
wire side
GRN
PSP SWITCH
Repairshort in GRNwi.e botwoon

ECM {881 and PSP switch.
ll wiro i3 OK, substitute a knowngood ECM and.ocheck. lI
proscribod vollage is now avail
able, replaco tho original ECM.
11-93
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ldle Control System

Fast ldle ThermoValve
DEscliptlon
To prevent erratic running when the engine is warming
up, it is ncessaryto raise the idle speed. The fast idle
thermo valve is controlledby a thermowax plunger,When
the engineis cold. the enginecoolant su.roundingthe
thermowax contracts the plunger,allowing additionalair
to be bypassed into the intake manifold so that the engine idlss taster. When the enginereachesoperatingtemperatur, the valve closss, reducing the amount of air
bypassing into the manifold.
Inspaction
NOTE: The tast idle thermo valve is factory adiustsd;
it should not be disassombld.
1.
Remove the intake air duct from the throttlg body.
2.
Stan the engine.
3.
Put your finger over ths lower port in throttle body

and make sure that there is 8ir flow with tho engine
cold (engine coolant temperatute below 86oF,
300c).
a lf not, leplace the fast idle thermo valvs and

retest.
FASTIDLETHERMO
VALVE
o-Rr{Gs
Replace
AIN EYPASSVALVE
llo kgf.m, 7 lbt.trl

4.
Start the engine. Hold the sngine at 3.0OOrpm with

no load (A/T in I or @ position, M/T in neutral]
until the radiator fan comes on, then let it idl6.
Checkthst valve is completelyclosed. lt not, air suction can be telt at the lower Don in the throttle body,
a It any suction is felt, the valve is leaking Check
engine coolant level and for air in tho engine
coolant system (see section 1O). ll OK, rsplace
the fast idle thermo valve and rechock.
11-94
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- ldle Speed Setting

Inspoction/Adiustment
NOTE:
a When the idle speedset, checkthe followingitems:
- The MIL has not been reported on.
- lgnitiontiming
- Sparkplugs
- Air cleaner
- PCV svstem
a (Canada)Pulltheparkingbrakeleverup. Stan the engine, then check that the headlightsare off.
1
Start the engine. Hold the engine at 3,000 rpm with

no load (A/T in S or @ position, M/T in neutral)
until the radiatortan comes on, then let it idle.
2.
Connecta tachometer.
3.
Disconnectthe 2P connectottrom the ldle Air Control {lAC) valve.

Reconnectthe 2P connectoron the IAC valve,then
removethe BACKUP (7.5 A) fuse in the under-hood
tuse/relavbox for 1O secondsto reset the ECM.
e
Restart8nd idlethe enginewith no-loadconditions

for one minute, then check the idle speed.
NOTE: (Canada)Pull the parking brake lever up.
Startthe engine,then checkthat the headlightsate
off.
ldlo speed should be;
4.
Start the engine with the sccelerator pedal slightly

depressed.Stabilizethe rpm at 1,OOO,then slowly
release the pedal until the engine idles.
Checkidlingin no-loadconditions:headlights,blower
fan, reardefogger,radiatorfan, and ai. conditioner
are not operatrng.
81881 ongino:
MTf
75O !
50 rpm
AIT
75O t 50 rpm
(in[]or@positionl
818C1 engine:750 1 50 rpm
ldl spood should bo;

81881 ongino:
MlT
48O ! 50 rym
An
48O I 50 rpm
lin@or@oosition)
818C7 engine:48O ! 50 rym

Adjust the idle speed, if necessary, by turnmg the
idle adiustingscrew.
NOTE: After adiustthe idle speedin this step, check
the ignitiontiming (see section 231.
lf it is out ot spec. go back to step 4.
(cont'd)
11-95
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ldle Control System

ldle Speed Setting (cont'd)
9. ldle the enginefor one minute with headlights{Low}
ON and check the idle sDeed.
ldla sp6od should bo;
81881 engine:
M/T
750 i
An
75O t 50 rpm
{in $ or p] positionl
50 rpm
818C1 engine:75O 1 50 rpm
1 0 .Turn the headlightsoff.

ldle the enginefor one minute with heatertan switch
at Hl and air conditioneron, then check the idle
speeo.
ldls spood should bo;
81881 ongino:
M/T
82O 1 50 rpm
AN
840 1 50 rpm
(in [N] or lll position)
818C1 engino:85O t 50 nm
NOTE: lf the idle speedis not within specitication,
see SystemTroubleshooting
Guideon page 1 1-78.
11-96
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Fuel Supply System

System TroubleshootingGuide
NOTE: Across each row in the chart, the sub-systemsthat could be sources of a symptom ara tanked in tho order they
should be inspected starting with O. Find the symptom in the left column, read across to the most liksly source, then
refer to the page listed at the top of that column. lf inspection shows the system is OK, try the next most liksly system
@, etc.
PAGE
FUEL
LINES
11-98
SYI\4
PTOM
FUEL
FUEL
PRESSURE
INJECTOR
REGULATOR
11-102
11 , 1 0 6
FUEL
FILTER
FUEL
PUMP
PGM-FI
MAIN
RELAY
l1-toa
11-109
t'l 'nl
ENGINE
WON'TSTART
DIFFICULT
TO START
ENGINEWHENCOLDOR HOT
\4
ROUGHIDLE
MISFIRE
OR
ROUGH
RUNNING
LOSS OF
POWER
FREOUENT
STALLING
FAILS
POORPER.
EMtSSION
FORMANCE
CONTAM'
INATEO
FUEI
WHILE
WARMING
UP
AFTER
WARMING
UP
11-97
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FuelSupplySystem
Fuel
NOTE:Check all fuel system lines and hoses for damage, leaks or deterioration, and replaco if ncessery.
11-98
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NOTE: Chock 8ll hoso clamps and rtighton if necossary.
Sot th centgr
l2 mm
(0.47 inl
12-15 mm
to.47-o.59 hl
t2 mm
{0.47 in}
11-99
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FuelSupplySystem
SystemDescription
FuelPressure
The fusl supply system consists ot a fuel tank, in-tank

high presssurefu6l pump, PGM-FImain relay, fuel filter,
tuel pressure regulatot, fuel inioctors, fusl pulsation
damper and fuol delivery and return linss. This system
deliverspressure-regulatored
fu6l to the fu6l injectorsand
cuts the fuel delivory wh6n the engine is not running.
a Do not smok6 while working on the fuol syst6m,

Keep open flames or spalks away tlom your work
aroa.
a 8e sure to raliavofuol p.essur6while th6 6n9in6is off.
NOTE: Eeforedisconnectingfuel pipes or hoses, release
pressure from the system by loosening the 6 mm se.vice bolt on top of the fuel filter.
1.
Disconnectthe batterynegativecablefrom the battery negativeterminal.

NOTE: The LS and GS-Rmodel radio may have a
coded theft protectioncircuit. Be sure to get the customer's code number betore disconnectingthe
batterv,
After service, reconnect Dowe. to the radio and turn
it on. When the word "CODE" is displayed.enter
the customer's s-digit code to restore radio
ooeration.
2.
Removethe fuel fill cap.
3.
Use a box end wrench on the 6 mm servicebolt at

the fuel tilter, while holdingthe specialbanjo bolt
with anotherwrench.
4.
Placea rag or shop towel over the 6 mm servicebolt.
5.
Slowly loosenthe 6 mm servicebolt one complete

turn.
SERVICEBOLT
15 N.m
(1.5 kgf.m,
11 rbr.ftl
FUELFILTER
NOTE:
a A fuel pressu.egaugecan be attachedat the 6
mm seryicebolt hole.
a Alwavs replacethe washerbetweenthe service
bolt and the specialbanio bolt. wheneverthe service bolt is loosened.
a Replace all washers whenever the bolts are
removeo.
11 - 1 0 0
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a lf the fuel pressureis not as specified, first check the

fuel pump (seepage 1 l - 1 1O).lf the fuel pump is oK,
check the following:
Insp6ction
1.
Relievefuel pressure(see page 11-1OO)
2.
Removethe servicebolt on the tueltilter while holding the banjobolt with anotherwrench. Attach the
specialtool
3.
Siart the engine.* Measurethe {uel pressurwith

the engineidlingand vacuumhoseof the fuel pressure regulatordisconnectedfrom the tuel pressure
regulatorand pinched.
Pressureshould b;
818B1 engins:
275-324 kPa (2.8-3.3 kgl/cm2,40-47
psil
818C1 ongine:
329-37a kPa (3.35-3.85 kgf/cmz,48-55
4.
- lf the fuel pressurois higherthan specified,inspectfor:

. Pinched or clogged tuel return hose or line.
. Faultyfuel pressureregulator(see page 11-106)
- It the fuel p.essu.eis lower than specitied,inspect fo.:
. Clogged fuel tilter.
. Faultyfuel pressureregulator(seepage '11-106).
. Leakagein the fuel line.
pei)
Reconnect vacuum hose to the tuel plessure

regulator.
Prossuroshould b;
Bl8Bl ongino:
216-245 kPa (2.2-2.5 kgf/cm' ,31 -36 psil
B18Cl on9in6:
27O-319 kPa 12.75-3.25 kgt/cm', 39-46
FUEL PRESSUREGAUGE
07406 - OO4000 1
psi)
CLAMP
lf the enginewill not stan, turn the ignitionswitch

on. wait for two seconds,turn it off, then back on
again and read the fuel pressure.
11 - 1 0 1
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Fuel Supply System

Fuel Injectors
- --l-
\-l-l
tc l1 1 6 l - /- l---i/---r-\
\
The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC) l6: A problemin

the Fuel lniectorcircuit.
The Fuel Injectors a.e a solenoid-actuatedconstant-stroke pintle type consisting of a solenoid, plungel nedlevalvs and
housing. When cur.ent is appliedto the solsnoid coil, the vslve litts up and pressurizedfuel is injected. Becausethe needle valve litt and the luel pressureare constant, the iniection quantity is determined by the length of time that the valv
is open (i.e.,the durationthe cu.rent is suppliedto the solenoidcoill. The Ful Iniectoris sealedby an O-ringand seal
ring at the top and bottom. These seals also reduce operating nois6.
FILTER
O.RII{G
PTUNGER
-_--
- ___L-
- I| r.G
- -l -- :l t_o- l - Tho MIL has boen roportod on.
- Wilh tho SCS .hon connocto.
conoctod (soo pago 11-34),
code 16 is indicalod.
Do the ECM Besel Procedure(see

page l l -351.
NOTE:lf enginewillnot start, it may tak6

lO secondsol cranking to sgt th6 code.
ls the MIL on and does it

indicatecode l6?
Intermittant tailura, aystam ir OK

at thir tim. (t..1 drivo m.y b.
nocaar!ry1.
Ch.ck lor poor connactiona ot
100!6 wir6!.t C221 (loortod rt
right .hock low.rl, C121,C122,
Cl23, Cl24 llu6l InFctorrl, lnd
ECM.
{To page 1 1-1O31
11-1 0 2
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FUEL RAIL
lFrompsge11-1021
St6n the enoin8nd listgnat oach

fuol inioctor fo. a clicking sound.
Disconnoct tho 2P cohnector from

th6 lul iniocto. th6l does not
click.
Mossur rggistancebatwson th
2 terminalEol fuol injocto..
FUEL
II{JECTOR
ls thoro 1O- 13 07
R.phce tho fuol ini.ctor/lni.ctor!

that ar not 10- 13 O.
T!.n tho ignition switch ON.
Moaaur voltage btweon

YEL/BLK { + I terminsl in ths 2P
connoctor and body ground.
ls thore battory volt6g7
B.prh op.n In tho YEL/BLK wlt6

botwaan tha luol inioctor aad lha
PGM- Fl main r.lsy.
(To p6ge I l-1O41
(cont'd)
11-103
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Fuel Supply System

Fuel Injectors (cont'd)
(Frompage 'l1-103)
Turn lhe ignitionswitch OFF.
Reconnect the 2P connector to

the tuel injector.

rhe ECM and connectors {seo
page'11-371.
Measure voltage between A23

{-) terminal and following
terminal:
. No. 1 tuel injector:
A1 (+ ) terminal.
. No. 2 fuel injector:
A3 {+ I terminal.
A5 {+ ) terminal.
A2 {+ ) terminal.
A3{+)
oooooooooo
oooooooooooo
oooooooo
oooooooo
A2{+}
Ropairopon in the wi.o betw6on

th6 ECM(A1, A3, A5 or A2l and
th6 tuel iniector.
Sub3titute a known-good ECM
and r6chock. lf symptom/indication goes away, .eplsco tho original ECM.
11-1 0 4
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ooooooooooo
ooooooooooo
Rapl!c!ment
7 . Slide new cushionrings onto the luel iniectors.
oo not smoko during tho work. Keep open

@
fllma3 lway from your wolk aloa.
t'.
Retievetuel pressure{see page 1 1-10O).
1.
9 . Insen the injectors into the tuel rail tirst.
2.
Disconnect the connectors trom the fuel iniectors.
3.
Disconnect the vacuum hose and fuel return hosa

from the fuel pressure regulatol.
NOTE: Placea r8g or shop towel over the hoses befor6 disconnecting them.
Loosenthe retainer nuts on the Juel rail and harness
holder.
4.
Coat new O-ringswith cleanengineoil and put them

on the fuel injectors.
1 0 . Coat new sealringswith cleanengineoil and press

them into the intake manifold.
1 1 .Installthe Jueliniectorsand fuel railassemblyin the
intake manilold.
CAUTION: To plovont damage to th O-dngs, instsll
tho fuol inioctors in tho fuol r8il first, thon install thm
in the intaks mEnitold.
5 . Disconnectthe tuel 18il.

6.
Removethe fuel injectors from the intake manifold.
cusHloN
RING
Replace.
12. Alignthe centerlineon the connectorwith the mark

on the fuel rail.
FUEI.RAIL
FUEL
MABKI'{GS
1 3 .Install and tighten the retainer nuts

1 4 .Connct the vacuum hose and tuel retuln hose to
the fuel pressure regulator.
lnstall the connecto.s on the fuel injectors.
1 6 . Turn the ignition switch ON, but do not operate the
starte.. After the tuel pump runs for approximately
two seconds,the tuel pressurein the fuelline rises.
ReDeatthis two or threetimes,then checkwhether
there is any fuel leakage
11-105
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Fuel Supply System

FuelPressureRegulator
Description
The fuel pressure.egulatormaintainsa constant Juel
pressureto the tuel injectors. When the difference between the fuel pressureand manitoldpressurexceeds
3.O kgf/cm' 1294 kPa, 43 psi) tB18C1 engine: 3.5
kgt/cm, (343 kPa, 50 psi)], the diaphragmis pushed upward, and the excessfuel is fed back into the fuel tank
through the retufn line,
Te6ting
oo not smoko during the tst. Ko6p opon
@
flames away from your work area,
1. Attach a fuel pressuregaugeto the se.viceport of
t h e l u e l f i l t e r{ s e ep a g e 1 1 - 1 0 1 ) .
Prossuroshould be;
Bl88l ongin:
275-324 kPa (2.8-3.3 kgf/cm', 40-47 psil
B18Cl ngino:
329-378 kPa (3.35-3.85 kgf/cm' .48-55 pEi)
(with tho tuol pressurersgulator vacuum hoso dlsconnoctod and pinched)
CLOSE:
FUELPRESSURE
GAUGE
1
07406 - oO/IOOO
DIAPHRAGM
\r__l FUELINLET
INTAKE
MA'{IFOLD
VACUUM
Reconnectthe vacuum hose to the fuel pressure

regulator.
DIAPHNAGM
Checkthat the tuel pressurerises when the vacuum hosefrom the fuel pressureregulatoris disconnected again.
a lf the fuel pressuredid not rise, replacethe fuel
pressure regulatot.
/1-
\J
FUELINLET
FUEL
RETURI{
11-106
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Raplacoment
oo not amoko whil6 working on fuel sys@
tam. Koop open flamo away tlom your work atea'
1. Placea shop towel under the fuel pressureregulator, then relievtuel pressure(seepage 1l-10O).
2.
Disconnectthe vacuum hose and fuel returnhose.
3.
Remove the two 6 mm retainer bolts.

12 N.m
{1.2 kgl.m,
9 rbf.ft)
Rsplace.
NOTE:
a Replacothe O-ring.
a When assemblingthe fuel pressureregulator,apply clean engineoil to the O-ringand assemble
it into its proper position, taking care not to
damagethe O-dng.
11-107
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Fuel Supply System

Fuel Filter
a Do not smoko while wo*ing on tusl system.

Keop open tlame away ftom your wotk area.
a While replaclng th6 tusl liher, be caletul to koop a safo
distanc6 betweon battery torminals and any tool3.
The Juelfilter should b replacedevery 4 years or 60,0O0
miles(96,OOO
km), whichevercomesf irst.or whenever
the fuel pressure drops below the specilied value
1275 - 324 kPa, 2.8 - 3. 3 kgJ/cmr,40-47 psi (Bl 8C 1
e n g i n e :3 2 9 - 3 7 8 k P a , 3 . 3 5 - 3 . 8 5 k g f / c m r ,4 8 - 5 5
psi) with the fuel pressure regulator vacuum hose disconnectedl afte. making sure that the tuel pump and the
fuel pressureregulatorare OK.
1,
SPECIAL
BOLT
33 N.m
(3.4 kgt.h,
25 rbf.ft)
Disconnectthe batterynegativecabletrom the battery negativeterminal.

NOTE; The LS and GS-Rmodel radio may have a
coded theft protectioncircuit, Be sureto get the customer's code number before disconnectingthe
batterv.
After service, reconnect power to the tadio and turn
it on. When the word "CODE" is displaved,enter
the customer's 5-digit code to restore radio
operation.
2.
Placea shop towel underand aroundthe fueltilter.
3.
Relievefuel pressure(see page 11-100).
4.
Removethe specialbanio bolt and the fuel feed pipe

from the fuel tilter.
Removethe fuel filter clamp and tuel Jilter.
When assembling,use new washers,as shown,
NOTE: Cleanthe llared joint ot high pressurehoses
thoroughlybefore reconnectingthem,
11 - 1 0 8
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SERVICEBOLT
15 N.m ll.5 kgt.m,
1 I rbr.ftl
WASHER
Replace
1Ottl.m
(1.Okgf.m,
7 tbt.ftl
[":::,::-'
Eecauseof its compactimpellerdesign,the fuel pump is installedinsidethe fueltank, therebysavingspaceand simplifyng the fuel line system.
FUELPUMP
FUEL FILTER
FUEL PUMP BRACKET
N lTop vi6w)
FUEL PUMP ASSEMBLY CROSSSECTION
FUEL PUMP CROSSSECTIONlsido vi6rvl
D|SCHARGEFORT ^
PORT
. tNLEr P
PUMPCOVER
IMPELLERS
CHECK VALVE
GROOVES
PUMP CASING
IMPELLER
line systems,
The fuel oumo consistsof a DC motor, a circumferenceflow pump, a reliefvalve for ptotectingthe fuel lir
emblyconsistsof
a check valve for retainingresidualpressure,an inlet port, and a dischargeport. The fuel pump assembly
pump cover.
the impellers(drivenby the motor),the fuel pump casing{whichforms the pumpingchsmber),and the fuel p
OPERATION
togetherwith the
(1) When the engineis started.the PGi/t-Flmain relay actuatesthe fuel pump, and the motor turns togeth
impellers.
Differentialpressureis generatedby the numerousgroovesaroundthe impellers.
rgh th
the discha.ge
(2) Fuelenteringthe inlet porr flows insidethe motor from the pumpingchambe.and is forced through
port via the check valve.
ss the fuel to the
lf tuel flow is obstructedat the dischargeside of the tuel line, the relief valve will open to bypass
pressure.
prevent
port
fuel
excessive
inlet
and
t retainthe
avitv to
(3) When the enginestops,the tuel pump stops automatically.However,a checkvalve closesby gravity
residualpressurein the line, helpingthe engineto aestanmore easily.
(cont'd)
11-109
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Fuel Supply System

FuelPump(cont'dl
Tc.ting
Roplacomont
o" not smoko during tho tesr. Koop open

@E
flrmo away fiom your work area.
oo not smoks whilo worklng on fuel syr@

tem. Kaop opon llamos away from your wolk araa.
lf you suspct a problem with the tuel pump, check that

the lusl pump actuallyruns;when it is ON, you will hear
some noise if you hold your ear to the luel lill oon with
the fuel fill cap remov6d. The fuel pumD should run for
two seconds, when ignition switch is first turned on. ll
the fuel pump does not make noiss, check as tollows;
1.
Removethe rear ssats {soe section 2O).
2.
Removethe accessoanel.
3.
Disconnectthe 2P connectorfrom the fuel pump.
4.
Removethe fuel pump mountingnuts.
5.
Removethe fuel pump trom the luel tank.
6.
Installa new washeron the banio bolt, then install

Darts in the revers order of removal.
1.
-'2.
3.
Removothe rear seat (see section 2O).

Removethe accesspanel.
Disconnect the 2P connector from the fuel pump.
CAUTION: 86 lure to tum th6 ignition switch OFF
botor6 disconnoctlng th wilos,
4.
Connect the BLK|yEL@ wire 8nd YEL/GRN@ wire

with a iumpe. wire 8t the PGM-FI main relav connectot.
l.t,
.\
.--/
.
re
-Fl
6 N.m
lO.6 kgl.m,.
4 tbt.ftl
MAll{ RELAY
Jumper
27 .m
(2.4 kgt.m,
21 tbt.ftl
BL&
YEL
Check that battery voltage is available at the tuel

pump connectorwhen the ignitionswitch is turned
ON (positive probe to the YEL/GRNwire, negative
probe to ths BLK/WHT wire).
ACCESS
PANEL
side
YEL/
GRN
a lf battery voltage is available, replace the fuel

pump.
a It there is no voltage, check the tusl pump ground
and wire harness{see page I 1-1 l2).
11-110
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PGM-FlMain Relay
Doscription
The PGM-Flmain relavactuallvcontainstwo individual
rerays.
This relay is locatedat the lett side of the cowl.
Onerelayis energizedwheneverthe ignitionis on which
suppliesthe battery voltageto the ECM, power to the
fuel injectors,and power for the secondrelay.
The secondrelay is energizedfor 2 secondswhen the
ignitionis switchedon, and when the engineis running,
to supply power to the fuel pump.
Relay Testing
NOTE: lf the car stans and continuesto rrun, the PGMFl main relay is OK.
1.
Removethe PGM-Flmain relay.
2.
Attach the batterypositiveterminalto

nalto the No. 2 terterminalto the No.
minal and the battery negativetermir
1 terminalof the PGM-FImain relay.
lay. T
Then checkfor
minaland No. 4 tercontinuity between the No. 5 terminal
minal of the PGM-FImain relay.
a lf there is continuity,go on 10
to step
ste 3.
a lt thereis no continuity,replace
ce the PGM-Flmain
relay and retest.
PGM-FI
MAIN RELAY
No.2
FUEL PUMP
To lGN. I
To GROUND
8Ar C)
ECM {425, 81)
To ST. SWITCH
To ECM {47}
J To FUELPUMP
inalto the No. 5 terAttach the battery positive terminalto

terminsl
negative
termil to the No.
battery
minal and the
ay. Then
checkthat
Tl
3 terminalof rhe PGM-Flmain .elav.
; terminaland
there is continuitybetweenthe No. 7
re
ain relay.
No.6 terminalof the PGM-Flmain
a lf there is continuity,go on to step
st 4.
th PGM-Flmain
ce the
a lf there is no continuity, replace
relay and retest.
inalto the No. 6 terAnach the batterypositiveterminalto
termil to the No.
minal and the battery negativeterminal
checkthat
Tl
ay, Then
1 terminalofthe PGM-Flmainrelay,
: terminaland
there is continuitybetweenthe No. 5
nainrelay.
r
No. 4 te.minalof the PGM-Flmain
-Flmain
a It there is continuitv, the PGM-FI
mi relayis OK.
ce the
a lf there is no continuity, replace
th( PGM-Flmain
relav and retest.
(cont'd)
11-111
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Fuel Supply System

PGM-FlMain Relay(cont'dl
Tloubloshooting
- Engino will not sran.
- Inspection oI PGM-FImain relay and rolay ha.n6!a.
Checklor continuitvbetweenBLK
terminal@ and body ground.
Rapairopen in BLK wire botwoon
PGM-FImain.el6yand GIO'l llocatod at thormostot housingl.
Measure the voltage between
YELMHT terminal@ and body
ground.
- Roplacoth. ECUIECMI(15Al
lus6 in tho under-hoodfu!o/r6lay box.
- Ropair opan or short in the
YEL/WHT wil6 botwosn the
PGM-FImain rolayand the ECU
{EcMl 115 A} luso.

BLK/YELterminal @ and body
ground.
Turn the ignition switch to the

STARTposition.

BLUMHT terminsl@ and body
ground.
- Reolac.ths No. 24 ACG {ALT}

{ l c l { 1 5 A : 8 1 8 8 1 6 n g i n o2, 0
A: Bl8Cl engin6)tuse in tho
undor-dashfuso/rolaYbox.
- Ropaii op6n or rhon in tho
BLK/YEL wiro botwoen tho
PGM-FImain ielay and th No.
24 ACG {ALT) flG} {'15 A:
818Bi ongine,20 A: 818Ci
onginol fuso.
NOTE:
. M/T: Clutch pedal must
be depressed.
. A/T: Transmission in
N or E] position.
- Replacothe l\lo. 18 STARTER
SIGNAL {7.5 A} fuso in tho
undor-dashfuaa/rolay box.
- R6pai. open or short in tho
BLU/WHT wire botweon ths
PGM-FImain relay and tho No.
1A STARTERSIGNALI7.5 AI
luse.
{ T o p a g e1 1 1 1 3 }
11-112
BLU
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BLU/
wHt
Bt-x
BLK/
YEL
YEL/
BLK
( F r o mp a g e ' l ' l - 1 1 2 1
Turn the ignitionswitch off.
Connectthe test harnossbtween

the EcM and conneclors.
Oisconnect "A" connector trom
the ECMonlv. not the main wire
harness(see page 1'1-37).
Check for continuity between

GRN/BLUterminal O and A7
lermrnal.
Roplir op.n in GRI{/BLUwirc botw..n ECM lATl lnd PGM-FI
main rolay.
YES
Reconnct"4" connector to the
ECM.
Bstt.ry vohago?
r-----r_-l
A 2 3 ( - l A 2 5B l
Measure the voltag between

A23l- ) trminaland the tollowing trminals;A25 (+ ) Bl (+ ).
- Ropair opon in rh. YEL/BLK
wir. @ btwoon the ECM
1A25, 8tl .nd PGM-FI mrin
raLy.
- Roplsc. ttro PGM+I min ru4.y.
Brttaiy voftago?
a7 (+l
A23(-)
Masurethe voltage betwen A7
(+)torminal and A23 { - } trminal when the ignition switch is
first turned ON for two soconds.
ls there 1.O V or lss?
Subrlitutc . known{ood ECM

.nd 6chock. lf p..crib.d volt.g.
ir now avallablo, rodaco lha otlginsl ECM.
Chod. th6 FGM-FI fioin relay {3o.

p 6 g 61 1 - 1 1 1 1 .
11-113
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Fuel Supply System

Fuel Tank
Replacement
@
oo not smoke while working on fusl syltem. Koep opon flame rway from your wort ar6a.
Relievethe fuel pressure{see page 11-1OO).

Jack up the car and support with jackstands.
Removethe drsin bolt and drain the fuel into an approvedcontainer.
Removethe rear seat, accessDanelsand disconnectthe 2P and 3P connectors.
Remove the EVAP two way valve cover and tuel hose protector.
Disconnectthe hoses.
CAUTION:
a Whan disconnacling tho hosos, slide back tho clampr, th6n twist horos as you pull, to lvold drmlglng thcm.
a Clean the tlarod roint ot high plossulo hosos thoroughly brforc roconnccling thsm.
7. Place a jack. or other support, under the tank.
8. Remove the strao nuts and let the straDs tall free.
9. Removethe Jueltank.
NOTE: The tank may stick on the undercoat applied to its mount. To remove, caretully pry it off tho mount,
1O. Installa new washer on the dlain bolt, then installpsns in the raverseordgr ot rsmoval.
1.
2.
3.
4.
56.
FUEL
PUMP
FUEL
TANK
EVAP
TWO WAY VALVE
38 l{.m
(3.9 kgt'm,
28 rbl.ftl
EVAP
TWO WAY
VALVE
COVER
FUELTAI{K
STRAPS
tO t{.m
ll.O kgt'm,
7 lbl.frl
11-114
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Intake Air System

NOTE: Across 6ach row in the chart, the sub-systems that could be sources of a symtom are ranked in the order they
should be inspected st8rting with O. Find the symptom in the left column, read across to the most likely source, then
retr to the page listod at the top of that column. tf inspection shows the system is OK, try the next system @, etc.
181881onglnol
't
11-118
1-117
WHENCOLD FAST IOLEOUT OF SPEC
WHENWARM IDLESPEEDTOO HIGH
lB18Cl cngin.l
PAGE
I sue-svsreu
_\.-..\
sYMPToM
\---...-
THROTTLE
CABLE
THROTTLE
BODY
INTAKEAIR
BYPASS(IAB)
CONTROL
AIR CLEANER
AND INTAKE
AIR DUCT
1 11 1 9
1't-120
11-124
1 l 117
WHENCOLDFAST IDLEOUT OF SPEC
WHENWARM IDLESPEEDTOO HIGH
o
o
LOSSOF POWER
11-115
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Intake Air System

SystemDescription
The system supplies air for allengine needs. lt consists of the intake air pipe, Air Cleaner(ACL), intake air duct, Throttle
Body (TB), ldle Air Control {lAC) Valve, tast idle thermo valve, and intake manifold.
A resonatorin the intake air pipe providesadditionalsilencingas air is drawn into the system.
na
cot{TRoL
To
ffi -------------+
i'"ii'i''
SOLENOID
VALVE
RELAY
VARIOUS
SENSORS
IAB
CONTROL
DIAPHRAGM
VALVE
-BLK
--L EI{GINE
cooLnnt
FAST
IDLE
THERMO
VALVE
INTAKE
AIR
DUCT
11-116
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INTAKE
AIR PIPE
Air CleanerIACL)
ACL Element Rsplacoment
ACL HOUSING
COVER
ACL ELEMENT
Clean air cleaner element everv
15,OOOmiles (24,OOOkm) or 'l2 months and reDlaceeverv 3O,OOOmiles
(48,00Okm) or 24 months underdusty conditions,rough or muddy roads.
AKE AIR OUCT
11-117
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Intake Air System

Throttle cable [81881 enginel
Inspection/Adiustment
Installation
'I .
Startthe engine.Holdthe engineat 3,000 rpm with

no load (A/T in $ or@ oosition,M/T in neutral)until
the radiatorfan comes on, then let it idle.
1.
Fullyopen the throttle valve.then installthe throttle cablein the throttle linkageand installthe cable
housingin the cable bracket.
2.
Checkthat the throttle cableoperatessmoothly with

no bindingor sticking.Repairas necessary.
2.
3.
Checkcablefree play at the throttle linkage.Cable

d e f l e c t i o ns h o u l db e 1 O - 1 2 m m ( O . 3 9 - O . 4 7i n . )
Start the engine.Holdthe engineat 3,OOOrpm with

no load (A/T in S or @ position,M/T in neutralluntil
the radiatortan comes on, then let it idle.
CABLE
ARACKET
THBOTTLELII{K
-l-r
,)
i;
ITINERCABLE
DEFLECTION
1O-12 mm
1O.39-0.47 in.l
5.
LOCKNUT
Hold the cablesheath,removingall slack from the

cable.
Turn the adjustingnut until it is 3 mm (O.12 in.) away
trom the cable bracket.
4.
lf deflectionis not within specs,loosenthe locknut

and turn the adjustingnut until the deflectionis as
specifled.
Tightenthe locknut. The cabledeflectionshouldnow

be 10- 12 mm (O.39-O.47 in.). lf not, see Inspection/Adjustment.
With the cableproperlyadjusted.checkthe throttle

valve to be sure it opens fully when you push the
acceleratorpedalto the floor. Also checkthe throttle valve to be sure it returnsto the idle oosition
wheneveryou releasethe acceleratorpedal.
3 mm {0.12 in)
LOCKNUT
1ON.m
{1.O kgl.m,
7 tbt.ft)
1 1 - 11 8
vnx.su
Throttlecable [B18C1enginel
Inspection/Adiustment
1. Start the engine. Hold the engine at 3,O0Olpm with
no load in neutraluntil the radiatorfan comes on,
then let it idle.
2.
Checkthat the throttl cableoperatessmoothly with

no bindingor sticking.Repairas necessary.
3.
Check csble free play at the throttle linkage, Cable

d e f l e c t i o ns h o u l db e 1 0 - 1 2 m m ( O . 3 9 - O . 4 7i n . )
lnstallation
1. Fullv open the throttle valve, then install the throttle cable in the throttle linkage and install th cable
housingin the cable bracket.
2.
Stan the engine. Hold the engine at 3,OOOrpm with

no load in neutraluntil the radiatorfan comes on,
then let it idle.
THROTTLELI K
CABLEBBACKET
I{UT
ADJUSTING
5.
DEFLECTIOI{
10-12 mm
(O.39-O.47in.l
4.
lf deflectionis not within sDecs,loosenthe locknut

and turn the adjusting nut until the deflection is as
specitied.
With the cable properly adjusted, check the throttle
valve to be sure it opens fully when you push the
acceleratorDedalto the tloor. Also checkthe throttle valve to be sure it retums to the idle position
whenever vou release the accelrator pedal.
With part A of the cabl bracket, support the cable

sheath so that there is no inner wire free play. Turn
the adjusting nut until it touches part A, leaving a
gap between the locknut and adiusting nul.
Move the cable sheath to psrt B of the cable bracket that so the bracket slides into the gap between
the locknut and adiusting nut. Tighten the locknul.
LOCKT{UT
lO t{.m (t.O kgl.m, pARTB
7 lbt.ftl
{Locked by bracket)
NUT
ADJUSTING
PABT A
LOCKNUT
NO GAP
AIUUSTING
NUT
5,
The cable deflectionshould now be 10-12 mm

{O.39-O.47 in.). lf not, see Inspection/Adiustmsnt
11-119
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lntake Air System

Throttle Body
Description
The throttle body is ot the single-barrel
side-draft1ype.
The lower portionof the throttle valve is heatedby engine coolantfrom the cylinderhead.The idle adjusting
screw which increases/dec.eases
bvDassair and the
EvaporativeEmission(EVAP)ControlCanisterport are
locatedon the top of the throttle body.
Insoection
CAUTION: Do not adiust the thlottle stop screw. lt is
preset at the lactory.
1.
Startthe engine.Holdthe engineat 3,OOOrpm with

no load (A/T in S or E position,M/T in neutral)until
2.
Disconnectthe vacuum hose (to the EVAPcontrol

canister)from the top of the throttle body; connect
a vacuum, gaugeto the throttle body.
IOLEAOJUSTING
VACUUM PUMP
GAUGE
A973X-O41-XXXXX
THROTTLE
STOP SCREW
(Non-adiustsb16l
3.
Allow the engineto idle and check that the gauge

indicatesno vacuum.
a li there is vacuum,checkthe throttle cable (see
p a g e1 1 - ' l1 8 , 1 1 9 ) .
Checkthat vacuumis indicatedon the gaugewhen
the throttle is openedslightlyfrom idle.
a lf the gaugeindicatesno vacuum,check the throttle body port. lf the throttlebody port is clogged.
clean it with carburetorcleaner.
5 . Stop the engineand check that the throttle cable

operatessmoothly without bindingor sticking.
a lf thereare any abnormalities
in the abovesteps,
check for:
- Excessive
wear or Dlavin the throttlevalveshaft.
Sticky or bindingthrottle lever at full close posrtron.
betweenthrottlestop screwand throtClearance
tle lever at tull close Dosition.
11-120
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818B1 engino:
There should be
no clearance.
THROTTLESTOP SCREW
(Non-adiustablel
818Cl engine:
THROTTLELINK
(Non-adjusrablel
Replacethe throttle body if there is excessiveplay in the

throttlevalve shalt or if the shaft is bindingor sticking.
11-121
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IntakeAir System
Throttle Body (cont'dl
Dirarssmbly
GAUTION:
a Ths throttlo stop scrow is non-adrustablo.
a Aftar reassombly, adiust rhr throttlo Gablo(pago 11-118, 1 19). and A/T throttlo contlol cabl6 (section 14) for c!r8
rYith A/T.
a Tho TP sonaor ir not lomovablo
MAP
SENSOR
Troubleshooting
p a g e1 1 - 5 2
O.BING
I
d^'%
TP
SETSOR
Troubleshooting
poge1l-60
IDLEADJUSTING
SCREW
o-RtftG
Replace.
FASTIDLE
THERMO
VALVE
page11-94
Inspection,
1ON.m
11.Okgl.m.
7 tbf.ftl
11-122
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IntakeAir Bypass(lABl ControlSystem tBl8C1 enginel

Osscription
t favorabl
for a
favc
Two air intakepaths are providedin the intake manifoldto allow the selectionof the intak path most
given enginespeed.
valve! HightorSatisfactorypower peformanc is achievedby closingand openingthe intakeair bypass(lAB)controlvslves.
que at low RPMis acheivedwhen the valvesare closed,whereashighpower at high RPMis achievedby when the valves
8re oDeneo.
IAB CONTROL
VALVES
To PGM-FI
MAIN RELAY
RELi
IAB
CHECK VALVE
(cont'dl
11-123
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IntakeAir System
IntakeAir Bypass(lAB) ControlSystemtBl8C1 enginel(cont'dl
Troublcahooting
Inspction of IAB Conltol Sytt.m
tA8 COI{TROL
DIAPHRAGM
Start engino and allow to idle.
VACUUIIPUMP/GAUG
A973X-041-XXXXX
Rmove# 13 vacuumhosetrom
the IAB control diaph.agm and
connect vacuum gauge to the
hose.
Rmove # 12 vacuum hose from
th IAB vacuum tank, then check
tor vaccum at the IAB vacuum
tank.
Rcplir lh. block.g. ot
vacuufi laak boiwaao
tha IAB vacuum tank
m!nilnd th. intlk
fold.
Disconnect the 2P connctor lrom
the IAB control solenoid valve.
Measure voltage between

YEL/BLK(+l torminal and
PNK/8LUl-) terminsl.
IAB CONTBOL
VALVE
SOLENOID
from
wiro haana
sid
PI{K/
B L UI - I
YEI/
a L Kl + l
ls thoro battery voltage?
Measure voltage btween

BLK^|/EL(+) torminal and body
ground.
vnx.su
(Frompage 1 1-124)
Raise engine speed to above

6,000 rpm.
{Frompago 1 1-124}
Repsirop6n in YEL/BLK
wiro botwoon tho 2P
connector and FGM-FI
main relaY.

Checklor vacuumat #'l3 vacuum hose.
Connectlhe test harnessbetween
the ECM and connectors lsee
p a g e1 1 - 3 7 ) .
Turn the ignitionswitch ON and
connect a lumper wke between
ECM (A17) terminal and ECM
{A26) terminal.
Ooes the solenoid valve click
when the jumper is connected?
RopaiioponinP K/BLU
wiao botwoen ECM
lAl7l and tho 2P connectot.
Sub3titute a known-good ECM

and rechock. lf symptom/indication goos away, r6placetho original ECM.
the IAB control solenoidvalve.
Checkfor continuity to ground on

the PNK/BLUwire.
ls there continuity to ground?
IAB control syst6m is OK.
Ropairshort to g.ound
at PNK/BLU wiro botwo6n ECM {A17) and
tho 2P connector.

and racheck. It symptom goos
swsy, roplace tho original ECM.
11-125
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a
Intake Air System
IntakeAir Bypass(lABl ControlValve IB18C1 enginel
Trlting
GAUTIOI{; Do not rdlust lho IAB control valvo tull-close screw. lt is prosot at th. t.ctoty.
1.
Chsck the IAB control valve shsft for binding or sticking.
2.
Check th6 IAB control valve for smooth movement.
3.
With the engine at idle, check that @ot the IAB control valve is in close contact with the stoppsr when vacuum
hose is disconnected.
With th ongine at idl6, check that @of the IAB control valve is in close contact with the full-closo acrew whsn
the vacuum hose is connectad.
a lf 8ny fault is lound, clean the linkage and shatts with carburetor claaner'
- lf the oroblam still exists after cleaning, disassemblethe intake manifold and check the IAB valvE body sss8mbly.
11-126
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Dls!$.muy:
ITTAKE
MANIFOLD
23 N.m
12.3kgt.m.
17 tbt.ftl
a a
GASXET
Rgplace.
|AA VALVEAODY
I]{TAKE MANIFOLD
CHAMBER
24 N.m
(2.4 kgf.m,
t7 tbf.ftl
11-127
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Intake Air System

IntakeManifoldIB18B1enginel
Disassembly:
{ uuu
24 N.m
12.4 kgf.m,
t7 tbt.ftl
11-128
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23 N'm
(2.3 kgt.m,
17 tbf.ftl
EmissionControl System
NOTE: Acrosseach row in the chart,the sub-systemsthat could be sourcesof a symptomare lanked in the ordrthey
should be inspected starting with O. Find the symptom in the lett column, read across to the most likely source, then
reJerto the page listd at the top of that column. lf inspection shows the system is OK, try the next most likely system
@, etc.
PAGE
SUB.SYSTEM
SYMPTOM
THREEWAY
CATALYTIC
CONVERTER
POSITIVE
CRANKCASE
VENTILATION
SYSTEM
1 1 - 1 3 21, 3 3
1 1 -1 3 4
1 1 tJo
ROUGHIDLE
POORPERFORMANCE
EVAPORATIVE
EMtSSTON
CONTROLS
FAILS
EMISStON
TEST
LOSSOF
POWER
11-129
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EmissionControlSystem
SystemDescription
Tailpipe Emission
The emissioncontrol system includesa ThreeWay Catalytic Convener (TWC), Positive Crankcase Ventilation
(PCV)system and EvaporstiveEmission{EVAP)Contfol
systm. The emissioncontrol system is designedto meet
federsl and stats emissionstandards.
Inspection
f!fifil
oo nor amoro ou]rngrnr! Foacqurr. ^!op
any open flame away from yout wotk atca.
Start the engine. Hold the engine at 3,OOOrpm with

no load (A/T in @ or@ position,M/T in neutral)until
the radiatorfan comes on, then let it idle,
Connect a tachometer.
Check and adiust the idle speed, if necessary (sss
p a g e11 - 9 5 ) .
Warm up and calibrate the CO meter according to
the meter manutacturer'sinst.uctions.
Check idle CO with the headlights, hester blower,
rearwindow defogger,coolingfan, and air conditioner otf.
NOTE: (Canada)Pull the parking br8ke lever up.
Stan the engine,then checkthat the headlightsare
off.
CO meter should indicate0.1
11-130
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maximum.
ThreeWay GatalyticConverterITWC)
Dr!criplion
Th6 Three Way Cstalytic Converter (TWC) is used to convert hydrocarbons (HCl, carbon monoxide (CO), and oxides
ot nitrogen{NOx) in the exhaustgas, to carbondioxide (COr},dinitrogen(N2land water vapo..
The illustrationshows the TWC tor the 818C1 engine.
THREEWAY
CATALYSTS
FBONTOF
VEHICLE
11-131
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ThreeWay CatalyticConverter(TWC)(cont'dl
Inspection
lf sxcessive oxhaust system back-pressureis suspected. remove the TWC trom the car and make a visual check for plugging, meltingor crackingof ths catalyst. Replacethe TWC if any of the visiblearea is damagedor plugged.
81881 ongino:
T SHIELO
TI{REEWAY
CATALYTIC
CONVERTER{TWCI
Removsl/installation,see section 9
Inspecthousingfor cracksor
other damage.
Inspect element tor clogging
by lookingthroughthe inside.
HEAT SHIELD
11-132
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818Cl engine:
HEAT SHIELO
THREEWAY
CATALYTIC
COI{VEBTEB{TWCI
Rmoval/installation.sso sction 9
Inspoct housing tor cracks or
othor damage.
Inspect elemont for clogging
by looking through the inside.
HEAT SHIELD
11-133
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EmissionControlSystem
PositiveCrankcaseVentilation(PCVISystem
Description
Inspcdon
The Positive Crankcase Ventilation (PCV) system is

designed to prevent blow-by gas {rom escaping to the
atmosphsre. The PCV valve contains a spring-loadsd
plunger. When the Bnginestarts, the plunger in the PCV
valve is lifted in proportion to intake manifold vacuum
and the blow-by gas is drawn directly into th intak
manifold.
1.
Check th PCV hos6sand connectionstor lsaks and

clogging.
SREATHER
FCV VALVE
.F: ILOW-BYVAFOR
er FRESHAIR
2 . At idle, mak6 sur th6fe is a clicking sound from th6

PCV valve when the hose between rcV valve and
intake manifold in lightly pinched with your fingors
or olirs.
Gontly pinch hero.
a lf thera is no clicking sound, ch6ck the PCV valve

grommet for cracks or damage. ll the grommet
is OK, reolace the PCV valve and recheck.
11-134
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EvaporativeEmission(EVAPIControls
Da.cdptlon
Thg avaporstive omission controls are designed to minimize the smount of fusl vapor escaping to the atmosphero. The
system conaists ot the following componnts:
A . Evlporttly. Emlttbn (EVAPI Control Caniltot
An EVAP control canistor is used lor the temporary storage ot fuel vapor until the fuel vapor can be purged lrom
th EVAP control canister into the engin and burned.
vlpor hr]gG Cmt]ol Syst m
VAp control canistgr puroing is accomplished by drawing fresh air through tho EVAP control canister and into a
pon on th6 throttl body. Th purging vacuum is controllsd by the EVAP purge control diaphragm valve end the
EVAP purge control solenoid valve.
C.
Ft|.l Tmk Vlpor Control Systom

When fuel vapor prassurein the fuel tank is higher than the set v8lue of the EVAP two way v8lv6, th valve opens
and regulates the flow ol fuel vapor to the EVAP control canister.
(cont'd)
11-135
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EmissionGontrol System
EvaporativeEmission(EVAPIControl(cont'd)
EVAP
TWO WAY VALVE
FUELTANK
EVAP
PURGE
CONTROL
SOLENOID
VALVE
EVAP VALVE
FUEL
FILLCAP
VARIOUS
sEt{soRs
EVAP CONTROL
CANISTEB
FRESH
AIR
11-136
vnx.su
BLK
#7 VACUUM HOSE
Troublclhooting
Disconnct #7 vacuum hose

trom the EVAP putgo control di'
aph.agmvalve lon the EVAPcont.ol canistor) and connoct a
vacuum gauge to tho hose.
VACUUM PUMP/
GAUGE
A973X-O41-XXXXX
COI{TROL
EVAPPTJBGE
VALVE
DIAPHRAGM
Stsrt the ngine and allow it to

idls.
NOTE: Engine coolant temperature must be blow 163oF (73ocl
Oisconnectthe 2P connegtortrom
the EVAP purge control solenoid
Bl8Bl .noin.:
YEL/
B L KI + I
EVAP
PUBGECONTROL
VALVE
YEL/
B L K( + I
(-t
wirg aide
--\
EVAP
R'RGECOI{TROL
VALVE
SOLENOID
M e as u r o v o l t a g o b e t w e n
YEL/BLK{+) terminsl 6nd RED
l-) terminal.
ls ther6 battery voltage?
Inapactvacuum hoa
ror.ring.
l| OK, toolrc. EVAP
purgo conttol solenoid
Moasule voltage botween

YEL/BLK {+) terminal bodY
ground.
(To page 1 'l-139)

(To pa96 1 1-138)
(cont'd)
11-137
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EmissionGontrolSystem
EvaporativeEmission(EVAP)Gontrols(cont'd)
(Frompage 1 1-137)

at 3,OOOrom with no load lA/T in
E orE position,M/T in neutrsl)
unlil lhe radiator tan comes on.
then let it idle.
{ F r o mp a g e 1 1 - 1 3 7 }
Ropair opon in YEL/BLK

wirc b.tw..n
EVAP
purgo control rolanoid
vrlvo and th. xiM-Fl
mlin r6lay.
Inspoct RED wirc for 6n opon to

trody g.ound botween ECM lA20)
and th6 conn6ctor.
It wir. b OK, substiluto a knowngood ECM and rochock, It symptom 9o6s away, roplaco tho
original ECM,
Checklor vacuum at # 7 vacuum

hose alter starting the engine.
Oisconnectthe 2P connoctorfrom
the EVAP purge control solenoid
ls there manifoldvacuum?
Inrpoct for a short i|t REDwire bolwoen ECM {A2Ol and th6 connoclor.
ll wiro la OK, substituto a knowngood ECM 6nd .echock. lf symptom goes away, loplacetho original ECM.
lTo page 1 1-'l39)
11-138
vnx.su
Intpoct vacuum hoaa

rcuting.
It OK, reolrco tr|c EVAP
Purge contlol lolanoid
(F.om pdge 1l-138)
VACUUMPRESSURE
GAUGEO-4 In.Hg
oTJAZ-OOIOOOB
Connoct a vlcuum gaugo to

caniator purg! lir ho!o.
Stsn tho onginc lnd rai!. spod

to 3,50O rpm.
PURGEAIR HOSE
Doavocuum opparon gougo

within 'l minuto?
Connect a vacuum gauge to the

csnister puag6hos6 and raisethe
sngin sped to 3,500 rpm.
Saa EVAP tso {ay vdv. t.!t io

conrDbta.
Evapoardva ambdon coartaoL|.|
Inapoct tha purga hoso

and drronl. body potl
for pinch or blocklga.
ox.
(cont'd)
11-139
vnx.su
EvaporativeEmissionControls
(cont'dl
Evaporativ Emission {EVAPI Two Way Valvo Tasting
l.
Removethe tuel fill cao.
2.
Removevapor line trom the two way valve on the

fuel tank and connect to T-fitting trom vacuum
gauge ano vacuum pump as snown.
VACUUM/
PRESSURE
GAUGE
oTJAZ-OOIOOOa
A973X-041-XXXXX
T-FITTING
Apply vacuum slowly and continuouslywhile watching the gauge.

Vacuum should stabilize momentarilv at 5-15
m m H g ( 0 . 2 - 0 . 6 i n .H g ) .
a It vacuumstabilizes(valveopenslbelow5mmHg
(O.2in.Hg)or above I 5 mmHg (O.6in.Hg),install
a new valve and retest.
4.
Move vacuumpump hosefrom vacuumto pressure

titting, and move vacuumgaugehosetrom vacuum
to oressureside as shown.
J-.
fF
,T
. -,-/asr^:
4?e
Slowly pressurize
the vaporlinewhile watchingthe
gauge.
Pressure
shouldstabilizeat 1O-35 mmHg(0.4- 1.4
i n .H g ) .
a lf p.essuremomentarilystabilizes{valveopensl
a t 1 O - 3 5 m m H g ( O . 4 - 1 . 4 i n . H g ) t, h e v a l v ei s
oK.
a lf pressurestabilizesbelow 10 mmHg {O.4in.Hg)
or above35 mmHg(1.4 in.Hgl,installa new valve
and retest.
11-1 4 0
vnx.su
Transaxle
12-1
Clutch
M a n u aTl r a n s m i s s i o. .n. . . . . . . . . . . . . . . . 1
. .3. .- 1
A u t o m a t iT
c r a n s m i s s i o. .n. . . . . . . . . . . . . 14-1
...
Differential
ManualTransmission
15-1
81881 engine
15-9
818C1engine
15-19
AutomaticTransmission
...............
16-1
Driveshafts
vnx.su
Glutch
. . . . . . . .1 2 - 2
S p e c i aTf o o l s . . . . . . . .
.... 12-3
f f f u s t r a t e Idn d e x . . . . . . . .
Clutch Pedal
................12-4
Adjustment
Clutch Master Cylinder
.... 12-5
Removal/lnstallation
Slave Gylinder
.... 12-6
PressurePlate
..... 12'7
Removal/lnspection
Clutch Disc
..... 12-8
lnspection/Removal
Flywheel, Flywheel Bearing
. 12-9
fnspection
R e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .1.2. .-.9
Clutch Disc, PressurePlate
12-10
Installation
ReleaseBearing
12-11
Removal/lnspection
vnx.su
SpecialTools
Ref. No,
o
/^
ri)
@
@
Tool Number
OTJAF_PM7011A
OTLABPVOO1
OOor
o7 924-PD20003
07NAF-PR30100
07746-0010100
07749-OO10000
07936-3710100
Description
Clutch AlignmentDisc
Ring Gear Holder
Clutch AlignmentShaft
Attachment, 32 x 35 mm
Driver
Handle
12-2
vnx.su
Oty
'I
Page Reference
12,7
1 2 - 1 ,8 , 9 , 1 0
I
1
I
I
1 2 - 7, 8 , 1 0
12-10
12-10
1 2 - 1, 8 , 1 0
lllustrated Index
NOTE:
a Wheneverthe transmissionis removed,clean and greasethe releasebearingslidingsudace.
a It the pans marked r are removed.the clutch hydraulicsystem must be bled (see page 12-6).
a Inspectthe hoseslor damage,leaks,interterence,and twisting.
*RESERVOIR
HOSE
ASSISI SPRING
COTTER
Beplace.
N
n Il
6 x 1,0 mm
9.8 N.m ll.0 ksf.m, 7 lbf.tt)
9 t
v-_fl
PEDAL PIN
1 5 N . m 1 1 . 5k g l . m ,
11 tbt.ftl
TCLUTCHMASTER CYLINDER
page 12-5
Removal/lnstallation,
.CLUTCH PIPE
CLUTCH PEDAL
Adjustment,
page 12-4
15 N.m {1.5kgl.m,
1 1 rbf.ft)
JOtt{T
8 x 1.25mm
25 N.m (2.6 kgl.m,
19 lbt.ttl
19 N.m ll.9 kgt.m,

14 lbf.ftl
FLYWHEEL
Inspection.page 12-9
page 12-9
Replacement,
RELEASEBEARING
Romovaf/lnspection, page 1 2-1 1
lnstaffation,page 12- 12
CLUTCH DISC
page'12-8
Removal/lnspection.
Installation,page 12-10
TRANSMISSION
Romoval. see
section 13
12 x 1.0 mm
103 N.m llO.5 kgt.m,
76 rbf.ftl
ICLUTCH PIPE
PRESSUREPLATE
page 12-7
Removal/lnspection.
Installation,page 12,10
8 x 1.25mm
22 N.m (2.2 kgf.m.
16 lbl.rr)
TSLAVE CYLINDER
Removaf/lnstallation. page 12-6
32 N.m {3.3 kgf'm,

24 tbf.ftl
ICLUTCH
15 N. m {1.5kgf.m,
'| I tbf.ftl
12-3
vnx.su
Pedal
Pedat
Clutch
ctutch
Adjustment
[-],ll'"-""
| :;i:'":fff*tr#:?iff:".,*::,::".
| .#::J:::
|
"orr,O",
CAUTION: It there
there is no clearanco
clearancobetween
between the master
mastel
cylinder piston and push lod. the releasoboaringis held
diaphragm spring,
which can result
result in clutch
clutch
against
againsl the diaphragm
spring, which
problems.
slippage
slippage 01 othel
othel clutch
clutch problems.
1.
1 . Loosenlocknut A, and back otf the clutch switch
bolt) until it no longertouchesthe clutch
adjustingboltl
{or adiusting
pedal.
sb''''""
| |
Turn the clutch switch (or adjustingbolt) in 3/4 to

1 full turn further.
NOTE:
a To check the clutch interlock switch and clutch
switch, see seclion 23.
a The clutch is selt-adjusting
to compensatefor wear.
6 . Tighten locknurA.
,.
switcl.
7. aoo""n
Loosenlocknut B and the clutch intertoct
interlockswitch.
|
|
|
|
|
I
|
I
I
I
p e d a l15-2O
1 5 - 2 0 mm
m m {(O.59-O.79
9.
9 . Release
R e l e a s the
teh e clutch
c l u t c hpedal
O.59-O.79 I
int
in) trom
from ttre
the fully depressedpositionand hold it there. I
Adiustthe positionof the clutch interlockswitch so
that the enginewill start with the clutchpedalin this
oosition.
I
I
floor boardand
8. Measuretne
the clearancebetweenthe tloor
depressed.
clutch pedalwith the clutch pedaltully deeressed.
I
|
I
push rod
in or
rurn
the
Loosenrocknut
locknut c,
C, and
and turn
the push
rod in
or out
out
,2 . ::":""
|
iliiiliffi:l1l:J"'1"-:H"l:tJ:i"i#fT:I
'-"'"'';*1,,0*
::***r**''
.,".,u"**;
|
II
,
to get the specifiedstroke(@)and height(O) at the
clutch pedal.
10. Turnclutchinterlockswitch 3/4 to 1 tull turn funher.
I tf
,:.;:,nterrockswitch3/4torrurrturnturtner.
1 1 . T i g h t e nl o c k n u tB .
. il*:*j':"'-(@)andheisht(olatthe
Tighten locknut C.
Turn the clutch switch (or adjustingbolt) until it contacts the clutch pedal.
ASSIST SPRING
LOCKNUTB
9.8 N.m (1.0 kgf.m,7 lbf.ftl
-6ll
CLUTCH INTERLOCK
PUSH ROD
swtrcH
CLUTCH MASTER CYLINDER
CLUTCH SWITCH
{or AOJUSTING BOLTI
LOCKNUTA
9.8 {N.ml (1.0 kgl.m, 7 lbt.ftl
LOCKNUTC
l3 N.m l'l.3 kgf.m, 9
(STROKEat PEDALI:130-140 mm 15.12-5.51 in)

{TOTALCLUTCHPEDALFREEPLAY):12-21 mm 10.47-0.83 inl includingtho p.dal play I -lO mm 10.04-0.39 inl
{CLUTCHPEDAL HEIGHTI: 164 mm (6.46 in} to tho lloot
{CLUTCHPEDAL DISENGAGEMENTHEIGHTI: 83 mm 13.27 inl minimum to tho lloo.
vnx.su
Clutch Master Cylinder

CAUTION:
a Do not sgill b.ake lluid on the car; it may damags the
painl; it biake fluid does contact tha paint. wash it
otf immediately with water.
a Pluglhe end ot the clutch pips and rservoilhose with
a shop towel to prsvent blake fluid ttom coming out.
1.
Remove the brake fluid from the clutch master

cylinde.reservoirwith a syringe.
2.
Disconnectthe clutch oioe and reservoirhosefrom

the clutch master cvlinder.
Removethe clutch mastercylinder.

NOTE: Do not spillbrakefluid on the clutch master
cylinderdamper.
CLUICH PIPE
15 N'm {1.5kgl.m,
1 1 tbf.ftl
OAMPER
CLU
CLUTCH
M
MASTER
AI
cYL
CYLINDER
!l rn
in Ine reverseorInstallthe clutch mastercylinder
der of removal.
(seepage
s\
c system
NOTE: Bleedthe clutchhydraulic
12-61.
CLUTCH
MASTER
CYLINDER
Pry out the cotter pin. and pull the pedal pin out ot
the yoke. Remove the nuts.
NUTS
13 N.m {1.3 kgf.m,
9 lbt.frl
12-5
vnx.su
Slave Cylinder
Install the slave cylinder in the reverseorder ol
removat.
CAUTION:
a Do not spill brake tluid on the car. it may damago tho
paint; it brake tluid doos conlacl tho paint, wash it
off immediately with watei.
a Plug tho nd of the clutch pipe with a shop lowsl to
plevcnt b.ake fluid from coming out.
NOTE: Make surethe boot is installedon the slave

cylinder.
Super High Temp Urea Grease {P/N
-61,
08798-9002).
: BrakeAssemblyLubeor equivalentrubber
grease.
'1.
CLUTCH PIPE
15 N.m (1.5 kgf.m, 11 lbf'ftl
Disconnectthe clutch pipe from the slavecylinder.

SLAVE CYLINOER
Removethe slavecylinderfrom the clutch housing.
-Cl
tP/N08798-90021
8 x 1.25mm
22 N.m 12.2 kgl'm,
16 rbt'ft)
...::
:^.
Gil^lt
(BrakeA$embry
Lubol
4.
BOOT
Remove and check for signs ol leaking and deterioration.
12-6
vnx.su
Bleedthe clutch hydraulicsystem.

a Attach a hose 1o the bleederscrew, and suspend
the hose in a containeroJ brakefluid.
a Make surethere is an adequatesupplyof tluid at
the clutch mastercylinder.then slowly pumpthe
clutch pedaluntil no more bubblesappearat the
bleederhose.
a Refillthe clutch mastercylinderwith fluid when
done.
a Use only DOT 3 or 4 braketluid.
PressurePlate
Removal/lnspection
Check the diaphragmspring fingers for height using the specialtools and a feeler gauge.
4.
StandardlNew): 0.6 mm (0.02 inl Max.

ServiceLimit: O.8 mm {O.O3in}
Inspectthe fingers of the diaphragm

diaphrag springfor wear
nracr area.
ar
at the releasebearingcontact
FEELER
GAUGE
CLUTCHALIGNMENTOISC
OTJAF_PM7011A
Inspectthe pressureplateI surfacefor wear, cracks,

and burning.
DIAPHRAGM
SPRING
PRESSUREPLAT
07936-3710100
07NAF-PR30100
lf the heightis morethanthe servicelimit,replace

the pressureplate.
2.
Installthe specialtools.
3.
To prevent warping, unscrew the pressureplate

mounting bolts in a crisscrosspattern in several
steps, then removethe pressureplate.
6.
Inspectfor warpageusinga stru

straightedge and feef
er gauge.
prer
plate at three
NOTE: Measureacrossthe pressure
pornls.
Standard(Newl: 0.03 mm (0.0
0.001 in) Max.
SorviceLimit:0.15 mm (0.0O6
)O6 inl
STRAIGHTEOGE
CLUTCH ALIGNMENTSHAFT
07NAF-PR30100
HANDLE
07936-3710'l OO
FEELERGAUGE
RINGGEARHOLDER
07LAB-PVOOlOOor
07924-PD20003
PI
lf the warpage is more than
replace the pressure plate.
PRESSUREPLATE
12-7
vnx.su
Disc
Disc
ctutch
Glutch
'.#fu;;
Removal/lnspection
'1.
Removethe clutch disc and specialtools.
Measure the depth trom the lining surface to the

rivets, on both sides.
Inspectthe liningof the clutchdiscJorsignsoJ slippingo. oil. lf it is bu.nedblackor oil soaked,replace

it.
Standard(Now): 1.3 mm (O.05 inl Min.

Se.viceLimit: O.2 mm {O.OO8inl
""-*":'--
''
inr
{o'oo8
=-.--']!
; i , n-\ ll
DISC
"LUrcH
CLUTCH Drsc
CLUTCHDISC
W@*-l
@
slbir":ix:l#
Ii!fr..;*'::l;'"o^"
\t'=f
|
CLUTCHALIGNMEI{T
SHAFT
07NAF-PR30100
HAt{DLE
07936-3710t0O
3.
thickness.
Measu.ethe clutch disc thic
Standard{Now}: 8.4-9.1 mm (o.33*0.36 inl

Sarvica Limit: 6.0 mm (O.24 in)
LINING SURFACE
CLUTCH DISC
It the rivet deDth is less than the service limit,

reolacethe clutch disc.
lf the thickness is less than the service limit,

reolacethe clutch disc,
vnx.su
II
Flywheel, Flywheel Bearing

Replacement
Inspection
Inspect the ring gear teeth for wear and damage.
Install the special tool.
Inspect the clutch disc mating surface on the

flywheel fo. wear, cracks, and burning.
Removthe flywhel mounting bolts in a criascross

pattern in severalsteps 8s shown, then remove the
tlywheel.
Measurethe flywheel runout using a dial indicator

through at least two full tu.ns. Push against the
Ilywheel each time you turn it to take up the crankshaft thrust washe. clearance.
FLYWHEEL
NOTE; The runoutcan be measu.edwith engineinstalled.

Standard (ttlervl: O.O5 mm (O.002 inl Max.
Service Limit: 0.15 mm 10.006 inl
RING GEAB
FLYWHEEL
MOUI{TII{G BOLTS
3.
Remov the flywheel bsaring from th tlywheel.
DIALII{DICATOR
It the runout is more than the servicelimit, leplace
the flvwheel.
Turn the inner race of the flywheel bearingwith your
finger. The bearingshould turn smoothly and quietly, Checkthat the bearingouter race fits tightly in
the flvwheel.
FLYWHEEL
BEARING
It the racedoes not turn smoothly,quietly,or fit
tight in the flywheel, replacethe flywheel bearing.
(cont'd)
12-9
vnx.su
Flywheel,FlywheelBearing
Clutch Disc,
PressurePlate
Replacement(cont'd)
4.
Installation
Drivethe new flywheelbearingintothe flywheelusing rhe specialtools as shown.
l.
Installthe ring gear holder.
Apply greaseto the splineof the clutch disc, then

install the clutch disc using the specialtools as
snown.
DRIVER
07749-O010000
NOTE: Useonly SuperHighTemp UreaGrease(P/N

08798-9OO2).
CLUTCH DISC
ATTACHMENT.
32x35mm
07746-OOlO100
FLYWHEEL
FLYWHEELBEARING
5 . Align the hole in the flywheel with the crankshaft

dowel pin and installtheflywheel.Installthemounting bolts finger-tight.
o.
Installthe specialtool as shown, then torque the

flywheel mounting bolts in a crisscrosspattern in
severalsteDsas shown.
RINGGEARHOLDER
OTLAB-PVOOI
O0ot
07924-PD20003
3.
07NAF-PR30100
HANDLE
07936-3710100
Instalithe pressureplate.
oTNAF-PR30100
HANDLE
FLYWHEEL
07936-3710100
PRESSUREPLATE
MOUNTINGBOLTS
12 x 1.0mm
1 0 3 N . m 1 1 0 . 5k g f . m ,
76 tbf.fr)
12-10
\_
vnx.su
ReleaseBearing
Removal/lnspection
4.
Torquethe mountingbolts in a crisscrosspatternas

shown.Tightenthe boltsin severalstepsto prevent
warping the diaphragmspring.
1 . R e m o v et h e release fork boot trom the clutch

housing.
2.
Removethe releasetork trom the clutchhousingby

squeezingthe releasefork set springwith pliers.Remove the releasebearing.
CLUTCHHOUSING
8 x 1.25mm
25 N.m 12.6 kgt'm,
19 tbt.ftl
RELEASEFORK
Checkthe releasebearingfor play by spinningit by

hand.
CAUTION: The release boaring i6 packed with
grease. Do not wash it in solvent.
Removethe specialtools.
Recheckthe diaphragmspring fingers tor height (see
page 12-7]..
-24/--2,t'.2424?'
IJ
l{ there is excessiveplaY,rep)acethe rdease\Earing with a new one.
,F=:=
vnx.su
ReleaseBearing
Installation
1 . With the releasetork slid betweenthe releasebearing pawls, installthe releasebearingon the mainshaft while insertingthe releasefo.k through the hole
in the clutch housing.
2 . Alignthe detentot the releasefork with the release

tork bolt, then pressthe releasefork over the release
fork bolt.
NOTE; Use only Super High Temp Urea G.ease(P/N
08798- 9002).
-611
lPlN 08798-
-6
{P/N0879a- 9002)
Move the releasefork right and left to make surethat

the fork tits properlyagainstthe releasebearing,and
that the releasebearingslidessmoothly.
4.
lnstallthe releasefork boot.
12-12
vnx.su
ManualTransmission
.............
13-2
SpecialToofs
Maintenance
Transmission
Oi1,...,........,........,.,.....
13-3
Back-upLight Switch
Replacement
.........13-3
TransmissionAssembly
Removal
..,.......,......
13-4
lllustratedIndex ...................................
13-8
TransmissionHousing
Removal
...........,.....
13-10
ReverseChangeHolder,Reverseldler Gear
lnspestion.......................
13-11
Glearance
Removaf
.................
13-12
ChangeHolderAssembly
Inspection.......................
13-13
Clearance
.................
13-15
Removal
Disassembly/Reassembly
...............
13-16
Mainshaft, Gountershaft,Shift Fork
...,.............
13-17
Removal
Shift Rod
13-18
Removal
.................
Shift Fork Assembly
Index ................
......13-19
13-20
Clearance
Inspection.......................
MainshaftAssembly
Index ................
......13-21
Clearancefnspection .......................
13-22
Disassembly
..........13-25
Inspection
..............
13-26
Reassembly
13-21
...........
Countershaft Assembly
Index ................
......13-28
13-29
ClearanceInspection .......................
Disassembly
..........13-30
Inspection
..............
13-31
Reassembly
...........
13-32
SynchroSleeve,SynchroHub
Inspection
..............
13-34
Installation
.............
13-34
SynchroRing,Gear
lnspection
..............
13-35
Clutch HousingBearing
Replacement
.........13-36
Mainshaft Thrust Clearance
Adiustment
............
13-38
Transmission
Reassembly
...........
13-tl1
.............
13-46
lnstallation
Gearshift Mechanism
................
13-50
Overhaul
vnx.su
SpecialTools
Rsf. No.
o
o
o
o
@
@
@
@
@
07GAJ- PG20110
07GAJ- PG20130
.07736 - A010004
07746- 0010300
07746- 0010400
07746- 0030r00
07746- 0030300
07746- 0030400
07745- 0041100
07749- 0010000
Oty
D!3cription
Tool Numbrr
MainshaftHolder
MainshaftBas
AdjustableBearingPuller,25 - 40 mm
Attachment,42 x 47 mm
Oriver,40 mm l.D.
Attachment,30 mm l.D.
Attachment,35 mm l.D,
Pilot,28 mm
Driver
1
1
1
1
1
1
1
1
1
1
13-40
13- 36,37
13-36
13- 36,37
1 3- 2 7 , 3 3
1 3- 2 7 , 3 3
1 3- 2 7 , 3 3
13-36
13- 36,37
* Must be usedwith commerciallvavailable3/ 8"- 16 SlideHammer.
ll
13-2
vnx.su
Prgc R.{.rcnc.
'13- 40
Back-upLightSwitch
Maintenance
- TransmissionOil
Replacement
NOTE:Checkthe oil with the engineOFF,and the car on

levelground.
1.
/itch, see section 23.

NOTE:To checkthe back-uplight switch,
1.
removethe back-up
Disconnect
the connector,then rem(
]onnectorclamp.
light switchconnectortrom the conn
2.
Removethe back-uplight switch.
Removethe oil filler plug, then checkthe level and

condition of the oil.
OIL FILLERPLUG
44 N.m lia.5kgf.m,
33tbtftl
ProperLevel
Replace.
2 . T h e o i l l e v e lm u s t b e u p t o t h e f i l l e r h o l e .l f i t i s
below the hole. add oil until it runs out, then reinstallrhe oil filler plug.
3.
l f t h e t r a n s m i s s i o no i l i s d i r t y , r e m o v et h e d r a i n
p l u ga n dd r a i nt h e o i l .
4.
R e i n s t a ltlh 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
refillthetransmissionoil to the properlevel.
NOTE:The drain plug washershouldbe replacedat
everyoil change.
BACX-UPLIGHTSWITCH
25 N.m 12.5kg[.m, 18 lbf.ftl
Replace.
-up light switch.

lnstallthe new washerand the back) page13-3).
Checkthe transmissionoil level(see
Reinstallthe oil filler plug with a new washer.

OilCapacity
2.2 ( ''2.3US.qt,1.9 lmp.qt) at oil chang.
2-3I l2.1Us.ql,2.0lmp.qtlat oyerhaul.
'10W - 40, API Service
Use only SAE 10 w - 30 or
grade.
or
SG
SF
PLUG
OILFILLER
a4N.ml{.5 kgf.m,33 lbf.ftl
ORAINPLUG
$ N.m 14.0kgf.m.
29 lbf.fr)
13-3
vnx.su
Removal
Mskc aurs iack! and safoty Etandsaro placod properly lsl8 saqtion 1|.
Apply parking brake tnd block rear whccl! to car
will not roll ofl stand3 and f.ll on you while wotking
undrr it.
4.
Disconnectthe back-up light switch connoctor and

the transmissiongroundwir.
5,
Remove the lower radiator hose clamp trom ths

transmissionhangerB.
BACK.UPLGHT
suTcH cot{t{EcToR
CAUTION: Use tondcr coyar3.to avoid drmlging

plintsd 3qrfaca3,
Disconnctthe negative {-) cable from the battery,
then the positive(+)cable.
Drain the transmissionoil, then reinstallthe drain
plug with a new washer(seepage 13-3),
Removethe intakeair duct and the air cleanerhousing assembly,
AIR CITANER
HOUSING
lnaNsMttistoN
WIRE
GROUND
tnaNsi ssloN
HANGEBB
o.
Rmovethe wire harnessclamPs.
1.
Disconnectthe stsrtr motor cables and the vahicla

soeed sensor (VSS)connector.
VSS OONNECTOR
13-4
vnx.su
Removotho clutch pip bracketand th slave cylinoer.
10. Removethe enginesplashshield.
NOTE: Do not operate the clutch pedal once th

slavg cvlinder has been rmoved.
Rmove the three uppor transmission mounting

bolts 8nd lower staner motor mounting bolt.
11. Disconnectthe heatedoxygen sensor(HO2S)connector,lhsn rsmove the exhaust pipe A, and the
threeway catalyticconverter(B18ClEngine).
HO2S
IIUT
SELF.LOCK
Ropl.ce.
STARTEB
MOTOB
MOUNNNG
BOLT
co NEctoR
EXHAUST
PIPEA
MOUNNNG
BOLTS
NUT
SELF.LOCK
THBEEWAY
Replace.
CATALYTIC
CONVEEIER
engin6)
1818C1
13-5
vnx.su
vnx.su
21. Placea transmissioniack under the transmission

and a jackstandunderthe engine.
19. Removethe clutchcover.
Removethe transmissionmount.
TRANSMISSIONMOUNT
23. Removethe rear mount bracketbolts and the transmissionmountingbolts.
MOUNT/BRACKET
BRACKET
24. Pull the transmissionaway from the engine until it

clearsthe mainshaft,then lower it on the transmission iack.
13-7
vnx.su
lllustratedIndex
Referto the drawingbelowfor the transmissiondisassembly/reassembly.
Cleanall the partsthoroughlyin solventand dry with compressedair.
I
ruurlcateattthe partswith oil beforereassembly.
NOTE:
the majorhousings;
useliquidgasket(P/N08718-0001)
. Thistransmission
between
usesno gaskets
page
13-43).
{see
a Alwavscleanthe magnet@ wheneverthe transmissionhousingis disassembled.
a Inspectall the bearingsfor wear and operation.
*N
o
@
o
@
@
@
@
@
@
(3
(,
@
@
@
lt
(9
@
^
I
'
Ej
11-4fi
,\|j Uh
@
B
t
o
@
@
@
[@.--oa
F5i,--@
:7
13-8
vnx.su
,
Bolt Size
6x1.0mm
6x1.0mm
I x 1 . 0m m
8 x 1 . 2 5m m
8 x 1 . 2 5m m
8 x 1 . 0m m
c
D
E
F
i)
e
9
A
O
.d
t
!)
O
1 2 N . m( 1 . 2k g i m , 9 l b n f t )
15 N.m (1.5kgnm,11 lbf.ft)
15 N.m (1.5kgf.m,11 lbf.ft)
24 N.m (2.4kgf.m,17 lbf'ft)
27 N.m (2.8kgnm,20lbnft)
30 N.m (3.1kgf.m,22 lbf'ft)
@ WASHERBeplace.
@ TRANSMISSIONHOUSING
BALLBEARING
sroPPER R|NG
TAPERRING
NEEDLEEEARING
SPACER
SYNCHRORING
sYNcHRo SPR|NG
sYNcHRo SLEEVE
5TH/REVEFSE
SYNCHROHUB
5TH/REVERSE
6980 mm SHIM(*1)
79.5mm SHIM{*21
@ THRUSTSHIM{*2I
T. 2.0 mm (0.079in)
@ BEARINGOUTERRACE{*2}
@ SHIFTPIECESHAFT
@ INTERLOCK
@ SHIFTPIECE
@ SHIFTARM HOLDER
@ SELECTARM
@ SELECTRETURNSPRING
@ 10 mm SHIM
6D 10 mm WASHER
q0 LOCKCOLLAR
nlruc
[0 sYrucxao
ii i) 5TH GEAR
O 38 x 43 x 26 mm NEEDLEBEARING
t3 SPACEECOLLAR
O 4TH GEAR
.iB SYNCHROFING
.Ii9SYNCHROSPRING
{, 3RD/,ITHSYNCHROHUB
@ 3RD/4THSYNCHBOSLEEVE
t9 3RDGEAR
O MAINSHAFT
3 x 16 mm SPRINGPIN Replace.
o
x8 mm SPRINGWASHER
v0 CHANGEPIECE
@ SETSCREW
22 N.m {2.2kgf.m, 16 lbf.ft}
O wasHER
@) SPRINGWASHER
40 BALLBEARING
O 28 x 41 x ? mm OIL SEALReplace.
ad 35 x 56 x 8 mm OIL SEALReplace.
a0 14 x 20 mm OOWELPIN
@ OIL CHAMBERPLATE
'A BEVERSEIDLENGEARSHAFT
@ SPRINGL.25.6mm {1.01inl
0! STEELBALLD. 5/16 in
IDLERGEAF
.A REVERSE
CHANGEHOLDER
O REVERSE
SHIFTPIECE
3A sTH/REVERSE
O 1ST/2NDSHIFTFORK
04 3RD/.TH sHlFr FoRK
SHIFTFORK
@ 5TH/REVERSE
O9'OIL GUTTERPLATE
6' SNAPRING
@ 72 mm THRUSTSHIM
) OIL GUIOEPLATE
i!0 10 mm WASHERReplace.
.4i]REVERSE
IDLERGEARSHAFTBOLT
54 N.m {5.5kgt m, 40lblftl
) TRANSMISSIONHANGERB
(3 BREATHER
CAP
@ TRANSMISSIONHANGERA
63 BACK.UPLIGHTSWITCH
25 N.m (2.5ksf.m,18lbfftl
@r 14 mrn waSHER Replace.
67 16 mm SEALINGBOLT
29 N.m (3.0kgl.m, 22 lbf ft)
@ 32 mm SEALINGBOLT
25 N.m (2.5kgf.m.18lbt'ft|
@ 40 x 62 x 9 mm OILSEALReplace.
D STEELBALLD. 5/16 in
Gl SPRINGL. 30 mm {1.2in}
@ 12 mm WASHERReplace.
63)SETSCREW
22 N.m 12.2kgl.m, 16 lbt'ft,
@ OILORAINPLUG
39 N.m {4.0 kgt.m,29 lbf'ftl
9 WASHERReplace.
@ oIL FILLERPLUG
4,1N.m14.5kgJm, 33 lblftl
61 BEARINGOUTERRACEI*2I
@ THRUSTSHIMI*2)
@ MAGNET
@ CLUTCHHOUSING
@ 14 x 25 x 16 mm OILSEALReplace.
@ SHIFTROD
ASSEMBLY
al DIFFERENTIAL
Seesection15
t-2)
@ wasHER
T. 2.5mm (0.098in,
SHIFTRODBOOT
OIL GUIDPLATE
33 x 60 x 20 mm NEEDLEBEARING
BEARINGRETAINERPLATE
LOCKWASHERReplace.
COUNTERSHAFT
THRUSTSHIM
37 x 42 x 25 mm NEEDLEBEARING
lST GEAR
FRICTIONDAMPER
SYNCHRORING
SYNCHROSPRING
lST/2ND SYNCHROHUB
REVERSE
GEAR
DOUBLECONESYNCHRO
I*2I
BINGI*1)
SYNCHRO
FRICTIONDAMPER
SPACER
42 x 6? x 24 mm NEEDLEBEARING
2NDGEAR
3RDGEAR
4TH GEAS
5TH GEAR
NEEDLEBEARING
BALLBEARING
SPRINGWASHER
LOCKNUTReplace.
108- 0- 108N.m
( 1 1 . 0- 0 * 1 1 . 0k g tm ,
80- 0- 80lbf.ft)
005 x 22 mm SPRINGPIN Replace.
*1:81881engine
*2:B18Clengine
13-9
vnx.su
Transmission
Housing
Removal
NOTE:
. l f t h e t r a n s m i s s i o nh o u s i n go r c l u t c h h o u s i n ga . e
r e p l a c e d ,t h e b e a r i n g p r o l o a d m u s t b e a d j u s t e d
(818C1
engine).
. Placethe clutchhousingon two piecesof wood thick
enough to keep the mainshaftfrom the hitting the
workbench.
1.
Removethe back-uplight switch.
2.
Removethe transmissionhangerB,
3.
Removethe set screws,the springs,and the steel

balls.
5.
Loosenthe transmissionhousingattachingbolts in
a crisscrosspattern in severalsteps.then remove
them.
TRANSMISSION
Tna sMtsstoN
ATTACHINGBOLT
SPBING
L. 30 mm
11.2inl
Removethe 32 mm sealingbolt.
7.
SETSCBEW
Expandthe snap ring on ths countershaftball bearing and removeit from the groove using a pair of
snap ring pliers.
WASHER
Replace.
4.
Removthe reverseidlergear shaftbolt,
32 mm SEALINGBOLT
L
WASHER
Replace.
SNAPRING
REVERSE
13-10
vnx.su
ReverseChangeHolder,
ReverseldlerGear
ClearanceInspection
Separstethe transmissionhousingfrom the clutch
housing,and wipe it cleanof the sealant.
cnange
re
Measurethe clearancebetween the reverse
holder and the sth/revsrseshift piece p t n .
R e m o v et h e 7 2 m m t h r u s ts h i m a n d t h e o i l g u i d e
platefrom the transmissionhousing.
Standard:
BevorseSido: 0.05- O.ilsmm (0.002-. 0( . 0 1 8i n l
),1in)
5th Sido:
o.ia- 0.9 mm 10.02- 0.0,1
t2 mm
THRUST
SHIM
SHIFTPIECEPIN
REVERSE
CHANGE
,
mealf the clearanceare not within the standard,
sti
change
re
surethe width of the groovesin the reverse
holder.
HOUSING
TRANSMISSION
1 0 . Removethe 16 mm sealingbolt and the oil gutter
plate.
Standsrd:
(
in)
RovsreaSide: 7.05- 7.25 mm {0.278- 0.285
I inl
7.1-7.7 mm (0.29- 0.30
sth Sido:
REVERSC
SIOE
REVERSE
OIL GUTTERPLATE
'
'--
sTHSIDE
lf the width of the grooves are n o t w i t h i n t h e

Ingeholderwith
standard,replacethe reversechan
a new one.
the stanwi
lf the width of the groovesare within
rift piece with a
dard, replacethe sth/reverseshift
new one,
(cont'd)
1 3 - 11
vnx.su
ReverseChangeHolder,Reverseldler Gear
ClearanceInspectionlcont'd)
Removal
Measurethe clearancebetween the reverss idler

gear and the reversechange holder.
1.
Standard:
0.5 - 1.1 mm (0.02- 0.04 inl
SorvicoLimit: 1.8 mm (0.07inl
REVERSECHAMiE HOII'ER
REVERSE
CHA'{GEHOLDER
4.
Removothe reversechangeholder.
2.
Remove the revorss idler gar, th rev6rs6 idlsr

gearshaft,and the washor{B18Clengine}.
lf the clearanceis more than the service limit, measurethe width ofthe reversechangehold6r.
St.ndrrd: 13.0- 13.3mm (0.512- 0.52/tinl
REVERSE
IDI.TR
GEAFSHAFT
REVERSE
CHANGEHOTI'ER
lf the width is not within the standard,replace

the reversechangeholderwith a new one.
lf the width is within the standard,reolacothe
reversaidler gearwith a new one.
13-12
vnx.su
ClearanceInspection
Measurethe clearancebetween the shift piece and
the shift arm holder.
3.
Measurethe clearancebetween the select 8rm and

the interlock.
0.05- 0'25 (0.002- 0.010in)
Standlrd:
Scrvica Limit 0.5 mm (0.02in)
0.1 - 0.3 mm (0.004- 0.012inl

Silndrd:
Limit:
0.6 mm (0.02inl
Scwic.
SHIFT PIECE
INTERLOCK
SHIFT ARM HOI.I'ER
It the cloaranceis more than the service limit, measureth width of the groovein the shift piece.
4.
lf the clearanceis more than the servicelimit, measurethe width ot the interlock.
Stlndrrd: 9.9 - 10.0mm (0.391t- 0.39ain)
Stlndffd: 8.1 - 8.2 mm (0.319- 0.323inl
SHIFTPIECE
ll the width of the groove is not within the standard,replscethe shift piecswith a new one.
lf the width of the grooveis within the standard.
roolacethe shift arm holder with a new one.
lf the width is not within the standard.replace

the interlockwith a new one.
lf the width is within the standard,replacethe
selectarm with a new one.
(cont'd)
13-13
vnx.su
ClearanceInspection{cont'd}
7,
Measurethe clearancebetweenthe selectarm

t h e 1 0m m s h i m .
9. Measurethe clearancebetweenthe shift arm holder

and the changepiece.
Stsndard: 0.01- 0.2 mm (0.0004- 0.008inl
Standard:
0.05- 0.35 10.002- 0.01i1in)
SorvicoLimit: 0.8 mm (0.03in)
SETICTABM
SHIFTARM HOLDER
10 mm SHIM
8.
lf the clearanceis not within the standard.select

and installthe appropriate10 mm shim for the correctclearancefrom the chan below.
1 0 . ll the clearanceis more than the servicelimit. measurethe grooveof the changepiece.
Standafd: 12.05- 12.15mm {0.47ilil- 0.iU83 in)
10 mm Shim
Part Numbsr
24435-689-000
B
24436-689-000
Thicknss
0.8 mm (0.03'lin)
'1.0mm (0.039
in)
24437-689-000
1 . 2m m ( 0 . 0 4 7i n l
24438-689-000
1 . 4m m { 0 . 0 5 5i n )
24439-689-000
1.6mm (0.063in)
lf the groove is not within the standard,replace

the changepiecewith a new one.
lf the groove is within the standard,replacethe
shift arm holderwith a new one.
13-14
vnx.su
Removal
Removs the shift piece shaft, then remove the shift
piecaand the interlock.
1 1 . Moasureth clsarancebetweenthe s6l6ctarm 8nd
thochangepiece.
0.05- 0.35mm (0'002- 0'014in)
Sundrrd:
S.rvic. Limit 0.5mm 10.02Inl
SHAFT
SHIFTPIECE
SEI.ECTARl,l
2.
Removethe changeholderassembly.
1 2 . lf the clesranceis more than the servicelimit, measurethe width ofthe changePiece.
- o.'U&l in)
Strndrrd: 12.05- 12.15mm {0./17,11
CHANGEHOLDERASSEMBLY
PIECE
CHANGE
lf ths width is not within the standard,replace

the changepiecwith a nw one.
lf the width is within the standard,replacoth
selectarm with a new one.
13-15
vnx.su
I
eriorto reassembling.
cleanall the partsin solvent,dry them and apply lubricantto any contactsurfaces.
10 mm SHIM
SELECTRETURNSPRING
3 mm PIN
13-16
vnx.su
Shift Fork
Mainshaft,Gountershaft,
- Removal
1.
Removethe mainshaftand the countershaftassemblieswith the shift forksfrom the clutchhousing.

NOTE:Tape the mainshaftspline belore removing
assemblies.
the mainshaftand the countershaft
4.
Removethe chamberplate.
CLUTCHHOUSING
Removethe springwasherand the washer.
CHAMBCRPLATE
Removethe differentialassemblyfrom the clutch

housing.
OIFFERENTIAL
CLUTCHHOUSING
13-17
vnx.su
Shift Rod
Removal
1.
Removethe shift rod boots.
2.
Romovethe change piece sttaching bolt and the

springwasher.
3.
Removethe set screw,then removethe spring and

the steolball.
4.
R e m o v t h o s h i t t r o d , t h e n r e m o v e t h e c h s n g e
piece.
5.
Removeth oilseal.
SETSCBEW
OIL SEAL
Roploc.
CHANGEPIECE
*q
SPRING
L 25.6
ll.0r in,
STEELAALL
(D.5/16
SPRINGWASHER
ACHINGBOLT
13-18
vnx.su
Shift ForkAssembly
I
erior,o ,"""sembling,cleanall the partsin solvent,dry them and apply lubricantto any contactparts
mm PIN PUNCH
5TH/REVEFSE
SHIFTFORK
3RD/{TH SHIFTFORK
13-19
vnx.su
Shift Fork Assembly

ClearanceInspection
NOTE:The synchroslvand the synchrohub should
be replacdas a set,
Measurethe clearancebetweenthe shift Dieceand

the shift fork shafts.
1.
Strndard:
0.2 - 0.5 mm {0.qt8 - 0.02 in]
S.rvico Limit: 0.8 mm (0.03inl
Measureth clearancebetweeneach shift fork and

its matching synchro sleeve.
Strndud:
0.35- 0.65 mm (0.014- 0.026in)
SrvicoLimit 1.0 mm (0.0'l in)
IFT FORK
SYNCHROSLEEVE
SHIFTPIECE
SHIFTFORK
lf the clearanceis more than the servicelimit. measure the thicknessof the shift fork finoers.
lf the clearanceis more than the servicelimit, measurethe width of the shift piece.
Standard:7.4 - 7.6 mm (0.291- 0.299inl
Stsndard: 11.9- 12.0mm (0.469- 0.472in)
lf the thicknessof the shift fork fingers is not

within the standard, replacethe shift fork with a
now one.
lf the thickness of the shift lork fingers is within
the standard, replace the synchro sleeve with a
new one.
1 3 -2 0
vnx.su
lf the width of the shift piece is not within the

standard,rsplacethe shift piecewith a new one.
lf the width of the shift pieceis within the standard,replacethe shiftfork with a new one.
MainshaftAssembly
NOTE:The 3rd/4thand the 5th svnchrohubsare installedwith a press.
cleanall the partsin solvent,dry them and apply lubricantto any contactsurfaces,The
Priorto reassembling.
3rdl,lthand the sth synch.ohubs,however,shouldbe installedwith a pressbeforelubricatingthem.
SYNCHROBING
page'13_35
Inspection,
818Cl cngino:
Inirllstion dstailr, pag. 13-27
STOPPER
RING
TAPERRING
NEEDLEBEARING
lnspectfor wear
and operation.
3RD/'TH SYNCHROSLEEVE
3RD/'TH SYiICHROHUB
SPACER
Insp6clron,
page13-35
SPRING
SPRING
3RDGEAR
Inspectaon.
page 13-22
NCEDE AEARING
Inspocltor wear
and operalton.
SYNCHROHUB
SYNCHROSI..EEVE
SYNCHRO
SPRING
Inspectaon.
pag6 13-35
5TH GEAR
rnspec!on,
page13-24
SPACER
COLLAR
4TH GCAR
Inspection,
page13-23
13-21
vnx.su
MainshaftAssembly
ClearanceInspection
NOTE: lf replacementis required.always replacethe
synchrosleeveand the synchrohub as a set.
1.
Measurethe clearancebetween2nd and 3rd gears.
2.
lf the clearanceis more than the servicelimit, measurethe thicknessof 3rd gear.
EngineType
Standard
Standard:
0.06- 0.21 mm {0.002- 0.008inl
Ssrvica Limit: 0.3 mm (0.01in)
ServiceLimit
818C1
34.92- 34.97mm
- 1 . 3 7 7i n )
(1.375
81881
34.42- 34.47mm
- 1 . 3 5 7i n )
(1.355
34.8 mm
( 1 . 3 7 0i n )
34.3mm
(1.350
in)
3RD GEAR
lf the thicknessof 3rd gear is lessthan the service limit, replace3rd gearwith a new one.
lf the thicknessof 3rd gear is within the service
limit, replacethe 3rd/4thsynchrohub with a new
one.
13-22
vnx.su
,
Measurethe clsarancebetwen,lth gear and the
soacercollar.
5.
0.06- 0.21 mm (0.002- 0.(xt8in)

St.ndffd:
Scwicr Limh: 0.3 mm (0.01in)
lf distanceO is not within the standard,replacethe

spacercollarwith a nw one. lf distance@ is within
th standard,measurethe thicknessof 4th gear.
EngineType
Standard
ServiceLimit
1.
818C1
3 1 . 4 2- 3 1 . 4 7m m
- 1.239
(1.237
in)
81881
30.92- 30.97mm
'1.2'19
inl
\1.211-
3 1 . 3m m
l'1.232inl
30.8mm
( 1 . 2 1i3n )
lf the clearanc8is more than the servicelimit, measuredistance@ on the spacercollar

Stlnd.rd: 26.03- 26.m mm 11.025- 1.027in)
lf the thicknessof 4th gear is less than the service limit, replace4th gearwith a new one.
lf the thicknessof 4th gear is within the service
limit, replacothe 3rdl4thsynchrohub with a new
one.
SPACERGOLLAR
(cont'd)
13-23
vnx.su
MainshaftAssembly
GlearanceInspection(cont'd)
M e a s u r et h e c l e a r a n c eb e t w e e n5 t h g e a r a n d t h e
spacerco ar.
8.
Standard: 0.06- 0.21mm (0.002- 0.008in)

Servicelimit: 0.3 mm 10.012
inl
lf distance@ is not within the standard,reDlacethe

sDacercollarwith a new one.
lf distance@ is within the standard,measurethe
thicknessof sth gear.
Standard: 31.12-31.47mm (1.237- 1.239in)
ServiceLimit:31.3mm (1.232inl
sTH GEAR
sTH GEAR
lf the clearance is more than the service limit, mea

s u r e d i s t a n c e B o n t h e s p a c e rc o l l a r .
Standard: 26.03 - 26.08 mm (1.025- 1.027 in)
SPACERCOLLAR
13-24
vnx.su
lf the thicknessof sth gear is lessthan the service limit,replacesth gearwith a new one.
lf the thicknessof 5th gear is within the service
l i m i t , r e p l a c et h e 5 t h s y n c h r oh u b w i t h a n e w
one,
- Disassembly
R e m o v et h e b a l l b e a r i n gu s i n ga b e a r i n gp u l l e ra s
3.
S u p p o r t3 r d g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
mainshaftout of the 3rd/4thsynchrohub, as shown.
BEARING
PULLER
BALLBARING
CAUTION: Removethe synchro hubs using a press

and the steel blocks .s shown. Use of a jaw-type
puller can cau3edamags to the gear teeth.
S u p p o r t5 t h g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
mainshaftout of the 5th synchrohub,as shown.
13-25
vnx.su
MainshaftAssembly
Inspection
1 . Inspectthe gear surfacesand the bearingsurfacss
for wear and damage,then measurethe mainshaft
at pointsA, B. and C.
2.
Standord:
- 1.102'linl
A: 27.987- 28.000mm 11.1018
B: 37.98/r- 38.q)0 mm {1.il95il- l.il960 in}
Ct 27.977- 27.99Omm {1.1015- 1.1020in}
Inspectfor runout.
Stlnd.rd:
0.02 mm (0.(xxl8inl M!I.
S.rvic. Limit 0.05 mm (o.qP inl
N O T E : S u D p o r tt h e m a i n s h f ta t b o t h e n d s a s
shown.
SrvicoLimit;
A: 27.9{, mm (1.1(XXlin}
B:37.930mm 11.4933
inl
C: 27.930mm {1.0996in}
Inspectoil passagestor clogging.
l f t h e r u n o u t i s m o r 6 t h a n t h s s e r v i c el i m i t ,
rsplacethe mainshaftwith a n6w one.
lf any parts of the mainshaftare less thsn the

servicelimit. .eolacemainshaftwith a new one.
13-26
vnx.su
ReassemblV
1_
CAUTION:
o Pless the 3rd/ilth and the 5th synchro hubs on the
msinshafi without lubrication.
. When installing the 3rd/4th and the sth synchro
hubs, support the mainshaft on the steel blocks, and
install synchro hubs using a press,
. Install the 3rd/,lth and the sth synchro hubs with a
maximum pressureof 19.6kN (2.000kgf, 1+466lbt).
^JOTEiReferto page 13-21for reassemblysequence.
Support 2nd gear on steel blocks,then install the
3rd/4thsynchro hub using the specialtools and a
press,as shown.
2,
Installthe sth synchro hub using the specialtools

ano a pressas snown.
OBIVER,,O mm LD.
0t7it6 - 003010O
ATTACHMENT,
35 mm l.D.
PRESS
sTH SYNCHROHUB
077t6- 00304{x)
NOTE:After installing,checkthe operationof the

3rd/4thsynchrosleeveand hub.
B18Blsngine:
ATTACHMENT,
35 mm LD.
07746- 0o30/rc0
DRIVER.40 mm l.D.
07746- 0030100
3RD/4TH
SYNCHROHUB
Installthe ball bearingusingthe specialtools and a

prsssas shown.
NOTE:Installthe ball bearingwith the taperedend
facingdown.
2NO GEAR
8l8Cl engine: Assemble the 3rd/4th synchro hub and

sreevetogether before installing them on the mainshaft.
PRESS
3RO/4TH
SYNCHROHU8
: osed end
DRIVER4o mm l.D.
07746- tD30100
3RD/TTH
SYNCHRO
SLEEVE
2NDGEAR
13-27
vnx.su
CountershaftAssembly
lndex
NOTE:The 4th and 5th gears are installedwith a press.
Priorto reassembling.
cleanall the pans in solvent,dry them and apply lubricantto any contactsurfaces.The 4th
and sth gears.however,shouldbe installedwith a pressbeforelubricatingthem.
SYNCHROSPBING
LOCKNUTReDlace.
l(E*0*10EN.m
/r1.0- 0 - 11.0kgtm,I
l8o- o-80rbf.ft
I
WASHER
BALLBEARING
Inspectfor wear
and operat|on,
NEEDLEBEARING
InspectIor wear
and operation.
SYNCHRORING
sTH GEAR
4TH GEAR
3RDGEAR
2ND GEAR
THRUST
BEARING
NEEDLEBEARING
Inspectfor wear
and operation.
SPACER
page13-29
Selection.
FRICTIONDAMPER
DOUB1I @NE
SYNCHROl818Cl .ngin.l
SYNCHRORINGlBl8Bl .ngin )
13-24
vnx.su
Inspection
Glearance
'L
Measurethe clearancebetweenthe thrust shim and

1stgear,
3.
Measurethe clearancebetween2nd and 3rd g68rs.

Stlndlrd:
0.05- 0.12 mm (0.002- o.(x}5inl
Scrvice Limlt 0.18 mm (0.007inl
0.0,1- 0.12 mm (0.fi12- 0.005inl

StEndard:
Servics Limit: 0.18 mm (0.007in)
'HRUST SHIM
2.
lf the cleatanceis more than the servicelimit,select

and installthe appropriatethrust shim to. the correctclearancefrom the chan below.
23922-PKs-900
1.95mm (0.0768in)
1.96mm (0.0772in)
Part Numb"r
2 3 9 1 7 - P 2 1- 0 1 0
23918-P2r-010
Thicknces
23924-PKs-900
1.97mm (0.0776in)
1.98mm (0.0780in)
23925-PKs-900
1.99mm {0.0783in)
2 3 9 2 6 - P K s - 9 0 0 2.00mm (0.0787inl
23923-PK5-900
23927-PKs-900
H
23928-PKs-900
lf the closranceis more than the service limit, selsct

and install the appropriatespacer for the corrct
clearancefrom the chartbelow.
Spaccl
Thrust Shim
Part Numbar
23921- PKs- 900
4.
Thickncla
29.02- 29.0,{mm
( 1 . 1 4 2-5 1 . 1 4 3i3n )
29.07- 29.09mm
( 1 . 1 4 4-5 1 . 1 4 5 i3n )
2.01mm (0.0791in)
2.02mm (0.0795in)
2 3 9 2 9 - P K s - 9 0 0 2.03mm (0.0799in)
K
2 3 9 3 0 - P K s - 9 0 0 2.04mm {0.0803in)
2.05mm (0.0807inl
23931- PKs- 900
23932-PK5-900
23933-PKs-900
23934-PKs-900
23935-PKs-900
2 3 9 3 6 - P K s - 9 0 0 2.10mm (0.0827in)
2.06mm (0.0811in)
2.07mm (0.0815in)
2.08mm (0.0819in)
2.09mm (0.0823inl
13-29
vnx.su
Disassembly
't.
2.
S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.
4,
Removethe bearing outer .ace, then remove the

needlebearingusinga bearingpulleras shown.
Raisethe locknuttab from the groove in the countershaft,then remove the locknut and the spring
washer.
BEARINGPULLER
BEARING
CAUTION: Romovethe gclrs using a pross and tho

steol blocks rs shown. U3a of a l.w.typo pullor can
cau36damaggto tho gsar iocth.
Removethe ball bearingusing a bearingpuller as
shown.
Support 4th gear on steel blocks. and press the

countershaft
out of sth and 4th gears,as shown.
PULlTR
13-30
\
vnx.su
Inspection
1.
Inspectthe gear surfacesand the bearingsurfaces

for war and damage,then measurethe countershaft at points A, B, and C.
St.ndard:
- 1.1021inl
A: 2/t.980- 27.9!13mm (0.91|:15
B: 36.984- 37.q)Omm {1.4551- 1.'156?in}
C: 33.qD - 33.015mm (1.2992- 1.2998inl
SorvicaLimit:
A: 2,a.930mm (0.9815in)
B: 35.930mm (1.a539inl
C: 32.950mm 11.2972inl
Inspgcttor runout.
0.02 mm {0.(xn8 inl Max.
Stlndrrd:
Srrvic. Limit 0.05 mm {0.(x)2in)
NOTE: Suppon the countershaftat both ends as
snown.
Rotate tl/vo compl6t

rcvolutions.
Inspecttor wear
6nd damage.
lor clogging.
Inspectoil passage
.
l f t h e r u n o u t i s m o r e t h a n t h e s e r v i c 6l i m i t ,
rgDlacethe countershaftwith a new one.
lf any parts of the countershaftare less than the

service limit, replacecountrshaftwith a new
one.
13-31
vnx.su
Reassembly
GAUTION:
. Pr93r 4th and 5th goar3 on the qountorshrft without
lubricrtion.
. Whon in3talling 4th and sth goa6, srpport the shaft
on st..l block3,8nd in3tall thc 9.116 uring a prors.
. Inst.ll 4th lnd 5th gcar with a maximum pro33urof
25.5 kN (2,6@ksr. 18,806lbo.
4.
Installthe reversegear.
I n s t a l lt h e s y n c h r os p r i n g , a n d t h e d o u b l e c o n e
s y n c h r o( 8 1 8 C ' le n g i n e ) ,o r s y n c h r or i n g ( 8 1 8 8 1
engine), as shown.
NOTE:Referto page 13-28for reassemblysequence.

Installthe thrust shim and the needlebearinoson
the countershaft.
SYNCHRO
SPRING
NEEDLEBEARING
REVERSE
GEAfi
THRUSTSHIM
COUNTERSHAFT
Assemblethe friction damper,the needlebearing,

and 2nd gear,then installthem by aligningthe fingers on the frictiondamper and the groovesin the
1sv2ndsynchrohub with the fingers of the double
c o n e s y n c h r o a n d t h e g r o o v e so n 2 n d g e a r , a s
shown.
Installthefrictiondamper.the synchroring,and the

synchrospringon lst gear,
Installthe lsv2nd synchrohub by aligningthe fingers on the friction damperand the groovesin the
'lsV2ndsynchrohub, as
shown.
Installthe spacer.
2ND GEAR
1ST/2ND
NEEDLEBEARING
SPACER
FRICTIONDAMPER
8.
lST GEAR
13-32
vnx.su
Install the parts assembledin steps 2 - 6 on the

countershaft.
9 . S u p p o r t t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d
install4th gear usingthe specialtools and a press,
as snown.
1 1 .Installthe needlebearing.then installthe ball bearing usingthe specialtoolsand a pressas shown.
PRESS
DRIVER.,l0
mm l.D.
07746- 0030100
DRIVER,40 mm l.O.
077{6 - 0030100
PRESS
ATTACHMENT,30 mm l.D.
07746 - d)30300
BALLBEARING
NEEDLEBEARING
1 0 . S u D D o r t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d
install5th gear using the specialtools and a press,
as shown.
12. S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.
1 3 . Installthe spring washer.tighten the locknut,then
stakethe locknuttab into the groove.
LOCKNUT
1 0 8 * 0 * 1 0 8N . m ( 1 1 . 0- 0 - 1 1 . 0k g f . m ,
80+0*80lbf.ftl
DRIVER,40 mm l.O.
07746- 0030100
LOCKNUT
30 mm l.O.
ATTACHMENT,
0?7a6- (X)303(x)
wooo BLocKs
13-33
vnx.su
SynchroSleeve,SynchroHub
Installation
Inspection
'1. Inspectgear teeth on all synchrohubs and synchro
sleevesfor rounded off corners,which indicates
wear.
2.
I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o
sleeveand checkfor Jrgedomof movement.
NOTE: lf replacementis required,always replace
the synchrosleeveand synchrohub as a set.
When assemblingthe synchrosleeveand synchrohub,

be sure to match the thre sets of longer testh (120
degreesapart) on the synchro sleevewith the three sots
of deepergroovesin th synchrohub.
CAUTION: Do not install thc synchro 3l.6yc with itt
longor tosth in tha 13t/2nd synchro hub 3lob, b.c!u3a
it will d.mago tho spring ring.
TEETH
LONGER
sYt{cHRo
HUBSLOT
SYNCHRO
HUB
SLEEVE
13-34
vnx.su
SynchroRing,Gear
r Inspection
1.
SYNCHROSPBING
Inspectthe synchroring and gear.

A: lnspectthe insideof the synchroring for wear.
B: Inspectthe synchro sleeveteeth and matching
teethon the synchroring for wear (roundedoff).
SYNCHRORING
CC
GOODWORN
C: Inspectthe synchro sleeveteeth and matching
teethon the gearfor wear (roundedoffl.
oo
GOODWORN
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe conesurfacefor wear and roughness.
F: Inspectthe teeth on all gears for uneven wear.
scoring,galling,and cracks.
Coatthe cone surfaceof the gearwith oil, and place
the synchroring on the matchinggear, Rotatethe
ring, makingsurethat it does not slip.
Measurethe clearancebetween the synchro ring
a n dg e a ra l l t h ew a y a r o u n d .
NOTE:Holdthe synchroring againstthe gear evenly while measuringthe clearance.
Synchro Ring-to-GgarClgarance
Standard: 0.85- 1.10mm
(0.033- 0.0/B in)
Limit:0.i1
mm 10.02inl
Service
Double Cone Synchro-to-GearCloaiance
Standald:
@: {Outer Synchro Ring to Synchro Cone)
0.5- 1.0mm 10.02- 0.0i1in)
@: lSynchroConeto Goar)
0.5- 1.0mm (0.02- 0.04in)
O: loutsr Synchro Ring to Gsarl
0.95- 1.68mm (0.037- 0.066inl
ServiceLimit:
6): 0.3 mm 10.01inl
@: 0.3 mm t0.01inl
G):0.6 mm (0.02in)
SYNCHROCONE
SYNCHRORING
lf the clearanceis lessthan the servicelimit, replace

the synchroring and synchrocone.
13-35
vnx.su
ClutchHousingBearing
Replacement
Mainrhaft:
1.
3.
Drivethe new oil seal into the clutch housingusing

the specialtoolsas shown.
Removethe ball bearingusing the specialtools as

shown.
3/8' - 16SI.IDEHAMMCR
(commercially
av6ilable)
CTUTCH
ATTACHMEIVT,
a2 x 4t rnm
0r7a5- 0010300
()|L SEAI
Roplacs.
ADJUSTABIT
AEARING
PULER,25- a0mrn
07736- A01moA
2.
Drive the ball bearing into the clutch housing usin!

the sDecialtools as shown.
Removethe oil sealfrom the clutchhousing.
CLUTCHHOUSING
BATI.BEAMIO
13-36
vnx.su
3.
Countcr'h!ft:
'1. Bsnd the tab on the lock washer down, then remove
the bolt 8nd bearingretainerplate.
Positionthe oil guide plate and new needlebearing

in the bore of the clutch housing,then drive in the
needlebearingusingthe specialtoolsas shown.
NOTE:Positionthe needlebearingwith the oil hole
facingup.
OIL GUIDCPLATE
CI-UTCH
HOUSING
CLUTCHHOUSING
Remove th needle bearing using the specisl lools

as shown,then removethe oil guide pl8te.
3rE' - 16SUI'HAiiMER
availabls)
{commorcially
Installthe bearingretainerplateand new lockwasher, then bendthe tab againstthebolt head.
8 x 1 0m m
15N.mll.5 kd.m, 11lbf.ttl
LOCK
WASHEA
Repl6ce.
AD.'USTABIIBEARIITG
PULIIR, 25- ao mm
07t36- A0rm0a
13-37
vnx.su
MainshaftThrustGlearance
Adjustment
1.
Removethe 72 mm thrust shim and oil guide plate

from the transmissionhousing.
Measure distance @ betlveenthe end of the clutch

housingand bearinginnerrace.
NOTE:
. Usea straightedgeand depthgauge.
a Measureat three locationsand averagethe readIngs.
72 mm THRUST
SHIM
TRANSMISSION
HOUSING
5.
OIL GUIDEPLATE
\.u
END of CLUTCHHOUSING
B
o
fr
INNEBRACEot BALLBEARltac
lnstall the 3rd/4th synchro hub, spacer collar, sth

synchrohub, spacer,and ball bearingon the mainshaft.then installthe above assemblyin the transmissionhousing.
Selectthe prcpet 72 mm thrust shim from the chart

by usingthe formulabelow.
Installthewasheron the mainshaft.
NOTE:Useonly one 72 mm thrustshim.
Measuredistance@ betweenthe end of the transmissionhousingand washer.
Shim Sslsction Formula:
NOTE:
. Usea straightedgeand verniefcaliper.
. Measureat three locationsand averaoethe readIng.
ENDol
TRANSMISSION
HOUSING
MAINSHAFT
WASHER
you made in steps4 and 5:

Fromthe measurements
-1. Add distance@ (step5lto distance@ (step4).
-2. From this number.subtract0.93 (which is the
midpointof the flex rangeof the clutchhousing
bearingspringwasherl.
-3. Takethis number and compareit to the avaif
ableshim sizesin the chart.
(Forexample)
B:2.39
+ C: O.22
2.61
- 0.93
1.68
. Try the 1.68mm (0.0661in) shim.
AALLAEARING
13-38
vnx.su
7.
72 mm Thrust Shim
Part Number
23931- P21-000
2 3 9 3 2 - P 2- 0
100
c
D
23933- P21-000
-000
23934-P21
- P21-000
23935
F
-000
23936-P21
2 3 9 3 7 - P 2- 0
100
2 3 9 3 8 - P 2- 0
100
-000
23939-P21
J
23940-P2r-000
23941- P21-000
23912-P21-OOO
-000
23943-P21
2 3 9 4 4 - P 2 -10 0 0
23915- P21-000
23946- P21,000
L
M
N
o
P
23947-P21 -000
23948- P21 000
-000
23919-P21
-000
23950-P21
23951- P21-000
23952- P21 000
2 3 9 5 3 - P 2- 0
100
23954-P2r-000
-000
23955-P21
2 3 9 s 6 - P 2, 0
100
AB
2 3 9 5 7 - P 2 -10 0 0
23958- P21-000
23959- P21-000
AC
AD
AE
AH
AI
AK
AN
AO
- P21-000
23960
23961-P21 -000
23962 P21,000
-000
23963-P21
23964- P2'1-000
23965- P2'1-000
-000
23966-P21
-000
23967-P21
23968- P21-000
23969- P21 000
-000
23970-P21
23971 P21 000
Thickness
0.60mm (0.0236in)
0.63mm (0.0248in)
0.66mm {0.0260in}
0.69mm (0.0272in)
0.72mm (0.0283in)
0.75mm (0.0295in)
0.78mm (0.0307in)
in)
0.81mm (0.0319
in)
0.84mm (0.0331
0.87mm (0.0343
in)
in)
0.90mm (0.0354
in)
0.93mm (0.0366
0.96mm (0.0378
in)
0.99 mm (0.0390in)
in)
1.02mm (0.0402
in)
1.05mm (0.04'13
1.08mm (0.0425
in)
in}
1.11mm {0.0437
1.14mm (0.0449inl
1.17mm (0.0461in)
1.20mm {0.0472in)
1.23mm {0.0484in)
1.26mm (0.0496in)
1.29mm 10.0508
in)
in)
1.32mm 10.0520
in)
1.35mm (0.0531
1.38mm (0.0543
inl
1.41mm (0.0555
in)
1.44mm (0.0567
in)
1.47mm (0.0579
in)
1.50mm {0.0591in)
1.53mm {0.0602in)
1.56mm {0.0614in}
1.59mm (0.0626in)
1.62mm (0.0638in)
1.65mm (0.0650in)
1.68mm {0.0661in)
1.71mm 10.0673
in)
in)
1.74mm (0.0685
'1.77mm (0.0697
in)
1.80mm (0.0709
in)
Checkthe thrust clearancein the mannerdescribed

below.
NOTE:Carryout the measurementat normal room
remperarure.
-1. Install the thrust shim selectedand oil guide
platein th transmissionhousing.
?2 mm THRUST
otL
PLATE
TRANSMISSION
HOUSING
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 springwasher,washerand thrust shim
throughlybeforeinstaliation.
. I n s t a l lt h e s p r i n g w a s h e r .w a s h e r a n d t h r u s t
shim properly.
a-=s-.r*os".^
.,,-B*ÎNGWASHER
Installthemainshaftin the clutchhousing.
- 4 . Placethe transmissionhousingover the main-
shaftand onto the clutchhousing.

Tighten the clutch and transmissionhousings
with severalSmm bolts.
NOTE:lt is not necessaryto use sealingagent
betweenthe housings.
8 x 1.25mm
27 N.m {2.8 kgf.m, 20 lbf.ft}
Tap the mainshaftwith a plastichammer,
(cont'd)
13-39
vnx.su
MainshaftThrustClearance
Adjustment (cont'd)
-7. Slidethe mainshaftbaseover the mainshaft.
- 11.Zeroa dial gaugeon the end of the mainshaft.
MAINSHAFT
12.Turnthe mainshaftholderbolt clockwise;stop turning when the dial gauge has reachedits maximum
m o v e m e n t .T h e r e a d i n go n t h e d i a l g a u g e i s t h e
amountof mainshaftend play.
CAUTION: Turning the mainshaft holder bolt mor
than 60 degrees after the needle ol the dial gauge
stops movingmay damagethe transmission,
DIALGAUGE
- ) , .
"7t/'-
'..' .'i'
i. ,
MAINSHAFTBASE
07GAJ- PG20130
-8. Attachthe mainshaftholderto the mainshaftas fol-
NOTE:
. Back-outthe mainshaftholder bolt and loosen
the two hex bolts.
. F i t t h e h o l d e r o v e r t h e m a i n s h a f ts o i t s l i p i s
towardsthe transmission.
. A l i g n t h e m a i n s h a f th o l d e r ' sl i p a r o u n dt h e
g r o o v ea t t h e i n s i d eo t t h e m a i n s h a f ts p l i n e s ,
then tightenthe hex bolts.
- 13.lf the reading is within the standard, the clearance is

correq.
lf the reading is not within the standard, recheckthe
shim thickness.
Standard: 0.11 - 0.18 mm {0.004- 0.007 in)
MAINSHAFT
HOLOER
BOLT
f- t{-c
l\-_.r'
nrTh
|
MAINSHAFTHOLDER
07GAJ- PG201r0
l\nex
\ ._/_/lrl Borrs
L ___E_J
\
MAINSHAFT
HOLDER
07GAJ- PG20110
MAINSHAFTBASE
07cAJ _ PG20130
- 9 . S e a t t h e m a i n s h a f tf u l l y b y t a p p i n g i t s e n d w i t h a
plastic hammer.
- 1 0 . T h r e a dt h e m a i n s h a f th o l d e r b o l t i n u n t i l i t j u s t c o n tacts the wide surface of the mainshaft base.
1 3 -4 0
vnx.su
Transmission
ReassemblV
;
8. Installthe differentialassembly.
1 . l n s t a l l t h en e w o i l s e a l .
DIFFERENTIAL
ASSEMBLY
2.
Setthe changePiece.
3.
lnstallthe shift rod.
Installthesteelball,the spring,and the set screw.
5.
lnstallthe changepieceattachingbolt.
6.
Installthe shift rod boots.
8x1.0mm
30 N.m 13.1kg{ m.
22 tbl.ltl
SETSCREW
1 2x ' 1 . 0m m
22N.m{2.2kg{.m,16lbl.ft}
SPRING
L. 25.6mm
9 . Set the spring washer and the washer.

1 0 . Install the mainshaft, the countershaft, and the shift
fork assemblies.
SHIFTROD
N O T E :A l i g n t h e f i n g e r o t t h e i n t e r l o c kw i t h t h e
groovein the shiftfork shaft.
MAINSHAFT
I n s t a l l t h eo i l c h a m b e r P i a t e .
6x1.0mm
12 N.m (1.2kgt'm,9lbtft)
COUNTERSHAFT
SHIFTFORKS
(cont'd)
13-41
vnx.su
Transmission
(cont'd)
Reassembly
11. Install the change holder assembly.
13. Measurethe distance@ after mounting the shift

pieceshaft.lf it's incorrect,checkthe installation.
6x1.0mm
15 N.m (1.5 kgf.m,
11 tbf.ftl
DistanceO: 11.9- 12.3mm 10.47- 0.48in)
CHANGE
HOLDER
ASSEMBLY
12. Installthe shift piece and the interlock,then install

the shift pieceshaft.
1 4 . lnstallthe washer (B18C1engine),the reverseidlo.
gear.and the reverseidler gearshaft.
REVERSE
IDLERGEAR
13-42
vnx.su
Installtheoil gutterplate.
15. Installthereversechangeholder.
'18. Bendthe hook of the oil gutterplate,then installthe

16 mm sealingbolt.
6x1.0mm
15 N.m (1.5kgt'm,11lbfftl
NOTE:Apply liquidgasket{P/N08718- 0001)to the

threads,
BOLT
16mm SEAI-ING
29 N.m t3.0kgf m, 22 lbl'ftt
Installtheoil guide plateand the 72 mm thrustshim

into the transmissionhousing.
1 9 . Apply liquid gasketto the surfaceot the transmission housingas shown.
72 mm THRUSTSHIM
NOTE:
a Use liquidgasket(P/N08718- 0001)
Removethe dirt and oil from the sealingsurface'

of the bolt holesto
a Sealthe entirecircumference
preventoil leakage.
lf 20 minutes have passedafter applying liquid
gasket,reapply it and assemblethe housings,
a n d a l l o w i t t o c u r e a t l e a s t 3 0 m i n u t e sa f t e r
assemblybeforefillingthe transmissionwith oil.
Liquid g.!k.t
(cont'd)
13-43
vnx.su
Transmission
(cont'd)
Reassembly
20. Installthedowel oins.
23, Check that the snap ring is securely seated in the

groova of th countershaftbearing.
2 1 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n gb y a l i g n i n gt h e
groove in the housing with finger on the stopper
.ing.
Dimcntion O as inst.lbd: il.6 - 8.3 mm

(0.181- 0.327inl
GROOVE
22. Lower the transmissionhousingwith the snap ring

pliers and set the snap ring in the groove of tha
countershaftbearing.
Installth6 transmissionhangrA and back-uplight

switch clamp,thon tighten th6 transmissionhousi n g a t t a c h i n gb o l t s i n t h e n u m b e r d s e q u o n c o
shown below.
6 | i.25 mrn
2t .m l2.8 lgf.m, 20 lbf.ftl
TNANSMISSION
HOUSING
13-44
vnx.su
{
27. I n s t a l l t h e s t e s l b a l l s , t h e s p . i n g s , a n d t h e s e t
24. Installth32 mm seslingbolt.
screws.
NOTE:Apply liquidgasket(P/N08718- 0001)to the
threads.
28. lnstallthe back-uplight switchand the transmission

hangerB.
32 mm SEALING BOLT
25 N.m {2.5 kgl'm,
SWITCH
LTGHT
BAC|(-UP
2s N.m{2.5kg{.m,18lbtft)
,*"""."'"
HAiIGER B
SPRIMi
L. 30 mm
{1,2in}
8 x 1.25mm
24 N.m(2.4kgfm,
17lbtftl
/
I
l /
12x 1.0mm
22 N.m(2.2kgi.m.
10tbtft)
26. Tightn ths teverse idler gear shaft bolt.
REVERSEIDI.^CR
SHAFT IOLT
l0 r 1.25rnm
5a t$m 15.5kg{.m.(} lbtftl
13-45
vnx.su
lnstallation
1.
Instllthedowel pins on the clutchhousing.
2.
Apply greaseto the partsas shown,then installthe

releasefork and releasebeaaing.
6,
N O T E :T o r q u et h e m o u n t i n gb o l t a n d n u t s i n t h e
sequenceshown.
NOTE:Use only SuperHigh Temp Urea Grease

(P/N08798- 9002).
3.
Raisethe transmission,
then installthe transmission
mounI.
CAUTION: Checkthat the bushings are not twistod

or offset,
Installthe releasefork boot.
BELEASEFORKBOLT
29 N.m (3.0kgl.m,
22 tbt-ttl
O 12 x 1.25mm
54 N.m {6.5kgt m,
47 tbtfrl
tPlN 08798- 90021

RELEASE
BEARING
@
I
RELEASE REEASE
FORK
FORK
BOOT
@ 12 x 1.25mm
7,1N.m 17.5kg{.m,
5/r lbtftl
{P/N 08798- 90021
7.
P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o ni a c k ,
and raiseit to the enginelevel.
Installthe three uppertransmissionmountingbolts

and lower startermotor mountingbolt.
Installthe transmissionmountingbolts and the rear

mount bracketbolts
sELF-LocKrNG
BoLT
12x 1.25mm
6it N.m 16.5kgl.m, 47 lbf.ftl
Replace.
1 4 x 1 . 5m m
1 2 x 1 . 2 5m m
64 N.m 16.5 kgf.m, 47 lbf.ftl
10 x 1.25mm
44 N.m lil,s kgt m,
33 tbf.ftl
13-4 6
vnx.su
8,
1 0 . lnstall the tront ( 8 1 8 C 1e n g i n e )a n d r e a r e n g i n e
Instsll the right tront mounvbracket.
stiffnsrs.
SELF.LOCKINGBOLT
Replac.
12 x 1.25mm
12 x 1.25mm
5t N.tn {5.8
42 tbt ftt
8 x 1.25mm
24 N.m l2.a kgf.]n,
17 tbtftl
8 x 1.25
FROifTENGINE 2r N'm (2.4kg['m, 12 x 1.25ftm
5? N.rn l5.Ekg[.m,
17lbf.ttl
SnFFENERS
42 tbl.ft)
lBl8Cl lngin.l
RIGHT
10 x 1,25mm
il a N.m (i4.5kgf..n,
33 tbtftl
11. Installthechangerod,the springpin, and the clip.
9.
NOTE:
. Installthe clip and the spring pin on the change
joint as shown.
. Turn the shift rod boot so the hole is facing
down as shown.
. Make sure the shift rod boot is installedon the
cnangeroo,
Installtheclutchcover.
12. Installthe changeextension.

1 3 . I n s t a l l t h eh e a ts h i e l d( 8 1 8 C 1e n g i n e ) .
6r1.0mm
12 N.m 11.2kgtm,
9 rbf.ftl
8 x 1.25mm
22 N.rn 12.2kgl-m.
16 tbtftl
CHANGEROD
SPRINGPIN
Replace.
.
l3-
e-- nrr,l
I
ll'--PuNcH
CHANGE
EXTENSION
8 x 1.25mm
12 x 1.25mm
2il N'm 12.4kg{.m,
57 N.m ls.E kgf.m, 17 tbffrt
a:I lbl.trl
l818Bl .ngin.l
5xl.0mm
9.8 N.m 11.0kgt'm,
7 tbf.ftt
HEATSHIELD
(B18Cl .nginol
/^
"-*
sHtFTROOaOOt
2M
i@
qlL#
--7
C LIP
HOt.C
(cont'dl
13-47
vnx.su
Transmission
Assembly
Installation (cont'd)
1 4 . I n s t a l lt h e i n t e r m e d i a t e
s h a f ta n d t h e d r i v e s h a f t s
(seesection16)-
17. lnstall the exhaust pipe A, and the three way cata l y t i c c o n v e r t e r( B l 8 C ' 1e n g i n e ) ,a n d c o n n e c tt h e
heatedoxygensensor(HO2S)connector.
NOTE:Replacethe set ringswith new ones.

DNIVESHAFTS
GASKET
SELF-LOCKING
NUT
Replace.
10 x 1.25mm
33 N.m (3.4 kgt.m,
HO2S
CONNECTOR
2s tbtftt
-Sl
SET RING
Replace.
::.t
INTERMEDIATE
SHAFT
GASKET
Replace.
SELF.LOCKING
NUT
Replace.
8 x 1.25mm
THREEWAY
CATALYTIC 16 N'm 11.6kgt m,
CONVERTER l2tbt.ftl
1818C'l
enginel
10x 1.25mm
38 N.m (3.9 kgt m,
28 tbtft)
Replace.
15. Installthe ball joints onto the lower arm (see section18).
16. Installthe right damperfork (seesection18).
10x 1.25mm
43 N.m{4.oksf.m.32lbf.ft)
RIGHT
DAMPER
FOBK
LOWERARM
SELF.LOCKING
NUT
Replace.
12 x 1.25mm
64 N.m {6.5 kgf.m,
47 tbtft)
:\
CASTLENUT
12x 1.25mm
49 - 59 N.m 15.0- 6.0kgf m.
36 - 43 tbf.frl
COTTERPIN
Reptace.
13-44
L
vnx.su
SELF.LOCKING
NUT
Replace.
10 x 1 25 mm
54 N.m 15.5kgt m,
iro lbf.ftl
18. Installthe enginesplashshield.
'19. Installthe slavecylinder,then installthe clutchpipe

bracket.
22, lnstallthe lower radiatorhose clamp on the transmissionhangrB.

2 3 . C o n n e c tt h e t r a n s m i s s i o ng r o u n d w i r e a n d t h e
back-uplight switchconnector.
N O T E :U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e
(P/N08798- 9002).
BACK.UPLIGI{T
SWITCHCONNECTOR
16 tbf.ftt
CLUTCHPIPE
6x1.0mm
9.8N.m {1.0kgf.m,7 lbfft)
GROUNDWIRE
8 x 1.25mm
22 N-m 12.2kgl.tr't,
tPlN 08798- 90021 16 rbf.ftl
HANGERB
24. Install the air cleaner housing assembly and the air
intake duct.
6x1.0mm
AIR CLEANER 9.8 N.m 11.0kgt'm,7 lbtftl
HOUSING
ASSEMALY
20. Connectthe vehiclespeed sensor(VSS)conneclor

and the startermotor cables.
2 1 . Installthe wire harnessclamPs.
6x1.0mm
9.8 N.m (1.0kgt m,7 lbf ftl
VSS CONNECTOR
9 \
AIR INTAKE DUCT
\<
8 x 1.25mm
8.8 N.m 10.9kgf.m,
6.s tbf.ft)
Refillthe transmissionwith oil (seepage 13-3).

Connectthe positive(+)cablefirst,then connectthe
negative( - ) cableto the battery.
27. Checkthe clutchoperation.
WIRE
HARNESS
CLAMPS
STARTER
MOTOR
CABLES
28. Shift the transmission.and checkfor smooth operatron.

29. Checkthe front wheelalignment(seesection18).
13-49
vnx.su
GearshiftMechanism
Overhaul
NOTE:
.Inspctrubberpartsforwearanddamagewhendisassembling;replaceanywornordamagedparts.
. lnstallthespringpin and the clip on the changejoint as shown.
. Turn the shift rod boot so the hole is facingdown as shown.
. Makesurethe shift rod boot is installedon the changerod.
t@)-I -/l
I t/
SHIFTIIVER KNoB
7.8N.m{0.8Isl.m, 6 lbt{tl
\U
8 x 1.25mm
22 N.m {2.2 kgt m, 16 tbtft)
#:
EXTENSION
END
WASHER
A
@-tHrFrLEVERaoor
SHIFTLEVER
DUSTSEALA
(7\
RUBBER
EXTENSION
WASHER
B
8x22mm
SPRINGPIN
Replace.
I
CHANGEROD
Replsc.
5x1.0mm
9.8 N.m 11.0kgf.m,
7 tbf.ftt
,,'/
"t't
9oo-
seu'locrtnc ruur
neptace.
8 x 1.25mm
22 N.m 12.2kg{ m, 16 tbtft)
SHIFTRODBOOT
;1tffi
=ff
NEARJOINT
BUSHING
O.RINGS
Replece.
REARJOINT BUSHING
THRUSTWASHER
13-50
vnx.su
CLIP
'l4-2
H v d r a u l i cF l o w
L o c k - u pS y s t e m
14-3
't
4-6
14-8
14-14
14-23
. . . - - . . . . .1. 4 - 2 4
. . . . . . . .1 4 - 3 8
Eloctrical Systom
C o m p o n e nLt o c a t i o n. . . . . . . . . . . . , . . . , . . . . . . . . . . . .I.4. .-.4 5
. . . . . . . . . . . . 1. 4 - 4 6
C i r c u i tD i a g r a m
' T r o u b l e s h o o t i nPgr o c e d u r e.s. . . . . . . , . . . . . . . . . .l.4, - 4 8
Symptom-to-Component Chart
...... 14-50
ElectricalSystem
ElectricalTroubleshooting
T r o u b l e s h o o t i nFgl o w c h a r t. . . . . . . . . . . . . . . . . .1. .4 - 5 2
Lock-uoControl SolenoidValve A/8
- - . . . .\ 4 - 8 2
Test ..................
, . . . , . . . , . . ,1
. 4-82
ReDlacement
Shift Control SolenoidVslve A/B
. . . . . .1 4 - 8 3
Test ..................
. . . . . . . . . . . . .1. 4 - 8 3
Reolacement
TransmissionControl Module (TCM)
*ReDlacement
. . . . . . . . . . .1 4 - 8 4
SDeedSensors
Mainshalt/CountershaJt
. . . . . . . . . . . .1. 4 - 8 5
Reolacement
Hydraulic Systom
Symptom-to-Component Chart
HydraulicSystem
Road Test
Slall Speed
T e s t. . . . . . . . . . . . . . . . . .
FluidLevel
Checking/Changing
Pressu.e Testing
14-86
14-90
't4-92
14-93
14-94
Transmission
Transmission
. . . . . .1 4 - 9 9
R e m o v a. l. . . . . . . . . . . .
lllustratedIndex
R i g h tS i d eC o v e r. . . . . . . . . . . . . . . . . . . . . . . . . . .1. 4. .-.1.0. 4
.
T r a n s m i s s i oHn o u s i n 9. . . . . . . . . . . . . . . . . . , , . . . .I.4. .- 10 6
Torque Converter HousingNalve
. . . 1 4 -1 O 8
B o d y. . . . . . . . . . . . . . . . . .
Right Side Cover
. . . . . .1 4 - 1 1 0
R e m o v a. l. . . . . . . . . . . .
TransmissionHousing
. - . . - .1 4 - 1 1 2
R e m o v a. l. . . . . . . . . . . .
Torque ConvenerHousingNalveBody
. . . . . .1 4 - 1 1 4
R e m o v a. l. . . . . . . . . . . .
Valve Caps
.............1
. .4. - 1 1 6
Description
Valve Body
. . . - . .1 4 - 1 1 7
R e p a i .r . . . . . . . . . . . . . . .
Valve
A s s e m b l y. . . . . . . . . . .
Oil Pump
Inspection
Main Valve Body

Disassembly/lnspection/Reassembly 1 4 - 1 2 0
RegulatorValve Body
Disassembly/lnspection/Reassembly 14-122
Lock-up Valve Body
....... 14-123
Disassembly/lnspection/Reassembly
Secondary Valve Body
....... 1 4 - 1 2 4
Servo Body
....... 14-126
1st-holdAccumulator/RightSide Covet
.,..,.. 14-124
Oisassembly/lnspection/Reassembly
Mainshaft
-..-... 14- 129
. . . . . . . . . . . . . . . .1. 4 -1 3 0
lnsDection
Countershaft
....... 14-132
D i s a s s e m b l y / R e a s s e m. .b. l.y. . . . . . . . . . . . . . . . .1.4. - 13 3
. . . . . . . . . . . . . . . .1. 4 - 1 3 4
lnsDection
One-way Clutch/ParkingGear
D i s a s s e m b l y / l n s p e c t.i .o. n. . . . . . . . . . . . . .-. . .- . 1 4 - 1 3 7
Sub-shaft
....... 14-138
D i s a s s e m b l v / R e a s s e m. .b. l. v. . . . . . . . . . . . . . . . .1.4. - 13 9
Sub-shaft Bearings
. . . . . . . . . . . . l. 4 - 1 4 0
Replacement
Clutch
f l l u s t r a t el n
d d e x. . . . . . . . . . . . . -. . . .- . . . - . . . . . . .1. 4. .- 14 1
, , , . , , . . . . . . .1. 4 - 1 4 4
Disassembly
. . . . . . . . . . . . .1. 4 - 1 4 6
Reassembly
Torque Converter Housing Bearings
MainshaftBearing/OilSeal
. . . . . . . . .1 4 - 15 0
Reolacement
CountershaftBearingReplacement.......,, 14-15l
TransmissionHousingBearings
Bearing
Mainshsft/Countershaft
...-..-..14-152
Repfacement
S u b - s h a fB
t e a r i n gR e p l a c e m e n. .t. . . . . . . . . . .1. 4 - 15 3
Reve.seldler Gear
. . . . . . . . . . . . . . .1. 4 - 1 5 4
lnstallation
ParkingBrakeStopper
l n s p e c t i o n / A d j u s t m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . ' 1 4 - ' 1 5 4
Transmission
.14_156
.............,.
Reassemblv
T o r o u eC o n v e r t e r / D r i vPel a t e. . , . . , . . . . . . . . . . . . .1. 4. - 16 3
Transmission
14-164
lnstallation
14-168
CoolerFlushing
'Shitt Cable
. .n. . . . . . . . . . . . . . . . . . . . . . . .14-'t
. . . 70
R e m o v a l / l n s t a l l a t .i o
. . . - . . - . . . . . . -1.4 - ' 1 7 1
Adiustment
*GearshiftSelector
D i s a s s e m b l y / R e a s s e m. .b. l.y. . . . . . . . . . . . . . . . .1,4. - 1 72
*Shift IndicatorPanel
-..........-...14-173
Adjustment
Throttle Control Cable
. . . . . . . , . . , . . . . .1. 4 - 1 74
fnspection
. . . . . . . . . . . . .1. 4 - 1 7 6
Adjustment
vnx.su
SpecialTools
Rol. No.
Tool Numbsl
Description
OTGAB PF50lOO
oTGAB-PF50101
oTGAE-PG40200
oTHAC-PK4010A
oTHAE-PL50lOO
oTLAE-PX40100
OTLAJ PT30lOA
OTMAJ-PY4O'I
1A
oTMAJ-PY40120
-OO10100
oTPAZ
07406-OO20003
o7406 0070000
07736 A01000A
o7746-O010100
o7746-O010500
07746-OO10600
07746 0030100
o7749-O010000
07947-6340500
IA\
,6\
@
/
@
rt)
@
@
\9
@
@
@
@
@
@
Oty
Page Reference
MainshattHolder
'I
1 4 - 11 1 . 1 6 0
Clutch SpringCompressorBolt Assembly

HousingPuller
Clutch SpringCompressorAttachment
Clutch SpringCompressorAttachment
Test Harness
A/T Oil PressureHose, 221O mm
A/T Oil PressureAdapter
SCS Short Connector
A/T Oil PressureGaugeSet w/panel
A/T Low PressureGaugew/panel
AdjustableBearingPuller,25-40 mm
D r i v e r ,4 0 m m l . D .
Driver
OriverAttachment
I
1
1
,1
14-144,147
1 4 - 113
1 4 -1 4 4 , 1 4 7
14 144,'t47
14-49,90
14-94
14-94
't
4-44
14-94
14-94
14-150,151
14-139,140
1 4 - 1 4 0 .510 , 15 1 , 15 2 ,15 3
14-150,152
14-134
14 - 13 9 , ' 1 4 01, 5 0 . 15 1 , 15 2
14,150
1
1
1
,|
1
1
1
1
1
I
I
'I
1
Edrn$r--
a)
a6l
*@ Must be used with commerciallyavailable

3/8 in. x 16 threads/in.slide hammer.
14-2
vnx.su
The Automatic Transmissionis a combination of a 3-e,ement torque convefter and triple-shaft electfonically controlled
automatictransmissionwhich provides4 speedsforward and 1 speedreverse.The entireunit is positionedin line with
the engine.
Torque Converter, Gears and Clutches
The torqueconverterconsistsof a pump,turbineand statorassemblyin a singleunit, The torqueconverteris connected
to the enginecrankshaftso they turn togetheras a unit as the engineturns. Aroundthe outsideof the torque converter
is a ring gearwhich mesheswith the starterpinionwhen the engineis beingstaned. The entiretorqueconverterassembly servesas a flywheel while transmittingpower to the transmissionmainshaft.
The transmissionhas three parallelshafts,the mainshaft.countershaftand sub-shaft.The mainshattis in line with the
enginecrankshaft.
The mainshaftincludesthe clutchesfor 1st, and 2ndl4th, and gearsfor 3rd. 2nd, 4th, reverseand l st (3rd gear is integral with the mainshaft,while reversegear is integralwith the 4th gear).
The countershaftincludesthe 3rd clutch and gearsIor 3rd, 2nd,4th, reverse,lst and parking.Reverseand 4th gears
can be lockedto the countershaftat its center, providing4th gear or reverse,dependingon which way the selectoris moved.
The sub-shaftincludesthe lst-hold clutch and gearsfor 1st and 4th
The gearson the mainshaitare in constantmesh with those on the countershaftand sub-shaft.When certaincombinations of gearsin the transmissionare engagedby the clutches,power is transmittedfrom the mainshaftto the countershaft via the sub-shattto provide@, E, tr. tr and @ position.
Electronic Control
ControlModule{TCM),sensors,and 4 solenoidvalves.ShiftThe electroniccontrolsystemconsistsof the Transmission
ing and lock-upare electronicallycontrolledfor comfortabledriving under all conditions.
The TCM is locatedbelow the dashboard,behindthe left side kick panelon the driver's side.
Hydraulic Control
The valvebodiesincludethe mainvalvebody, secondaryvalvebody, regulatorvalvebody. servobody, and lock-upvalve
body throuqh the respectiveseparatorplates.
They are bolted on the torque converterhousing.
The main valve body containsthe manual valve, 1-2 shift valve, 2-3 shift valve, Clutch PressureCont.ol (CPC)valve,
4th exhaustvalve, relief valve, and oil pump gears.
The secondaryvalve body containsthe 4-3 kick-down valve,3-2 kick-down valve,2-3 orifice cont.ol valve, 3-4 shitt
valve, orifice control valve. modulatorvalve, and servo control valve
The regulatorvalve body containsthe pressureregulatorvalve.lock-upcontrolvalve,torqueconvertercheckvalve,and
cooler check valve.
The servo bodv containsthe servo valve which is integratedwith the reverseshift fork, throttle valve B, and accumulators.
The lock-ugvalve bodv containsthe lock-upshift valve and lock-uptiming B valve.and is boltedon the secondaryvalve
body.
Fluidfrom the regulatorpassesthrough the manualvalve to the variouscontrol valves.
Shitt Control Mochanism
Input to the TCM i.om varioussensorslocatedthroughoutthe car determineswhich shift controlsolenoidvalve should
be activated.
Activatinga shift control solenoidvalve changesmodulatorpressure,causinga shift valve to move. This pressurizes
a line to one of the clutches.engagingthat clutch and its correspondinggear.
Lock-up Mechanism
In @ position.in 2nd, 3rd and 4th, and E positionin 3rd, pressurizedtluid can be drainedfrom the back of the torque converterthroughan oil passage,causingthe lock-uppistonto be held againstthe torque convertercover. As this
takes Dlace,the mainshaftrotatesat the samespeedas the enginecrankshatt.Togetherwith hydrauliccontrol,the TCM
optimizesthe timing ol the lock-upmechanism.
The lock-upvalvescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and throttlevalveB
When lock-upcontrol solenoidvalves A and B activate,modulatorpressurechanges.Lock-upcontrol solenoidvalves
A and B are mountedon the torque converterhousing,and are controlledby the TCM.
(cont'd)
14-3
vnx.su
Description
(cont'd)
Gear Selection
The selectorlever has sevenposirions;E PARK,E REVERSE,
N NEUTRAL,@
, l 2 n d g e a ra n d [ ] 1 s t g e a r .
t h r o u g h3 r d p o s i t i o n sQ
Position
PARK
l3?]]
1st through 4th positions.E
1st
Description
Front wheels locked; parkingpawl engagedwith parkinggear on countershatt.All clutches
reteaseo,
[R] REVERSE
N
NEUTRAL
Reverse;reverseselectorengagedwith countershaltreversegear and 4th clutch locked.

A l l c l u r c h e sr e l e a s e d .
'lst,
D+l DRIVE
shifts automaticallyto 2nd, 3rd, then 4th, dependingon vehicle
Generaldriving;starts off in
('lst through 4th) speed and throttle position.Do'vnshiftsthrough 3rd, 2nd and 1st on decelerationto stop.
The lock-upmechanismcomes into operationin 2nd, 3rd and 4th when the transmissionin lDt
posrtron.
Dgi DRIVE
For rapid accelerationat highway speedsand generaldriving; starts off in 1st. shifts automatical(1st through 3rd) ly to 2nd then 3rd, dependingon vehiclespeed and throttle position.Downshiftsthrough lower
gearson decelerationto stop. The lock-upmechanismcomes into operationin 3rd.
El SECOND
Drivingin 2nd geari stays in 2nd gear, does not shift up and down.
For enginebrakingor better traction starting off on loose or slipperysurfece.
L]l FIRST
Drivingin 1st gear; stays in lst gear, does not shilt up.
For enginebraking.
Starting is possibleonly in @ and I
Oositionthrough use ot a slide-type,neutral-safetyswitch.
Automatic Tlansaxle{A/T) Gear PositionIndicatol

A/T gear pos;tionindicatorin the instrumenlpanel shows what gear has been selectedwithout having look down at
the console.
14-4
vnx.su
VALVE
BODIES
TOROUECONVERTER
ASSEMBLY
1ST-HOLDCLUTCH
VEHICLESPEEDSENSORIVSSI
3RD CLUTCH
SUB SHAFT
MAINSHAFT
SPEEDSENSOR
SPEEDSENSOR
1ST CLUTCH
COUNTERSHAFT
14-5
vnx.su
Description
Clutches
gears.
the transmission
The four speedautomatictransmission
useshydraulically
actuatedclutchesto engageor disengage
When clutch pressureis introducedinto the clutch drum, the clutch piston is applied.This pressesthe iriction discs and
steel platestogether,lockingthem so they don't slip. Power is then transmittedthrough the engagedclutch pack to
jts hub-mountedgear.
Likewise,when clutch pressureis bled from the clutch pack. the pistonreleasesthe friction discs and steel plates,and
they are {ree to slide past each other while disengaged.This allows the gear to spin independentlyon its shaft, transmitting no power.
1st Clutch
The l st clutch engages/disengages
1st gear,and is locatedat the end of the mainshaft,just behindthe right sidecover.
The 1st clutch is suppliedclutch pressureby its oil feed pipe within the mainshaft.
1st-holdclutch
The 1st-holdclutch engages/disengages
1st-holdor I Fosition,and is locatedat the centerol the sub-shaft.The 1sthold clutch is suppliedclulch pressureby its oil feed pipe within the sub-shait.
2nd Clutch
The 2nd clutch engages/disengages
2nd gear, and is locatedat the center of the mainshaft.The 2nd clutch is joined
back-to-backto the 4th clutch. The 2nd clutch is suppliedclutch pressurethroughthe mainshaftby a circuitconnected
to the regulatorvalve body.
3rd Clutch
The 3rd clutchengages/disengages
3rd gea..and is locatedat the end oJthe countershaft,oppositethe right sidecover.
The 3rd clutch is suppliedclutch pressureby its oil feed pipe within the countershaft,
4th clurch
The 4th clutch engages/disengages
4th gear. as well as reversegear, and is locatedat the center of the mainshaft.
The 4th clutch is joined back-to-backto the 2nd clutch. The 4th clutch is suppliedclutch pressureby its oil feed pipe
within the mainshalt.
One-way Clutch
The one-wayclutch is posjtionedbetweenthe parkinggear and 1st gear. with the parkinggear splinedto the countershaft. The 1st gear providesthe outer race, and the parkinggear providesthe inner race surface.The one-way clutch
locks up when power is transmittedfrom the mainshaft 1st gear to the countershaftlst ggel _
The 1st clutch and gears remainengagedin the 1st. 2nd. 3rd, and 4th gear rangesin the @, E or E position.
However,the one-way clutch disengageswhen the 2nd. 3rd, or 4th clutches/gearsare appliedin the E, lD.l o, E
oosttton.
This is becausethe increasedrotationalspeedof the gearson the countershaftover-ridethe locking"speed range" of
the one-way clutch. Thereafter,the one-way clutch free-wheelswith the lst clutch still engaged.
1ST GEAR
COUNTERSHAFT
LOCKS
aF
FREE
:>
NOTE:
Viewtrom rightsidecoverside.
14-6
vnx.su
MAINSHAFT
4TH GEAR
SUB.SHAFT4TH GEAR
MAINSHAFT3RD GEAR
lST,HOLD CLUTCH
MAINSHAFT
2ND GEAR
TOROUE
CONVERTER
SUB-SHAFT1ST GEAR
2ND CLUTCH
SUB.SHAFT
STARTER
NINGGEAR
4TH CLUTCH
MAINSHAFT1ST
GEAR
LOCK-UP
CLUTCH
1ST CLUTCH
DRIVE PLATE
MAINSHAFT
ONE-WAY CLUTCH
PARKINGGEAR
,IST GEAR
COUNTERSHAFTREVERSEGEAR
REVERSESELECTOR
HU8
REVERSE
SELECTOR
COUNTERSHAFT4TH GEAR
COUNTERSHAFT2ND GEAR
COUNTERSHAFT
3RD GEAR
FINALDRIVENGEAR
3RD CLUTCH
DIFFERENTIAL
14-7
vnx.su
Description
Power Flow
--.-.-___-t.-t*
REVERSE PARKING
4TH
1STGEAR2ND GEAR3RDGEAR
t5tGEAR
GEAR
3RD
2ND
1ST
HOLD
VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
TOROUE
coN-
tr
1ST
2ND
3RD
4TH
1ST
2ND
3RD
tr
tr
o
o
o
o
o
o
o
o
o
o
o
o
X
X
o
'o
X
X
X
X
x
X
.o
-o
o
-o
-o
.o
X
X
o
X
':
Q: Operates,X: Doesn'toperate, Althoughthe 1st clutch engages,drivingpowe. is not transmittedas the one-way
clutch sliDs.
14-8
vnx.su
@ Position
pressure
to the countershaJt.
Hydraulic
is not appliedto the clutches,Poweris not transmitted
@ Position
Hydraulicpressureis not sppliedto the clutches.Poweris not transmittedto the countetshaft.
the parkinggear.
is lockedby the parkingpawl interlocking
The countersha{t
TOROUECONVERTER
REVERSESELECTOR
HUB
PARKINGGEAR
REVERSESELECTOR
REVERSEGEAR
SERVOVALVE/
SHIFTFORKSHAFT
14-9
vnx.su
Description
Power Flow lcont'dl
Lll Position Acceloration
In f
position,hydraulicpressureis appliedto the lst clutch and lst-hold clutch.
The power flow when acceleratingis as tollows:

1.
Hydraulicpressureis appliedto the 1st clutch on the mainshaltand power is transmittedvia the lst clutch to the
mainshaft1st gear.
2.
Hydraulicpressureis also appliedto the 1st-holdclutch on the sub-shatt.Powertransmittedto the mainshaft1sl

gear is conveyedvia the countershaft1st gearto the one-wayclutch. and via the sub-shaft1st gearto the l st-hold
clutch. The one-way clutch is used to drive the countershaft.and the 1st-holdclutch drivesthe countershaftvia
the 4th gears.
3.
Power is transmittedto the finai drive gear and drivesthe final d.iven gear,
SUB.SHAFT 'IST GEAR
SUB-SHAFT4TH GEAR
lST-HOLD CLUTCH
SUB-SHAFT
MAINSHAFT1ST GEAR
1ST CLUTCH
COUNTERSHAFT
ONE-WAY CLUTCH
PARKINGGEAR
,IST GEAR
FINAL DRIVENGEAR
14-10
vnx.su
L!_jPosition Deceleration
The power tlow when deceleratingis as follows;
1.
Rollingresistancelrom the road surfacegoesthroughthe tront wheelsto the final drive gear,then to the sub-shaft
1st gear via the 4th gear, and lst-hold clutch which is appliedduring deceleration.
2.
The one-way clutch becomesfree at this time becausetorque reverses.
3.
The counterforceconveyedto the countershaft4th gear turns the sub-shaft4th gear via the mainshaft4th gear.
At this time, sincehydraulicpressureis also appliedto the 1st clutch, counterfo.ceis alsotransmittedto the mainshaft. As a result, enginebrakingcan be obtainedwith lst gea.-
CLUTCH
TOROUECONVENTER
SUB-SHAFT
4TH GEAR
SUB-SHAFT1ST GEAR
SUB'STIAFT
lST CLUTCH
MAINSHAFT
COUNTERSHAFT
FINAL DRIVE
REVEFSESELECTORHUB
REVERSESELECTOR
4TI1 GEAB
(cont'dl
14-11
vnx.su
Description
Power Flow (cont'd)
Ll Position
@ Positionis providedto drive only 2nd speed.
1.
Hydraulicpressureis appliedto the 2nd clutch on the mainshattand power is transmittedvia the 2nd clutch to the
mainshaft2nd gear.
2.
Powertransmittedto the mainshalt2nd gearis conveyedvia the countershaft2nd gear,and drivesthe countersha{t.
3.
Power is transmittedto the final drive gear and drives the final driven gear.
NOTE:
Hydraulicpressureis also appliedto the lst clutch, but since the rotationspeedof the 2nd gear exceedsthat of
1st gear, power from 1st gear is cut off at the one-way clutch.
TOROUECONVERTER
2ND CLUTCH
MAINSHAFT
COUNTERSHAFT
FINAL DBIVE
2ND GEAR
FINALDRIVENGEAR
14-12
vnx.su
In [Q! or l!31 position.the optimumgear is automaticallyselectedfrom 1st, 2nd, 3rd and 4th speeds,accordingto conditionssuch as the balancebetween throttle opening(engineload) and vehiclespeed.
D! or lE.l Position, lst speed
1. Hydraulicpressureis appliedto the lst clutch. which rotatestogether with the mainshaft,and the mainshaftlst
gear rorares.
2.
Power is transmittedto the countershaft1st gear, and drivesthe countershaftvia the one-way clutch.
3.
Power is transmittedto the final drive gear and drives the final driven gear.
NOTE:
In lDil or [Dl]l position,hydraulicpressureis not appliedto the 1st-holdclutch.
TOROUECONVERTER
1ST CLUTCH
MAINSHAFT
COUNTERSHAFT
FINALDRIVEGEAR
FINALDRIVENGEAR
(cont'd)
14-13
vnx.su
Description
PowerFlow (cont'd)
JD.l or lD"l Position, 2nd speed
1.
Hydraulicpressureis appliedto the 2nd clutch, which rotatestogetherwith the mainshaft,and the mainshatt2nd
gear rotates.
2.
Power is transmittedto the countershaft2nd gear, and drivesthe countershaft.
3.
Power is transmittedto the tinal drive gear and drives the final driven gear.
NOTE:
In @ or @ position,2nd speed,hydraulicpressureis also appliedto the lst clutch. but sincethe rotationspeed
of 2nd gear exceedsthat of 1st gear. power trom lst gear is cut off at the one-way clutch.
2ND CLUTCH
TOROUECONVERTER
MAINSHAFT
COUNTERSHAFT
FINAL DRIVE GEAR
FINAL DRIVEN GEAR
14-14
vnx.su
I o.l or 16ll Position, 31d spod

1.
Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshatt3rd gearis transmittedto the countershaft
3rd gear,
2.
Power is transmittedto the tinal drive geat and drives the final driven gear.
NOTE:
In ]Dil or lDJl position.3rd speed.hydraulicpressureis also appliedto the Ist clutch, but sincethe rotationspeed
of 3rd gear exceedsthat of 1st gear, power trom lst gear is cut ofJ at the one-way clutch,
TOROUECONVERTER
MAINSHAFT 3RD GEAR
MAINSHAFT
COUNTERSHAFT
FINAL DRIVE
GEAR
3RD CLUTCH
FINAL DBIVEN
GEAR
14-15
vnx.su
Description
Power Flow (cont'dl
E
Poshion. 4th sp6od
1.
Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshatt, and th mainshaft 4th
gear rotates.
2.
Power is transmifted to the countershaft 4th gear, and drives the countershaj-t.
3.
Power is transmittedto the final drive gear and drivesthe final driven gear.
NOTE:
In @ Oosition,4th speed, hydraulic pressure is also applied to the 1st clutch, but since the rotation sped of 4th
gear exceedsthat oJ 1st gear, power from 1st gear is cut off at the one-way clutch.
TOROUECONVERTEB
MAINSHAFT 4TH GEAR
4TH CLUTCH
MAII{SHAFT
COUI{TERSHAFT
REVERSE
SELECTOR
HUB
REVERSESELECTOR
14-16
vnx.su
llj
Po.ltbn
1.
Hydraulic pressure is swilched by the manual valve to the se.vo v8lve, which moves the reverse shilt tork to the
rverseposition. The reverseshiJt fork engageswith the reverseselector, reverseselsctor hub,and the countershaft
raverss gar.
2.
Hydraulic pr6ssure is also applid to the 4th clutch. Power is transmifted from the mainshaft reverse gear via the
revetse idler g6ar to the countershaft reverse gear.
3.
Rotation dirsction ol the countershsft reverse gear is changed via the .everse idler gear.
4.
Powef b transmitted to the linal drive gear and drives the final driven gear.
TOROUECONVEBTER
4TH CLUTCH
MAI SHAFTREVERSE
GEAR
COUNTERSHAFf
REVERSE
SELECTOR
HUB
FII{AL DRIVEGEAR
REVEFSESELECTOR
COUIITERSHAFT
REVERSE
GEAR
14-17
vnx.su
Description
ElectronicControlSystem
Electronic Control System
The electroniccontrolsystemconsistsof the TransmissionControlModule(TCM),sensors.and 4 solenoidvalves.Shifting and lock-upare elect.onicallycontrolledfor comfortabledriving under all conditions.
The TCM is locatedbelow the dashboard,behindthe left side kick panel on the driver's side.
Lock-up Control
Solonoid Valvo A
14-18
vnx.su
Lock-up Control
From sensorinput signals,the TCM determineswhether to turn the lock-upON or OFF and activateslock-upcontrol
solenoidvalve A and/or B accordingly.
The combinationof driving siqnalsto lock-upcontrol solenoidvalves A and B is shown in the table below.
Lock-upcontrol Solenoidvalve
\
B
Lock-upcondition
Lock-upOFF
OFF
OFF
Lock-up,slight
ON
OFF
Lock-up.halt
ON
ON
Lock-up.full
ON
ON
Lock-up
during deceleration
ON
Duty operation
OFF-ON
Shifl Conrrol
The TCM instantaneously
determineswhich gear shouldbe selectedby varioussignalssent trom sensors.and actuates
the shift controlsolenoidvalvesA and B controlshitting.Also. a GradeLogicControlSystemhas beenadoptedto control
shifting in E] positionwhile the vehicleis ascendingor descendinga slope, or reducingspeed.
Shift control solenoidvalve

------\
t"*b"
,t"-l
E,E
E
a
tr
l-Rl
('lst)
(2ndl
OFF
ON
ON
ON
(3rd)
ON
OFF
(4th)
OFF
OFF
(2nd)
ON
ON
(lst)
ON
OFF
{Reverse)
ON
OFF
(cont'd)
14-19
vnx.su
Description
ElectronicControl System (cont'd)
.
GRADE LOGIC CONTROLSYSTEM
How it works:
The TCM comparesactual drivingconditionswith drivingconditionsmemorizedin the TCM. basedon the input trom
the vehiclespeed sensor,throttle positionsensor,enginecoolanttemperaturesensor,brake switch signaland select
lever positionsignal,to control shifting while a vehicleis ascendingor descendinga slope. or reducingspeed.
SIGNALSDETECTED
Dliving Resistance
Judgement of Controlling Area
Engine Coolant
TemDerature Sensor
. Flat road mode

. Asconding mode
(Fuzzylogic)
. Gradual Ascending
mode
. Steep Ascending
14-20
vnx.su
. Ascending Contlol
When the TCM determinesthat the vehicleis climbinga hill in @ position,the system extendsthe engagementarea
Irom frequenrlyshittingbetween3rd and 4th gears,so the vehiclecan run smooth
of 3rd gearto preventthe transmission
and have more power when needed.
NOTE: Shift schedulesbetween 3rd and 4th gear are stored in the TCM to enablethe transmissionto automatically
selectthe most suitablegear accordingto the magnitudeof a gradientby Fuzzylogic.
. Descending Control
When the TCM determinesthat the vehicleis going down a hill in @ position.the shift-upspeedfrom 3rd to 4th gear
when the throttle is closedbecomestaster than the set speedfor tlat road drivingto widen the 3rd gear drivingarea.
This, in combinationwith engine brake from the decelerationlock-up, achievessmooth driving when the vehicle is
descending.
Thereare two ascendingmodeswith different3rd gear driving areasaccordingto the magnitudeof a gradientstoredin
theTCM.
When the vehicleis in 4th gear, and you are deceleratingon a gradualhill, or when you are applyingthe brakeson a
steephill,the transmissionwill downshittto 3rd gear.When you acceleratethe transmissionwill then returnto 4th gear.
Vohicle SDood
. DecelerationControl
When the vehiclegoes around a corner,and needsto deceleratefirst and then accelerate,the TCM sets the data for
decelerationcontrolto reducethe numberof times the transmissionshiftsto obtain smooth driving.When the vehicle
is decelerating
from speedsabove27 mph (43 km/h).the TCM shiftsthe transmissionfrom 4thto 3rd earlierthan normal
to cope with upcomingacceleration
to maintainsmooth driving.
NOTE:
FuzzyLogic:Fuzzylogic is a from at artificialintelligencethat lets computersrespondto changingconditionsmuch like
a human mind would.
14-21
vnx.su
Description
ElectronicControl System {cont'dl
*t-l
777
TH
SCI
sHtfTc0mRoL
scs
ECM
SHFTCOI{rFOL
VALVEB
SOLINOIO
ACCL
AFSB
NEP
LG1
TOCK-UPCONTROL
SOLENOIOVALVE
A
LG2
SPEEO
SENSOF
COUNTE8SHAFI
SPEEO
SENSOR
L_______.1
tGcotL
LOC(- UPCONTROL
SOLENOIO
VALVEB
f-r,'__l
I Jll6
i
A/T CEANPOSITION
INDICATOR
14-22
vnx.su
Hydraulic Control
The valvebodiesincludethe main valvebody, secondaryvalvebody, regulatorvalvebody, servobody and lock-upvalve
body.
The oil pump is driven by splinesbehindthe torque converterwhich is attachedto the engine.Oil flows th.ough the
regulatorvalve to maintainspecifiedpressurethrough the main valve body to the manualvalve, directingpressureto
each of the clutches,
SHIFT CONTROLSOLEIIOID
VALVE ASSEMBLY
RTGHTSIDECOVER
LOCK.UPVALVEBODY
VALVEBODY
V
REGULATOR
BODY
4<.__i
:
)o.-
OIL PUMP GEARS

SOLENOIDVALVE
ASSEMBLY
14-23
vnx.su
Description
HydraulicControl(cont'dl
Ragularol Valve Body
The .egulator valve body is located on the main valve body. The regulator valve body consists of th regulator valva,
toroue converter check valve, cooler check valve, and lock-up contlol valve.
VALVE
REGULATOR
VALVE
REGULATOR
BODY
COOLERCHECKVALVE
LOCT.UPCONTROI.
VALVE
TONOUECOI{VERTEB
CHECKVALVE
Lock-up Valvo Body

The lock-up valve body with the lock-up shilt valve and lock-up timing B valve is located on th regulator volvs body.
LOCK.UPSHIFT VALVE
TIMITG B VALVE
14-24
vnx.su
Rcgulator Valve
The rgulator valve maintains a constant hydraulic pressure from the oil pump to the hydraulic control system, whil
alEofurnishingoil to the lubricatingsystem and torque convener.
Oil flows through B and B'. The oil which entersthrough B flows thfough the valve orificeto A, pushingthe regulator
valve to the right. Acco.dingto the level of hydraulicpressurethrough B, the positionof the valve changes,and the
amount of the oil thlough D from B'thus changes.This operationis continued.thus maintainingthe line pressure.
IEI{GINE]IIOT RUNNINGI
{ENGINERUNNING)
From OIL PUMP
Siator Reaction Hydtaulic PressureControl

Hydraulicpressureincrease,accordingto torque, is performedby the regulatorvslve using stator torque reaction.The
stator shaft is splinedto the stator and its a.m end contacts the fegulatorspring cap. When the car is acceleratingor
climbing (Torque Convener Range).stator torque reaction acts on the stator shalt and the stator shaft arm pushes the
rsgulator spring cap in this - direction in proportionto the reaction.The spring compressesand the regulatorvalve moves
to increasethe regulatedcontrol pressureor line pressure.Line pressureis maximum when the stator reactionis maximum.
TOR VALVE
STATOR SHAFT ARM
STATOR SHAFT
(cont'd)
14-25
vnx.su
Description
Hydraulic Control (cont'dl
Main Valvo Body
The manualvalve, 1-2 shift valve, 2-3 shift valve. 4th exhaustvalve. CPC valve, and relief vatve are all assembledin
the main valve body,
The primaryfunctionof this valve body is switchingoil passageson and off and controllingthe hydraulicpressuregotng
to the hydrauliccontrol system.
CPC VALVE
4TH EXHAUSTVALVE
RELIEFVALVE
MANUAL VALVE
MAIN VALVE BODY
1.2 SHIFT VALVE
Scondary Vslve Body

The secondaryvalve body is locatedon the main valve body. The 3-2 kick-downvalve,4-3 kick-downvalve. 2-3 orifice
controlvalve.orificecontrolvalve,3-4 shift valve,modulatorvalve,and servocontrolvalveare assembledin the seconda.y valve body.
ORIFICECOIITROL
VALVE
2-3 ORIFICECONTBOLVALVE
3.4 SHIFT VALVE
VALVE BODY
COITTROLVALVE
MOOULA
14-26
vnx.su
S6rvo Body
The servo bodv is locatedon the secondaryvalve body.
The servovalveis integratedwith the shiit fork shatt, throttlevalve B. and accumulatorpistons,which are all assembled
in the servo bodv.
SERVOVALVE/
SHIFTFORKSHAFT
THROTTLEVALVE B
SERVOBODY
THROTTLELONG VALVE
Accumulator Pislons
piston
The accumulatorpistonsare assembledin the servo body and right side cover. The l st-holdclutch accumulator
pistons
in
lhe
servo
body.
assembled
are
is in the right side cover, and the 1st, 2nd 3rd, and 4th accumulator
1ST-HOLDACCUMULATOR
RIGHTSIDECOVER
4TH ACCUMULATOR
IST ACCUMUI-ATOR
2ND ACCUMULATORPISTON
3RD ACCUMULATORPISTON
14-27
vnx.su
Description
HydraulicFlow
Genelal Chart ol Hydraulic Pressure
Oil Pump - RegulatorValve -
Line Pressure
Torque ConverterPressure
LubricationPressure
Distribution ot Hydraulic Pressure

. RegulatorValve
- , .
Ltne rressure
Torque ConverterPressure
]
LubricationPressure
L
. M a n u a lV a l v e
To Select Line Pressure
. ModulatorValve
ModulatorPressure
. 1-2ShiltValve
l
. 2-3 Shitt Valve
. 3 4 Shift Vlave
]
. Throttle Valve B
NO.
Clutch Pressure
Throttle B Pressure
D E S C R I P T I OONF P R E S S U R EN O .
LINE
6C
LINE
6D
LINE
3'
LINE
10
3"
LINE
LINE
D E S C R I P T I OONF P R E S S U R EN O .
MODULATOR
CONTROL
SOLENOID
VATVE
AI
ITOCK-UP
MODULATOR
(IOCX.UP
CONTROT
SOTENOID
VALVE
B)
D E S C R I P T I OONF P R E S S U R E
55
THROTTLEB
56
THROTTLEB
LINE
57
THROTTLEB
l ST CLUTCH
58
THROTTLEB
1ST-HOLD
CLUTCH
90
T O R O U EC O N V E R T E R
It)
l ST.HOLDCLUTCH
91
TOROUECONVERTER
LINE
18
LINE
92
T O R O U EC O N V E R T E R
LINE
20
2ND CLUTCH
93
O I LC O O L E R
5'
LINE
21
2ND CLUTCH
94
TOROUECONVERTER
5"
LIN E
25
LINE
95
LUBRICATION
MODULATOR
30
3RD CLUTCH
96
TOROUECONVERTER
6'
MODULATOR
31
3RD CLUTCH
97
TOROUECONVERTER
6A
MODULATOR
(SHIFT
CONTROL
SOTENOID
VALVE
A
MODULATOR
(SHIFT
CONTROL
VALVE
SOLENOID
B
40
4TH CLUTCH
99
SUCTION
41
4TH CLUTCH
6B
14-28
vnx.su
BLEED
E Position
(99) and disAs the engineturns, the oil pump also startsto operate.Automatictransmissionfluid (ATF)is drawn from
(
chargedinto (1). Then,ATF pressureis controlledby the regulatorvalve and becomesline pressure 1). The torqueconverter inlet pressure(92) enters (94) of torque converterthrough the orifice and dischargesinto {90}.
The torque convertercheck valve preventsthe torque converterpressurefrom rising'
Under this condition,the hydraulicpressureis not appliedto the clutches.
NOTE:
. When used, "left" or "right" indicatesdirectionon the llowchart
. SOL-@: Shift Control SolenoidValve A
' SOL{D:Shift ControlSolenoidValve B
. SOL@: Lock-upControl SolenoidValve A
. SOL-@: Lock-upControl SolenoidValve B
(cont'd)
14-29
vnx.su
Description
HydraulicFlow (cont'd)
L1l Position
The line pressure{1) becomesline pressure(4) at the manualvalve and passesto the lst clutch and 1st accumulator.
Then line pressure(41flows through the 1st-holdclutch and lst-hold accumulator.
Fluid flows by way of:
- LinePressure{4} - 1-2 Shitt Valve * 2-3 Shitt Valve - 3rd Clutch Pressure{31) - 3-4 Shift Valve - 4th Clutch
Pressure(41) - ManualValve - lst-hold Clutch Pressure{15) - 1st-holdClutch
The modulatorpressure(6) is suppliedto the 1-2 and 2-3 shift valves.
The line pressure(1) also flows to throttle valve B.
NOTE:
. When used. "left" or "right" indicatesdirectionon the flowchart.
. SOL@: Shift Control SolenoidValve B
. SOL-@: Lock-upControlSolenoidValve A
14-30
vnx.su
f4 Position
ihe line pressure(11becomesline pressure(41as it passesthrough the manualvalve.lt then goes through line l2O)
to the 2nd clutch via the 1-2 and 2-3 shift valves.Also, line pressure(1) goes to the modulatorvalve throughthe filter
and becomesthe modulatorpressure(6). Modulatorpressure(6) is not suppliedto the 1-2, 2-3 and 3-4 shift valves
becausethe shitt control solenoidvalves A and B are turned on by the TCM.
NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart
. SOL-@: Shift ControlSolenoidValve A
. SOL-@: Shilt Control SolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOt -@ : Lock-upControl SolenoidValve B
(cont'd)
14-31
vnx.su
Description
HydraulicFlow (cont'dl
@
or @
Position
1.
lst Sped
The flow of fluid throuth the torque convener circuit is the same as in S Oosition.
The line pressure( 1) becomesline pressure(4) and it becomesthe 1st clutch pressure(1O).The I st ctutchpressure
is appliedto the lst clutch and l st accumulator;consequently,the vehiclewill move as the enginepower is transmitted.
The line pressure(1) becomesthe modulatorpressure(6) by the modulatorvalve and travelsto 1-2 and 3-4 shift valves.
The 1-2 shift valve is movedto the right sidebecausethe shilt controlsolenoidvalveA is turnedoff and B is turned
on by the TCM. This valve stops 2nd clutch pressureand power is not transmittedto the 2nd clutcn.
Line pressu.e{4) also tlows to the seryo valve and line pressure(1} also flows to throttle valve B.
NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart.
. SOL-@: Shitt ControlSolenoidValve A
. SOL-@:Shift ControlSolenoidValve B
. SOL-@: Lock-upControlSolenoidValve B
14-32
vnx.su
2nd Sgeed
prescribed
The llow of fluid up the 1-2 shift valve is the same as in 1st speed.As the speedof the car reachesthe
to the left
is
moved
valve
the
1-2
shift
value,the solenoidvalve A is tulned on by meansot the TCM. As a result,
is
engaged'
2nd
clutch
and uncoversthe port leadingto the 2nd clutch; the
Fluidflows by way of:
- Line Dressurel4l -
'l-2
Shift Valve - 2-3 Shitt Valve - 2nd Clutch Pressure(2'1) * 2nd Clutch
The hvdraulicpressurealsoflows to the 1st clutch,However,no power is transmittedbecauseof the one-wayclutch.

NOTE:
. When used, "lett" or "right" indicatesdirectionon the flowchart
. SOL@: Shift ControlSolenoidValve B
. SOL-@: Lock-upControl SolenoidValve A
{cont'd)
14-33
vnx.su
Description
3rd Speed
The tlow of fluid up to the 1-2 and 2 3 shift valves is the same as in 2nd speed.As the speedof the car reaches
the prescribedvalue,the shift controlsolenoidvalve B is turned off {shilt controlsolenoidvalveA remainson). The
2-3 shift valve is then movedto the left, uncoveringthe oil port leadingto the 3rd clutch. Sincethe 3-4 shitt valve
is moved to the right to cover the oil port to the 4th clutch, the 3rd clutch is turned on.
Fluid tlows by way of:
- Line pressure l4l - 1-2 shift valve - 23 Shift Valve *
(not controlled) 3rd Clutch Pressure(3O) - 3rd Clutch
3rd ctutch pressure(31) -
3-4 shift valve
The hydraulicpressurealsoflows to the l st clutch.However,no power is transmittedbecauseof the one-wayclutch

as in the 2nd speed.
NOTE:
. When used, "lett" o( " tight" indicatesdirectionon the flowcharl.
. SOL-@: Shift ControlSolenoidValve A
. SOL-@:Shift ControlSolenoidValve B
. SOL-@: Lock-upControlSolenoidValve B
14-34
vnx.su
Lq4 Position
4.
4th Spe6d
The flow of tluid up to the 1-2, 2-3 and 3-4 shift valvesis the sameas in 3rd speed.As the speedof the car reaches
the prescribedvalue, the shift control solenoidvalve A is turned oJt (shift control solenoidvalve B remainsoff).
As this takes place,3-4 shift valve is moved to the left and uncoversthe oil port leadingto the 4th clutch. Since
the 1-2 and 2-3 shift valvesare kept on the left side,the fluid flows throughthe 4th clutch;the power is transmitted
through the 4th clutch.
Fluid flows by way of:
- Line Pressurel4l - 'l'2 Shift Valve -t 2-3 Shitt Valve - 3rd Clutch Pressure(31) 4th Clutch Pressure{4O) - 4th Clutch
4th Clutch pressure(41) - ManualValve
The hvdraulicpressurealsotlows to the
as in 2nd and 3rd soeed.
3-4 Shift Valve
'1st
clutch.However,no power is transmittedbecauseof the one-wayclutch
NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchan.
. SOL-@: Shitt Control SolenoidValve A
. SOL-@: Shift Control SolenoidValve B
. SOL-@: Lock-upConttol SolenoidValve B
(cont'dl
14-35
vnx.su
Description
LEI Position
The flow ot fluid throughthe torqueconvenercircuitis the same as in S position.The tluid ( 1) trom the oil pump flows
through the manualvalve and becomesline pressure(31.lt then flows through the 1-2 shift valve to the servo varve
via the servo control valve, causingthe shift tork shatt to be moved in the reversedirection.
Underthis condition,the shift control solenoidvalve A is turned on whereasthe valve B is turned ofJ as in 3rd speed
in [Dil or lDs]lposition.As a result,the 1-2 shift valve is also moved to the left. The ftuid (3'] will ftow throughthe servo valve and manualvalve to the 4th clutch; power is transmittedthrough the 4th clutch.
ReverseInhibitorControl
When the @ positionis selectedwhile the vehicleis movingforward at a speedover 6 mph ( 1Okm/h).the TCM outputs
1st signal (A: OFF, B: ON), and the 1-2 shift valve is moved to the right side. The line pressure{3) is interceptedbv
the 1-2 shift valve; consequently,power is not transmittedas the 4th clutch and servo valve are not oDerareo.
NOTE:
. When used, "lefl" ot "tight" indicatesdirectionon the flowchart.
. SOL: Shift Control SolenoidValve B
. SOL: Lock-upControlSolenoidVatve A
. SOL-@: Lock-upControlSotenoidVatve B
14-36
vnx.su
Lll Position
The flow of fluid throughthe torque convertercircuit is the same as in I position.The line pressure( l ) becomesline
pressure(3) as it passesthroughthe manualvalve.Then line pressure(3) flows throughthe 1-2 shift valveto the servo
valve via the servo control valve. causingthe shift fork shaft to be moved to the reversepositionas in E position.
However.the hydraulicpressureis not suppliedto the clutches.Power is not transmitted.
NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart.
. SOL-@: Shitt ControlSolenoidValve A
. SOL-@: Shift Control SolenoidValve B
. SOL-O: Lock-upControl SolenoidValve B
14-37
vnx.su
Description
Lock-up System
Lock-up Clutch
1. Operation(clutch on)
With the lock-upclutch on, the oil in the chamberbetweenthe torque convenercover and lock-uppiston is discharged,
and the converteroil exerts pressurethrough the piston againstthe convertercover. As a result,the converterturbine
is locked on the convertercover firmly. The etfect is to bypassthe converter,thereby placingthe car in direct drive.
tpowefJlo-wl
LOCK-UP
TURBINE
The power tlows by way of:

Engine
I
Drive plate
I
Torque convener cover
I
Lock-uppiston
I
Damperspring
I
Turbine
t
Mainshaft
TOROUECONVERTER
COVER
To oil cooler
OUTLET
2. Operation(clutch off)
With the lock-upclutch off, the oil tlows in the reverseof CLUTCHON. As a result,the lock-uppiston is moved away
from the convertercover; that is, the torque converterlock-upis released.
Fowtttowl
Engine
I
Drive plate
I
Torque convertercover
TURBINE
Pump
I
Turbine
I
Mainshaft
14-38
vnx.su
fluid is drainedfrom the back of the torqueconIn E positionin 2nd, 3rd and 4th, and @ positionin 3rd, pressurized
verter through an oil passage,causingthe lock-uppiston to be held againstthe torque convertercover. As this takes
place,the mainshaftrotatesat the same speedas the enginecrankshaft.Togetherwith hydrauliccontrol,the TCM optimizedthe timing ot the lock-upsystem. Undercertainconditions,the lock-upclutch is appliedduringdeceleration,in
3rd and 4th sDeed.
The lock-upsystemcontrolsthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and throttlevalveB.
When lock-upcontrol solenoidvalves A and B activate.modulatorpressurechanges.Lock-upcontrol solenoidvalves
A and B are mountedon the torque converterhousing,and are controlledby the TCM.
NOTE:
When used, "left" or " tight" indicatesdirectionon the tlowchart.
Solenoid valve
L""f."p
LOCK IJP COIITBOL
"."aiti""\
Lock-upOFF
OFF
OFF
Lock-up,slight
ON
OFF
Lock-up,half
ON
ON
Lock-up.full
ON
ON
ON
Duty operation
O F F- O N
Lock-up
during deceleration
LOCI( UP TIMII{G B VAIVE
ott cootR
{cont'd)
14-39
vnx.su
Description
Lock-upSystem(cont'dl
No Lock-uo
The pressurizedfluid regulatedby the modulatorworks on both ends of the lock-upshift valve and on the left side ot
the lock-upcontrolvalve.Underthis condition,the pressu.esworking on both ends ol the lock-upshitt valve ate equal.
the shift valve is moved to the right side by the tensionof the valve springalone.The tluid from the oil pump will flow
through the left side of the lock-upclutch to the torque converter;i,e., the lock-upclutch is in OFF condition.
NOTE: When used.
"left" or "right" indicatesdirectionon the flowchart.
LOCK.UPCONTRO!
<-
L O C K . U PT I M I G A V A L V E
14-40
vnx.su
MOOULATOi PBfSSURE
{
Partial Lock-up
Lock-upControlSolenoidValve A: ON
Lock-upControl SolenoidValve B: OFF
The TCM switchesthe solenoidvalve A on to releasethe modulatorpressurein the left cavity ol the lock-upshift vatve.
The modulatorpressurein the right cavity of the lock-upshift valve overcomesthe springforce, thus the lockiup shifi
valve is moved to the left side.
The modulatorpressureis separatedto the two passages:
F1: Torque ConverterInner Pressure:enters into right side-toengagelock-upclutch
F2: Torque ConvenerBack Pressure:enters into left side-todisenqagelock-upclutch
The back pressure(F2) is regulatedby the lock-upcontrol valve whereasthe positionof the lock-uptiming B valve is
determined by the throttle B pressure, tension of the valve spring and pressure regulated by the modulator, Also the
positionof the lock-upcontrolvalveis determindedby the back pressureof the lock-upcontrolvalveand torqueconvener pressureregulatedby the check valve.With the lock-upcont.ol solenoidvalve B kept oft, the modulatorp.essu.eis
maintainedin the left end of the lock-upcontrolvalve;in other words, the lock-upcontrolvalveis moved slightlyto the
left side. This slight movementof the lock-upconlrol valve causesthe back pressureto be loweredslightly.resulting
in panial lock-up.
NOTE: When used. "left" or "right" indicatesdirectionon the flowchart.
LOCK.UPCOIIIROL
SO!ENO|o VALVE A
LOCK UP COIITROI
SOTENOIDVALVE B
<-
MODUI.AIOi
PAESSUFE
LOCK-UPIIMII{G B VATV
otl coolEn
l.ont'al
14-41
vnx.su
Description
Lock-upSystem (cont'dl
Halt Lock-up
Lock up Control SolenoidValve A: ON
Lock-upControl SolenoidValve B: ON
The modulatorpressureis releasedby the solenoidvalve B, causingthe modulatorpressurein the lett cavity of the lockuD control valve to lower.
Also the modulatorpressurein the left cavity of the lock-uptiming B valve is low. Howeverthe throttle B pressureis
still low at this time; consequently.the lock-uptiming B valve is kept on the right side by the spring force.
With the lock-upcontrolsolenoidvalve B turnedon, the lock-upcont.ol valve is moved somewhatto the Ieft side.caus
ing the back pressure(F2)to lower. This allows a greateramount of the fluid (F'1)to work on the lock,up clutch so as
to engagethe clutch. The back pressure(F2) which still exists preventsthe clutch from engagingtully
NOTE: When used, "left" or "right" indicatesdirectionon the flowcnarr.
LOCX UP CONTROL
r.oct( uP corlTRol
sorENoto vatvE a
<-_
LOCK UP IIMiI{G B VAI-VE
orr coorER
14-42
vnx.su
MOOULATORPRESSTJBE
Full Lock-uo
Lock-upControlSolenoidValve B: ON
Lock-upControl SolenoidValve A: ON
When the vehiclespeedfufther increases,the throttle B pressureis increasedin accordancewith the throttle opening.
The lock-uptiming B valve overcomesthe spring force and moves to the left side. Also, this valve closesthe oil port
leadingto the torque convertercheck valve.
Underthis condition,the throttle B pressureworking on the right end of the lock-upcontrolvalve becomesgreaterthan
that on the left end (modulatorpressurein the lelt end hasalreadybeenreleasedby the solenoidvalveB); i.e.,the lock-up
control valve is moved to the left. As this happens,the torque convener back pressureis releasedfully, causingthe
lock-upclutch to be engagedfully.
"right" indicatesdirectionon the tlowchart.
NOTE: When used, "left" or
LOC( UP COi{TAO!
toc( uP coNtnol
SOIENOID
VAIVEB
THRO]TIE A PFESSURE
PNESSUFE
FEGUTATOFVAIVE
LOCK-UPTIMIIIG B VALVE
orl cootER
(cont'd)
14-43
vnx.su
Description
Lock-up System (cont'dl
Dacslsration Lock-uD
Lock-upcontrol solenoid valve A: oN
Lock-upcontrol solenoid valve B: Duty operation {oN - oFFl
The TCM switchessolenoidvalveB on and off rapidlyundercertainconditions.The slightlock-upand half lock-upregions
are maintainedso as to lock the torque converterproperly.
NOTE; When used, "left" or "right" indjcatesdirectionon the flowcnarr.
LOCK-I.PCOt{lFOt
loc(,uP cot{TRoL
SOIENOID
VATVEB
LOCI(,UPTtMt G B VAIVE
14-44i
vnx.su
Component Location
,/s\
)/
{ 7 v
A0t
AUTOMATIC TRANSAXLE IA/TI

GEAR POSITIONSWITCH
COUNTERSHAFT
SPEEDSEf{SOR
VEHICLESPEED
SENSOR{VSSI
MAINSHAFTSPEED
THROTTLEPOSITION(TP}
SENSOR
SENSOR
at
,
(ECTI
ENGINECOOLANTTEMPERATURE
SENSOR
)''
14-45
vnx.su
Circuit Diagram
UNDERHOODFUSE/RELAY
80X
No.411100A)
(7.5A)
No.32
tGNtTtoN
c0 -
II
BLU
423 424
Ar0
A20
D2
TRANSMISSION
CONTROL
MOOUI.E
{TCM)
A19
A18
A21
A8
AN GEAR
POSITION
INDICATOR
A'
*---i.
A17
A15
A13
A-"
t2
t,,,:----<)
A/'I GEARPOSIIION
swtrcH
BLK
8LK
G201
G201
14-46
vnx.su
Alt
l1
. VEHICI.E
A/C
SPEED
COMPRESSOR SENSOR
. SPEEOOMETER
CLUTCH
REI.AY
SERVICE
CHECK
CONNECTOR
/8tK
'HBOTfLE ENE'NE
Postto^l coolAlvr
SENSOR TEMPERA.
TURE
SENSOR
D 9 0 1 3 0 1 1D l 6 D 3
D6
D7
D5 A25
A26
TMNSMISSION
CONTROL
MODULE
{TCM}
Dls
019
Dl2
A5
A3
I.OCK'UPCONTROL SHIFTCONTROL
VATVE SOLENOIO
VALVE
SOLENOID
COUNTERSHAFT
SPEEO
SENSOR
A3 A5
A9
A6 A8 A 1 (
A1:
MAINSHAFI
SPEED
SENSOR
421
,/1,/1,/A 1 t
TCMT6rmin6lLocations
14-47
vnx.su
Troubleshooting
Procedures
when the TcM sensesan abnormalityin the input or output systems.the
E]indicator light in the gaugoassemblywill
blink.
when the service check Connector{locatedunder the dash on the passengerside} is connectedwith the
specaat
tool
as shown, the E] indicatorlight will blink the DiagnosticTroubleiode {DTCI when the ignitionswitch is turned
on.
When the lDil indicator light has been reported on, connect the service check connector with the
special tool.
Then turn on the ignition switch and observethe
@ indicatorlight.
GAUGEASSEMSLY
DAI'A LI]TK
(3P)
cor{r{EcToR
't
NOTE:
Do not atlach
jumpe.wire.
scs sHoRTCO[{]{ECTOR
oTPAZ-OOl0too
codes 1 through I are indicatedby individualshort blinks,codes 1o through 15 are indicatedby a series tong
of
and
shon blinks.one long blinkequals l0 short blinks.Add the long and short blinkstogetherto dete;minsthe cod.
Aft6r
determiningthe code, refer to the erectricarsystem symptom-to-componentchart on pages 14-5o and 51.
ahon
f"l
Sc. DTCI
So. DTC2
S.. DTC14
some PGM-FIproblemswill also make the @ indicatorlight come on. After repairingthe pGM-Frsystem, disconnect
the BACK UP tuse (7.5 Al in the under-hoodfuse/relaybox tor more than 1o secondsto reset the TcM memorv.
NOTE:
a PGM-FIsvstem
The PGM-FIsystem on this model is a sequentialmultipon fuel iniectionsvstem.
' Disconnectingthe BACK UP tuse also cancelsthe radio anti-theftcode, presetstationsand the clock
setting. G6t
the customer's code numbe. and make note of the radio presets befote temoving the fuse so you can reset them.
14-48
vnx.su
CAUTIOI{:
a All SRS eloctdcal wiring harna$os are covcred whh
yollow lnaulation.
a Sofora disconnecting any pan ot tho SRS wirc har'
n6ss, connoct the short connoctots (s6 pago 23-701.
a Roplacs tho entiro aff.ct d SRS ham6t. rssombly it
ii has an opon circuil or damagcd wlrlng.
a TCM Ro3at Procoduro

1.
Tum the ignition switch off.
2.
Removethe No. 32 BACK UP fuse {7.5 A} from the

under-hoodluse/relay box 'or 10 seconds to reset
the TCM.
NOTE; Disconnoctingthe No. 32 BACK UPtuse also
cancelsths radioanti-theft code, presetstations and
tho clock sefting. Get the customer's code number
and make note ol the radio presets before removing
the fuss so you can reset them.
BACKUP(7.5 A} FUSE
lf the inspection to. a particularlailure code requir6sthe

use of Test Harness {07LAJ - PT3O1OA):
1,
Removethe left side kick panelon the driver'sside

(seepage 1+84).
2.
Connect the wire harness to the Tsst Harness.

and/or connect the Test Harnessto the TCM sccording to the troubleshooting flowchart.
NOTE:
a Onlythe A and D terminalsof the TestHarnsssaro
used for Ay'Ttroubleshooting.
a Unless otherwise noted, use only the Digital
Multimeter, commerciallv available or KS-AHM32{)03, for testing.
a Finll hoc.dulr
NOTE: This procedure must be done after any

troubleshooting.
1.
Removsths s9ocialtoolfrom the ServiceCheckConnoctor.
2.
Resetthe TCM.
3,
S6t th radio preset stations and clock setting.
DIG]TALMULTIMETER
Commrciallvavailable
KS-AHM-32-.003,
or gouivalEnt
) o o o o o o o o o o ) olo D o o o o o qoo o o o olo o o o o . o o o . c
To.miml Locrtlonr
14-49
vnx.su
Symptom-to-ComponentChart
ElectricalSystem
Numberof @
indicatorlight
blinks while
indicaror
Service Check @]
light
Connectoris
connectedwith
the specialtool.
Blinks
Blinks
Blinksor
OFF
Blinks
Blinks
OFF
Blinks
Blinks
Blinks
PossibleCause
Symptom
Referto
page
Disconnectedlock-upcontrol solenoid
valve A connector
Short or open in lock-upcontrol solenoid valve A wire
Faulty lock-upcontrol solenoidvalve A
Disconnectedlock-upcontrol solenoid
valve B connector
Short or open in lock-upcontrol solenoid valve B wire
Faulty lock-upcont.ol solenoidvalve B
Lock-upclutch does not

engage.
disengage.
Unstableidle speed.
14-52
. Lock-up clutch does not

enga9e.
14-54
Disconnectedthrottle position (Tp)

sensorconnector
Short or open in TP sensorwire
Faully TP sensor
. Lock-upclutch does not

engage.
Disconnectedvehiclespeed sensor
(VSS)connector
Short or open in VSS wire
Faulty VSS

engage.
. Short in A/T gear positionswitch wire

. Faulty A/T gear positionswitch
. Failsto shift other than

2nde4th gears.
. Lock-up clutch does not
engage.
14-58
DisconnectedA/T gear positionswitch

connector
Open in A/T gear positionswitch wire
Faulty A/T gear positionswitch
Failsto shift other than

2nd-4th gears.
Lock-up clutch does not
en98ge.
Lock-upclutch engages
and disengagesalternately.
14-60
Disconnectedshift control solenoid

valve A connector
Short or open in shitt control solenoid
valve A wire
Faulty shift control solenoidvalve A
Disconnectedshitt control solenoid
valve B connector
Shon or open in shift control solenoid
valve B wi.e
Faulty shift control solenoidvalve B
. Failsto shift (between

1st-4th, 2nd-4th or
2nd-3rd gears only).
. Failsto shift (stuck in
4th gear).
Disconnectedcountershattspeed sensor connector

Short or open in the countershaft
speed sensorwire
Faultycountershaftspeed sensor

engage_
14-50
vnx.su
. Failsto shiJt (stuck in

lst or 4th gears).
14-56
't
4-57
14-62
't 4-64
Numberof @
indicatorlight
blinks while
indicator
ServiceCheck @
light
Connectoris
connectedwith
the specialtool.
'lo
Blinks
1l
OFF
13
Blinks
14
't5
Blinks
PossibleCause
Symptom
Disconnectedenginecoolant temperarure (ECT)sensorconnector

Short or open in ECT sensorwire
Faulty ECT sensor

engage.
Disconnectedignitioncoil connector
Short or open in ignition coil wire
Faulty ignitioncoil
. Shon or open in LT GRN wire between
the D3 terminaland ECM
. Faulty barometricpressure{BARO)
sensor
NOTE:The BAROsensor is built into
the ECM
. Short of open in FAS {YEL}wire between the D16 terminaland ECM
. Faulty ECM
OFF
Disconnectedmainshaftspeed sensor
connecror
Short or open in mainshaftspeedsensor wire
Faulty mainshaftspeed sensor

engage.
Refer to
page
14-68
't4-70
. No specificsymptom
appears.
14-71
. Transmissionjerks hard
when shitting.
. Transmissionjerks hard
when shifting.
14-75
It the self-diagnosis
LQ4 indicatorlight does not blink, perform an inspectionaccordingto the table below.
Symptom
ProbableCause
LQ! indicatorlight is on steady, not blinkingwheneverthe ignitionis on.

[Q3]indicatorlight does not come on for 2 secondsafter ignitionis first
turned on.
Lock-upclutch does not have duty operation(ON-OFFI.
Ret.page
14-77
14-78
Lock-upclutch does not engage.
Check A/C signalwith

A/C on.
14-80
Shitt leve. cannot be moved lrom @ positionwith the brake pedal

depressed.
Check brakeswitch signal,
14-41
a lf a customerdescribesthe symptoms for codes 3, (yet the LQ! indicatorlight is not blinkingl,6, 1 1 or 15, it will
be necessa.yto recreatethe symptom by test driving.and then checkingthe @ indicatorlight with the ignitionstill
oN.
e lt ttre @ indicatorlight displayscodes olher than those listed above or stays lit continuously,the TCM is faulty.
. Sometimesthe Lqd indicatorlight and the MalfunctionIndicatorLamp (MlL)/CheckEnginelight may come on simultaneously.lf so, check the PGM-Flsystem accordingto the numbe. of blinks on the MIL/CheckEnginelight. then
resetthe memoryby removingthe BACK UP fuse in the unde.-hoodfuse/relaybox for more than 1Oseconds.Drive
the vehicle for several minutes at speed over 30 mph (5O km/h), then recheck the MIL/Check Engine light.
NOTE:
. PGM-FIsystem
The PGM-Flsystem on this model is a sequentialmultiportfuel injectionsystem.
a Disconnectingthe BACK UP luse also cancelsthe radioanti-theftcode. presetstationsand the clock setting.Get
the customer'scode numberand make note ot the radio
the fuse so vou can resetthem.
14-51
vnx.su
TroubleshootingFlowchart
Possible Cause
. Disconnected lock-up control

s o l e n o a dv a l v e A c o n n e c t o r
. Short or open in lock-up control
solenoid valve A wire
. Faulty lock-up control solenoid
Check whether the Malfunction

IndicatorLamp (MlL) blinks (see
section I 1).
ls the MIL blinking?
Repair the PGM-FI System (see

section 1 l ).
NO
Disconnectthe 26Pand 22Pconnectorsfrom the TCM.

Connectthe Test Harness"A"
and "D" connectorsto the wire
harnessonly, not to the TCM {see
page 14-49).
ooooooooooo
oooooooo9oo
oooooooooooo
oooooooooooo
Measure the voltage between the

D18 and A25 or 426 terminals.
f s t h e v o f t a g e4 . 7 5 5 . 2 5 V ?
Repair open or shorl in WHT/

BLK wir botwen th D18 terminal and the ECM.
YES
A25
Measurethe voltagebetweenthe
46 and A25 or A26 terminals-
ls there voltage?
NO
(-)
" "" o" " oooo" I

| | o" q" " ooo oo ooq litigse.*grq$:,1:d:sd:siia:l
r
z
6
r
o
'
r
+
r
r-t
IL--l
l
/trtr-Repail short to power sourco in
YEL wi.e between the A6 terminal and the lock-up control solenoid valve A.
To page 14'53
14-52
vnx.su
Me6surethe resistancebetween
the 46 andA25 or A26terminals.
ls the resistance14
16 O?
Checkfor loos TCM connectors.

It necessary,substitute a known_
good solenoid valve assembly or
TCM and recheck.
the lock-upcontrol solenoidvalve
CheckIor continuitv between the

46 and A25 or 426 terminals.
Repairshort to groundin YELwiro

between tho AG trminal and th
lock-uo control solsnoid valve A.
View lrom terminalside
Measurelhe resistanceof the

solenoidat the 2P connector.
ls the resistance14- 16 0?
Chck tor open in YEL wire botween the A6 terminal and the
lock-uDcontrol solenoidvalve A.
RoDlacath6 lock-up control solnoid valv6 assembly.
{cont'd}
14-53
vnx.su
Troubleshooting
Flowchart(cont'dl
PossibleCause
. Disconnectedlock-up conlrol
solenoidvalve B connector
. Short or open in lock-up control
solenoid valve B wire
. Faultylock up controlsolenoid
valve B

IndicatorLamp (MlL) blinks (see
section 1 1).
Ropair tho PGM-FI Sysrom (se

soction 11).
Disconnectthe 26P and 22P connectorstrom the TCM.

Connect the Test Harness "A"
and "D" connecto.slo the wire
harnessonly, not to the TCM (see
page 14-49).
Measurethe voltage between the

D'18and A25 or 426 terminats_
ls the voltage4.75-5.25 V?
Rapair opon or shon in WHT/

BLK wi.e botweon the O18 te.minal rnd the ECM.
lvleasurethe voltage between the

44 and A25 or 426 rerminals.
Ropsir shon to power source in
GRN/BLK wi.o betwoon the A4
t6.minal and th lock-up control
solonoid valve B.
14-54
vnx.su
Measurethe resistancebetween
the A4 and A25 or A26 terminals.
is the resistance14- 16 0?
Check for loosoTCM connocto.s.

lf nocoasary,substitute a knowngood solenoid valvo assombly ot
TCM and rochock.
the lock-upcontrol solenoidvalve
assemory,
Checklor continuitv between the

A4 and A25 or A26 terminals.
Ropair 3horl to Itound in GRN/

BLK wir6 botwoon tho 44 totminal and th6 lock-up cont.ol solonoid valv6 B.
2P CONNECTOR
View trom terminal side.
Measure the resistance ol the

solenoid at the 2P connector.
q
.UP CONTROL
ls the resistance14- 16 07
Chock lor opon in GRN/BLKwiio

botwaen tho A4 torminal and th6
lock-up contrcl solonoid valvo B.
SOLENOID
VALVE
ASSEMBLY
R6Dlacotho lock-up conttol 3016noid valvs assembly.
(cont'd)
14-55
vnx.su
TroubleshootingFlowchart (cont'd)
Sof{irgnolis
D! indictor tight
blinks throo rim6s.
Possible Cause
. Disconnocted throttle position
{TP) sensoaconnoctor
. Short or oDenin TP snsorwire
. Faulty TP senaor
Check whother the Malfunction

IndicatorLamp (MlL) blinks(see
section 1 1).
Replir thc PGM-FI Syrtom l.s.

!.ction 111.
Oisconnectrho 26P 6nd 22P connectors lrom the TCM.

and "D" connectors to the wire
harnessonly, not to the TCM lsee
page |4-491.

Dl8 and A25 or A26 teiminats.
Rcpalr opon or shon In WHT/

BLK wlr. botw.cn th. D18 t.minsl rnd th. ECM.
Turn the ignirionswirch OFF.

and "D" connectorsto the TCM.
Measurethe voltage betwen the

D7 and A25 or 426 rerminals.
Roprlr oprn o. lhon in RED/BLK

wil. botwaan tha DT ta]minal and
tha TP ranaor.
Chock tor looro TCM connoctora.

ll noce$rry, subatitulo r knowngood TCM and rechock.
vnx.su
S. d.gno.b lql
bllnkr tour tlm...
indic.to. light
PossibleCaus6
. Disconnectsd vehicle speed
sensor{VSS}connector
. Short or open in VSS wire
. Faulty VSS
R.lor to Soctlon 23 for vohicle

rpood lonsoi {vSSl to!t.
Shift t.nsmisiion
to A
position.
a Mak sure lifts,lacks, and safety stands aro placod ploporly {see Eaclion 1}.
a S6t th6 parking brake eecurely and block tho tear wh6ol3'
a Jack up tho f.ont ot tho car and rupport whh sstoty standa.
Disconn6ctthe 26Pand 22P conn.ctors trom th TCM.

"A"
Connect ths Tgst Harnoas
"O"
connectors to tho wire
8nd
harnsssonly, not to the TCM (see
page 1+49).
Turn the ignilionswitch ON.
Rotatth tront wh6ol and chsck

fo. volt6g botwean the D9 and
A25 o. A26 terminals.Blockthe
other whaol 30 it dos not turn.
Doss lhe voltage O V and app.ox. 10 V appe.r alternately?
Ch6ck to. shoft or opon in OFil

wlro btwoen tho .)9 t6tminsl and
rho VSS. lf wiro is OK, chck tho
VSS lsoo soction 231.
Ch.d( tor loo.. TCM co.!n.cto.r.

ll nacaaalay, lubrtituta ! known_
geod TCM and t chock.
(cont'd)
14-57
vnx.su
TroubleshootingFlowchartlcont'dl
Solt-diagno8isl!4 indicato. tight
blinks fiv6 timos.
PossibleCause
'Short in A/T gear posilion
switch wire
. Faulty A/T gear position switch
Observethe A/T gear position indicator,and selecteach position

separately.
Do any indicators stay on

when the selectorlever is
not in that position?
NOTE:Code 5 is causedwhen
the TCM receivestwo gear position inputsat the sametime.
The systom is OK ai this timo.

Ch.ck tho wiro ha|noss tor
oamago.
Connect the Test Harness be,

tween the TCM and connectors
{see page 14-49}.
Turn the rgnitionswitch ON.
Or
4 2 5t - |
Shilt to other than E position.
Measurethe voltage btween the

A21 and A25 or 426 terminats.
Chock for short in GRN/REDwi.o botwoon tho A2t torminal
and th6 A/T goar po6ition swirch or A/T 96ar posirion indicator. lf wire is OK, chock for loo8o TCM connocioF. lf
necassary,subatituto a known-good TCM and rochsck.
-l@r
A 1 9 l + ) A 2 5( - )
419 and A25 or 426 terminals.
ls the battery voltage?

YES
Ch6ck for 6hon in LT GRN/BLKwi.e borwoon tho A19 torminal and tho A/T goar position indicato., o. a shon in
GRN/WHT or GRN wiros botwson tho A/T goa. position indicato. and tho A/T goa. position swhch. ll wire is OK. chock
for looso TCM connactoE. lf nocos$sry, substituto a knowngood TCM and .ech6ck,
To page 1 4 , 5 9
14-5 8
vnx.su
14-58
shift ro other than E
posirion.
Measurethe voltage belween lhe

Shifi to other than E]
Chock to. short in PNK/GRNwire betwoon tho Al7 torminal and

th6 A/T gsar position switch. It wire is OK, chsck for looso TCM
connoctors. lf nocessary, substitute a known-good TCM and
rochck.
position.
oooooooooooo
oooooooooooo
ooooooooooo
oooooooo ooo

A15 and A25 or 426 terminals.
ls there batteryvoltage?
Chock for short in GRN/BLUwire betweon the A15 terminal and

the A/T gosr position switch or A/T ga. position indicato.. ll wiro
is OK, chock for loose TCM connectors. ll nocessary,substituls
a known-good TCM and rochock.
Shilt to other than E position.
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo

A13 and A25 or 426 terminals.
Shift to other rhan I
oosirion.
Chock for short in GRN/YELwire betweon ths A13 torminal and

the A/T gear position switch or A/T gear posilion indicator. l{ wiro
is OK, check lor loose TCM connectors. lI necessarv,substituta
a known-good TCM and rechsck.
oooooooooooo
oooooooooooo
ll
ooooooooooo
ooooooooooo

Al l and 425 ot 426 tetminals.
ls thgre battery voltage?
YES
Chock tor shon in LT GRN/WHT wi.e btwoan th6 A1'l lerminal

and the A/T gear position switch or A/T gear position indicator.
lf wira b OK, ch6ck foi loose TCM conneclors. lf nocssary,substituto a known-good TCM and rocheck.
Chock for looso TCM connctors.

lf noce$ary, substitute a knowngood TCM and recheck.
{cont'd)
14-59
vnx.su
TroubleshootingFlowchart{cont'dl
Self-diagnosisE indicator light
blinkasix timos.
Connect the Test Harnessbe,

tween the TCM and connectors
(seepage '14-49).
PossibleCause
. DisconnectedA/T gear position
swrtcn connector
' Open in A/T gear positionswitch
. FaultyA/T gear positionswitch
- r9t
a 2 1 ( +I A 2 5 { - )
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
A21 and 425 or 426 terminals.
ls there voltage?
Shilt ro N or E position.
Ropairopen in GRN/REDwire be,

tweon th6 A21 terminal and the
A/T gssr position switch.
A25t-l
oooooooooooo
oooooooooooo

ls there voltage?
Ropairopen in LT GRN/BLKwire
btw6onthe 419 torminaland th
A/T gear position indicato..
NO
T o p a g el 4 - 6 1
14-60
vnx.su
ooooooooooo
ooooooooooo
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
Measurethe voltage betweenthe

A 1 7 a n d4 2 5 o r A 2 6 t e r m i n a l s .
voltage?
Roprir opon in PNK/GRNwire botwoon

the A17 torminal and rh6 A/T goar position switch.
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
Measurethevoltagebetweenthe
A 1 5 a n dA 2 5 o r A 2 6 t e r m i n a l s .
Ropairopen in GRN/BLUwir6 bolwoen
the A15 r6.minal and tho A/T goar position switch.
oooooooooooo
oooooooooooo
ooooooooooo
ooOoooooooo

A 1 3 a n dA 2 5 o r A 2 6 t e r m i n a l s .
voltage?
ReDairopen in GRN/YELwito botwon

the Al3 torminalandth A/T goarposilion switch.
All(+ I
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo

voltageT
Ropaii opon in LT GRN/WIIT wiro botwen the A 11 te.minaland tho A/T goar
oosition switch.
Checklor loos TCM connectors.

It necossaty,substituto a known_
good TCM and r6ch6ck.
(cont'dl
14-61
vnx.su
Troubleshooting
Flowchart(cont'dl
Sltdiagno3b Lql indicaror lighr
blinks sovon timgs.
PossibleCause
. Discohnectedshift control solenoid valve A connector
. Short or open in shift control
solenoid valve A wire
. Faulty shill control solenoid

IndicatorLamp {MlL) blinks(see
section 11).
Ropai lhe PGM-FI Sysrem (so

Bection1 11,
Turn th6 ignition switch OFF.

Disconnect
the 26P and22P connectors from the TCM.
and "D" connectors to the wire
harnessonly not to the TCM (see
page 14-49).
D l 8 (r I
Measurethe voltage betwn the
D18 and A25 or A26 lerminals.
fs the voftage4.75-5.25 V?
Repairopon o. sho.t in WHT/BLK

wire botwoon th D18 tarminal
and the ECM.
oooooooooooo
ooooo oooooooa
ooooooooooo
t:tJio*ie*O:lt$!l$4lrulitEijt'lo oo oooooooo

Ropair lhon to powor sourc6 in

BLU/YEL wiro botwoon the A5
torminal and th6 lhift control solonoid valve A.
vnx.su
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
the A5 and 425 or 426 terminals.
ls the resistance14-16 0?
NO
Chock lor loora TCM connectoE.

lf n6c53ary,sub3titut6a knowngood solonoid valvo assembly or
TCM and r6check.
the shift control solenoidvalveassembly.
Check for continuitv between the

A5 and A25 or 426 torminals.
Ropair shon to ground in BLUI'EL

wir6 botwoon tho A5 tstminal and
tho shift conlrol solonoidvalvo A.
3P CONNECTOR
View from terminalside.
Measure lhe resistance of the
solenoidat lhe 3P connector.
ls the resistance'14-16 0?
Check fo. opon in BLU/YELwiro

bolween th6 A5 torminal and tho
shift control solenoid valve A.
SHIFT CONTROL
SOLENOIDVALVE
ASSEMBLY
(cont'd)
14-63
vnx.su
Troubleshooting
Flowchart(cont'dl
Solfdiagnolir [!4 Indicato. light
bllnk! eight tim6r.
PossibleCau6e
. Disconnected shift control solenoid valve B connector
. Short or open in shift control
solenoid valve B wire
. Faulty shilt control solenoid
valve B
Check whother the Malfunction

Indicator Lamp {MlL) blinks (see
section I 11.
Rcpsir rho FGM-FI Syrtem lso6

scciion l1l.
Turn the ignition swirch OFF.

Oisconnctthe 26P and 22P connectors trom the TCM.
and "D" connectors to the wiro
hamessonly. not to the TCM {ses
p6ge 14-49).
A2s(- |
o oooooooooo
oooooooooooo
D l A (+ I
Measurethe voltage betwen the

D18 and A25 or A26 terminals.
oooooo ooooo
oooo oooo
Ropeiropon or short in WHT/BLK

wiro trotweon th6 D18 terminel
and tho EcM.
Measurethe voltage between th

Ropair rhort to powor rourco in

GR /WHT wir6 btwgan tho A3
tormirEl and shift conLol lolonoid
valve B.
To page
vnx.su
Measurethe resistance between

the A3 and A25 or A26 terminals.
ls the resistanceI +16 07
Chod. lor looro TCM connoctoB.

lf nocdaary. 3ubatltute a knowngood rolonold valv6 6ra6|nbly ot
TCM snd recheck.
Disconnctth6 3P conngctorfrom
the shift control solenoid valve
assembly.
oooooooooooo
Check for continuity between the
oooooooooooo
ooooooooooo
ooooooooooo
Ropair short to ground in GRt{/

WHT wiro botwoon th6 A3 torminrl and tho shitt control aolonoid
valve B.
Measure the resistance ot the

solenoid at the 3P connector.
ls the rsistance14- 16 O?
Chock to. open in GRN/WHT wiro

b6twe.n th A3 lerminal and tho
shifl control solonoid valvo B.
SHIFT CONTROL
SOLENOIDVALVE
ASSEMELY
Roplace lhe rhift control solenoid

valve arrmblv.
(cont'd)
14-65
vnx.su
Self-diagnosisLq! indicator lighr
blinks nino timos.
PossibleCause
. Loose or faulty connection berween the TCM and car harness.
. Disconnectedcountershaft speed
sensor connector
. Short or open in the countershatt speed sensor wire
. Faulty counlershaft speed sensor
ls the countershaftspeed
sensor installed properly
Disconnectthe 2P conneclorlrom
the countershaft speed sensor
connector,
Measure the resistance ot the

co!ntershaft speed sensor.
2P CONNECTOR
COUNTERSHAFT
SPEEDSENSOR
ls the resistance 4OO 600 0?
To page 14-67
14-6 6
vnx.su
Disconnoct the 22P connector

trom the TCM. Connecr tho Tst
Harness "D" connector to the
whe harnessonlv, not to the TCM
'14-49).
lsee page
Check for continuitv between

body ground and 017 terminal
and D15 terminslindividually.
Rgpllr short in BLU/GRI{ ot
BLU|/EL wlro btwgon Dl7 and
Dl5 torminsla and ths countarrhaft apod sengor.
Reconnect the countershaft
sDe00sensor connector.
Msasure the rgsistancebetween

D 17 and 015 terminals.
ls the rsistance4OO-600 07
Rgpairlooa6 ta.minsl or opon in

8LU/GRN o. 8LU/YEL wiro botrvaon D'17 and D15 tormindg
and tho count6rlhafl !p6gd
!ntor,
Ch6ck for looaa TCM conn6cto..

ll nocaslrry, aubrlitut6 a knowngood TCM a.d .6ch.ck.
(cont'd)
vnx.su
4-67
Troubleshooting
Flowchart(cont'dl
Self-diagnosisE indicator light
blinks ten times.
PossiblCaus6
. Disconnoctdengine coolant
tmprature (ECTI sensor connoctor
. Short or open in the ECT sensor
. Faulty ECT snsor

IndicatorLamp {MlL} blinks(see
section 11)-
Rop.ir tho PGM-FI Syrt.m (!go

!.ction 111.
Disconnectthe26P and 22P connectorstrom the TCM.

and "D" conneclorsto the wire
harnessonly, not to the TCM (see
p a g e1 4 4 9 ) .
oooooooooooo
oooooooooooo
ooooooooooo
oooo oooo
Dlal+ I

D'18and A25 or A26 lorminals.
Bopairop.n or .hofi In WHT/BLK

wiro botwoon tho O18 tanni.|al
.nd the ECM.
vnx.su
Conneci the Test Hs.ngs6 "A"

and "O" connectorsto thg TCM.
Start the engine and warm it up

to normal ope.ating tmpsratuG
(the rsdiator fan comes on).
Measurgthe voltage between the

05 and A25 or A26 terminals.
ls the voltago less th6n lV?
Rlplir opsn or rhort in BED/WHT

wira botwaan tra D5 torr nC lnd
tha ECT lanaor.
Ch.ct tor loora TCMco.rmcror..

It nocgallry, sublthuta a knowngood TCM .nd rechrck.
14-69
vnx.su
TroubleshootingFlowchart(cont'd)
Solt-diagnosislq.l indicstor light
blinks elovon tim6s.

Irom the TCM.
PossibleCause
. Disconnected ignition coil conneclor
. Short or open in ignition coil
. Faulty ignition coil

Ag (BLU)and A25 (BRNiBLK)
or
A26 (BRN/BLK)
terminals.
NOTE: View from wire side.
R6pai?opon or short in BLU wiro

lrotwqan lh. A9 torminll 6nd th.
ignilion c!il.
Ch6ck lor loos6 TCM connactora.

It nacosaary,substituto a knowngood TCM and rochock.
14-70
vnx.su
Soll-diagnosisLq! indicator light

blinks thirtoon tim6.
ls rhe Malfunction lndicator

Lamp (MlL) on and does it
indicatecode 13?
Possible Cause
. Short or open in LT GRNwire betweenthe D3
terminaland the ECM.
. Faukythe barometricpressure{8ARO}sensor.
NOTE:The BAROsensoris built into lhe ECM.
Do the TCM Rest Procedure(see

page 14-49).
ls the MIL on and does it

indicarecode 13?
Substituto a knowngood ECM and rechock.

ll symptom/lndication
goos away, .oplacethe
originalECM.
Disconnectlhe 26Pand 22P connectors trom the TCM

Connect the Test Hahess "A"
and "D" connectorsto the wire
harnessonly, not to th TCM {see
pare'14-49).
Turn the ignitionswirch ON.
A25t-|
o o o o o o o o o o o o o o O O q g o p g I , o i O O O O ool o o o o o o o o o o
o o o o o o o o o o o o 0 ooocqooo:Joo.oipggl o oooooo o 9oo

D18 and A25 or A26 terminals.
Ropairopon or short in WHT/BLK

wir6 botwoon th D18 to.minal
and tho EcM.
Turn the ignitionswith OFF.
fo page 14-72
14-71
vnx.su
ElectricalTroubleshootang
TroubleshootingFlowchart (cont'd)
From page
'14-71
NOTE: View from wire side.
Disconnect the 22P connectors

lrom the TCM and ECM.
ECM 22P COiINECTOR
D3 {LTGRN)terminalol the TcM
22P connecrorand the D8 ILT
GRN) terminalof the ECM 22P
connector.
TCM 22P CONNECTOR

Ropai. opon In LT GRN rvi.a b.twoon tho TCM and ECM.
Checklor continuity between the

LT GRN wire and body ground.
Ropair short lo body ground in

LT GRN wir6.
Chck lor loos6 TCM and ECM

connectors, lf necessary,aubaritute a known-good TCM and
rccheck.
14-72
vnx.su
S.fdl.enorl!
L&l indicdor lighl
blinks fourtoon tlmoa.
PossibleCause
. Sh"rt ". "e"" i" FAS |YEU ,"rirt
. FsultyECM.
ls the Malfunction Indicator

Lamp (MlL) onl
Ropair tho PGM-FI Syrtom lloo

..ctlon 111.
Stan the ongine and warm it up

to normal operating temperature
{th radiatorlan coms on).
Shift to E position,
Turn rhe ignition switch OFF.
Connect the Test Harness between the TCM and connociors

{seepage 14-491.
Turn the ignition switch ON and

wsit for at least two seconds.
o oooooo ooo ooo l.tto.oodooo l:,gEoo.ottl o ooooo oooo o

o oooo oooooooo
o oooooooooo
l:OOOOOO60 l.,OO{tO.O6,'l
Measure
lhe voltagebetwganths
o16l+ ) andA25 or A26(- | tormrnals.
ls thoro approx. 5 V?
Chock for looro TCM connoctora.

lf noco$ary, subatituta a knowngood TCM and .echck.
Dkconnectthe TestHarnessfrom
the TcM.
Leaveconnectdto car harness.
fo page 14-74
lcont'd)
14-73
vnx.su
TroubleshootingFlowchart(cont'd)
From page 14-73
o o o o o o o o O o O o O $:O.COOtt9O$:l:OtO:CtOiOi:l
Oo OO OOo Oo o O
o o o o o o o o o o o o O I:f(O.{iltltO{t{t:I:OFA:F:d:O:l o o o o o o o Oo o o
D 1 6 { + ) a n dA 2 5 o r A 2 6 { - ) t e r mtnals.
Check for loos TCM connoctors.

ll ngcossary,substituto a knowngood TCM and rechock.
Disconnectthe 26P connector

from the ECM.
Check for continuitv between the

D16 andA25 or A26 rerminalsof
the Test Harness.
oooooooooooo
oooooooooooo
Ropairshortin YEL IFAS)wire betw6on TCM and ECM.
Disconnectthe 26P and 22P connectors from the Test Harness.

22P CONNECTOB
Check for continuity betweenthe
D16 (YEL)terminalot fCM 22P
connectorand A19 (YEL)terminal
of ECM 26P connector.
NOTE:View lrom wire side.
Chgck tor loos TCM connoctofs.

lf nocassary,substitute o knowngood TCM and rech6ck.
NO
Ropairopon in YEL {FAS}wiro botrven TCM and ECM.
vnx.su
ooooooooooo
ooooooooooo
solf-diagnosisE indicator light

blink tiftoon timos.
PossibleCause
. Disconnected mainshaft speed
sensor connecror
. Short or open in mainshalt
speedsensorwrre.
. Faulty mainshatt speed sensor.
NOTE:
. A code 15 on the TCM doesn't alwsys
mean there's an electrical problem in the
mainshaftor countershaftspeedsensorcir'15may also indicatea mechanicuit; code
cal Droblemin the transmission.
Are the mainshaft and countershalt speed sensors installed

properly?
the mainshaftspeedsensor.
Measurethe resistanceot the

mainshaftspeedsensor.
3P CONNECTOR
ls the resistance4OO-600 O?

from the TCM.
Connectthe Test Harness"D"
conneclor to the wire harness
only, not ot the TCM (see page
14-49).
I o o o o o o o oo o o o o I:OtlO$O$g:Sl!:OlXOl*Ofill
o o o o o o o o o Oo |
I|
o oooop oo ooo | 6
I ooooooooooooo l Sciii:ddii:ijii:l:i$idi$;d6#:l
"
f
1(0) - L
Check the continuity between

D19 and D12 terminalsand body
ground.
Y
-!
Rcoair short in ORN/BLU ot
WHT/BLU wiros botween Dlg
and Dl2 to.minals and tho mainshatt speod ronsor.
Reconnectthe 3P connectorto
the mainshattspeedsensor,
To page 14-76
(cont'd)
14-75
vnx.su
TroubleshootingFlowchalt (cont'd)
From page 14-75
ooooooooooooo
ooooooooooooo
ooooooooooo
ooooooooooo
D19 and D12terminals.
ls the resistance4O0-600 0?
Disconneclthe 3P connectorfrom
the mainshaft speed sensor.
RunElectricalTroubleshootingfol
code 9.
Check for loos6TCM connectors.
It nocessary,substitute a knowngood TCM and r.check.
ooooooooooooo
ooooooooooooo
oooooooooo
ooooooooooo
Check tor continuitv between

D19 terminaland the mainshalt
speedsensotconnector.
MAINSHAFTSPEEDSENSOR
Ropairop.n in ORN/BLUwir6 b6tweon D19 terminalsnd th main'

shaft spa6d sensor.
Chock tgr continuity between
D12 terminaland the mainshatt
speed sensor connector.
ooooooooooooo
ooooooooooooo
ooooooooooo
ooooooooooo
3P CONNECTOR
View from terminalside
MAINSHAFTSPEEDSENSOR
Ropairopen in WHT/BLUwire betwen D12 tgrminaland th mainshaft sD6ed sonsor.

Chsck for loosTCM connoctors.
ll noco$ary, substitute a knowngood TCM and rocheck.
14-76
vnx.su
@ indic"to, light i8 on st6sdy

Inot blinkingl whenevor the ionition switch is ON.

from the TCM.
connector to the wite harness
only, not to the TCM (see page
14-49).
o o o o oo o oo o oo o l:qssoo9pc,I:oocto:osil
oooQooooooooo
o o o oo o o o o oo
o ooooooo ooo

A8 terminaland body ground.
ls there voltage?
Ropairshon to power in GRN/BLK

wiro botwoen A8 terminal and
gauge assembly.

conneclorto the TCM.

417 terminal and body ground
with the selectorleverin anv oo'
sition other than El.
ls there volrage?
Check for a sho.t to ground on the

PNK/GRNwi.e. ll th wir. is OK,
roplac the A/T gear poaition indicator.
ReDlace tho TCM.
{cont'd)
14-77
vnx.su
TroubleshootingFlowchaft (cont'dl
Lq4 indicatorlight do6s not come
on with the ignitionswitch ON. (lt
should come on Ior about 2
seconds.l
ls the servicecheck connector

connectedwith the special
tool ISCS Short Connectod?
Does the @
come on?
Diaconnect tho spocial tool from

th6 sgrvice check connoctor and
recheck.
Check {or loos6 TCM connoctors.

lf necessaw,substitute a knowngood TCM and recheck.
indicatorlighr

from the TCM.
conneclor to the wile harness
only, not to the TCM (see page
14-49).
A25
ooo oo oooooo I
| o ooooo o oo o ooo r:sjc.o.sl'1*st,li*os.s.4tcl
ooooooooooooq lifrif.S..n${5git:li$gg-:aiiigitll
ooooooooooo I
I| - - . -I T
..a26

A25 terminal and body ground
and A26 and body ground.
Rpair open BRN/BLK wires betwe6n A25 or A26 torminals and
G1 0 1 .

A23 or A24 and A25 or A26 ter
mrnals-
YES
I + )A23A25l- l
(+ tA24426(- |
t \
@
Repaii open or short in BLK/YEL
wire between tho A23 and /ot
424 terminals and underhood
tuse /relav box.
To page 14-79
14-78
vnx.su

connectorto the TCM.

8e sure that voltage is available
for 2 secondsbetweenthg A8 torminal and A25 or A26 terminal.
a26t- |
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
A8(+)
Chrck for opon or rhort in GR /

8LK wirc bctw.on th. A8 terminal and tha gauOaarrambly.
Disconnectthe Test Harness"A"

connector from the TCM.
Checkfor continuity between the

A8 terminal and the GRN/BLK
wire at tho gaugo assgmbly (see
section23).
B.p.ir op.n in GRI{/BLKwi.. bolwaen the A8 terminal and th.
gauga 6aaombly.
Chck for loor6 TCM conn6ctor3.
Check the A/T goa. polition
awitch. ll noc$ary, subrtitutg a
known-good TCM .nd rochock.
(cont'd)
14-79
vnx.su
In3poction ol ths A/C aign6l.

. Lock-up clutch does not have
duty operation(ON-OFF).
. Lock-upclutch does not engage.
TLrrnthe blower switch ON.
Pushthe A/C switch ON.
Soe Air Condilioning inspoction

lsee rection 221.
Disconnect the 26P conneclor

from the TCM.
BR /ALK

A22 {BLK/RED)and A25 (8RN/
BLKI or A26 IBRN/BLK)terminals.
(A/C compressorOFFI
Repairopon in 8LK/REDwiio b6twoon lho A22 torminal and A/C
comprossor clulch rel6y.
. A/C aignal ls OK.
. Chock lor looso TCM connectoB. lf n6co$ary, substitute a
known-good TCM and rschock.
. Inrpoct tho 6ir condhioning lsoo
loction 221.
vnx.su
Symptom
Shift lever cannot be moved lrom
E position with the brake pedal
depressed.
Check thar the brake lights come
on with the brake pedal depressed.
Aro brake lights ON?
Disconnecllhe 26P and 22P connectors from the TCM.

Connoct the Test Harness "A"
and "D" coonectors to th wire
harnessonly, not to the TCM {see
page 14-49).
R.prir l.ulty br6ko rwitch

cuita 18o6lactlon 231.
cir-
A 2 5t - )
oooooooooooo
oooooooooooo
ooooooooooo
oooooooooo
D 2l + )

02 and 425 or A26 terminals
with the brake pedal dopressed.
Ropalrop6n in GRt{/wHT wiro b.tween tho D2 to7minsland brak.

!witch.
. Bfako switch signal OK.

. Check for 10036TCM connectors. It noco$ary, sub3tiluto a
known-good TCM and ioch6ck.
. Insp6ct tho brako switch circuii
lsoo soction 23).
vnx.su
Lock-up Control SolenoidValve A/B

Replacement
NOTE: Lock-uDcontrolsolenoidvalvesA and B must be
removed/replaced
as an assemblv.
Removethe mountingboltsand lock-upcontrolsolenoid valve assembly.
l.
Disconnect2P connectortrom the lock-uocontrol

solenoidvalve A/8.
NOTE: Besureto removeor replacethe lock-upcontrol solenoidvalves A and B as an assembly.
2.
Measurethe resistancebetweenthe No. 1 terminal

(solenoidvalve A) ot the lock-up cont.ol solenoid
valveconnectorand body ground,and betweenthe
No. 2 terminal(solenoidvalve B) and body ground.
Checkthe lock-upcontrol solenoidvalve oil passages

tor dust or dirt. and replace as an assembly,if
neceSsary.
STANDARD:14- 16 O
2P CONI{ECTOR
View trom terminal side.
6 x 1.0 mm
12 N.m (1.2 kgf.m,8.7 lbf'ft)
Cleanthe mountingsudace
and oil passages.
VAI-VE
SoLENOTO
ASSEMBLY
?
Reolacethe lock-uocontrol solenoidvalve assembly if the resistanceis out of specitication.
4.
lf the .esistanceis within the standard,connectthe

No. 1 terminalot the lock-uocontrolsolenoidvalve
connectorto the battery positiveterminal.A clicking sound shouldbe heard.Connectthe No. 2 terminal to the battery positive terminsl. A clicking
soundshouldbe heard.Replacethe lock-upcontrol
solenoidvalve assemblyif no clickingsound is heard.
14-82
vnx.su
Cleanthe mountingsurtaceand oil passagesof the

lock-upcontrolsolenoidvalveassembly.and install
a new filter/gasket.
Checkthe connectorfor rust, dirt or oil and reconnect rt securely.
Shift Control SolenoidValve A/B

Test
NOTE: Shift controlsolenoidvalvesA and B must be removed/replaced
as an assembly.
1 . Removethe shift control solenoidvaive assembly

protector.
1 . Disconnect3P connectorfrom the shitt controlsolenoid valve A/8.
Removethe mountingbolts and shift control solenoid valve assembly.

(solenoidvalveA) of the shift controlsolenoidvalve
connecto.and body ground,and betweenthe No.
2 terminal(solenoidvalve B) and body ground.
NOTE: Be sure to removeor replacethe shitt control solenoidvalves A and B as an assembly.

Checkthe shitt controlsolenoidvalve oil passages
for dust or dirt, and replace as an assembly, it
necessary.
S T A N D A R D1: 4 - 1 6 O
6 x 1.0 mm
12 N'm (1.2kgl.m,4.7 lbl.ftl
SHIFT CONTROLSOLENOIO
VALVE ASSEMBLY
VALVE ASSMBLY
Clean the mounting

surfaceand oil passages.
Replace.
3 . Replacethe shift controlsolenoidvalve assemblyif

the resistanceis out oI sDecificaiton.
lf the resistanceis within the standard,connectthe
No. 1 terminalofthe shift controlsolenoid
valveconnector to the battery positiveterminal.A clicking
soundshouldbe heard.Connectthe No. 2 terminal
to the battery positiveterminal.A clicking sound
shouldbe heard.Replacethe shift control solenoid
valve assemblyif no clickingsound is heard.
Cleanthe mountingsurfaceand oil passagesof the

shitt control solenoidvalve assembly,and installa
new filter/gasket.
Checkthe connectorfor rust, dirt or oil, and reconnect it securely.
14-83
vnx.su
TransmissionControl Module
Replacement
I The Transmission
ControlModule(TCMIis locatedbelow the dashboard,behindthe lelt side kick panelon
the driver's side.
1.
Removetwo clips securingthe kick panelthen

move it.
CAUTION:
a All SRS electrical wiring hahesses are covered with
yellow insulation.
a Betore disconnecting any pan ot the SRS wile harness. connect the short connectorslsee page 23-7O).
a Replacethe entir6 affected SRS harness assmbly if
it has an open circuit or damaged wiring.
KICK PANEL
2.
Disconnectthe connectorsand removethe TCM.
6 x 1.0 mm
12 N'm
{1.2kgf.m,
8.7 tbf.Itl
SRS MAIN HARNESS
WIREHARNESS/
CONNECTORS
14-84
vnx.su
6 x 1.0 mm
12 N.m
(1.2 kgf.m, 8.7 lbt.ftl
Mainshaft/Countershaft
SpeedSensors
Replacement
Disconnectthe speed sensorconnectors,then remove the harnessclampon the countershattspeed
sensorharnessfrom the harnessstay.
Removethe 6 mm boltssecuringthe mainshaftand
countershaltspeedsensorsfrom the transmission
housrng.
Remove the mainshaft and countershaft speed
sensors,
Installthemainshattand countershaltspeedsensors
in the reverseorder of the removal.
I{ARNESSSTAY
6 x'l,Omm
l2 N.m
{1.2kgf.m,
8.7 tbf.fr)
6 x 1 . Om m
12 N.m
(1.2kgf.m,
8.7 tbf.ltl
COUNTERSHAFT
SPEEDSENSOR
14-85
vnx.su
Chart
Symptom-to-Component
Hydraulic System
Check these items
on the NOTESList
Check these items on the

PROBABLE
CAUSEList
SYMPTOM
Engineruns, but car does not move in any gear.
1, 6, 7, 16
K,L,R,S
Carmovesin @ and@, but not in @, @ or I

posataon.
a, 29, 44. 4a
c,M,o
9,30,49
C, L
1, 11, 22, 34, 38, 39, 40
c,L,o
1,8, 9, 10,11,46,47
C,D
Carmovesin E, @, [, @, uut not in E position.

car movesin p:1, [o-il, [2-],[!, uut not in E position.
Car moves in N
position.
Excessiveidle vibration.
5, 1'1
B,K,L
Slips in all gears.
6, 7, 16
C,L
No enginebrakingin E position.
12
C,D,L
Slips in 1st gear.
8, 29, 44, 4A
c,N,o
Slips in 2nd gear.
9, 20, 23, 30, 49

1 0 ,2 1, 2 3 , 3 1, 4 9
C,L
Slips in 3rd gear.
C,L
Slips in 4th gear.
1 1 ,2 3 , 3 2 , 4 4
C,L,N
Slips in reverse gear.
11,32,34,44
C,N
Flareson 1-2 upshilt.
3 , 1 5 ,2 3
E,L,V
Flareson2 3 upshilt.
3, 15, 23, 24, 49
E,L,V
Flareson 3-4 upshift.
3, 15, 23, 25, 49
E,L,N,V
No upshift;transmissionstays in 1st gear.
14,19,
G, L
No downshift to lst gear.
1 2 .1 9
G,L
Late upshift.
14
Erraticshitting.
2, 14,26
Harshshift (up and down shiftingl.
2, 4, 15, 23, 24, 25, 26, 27,

47
A , E ,H , I ,L , V
H a r s hs h i t t { 1 - 2 ) .
2 , 9 . 1 5 ,2 3
C,D,E,V
Harshs h i l t ( 2 - 3 ) .
2, 10, 15, 23, 24
C,D,E,H,L,V
Harshshift (3-4).
2 , | 1, 15, 23, 25
C , D , E ,I , L , V
Harshkick'down shifts.
2, 15, 23, 26, 27. 2A
E,L,O,V
Harshkick-downshift 12 1)
48
Harshdownshift at closedthrottle.
2 , 1 5 ,2 3
F T
Harshshift when manuallyshiftingto E] position.

Axle{s}slips out of transmissionon turns.
33
43,50
Axlels) stuck in transmission.
43
L,O
Ratchetingnoise when shiftinginro E position.
6,7,38,39,40
K,L,O
Loud poppingnoise when taking ott in E position.

Ratchetingnoise when shiftingfrom E to E positionor from E
to N I oosition.
3a,39,40
L,O
38,33,40,45
L,O
6, 11
K,L,O
Noisetrom transmissiononly when wheels are rolling.
39, 42
L,O
Gear whine, rpm related(pitchchangeswith shitts).
a, 13, 41
K,L,O
Gearwhine, speedrel6ted(pitch changeswith speed).
38, 42
L,O
Transmissionwill not shift into 4th gear in @
1,21,24.32
Lock-upclutch does not lock-upsmoothly.
17,36, 37
Lock-upclutch does not operateproperlV.
2.3. 14, 15. 18,35, 36, 37
E,L,V
Transmissionhas multitudeof problemsshitting.

At disassembly,largeparticlesoI metal are found on magnet.
43
L,O
Noisefrom transmissionin all selectorlever positions.
14-8 6
position
vnx.su
PROBABLECAUSE
1
o.
7.
8.
9.
10.
11
12.
13.
14.
lo.
18.
'I
9.
21
23.
26.
27.
24.
29.
30.
31
35.
36.
37.
38.
39.
40.
41
43.
44.
45.
47.
48.
49.
50.
Shitt cable broken/outof adiustment.

Throttle cabletoo short.
Throttle cabletoo long.
Wrong type ATF.
ldle rpm too low/high.
Oil pump worn or binding.
Pressureregulatorstuck.
l st clutch detective.
2nd clutch detective.
3rd clutch defective.
4th clutch defective.
1st'hold clutch defective.
Mainshattworn/damaged.
Modulatorvalve stuck.
Throttle valve B stuck.
ATF strainerclogged.
Toroue converterdefective.
Torque convertercheck valve stuck.
1-2 shift valve stuck.
Servo control valve stuck.
Clutch Dressurecontrol (CPC)valve stuck.
2-3 orifice control valve stuck.
Orificecontrol valve stuck.
3-2 kick-downvalve stuck.
4-3 kick-downvalve stuck.
4th exhaustvalve stuck.
1st accumulatordetective.
2nd accumulatordetective.
3rd accumulatordefective.
4th accumulatordefective.
1st-hold accumulatordefective.
Servo valve stuck.
Lock-uptiming B valve stuck.
Lock-upshift valve stuck.
Lock-uocontrol valve stuck.
Shift fork benr.
Reversegears worn/damaged(3 gears).
Reverseselectotworn.
3rd gearsworn/damaged(2 gears).
Finalqearsworn/damaged(2 gearsl.
DifferentialDinionshatt worn.
FeedpipeO-ringbroken.
4th qearsworn/damaged(2 gearsl
Gearclearanceincorrect.
Clutch clearanceincorrect.
One-way (sprag)clutch defective.
Sealinqrings/quideworn.
Axle-inboardjoint clip missing.
vnx.su
Symptom-to-ComponentGhart
HydraulicSystem(cont'd)
Checkthese items on the
PROBABLECAUSEDUETO
IMPROPER
REPAIR
List
The following symptoms can be caused

by improperrepairor assemblv
Carcreepsin E position.
R 1 ,R 2
Car does not move in @ or @ position.

Transmissionlocks up in @ position.
R4
Excessivedrag in transmission.
Excessivevibration,rom related.
R6
R 3 ,R l 2
R7
Noise with wheels moving only

Main seal pops out.
R5
Variousshifting problems.
R9, R1O
Harshupshifts.
R11
R8
PROBABLE
CAUSEDUE TO IMPROPER
REPAIR
R1
Items on the
NOTESList
R2.
lmproperclutch cleatance.
lmDroDerqear clearance.
R3.
Parkingbrake lever installedupsidedown.
R4.
One-way (spraglclutch installedupsidedown,
R5.
Reverseselectorhub installedupsidedown.
R6.
Oil oumo bindind
R7.
R8.
Torque converternot fully seated in oil pump.

Main seal improperlyinstalled.
R9.
Springsimproperlyinstalled,
R10.
Valves improperlyinstalled.
R11
Ball check valves not installed.
R12.
Shitt fork bolt not installed.
14-8 8
vnx.su
K.R
NOTES
A.
B.
E.
H.
K.
L.
M.
N.
o.
P.
o.
R.
q
T,
See flushing procedure,page l4-168 and 169.

Set idle rpm in gear to specitiedidle speed.lf still no good, adiust motor mounts as outlinedin engine
section of servicemanual.
lf the largeclutch piston O-ringis broken,inspect the piston groove for rough machining.
lf the clutch pack is seizedor is excessivelyworn, inspectthe other clutchesJor wear, and check the
orifice control valves and throttle valves for free movement.
It throttle valve B is stuck, inspectthe clutchesfor wear.
lf the 1-2 shift valveis stuck closed,the transmissionwill not upshift.lI stuck open,the transmission
has no lst gear.
lf the 2-3 orifice control valve is stuck, inspectthe 2nd and 3rd clutch packs for wear.
ll the orifice cont.ol valve is stuck, inspect the 3rd and 4th clutch packs for wear.
lf the clutch Dressurecontrol valve is stuck closed,the transmissionwill not shilt out of 1st gear.
improperalignmentor main valve body and torqueconverterhousingmay causeoil pump seizure.The
symptoms ale mostly an rpm-relatedticking noise or a high-pitchedsqueak.
ll the ATF straineris ctoggedwith paniclesof steelor aluminum,inspectthe oil pump and ditferential
pinionshaft. lt both are OK and no causelor the contaminationis found, replacethe torqueconverter.
lf the 1st clutch feedpipeguidein the right sidecover is scoredby the mainshaft,inspectthe ball bearing for excessivemovementin the transmissionhousing.lf OK. replacethe rightsidecover as it is dented. The O-ringunderthe guide is probablyworn.
ReDlacethe mainshsttif the bushingfor the 4th feedpipeis loose or damaged.
It the 4th feedpipeis damagedor out ot tound, replacethe right side cover'
Replacethe subjshaft it thtbushing for the 1st-holdJeedpipeis loose or damaged.
lf the 1st-holdfeedpipeis damagedor out of round, replaceit.
Replacethe mainshaftif the bushinglor the 1st feedpipeis loose or damaged.
lf the lst feedpipeis damagedor out ot round, replaceit.
A *o- r, da."s"d "p-g clutch is mostly a result of shifting the transmission in El or Lq! position
while the wheels rotate in reverse,such as rockingthe car in snow.
InsDectthe frame for collisiondamage.
Inspectfor damageor wear:
1. Reverseselectorgear teeth chamfers.
2. Engagementteeth chamtersof countershaft4th and reversegear.
3. Shift fork for scutt marks in center.
4. DifferentialDinionshaJtfor wear under pinion gears.
5. Bottom of 3rd clutch for switl marks.
Replaceitems 1, 2, 3 and 4 it worn or damaged.lf transmissionmakesclicking,grindingor.whirring
noise,atso replacemainshaft4th gear and reverseidler gear and countershaft4th gear in additionto
1,2,3ot4.
lf ditiersntialDinionshaft is worn, overhauldifferentialassembly,and replaceATF strainel,and thoroughly
clean transmission,tlush torque convertet,cooler and lines.
lf bottom of 3rd clutch is swirled and transmissionmakes gear noise, replacethe countershaft and tinal
driven gear.
Be wry carefulnot to dsmagethe torque converterhousingwhen replacingthe main ballbearing.You
may al;o damagethe oil pump when you torque down the main valve body. This will resultin oil pump
seizureit not detected.Use propertools.
Install the main seal tlush with the torque converter housing, lf you push it into the torque converter
housinguntil it bottoms out. it will block the oil return passageand result in damage.
coasting to a stop with zero th.ottle may be caused by a bent-in throttle valve
Harsh do\/vnshiJt"\./l,'hen
cable adjustmentmay clear this problem.
Throttle
stopper.
retainer/cam
ifuitle cable adjustment is essentialfor proper operation of the transmission. Not only does it affect
the shift points if misad,usted, but also the shift quality and lock-up clutch operation'
A cableadjustedtoo long will resultin throttle pressurebeingtoo low for the amountof enginetorque
input into ihe trsnsmissionand may causeclutch slippage.A cableadjustedtoo short will resultin too
hi;h throttle pressurewhich may cause harsh shitts, erraticshrfts and torque con
14-89
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Road Test
NOTE: Warm up the engineto operatingtemperature(the coolingfan comes on).
1
Apply parking brake and block th wheels. Start the engine, them move the selector lever to E] position while
depressingthe brake pedal.Depressthe acceleratorpedal, and releaseit suddenly.The engineshould not stall,
2.
Repeatsame test in @
3.
Shift the selecto.lever to E position,and chock that the shift points occur at approximatespeedsshown. Also
check fof abnormalnoise and clutch slippage.
position.
NOTE: Throttle positionsensorvoltage fepresentsthe throttle opening.

- 1. Connect the Test Harness between the ECM and connector (see section 1 1).
-2. Setthe digitalmultimeterto check voltagebetweenD1 1{+)terminal and D22 - terminalfor the throttle
{ )
Dosition sensor.
TEST
HARI{ESS
OTLAJ_PT3OlOA
DIGITAL MULTIMETER
Commarciallyavsilablo o.
KS-AHM-32-OO3
0 1 1{ +
ooooooooooooo oooooooo oooooo ooooooooooo
o o o o o o o o o o o o o o o o o o o o o oooooo ooooooooooo
14-9 0
vnx.su
@ or @ Position
. Upshitt
Throftle Opening
Unit of spe6d
Throttle positionsensor
voltage:O.75 V
17,O 19.O
Km/h
27,30
20-22
3 2 . 5- 3 5 . 5
mph
v o l t a g e :2 . 5 V
3rd-4th
2nd-3rd
l st- 2nd
43.5-48.5
mpn
3 3 . 5- 3 6 . 5
30- 34
Km/h
mph
Km/h
Unit ot speed
Full-openedthrottle
49.O- 55.O
57.O-63.O
62-65
99.O- 105.O
89.O-95.O
98- 101
15 7 . O - 1 6 3 . O
4th- 3rd
3rd - 2nd
2nd- l Et
Downshift
Throttle Opning
1a-21
29.O-33.O
mph
Full-closedthrottle
Km/h
13 7 . O - 1 4 3 . 0
Km/h
23-27
37.0-43.O
54- 58
85-89
mph
Full-openedthrottle
6-g (3rd- 1st)

1O- 14 (3rd- lst)
87 . 0- 9 3 . 0
LOCK-Up
@ Position
Throttle Opening
Unit of speed
voltage: 2,5 V
km/h
throttle
Full-opened
mpn
Lock-uo control solenoid

valve A ON
mpn
tJ-
Lock-up control solenoid

valve B ON
1 7- 2 0
2A.O-32.O
92-96
r48.0,1 54.O
to
21.O- 25.O
92-96
1 4 8 . O- 1 5 4 . 0
km/h
E
Throttlo Opening
Unit of sp6ed
v o l t a g e :1 . OV
Lock-up control solenoid

valve A ON
mph
kmih
mph
Full-openedthrottle
Lock-up control solnoid

valv6 B ON
b|-oJ
98- 102
85 89
137 143
km/h
4.
Position
Accelerateto about 35 mph {57 km/h) so the transmissionis in 4th, then shift from @
The car should immediatelybegin slowing down from enginebraking.
CAUTION: Do not shift from @
may damage the tlansmission,
or @
61 63
98- 102
85-89
137- 143
Oositionto E position.
positionto @ of E positionat speedsover 1OOmph (160 km/h); you
5. Check lor abnormalnoise and clutch slippagein the following positions.

E (1st Gear)Position
- 1 . Acceleratefrom a stop at full throttle. Check that there is no abno.malnoise or clutch slippage.
-2. Upshiftsshould not occur with the selectorin this position
E (2nd cear) Position.
- 1 . Acceleratefrom a stop at full throttle. Check that there is no abnormalnoise or clutch slippage.
-2. Upshittsand downshitts should not occur with the selectorin this position.
E {Reverse)Position
Acceleratefrom a stop at full throttle, and check for abnormalnoise and clutch slippage.
6. Test in E {Parking)Position
Parkcar on slope(approx.16o ), applythe parkingbrake,and shift into LE position.Releasethe brake;the car should
not move.
14-91
vnx.su
Stall Speed
CAUTION:
a To plevent transmission damage, do not test stall speed fot mote than 1O seconds at a time.
a Do not shift the level while raising th engine speed.
a Be sure to remove the pressure gauge belot testing stall speed.
1.
2.
3.
4.
5.
6.
Engagethe parkingbrakeand block all four wheels.

Connectthe tachometer,and start the engine.
Make sure the A/C switch is OFF.
After the enginehas warmedup to normaloperatingtemperature(the coolinglan comeson), shift into ft position.
Fully depressthe brake pedal and acceleratorfor 6 to 8 seconds.and note enginespeed.
Allow 2 minutesfor cooling,then repeatthe test in [, fDil and @ positions.
NOTE:
a Stall speedtests should be used lor diagnosticpurposesonly.
. Stall speed should be the same in E, tr. tr and @ positions.
Stall SpeedRPM: rpm
Specification: 2,400 rym
Service Limit: 2,2OO-2,600 tpm
TROUBLE
Stallrpm hish in E,
posrtron
Stall rpm high in I
PROBABLE
CAUSE
and@
E, I
position
Stall rpm high in @ position

Stall rpm high in @
position
Low fluid level or oil pump output

CloqgedATF strainer
Pressureregulatorvalve stuck closed
Slippingclutch
Slippageof 1st clutch, 1st-holdclutch or 1st gear one-way clutch
Slippageof 2nd clutch
Slippageof 1st clutch, lst gear one-way clutch
Stall rpm high in @ position
Slippageof 4th clutch
Stallrpm low in E,
position
Engineoutput low
Torque converterone-way clutch slipping
E, I
ana@
14-92
vnx.su
Fluid Level
Checking/Changing
Checking
Changing
NOTE: Checkthe fluid levelwith the engineat normal

operatingtemperature(the cooling lan comes on).
1.
Bringthe transmissionup to operatingtemperature

by drivingthe car. Parkthe car on levelground,turn
the engineoft, then removedrain plug.
1. Parkthe car on levelground. Shut otf the engine.

2.
Removethe dipstick (yellow loop) from the transmission,and wipe it with a clean cloth.
3.
Insertthe dipstick into the transmission.
NOTE: lf a cooler flusher is to be used, see page

1 4 - 1 6 8a n d 1 6 9 .
2.
Reinstailthe drain plug with a new sealingwasher,

then refillthetransmissionto the uppermark on the
dipstick.
Automatic Transmission Fluid Capacity:
2.1 | l2.S US qt, 2.4 lmp qt) at change
5.9 ? (6.2 US qt, 5.2 lmp qt) at overhaul
TRANSMISSIONRIGHT SIDE COVER
DIPSTICK(YELLOWLOOPI
4.
Removethe dipstick and check the fluid level.

should be betweenthe uoDerand lower marks.
P
il
\---
1 8 x 1 . 5m m
49 N.m (5.0 kgl.m, 36 lbl.ft)
IT
{J.
t)-i-
U P P EM
RARK
LowERMARK
5 . lf the level is below the lower mark, add fluid into

the tube to bring it to the upper mark. Use Honda
PremiumFormulaAutomaticTransmissionFluidor
a n e q u i v a l e n t D E X R O Nl l@
Fluid (ATF)only.
6.
lnse.t the diDstickback into the transmission.
14-93
vnx.su
PressureTesting
a While testing, be caretul of the rotating flont wheels.
a Make aura litts, jacks, and satty stands alo placed
plop6rly {see section 1}.
4.
Start the engine,and measurethe respectivepressure as follows.

a Line Pressure
a Clutch Pfessure
a Clutch Low/High Pressure
a Throttle B Pressure
5.
Installa new washer and the sealingbolt in the inspectionhole and tighten to the specifiedtorque.
CAUTION: Betoretsting, be sure the transmissionfluid

is tilled to rh6 ploper lvet.
1.
Raisethe car (seesection i),
2.
Warm up the engine{thecoolingfan comesonl, then

stop the engineand connect a tachometer.
3.
Connectthe oil pressuregaugeto each inspection

holels).
TOROUE:18 N.m (1.8 kgf.m, 13 tbf.fr)
CAUTION: Connect ths oil prsssure gauge scur_
ly; be sule not to allow dust and other foleign pani_
cl6s to 6nt1 th inspection holo.
A/T OILPRESSURE
GAUGE
SETWPANEL
07406-002oi+oo
TOROUE:18 N'm {1.8 kgf.m, 13 tbf.ft)

NOTE: Do not reuseold aluminumwashers.
a Line Pressure Masurement
- 1 . Set the parkingbrakeand block both rear wheels
securely.
-2.
Run the engineat 2,OOOrpm
-3.
Shift the selecr lever to S
-4.
Measureline pressure.
or @ position.
LINEPRESSURE
INSPECTION
HOLE
A/T LOW PRESSURE
GAUGE W/PANEL
07/rO6-0O70300
A/T OIL PRESSUREHOSE,

22'10 mm
OTMAJ_PY4OITA
{4 Roquirod)
A/T OIL PRESSUBEHOSE
ADAPTER
OTMAJ - PY/+O120
14 Roqui.odl
NOTE: Use the A/T Oil PressureGaugeSet (07406_

O02OOO3)or A/T Low Pressure Gauge (07406OOTO0OO).
and the oil pressuregaugehosesand adap_
ters shown above.
PRESSURESELECTOR
POStTTON
Line
No'E
SYMPTOM
PROBABLE
CAUSE
FLUIDPRESSURE
Standard
No (or low)
Torque converter, 83O-88O kPa
lrne pressure orl pump, pressure ( 8 . 5 - 9 . O k g f / c m , ,
regulator,to.que
120- I 30 psi)
convener check
valve
Service Limit
78O kPa
{8.0 kgl/cm,,1lO psi}
NoTE: Higherpressuresmay be indicatedit measurementsare made in selectorpositionsother than

@ or @ position.
14-94
vnx.su
a Clutch Pressuro Masurment

wtit" testing, be careful ot the rotating front wheols.
@
1.
2.
-3.
-4.
-5.
Set the parkingbrake and block both rear wheels securely.

Raisethe front of the car and supportwith safety stands.
Allow the front wheels to rotate freely,
Run the engineat 2,OOOrpm.
Measureeach clutch Pressure.
LOCK.UPCONTNOLSOLENOID
VALVE ASSEMBLY
INSPECTIONHOLE
rl|E!!UltE
1st Clutch
l st-hold
Clutch
SELECTOB
POST ON
Eo'E
tr
2nd Clutch
2nd Clutch
FLUIDPRESSURE
SYMPTOM
PROBABLE
CAUSE
1st Clutch
No or low
lst Pressure
No or low
1st-hold
pressure
1st-holdCIutch
83O-880 kPa
(8.5-9.O kgf/cm',
120- 130 psi)
Service Limit
78O kPa
{ 8 . Ok g f / c m ' ,1 1 O p s i )
2nd Clutch
No or low
2nd pressure
2nd Clutch
No or low
2nd pressure
3rd Clutch
3rd Clutch
No or low
3rd pressure
4th Clutch
4th clutch
No or low
4th pressure
Standard
Servo Valve or 4th

Clutch
4'l o kPa
460 kPa
(4.2 kgt/cm' , 60 psi)
|'4.7 kgtlcm2, 67 psil
throttle control lever
fully closed
fully closed
78O kPa
830-880 kPa
(8.O kgf/cm' , 1 1O psi)
(8.5 - 9.0 kgt/cm' ,
120- l30 psi)
m o r et h a n 3 / 1 6 o p e n e d
m o r et h a n 3 / 1 6 o p e n e d
830-880 kPa
(8.5 9.0 kqf/cm' ,
120- 130 psi)
780 kPa
(8.0 kgf/cm' , 1 1O psi)
(cont'd)
14-95
vnx.su
PressureTesting
(cont'dl
a
-6.
Clutch Low/High P.essure Measuroment
wtite resring. b calefut ot tha loraring

@[
flont wh66ls.
- 1. Allow the front wheels to rotate freely.
-2.
Removethe cableend of the throttlecontrolcable

from the throttle control lever.
- 7. Repeatsteps 5 and 6 for each clutch pressurebeing inspected.
NOTE: Do not loosenthe locknuts.simplvunhook

the cable end.
CAALE END
-3.
Start the engineand let it idle.
-4.
Shitt the select leve. to E
-5.
Slowly move the throttle linkageto increaseengine

rpm until pressureis indicaiedon the oil oressure
gauge.
Then releasethe throttlelinkage,allowingthe engrneto returnto an idle,and measurethe Dressure
resding.
With the engine idling, lift the throttle control lever

up approximately1/2 of its possibletravel and increase the engine rpm until pressure is indicated
on the gauge,then measurethe highestpressure
readingobtained.
position.
14-96
vnx.su
LOCK.UPCONTROL
SOLENOIDVALVE
4TI{ CLUTCH PRESSURE

INSPECTIONHOLE
SHIFT CONTROL
SOLENOIDVALVE
ASSEMBLY PROTECTOR
3RD CLUTCH PRESSURE
INSPECTIONHOLE
INSPECTIONHOLE
PRESSUNE
2nd Clutch
SELECTOR
POStTtON
SYMPTOM
PROBABLE
CAUSE
FLUIDPRESSURE
Standard
No or low
2nd Clutch
2nd pressure
3rd Clutch
No or low
3rd pressure
3rd Clutch
4th Clutch
No or low
4th pressure
4th Clutch
460-88O kPa
(4.7 -9.O kgtlcmt,
67- 130 psil
varies with throttle
openrn9
Service Limit
41OkPa
{4.2 kgf/cm,, 60 psi}
with throttle control
lever released
78O kPa
l8.O kgtlcm,, 1'lO psil
with throttle control
lever more than 3/1 6
opened
(cont'd)
vnx.su
14-97
PressureTesting
(cont'dl
a Throttle B Ptsssure Measuremcnt
wrril" resring, be caretut ot rhe rotaring
@@
front wheels.
1. Allow the front wheels to rotate treelv.
-2. Removethe cableend of the throttlecontrolcable
3.
-4.
-5.
-6.
-7.
Shift the selectorlever to @ or @ position.

Run the engineat 1,OOOrpm
Measurefull-closedthrottle B pressure.
Move the throttle control leverto full-openedthrottle position.
Measurefull-openedthrottle B pressure.
NOTE: Do not loosenthe locknuts,simplyunhook

the cable end.
PRESSURE
SELECTOR
SYMPTOM
POSTTTON
PROBABLECAUSE
Throttle B
loil orlDll
Thfottle Valve B
Pressuretoo
high
FLUIDPRESSURE
Standard
No or low
Throttle B
pressure
O-15 kPa
{ O - O . 15 k g f / c m , ,
0-2.1 psi)
fully closed
83o 88O kPa
(8.5-9.O kgf/cmz,
120 130 psi)
thfottle control levet
fully closed
14-98
vnx.su
Srvica Limit
78O kPa
(8.O kgl/cm,, l lO psi)
tully closed
Transmission
Removal
a Make sur lifts. iacks and safety stands are placad
properly, and hoist brackots are attachod to tho correct position on ths sngine {seo sectionl }.
o Apply parking brake and block rear wheels, so car will
not roll off stands and fall on you whil6 working undel it
4.
Bemove the t.ansmissionground cable from the

transmissionhanger.
Disconnectthe lock-uDcontrol solenoidvalve connectorand the shitt controlsolenoidvalve connector, then removethe harnessclamp on the lock-up
control solenoidharnessfrom the harnessstav.
CAUTION: Use tender covers to avoid damsging painted surlaces,

1.
Disconnectthe battery negative{ - } and positive( + )

cables from the battery.
2.
Removethe intakeair duct and air cleanerhousino

assembly.
HARNESSCLAMP
LOCK-UPCONTROL
SOLENOIDVALVE
CONNECTOR
AIR CLEAI{ER
HOUSINGASSEMBLY
SHIFT CONTROL
SOLENOIDVALVE
CONNECTOR
TRANSMISSION
GROUNDCABI-E
Disconnectthe vehiclespeed sensor(VSS),mainshaft sDeedsensorand countershaftspeedsensor

connectors.
3 . Removethe startermotor cablesand cable holder
VEHICLESPEED
SENSORCONNECTOR
from the starter motor.
STARTERMOTOR CABLE
CABLE HOLDER
VEHICLESPEED
SENSOR
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
STARTERMOTOR
?/\
STARTERMOTOR CABLE
vnx.su
MAINSHAFTSPEED
SENSORCONNECTOR(cont,d)
4-99
Transmission
Removal{cont'd)
7.
Removethe transmissionhousingmountingbolts.
9. Removethe splashshield.
6 x 10
CLIP
S pcs.
Removethe drainpluganddrainthe automatictransmissiontluid (ATF).Reinstallthe drain plug with a
new sealingwasher lsee page 14-93).
10. Remove the cotter pins and castle nuts, then

separatethe balljointsfrom the lower arm {seesection 18).
11. Removethe right dampe. fork bolt. then separate
right damperfork and damper.
PINCI{ BOLT
/\
SELF.LOCKING
NUT
Replace.
DAMPERFORK
DRAINPLUG
1 8 x 1 . 5m m
49 N'm 15.0 kgt-m,36 tbt-fr)
14-100
vnx.su
CASTLE NUT
COTTERPIN
Replace.
12. Pry the right driveshaftout of the differentialand pry

the lett driveshattout of the intermediateshaft.
'13.
Pull on the inboardjoint and removethe right and

left driveshafts(see section 16).
'14.
Tie plastic bags over the driveshaftends.
17. Removethe intermediateshaft.
NOTE: Coat all precisionfinished surfaces with

clean engineoil.
1 8 . Removethe shift cablecover,then removethe shift

cable by removingthe control lever.
PLASTICBAG
Disconnectthe heatedoxygen sensor(HO2S)connecror.
CAUTION: Take care not to bend the shift control

cabls whilo removing it.
1 6 . Removethe exhaust pipe A.

SHIFT CABLE
LOCKWASHER CONTROLLEVER
Replace.
SELF-LOCKING
NUT
Replace.
(cont'dl
Replace.
14-101
vnx.su
Transmission
Removal(cont'dl
'1
9. Removethe right tront mount/bracket,then remove
the end ol the throttle cont.ol cabletrom the throttle control lever.
23. Placea jack underthe transmission,raisethe lransmission just enough to take weight off ol the
mounts. then removethe transmissionmount.
20. Removethe ATF coolerhosesat the joint pipes.Turn

the endsof the coolerhosesup to preventATF from
flowing out, then plug the joint pipes.
NOTE: Check tor any sign ot leakageat the hose
joints.
'i
THROTTLE
CONTROL
"
z/'l e
(-J
t'
RrcHTFRoNTiiouNT/BRAcKET BoLTs
ATF COOLER
Replace. HOSES
21. Removethe enginestiftenerand totque converter

cover.
22. Removethe eight drive plate bolts one at at time
while rotatingthe crankshaftpulley.
24. Removethe t.ansmissionhousingmounting bolts

and rear enginemounting bolts.
25. Pullthe transmissionaway from the engineuntil it
clearsthe 14 mm dowel Dins,then lower it on the
transmissioniack.
WASHERS
Replace.
14-102
vnx.su
lllustrated Index
Right Side Cover
14-104
vnx.su
O RtcHTslDEcovERpRoTEcToR
@ RrcHTstDEcovER
spEEDsENsoR
O MAtt{sHAFr
@ o-RtNGReptace.
SPEEO
SENSOR
@ cour{TERSHAFT
STAY
@ HARNESS
O RoLLCR
@ COLLAR
O O-RINGReptace.
@ FEEDPIPEFLAI{GE
@ o-RrNG
@ sIrlAPRING
@ 3RDCIUTCHFEEDPIPE
LOCKNUT(FLAt{cEf{UTl Reptace.
@ COUNTERSHAFT
@ coultTERsHAFf col{tCAL SpRtt{cWASHERReotace.
@ PARKI G GEAR
@ oNE-waY cLUTcH
@ couNTERsHAFrlsr GEAR
BEARING
@ NEEDLE
@ couNTERsHAFrtsr GEARcoLLAB
@ O-RINGReptace.
@ l sT-HoLDaccuMuLAToR ptsToN
spBfi{c
@ isT-HoLD ACCUMULAToR
@ o-RtNGReptace.
covER
@ rsT-HoLDACGUMULAToR
@ SNAPRrr{G
@ PAFKINGBRAKEPAWL
BRAKEPAWLSPRII{G
@ PARKING
BRAKEPAWLSHAFT
@ PARKING
aRAKEPAWLSToPPER
@ PARKING
@ LOCKwasHEn Reptace.
@ PARKI G BRAKEs?oPPER
BRAI(ELEVER
@ PARKING
@ PARKI G BRAKELEVERSPBING
@ DowEL PrN
@ O-RltIGReptace.
stoE covER GASKETFeptace.
@ RTGHT
@ isT ct-uTcH FEEDptpE
@ o-RtNGReptace.
@ FEEDPIPEGUIDE
@ SNAPRING
NUT)ReDIace.
@ MAINSHAFTLocKNUT{FLANGE
SpRtNGWASHERReotsce.
@ MAfISHAFTCONTCAL
@ IsT cLUTcHASSEMBLY
@ O-RINGReptace.
@ THRUSTWASHER
BEARIG
@ THRUSINEEDLE
@ EEDLEBEARING
@ MAI'{SHAFTlsT GEAR
@ THRUSTWASHER
@ MAINSHAFTlsT GEARcoLLAR
@ RoLLER
@ coLLAR
@ O-Rlt{cReptace.
@ FEEoPIPEFLANGE
@ o-RINGRptace.
@ SNAPRING
@ lsr-HoLD cLUTcH FEEDptpE
LoCKNUTIFLAt{cNUTIReptace.
@ SUB-SHAFT
@ suB-sHAFr cot{tcAl spRtNGWASHERReptace.
lST GEAR
@ SU8-SHAFT
@ LOCKWASHERf,eptace.
@ THRoTILEcor{TRoL LEVER
@ THRoTTLEcoNTRoL I.EVERSPRING
@ oll sEAt Reptace.
coNTRoL CABLESTAY
@ THRoTTI"E
SOLEI{O|O
HARNESS
@ sHtFTCONTROL
@ Jor T BoLT
PIPE
@ ATF COOLER
Roptace.
@ SEAL|NGWASHERS
@ ATF cooLER P|PE
@ ATF LEVELGAUGE
@ JOINTEOLT
@ vEHtcLEspEEDsEf{soR
@ o-RtNGReptace.
@ DRAINPLUG
@ SEALINGWASHERReplace.
TOROUESPECIFICATIONS
Ret No.
B
D
F
Torque Value
'12 N.m (1
.2 kgf.m, 8.7 lbJ.tt)
14 N.m (1.4 kgf.m, 10lbf.ft)
22 N.m 12.2 kgf.m, 16 lbf.ft)
8 N.m (O.8 kgf.m, 6 lbf.ftl
28 N'm (2.9 kgf.m, 21 lbf.ttl
49 N.m (5.O kgf.m, 36 lbf'ft)
93 N.m {9.5 kgf.m, 69 lbt.ft}
Bolt Size
6 x 1 , Om m
6 x 1 . Om m
I x 1 . 2 5m m
5x0.8mm
12 x 1-25mm
'1.5
18 x
mm
t Y x t . z 5m m
1 0 3 N . m { 1 O . 5k g f . m , 7 5 . 9 l b f . f t l - O 1 O 3N . m ( 1 0 . 5 k g f ' m . 7 5 . 9 l b f . f t )
2 3 x 1 . 2 5m m
93 N.m (9.5 kg-m, 69 lb-ft)
'19
x 1 . 2 5m m
Remarks
Specialbolt
ATF cooler pipe joint bolt

Drainplug
Mainshaftlocknut
(flangenut):
Left-handthreads
Countershaftlocknut
(tlangenut)
Lett-handthreads
Sub-shattlocknut
(flangenut)
14-105
vnx.su
lllustrated lndex
Transmission
Housing
I ',
TTI]
a''-.2
14-106
vnx.su
O) COUNTERSHAFTREVERSEGEAR COLLAR
@ NEEDLEBEARING
G) COUNTERSHAFTREVERSEGEAR
@ LOcK WASHERReptace.
sHIFT FoRK
@ REVERSE
@ BEVERSESELECToR
O REVERSESELECToRHUB
@ couNTERSHAFT 4TH GEAR
@ NEEDLEBEARING
@ DTSTANCECOLLAR, 29 mm Setecrivepart.
@ coUNTERSHAFT2ND GEAR
@ THRUSTNEEDLEBEARING
@ GoUNTERSHAFT3RD GEAR
@ NEEDLEBEARING
@ THRUSTNEEDLEEEARING
G) COUNTERSHAFT3RD GEAR COLI-AR
O 3RD cLuTcH ASSEMBLY
(!) O-RINGSReplace.
@ coUNTERSHAFT
@ REVERSEIDLERGEAR
@ SNAP RING
@ THRUSTWASHER
@ MAINSHAFT4TH GEAR
@) NEEDLEBEARINGS
@ MAINSHAFT 4TH GEAR coLLAR
@ 2ND/4TH cLUTcH ASSEMBLY
et O-RINGSReplace.
@ THRUSTwaSHER, 36.5 x 55 mm Setectivepan.
@ MA|NSHAFT2ND GEAR
, NEEDI.EBEARING
.O MAINSHAFT
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
SEAL|NGRtNGs, 3s mm
SEAL|NGR|NG,29 mm
NEEDLEBEARING
sET RING
1ST-HOLDCLUTCH
O-RINGReplace.
THRUST WASHER
THRUST NEEDLEBEARING
NEEDLEBEARING
SUB.SHAFT4TH GEAR
THRUST NEEDLEBEARING
SUB.SHAFT4TH GEAR COLLAR
SUB-SHAFT
SUB.SHAFTNEEDLEBEARING
NEEDLEBEARINGSToPPER
otL GUTDEcAP Reptace.
REVERSEIDLERGAR SIIAFT/HOLDER
NEEDLEBEARII{G
sHIFT GONTROLSOLENOIDvAI.vE ASSEMBLY
PROTECTOR
VALVE A/B
sHrFT CONTROLSOLENOTD
SHIFT CONTROLSOLENOIDVALVE A/B FILTER/GASKET
Replace.
TRANSMISSIONHANGR
TRANSMtsstoN MouI{T BRAGKET
oll SEAL Replace.
sET RING Replace.
TRANSMISSIONHOUSINGGASKET Replace.
DOWEL PrN
SNAP RI G
SUB-SHAFTIRANSMtSStON HOUSNG AEARTNG
MAINSHAFT TRANSMISSIONHOUSINGBEARING
coUNTERSHAFT TRANSMISSIONHOUSINGBEARING
DIFFERENTIALASSEMELY
OtL SEAL Replace.
CoNNECTORSTAY
Rel No.
B
E
H
Bolt Size
Torque Value
1 2 N . m ( 1 . 2 k g f . m , 8 . 7l b t . t t )
1 4 N . m ( 1. 4 k g f. m . 1 0 l b f. f t )
44 N.m (4.5 kgt.m, 33 lbf.ft)
6 4 N . m ( 6 . 5 k g f. m , 4 7 l b f. f t )
6 x 1 . Om m
6 x 1 . Om m
' l Ox 1 . 2 5m m
Remarks
Specialbolt
1 2 x 1 . 2 5m m
14-107
vnx.su
lllustratedIndex
Torque Converter Housing/ValveBody
^\
14-108
vnx.su
OIL FEEDPIPE
ACCUMULATORCOVER
O-RINGReplace.
OIL FEEDPIPE
OIL FEEDPIPE
SERVOOETENTEASE
LOCNWASHERFeplace.
ATF STRAINER
SUCTIONPIPECOLLAR
SERVOBOOY
THROTTLECONTROLSHAFT
E RING
SERVOSEPARATORPLATE
1ST ACCUMULATORCHOKE
CHECKBALL
STOPPERSHAFT STAY
SECONDARYVALVE BODY
DOWEL PIN
SECONDARYSEPARATORPLATE
LUBRICATORPLATE
OIL FEEDPIPE
LOCK.UPVALVE BODY
DOWEL PIN
LOCK-UPSEPARATORPLATE
TOROUECONVERTERCHECKVALVE SPRING
TOROUECONVERTER
CHECKVALVE
COOLERCHECKVALVE SPRING
COOLERCHECKVALVE
@ REGULAToRvALvE BoDY
@ STOPPERSHAFT
@ O-RINGReptace.
@ STATOR SHAFT
@ otl FEEDPIPE
@ MAIN vALvE BoDY
@ CHECK EALL
@ DowEL PIN
@ oIL PUMP DRIVEGEAR
@ OIL PUMPDRIVENGEARSHAFT
Q9 OIL PUMPDRIVENGEAR
@ MAIN SEPARAToR PLATE
@ DowEL PrN
@ coNTBoL sHAFT
@ DETENTSPRING
@ DETENTARM SHAFT
@) DETENTARM
@ ATF MAGNET
TOROUECONVERTER
HOUSING
@ COUNTEBSHAFT
NEEDLEBEANING
@ oIL GUIDE PLATE
@ TOROUECONVERTERHoUSING
HOUSINGBEARING
@)MAINSHAFTTOROUECONVERTER
@ oll SEAL Reptace.
soLENotD
vALvEA/B
@ LocK-upcoNTRoL
STAY
@ coNNECTOR
VALVE A/B
@ LOCK-UPCONTROLSOLENOTD
FILTER/GASKET
Replace.
ReI No.
Torque Value
Bolt Size
1 2 N . m ( 1. 2 k g f . m , 8 . 7 l b f . f t )
6 x 1 . Om m
Remarks
14-109
vnx.su
Right Side Cover

Removal
NOTE:
a Cleanall pans thoroughlyin solvent or carburetorcleaner,and dry with compressedair,
a Blow out all passages.
a When removingthe transmissionright side cover, replacethe following:
. Right side cover gasket
. Lock washers
SIDE COVER PROTECTOR
. O-rings
. Each shaft locknut
1.O mm BOLTS
. Conicalspring washers
. Sealingwashers
RIGHT SIDE COVER
SUB.SHAFT
Replace.
CONICAL
SPRING
WASHER
Replace.
WASHER
Replace.
MAINSHAFT
1ST GEAR
PARKINGGEAR
ONE.WAYCLUTCH
SUB.SHAFT 1ST GEAN

THROTTLECONTBOL
LEVER
1STGEAR
THRUST WASHER
,IST GEAB COLLAR
BEABING
NEEDLE
lST GEARCOLLAR
JOINT AOLT
ATF LEVELGAUGE
ATF COOLERPIPES
SEALINGWASHERS
Replace.
14-110
vnx.su
'1.
Removethe 13 bolts securingthe right side cover

and right side cover protector,then removethem.
Slip the specialtool onto the mainshaftas shown.
5. Pry the lock tab of the mainshaftlocknut.

6. Cut the lock tabs of the countershaftand sub-shaft
locknutsusinga chiselas shown. Then removethe
locknut from each shatt.
MAINSHAFTHOLOER
07GAB-PF50101
NOTE;
a Mainshaftand countershaftlocknuts have letthand threads.
a Cleanthe old countershaftlocknut,it is used to
installthe parkinggear on the countershaft.
a Always wear safety glasses.
CAUTION:
Keop all of th chisled panicles out of the
tlanamigsion.
llrF-"""*
LocKNUr
,fl(,-..-
@-.**'o'
7 . Removethe lock pin that was installedto hold the
sub-shaft.
3.
Engagethe parkingbrakepawl with the parkinggear.
4.
Align the hole ot the sub-shaft l st gear with the hole

of the the transmissionhousing,then inserta pin to
lock the sub-shaft while removing the sub-shaft
locknut.
8 . Removethe specialtool from the mainshaftafter

removingthe locknut.
q
Removethe 1st clutch and mainshaft1st gear assembly from the mainshaft.
1 0 .Removethe sub-shaft 1st gear,

1 1 .Removethe parkingbrake pawl.
COUNTERSHAFT
LOCKNUT
Replace.
MAINSHAFT
LOCKNUT
Replace.
8 mm pin.
commrcially
available
SU8-SHAFT
LOCKNUT
Replace.
1 2 . Usinga universaltwo jaw puller.removethe parking gea..one-wayclutch and counlershatt1st gear

assembly.
PARKINGGEAR
1 3 .Removethe parking brake lever from the control

shaft.
Align the holes.
CONICAL SPNING
WASHERS
Replace.
1 4 . Removethe throttle control lever from the throttle

control shaft.
1 5 . Removethe ATF cooler pipes.
t o . Removethe ATF level gauge.
14-111
vnx.su
Transmission Housing
Removal
TRANSMTSSTOIr
HOUSIIG
MOUNTING
BOLTS
fl
TSAt{SMtSStOt{
HANGER
TRANSMISSIO HOUSII{G
TRA[{SMrSSrOr{
MOUNTBRACKET
'RAI{SMTSSTOHOUS|IG
GASKET
Rgolace.
REVERSEGCAR COLLAR
]{EEDLEBEARII{G
NEVERSE
GEAR
MAINSHAFT
SUA.ASSEMBLY
LOCTWASHEF
Replace.
SHIFT FORX
REVERSE
SELCTON
COUI{TERS}IAFT
SUB-ASSEMEI.Y
DIFFEFEI{IIAL
ASSEMBIY
(-t\
14-112
vnx.su
NOTE:
a Clean all parts thoroughly in solvent o. carburetor
cleanerand d.y with compressedair.
a When removingthe transmissionhousing,replacethe
following:
. Transmissionhousinggasket
. Lock washer
1.
Removethe countershaft reversegear with the collar and needlebearing.
6 . Remove the lock bolt securing the shitt fork. then

remove the fork with the reverse selector trom the
countershatt.
Remove the countershaft and mainshaft subassemblytogether.
Removethe transmissionmount b.acket.
2 . Remove the transmission housing mounting bolts

and hanger.
Align the spring pin of the control shaft with the
transmissionhousinggrooveby turningthe control
shaft.
4.
Installthe specialtool on the transmissionhousing,

then removethe housingas shown.
HOUSING
PUI-LER
07HAC-PK4010A
8.
Removethe ditferentialassemblv.
14-113
vnx.su
Torque GonverterHousing/ValveBody
Removal
Bolts, 7
\
LOCK-UP
VALVE
B . D Y \ u ll
DOWELPIN
LOCK-UPSEPARATOR
PI.ATE
REGULATORVALVE
AODY
otL
FEED
PIPES
OII- FEEDPIPES
TOR COVER
OIL FEEOPIPE
Ll
ll|i
8oll3.3
SERVODETENT
BASE
|]V
ATF STRAINER
OIL FEED PIPES
SUCTION PIPE
COLLAR
8olts, 4 Boll
DOWEL PIN
MAIII VALVE
BODY
OIL PUMP DRIVENGEAR SHAFT
SECONDARYVALVE
BODY
OIL PUMP DRIVEN

DOWEL PIN
SECONDARYSEPARATOR
PLATE
MAIN SPARATOR
PLATE
ft--
rrr urcler
TOROUECONVERTER
HOUSING
14-114
vnx.su
NOTE:
a Clean all parts thoroughly in solvent or carbuetor
cleanerand dry with compressedair.
a Whenremovingthe valvebody replacethe following:
. O-rings
. Lock wsshers
1 5 .Cleanthe inlet opsningof the ATF strainerthoroughly with compressedair, then check that it is in good
condition,and the inlet openingis not clogged.
1 . Removethe oil feed pipes from the servo body, srvo detent base, accumulatofcover, lock-uDvalve
body and main valve body.
2, Removethe three bolts securingthe ATF strainerand
servo detent base, then remove them.
3. Removethe three bolts securingthe accumulator
cover. then removethe accumulatorcover.
4. Removethe six bolts secu.ing the servo body, then
removethe servo body and separatorplate.
5. Removethe bolt securingthe secondaryvalve body,
then removethe secondaryvalve body and separator plate.
6. Removethe eight boltssecuringthe lubricatorplate
and lock-upvalve body, then removethe lubricator
plate, lock-upvalve body and separatorplate.
II{LET OPENING
1 6 . Replacethe ATF strainerit it is cloggedor damaged.

NOTE: The ATF strainer can be reused if it is not
clo9ged.
7. Femovethe bolt securingthe.egulatorvalvebody,

then.emove the regulatorvalve body.
8. Remove the stator shaft and stopper shaft.
9. Removethe detent spring t,om the detent arm. then
remove the control shaft from the torque convener
housing.
1O. Removethe detent arm and detent afm shaft t.om
the main valve bodv.
1 1. Removethe four bolts secu.ingthe main valve body,
then removethe main valve body.
12. Removethe oil pumpdrivengearshaft,then remove
the oil pump gears.
'13.
Removethe main separatorplate with two dowel

Dtns.
14, Removeand clean the ATF magnet.
14-115
vnx.su
Valve Caps
Description
Caps with one projectedtip and one flat end are installedwith the llat end toward the insideot the valve
body.
Caps with a projectedtip on each end are installed
with the smallertip toward the insideof the valve
body. The small tip is a spring guide.
Capswith hollow ends are installedwith the hollow

end away from the insideof the valve body.
Capswith notchedends are installedwith the notch
toward the insideof the valve body.
Capswith flat ends and a holethroughthe centerare
installedwith the smallerholetowardthe insideof the
valve body.
Toward outside oI valv bodv.
Toward outside ot valv6 bodv.
lrj taj u
rq
fq1 @.
Toward inside of valve body.
Towa.d inside of valve body.
Caps with one projected tip and hollow end are installed with the tip toward the inside of the valve body.
The tip is a springguide.
Capswith llat ends and a groovearoundthe cap are

installedwith the groovedsidetoward the outsideof
the valve body.
Toward outside of valve bodv.
Towa.d outside ot valve body.
Sectional view
14-11 6
vnx.su
Valve Body
Repair
NOTE: This repairis only necessaryil one or more of
the valvesin a valve body do not slidesmoothlyin their
bores.You may use this procedureto lree the valvesin
the valve bodies.
1. Soak a sheet of #600 abrasivepaper in ATF for
about 30 minutes.
2.
5 . Removethe #600 paperand thoroughlywash the

entire valve body in solvent, then dry with comperssedair.
6 . Coat the valve with ATF then drop it into its bore.
It shoulddrop to the bottom o{ the bore under its
own weight. lf not. repeatstep 4 then retest.
Carefullytap the valve body so the stickingvalve

drops out of its bore.
CAUTION: lt may be necessaryto use a small
screwdiiver to pry the the valve lree. Be carelul not
to sclatch the bore with ihe sc.ewdliver.
3.
4.
Inspectthe valvetor any scuff marks.Usethe ATFsoaked# 600 pagperto polishoff any burrsthat are
on the valve,than wash the valvein solventand dry
it with compressedair.
VALVE BODY
Rollup halt a sheetoI ATF-soakedpaperand insert

it in the valve bore of the stickingvalve.
Twist the paper slightly,so that it unrollsand fits
the boretightly,then polishthe boreby twistingthe
paper as you push it in and out.
CAUTION: The valve body is aluminumand doesn't
requiremuch polishingto removeany burs.
W
7 . Remove the valve and thoroughly clean it and the
valve body with solvent. Dry all parts with com
pressed air, then reassemble using ATF as a
lubricant.
14-117
vnx.su
Valve
Assembly
NOTE:
Coat all parts with ATF belore assemblv.
a Set the springin the valve and installit in the valve

body.
Pushthe springin with a screwdriver,then installthe
spring seat.
a Installthe valve, valve springand cap in the valve body

and secure with the 10116r.
-6^<
ROLLER
5-1
SPBINGSEAT
VALVE BODY
VALVE BODY
Installthe valve, spring and cap in the valve bodv.

Pushthe cap, then installthe cliD,
ROLLER
VALVE EODY
VALVE
CAP
14-118
vnx.su
Oil Pump
lnspection
l.
Installthe oil pump gearsand oil pump driven gear

shait in the main valve body.
Measurethe sideclearanceot the oil pumpdriveand

driven gears.
Oil Pump Gsars Sido (Radisl) Clsarance:
Stsndard {Nw}: Drive gar
n)
O . 2 1 O - O . 2 6 5m m ( O . O O 8 3 - O . O 1 0i 4
Drivon g6al
O . O 7 O - O . 1 2 5m m ( O . O O 2 8 - O . O O 4i n9)
CHAMFER
GROOVE
YI
Grooved and chamfered side
faces separator plate.
OIL PUMP
DRIVENGEAR
Inspect teeth tor wear or damago.
DRIVEGEAR
Inspectteethlor wearor damaage.
Removethe oil pump drivengear shaft, and measure the thrust clearanceof the oil pump drivengearto-main valve body.
Oil pump Drive/DrivenGearthrust (Axiall Clearance:
Standard(Nawl:
0 . 0 3 - O . O 5 m m { O . O O-lO . O O 2i n )
Sorvice Limit:
O.O7mm {O.0O3in}
MAIN VALVE BODY
STRAIGHTEDGE
vnx.su
14-11 9
Main Valve Body

NOTE:
a Clean all parts thoroughly in solvent or carburetor cloaner and dry with compressed air.
a Blow out all passaoes.
a Replacevalve body as an assemblyit 8ny parts are worn or damaged.
a Check all valves lor free movement.lf any fail to slide freely, see Valve Body Repairon page 14-117.
CAUTION: Do not use a magnot to romovo ths check batb; it may magnotize the balls.
2.3 SHIFTVALVE
CHECK BALLS, 3
DETENTARM SHAFT
DETEfITARM
rrl\.
J ST VALVE
'-ir,
,^r @
q---
t'-'t @
RELIEFVALVE
\\ i f l
@
MANUAL
VALVE
VALVECAP CLIP
MAIN VALVE BODY
14-120
vnx.su
Qr
DETENTARM SHAFT
MANUAL VALVE
sPat G sPEctFtcaTtot{s
Unit ot length: mm (in)
Standard lNowl
o,
o
@
o
o
@
Epfng
Relief valve spring
4th oxhaust valve spring
CPC valve spring
1-2 shift valv6 spring
Wiro Dia.
1. 1 { O . O 4 3 l
1. 0 { 0 . 0 3 9 t
0.9 {0.035t
1 . 3{ O . 0 5 1 )
0.9 {0.03s)
o.D.
8.6 (0.339)
7.1 (O.2801
7.6 (O.2991
9.4 (0.370)
8.6 (O.339)
F.oo Lsngth
3 7 . 1{1 . 4 6 1 )
60.3 12.3741
57.O 12.2441
3 5 . 3{ 1 . 3 9 O )
4 0 . 4{ 1 . s 9 1 t
No. ot Coils
13 . 4
18.5
26.4
12.4
14.5
14-121
vnx.su
RegulatorValve Body
NOTE:
a Cleanall pans thoroughlyin solvent or carburetorcleaner,and dry with compressedait.
a Replacevalve body as an assemblyit any parts are worn or damaged.
a Check all valves for free movement.lf any fail to slide freely, see Valve Body Repairon page 14-117.
1.
Hold the .egulatorspring cap in place while removingthe lock bolt. Once the bolt is removed.releasethe spring
cap slowlv.
CAUTION: The .egulator spring c8p can pop out whsn the lock bolt is removod.
Reassemblyis in the reverseorder of the disassemblyprocedute.
2.
NOTE:
. Coat all pans with ATF.
a Align the hole in the regulatorspringcap with the hole in the valve body, pressthe springcap into the body and
tighten the lock bolt.
t,-V
REGULATORVALVE
,*6t'"
LOCK.BOLT
6 x 1 . 0m m
12 N.m (1.2 kgl.m,8.7 lbf.ftl
REGULATORSPRINGCAP
COOLERCHECK
OOWELPINS, 2
ROLLER
REGULATORVALVE BODY
"%=
.
I',.-2"
ll
VALVESLEEVE
SPRINGSPECIFICATIONS
Standard (New)
No.
o
/a
@
\9/
Spring
Regulatorvalve spring A
Regulatorvalve spring B
Stator reactionspring
Lock-upcontrol valve spring
Coolercheck valve spring
Torque convertercheck valve spring
Wiro Dia.
o.D.
1 . 8 0 ( O . O 7 1 ) 1 4 . 7 0( O . 5 7 9 18 8 . 6 0( 3 . 4 8 8 t
1 . 8 0 ( 0 . 0 7 1 ) 9 . 6 0 ( 0 . 3 7 8 ) 44.OOt't.7321
5 . 5 0 ( O . 2 1 7 1 ' 2 6 . 4 0 ( 1 . O 3 9 )3 0 . 3 0( 1. 19 3 t
o.80(o.o31) 6.60 (O.260) 3 9 . 5 0( 1 . 5 5 5 )

1.10(0.043) 8 . 4 0 ( O . 3 3 1 ) 3 3 . 8 0( 1. 3 3 1I
1.10(O.O43t 8 . 4 0 ( 0 . 3 3 1 ) 3 3 . 8 0( 1. 3 3 1)
lnside Diameter
14-122
Free Longlh
vnx.su
No. of Coils
16.5
2.1
25.O
'l2.5
12.5
NOTE:
a Cleanall paris thoroughlyin solvent or carburetorcleaner,and dry with compressedair.
a Replacevalve body as an assemblyit any parts are worn or damaged.
a Check all valves tor free movement.lf any fail to slide frely, see Valve Body Repairon page 14-117.
a Coat all parts with ATF before reassembly.
LOCK-UPSHIFT VALVE
TIMING8 VALVE
LOCK.UP
,ar
CAP
\,/
Unit ot length; mm (in)
Standard {Nsw}
No.
Spring
Wile Di8.
Lock-upshift valve spring

Lock-uptiming B valve spring
o . 9 0( o . 0 3 5 )
o . 8 0( o . 0 3 1 )
o.D.
Flee Length
7 . 6 0 ( 0 . 2 9 9 ) 73.70 i.2.9021
6 . 6 0 { O . 2 6 0 ) 6 0 . 8 0( 2 . 3 9 4 )
No. of Coils
32.O
22.1
14-123
vnx.su
SecondaryValve Body
NOTE:
a Cleanall parts thoroughlyin solvent or carburetorcleaner.and dry with compressedair.
a Replacevalve body as an assemblyif any parts are worn or damageo.
a check all valves for lree movement.rf any fair to sridetreery,see varve Body Repairon page
14-1r7.
a Coat all parts with ATF betore reassembly.
CAUTION: Do not use a magnetto removethe check balls; it may magnetizethe balls.
CHECKBALLS.7
1ST ACCUMULATOR
CHOKE
a/
\.^l
"i\
SPRINGSEAT
\ll /
'.'.)
'-
-\)--
o{
\
@
2.3 ORIFICECONTROL
VALVE
3-4 SHIFT VALVE
le
, r /
\i\
DOWEL PIN, 2
SECONDARYVALVE EODY
MODULATORVALVE
a
)
');fi
l"
a-/ xii;.
trd
\
VALVE
14-124
vnx.su
CHECK BALL
CHECKBALLS
FILTER
Unit ot length: mm (in)
Standard(Nwl
No.
o
@
tcl
\9
Spring
3-2 kick-down valve spring
4-3 kick-downvalve spring
Orifice control valve spring
2-3 orifjce control valve spring
Servo control valve spring
Modulatorvalve spring
Wire Dia.
1. 3 { O . 0 5 1 )
1. O ( O . O 3 9 )
o.8 (o.031)
o.9 (o.03s)
0.9 {0.035)
o.9 (o.o35)
1.3(O.O51)
o.D.
8.6 tO.339)
6.6 (O.260)
6.6 (0.260)
6.6 (0.260)
7.6 (O.299)
6.4 lO.252l
9.4 (O.370)
Free Length
45.6
28.5
48.2
33.O
52.O
34.1
37.3
1.795)
1.1221
1.898)
1.299)
2.O47l
1.343)
1. 4 6 9 )
No. of Coils
1 7. O
14.7
33.O
14.9
26.8
12.4
14-125
vnx.su
Servo Body
Disassembly/lnspection/Reassernbly
NOTE:
a Cleanall pSrtsthotoughlyin solvent or carbu.etorcleaner,and dry with compressedair.
a Replacevalve body as an assembly it any parts are worn or damageo.
a Coat all parts with ATF before resssemblv.
a Replacethe O-rings.
THROTTLECAM
SYOPPER
\P
O-RING
Replace.
4TH
PISTON
6 r 1 . Om m
12 N.m
(1.2 kgf.m,
8.7 rbt.ftl
SERVOBODY
THROTTLEADJUSTIIIIGBOLT
CAUTION: Do not loo3on or
THROTTLE
VALVEB
o
LONG VALVE
'
r
Replace.
V8;lilSl
O-RING
Replace.
3RD ACCUMULATOR
PISTON
14-126
vnx.su
St8ndard {Newl
No.
o
rar
6\
ra\
@
(!,
Spring
Throttle valve B adiustingspring
Throttle valve B sp.ing
Throttle valve B spring
Throttle valve I spring
4th accumulatorspring
1st accumulatorspring
3rd accumulatorsp.ing
2nd accumulatorspring
Wire Dia.
0.7 (0.028)
1.4 (O.O55)
1.4 (O.O55)
1.4 (O.O55)
2.6 l0.102l
2.5 (O.O98)
2 . 8 ( O . 11 0 )
3.6 (O.142)
vnx.su
o.D.
6.2 t0.244l
8.5 (O.33s)
8.5 (O.3351
8.5 {0.33st
1 6 . 3( O . 6 4 2 )
1 6 . 3( O . 6 4 2 )
1 7 . 5( O . 6 8 9 )
2 2 . O( O . 8 6 6 )
Fre6 Longth
3 4 . O( 1 . 3 3 9 )
4 1 . 5 ( 1. 6 3 4 1
4 1 . 5 ( 1. 6 3 4 )
41.6(1.638)
103.3(4.067)
'l
05.4 (4. 150)
105.2 14.142].
108.9(4.287)
No. ot Coils
15.2
10.5
11.2
12.4
16 + 8.6
19.1
15.2
14-127
1st-hold Accumulator/RightSide Cover

NOTE:
a Clean all pans thoroughly in solvsnt o, carburetor cleaner, and dry with compressed 8ir.
a coat all parts with ATF betors raassembly.
SNAP RI]TG
l ST.HOLOACCUMULATORCOVER
1ST-HOLDACCUMULATORSPRING
PISTON
IST.HOLDACCUMULATOR
O.BING
R6place.
RIGHT SIDE COVER

St8ndard lt{ew)
Spring
No.
1st-hold accumulatorspring
14-128
Wlro Dia.
4 . 0 0 ( o . 15 7 )
vnx.su
o.D.
Froo Length
2 1 . 5 0 ( 0 . 8 4 6 ) 7 1 . 7 0l 2 . A 2 3 l
No. of Coils
8.3
Mainshaft
NOTE:
a Lubricateall pans with ATF during reassembly.
a Installthe thrust needlebearingswith unrollededge of bearingretainerlacing washer.
a Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement.
a Betoreinstallingthe O-rings,wrap the shaft splineswith tape to preventdamagingthe O-rings.
a Locknut has lett-handthreads.
CONICAL SPRINGWASI{ER
Replace.
LOCKNUT(FLANGENUT)
19 x 1.25mm
93 N.m {9.5 kgf.m, 69 lbf.ftl
Replace.
Left-hand threads
lST CLUTCH
ASSEMBLY
SNAP RING
\
MAINSHAFT
Check splinestor excessive
wear or damage.
Check bearing surface for scoring,
scralches or excessive wear,
THRUSTWASHER
THRUSTNEEDLE
BEARING
4TH GEAR
o-ntNGs
Replace.
THRUSTWASHER
THRUSTNEEDLE
BEARING
BEANING
NEEOLEBEARIT{GS
lST GEAR
THRUST WASHER
1ST GEAR
COLLAR
4TH GEAR COLLAR

2ND/4TH CLUTCH
ASSEMBLY
O.RINGS
Replace.
THRUST WASHER, 36.5 x 55 mm
Solective part.
THRUST NEEDLE
BEAFING
SEALINGRINGS,
35 mm
SEALINGRING.
29 mm
NEEDLEBEARING
2ND GEAR
NEEDLEBEARING
THRUST NEEDLE
BEARING
SET RII{G
vnx.su
TRANSMISSION
HOUSINGBEARING
Mainshaft
Inspection
Torque the mainshaft locknut to 29 N.m (3.0
kgf.m, 22 lbf.ft).
a ClearanceMeasurement
NOTE: Lubricateall parts with ATF during assembly.
NOTE: Mainshaftlocknut has lett-handthreads.

1.
Removethe mainshaftbearinglrom the transmission

h o u s i n g( s e ep a g e 1 4 - 1 5 2 ) .
2.
Assemblethe parts below on the mainshaft.

NOTE: Do not assemble the O-rings while inspecting.
29 N.m (3.0 kgl.m, 22 lbt.ft)

LOCKNUT
1ST CLUTCHASSEMBLY
THRUSTWASHER
lST GEARCOLLAR
TBANSMISSION
HOUSINGBEARING
THRUSTWASHER
4.
Hold 2nd gear againstthe 2nd clutch. then measure the clearancebetween 2nd gear and 3rd gear
with a feelergauge.
in at leastthree Dlaces
NOTE: Takemeasurements
and take the averageas the actual clea.ance.
STANDARD:0.05-0.13 mm {0.002-0.005 inl
4TH GEAR COLLAR

2ND/4TH CLUTCH
ASSEMBLY
3RD GEAR
2ND GEAR
THRUSTWASHER
Selectivepart.
TI{RUSTNEEDLE
BEARING
2ND GEAR
NEEDLEBEARING
THRUSTNEEOLE
BEARING
THRUSTWASHER36.5 x 55 ftm
MAINSI.IAFT
3RD GEAR
14-130
vnx.su
2ND GEAR
5.
lf the clearanceis out of tolerance,removethe thrust

washer and measurethe thickness
6.
Selectand installa new washer then recheck.
THRUSTWASHER36.5 x 55 mm
No,
Thickness
9 0 4 4 1- P G 4 - O 1 0
4 . O Om m ( O . 15 7 i n )
90442 PG4-010
90443-PG4-O10
4 . 0 5 m m { O .15 9 i n )
4 . 1 Om m ( O . 1 6 1i n )
90444-PG4-O10
4 . 15 m m ( O . 1 6 3i n )
90445-PG4-O10
4 . 2 0 m m ( O . 1 6 5i n )
90446-PG4-Ol O
4 . 2 5 m m ( O . 1 6 7i n )
90447,PG4 0r0
4 . 3 O m m ( O . 1 6 9i n )
90448-PG4-O10
4 . 3 5 m m { O . 17 1 i n )
9 0 4 4 9 - P G 4 - O r0
4 . 4 O m m ( O . 17 3 i n )
7,
Part Number
AIter replacingthe thrust washer, make sure the

clearanceis within tolerance.
vnx.su
14-131
Countershaft
NOTE:
a Lubricateall parts with ATF belore reassembly.
a Installthe thrust needlebearingswith unrollededge of bearingretainerfacing washer.
a Inspectthe thrust needlebearingsand the needlebearingstor gallingand rough movement.
a Beforeinstallingthe O rings, wrap the shaft splineswith tape to preventdamagingthe O-rings.
a Locknut has left-handthreads.
CONICAL SPRING
WASHER
Replace.
REVERSE
GEARCOLLAR
NEEDLEEEARING
LOCKNUT{FLANGENUTI
23 x 1.25mm
1O3-0-lO3N.m
{10.5-O-'l0.5ksf.m,
75.9*O-75.9tbf.fr)
Replace.
Left-hand threads
PARKINGGEAR
REVERSE
GEAR
BEVERSE
SELECTOR
ONE.WAY
CLUTCH
.IST GEAR
REVERSESELECTOR
HUB
NEEDLEEEARING
4TH GEAR
lST GEAR COLLAR
NEEDLEBEARING
DISTANCECOLLAR,
28 mm
Selectivepart.
COUNTERSHAFT
Check splinesfor excessive
wear or damage.
Check bearingsurfacefor scoring,
scratchesor excessivewear_
2ND GEAE
THRUST NEEDLE
BEARING
3RD GEAR
NEEDLEBEARING
THRUSTNEEDLEBEARING
3RD GEARCOLLAR
3RD CLUTCH ASSEMBLY
O-RINGS
Replace.
vnx.su
TRANSMISSION
HOUSINGBEARING
1,
Usinga hydraulicpress,pressout the countershatt

while supponing4th gear.
NOTE: Placean attachmentbetweenthe pressand
the countershattto preventdamageto the shaft.
CAUTION: Do not allow the countershaftto lall and
hit the ground.
2 . Assemblethe parts on the countershaftas shown

oetow.
NOTE:
a Lubricateall parts with ATF duringassembling.
a Before installingthe O-rings, wrap the shalt
splines with tape to prevent damaging the
O-rings.
4TH GEAR
NEEDLEBEARING
DISTANCECOLLAR. 29 mm
Selectivepart.
2ND GEAR
THRUSTNEEDLEBEARING
3RD GEAR
NEEDLEBEARING
THRUSTNEEDLEBEARING
3RD GEAR COLLAR
3RD CLUTCHASSEMBLY
O-RINGS
Replace.
COUNTERSHAFT
{cont'd)
vnx.su
Countershaft
(cont'd)
a
Installthe reverseselectorhub on the countershaft

sub-assemblV,
and then pressthe reverseselector
hub using the specialtool and a press as shown.
Inspection
a ClearanceMeasurement
NOTE: Lubricateall parts with ATF during assembly.
1.
Removethe countershaftbearingfrom the transmiss i o n h o u s i n g( s e ep a g e l 4 - 1 5 2 ) .
2.
Installthe pans belowon the counte.shaftusingthe

specialtool and a pressas describedon this page.
NOTE: Do not assemble the O-rings while inspecting.
REVERSESELECTOR
HUB
4TI{ GEAR
NEEDLEBEAFING
DISTANCECOLLAR, 28 m|n
Selective part.
COUNTERSHAFT
14-134
vnx.su
Install the parts below on the countershaftsubassembly,then torque the locknut to 29 N'm (3.O
kgf.m, 22 lbf.ft).
Measurethe clearancebetweenthe 2nd gear and

the distancecollar, 28 mm wilh a feelergauge.
in at leastthreeplaces.
NOTE: Takemeasurements
and take the averageas the actual clearance.
S T A N D A R DO
: . O 5 - 0 . 1 3 m m ( 0 . O O 2 - O . O 0 i5n )
2ND GEAR
DISTANCECOLLAR,
28 mm
LOCKNUT
Left-hand threads
CONICALSPRI G
WASHER
PARKINGGEAR/ONE-WAY
CLUTCH/1STGEAR
ASSEMBLY
NEEEDLEBEARING
lST GEARCOLLAR
TRANSMISSIONHOUSING
BEARING
REVERSEGEAR
COLLAR
2ND GEAR
(cont'd)
14-135
vnx.su
Countershaft
Inspection(cont'dl
5.
lf the clearanceis out of tolerance,removethe distance collaf, 28 mm and measurethe width,
6.
Select and install a new distance collar, then

recheck.
DISTANCECOLLAR,28 mm
No.
Part Number
Width
90503-PC9-OOO
3 9 . O 0m m ( 1. 5 3 5 i n )
90504-PC9-OOO
3 9 . 1 0m m ( 1 . 5 3 9i n )
3 9 . 2 0 m m ( 1 . 5 4 3i n l
90sos,Pc9-ooo
5
90508-PC9-000
3 9 . 3 0 m m ( 1 . 5 4 7i n )
3 9 . 0 5 m m ( 1. 5 3 7 i n l
6
7
90509-PC9-000
90510 PCg*000
3 9 . 15 m m { 1 . 5 4 1i n )
3 9 . 2 5m m ( 1 . 5 4 5i n )
9 0 5 1I - P C g - O O O
3 8 . 9 0 m m { 1 . 5 3 1i n )
90512 PCg 000
3 8 . 9 5m m { 1 . 5 3 3i n )
90507-PC9-000
7,
Altet selectinga new distancecollar,recheckthe

clearanceand make sure it is within tolerance.
14-136
vnx.su
One-way Clutch/ParkingGear
Disassembly/lnspection
1 . Separatecountershaft1st gearfrom the parkinggear
by turningthe parkinggear in the directionshown.
Inspoct tha psrta a3 tollows:
PARKII{GGEAR
Inspectthg parking
tor ws. or acoring.
COUNTERSHAFT1ST GEAR
O E.WAY
2.
Inspect tho ono-way

clutch fo. damageaor
faultv movement.
Removethe one-way clutch by prying it up with the

end of a screwdrive..
courrERsHAFrlsr.EAR
9IlYlL9iY^t.?I
NOTE: lnstall in this direction.
l ST GEAR
Inspect counior6haft 1
tor wegr or scoaing.
3.
After the Dartsare sssembled,hold counte.shaft lst

gear and turn tho parkinggear in the directionshown
to be sur6 it turns freelv,
CLUTCH
O'TE.WAY
COUNTERSHAFTlST GEAR
1STGEAR
COU TERSHAFT
SCREWDRIVER
14-137
vnx.su
Sub-shaft
NOTE:
a Lubricateall parts with ATF during reassembly.
a Installthe thrust needlebearingswith unrollededge ot bearingretainertacing washer.
a lnspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement.
a Beforeinstallingthe O-rings,wrap the shaft splineswith tape to preventdsmagingthe O-.ings.
TRANSMISSIOI{HOUSING
TRANSMISSION
HOUSINGBEARING
lST-HOLD CLUTCH
ASSEMELY
O.RINGS
Replace.
6 x 1.0 mm
12 N.m
(1.2 kgf.m, 8.7 lbf.ft)
THRUST WASHER
THRUST NEEDLE
BEARING
NEEDLEBEARING
SUB.SHAFT
Checksplinestor excessive
wear or damage.
Check bearingsurlacetor
sconng.scratchesor excessive
4TH GEAR
THRUST I{EEDLE
AEARIIIG
OIL GUIDECAP
Replace.
NEEDLEBEARIT{G
STOPPER
4TH GEAB COLLAR
NEEDLEEEARING
vnx.su
Removethe oil guide cap by pushingthe sub-shaft
insidethe transmissionhousing.
Removethe 1st-holdclutchassemblyby pullingthe
sub-shaft,then removethe sub-shatt.
Installnew O-ringson the sub-shaft.
NOTE: Wrap the shaft splineswith tape to prevent
damagingthe O-rings.
Placethe sub-shaftin the transmissionhousingand
installthe 1st-holdclutch assembly.
Installnew oil guide cap usingthe specialtools as
snown.
DRIVER
07749-0010000
ATTACHMENT32x35mm
07746-0010100
,IST.HOLD CLUTCH
ASSEMBLY
14-139
vnx.su
Sub-shaft Bearings
Replacement
Installthe new needlebearingin the transmlsston
anda pressas shown.
housingusingthe specialtools
NOTE: Lubricateall parts with ATF beforereassembly

'l . To removethe sub-shaftballbearingtrom the transmissionhousing.expandthe snapringwith snapring
pliers,then push the bearingout using the special
tools and a Dressas shown.
PRESS
ATTACHMENT,
32 x 35 mm
07746-0010100
ATTACHMENT,
62 x 68 mm
07746-0010500
5 . Expandthe snap ring with snap ring pliers,then insert the ball bearingpart way into the housingusing the specialtoolsand a pressas describedin step
1. Installthebearingwith the groovefacingoutside
the housing.
Removethe needlebearingstopper.
Removethe needlebearingfrom the transmisslon
housingusing a drilt Punch.
DRIFTPUNCH
Releasethe pliers,then push the bearingdown into

the housinguntilthe snapringsnapsin placearound
rt.
7 . After installingthe ballbearing,verifythe following:
a The snap ring is seatedin the bearingand housing grooves.
a The snap ring ope.atesproperly
a The ring end gap is correct.
E N DG A P :0 - 7 m m
?A
SNAP RING
14-140
vnx.su
Clutch
lllustratedIndex
3RD CLUTCH
CLUTCH
DRUM
O-RINGS
Replace.
CLUTCH PISTON
DISC SPRING
RETURNSPRING
SPRINGRETAINER
SNAP RING
1ST CLUTCH
CLUTCHEND
CLUTCH DISCS
PLATE
Stsndard thickness:
1.94 mm {0.076 in)
SNAP RING
SNAP RING
O-RINGS
Replace.
SNAP RING
CLUTCH PLATES
Standard thicknass:
2.00 mm {0.079 in}
CHECKVALVE
(cont'd)
14-141
vnx.su
Clutch
lllustratedIndex (cont'd)
2ND/4TH CLUTCH
SNAP RING
CLUTCH END PLATE
CLUTCH DISCS
Standard thickno3s:
1.94 mm 10.076in)
CLUTCH PLATES
Standard thickness:
2.OOmm 10.079inl
SNAP RING
SPRINGRETAINER
RETURNSPRING
CLUTCH PISTON
SPRING
RETURNSPRING
CHECKVALVE
RETAINER
SNAP RING
4TH CLUTCHDRUM
CLUTCH PLATES
Standa.d thickness:
2.00 mm 10.079 in)
;;i;;;
( / \
Y)
CLUTCH DISCS
Stsndard ihicknss:
1.94 mm 10.076in)
CLUTCH END PLATE
SNAP RING
14-142
vnx.su
lST.HOLD CLUTCH
SNAP RING
CLUTCH END PLATE
CLUTCH DISCS
Standard thicknoss:
1.94 mm 10.076 inl
DISC SPRING
CLUTCH PISTON
O-RINGS
Roplace.
CLUTCH PLATES
Standard thickno3si
2.00 mm (0.o79 in)
14-143
vnx.su
Clutch
Disassembly
Removethe snap ring. then.emove the clutch end
plate, clutch discs and plates.
3.
Installthe sDecialtools as shown.

CLUTCHSPRIT{G
COMPRESSOR
ATTACHMET
oTLAE-PX40100
SNAP RII{G
cLuTcHspnrc
2.
COMPNESSOR
ATTACHMET
oTHAE-Pr60tOO
Removethe disc spring.

SPNING
otsc sPfit c
CLUTCH SPRII{C
COMPNESSOR
ATTACHi'ENT
OTLAE-PX,l{,TOO
2ND CLUTCH
DISC SPBING
CLUTCH SPBII{G
COMPRESSOR
ATTACHMEI{T
oTHAE-Pt50100
1ST, 3RD, 4TH .nd

l ST.HOLD CLUTCH
14-144.
vnx.su
CAUTION: lf either end ot the comprassol attachmnt

is sel ovsl an araa ol the spdng retaine. which is unsupported by the retum spring.the letainermay be damag6d,
5 . Remove the snap ring. Then remove the special

tools, spring retainerand return spring.
S AP RING
Do not set horo.
6.
4.
Compressthe return spring.
Wrap a shop towel aroundthe clutch drum and apply air pressureto the oil passageto remove the
piston.Placea fingertip on the other end while applying air p.essure.
COMPRESSEDAIR
HOSE NOZZLE
OSHA-approved30 psi
rype onry
CLUTCH
RETURNSPRING
PISTON
14-145
vnx.su
Clutch
Reassembly
NOTE:
a Clean all psrts thoroughly in solvent or carburetor
cleaner.and dry them with compressedair.
a Lubricateall pans with ATF before .eassembly.
1.
3,
Installthepistonin the clutchdrum. Apply pressure

and rotate to ensureproper seating.
NOTE: Lubricatethe pistonO-ringwith ATF before
installing,
Inspectthe check valve; if it's loose, replacethe

prston,
CAUTION: Do not pinch rh6 O-ringby installingth

piston with too much lorco.
NOTE: Except 1st-holdclutch.

CLUTCH DRUM
CHECKVAIVE
4.
Installthereturnspringand springretainer.and position the snap ring on the retainer
SNAP RING
SPRINGRETAINER
RETURNSPRING
CLUTCHORUM
PISTON
14-146
vnx.su
r
5,
Installthe specialtools as shown.
CAUTION: lf ithor end of the comprossor attachment is set over an area of the spring rotainerwhich
iE unsupportedby tho retum spring, the latainer may
bo damaged.
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE-PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
oTHAE-Pl50100
Do not set here.
CLUTCH SPRING
COMPNESSOR
BOLT ASSEMBLY
oTGAE-FG40200
6,
Compressthe return spring.
CLUTCII SPRING
COMPRESSOR
ATTACHMENT
oTLAE-PX40100
CLUTCH SPRIIIG
COMPRESSOR
ATTACHMENT
oTHAE-Pl50100
CLUTCH SPRING
COMPRESSOR
AOLT ASSEMBLY
07GAE-PG40200
RETURNSPRING
(cont'd)
14-147
vnx.su
Clutch
Reassembly(cont'd)
7.
Installthe snap ring.
1O. Soakthe clutch discsthoroughlyin ATF for a minimum of 30 minutes.

11. Starting with a clutch plate, alrernatelyinstallthe
clutch platesand discs. Installthe clutch end plate
with flat side toward the disc.
NOTE: Beforeinsrallingthe platesand discs,make
sure the insideof the clutch drum is free ot dirt or
other toreign matter.
CLUTCH END PLAT

Installin this direction
SNAP RING
Removethe specialtools.
Installthe disc spring.
NOTE: Installthediscspringin the directionshown.
DISCSPRING
1 2 . I n s t a l tl h e s n a p r i n g .
SCREWDRIVER
SNAP RING
.\
):ll
1ST, 3RD, 4TH and
l ST.HOLDCLUTCH
14-148
vnx.su
'13. Measurethe clearancebetweenthe clutchend plate

and top disc with a dial indicator.Zerothe dial indicatorwith the clutchend plateloweredand lift it up
to the snap ring. The distancethat the clutch end
platemovesis the clearancebetweenthe clutchend
plate and top disc.
N O T E r M e a s u r ea t t h r e el o c a t i o n s .
Clutch End Plate-to-Too Disc Clearance:
Clulch
lst
2nd
3rd
4th
1st-hold
Service Limit
O.65 o.85 mm
O . 6 5- O . 8 5 m m
O . 4 O - O . 6 0m m
0.4O-0.60 mm
0.50-0.8O mm
( O . 0 2 6 O . O 3 3i n )
{ O . 0 2 6 - O . O 3 3i n )
( 0 . O 1 6 o . O 2 4i n )
(0.016-0.024 in)
{ O . 0 2 O - 0 . 0 3 1i n }
lST CLUTCHEND PLATE

PlateNo.
1
2
3
4
5
6
7
8
I
10
11
1 )
I J
14
PartNumber
Thickness
2 . 1 m m 1 0 . 0 8 3i n )
22551-PF4-000
2 . 2 m m ( 0 . 0 8 7i n )
22552-PF4 000
2 . 3 m m ( 0 . 0 9 1i n )
22553 PF4 000
2 2 5 5 4 - P F 4 - O O O 2.4 mm (0.094in)
2 . 5 m m ( 0 . 0 9 8i n )
22555 PF4-000
2 . 6 m m { 0 . 1 0 2i n }
22556 PF4-000
2 . 7 m m i 0 . 1 0 6i n )
22557-PF4 000
in)
2 . 8m m ( 0 . 1 1 0
22558-PF4 000
2 . 9m m ( 0 . 11 4 i n )
2 2 5 5 9 -P F 4 -0 0 0
3 . 0 m m ( 0 . 11 8 i n )
22560-PF4 000
3 . 1 m m ( 0 . 12 2 i n l
22561 PF4-000
3 . 2 m m { 0 . 1 2 6i n }
22562-PF4 000
3 . 3 m m ( 0 . 13 0 i n )
22563-PF4 000
3 . 4 m m ( 0 . 1 3 4i n )
22564 PF4-OOO
2ND- 3RD and 4TH CLUTCHEND PLATE
IAL INDICATOR
PlateNo.
PartNumber
Thickness
1
2.
3
4
5
6
7
8
I
10
22551 P56,N00
22552-P56-N00
22553-P56-N00
2 2 5 5 4 -P 5 6- N 0 0
22555-P56 N00
22556 Ps6-N00
22557- P56 N00
22558 P56-N00
22559-P56 NOO
22560 P56-N00
2 . 1 m m ( 0 . 0 8 3i n )
2 . 2 m m ( 0 . 0 8 7i n )
2 . 3 m m ( 0 . 0 9 1i n )
2.4 mm (0.094in)
2 . 5 m m ( 0 . 0 9 8i n )
2 . 6 m m { 0 . 1 0 2i n )
2 . 7 m m { 0 . 1 0 6i n i
in)
2 . 8m m ( 0 . 1 1 0
2 . 9 m m ( 0 . 11 4 i n )
3 . 0 m m ( 0 . 11 8 i n )
lST.HOLD CLUTCHEND PLATE

PlareNo.
22551-PS5 003
22552 PS5-003
22553-PS5 003
4
22554-PS5-003
5 (Nomark) 2 2 5 5 5 - P S 5 - 0 0 3
22556 PS5-003
6
7
22557 PS5-003
1
2
3
14. lf the clearanceis not withinthe servicelimits,select

a new clutch end plate lrom the following table.
Part Number
ThicknEss
2 . 1 0m m ( 0 . 0 8 3i n )
2 . 2 0m m ( 0 . 0 8 7i n )
2.30 mm (0.09'1in)
2 . 4 0m m ( 0 . 0 9 4i n )
2 . 5 0m m { 0 . 0 9 8i n )
2 . 6 0m m { 0 . 1 0 2i n }
2 . 7 0m m ( 0 . 1 0 6i n )
NOTE: It the thickest clutch end plate is installed,

but the clearanceis still over the standard,replace
the clutch discs and clutch Dlates.
PLATENUMBER
Thicknss
CLUTCHEND PLATE
14-149
vnx.su
Torque Converter Housing Bearings

MainshaftBeadng/OilSeal Replacement
1.
Driveout or pull up the mainshaftbearingand oil seal,

using the specialtools as shown.
2 . Drivein the new mainshaftbearinguntil it bottoms

in the housing,using the specialtools as shown.
DRIVEN
07749 -OOIOOOO
ATTACHMENT,
62x68mm
07746-0010500
3 . Installthenew oil sealflush with the housingusing

the sDecialtools as shown.
Slide Hammer
CommerciallyAvailable
3/8 in.x 16
ATTACHMENT,
72x75mm
07746-0010600
14-150
vnx.su
CountershaftBearingReplacement
l.
Removethe countershattbearingusingthe special

tools as shown.
SlideHammer
CommerciallyAvailable
3/8 in. x 16
ADJUSTABLE
BEARING
PULLER,
25-40 mm
07736-AOIOOOA
K-i.<trE)t
'/'
',--CZ_
( (
-)
_-=\._
-) ))\
-:-:-:1.-=41"
Installthe oil guide plate.
Drivethe new bearinginto the housingusingthe special tools as shown.
14-151
vnx.su
TransmissionHousingBearings
Mainshaft/Countershaft
BearingReplacement
1. To removethe mainshaftand counte.shaftbearings
trom the transmissionhousing,expandeach snap
ring with snap ring pliers,then pushthe bearingout
using the specialtools and a press as shown,
Expandeach snap ring with snap ring pliers,insert

the new bearingpan-wayinto the housingusingthe
specialtoolsand a pressas shown. Installthebearing with the groove tacing outsidethe housing.
NOTE: Do not remove the snap rings unless it,s

necessafyto cleanthe groovesin the housing.
NOTE: Coat all parts with ATF.

Releasethe pliers.then push the bearingdown into
the housinguntil the ring snaps in placearoundit,
PRESS
ATTACHMENT,
62x68mm
o7746-
DRIVER
o7749-OOIOOOO
GnoovE
Mainshatt Inltallation us6:

ATTACHMENT,
72x75mm
07746-0010600
Counto.shalt In3talldtion uso:
ATTACHMENT.
62x68mm
07746-O010500
---7i
\)
4.
After installingthe bearingverify the lollowing:

a The snap ring is seatedin the bearingand housIn9 grooves.
a The snap ring operatesproperly
MAINSHAFT
END GAP: O-7 mm

Mainshaft Removal uaoi
ATTACHMENT72 ,, 75 mm
o7746-OOlO600
Counterrhaft Removal uao:
ATTACHMENT,
62x68mm
07746-O010500
SNAP BING
TRANSMISSION
t|oustitc
14-152
vnx.su
Sub-shaftBearingReplacement
I.
To remove the sub-shaft bearinglrom the transmission housing,expandthe snap ring with snap ring
pliers, then push th bearing out using the special
tools and a Dressas shown.
NOTE: Do not remove the snap ring unless it's
necessary to clean the groove in the housing.
2 . Expandthe snap ring with snap ring pliers,insert the

new bearingpart-way into the housingusingthe special tools and a pressas shown. Installthe bearing
with the groove facing outside the housing.
NOTE: Coat all parts with ATF.
a
PNESS
Releasethe pliers,then pushthe bearingdown into

the housinguntil the ring snapsin placearoundit,
DRIVER
07749-0010000
ATTACHMEI{T,
62 x 68 mrn
077/+6-OOlO500
GROOVE
4.
ATTACHMENT,
62x68m|n
07746-(Xr10500
After installingthe bea.ingverify the following:

a The snap ring is seatedin the bearingand housing grooves.
a The snap ring operatesProperlv
El{DGAP:o-7 mm
HOUS[{G
14-153
vnx.su
Reverseldler Gear
ParkingBrake Stopper
Installation
1.
Inspection/Adjustment
Installthe reverseidler gear.
1 . Set the parkingbrake lever in the E position.

2.
Measurethe distancebetween the parking brake

pawl shaft and the parkingbrakeleverrollerpin as
shown.
STANDARD:72.9-73-g mm (2.87-2.91 in)
ROLLERPIN
PANKING
BRAKE
LEVER
7A\
Meaauring
\v
Installthereverseidle,gearshaft holderand needle

bearinginto the transmissionhousing,then tighten
the bolts.
PARKING
BBAKE
PAWLSHAFT
PARKINGBRAKE
STOPPER
lf the measurementis out of tolerance,select and

installthe appropriateparkingbrakestopperfrom the
table below.
6 x l.O mm
12 N'm 11.2 kgt.m.
4.7 lbf.ft)
PARKINGBRAKESTOPPER
Mark
1
4.
14-154
vnx.su
PartNumbol
Lz
- PA9-003 11 . 0 0m m
24537
{0.433in}
1 1 . 0 0m m
{0.433in)
-003
24538-PA9
10.80mm
(0.425in)
1 0 , 6 5m m
( 0 . 4 1 9i n l
24539- P49,003
1 0 . 6 0m m
( 0 . 4 1 7i n )
1 0 . 3 0m m
{0.406in)
After replacingthe parkingbrakestopper, make su.e

the distanceis within tolerance.
Transmission
Reassembly
NOTE:
a Coat all parts with ATF.
a Replacethe parts below:
. O-rings
. Lock washers
. Gaskets
. Locknuts
. Conicalspring washers
. Sealingwashers
T O R O U E1: 2 N . m ( 1 . 2 k g t . m , 8 . 7 t b f . f r )
OIL FEEDPIPE
LUBRTcAToR orL
PLATE
FEED
PIPES
LOCK-UPVALVE
f| l n /
EODY
OOWELPINS,2
OIL FEEDPIPES
ACCUMULATOBCOVER
/""n
v{
e'f
*'
OIL FEEDPIPE
_\
_! 1.-...-]]
vaLVE spRtNGS
ToRouE coNvERTE
n \-\.-CHECK VALVE
----.-.
--'r
LOCKWASHER
"o't
\_(<
Bolts,3
e
E
SERVODETENT
BASE
CONTROL
SHAFT
COOLERCHECKVALVE
-. :-,.
REGULATORVALVE
BODY
OIL FEEDPIPES
Bolts,4
SERVOBODY
DOWELPINS.2
MAIN VALVE
.
EoDY
|
SERVOSEPARATOR
PLATE
"1-
Bolt
OIL PUMPDRIVEN
GEARSHAFT
SECONDARYVALVE
BODY
OIL PUMP DRIVENGEAR
DOWELPINS,2
MAIN SPARATOR
PLATE
OOWELPINS,2
SECONDARYSEPARATOR
PLATE
ATF MAGNET
14-156
vnx.su
E
'.
1 . Installthe ATF magnetand suctionpipecollarin the

torque converternousrng.
7. Installthe servo body and separatorplate with six

bolts.
2 . Installthe mainseparatorplatewith two dowel pins
8. lnstallthe accumulatorcover with three bolts
on the torqueconverterhousing.Then installthe oil

pump drivegear,drivengearand drivengearshalt.
NOTE| Install the oil pump driven gear with its
groovedand chamteredside facing down.
OIL PUMP
DRIVEGEAR
Groovedand chamfered
side faces separator
plate.
CAUTION: Failureto align the oil pump d1iv6ngear

shaft corroctly will result in a seizedoil pump drivo
geal of oil pump drivon gear shatt.
Loosely install the main valve body with Iour bolts.

Make sure the oil pump drive gear rotates smoothly
in the normal operating direction and the oil pump
driven gear shaft moves smoothly in the axial and
normal operating directaons.
Installthe secondary valve body, separator plate and
two dowel pins on the main valve body.
Installthe control shaft in the housing, with the control shatt and manual valve togelher.
6.
1 0 . T i g h t e nt h e f o u r b o l t st o 1 2 N . m ( 1 . 2 k g f ' m , 8 . 7
lbf.ft) on the main valve body.
Make sure the oil pump drive gear and oil pump
driven gear shaft move smoothly same as in the step
11. lf the oil pump drive gear and oil pump driven gear
shaft do not move freelY.loosenthe four bolts on
the main valve body and disassemblethe valve
bodies.
Realignthe oil pumpdrivengearshaft and reassemble the valvebodies,then retightenthe bolts to the
specifiedtorque,
OIL PUMP
ORIVENGEAR
J.
9. lnstallthe servodetent base and ATF strainerwith

three bolts and new lock washers.
Installthe detent arm and arm shatt in the main valve

body, then hook the detent spring to the detent arm.
36
DETENT
SHAFT
SERVOSEPARATORPLATE
--- 8ixli"'
(l . . \. l
=L,1ffi#
.. N
j-*/:
OIL PUMP
DRIVEGEAB
OIL PUMP
DRIVENGEAR
OIL PUMP
DRIVENGEAR
SHAFT
12. Installthe stator shaft and stoppershatt.

13. Installthe stoppershatt stay on the secondaryvalve
body with the bolt.
14. Installthe regulatorvalve body with the bolt.
DETENI SPRING
DETENTARM
15. Installthe torque convertercheck valve,coolercheck

valve and valvespringsin the requlatorvalve body.
16. Installthe lock-upvalvebody, separatorplate,two
dowel pins and lubricatorplatewith the eight bolts.
1 7 . I n s t a l tl h e o i l f e e d p i p e s .
MANUAL VALVE
(cont'dl
14-157
vnx.su
Transmission
(cont'dl
Reassembly
TRANSMISSIONHOUSING
MOUNTINGBOLTS,18
l0 x 1.25mm
44 N.m (4.5 kgl.m. 33 lbf.trl
fl
TRANSMISSION
HANGER
TRANSMISSIONHOUSING
TRANSMISSION
MOUNT BBACKET
12 x
'1.25
fifi
64 N.m {6.5 kgt'm,
47 tbt'tr)
CONNECTORSTAY
T=
MAINSHAFT
SUB-ASSEMBLY
TRANSMISSION
HOUSING
GASKET
Replace.
REVERSEGEAR COLLAR
NEEOLEBEARING
REVEBSE
GEAR
LOCKWASHER
Replace.
SHIFTFORK
DOWELPINS,3
REVERSESELECTOR
COUNTERSHAFT
SUB.ASSEMBLY
DIFFERENTIAL
ASSEMBLY
TOROUECONVERTER
HOUSING
14-158
vnx.su
18. Installthe sub-shaftassemblyin the transmission

h o u s i n g{ s e ep a g e 1 4 - 1 3 8 ) .
,,1
19- Installthe reverseidler gear and gear shatt holder

( s e ep a g e 1 4 - 1 5 4 ) .
24. Align the spring pin of the control shaft with the
20. Installthe differentialassemblyin the torque converter housing.
lnstall the reversegear with the collar and needle

bearingon the countershalt.
transmissionhousinggrooveby turningthe control

shalt.
25. Placethe transmissionhousingon the torque converterhousingwith a new gasketandthe dowelpins.
21. Installthe mainshaftand countershaftsub-assembly

together in the torque converterhousing.
CONTROL
MAINSHAFT
SUB.ASSEMBLY
COUNTERSHAFT
SUB.ASSEMBLY
/K"\
// 2 " \
TRANSMISSION
HOUSING
Installthe transmissionhousingboltsalongwith the

t.ansmissionhangerand the connectorstay, then
torque the bolts in two or more steps in the sequence
shown.
2 2 . Turn the shift fork so the largechamteredhole is facing the fork bolr hole.then installtheshift fork with
the reverseselectorand torquethe lock bolt. Bend
the lock tab againstthe bolt head.
TOROUE:44 N.m (4.5 kgf.m, 33 lbf'ft)

TRANSMISSION
HANGER
CONNECTOR
SHIFTFORK
LOCI( WASHER
Replace.
6 x 1.0 mm
4 N.m
(1.4 kgl.m, rO lbt.ft)
Largechamferedhole
faces this way.
vnx.su
14-159
Transmission
(cont'dl
Reassembly
27. Slip the specialtool onto the mainshaftas shown.
32. Use th6 old locknut and old conicsl spring washot
to tighten th parking gear to th spcifid torque,
then loosen the locknut.
MAII{SHAFT HOLDER
oTGAa - PF5010I
TOROUE:103
.m (1O.5 kgf.m, 75.9 lbf'ftl
NOTE: Locknut has left-hand threads.
PARKII{GGEAR
24. Install the parking b.ake lever on the control shaft.

29. Installthe mainshaft 1st g6ar collar and thrust washer on the mainshaft.
30. Installthe countershaft1st gear collarand n6dls

bearing,then installthe countrshatt1st gear/oneway clutch/parking gea, assembly on the countershalt.
3 1 .Install the parking b.ake pawl in th transmission

housing,then engageit with the parkinggear.
33. Install the sub-shaft lst gear on thg sub-shaft.

34. Install new O-rings on the mainshaft.
lST CLUTCH
PARKI''IGGEAR
PARTI G
ARAKE
LEVER
SUB-SHAFT
14-160
MAIt{SHAFT
COU TERSHAFT
vnx.su
NOTE: Wrap the shaft splines with tspa to prevont

damago to the O-rings.
Assembloth thrust wash6r, thrust naedle bearing,
needlebearingand msinshsft lst gear on tho lst
clutch assombly,then installthem on the mainshaft.
36. Alignthe holeof the sub-shaft1st gearwith the hole

of the transmission
housing,then inserta pinto lock
the sub-shaftwhiletighteningthe sub-shaftlocknut.
3 9 . Stake each locknut using a 3 . 5 m m p u n c h .

. MAINSHAFT
37. Installnewconicalspringwashersand new locknuts

on each shaft.
CAUTION: Installthe conical spdng washers in the
dilection shown.
38. Tightenthe locknutsto the specifiedtorque.
TOROUE:
MAINSHAFT
93 N.m (9.5 kgf'm, 69 lbf.ft)
COUNTERSHAFT
103 N.m
(1O.5 kgf.m, 75.9 lbf.ft)
SUB-SHAFT
93 N.m (9.5 kgf.m. 69 lbf.fi)
NOTE: Mainshaltand countershaftlocknutshave
left-handthreads.
. COUNTERSHAFT
O,7- 1.2 mm
CONICAL DISC SPRINGS
lnstallin rhis direcrion.
0.7- 1.2 mm
in)
1O.03-O.05
SUB-SHAFTLOCKNUT
vnx.su
14-161
Transmission
Reassembly(cont'dl
40. Set rhe parkingbrakelever in the E position,then
verifythat the parkingbrakepawl engagesthe parkIng gear.
44. Installthe throttlecontrolleverwiththe leverspring

on the throttle control shaft.
TOROUE:7.8 N.m (O.8 kgf.m, 5.8 tbf.ft)
4 1 . l f t h e p a w l d o e sn o t e n g a g e f u l l yc,h e c k t h ep a r k i n g
brakepawl stopperclearanceas describedon page
14-154.
45. Installthe tramsmissionmount bracket.

TOROUE:64 N.m (6.5 kgf.m, 47 lbf.trl
42. Tightenthe lock bolt and bend the lock tab.

46. Installthe ATF cooler pipes and ATF level gauge.
6 x 1 . 0m m
10 tbf.frl
PARKINGGEAR
PARKINGBRAKEPAWL
Installthe right side cover and right side cover pro

lecror.
TOROUE:12 N.m {1.2 kgf.m, 8.7 lbf.ftl
14-162
vnx.su
Torque Converter/DrivePlate
6 x'l.Omm
12 N.m {1.2 kgf.m, 8.7 lbf'tt)
12 x 1.0mm
74 N.m {7.5 kgf.m, 54 lbl.ftl
Torquein a crisscrosspattern.
0d
DRIVE PLATE
TOROUECONVERTER
ASSEMELY
14-163
vnx.su
Transmission
Installation
1 . F l u s ht h e A T Fc o o l e ra s d e s c r i b eodn p a g e sI 4 - 1 6 8
'l
thru 69.
2.
5.
12 x 1.25mm
64 N.m 16.5 kgl.m, 47 lbf.ft)
Installthe starter motor on the transmissionhousi n g ,t h e ni n s t a l l t h el 4 m m d o w e lp i n si n t h e t o r q u e

converrernousrng.
STARTERMOTOR
Installthe transmissionmount.
45 N.m 14.5 kgf'm,
'14 mm DOWELPIN
i.'l,i;
TOROUE
CONVERTER
J.
O-RING
Replace.
1 2 x 1 . 2 5m m
74 N.m 17.5kgf'm,
54 rbt'ft)
14 mm OOWELPIN
Placethe transmissionon a transmissionjack, and

raiseto the enginelevel.
6.
Installthe transmissionhousingmountingbolts.
Attach the transmissionto the engine,then install

the transmissionhousingmounting bolts and two
rear enginemounting bolts with new washers.
TRANSMISSION
HOUSING
MOUNTINGBOLTS
REARENGINE
MOUNT BOLTS
1 4 x 1 . 5m m
59 N.m 16.0 kgf.m,43 lbl.ftl
TRANSMISSION
HOUSING
MOUNTING BOLTS
12 x 1.25 rnm
74 N.m (7.5 kgf'm, 54 lbf.ftl
14-164
vnx.su
7 . Removethe transmissionjack.
11. Connectthe ATF cooler hosesto the joint pipes.
L Attach the torque converterto the drive plate with

eight bolts and torque:
Rotatethe crankshattas necessaryto tighten the
boltsto 1/2 of the speciliedtorque,then to the final
toaque,rn a cnsscrosspattern.
After tighten the last bolts, check that the crankshaft
rotatesfreely.
12. Connectthe throttlecontrolcableto the throttlecontrol lever and installthe right front mount/bracket.
THROTTLECONTROLLEVER
THROTTLECONTROL
CABLEEND
JOINT PIPES
T O R O U E1: 2 N . m { 1 . 2 k g l . m . 8 . 7 l b f . f t }
9 . Install the torque converte. cove. and engine

stiffener.
6 r 1 . Om m
12 N.m 11.2 kgt.m, 8.7 lbl.ltl
ATF COOLERHOSES
10 x 1.25mm
RIGHT
44 N.m (4.5 kgf'm, FRONT
MoUNT/
33 rbl.ftl
BRACKT
t5.
1 2 x 1. 2 5 m m
64 N.m {6.5 kgf.m,
47 tbf.ftl
Replace.
Install the control lever with a new lock washer to

the control shalt. then install the shift cable cover.
CAUTION: Take care not to bend the shift cable.
10 x 1.25mm
44 N'm {4.5 kgf.m.
33 rbt'frl
SHIFTCABLE
CONTROL
SHAFT
8 x '1.25mm
24 N.m (2.4 kgl.m,
17 tbf.trl
1 2 N . m 1 1 . 2k g f . m ,
8.7 rbt.ft)
l O x ' 1 . 2 5m m
43 N.m
14.4 kgf.m, 32 lbf.ltl
1 0 .Tighten the crankshaft pulley bolt to specified

rorque.
6 x 1.0 mm
12 N.m
{1.2kgf.m,
8.7 lbl.rr)
TOROUE:177 N.m {18.O kgt.m, 130 lbf'ft}

SHIFT CABLE
COVER
LOCK ASHER
Replace.
CONTROLLEVER
6 x 1.0 mm
1 4 N . m 1 1 . 4k g l . m ,
10 lbf.fr)
(cont'dl
14-165
vnx.su
Transmission
Installation{cont'd)
1 4 . Installnew set ringson the end of the intermediate
shaft and the driveshaft.
17. Installthe right and left drivershafts(seesection l6l.

NOTE: Turnthe right and left steeringknucklefully
outward, and slide the right driveshaft into the
differentialuntil you feel its springclip engagesthe
side geaf. Slidethe left driveshaftinto the intermediate shaft until you teel the springclip of the intermediateshaft engagethe driveshaft.
1 5 . Installthe intermediateshaft.
18. Installright damperfork, then installthe right and

lett balljointsto eachlowerarm with the castlenuts
and new cotter Dins.
DAMPER PINCH BOLT
10 x 1.25mm
43 N.m 14.4 kgf.m,
32 tbr.ftl
SET RING
Beplace.
10 x 1
39 N.m
14.Okgf.m, 29 lbf.ftl
SHAFT
1 6 . Installexhaustpipe A. and connectthe heatedoxvgen sensor{HO2S)connector.
\
SELF.LOCKINGNUT
1 2 x 1. 2 5 m m
64 N.m (6.5 kgl.h, 47 lbt.ftl
Replace.
COTTER
Replace.
CASTLE NUT
1 2 x 1 . 2 5m m
49-59 N.m
{5.O-6.0 ksf.m, 36-43 rbt'ft1
1 9 . I n s t a l tl h e s p l a s hs h i e l d .
SELF-LOCKINGNUT
10 x 1.25mm
54 N.m (5.5 kgl.m,
40 rbt.trl
Replace.
GASKET
Replace.
SELF.LOCKINGNUTS
I x 1.25mm
22 N.m 12.2 kgl'n,
16 lbt.trl
Repl6ce.
14-166
vnx.su
6 x 10 mm BOLT
cltPs, 5
20. Connectthe vehiclespeedsensor(VSS),mainshatt

speed sensor and counterchalt speed sensor con
nectors.
VEHICLESPEEDSEiISOR
CONNECTOR
23. Connectthe startercableto the startermotor, and

install the cable holder.
NOTE: When installingthe starter motor cable,
makesurethat the crimpedsideof the ringterminal
is facing out (see section 23).
CABLE
HOLDER
6 x 1 . 0m m
'12 N.m (1.2 kgf'm,8.7 lbt.tl)
N.m
lO.9 ksr.m, 7 tbr-rtt
STARTERCAELE
2 4 . Installthe air cleanerhousingassemblyand intake

a r ro u c l .
AIR CLEANERHOUSING
ASSEMBLY
INTAKEAIR
DUCT
21. Connectthe lock-uDcontrolsolenoidvalveconnector and shift controlsolenoidvalveconnector.then

clampthe lock-upcontrolsolenoidharnesswith the
harnessstay.
22. Connectthe transmissionground cable.
LOCK-UPCONTROL
SOLENOIDVALVE
HARNESSSTAY
25. Retillthe transmissionwith ATF(seepage '14-93).

26. Connectthe battery positive( + ) and negative( - )
cablesto the battery.
Startthe engine.Setthe parkingbrake,and shift the
transmissionthrough all gearsthree times.
24. Checkshitr cableadjustmentas describedon page

14-171
.
2 9 . C h e c kt h a t f r o n t w h e e la l i g n m e n(ts e es e c t i o n1 8 ) .
(thecool30. Letthe enginereachoperatingtemperature
ing tan comeson) with the transmissionin S or @
position,then turn it off and check the fluid level.
3 1 . R o a dt e s t a s d e s c r i b e do n p a g e 1 4 - 9 o a n d 9 1 .
14-167
vnx.su
Transmission
CoolerFlushing
ro prevent iniury to tace and eyes, always
S!@
wear safety glas$esor a tace shieldwhen usingthe transmission flusher.
7. With the water and air valvesoff. attach the water

and air supplies to the flusher. (Hot water it
available.)
NOTE: This procedureshouldbe performedbeforereinstallingthe transmission.
OFF
1. Check tool and hoses for wear or cracks before

using.
lf wear or cracks are found, replacethe hoses before using.
2.
Usingthe measuring
cup, tillthe tank with 21 ounces
{approximately213 lulll of biodegradabletlushing
fluid (J35944-20).Do not substitutewith any other
fluid.
Followrhe handlingprocedure
on the fluidcontainer.
Securethe tlusherfillercap and pressurizethe tank
with compressedair to between 550-829 kPa
( 5 . 6 - 8 . 4 5 k g t / c m , ,8 0 - 1 2 0 p s i ) ,
NOTE: The air lineshouldbe equippedwith a water
trap to ensurea dry air system.
Hang the tool under the vehicle.
Attach the dischargehoseof the tank to the return
line of the transmissioncooler using a clamp.
6.
Connectthe drainhoseto the inlet lineof the transmissioncoolerusinga clamp.Securelyclampthe opposite end of the drain hoseto a bucket or floor drain.
8. Turn on the flusherwater valve so water will tlow

throughthe oil coolerfor 1Oseconds.lf water does
not flow through the oil cooler it is completely
plugged,cannot be flushed,and must be replaced.
9. Depressthe triggerto mix the tlushinglluid into the
water tlow. Use the wire clip to hold the trigger
oown.
10. While flushingwith the water and flushingfluid for
2 minutes.turn the air valveon for 5 secondsevery
15-20 secondsto create a surgingaction.
AIR PRESSURE:
MAX 829 kPa (8.45 kgt/cm,, 12O psi)
DISCHARGEHOSE
1 1. Turn the water valve off. Releasethe trigger,then

reversethe hosesto the coolerso you can flush in
the oppositedirection.Repeatsteps 8 through 1O.
12. Releasethe triggerand allow water only to rinsethe
cooler with water for one minute.
13. Turn the water valve off and turn off the water
supply.
14. Turn the air valve on to dry the systemout with air
for two full minutesor until no moistureis visible
leavingthe drain hose.
CAUTION: Residual moisture in the oil cooler 01
pipes can damage the transmission.
DRAIN HOSE
TRANSMISSION
BUCKET
TRANSMISSION
COOLERFLUSHEB
CommorciallyAvailablo
KENT MOORE#J38405_A
15. Removethe flushertrom the coolerline.Attach the

drain hose 10 a oil container.
16. lnstallthetransmissionand leavethe drainhose attached to the cooler line.
14-168
vnx.su
't 7. Make sure the transmission is in

@ position.
TOOL MAINTENANCE
Then fill the transmission with ATF and run the engins tor 30 sacondsor until spproximatelyons quart
iB discharged.
1.
Empty and rinse aftor each use. Fill the can with
water and pressurizethe can. Flush the discharge
line to ensurethat the unit is clean.
2.
lf dischargeliquiddoesnot toam, the orificemay be

blocked.
3.
To clean,disconnectthe plumbingtrom the tank 8t

the large couplingnut.
4.
Removthe in-linefilter trom the dischargeside and

clean it necossarv.
5.
The fluid orilice is located behind the tilter.

Cleanit with the Dickstoredin the boftom ot the tank
handleor blow it cl6anwith air. Securelvreassemble all Darts.
1 8 .Rsmove the drain hose and reconnect the cooler

return hoae to th transmission.
1 9 .Refillth trsnsmission with ATF to the propr levol.
FILLERCAP
COUPLII{GI{UT
FILTER
---0--L--
O.BI G
ORIFICE
14-169
vnx.su
shift cable
a All SRS electrical wiring hamosses are covord with
yellow insulation.
a Before disconnecting any pan ot th SRS wire harnoss, connect the short connectorc(soepage 23-7O1.
a Roplaceth entiro attectd SRS haness assembly it
it has an open circuit ot damaged wi.ing.
3.
Removethe shift cable bracket.
6x1.0mm
1 2 N . m 1 1 . 2k g f . m , 4 . 7l b f . f t l
uar"
@@[
section 1).
4.
Removethe shitt cable holder.
5.
Removethe shift cable cover.
6.
Removethe control leverfrom the control shaft, then

removethe shift cable.Take care not to bend the
cable when removing/installing
it.
sul litts are placed proparty {so6
1.
Removethe center console {seesection 20).
2.
Shift to N position.then removethe lock pin from

the cable adjuster.
SHIFT CABLE I{OLDER
@J^ll
AJUI
[qJ ]l tl
---l
LOCK NUT
7 N.m
(O.7 kgf.m, 5 lbf.ft)
12 N.m 11.2 kgf.rh, 8.7 lbf.ftl

14 N.m 11.4 kgl.m, 10lbt.ft)
7 . Installthe shift cable in the reverseorde. of removal.

8.
14-170
vnx.su
Checkthe cableadjustmenton reassembly,

on page
14-171.
Adjustment
CAUTION:
a All SRS electrical widng harnssesare covard with
yollow insulation.
a Before disconnecting any part of ths SRS wire harness, connect the shon connectors(seepage 23-701.
a Rplacethe entire affected SRS halnass asssmbly it
it has an opn circuit or damaged wiring.
4. Check that the hole in the adiuste. in perfectly

alignedwith the hole in the shift cable.Thereare two
holes in the end of the shitt cable, They are positioned 9Oo apart to allow cable adiustmentin 1/4
lurn Incremenls.
ADJUSTER
Cable
I oo snon
Cable
Too Long
Exact
Alignment
tu"t" sure lifts a.e placed properly ls66

@
ssction 1).
5. It not perfectlyaligned,loosenthe locknut on the

shift cable and adjust as required.
'1.
6. Tightenthe locknut to 7 N.m (O.7kgf.m, 5lbf.ft).
Start the engine.Stritt to @ positionto see if the

reversegear engages.lf so, refer to troubleshooting on page 14-86 thru 89.
Wilh the engineoff, removethe centerconsole{see
section 20).
Shilt to N position.then removethe lock pin from
the cable adjuster.
''fidlfr
8. Move the selector to each gear and verify that the

automatictransaxlegear positionindicatortollows
the automatictransaxlegear positionswitch.
9. Startthe engineand checkthe shift leverin allgea.s.
lf any gea. does not work properly, refer to
troubleshootingon page 14-86 thru 89.
]H
@
@
@
7. Installthe lock pin on the adiuster.lf you feel the

lock pin bindingas you reinstallit, the cable is still
out of adjustmentand must be readjusted.
1O. lnsert the ignitionkey into the key cylinderon the

shift indicatorpanel,ve.ify that the shift lock lever
is released,
t+@
\
\ /
CABLE
-.'.-_--l../
ADJUSTER
14-17 1
vnx.su
GearshiftSelector
CAUTION:
a All SRS electrical wiing halnssss are covered with
y6llow insulation.
a 8fore disconnecting 8ny pan of the SRS wire harneaa.connOctth6 short connectors(sse page 23-701.
a Roplacethe entire affected SRS hahess assembly if
il has an opon circuit or damaged wiring.
SRS MAIN HARNESS
[E--__
9.8 N.m {1.O kgf.m, 7.2 lbf.frl
SHIFT LOCK SOLENOID
rocK ptN
ADJUSTER
-6{
stLtcoNE
GREASE
e-
LEVERCOVER
-#q
SILICONEGREASE
CONTROLBRACKET
LOCK PIN ROD
5 N.m (0.5 kgt.m, 4 lbt.ftl
@6
SELECTLEVERBRACKET
9.8 N.m (1.0

7 .2 tbt.ltl
AUTOMATIC TRANSAXLE
GEAR POSITIONSWITCH
Testing,see Section23
CONTROLSEAL
12 N.m (1.2 kgf.m, 8.7 lbf.ftl

9 . 8 N . m 1 1 . 0k g f ' m , 7 . 2 l b f . f t l
14-172
vnx.su
Shift Indicator Panel

Adjustmet
CAUTION:
a All SRS olectrical wifng harnessesaro covered with
yellow insulation.
a Bofors disconnecting any pan of the SRS wire harness, connect tho sho.t connectors{sse page 23-7O),
a Replacethe entire aflectd SRS harness assembly if
it has an open circuit or damaged wiring,
1 . Check that the index mark on the indicatoraligns

with the N]mark on the shift indicatorpanelwhen
the transmissionin NEUTRAL.
lf not aligned,removethe centerconsole(seesection 2O).
Removethe shift indicatorpanelmountinqscrews
and adjust by moving the panel.
NOTE: Wheneverthe shift indicator panel is removed, reinstallthe panel as describedabove.
INDEXMARK
@
@
@
SRS MAIN HARNESS
MOUNTING SCREW
3 N'm lO.3 kst.m, 2 lbf.ftt
14-173
vnx.su

Inspection
Verify that the throttlecontrollevelis synchronized
and releaswith the thronlelinkagewhiledepressing
ing the acceleratorpedal.
NOTE: Betoreinspecting
the throttlecontrolcable,make
sure:
a Throttle cable free play is correct (seesection 1 1).
a ldle speed is correct (see section 1l).
a To warm up the engineto normaloperatingtemperature {the coolingfan cor'reson)
1.
Verifythat the throttlecontrolcableis clampedcorrectly with three positions.
lf the throttlecontrolleveris not synchronizedwith

the throttle linkage.adjust the throttle control cable.
,r:
14-174
vnx.su
4.
Check that there is play in the th,ottle control lever

while dep.essing the accelerator pedsl to th full
throttle Dosition.
F.o. play
Remove the cable end of the th.ottle control cable

o.
Check that the throttle control lever moves

smoothlv,
14-175
vnx.su

Adjustment
NOTE: Beforeadjustingths throttle control cable, make
sute:
4.
Remove the free play of ths throttl6 control cabl

with the locknut, whils pushing thg throttlo control
leve. to the full-closed Dotision as snown,
5.
Tighten the locknuts.
a Throttle cable free play is correct {see section 11).

a ldle speed is correct (seesection 11).
a To warm up the engine to normal oporsting temperature {the coolinglan comes on}.
I.
Verify that the throttle control c8ble is clamDedcorrsctly with three positions.
THROTTLE
COI{TROL
CABLE
ATF COOLER
PIPE
Clamp on blu6
CLAMP
Verify that the throttle linkage is in the full-closed
position.
5.
Loosen the locknut of the throttle control cable at

the throttle linkage.
THROTTLELII{KAGE
After tightening the locknuts, inspect the synchronization and throttlg control l6ver movemenr.
LOCKI{UTS
14-176
vnx.su
Differential
ManualTransmission
81881 engine
15-1
8 1 8 C 1e n g i n e. . . . . . .
15-9
..................
15-19
vnx.su
Differential(81881 enginel
........15-2
S p e c i aTf o o l s. . . . . . . .
Differential
lllustrated
Index.........
. 15-3
BacklashInspection
.... 15-4
FinalDrivenGearReplacement
...... 15-4
15-5
BearingReplacement
....................
Oil SealRemoval
........15-5
SideClearance
Adiustment...........15-6
Oil Seallnstallation
..... 15-8
vnx.su
SpecialTools
Ref. No.
o
ra)
@
Tool Numbol
oTJAD-PH80101
07746-OO30100
o7749-OO10000
o7947-SO90200
Description
Oty
Seal DriverAttachment
D r i v e r ,4 0 m m l . D .
Driver
15-8
15 - 5 . 6
15-8
15-8
(^
s
F
$-l)
o
15-2
vnx.su
I Pag Reference
Differential(B1881 engine)
lllustrated Index
OIL SEAL Replace.

Removal,page 15-5
FINAL DRIVENGAR
Inspectfor wear and damage,
page 15-4
Replacement,
DIFFERENTIALCARRIER
Inspection.page 15-4
BALL BEARING
Inspect lor wear and operation.
page 15 5
Replacement,
BALL BEARING
Inspect for wear and operation.
page'15-5
Replacement,
10 x 1.0 mm
101 N.m llO.3 kgt'm,74.5 lbf.ftl
Left-handthreads
80 mm SHIM
Selection,page 15-6
'l5-5
Removal,page
lnstallation,page 15-8
15-3
vnx.su
Differential(818B1 enginel
BacklashInspection
'1.
Placedifterentialassemblyon V-blocksand install

both axles.
1 . Remove the bolts in a crisscross Dattrn in several

steps, and remove the final driven gear from the
differentialcarrier.
Masurethe backlashof both pinion gears.

NOTE: The final driven gear bolts have left-hand
threads.
Standard(New):0.05-O.15mm (0.OO2-0.006 inl
1 0 x 1 . 0m m
101 N.m llO.3 kgl.m,74.5 lbf.ftl
Lelt-handthreads
DIAL II{OICATOR
FINAL DRIVEIIIGEAR
Chamfer on inside diameter ot
linal driven gear taces carrier.
DIFFEREI{TIAL
CARBIER
3.
It the bscklsshis not within the standard,reDlace

the differential carrier.
15-4
vnx.su
Installthe final driven gear by tighteningthe bolts

in a c.isscross pattern in several steps.
Oil Seal Removal
Bearing Replacement
NOTE: Checkthe ball bearingsfor wear and rough rotation. It bearingsare OK, removalis not necessary.
1.
1 . Remove the ditterential assembly.

Remove the 8O mm shim from the transmission
housing.
Removethe ball bearingsusing a standatdbearing

puller and bearingseparatoras shown.
BEARINGPULLEB
80 mm SHIM
TRA[{SMtSStON
HOUSING
3.
Removethe oilseal from the t.ansmissionhousing.
4.
Removethe oil seal from the clutch housing,
BALL BEARING
Installnew ball bearingsusing the specialtool as

snown.
NOTE: Drivethe bearingssquarelyuntil they bottom againstthe carrier.
DRIVER,40 mm l.D.
07746-0030100
BALL BEARING
OIL SEAL
Rplac6.
15-5
vnx.su
Differential(81881 engine)
Side ClearanceAdjustment
l.
Installthe diflerentialassembly,makingsureit bottoms in the clutch housing.usingthe specialtoolas

shown.
Installthe transmissionhousing(seesection 13).

NOTE: Do not applyliquidgasketto the matingsur,ace ot the clutch housing.
4.
Tighten the transmissionhousing attaching bolts

(see section 13).
8 x 1.25 mm
27 N.m 12.8 kgf'm, 20 lbf.ftl
Usethe specialtool to bonom the differentialassembly in rhe clutch housing.
tt.
HOUSING
2.
Installthe 80 mm shim.
NOTE: Instsllthe 80 mm shim that was removed.
mm SHIM
15-6
vnx.su
Measure clearance between the 80 mm shim and

bearing outer race in the transmission housing.
'l
lf the clearanceis not within the standard, select a

new 80 mm shim from the following table.
1 0 . Reassemblethe transmission and install the trans-
8O mm Shim
missionhousing{see section 13).
Pan Number
Thicknoss
41441-PL3-BO0
41442-PL3-BOO
1 . Om m 1 0 . 0 3 9 4i n )
1 . 1 m m ( O . O 4 3 3i n )
1 . 2 m m ( O . O 4 7 2i n )
1 . 3 m m ( 0 . 0 5 1 2i n )
41444-PL3-BOO
41445-PL3-BO0
41446- PL3-BO0
1 . 4 m m { 0 . 0 5 5 1i n l
1 . 5 m m ( O . O 5 9 1i n )
41447-PL3 -BOO
1.6 mm (0.0630in)
41448-PL3- B00
41449-PL3- BO0
1 . 7 m m ( 0 . 0 6 6 9i n )
1 . 8 m m ( 0 . 0 7 0 9i n l
41450- PL3-BOO 1 . 0 5m m { o . o 4 1 3i n l
4 1 4 5 1 - P L 3 - B O O 1 . 1 5m m ( 0 . 0 4 5 3i n )
in)
4 1 4 5 2 - P L 3 - B O O 1.25 mm (O.O492
4 1 4 5 3 - P L 3 - B O 0 1. 3 5 m m ( 0 . 0 5 3 2i n )
41454-PL3-BOO
41455-PL3-BOO
1 . 4 5 m m ( 0 . 0 5 7 1i n )
1. 5 5 m m ( 0 . 0 6 1 Oi n )
41456-PL3-800
41457 - PL3-BOO
1 . 7 5m m ( 0 . 0 6 8 9i n )
41441-P21-OOO
1 . 8 5 m m ( 0 . 0 7 2 8i n )
41442-P21-OOO
1.90 mm (o.o748in)
41443-P21-OOO
1 . 9 5 m m ( 0 . O 7 6 8i n )
H
J
K
L
M
9 . Replacethe 8O mm shim selected in step 7, thon

recheck the clearance.
Strndard: 0-O.1O mm (O.O04inl
41443-PL3- BOO
8 . Remove the bolts and transmission housing.
1 . 6 5 m m ( 0 . O 6 5 0i n )
NOTE: lf tho clearancemeasuledin step 6 is within

th standard, it is not necessary to go to step 9.
15-7
vnx.su
Differential(8188l enginel
Oil Seal Installation
1.
Installthe oil sealinto the t.ansmissionhousingusing the specialtools as shown
DRIVER
07749-0010000
Installthe oil seal into the clutch housingusingthe

soecialtools as shown.
DRIVER
07749-0010000
OIL SEAL
Replsce.
OIL SEAL
Replace.
HOUSING
15-8
vnx.su
Dif f er en ti a(8
l 18C1enginel
15 - 1 0
S p e c i aT
l ools ........
Differential
1 5 - 11
l l l u s t r a t e dI n d e x . . . . . . . . .
15-12
BacklashInspection
F i n a lD r i v e nG e a rR e p l a c e m e n.t. . . . . 15-12
TaperedRollerBearingReplacement.1 5 - 1 3
15-13
Oil Seal Removal
BearingOuter Race Replacement... 15-14
TaperedRollerBearingPreload
15-15
Adjustment
15-17
Oil Seal Installation
vnx.su
SpecialTools
Ref. No. I
(
,a\
@
r.l
@
TootNumber
oTHAJ-PK40201
oTJAD-PH80101
oTNAD-PX40100
o7746-O030'l
OO
o7749-OO10000
o7947-SD90200
Descriprion
PreloadInspectionTool
DriverAttachment
Driver,40 mm l.D.
Driver
Seal Drive. Attachment
rt\
$
s
tl
15-10
vnx.su
Oty
I
I
1
I
I
1
aa\
I Page Reference
1 5 - 15
15- 14
1 5- 14
15-131 4
15- 14 1 7
15 - 1 7
Differential(B18C1 engine)
lllustrated Index
NOTE: lf the ' mark parts were replaced,the tape.ed roller bearingpreloadmust be adiusted(see page 15-15).
OIL SEAL Replace.

Removal,page 15-13
'THRUST SHIM
T. 2.5 mm lO.O98inl
ROLLER
TAPERED
BEARING
Inspectfor wear and oporation.
page'15-13
Replacement,
*BEARING OUTERRACE
Inspect tor wear and damage.
page 15-14
Replacement.
10 x 1.0 mm
101 N.m 11O.3kgt.m,74.5 lbt.ft)
Left-hand threads
FINAL DRIVENGEAR
Inspectlor wear and damage.
page 15-12
Replacement,
}DIFFERNTIALCARRIER
.TAPERED ROLLERBEARING
Inspect for wear and operation.
page 'l5-13
Replacement,
T. 2.0 mm (0.079 inl

*79.5 mm SHIM
Selection,page 15-16
OIL SEAL Replace.
R e m o v a lp, a g e ' l 5 - 1 3
vnx.su
Differential(818C1 enginel
BacklashInspection
Placeditterentialassemblyon V-btocksand instatl

both axles.
1. Romovethe bolts in a crisscrossDatternin several

steps, and remove the tinal driven gear f.om the
differentialcarrier.
Measurethe backlashof both pinion gears.

NOTE: The tinal driven gear bolts have lett-hand
threads.
Standard(Now):0.o5-o.15 mm {0.oo2-0.O06 in)
1 0 x 1 . Om m
101 N.m (10.3 kgt.m, 74.5 lbf.ftl
Left-hand threads.
FII{AL DN|VENGEAR
Chamfer on inside diameter
of linal drivengar taces carrier.
DIFFERETTTIAL
CABRIER
lf the backlashis not within the standard,reDlace

the differentialcarrier,
Installthe final driven gear by tighteningthe bolts
in a crisscrosspattern in severalsteps.
15-12
vnx.su
TaperedRollerBearingReplacement
NOTE:
a The tapered roller bearingand bearing outer race
should be replaced as a set.
a Inspectand adjustthe taperedrollerbearingpreload
whenevef the taperedrollef bearingis replaced.
a Checkthe taperedrollerbearingstor wear and rough
rotation.lf taperedrollerbearingsare OK, removalis
not necessary.
1.
oil SealRemoval
1 . Removethe differentialassembly.
Removethe oil sealfrom the transmissionhousing.
Removethe taperedrolle. bearingsusinga bearing

puller and bearingseparatoras shown,
BEARING
BEARII{G
SEPANATOR
(Commercially
available)
3.
Removethe oil seal from the clutch housino.
Installnew taperedrollerbearingsusingthe special

tool as shown.
NOTE: Drivethe taperedrollerbearingson until they
bottom againstthe differentialcarrier.
15-13
vnx.su
Differential(B18c1 eng:nel
BearingOuter RaceReplacement
CAUTION: Do not rous the thrust lhim and tho 79.8
mm shim il tho outer rac6 was ddvon out.
4.
NOTE;
a The bearing outer race and taperd toller bearing
should be reDlacedas a set.
a Inspect and adjust the tapered roller bearing proload
whenever th tapered rollf bearing is roplacd.
1.
Removethe oil seals from the transmissionhousing

and clutch housing(see page 15-13).
2.
Removethe bearingouter raca, the thrust shim, and

the 79.5 mm shim from th transmissionhousing.
Installthe new thrust shim and 79.5 mm shim,then

drive the bearing outer races in the both housings
NOTE:
a Install the bearing outsr race squarely.
a Check that there is no clearance between tha
bearingouter race, thrust shim, and transmission
housing.
BEARIl{G
OUTER
TRANSMtSStOl{
HOUStl{c
Removethe bearingouter racs and thrust shim trom

the clutch housing.
07749-OOTOOOO
ONNER
ATTACHMENT
OTttAD-PX/IOlOO
5.
15-14
vnx.su
lnstallthe oil sesl (see page 15-171.
Tapered Roller BearingPreloadAdjustment

Instsllthethrustshim and 79.5 mm shim,then drive
the bearingouter race in the transmissionhousing
{ s e ep a g e l 5 - 1 4 ) .
NOTE: lf any of the items listedbelow were replaced,

the taperedrollerbearingpreloadmust be adjusted,
a
a
a
a
a
1.
Transmissionhousing
Clutch housing
Diffe.entialcarrier
Taperedrollerbearingand bea,ingouter race
Thrust shim
NOTE:
a Installthe bearingouter race squarely.
a Check that there is no clearancebetween the
bearingouter race.thrust shim and transmission
housing.
Removethe bearingouterrace,the thrust shim,and

the 79.5 mm shim from the transmissionhousing
(see page 1 5- 14).
4.
CAUTION: Do not reuss lhe thrust shim it the bearing outer raco was driven out.
2.
With the mainshaftand countershaft.emoved,instsllthe differentialassembly,andlorquethe clutch

housingand transmissionhousing,
8 x 1.25 mm
27 N.m 12.8 kgf.m, 20 lbf.ft)
First t.y the same size 79.5 mm shim that was

removeo.
NOTE: lt is not necessaryto use sealingagent between the housings.
CAUTION; Do not uso moro than two shims.

Rotate the ditterential assembly in both directions
to seat the taperedrollerbearings.
o.
Measurethe starting torque of the differenlialassembly with the specialtool and a torque wrench.
79.5 rnm SHIM
NOTE: Measurethe taperedrollerbearingpreload

in both directions.
STANDARD:2.1 1 -3.O4 N.m
(21.5-31.0 kgf'cm,
18.7-26.9 lbf.inl
HOUSING
{cont'd}
15-15
vnx.su
Differential(B18C1 enginel
TaperedRollerBearingPreloadAdjustment(cont'dl
7.
It the taperedrollerbearingpreloadis not within the

standard,selectthe 79.5 mm shimlrom the following table which will give the taperedrollerbea.ing
preloadclosestto the standardmeanvalueof 2.50
N . m ( 2 5 . 5 k g J . c m ,2 2 l b f . i n ) .
NOTE: Changingthe 79.5 mm shimto the next size
will increase or decreasetapered roller bearing
p r e l o a da b o u t O . 3 - O . 4 N . m ( 3 - 4 k g f . c m ,
2 . 6- 3 . 5 l b t . i n ) .
79.5 mm SHIM
Recheckthe taperedroller bearingpreload.

9 . How to selectthe correct 79.5 mm shim:
- 1) Comparethe taperedrollerbearingpreloadyou
get with the 79.5 mm shim that was removed
with the specifiedmean preloadof 2.50 N.m
(25.5 kgf.cm. 22 lbf.inl.
-2) lf your measuredtaperedrollerbearingpreload
is lessthan specified,subtractyour's from the
soecified.
lf your's is more than specified,subtractthe
specifiedfrom your measurement.
Forexamplewith a 1.38 mm (O.O543in) shim:
Part Numbel
Thickness
41460-PY4-000
0 . 6 6 m m ( 0 . 0 2 6 0i n )
AB
41461-PY4-000
1 . 1 7 m m ( O . 0 4 6 1I n ,
AC
2 . 0 N . m { 2 0 k g f . c m ,1 8 l b t . i n }l e s s
AD
41462-PY4-000 1 .2O mm (0.0472 in)

41463-PY4-000 1 . 2 3 m m ( O . O 4 8 4i n )
AE
41464-PY4-000
1 . 2 6 m m ( 0 . 0 4 9 6i n )
AF
41465-PY4-OOO 1 . 2 9 m m ( O . O 5 O i8n )
3.29 N.m {33.5kgl.cm,29 lbl.in)

@you measure
- specified
2.50 N.m {25.5kgf.cm,22 lbf.in)
AG
41466-PY4-OOO 1 . 3 2 m m ( O . O 5 2 O
in)
AH
41 467-PY4-000
@ specified2.50 N.m (25.5 kgf.cm, 22 lbf.in)

- you measure0.54 N.m (5.5 kgt.cm, 5lbt'in)
0.8 N.m (8 kgf.cm,7lbt.in) more

3) Each shim size uD or down from standard
makesabout O.3-O.4 N.m (3-4 kgf.cm,
2.6-3.5 lbf.in) difJerencein tapered roller
bearingpreload.
AI
1 . 3 5 m m { O . O 5 3 1i n )
41468-PY4-000 1 . 3 8 m m ( O . O 5 4 3i n )
AJ
41469-PY4-000
AK
AL
41470-PY4-OOO 1 . 4 4 m m ( 0 . 0 5 6 7i n )
41 47 1-PY4-OOO 1 . 4 7 m m ( 0 . 0 5 7 9i n )
AM
41 47 2-PY4-OOO
AN
41473-PY4-000
AO
1 . 5 6 m m ( 0 . 0 6 1 4i n )
'
4 1 4 7 5 - P Y 4 - O O O l. 5 9 m m ( O . 0 6 2 6i n )
4'1476-PY4-O00 1 . 6 2 m m ( 0 . 0 6 3 8 i n )
41 47 7 -PY4-OOO 1. 6 5 m m ( 0 . 0 6 5 0 i n )
AP
AO
AR
AS
AU
1. 4 1 m m ( O . 0 5 5 5i n )
a In example@, your measuredtaperedroller

bearingpreloadwas 2.O N.m (20 kgf'cm,
I 8 lbl.in) less than standard so you need a
79.5 mm shim five sizesthickerthsn standard {trv the 1.53 mm (0.0602 inl shim and
recheck).
a I n e x a m p l e@ y o u r ' s w a s O . 8 N . m ( 8
kgf.cm, 7 lbJ.in)more than standard, so
you needa thrust shim two sizesthinner (try
the 1.32 mm (0.0520in) shimand recheck).
1 . 5 0 m m { O . O 5 9 1i n )
1. 5 3 m m ( 0 . 0 6 0 2i n )
41 47 4-PY4-OOO
41478-PY4-000
1. 6 8 m m { 0 . 0 6 6 1 i n )
41479-PY4-OOO 1 . 7 1 m m ( O . 0 6 7 3i n )
41480-PY4-OOO 1 . 7 4 m m ( 0 . 0 6 8 5i n )
1 0 . After adjustingthe tapered.oller bearingpreload,assemblethe transmission,

and installthetransmission
housing{see section 13).
41481-PY4-OOO 1 . 7 7 m m { 0 . 0 6 9 7 i n }
41442-PY4-OOO 1 . 8 0 m m ( O . O 7 O i9n )
AX
8 x 1 . 2 5m m
27 N.m 12.8 kgt.m. 20 lbf.ttl
41483-PY4-OOO 1 . 8 3m m ( 0 . 0 7 2 0i n l
1 1 .Rotatethe diJJerential
assemblvin both directions
to seat the taperedrollerbearings.
15-16
vnx.su
Oil Seal lnstallation

1 . lnstalltheoil seal into the transmissionhousinqusing the specialtools as shown.
DRIVER
07749-OOIOOOO
Installthe new oil sealinto the clutch housingusing

the soecialtools as shown.
DRIVER
07749-OOlOO00
OIL SEAL
Replace.
OIL SEAL
Replace.
HOUStl{G
15-17
vnx.su
Differential(AutomaticTransmissionl
. . . . . . . .1 5 - 2 0
S p e c i aTl o o l s . . . . . . . .
Differential (Automatic Transmission)
.15-21
f l f u s t r a t eIdn d e x . . . . . . . . .
.... 15-22
BackfashInspection
B e a r i n gR e p l a c e m e n.t. . . . . . . . . . . . . . . . . 1 5 - 2 2
DifferentialCarrierReplacement.... 15-23
........15-24
O i l S e a fR e m o v a l
Oil Seal Installation/
15-24
S i d eC l e a r a n c .e. . . . . . . . . . . .
vnx.su
SpecialTools
Ref. No.
o
r^
aa)
@
Tool Number
Dascription
oTJAD-PH80200
oTNAD-P200100
07746-0030100
07749-0010000
o7947-SD90200
Oty
Pilot, 26 x 30 mm
Driver, 52 x 55 mm
Driver,40 mm l.D.
Driver
OriverAttachment
15-20
vnx.su
15-26
15-26
15-22,24,25
't 5-26
15-26
1
1
1
I
1
I Pago Retelonco
Differential(AutomaticTransmissionl
lllustrated Index
FINAL DRIVENGEAR
BALL BEARING
ENTIAL.ARRIER
--ttot"'
'
6
ROLLER.5xlOmm
BALL BEARING
15-21
vnx.su
Differential(Automatic Transmission)
BearingReplacement
BacklashInspection
1 . Placethe differentialassemblyon V-blocksand install both axles.
Check backlashof both pinion gears.
NOTE: Checkthe bearingsfor wear and roughrotation.

lf the bearingsare OK, removalis not necessary.
1.
Removethe ball bearingsusing a bearingpuller.
Standard(New):0.05-O.15 mm (0.002-0.006 inl

BEARINGPULLER
SIDE GEARS
BALL BEAING
3.
lf backlashis out of tolerance,replacethe differential carrier.
Installthe new ball bearingsusing the specialtool

with a Dressas shown.
DRIVER,40 mm l.D.
07746 0030100
15-22
vnx.su
DifferentialCarrierReplacement
1 . Remove the final driven gear from the differential
carrier.
5.
Align the hooked end of the snap ring with the pinion shaft as shown, then installthesnap ring in the
diffrential carrior groove.
NOTE: Tho final driven gear bolts have left-hand

threads.
Hooksd nd
SI{APRII{G
Installin this direction.
Pry the snsp ring ofl differentialcarrier.then remove

the speedometerdrive gear 8nd 5 x 1O mm roller.
DRIVE GEAR
o.
5.
lnstall th6 5 x 1Omm roller in the differentisl csrrier'
4.
Installthe speedomterdrive gear with its chamfered

side facing the carrier, Align the cutout on the bore
of the speedometerdrive gesr with the 5 x 10 mm
rollr.
Install the final driven gear, then tighten the bolts

to th6 spscified torque.
TOROUE:101 N.m (10.3 kgf.m, 74.5 lbf.ft)
NOTE: The final driven gear bolts have left-hand
threads.
BOLTS
10 r 1.0 mm
lOi N.m (1O.3 kgf.m,
74.5 tbt'ft)
Left-hand thrgads
SPEEDOMETEB
DRIVEGEAR
Instsllin this
diroction.
7.
Installthe ball bearings{see page 15-22).
15-23
vnx.su
Differential(Automatic Transmissionl
Oil Seal Removal
Oil Seal Installation/SideClearance-
1 . Removethe differentialassembly.
1.
lnstalla2.50 mm (O.O98in)thrustshim in the rransmissionhousing.
2 . Removethe oil sealfrom the transmissionhousino.

NOTE: Do not installthe oil seal yet.
TRAt{SMtSStON
HOUSING
TRANSMISSIO
HOUSING
OIL SEAL
Replace.
seal from the rorque convener
Installthe differentialassemblyinto the torquecon_

vner housingusing the specialtool as shown.
DRIVER,40 mm l.D.
07746-OO30100
DIFFERENTIAL
ASSEMBLY
/-l
TOROUE
CONVERTER
HOUSING
Assemblethe transmission(see section 14).

Installthe transmissionhousingand tighten the bolts
(see section 14).
TOROUECONVERTER
HOUSING
15-24
vnx.su
Measurethe clearancebetween the thrust shim and

outer race of the ball bearingin the t.ansmission
housing.
Tap on the transmissionhousingsideof the differential assembly with the special tool to seat the
dilferentialassemblyin the torque converterhousing.
STANDARD:O-0.15 mm {0-O.OO6 in}
lf out of limits, selecta new thrust shim from the

following table:
THFUSTSHIM, 80 mm
Pan Numbr
90414-689-OOO
90415-689-OOO
90416-689-000
9041 7- 689-000
904r 8-689-OOO
90419-PH8-OOO
Thickness
2.50 mm (O.O9843in)
2.60 mm {0. I 0236 in)
2 . 7 0 m m ( O . 1 0 6 3 0i n )
2 . 8 Om m ( O .1 1 O 2 4i n )
2 . 9 0 m m ( 0 . 11 4 1 6 i n )
3.OOmm{O.11811in)
NOTE: It the thrust shim-to-ballbearingouter race

clearancemeasuredin step 5 is lessthan the specification, it is not necessa.yto pertorm steps 7 and 8.
Removethe transmissionhousing.
8.
ReDlacethe 2.50 mm (0.098 in) thrust shim with

the one oJ the correct thickness selected in step 6.
9.
Installthe transmissionhousing(see section 14).
(cont'd)
15-25
vnx.su
Differential(Automatic Transmissionl
Oil Seal Installation/SideClearance
(cont'dl
9. Installtheoil sealin the transmissionhousingusing
the specialtools as shown.
DRIVER
07749-0010000
ATTACHMENT
07947 -SD90200
PILOT
26x30mm
oTJAD-PH80200
10. Installthe oil seal in the torque converterhousing

DFIVER
07749-0010000
DRIVER,52 x 55 mm
oTNAD-P200100
15-26
vnx.su
vnx.su
SpecialTools
R!t. No.
o
@
o
@
@
@
Tool Numbcr
07JAF- SH20400
07LAD- PW50601
07MAC- 5100200
07746- 0010300
07746- 0010400
07746- 0030400
07749- 0010000
07965- SD90100
D.lcription
Oty
Suppon BsseAttachment
Attachment,40 x 50 mm l.O.
BallJoint Remover,28 mm
Anachment, 42 x 47 mm
Attachment,35 mm l.D.
Driver
Support Bas
1
1
1
1
1
1
1
1
Psgo Rctcr.nct
1 6 -1 3
16-14
16-4
16-13
16-14
16-'r4
1 6 - 1 31, 4
16-13
(4,
16-2
vnx.su
Driveshafts
Inspection
Removal
DriveshaftBoot
Checkthe boots on the driveshaftfor cracks,damage,
leakinggreaseor looseboot bands.
l f a n y d a m a g e i s f o u n d , r e p l a c et h e b o o t a n d b o o t
Danos.
Loosenthe wheel nutsslightly.

Raise the front of car and support it with safety
(seesection1),
standsin the properlocataons
Removethe wheel nutsand front wheels,
Looso Splines
Turn the driveshaftby hand and make sure the splines
and joint are not excessivelV
loose.
lf damageis found, replacethe inboardjoint,
Drainthe transmissionoil or fluid (seesection13 or

14).
NOTE:lt is not necessary
to drainthe differentialoil
when the left driveshaftis removed.
Twistod or Cracked
Makesurethe driveshaftis not twistedor cracked.
Replaceit if necessarv.
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.
WHEELNUT
DBIVESTIAFT
Replace.
6.
Removethe self-lockingnut and self-locking

bolt.
EOOTBANDS
GAUTION: Roplacoth slt.locking bolts if you can

sasily thread a nonelf-locking nut prst thoir nylon
locking inserts.
(lf should require I N.m (0.1 kgt.m, 0.7 lbf.ft) ol
torqus to turn lhs nut on the bolt).
Removethe damDerfork.
BOLT
SELF.LOCKING
10 x 1.25mm
NUT
SELF-LOCKING
12 x 1.25mm
Replace.
(cont'dl
16-3
vnx.su
Driveshafts
Removal(cont'dl
8. Removetha cotter pin from the lower arm ball joint
castlenut, and removethe nut.
12. Pull the inboardjoint, and removeth6 right driveshaft from the differentialcase as an assemblv.
9. Installa 12 mm hex nut on the ball ioint. Be sure

that the hex nut is flush with the ball joint pin end,
or the threaded section of the ball ioint pin might be
damag6dby the balljoint remover.
CAUTION:
. Do not pull on tha dlivo3haft, a! th! inborrd
ioint may comc !p!rt,
. U3c carc when prying out tha a$qnbly, lnd pull
it rtraight to lvoid drmlging thc diftcrrntial oil
soal or thc int.rmcdirto shrft outel saal.
10. Use th ball joint remover, 28 mm, as shown on

page 18-11.to separatethe ball joint and lower arm.
CAUTION: Bo crrolul not to damrgo th. ball ioint
boot.
NOTE: lf necesssry,apply penetratingtype lubricantto loosenthe ball joint.
SCREIYDRIVER
1 1 . Pry the driveshaft assembly with a screwdriver, as
shown, to force the set ring at the driveshaftend

past the groove.
Left Driveshaft:
Removethe left driveshaftfrom the bearing support by tapping the inboard joint of the driveshaftwith I Dlastichammer.
SCREWDRIVER
BEARINGSUPPOFT
16-4
vnx.su
13. Pullthe knuckleoutward,and removethe driveshaft

outboard joint from the front wheel hub using I
Dlastichammer.
1 . Removethe set ring from the inboardjoint.

To removethe boot band, pry up the lockingtabs
with a screwdriverand raisethe end of the band,
CAUTION: Taks caro not to damagc thc boot.
KNUCKLE
NOTE:Carefullyclamp the driveshaftin a vise with

soft iaws.
DRIVESHAFT
SET RING
Replace.
lf the boot band is the welded type, cut it off as

snown,
16-5
vnx.su
Driveshafts
Disassembly(cont'd)
3,
Mark each roller and inboard joint to identify the

locationsof rollersand groovesin the inboardjoint.
Then removethe inboardjoint on the shop towel.
9. Wrap the splineson the driveshaftwith vinyltape to

preventdamageto the bootsand dynamicdamper.
10. Removethe boot bandand inboadboot.
NOTE: Be carefulnot to drop the rollerswhen separatingthem from the inboardjoint.

INBOARD
JOINT
Check
splines
tor w6aror damage.
Chckinsideborefor wear.
Inspecttor cracks.
CAUTION: Take car. not to damageth boot.

1 1 . R e m o v et h e d y n a m i cd a m p e r b a n d a n d d y n a m i c
damoer.
CAUTION: Tako cars not to damage the dynamic
damper.
12. Removethe boot bands and outboard boot, then
removethe vinyltape.
CAUTION: Take csre nol to damagetho boot.
INBOARD
BOOT
DYNAMICDAMPER
Inspectlor cracking,
Checktor damage.
splitting
andwear.
DYNAMICDAMPER
Marka
Mark the rollersand spiderto identifythe locations

of rollerson the spider.Then removethe rollers.
Removethe circlip.
o.
Mark the spider and driveshaftto identifythe position of the spideron the shaft.
Removethe spider using a commerciallyavailable
bearingremover.
OUTBOARD
BOOT
lnspectfor cracking,
splining
andwear.
13. Inspectthe outboardjoint for faulty movementand
wear. lf any roughnessor excessplay is felt, replace
the outboardjoint.
Removethe stopperring.
BEARING
14. Checkthe outboardring for damage.
,'0
STOPPER
RING
CIRCLIP
OUTBOARDJOINT
ROLI-RlFor loft ddvcshrfrl
16-6
vnx.su
Reassembly
NOTE:
panswith solvent,
o Cleanthe disassembled
anddrythemthroughly
with compressed
air.Donotwashthe rubberparts
with solvent.
o *.'.l|@l
: Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft
ser.
G.ea3o quontity:
120- 130g |'4.2- 4.6 ozl
90 - 100g {3.2- 3.5oz}
lnboardJoint
OutboardJoint
SETRING
Replace.
RIGHTINBOARDJOINT
ROLI.TR
{For lcft
b
,RDJOINT
INAOARDBOOT
---"-G1
Packcavity with grase.
-Gl
DYNAMICDAMPER
Pack cavity wrth grease.
EOOTBANDS
Replace.
(cont'd)
16-7
vnx.su
Driveshafts
Reassembly(cont'dl
1.
Wrap the splineswith vinyl tape to preventdamage

to the bootsand dynamicdamper.
2.
I n s t a l lt h e o u t b o a r d b o o t , d y n a m i c d a m p e r a n d
i n b o a r db o o t t o t h e d r i v e s h a f tt,h e n r e m o v et h e
vinyl tape.
6.
Packthe outboardjoint with the joint greaseincluded in the new driveshaftset,

Greasequantity: 90 - 100 g (3.2- 3.5 oz)
CAUTION: Take care not to damage the boots and

dynamicdampr.
,.%
VINYLT
OUTBOARDBOOT
DYNAMICDAMPER
7.
INBOARD
BOOT
Installthestopperring into the driveshaftgroove.

NOTE:Always rotatethe stopperring in its groove
to be sure it is fully seated.
Fit the rollersto the spiderwith their high shoulders

facingoutward.
NOTE:
. Reinstallthe rollersin their originalpositionson
the spiderby aligningthe marks.
. H o l d t h e d r i v e s h a f tp o i n t e du p t o p r e v e n tt h e
rollersfrom fallingoff.
Installthe spider on the driveshaftby aligningrhe

markson the spiderand end of the driveshaft.
-r
+ {l-
Fit the circlipinto the driveshaftgroove.

NOTE:Always rotatethe circlip in its grooveto be
sure it is fully seated.
CIRCLIP
SPIDER
STOPPER
RING
16-8
vnx.su
SPIDER
ROLLER
ROLLER
{For left driv8hattl
8.
Packthe inboardjoint with the ioint greaseincluded

in the new driveshaftset.
Greasequantity; 120- 130 g 11.2- 4.6 ozl
1 0 .Adjust the length of the driveshaftsto the figure

below. then adjust the boots to halfway between
full compressionand full extension.
NOTE:The ends of boots seat in the groove of the
driveshaftand joint.
Left:475- 480mm {18.7- 18.9inl
Right: 475 - 480 mm (18.7- 18.9inl
9.
Fitthe inboardjoint onto the driveshaft.

NOTE;
. Reinstallthe inboardjoint onto the driveshaftby
aligningthe marks on the inboardioint and the
rollers.
. Holdthe driveshaftso the inboardjoint pointsup
to preventit from fallingoff.
Left drivoshaft:
Align the holder directionof the rollers
toward the slot ot inboard joint as
1 1 . lnstallnew boot bandson the boots,and bend both
setsof lockingtabs.
Lightlyrap on the doubled-overportionsto reduce
their height.
\
/,.-:--\\\
di,ection
sotine
I
INBOARD
JOINT
A\
{(@}
HOLDER
{cont'd)
16-9
vnx.su
Driveshafts
(cont'dl
Reassembly
t5.
Installation
Positionthe dynamicdamperas shown below.

. Installa new dynamic damper band. and bend
down both sets of locking tabs.
Lightly tap on the doubld-overponion of the
bandto reduceits height,
1.
Installthe outboardjoint into the knuckle.
KNUCIGE
Loft/Right 29 r 2 mm (1.1r 0.1 inl

DAMPER
DYNAMIC
DYNAMICDAMPERBANO
OUTBOARD
JOINT
Apply 1.0- 1.5s (0.04- 0.05oz) of specifiedgroase

to the whole splined surtace of the intermediats
shaft.
NOTE: After applying grease,remove the grsase
f.om the splinedgroovesat intervalsof 2 - 3 sDlines
and from the set ring grooveso air can bleedfrom
the inboardjoint.
Installthe new set ring onto the driveshaftor intermediateshaftgroove.
CAUTION: Always uso a now sot ring whcncycr
tho driveshaft is boing in3tallod.
RING
b
SET RINGGROOVE
16-10
vnx.su
Insertthe inboardend of the driveshaftinto the diff e r e n t i a lo r i n t e r m e d i a t es h a f t u n t i l t h e s e t r i n g

locksin the groove.
1 . Installthe knuckleon the lower arm, then tighten

the castlenut and installa new cotterpin.
NOTE: Wipe off the grease before tightening the
nut at the ball joint.
INBOARD
JOINT
CAUTION:
. B careful not to damago tho ball ioint boot.
. Torqu tho castle nut to ths lower torquo 3paci.
fication, then tighlon it only tar snough to slign
the slot with th pin hole. Do not align tho nut
by loossning,
INAOARDJOINT
GROOVE
OIFFERENTIAL
5.
CASTLENUT
12 x 1.25rnm
Installthe damperfork over the driveshaftand onto

t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r
fork so the aligning tab is alignedwith the slot in
the damperfork.
a9- 59N.m15.0- 6.0kgt.m,36- a:tlbtftl
8. Installa new spindlenut,then tightenthe nut,

9. Installthe front wheelwith the wheel nuts.
NOTE: Beforeinstallingthe wheel,cleanthe mating
surfacesof the brakediscand the wheel.
L o o s e l yi n s t a l lt h e s e l f - l o c k i n gb o l t a n d t h e n e w
self-lockingnut.
FRONTWHEEL
NOTE:The bolts and nut should be tightenedwith

the vehicle'sweight on the damper.
SELF.LOCKING
BOLT
10 x 1.25mm
a:' N.m lir,4 kgt m, 32 lbf.ftt
COT1ERPIf{
On reassembly,
bend the cotter pin
as shown.
WHEELNUT 12 x 1.5 mm
108N.m (11.0kgf.m,80lbtft,
ALIGNINGTAB
NUT 22 x 1.5mm
kgl'm,134lbt'ftl
181N m 118.5
NOTE:Altortightening,usea driftto
nutshoulder
stakethesPindle
againstthe driveshaft
1 0 . Tightenrhe self-lockingbolt and the new self-locking nut with the vehicle'sweighton the damper.
1
SELF.LOCKING
NUT
12x 1.25mm
64 N.m (6.5 kgt m, 47 lbf.ftl
'I.
Refill the transmissionwith recommendedoil or

fluid (seesection13 or 14).
12. Checkthe front wheel alignmentand adjust if necessary{seepage 18-4).
1 6 - 11
vnx.su
Intermediateshaft
Removal
2.
Disassembly
Drsinthe transmissionoil or fluid (seesection13 or

14).
NOTE:Be carefulnot to damagethe metal rings on the

intermediate
shaftduringdisassembly.
Removethe left driveshaft(see page 16-3).
1.
Removethe set ring,
Removethe three dowl bolts.
2.
Removethe intermediateshaft outer seal from the

bearingsupport.
3.
Removethe eldernalcirclip.
Removethe intermediateshaft f.om the differential.

CAUTION; Hold the intormediato shaft horizontrl
until it b clear of the dittorential to prevent damago
to thr dittarontial oil so!|.
16-12
vnx.su
OUTEBSEAL
Replsce.
t
SETRING
Replace.
1.
Pressth6 intermBdiateshaft out of the shaft bearing

using the specialtools and a press as shown.
5.
Removethe internalcircliD.
Pmar
INTEBNALCIRCLIP
Pressthe intermediateshaft bearing out of th boaring support using ths spscialtools and a prsss as
snown.
Praa!
BASE
SUPPORT
ATTACHMENT
07JAF- SH2oalXt
FLOANNGRUBBR
DA'iIPER
Checkfor detrioration
and dama9e.
ATTACHMENT,
1i2xa7fim
07ta6 - 00ro:!00
SUPPORTBASE
ATTACHMENT
- SHZ!(|O
BEARINGSUPFORTRING
Chscktor damagg or distonion.
BASE
07965- Sll9or00
SUPPORTBASE
07965 - SDg,|q'
INIERiIEDIAIE SHAFT
Checkfor damage.
BEARINGSUPPORT
Checkfor damage.
NOTE:
. Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber
parts with solvent.
. Be carful not to damagethe metal rings on the intermedists shaft during reassmbly
DOvvELBOLTS
10r 1.25ftm
:tlt N.m {a.Otgt m, 29 lbfftl
EXTENTALCIRCUP
ob.
Packthe intorior
of the outer saal.
2.0- 3.5 g {0.07- 0.12oz}
SETRING
Replace.
INTERMEOIATESHAFT BEABING
Reolaco.
BEARING
v
ourER SEAL
Rspbce.
vnx.su
{conr'd)
IntermediateShaft
(cont'dl
Reassembly
'1. Press
the intermediateshaft bearinginto the bearing support using the specialtools and a press as
shown.
Seatthe externalcirclip in the groove of the intermediate shaft.

NOTE:Installthecirclipwith the taperedend facing
our.
Installthe outer seal into the bearingsupportusing
the specialtools as shown.
NOTE: Installthe seal flush with the bearingsupport.
ATTACHMENT,
52x55mm
07716- 001o/UX)
DRIVER
07749- 00t(xD0
Packthe interior
ol the olter seal.
2.0 - 3.5 g 10,07- 0.12 o2l
Seatthe internalcirclipin the grooveof the bearing

suoDon.
OUTERSEAL
CAUTION: Install the circlip with the tapersd end

facing out.
Pressthe intermediateshaft into the shaft bearinq
usingthe specialtoolsand a press.
ATTACHMENT,
aOx 5{)mm l.D.
07LAD - PW50601
Pross
lnstall the new set ring in the intermediateshaft

groove.
16-1 4
vnx.su
lnstallation
lnsert tha intermediate shaft assembly into the differential.
CAUTION: Hold th inlorm.diltc ahrft horizontsl
to prryonl dsmrge to thc difflrontill oil taal.
INTERMEDIATESHAFT
2.
Installthe threedowel bolts,then tightenthem.
DOWELBOLTS
10x 1.25mm
39 N.m {a.Orgl.m, 29 lbl.ft}
INIERMEDIATESHAFT
16-15
vnx.su
Steering
.............
17-2
SpecialTools
Component Location
lndex ................
......17-3
System Description
Ffuid Flow Diagram .........................
17-1
17-5
SteeringPump .................................
17-7
SteeringGearbox.............................
Troubleshooting
17-10
GeneralTroubleshooting................
17-14
Noiseand Vibration.........................
.............
17-16
FluidLeaks
Inspection and Adiustment
17-14
SteoringOperation ..........................
Power Assist Check
with CarParked...........................
17-18
SteeringLinkageand Gearbox.......17-19
..............
17-20
Pump Beh
.....17-21
RackGuideAdjustment .............
......................
.....17-21
Ffuid Replacement
.... 17-22
Pump PressureCheck..................
17-23
FfuidLeakagelnspection ................
+Steering Wheel
Removal
..,,,,,,,........
17-24
-25
...............
17
17-26
fnstallation
,......,,,,,.
* SteeringColumn
Removaf
.................17-28
Inspection
..............
17-30
.............
17-31
Installation
Power Steering Hoses.Pipes
.........17-3tl
Replacemont
Power SteeringPump
Removal
.................
17-35
Disassembly
..........17-35
Reassembly
...........
17-'10
lnstallation
........,...,
l7-tltl
Steering Gearbox
.,.,.............
17-45
Removaf
..........17-/E
Disassembly
...........
17-53
Reassembly
.............
17-63
lnstallation
Ball Joint Boot Replacement..........17-65
SUPPLEMENTALRESTRAINTSYSTEM{SRSI
The IntegraSRS includesa driver's airbag.locatedin the steeringwheel hub, In addition,all modelsexcept the
RS modelfor Canadahave a front passenger'sairbaglocatedin the dashboardabovethe glove box. Information
necessarvto safelyservicethe SRS is includedin this ServiceManual.ltems markedwith an asterisk{') on the
or replacingthese items
contents page include,or are locatednear, SRS components.Servicing.disassembling
Acura dealer.
done
by
an
authorized
precautions
should
therefore
be
and tools, and
will requirespecial
a To avoid rsndering ths SRS inoporative, which could load to po.sonal iniury 01 dath in th event ot a ssvare
lrontal collision, all SRS service work muat be performod by an authorizod Acura deal6t.
a lmploper service procodules. including incorloct romoval and installation of the SRS,could lead to personaliniury caused by unintontional activation ot the airbags.
a All SRS elsctdcal wiring harnessesara covorod with ysllow insulation. Rolalod componnts 8re locatsd in tho
stse ng column, tront console, dashboard, and dashboard lower panel, and in the dashboard above the glove
box. Do not use oloctrical tost equipmoni on thosa cilcuits.
NOTE: The originalradiohas a codedthett protectioncircuit. Be sure to get the customer'scode numberbefore
- disconnectingthe battery.
- removingthe No. 32 (7.5 A) tuse from the under-hoodfuse/relaybox.
"CODE" is displayed'enter the cusAlter service,reconnectpower to the radioand turn it on. When the word
tomer's 5-digit code to restoreradio operation.
vnx.su
Rcf. No.
Tool Numbl
07GAF- PH70100
07GAF- SD40700
07GAG- SD40100
07GAG- SD40200
07GAG- SD40400
07JGG- 0010104
07MAC- 5100200
07MAG - 5100100
07NAD- SR30200
07NAG- SR30900
OTNAK- SR3O11A
OTNAK- SR3O12A
07406- 0010001
07406- 0010300
07405- 0010400
07725- 0030000
07746- 0010100
07746- 0010200
007i$ - 0010000
07916- SA50001
07947- 6340500
07974- 6890801
0797,1- SA50200
@
@
(t
@
@
@
@
@
@
@
@
@.r
@-2
@
@
@
@
@
@
@
@
F--,'---l
@@
1
'I
1
1
1
1
vnx.su
17-22
1
1
'l
1
I
1
1
1
1
17-35,53
17-55,56
17-1'l
t7-55
17-2'l
17-11
17-57,58
17-55
6
w
@,2
^dN
17-2
17-50
17-5{
17-22
1 7- 2 2
't1-22
@:
@
17-20
't7-15
1
1
@-r
17-EO
lx:__E
1
1
1
1
@
16)
17-39
17-57
17-57
\v
,h
z6)
<Z
V,.)
@
'17-52
\,
P!9. Relrrrncc
t.-,
TJ
O'ty
PilotCollar
Hub DivAssembly Base
PistonSealRingGuide
PistonSealRingSizingTool
Cylinde.End Sealcuide
BeltTensionGauge
BallJoint Remover,28 mm
BallJoint BootClip Guide
Cylinder End Seal RemoverAttachment
ValveSsalRingSizingTool
P/SJoint Adapter(Pump)
P/SJoint Adapter (Hos6)
P/S PressureGsuge
PressureControl Valve
PressureGauge
UniversalHolder
Driver
LocknutWrench, i[0 mm
Driver Anachment
CylinderEnd SealSlider
SleeveSesl RingSizingTool
re
aL2
Dcscription
ComponentLocation
lndex
Powar Siooring:
NOTE:
It an intact airbag assmbly has been rmoved from a scrappedcar or has been found defective or damaged during
transit. storage or service,it should be doployd (seesection 23).
a Before removing tho gearbox, remove ths ignition key to keep the steering shaft Jrom turning.
a After installingthe gearbox,checkths whel alignmentand adiustif necessary.
CAUTION:
. All SRS aloctricll wiring h!m!|$a
rrc covcred with
yrllow in3uhtion.
. 8for disconnocling lny ptrt ol thc SRS wiro h!r'
ne*r, connect thc lhort conncctor{3l.
. Rcplsce lhc ontira ttfact d SRS harnccc a$embly il
it hs3 !n oprn circuh 01 dtm!9.d wiring.
SIEERING COLUiIN
Removal,page 17-28
Inspection,pago 17-30
Installation,p6ge 17-31
rcNMON SwlTCH
See s6ction23
STEERII{GGEARBOX
RackGuide Adjustment,pag.11-21
Removal,pags 17-45
Diossombly,page 17-{8
Bea65mbly,page 17-53
POWENSTEERINGPUMP
Pump Beft Inspoction.page 17-2O
Pump EeftAdjustm6nl, pago 17-2O
Pump PressurgChck,page 17-22
Removai,p6go 17-35
Disassembly,p3gs 17-35
Reassombly,psge l7-40
lnstallation,page 17-44
STEERINGWHEEL
Removal.page 17-24
page 17-25
Oisassembly/Reassembly,
page17-26
Installation,
TIE'RODEND BALLJOINT
Ball Joint Eoot Replacement,page 17-63
17-3
vnx.su
System Description
FluidFlow Diagram
The system is a compact rotary-valvs-typepower stssring, connoctedto the storing gearbox. Th6 fluid pressureis provided by a vane-type pump which is driven by the engine crank pulley. The amount of fluid and pressurs is regulsted by
the flow control valve built into ths pump, The fluid prssaursfrom th6 pump is dolivsred to tho valve unit sround the pinion of the steering garbox. The vslv inside the valvs unit controls the hydraulic prossurEnd changosthe direction ot
the flow. The fluid then flows to the power cylinder, where rack thrust is gen6rat6d.Fluid returning from th6 powsr cylinder flows backto the .eservoir,where the fluid is 'filtered" and supplied to the pump Egain.
17-4
vnx.su
Construetion
The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is driven by a V-beltfrom
the crank pulley. The pump features 10 vanes, Each vane performs two intake/dischsrgeoperations for every rotation of
the rotor.This meansthat the hydraulicfluid pressurepulsebecomesextremelysmallduringdischarge.
INLETPORT
CAM RING
VALVE
FLOWCONTBOL
DRIVESHAF'
VANE
Operation
The belt-drivenpulley rotatesthe rotor through the drive shaft,As the rotor rotates,the hydraulicpressureis appliedto
of the cam .ing.
the vanechamberof the rotor and the vaneswitl rotatewhile beingpushedonto the innercircumference
so the rollers
portion
of
the
shaft.
respect
to
the
center
with
ring
has
an
extonded
of
cam
inner
circumference
the
The
move downwardin the axialdirectionas the carrierrotates.As a resultof this rollermovemsnt,the internalvolumeof the
vane chamberwill change,resultingin fluid intakeand discharge.
STARTOF FLUIDINTAKE:
FLUIDMOVEMENT:
FLUIDINTAKE:
FLUIDDISCHABGE:
DISCHARGE
P('BT
The vanes are pushed onto

the inner circumferenceof th6
cam ring.
Th6 volumsotth vanchamber increasosso that lluid is

suckodin.
T h 6 s u c k e d - i nf l u i d m o v e s
towsrd the discha196pon.
As the vanes returnto th

their original positionon the
inner side,the volume of the
vane chamber decreasesso
the fiuid is discharg6dfrom
the dischargeport.
(cont'd)
vnx.su
System Description
SteeringPump(cont'dl
Flow Control
FLOWCURVE
The flow controlvalve in the pump performsthe following steps@ throughO to controlthe flow of fluid, i.e.to
increasethe dischargevolum wh6n engine speed is
low and to decreaseit when the enginespeedincreases.
The assistance
thrust of the steeringgearboxchangesin
compliancewith the changein the dischargevolume.
. J5
l o
tr o=
PUMPR.P,M.
When the engine starts,fluid dischargedfrom the

dischargeport starts to run through the metering
orificein the pump.The dischargevolume increass
as the enginespeedincreases,
@ A s t h e f l o w h a s a l r e a d y b e e n r e g u l a t e db y t h e
meteringorificewhen the enginespeedis at or near
the idle speed,a constantand regulatedamount ot
fluid is dischargeduntil the engine speed reaches
t h e m i d d l e s p e e d r a n g e .A s t h e e n g i n es p e e d
increases,
the pressuredifferencebetweenthe ends
of the meteringorificeincreases.A pressuredifference is createdbetweenthe top and bottom ends of
the flow controlvalve,too, pushingthe flow control
valveto open the by-passpassage.This allowsthe
excessfluid to return to the inlet pon preventing
pressureat the dischargeport trom rising excessively.
@ As the enginespeedcontinuesto increase,the tlow

c o n t r o l v a l v e i s p u s h e d b a c k f u r t h e r .W h e n t h e
enginespeedreachesa given speed.the returnpassage outside the metering orifice is connectedto
t h e i n l e t p o r t , a n d t h e o p e n i n gt o t h e i n l e t p o r t
w i d e n s i n p r o p o r t i o nt o t h e i n c r e a s ei n e n g i n e
speed.This makespan of the fluid regulatedby the
meteringorificereturnto the inlet pon of the pump;
t h e r e b y d i s c h a r g e df l u i d f r o m t h e p u m p i s
decreasedslowly by this amount.
@ T h e o r i f i c e i n t h e r e t u r n p a s s a g er e g u l a t e sa n d
m a i n t a i n st h e f l o w o f f l u i d d i s c h a r g e df r o m t h e
pump at a given level until the enginespeedreaches the high speedrange.
17-6
vnx.su
VALVE
PressureRelief
Pressu.6outside of the metering orifice is directedto
the bonom ot the flow control valve. When the pressure
buildsup, the relietvalvein the flow controlvalveopens
to relieve the pressure.As the flow control valve is
pushed back by the pressuredifferencethis time, the
convolling
flow of fluid in the bypasspasssgeincreases,
the pressureoutside the metering orifice. The above
operationsare repeatedto provide constantdischarge
prsssurelrom the pump,
VALVE
{Dacrarlai cxco33iva
Yibrationin iha valva.l
(cont'dl
17-7
vnx.su
SystemDescription
SteeringGearbox
The rack-and-pinion
type steeringgearboxhas a valve unit incorporatedwith the pinionto controlthe steeringfluid pressure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve unit and is sentthroughthe cylinderpipe to
the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylinderreturns
throughthe cylinderpipe and valveunitto the reservoir.
VALVEUNIT
CYLINDERPIPE
POWEBCYLINDER
Valve Unit
Insidethe valve unit is the valve,which is coaxialwith the pinionshaft,and controlsthe steeringfluid pressure.The valve
housingis connectedwith the fluid pipe from the pump, return pipe to the pump, and the two cylinderpipesfrom the
respectivepowercylinder.
The pinionshaft is double- structuredwith the input shaftconnectedto the piniongear,both of which are interconnected
with the torsionbar.
The pin insenedin the valve and the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the
directionbetweenthe input shaftand the valve
Becauseof this construction,
the differencein angle in the circumferential
becomeslarger accordingto the torsional strength of the pinion or steering resistance.However,maximum torsion
betweenthe shaftsis regulatedby the engagedsplinesof the shaftsat the pin engagementsectionto hold the torsion bar
within the set value.
type steeringif the steeringfluid is not pressurThis allowsthe steeringsystemto lunctionas an ordinaryrack-and-pinion
izedbecauseof a faulty pump.
VALVE
Difforcnco in .ngl. bo{wcn tha
input shalt rnd pinion !h.tt
ln
-1
INPUTSHAFT
B
lEngagwith the pinion
shaft groove)
1 7 -8
vnx.su
<sEcnoN B-B>
PressureControl
Low assistat higherspeeds:
When steeringresistanceis low. such as when driving at high speeds.or when driving straightahead,the input shaft is
near or in the neutralposition,so there is little or no flow to any of the power cylinderorifices,Most of the feed pressure
trom the pump is bypassedto the reservoir.Becauseof this, the pressurestaysthe same in both sidesof the power cylinder, resultingin low or no assist.
RESERVOIR
vALVE
az =- S
\->/
-\7/
F.om PUMP
RETURNPASSAGE
(To RESERVOIRI
VALVE UNIT
A
<sEcnoN A-A>
INPUTSHAFT
Highassistat lower speeds:

When steeringresistanceis high, suchas when drivingat low speed,or when turningthe wheelwith the car stopped,the
differencein anglecreatedbetweenthe input shaftand the valveopensthe fluid passageon one side,and closesthe fluid
passageon the other side,at each pair of orifices.The fluid pressureincreasesin the side of the powercylinderfed by the
largerfluid passage.This increasedpressurepusheson the rackpiston,allowingthe steeringwheelto be turnedwith light
effon. On the other side of the power cylinder,the returnpassageopensallowingthe steeringfluid to returnthroughthe
input shaftto the reservoir.The fluid passagesto the power cylinderautomaticallychangein size,increasingas the steerIn other words,the passagesbecomelargerand power assistincreaseswhen the steeringeffort
ing resistanceincreases.
would normallybe high, (for example.when parkingor makinglow speedturns).and the passagesbecomesmallerand
power assistdecreaseswhen the steeringeffort would normallybe low, (for example,when driving at high speedsor
straightahad).
/t-:\
FLUIOPASSAGETO
POWERCYLINDER
From PUMP
v"=iJ
RETURN
PASSAGE
FLUIDPASSAGEFROM
POWERCYLINDER
<SECTIONA.A>
17-9
vnx.su
Troubleshooting
GeneralTroubleshooting
Checkthe followingbetoreyou begin:
. Hasthe suspnsionbeenmodifiedin a way that would affectsteering?
. Are tire sizesand air pressurecorrect?
. ls the steeringwheloriginalsquipmentor equivalent?
. ls the power steering pump belt properly adiusted?
o ls steering fluid reservoirfilled to proper level?
o ls the engineidle speedcorrectand steady?
r Fluid pro$ure is too low:

Chockth rgturn circuit pipe and hose between tho
gearbox and pump tor clogging and dotormation.
* Fluid pressureis too hioh:
Checkthe pipe and hosg connectedfrom th6 pump
to tho georboxtor clogging and delormation.
Checkpump fluid pressurg(soe

page 17-221,
Measure steady-statefluid pressure while idling with the shut-off
valve fully open.
I r s h o u t db e 1 , 5 0 0k P a ( 1 5 k g t
cm' ,213 psi)or bolow.
Normal
Checkpump fluid prssur{se

page 17-221.
M e a s u r ep u m p r e l i e f p r e s s u r e
while idling with the shut-off
valvefullyclosod.
h should be 6,400- 7,400kPa {65
- 75 kgtcm,, 924- 1,067psi)
Checkthe flow control valve.

* Checklhe valve for smooth movement in thg hou6Ing.
* Chockthg relif valve for leaks.
Normal reliel pressure
Abnormal
II
II
Goto patetu.lt
Faultyflowtontroi valve
17-10
vnx.su
Ch6ck force r6quired to turn tho

wheel(seepage17-18).
S t 6 t h e e n g i n ea n d m 6 a s u r e
force required to turn the whgel
to the right and left. Dilferenceol
t h e l o . c e r e q u i r e dt o t u r n t h e
whol to the right and to the lett
should be 5 N (0.5 kgf, 1 lbf) or
below.
Normal
Ch6ckpump fluid pressure(see

page 17-221.
Turn the steeringwheel lully to
the right and left whil idling
with the shut-off valvo fully op6n,
and measuretho fluid pressu.e.lt
should be 6,400- 7,400kPa (65 75 kg?cm,,924- 1,067psil.
Abnormal -----|.
Faultygearbox
Abnormal
Chsck the other parts than the gearbox-ralatedpsrts for

propor rotstion,
* lmpropor rotation ofthe steeringcolumn-rolatdpan(sl
'Faulty st6ringjoint
a Faultyrack endîe-rodend balljoints
'Intederence in the steeringsystem
Normal
Chockthe gearbox.
Removethe goarbox and measurethe piniontorque.
The torqueshouldbe;
* 0.7- 1.2N.m (7 - 12 kgf.cm,6 '10lbt in) with the steering rack
in the straightdrivingposition.
|r
Normal
Adjust the rack guide (see page

11-211.
Adiust the rackguide and recheck
the pinion torque.
lmproperly adjustedrackguide
(cont'dl
17-11
vnx.su
Troubleshooting
GeneralTroubleshooting{cont'd}
Assist (excessivelylight steering)at
high speed.
Check the rack guido proper ad'

justment (seepago 17-21).
Shockor vibration when wheel is

turned to tull lock.
Checkthe rack guide tor proper

adjustment(ses psge 17-21).
ll the problem is not correctedby

adjustingth6 rack g!ide. adjust
the front wheel alignment (see
section 18).
Rackguide is adjustedproprly.
Ch6ckthe belt tor slip and adjust

as nocessary(see page 17-20).
lf th problem is not correctdby

adiusting the rack guide, roplace
the gesrbox.
lf oither one or both of the cylinder pip A and B is/aredeformed,

rsplace,
Wheelwillnot returnsmoolhly.
lf the cylinderpip6 A and B are

normal, remove the gearbox
from th f.ame and mossure the
pinion torqug on the gearbox.
It shouldbe 0.7- 1.2N.m {7 - 12

k g f . c m ,6 - 1 0 l b f . i n )o r b e l o w
with the sleering rack in the
straight aheaddriving position.
lf lhe measuremntsare out of

specilications.adjust the rack
guid6.
ll ihe problem is not correctedby

adjusting the rack guide, replace
ihe gearbox.
1 7 -1 2
vnx.su
Unovonor rcugh 8te6ring.
Adjustrackguide(sepoge 17-21).
ll the probl6m is not correctedbY

adjusting lhe rack guide. replaco
the gearbox.
Adiud bolt tnsion.Roplaceblt, if

ncssary{se page 17-20).
ldl6 soosd low or orrrtic.
lf the ongin stallswhen wheel is

turned whil car is stoDPedor
moving at low spoed,adjust idle
spd (soesection 11).
Air in rssorvoir. or chck pow6a

steoringfluid l6v6l.
Chockpower sieeringIluid levol.It

lgv6l ie excessivoly low, chck for
leaks in the system. Add fluid to
tho spocifiod level.
lf fluid lev6l is OK, check o-rings

and seals on both nds of iho
pump inlet hose, and th oil
pump housing mating surfacos
for suction leaks. Reolace oarts
65 nCeSSAry.
Pump b6lt slippingon pull6y

(pump stops momontarily).
Adjust belt tonsion (see page 17m) or rDlacobeh.
Sel the power itooring p.oasure

gaug6. Cl066th shut-off v6lv6
f u l l y a n d m a 5 u r ot h o p u m p
pr6ssur6(6spagg 17-221,
Checkif pump prossureis within

the ranoe6.400- 7,100kPa(65- 75
kgr/cm,, 924 - 1,067psil and th6
gsuge needls travol is 1500 kPa {15
kgflctn2,t71 p6i) or less. Checkthe
flow control valve if the needle
tr.vel xcoods 1500 kPa {15
kg?cm,,i71 psi).lf rhe flow control
valvo is normal, replaceth pump
as an assomblv.
7-13
vnx.su
Troubleshooting
Noiseand Vibration
NOTE:Pump noisein first 2 - 3 minutesafterstartingin cold weather(-20.C,-4"F or colder)is normal.
Humming
Humming due to pulsation ol fluid is no.mal, paniculady when wheel is turned

with ca. stopped.
lf equippedwith automatictransmission,the hum could b torque conveneror pump notse.
Confirm by temporarily removing

pump blt.
High pressureline touching the

frame,
Reposhiontho line.
Right cylinder end soal squeak
Rattleor chattering
Loose steeringshaft connector.

tie-rod,or balljoint.
C h e c ka n d t i g h t e n , o r r e p l a c e
pa s as necessary.
Column shaft wobbling.
Replacecolumnassembly.
Checkthe rack guide for proper

adjustment(16opage17-21).
Adjust, if ncassry.
Rattlingsound and feeling when turning the steoringwheel right and lett with tho
engine OFFis a sound when th6 valve unit contactstho stopper.This is normal.
Striking sound wh6n turning the steringwhoglfully right o. left is a sound when
the r6ckend contactsth6 stopper.This is normal.
Pump noise. though not loud,lrom the vslvo bodv unit can be heard when turning the steeringwheel right or left. This is normsl.
17-14
vnx.su
Checkfluid level.
l f l o w . f i l l r e s e r v o i rt o p r o p e r
level,and checktor laks.
Tighten or roplac6as ncessary.
Gratingnoisefrom pump
Checkfor crushedsuction hose

or a loose hose clamp allowing
air into the system.
Tighten or replaceas noce$ary.
Pumpgearnoise
NOTE: Pump noise up to 2 - 3

m i n u t e sa l t e r s t a r t i n gi n c o l d
weather (-20'C, -4'F or colder) is
normat,
Comparopump noise at operatin9 temperatureto anothercar.
lf pump noiseis abnormallyloud,

chgckthe pump ball baringand
any pans (seepage 17-351.
1 7 -1 5
vnx.su
Troubleshooting
Fluid Leaks
Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points.dependingon locationof the
faultyoil seals/seal
rings.Checkthe followingbeforeremovingthe gearboxfrom the frame.
SteeringGearbox
Leakingfrom the oil seal on the

top of the valvehousing.
Roplacethe valve oil seal from

the valvehousing.
Leakingfrom cylinder end into

left tie'rod boot.
Replacethe valve oil seal lrom

the pinion shaft.
R e o l a c et h e c v l i n d e r e n d s e a l .
Leakingfrom cylinder end into

right tie rod boot.
Leaking from the vslve body

uniVhousingmounting soction.
Tighten attachingbolts or replace

the valvebody unit or gearhousIng.
Leakingfrom cylind6rpipeA or B
connection(attlarenut).
Tightenconnector.It still leaking.

r e p l a c et h e p i p e , c y l i n d e r o r
valvehousingunil.
Leakingcausedby damagedcylinderpipeA or B.
R e p l a c et h e c y l i n d e r p i p e A o r B .
L e a k i n gf r o m f e e d p i p 6 a n d
returnpipe of the valvebody unit
(atflarenut).
Tightenconnector.lI still leaking,

replacethe pipe or valve hous
In9,
17-16
vnx.su
ReplacehousingO-rings.
lI the housingstill leaks,replace
the pump.
Reservoiroverfilled.
Pullotfthe hoseand drainto pro'
per tevet.
Air leakin suctionside of system

lreservoitinlet hose,front pump
seal),
Pump outlet line

(highpressure)
Low pressurehoses
Leaking bcauseol dsmage, de'

terioration,or impropr assem-
Replaceor repairas necessary.
Leakingat g6srboxconnection.
{atflarenut}.
Tightenconnector.lf still leaking,

replacethe pipe or vlve hous'
Ing,
17-17
vnx.su
Inspectionand Adjustment
SteeringOperation
PowerAssist Gheckwith
GarParked
Placethe front wheelsin the straightahesdpositionand

measurethe distSncethe steeringwheel can be turned
without moving the front wheels.
1.
Checkthe power steeringfluid level (see page 1721) and pump belttensionlsee page l7-20).
2.
Startthe engine,allow it to idle, and turn the steering wheel from lock-to-locksevraltimes to warm
uo the fluid.
ROTATIONALPLAY:0 - 10 mm l0 - o.:Xlinl
lf the plsy excsedsthe service limit, psrform rack guide
adjustment (see page 17-211.
lf the play is still excessiveafter rackguide adjustment,
inspectthe stsering linksgoand gearbox as described
on the next page.
Attacha springscaleto the steeringwheel.With the

engine idling and the car on a clean,dry floor, pull
the scaleas shown and read it as soon 8s the tires
beginto turn,
ROTANONAL PLAY
il.
17 -18
vnx.su
The scal6should read no more than 33 N (3.4 kgf,

7.5 lbf). lf it reads more or less, chck the gearbox
and pump.
SteeringLinkageand Gearbox
STEERINGCOLUMN
lnsoecttor loosecolumn
mountingboltsand nuts.
BOOT
Inspect
f6r damage
anddeterior6tion.
STEERINGJOINTS
Checktor loosejoint bolts.
PINIONSHAFTGROMMET
Inspectlor damage and deterioration.
TIE.RODLOCKNUT
Checkfor looselocknut.
STEERING
Inspectlor loose mounting bolts.
GEARBOXMOUNTINGCUSHIONS
Inspectfor deterioration.
BALLJOINT BOOT
Inspecttor damageand deterioration.
Seepsge 17-63for replacement.
17-19
vnx.su
Inspectionand Adjustment
PumpBelt
NOTE: When using a new bli, first adiust the deflection
or tnaion to the values for the new belt, thsn readiust
ths deflection or tension to the values tor the used blt
after running sngine for five minutss.
Adiu3tmant
1,
Loosenthe power stesring pump mounting bolts.
2.
Turn ths adiusting bolt to gst the propor bolt tension, then rstighten the bolts.
3,
Start ths ngine and turn the steering wheel trom

lock-tolock sveraltimes, then stop the engino and
recheckths deflection of the belt.
lnspoction
Attach th belt tonsion gauge to th6 belt and measure
ths tension of the bslt.
Tanaion:
U3.d Brft: 391,- 5/O N (lO - 55 kgf, 88 - r20 |bf)
Ncw Bch: 7aO- 89, N (75 - 90 kgt, 170 - 20OlbO
AD'USN G BOLT
NOTE:
. lf thsre are cracksor any damage evident on the belt,
raplacait with a now ono.
. Follow the manufacturer'sinsructions for the tonsion
g8uge.
PUII"EY
07JGG- 00r0r0a
Inspectthe pump belt for cracksor any damage.
Replacethe belt with a new one if necssary.
Mc!3uramrnl without Bch Tcntion Grugr:
Apply a torce of 98 N (10 kgl, 22 lbll and measure ths
deflectionbetweentho power sterin9 pump and tho
crankshaftpulleys.
Daffaction:
U:ed Bch: 11.5- 13.5mm (0.,t5-0.53 inl
Nlw Brh: 8.0 - 10.0mm (0.31- 0.39 inl
here,
17-20
vnx.su
NOTE:Performrack guide adjustmentwith the wheels

in the straightaheadposition.
Checkthe reservoirat regularintervals.and add fluid as

necessary.
1 . Loosenthe rack guide screw locknutwith the specialtool,then loosenthe rackguidescrew.
GAUTION: Use only Genuine Honda Power Stosring

Fluid-V. Using othsr fluids such as ATF or other manufacturer's power stoering fluid will damags ths systcm,
the
Tightenthe rackguide screwuntil it compresses
springand seatsagainstthe .ackguide,then loosen
it.
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.
SYSTEMCAPACITY:
LO6 litor (1.12US. qt, 0.93lmp.qtl
at disasssmbly
RESERVOIR
CAPACITY:
0.79lit6r (0.8:lUS.qt, 0.70 lmp.qt)
SpecifiedR6turn Angle: 20 t 5"

UPPERLEVELUNE
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.
LOWERLEVELLINE
Raisethe reservoirand disconnectthe return hose
that goesto the oil cooler.
Connecta hose of suitablediameterto the disconnectedreturn hose and put the hose end in a suitablecontainer.
RACKGUIDESCREW
CAUTION:Tako caro not to 3pill tho tluid on tho

body and parts. Wipe off the spilled tluid at onqe.
,l
25 N.m
12.5kgf.m, 18lbtftl
Startthe engine.let it run at idle.and turn the steering wheel from lock-to-lockseveraltimes. When
f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
engine.Discardthe fluid,
40 mm
L(rcKNUTWRENCH,
07916- SAs(xtOl
Checkfor tight or loose steeringthrough the completeturningtravel.

6.
Performfollowinginspections:
. Steeringoperation(seepage 17-18).
. Power assistwith car parked.
7.
Refitthe returnhoseon the reservor.

Fillthe reservoirto the uDoerlevelline.
Startthe engineand run it at fast idle,then turn the
severaltimes to bleedair
steeringfrom lock-to-lock
f.om the system.
Recheckthe fluid leveland add some if necessary.
CAUTION: Do not lill the roservoir beyond tho
uppgr lovel line.
vnx.su
lnspectionand Adjustment
PumpPressureCheck
C h e c kt h e f l u i d p r e s s u r ea s f o l l o w s t o d e t e r m i n e
whetherthe troubleis in the pump or gearbox.
NOTE: First check the power steering fluid level and
pump belttension,
CAUnON: Dilconnst the high pros3uroho3s with cale
!o e3 not to spill tho powor stooring fluid on th6 lramo
lnd olhor parG.
1.
2,
3.
Disconnect
the outlet hosefrom the oumo outletfitt i n g , 8 n d i n s t a l lt h e p u m p j o i n t a d a p t e ro n t h e
pump outlet.
Connectthe hose joint sdapterto the power steering pressuregauge,then connectthe outlet hoseto
the adaotor.
Instsll the power steering pressuregauge to the
pump joint adaptoras shown.
OUTLETHOSEFlTnNG
HOSEATTACHINGBOLT
1l Nm11.1kg{ m 8lbf.ftl
Startthe engineand let it idle.

1 . Turn the stee.ing wheel from lock-to-lockseveral
timesto warm the fluid to operatingtemperature.
M e a s u r es t e a d y - s t a t fel u i d p r e s s u r ew h i l e i d l i n g
with the shut-offvalvefully open. lf the pump is in
good condition, the gauge should read less than
1500kpa (15 kgf/cm,,213psi).
lf it reads high, checkthe feed line or valve body
unit (seeGeneralTroubleshooting
l7-10).
Close the shut-off valve. then close the pressure
c o n t r o l v a l v e g r a d u a l l yu n t i l t h e p r e s s u r eg a u g e
needleis stabl6,Readthe pressure.
1 0 . lmmediatelyopenthe shut-offvalvefully.
CAUTION: Do not keep the shut-ott valvs closod
moro thgn 5 soconds or th9 pump could b6 dam"
agod by over-h6ating,
lf the pump is in good condition,the gaugeshould
read at least 6.400- 7,400 kpa (65 - 75 kgIlcm,,924
- 1,067psi). A low readingmeans pump output is
too low for full assist.Repairor replacethe pump.
P/S PRESSURE
GAUGE
6 x 1.0 m.n BOLT

{P!rt of tooll
11 N.m
11.1kgtm,8lbf.ftl
P/S JOINTADAPTORIPUMPI
o?NAK- SmolrA
PUMPOUTI.TT
FITIING
Openthe shut-offvalvefully.
Openthe pressurecontrolvalvefully.
1 7- 2 2
vnx.su
FluidLeakageInspection
BOOT
Check
lor leaks.
GEARBOXrnd VALVEBODYUNIT
Checkfor leaksat the matingsurface
and rlare nut connections.
PUMPASSEMBLY
Chckfor leaksat the pump
seal, inlet and outlet fiftings.
Inspecthosesfor d6mage,leaks,
interferenceor tlvisting,
Inspectfluid linesfor damage,
rustingor leakage.
Inspectfor leaksat hose and
lineiointsor connections,
17-23
vnx.su
Steering Wheel
Removal
Airbag Removal
1 . Disconnect
the negativeand positivecablefrom the
battery.
CAUTION:
. All SRS electrical wiring harnossesare covered with
yellow insulation.
. Before disconnecting any part oI the SRS wiro harness,connect the 3hort connector{g}.
. Replacethe entire sffected SRS harness assembly it
it has an opon circuit or damagedwiring.
Removethe accesspanel from the steeringwheel

lowercover,then removethe shon connector.
Disconnectthe connectorbetweenthe airbag and
cablereel.
Connectthe shon connectorto the airbag side of
the connector.
AIRBAG
CONNECTOR
CABLEREEL
CONNECTOR
R e m o v et h e l i d B a n d c r u i s ec o n t r o l s e t / r e s u m e
switch cover.
Removethe TORX@
T30 bit bolts then removethe
airbagassembly.
AIRBAGASSEMBLY
17-24
vnx.su
Removal
Disconnect
the connectorstrom the horn and cruise
controlsevresumeswitches.
8.
Removethe steeringwheel nut.

R e m o v et h e s t e e r i n gw h e e l b y r o c k i n gi t s l i g h t l y
from side-to-sideas you puil steadily with both
STEERING
WHEEL
hands.
NUT
STEERINGWHEEL
Replace.
HORN
store a removed airbag assembly with
@
the pad 3urfacs up. lf the airbag is improperly stored
face down, accidntaldaployment could propl tho unit
with enough forca to causeserious iniury.
NOTE:lf an intact airbag assemblyhas been removed
f r o m a s c r a g o e dc a r o r h a s b e e n f o u n d d e f e c t i v eo r
damagedduring transit.storageor service,it should be
deployed(seesection23).
TORX6BOLT
10 N.m {1.0 kgf m, Tlbt.ttl
CAUTION:
C8r{ully inspoct ihe sirbag assombly betors install.
ing. Do not install an airbag ass6mblythat 5how3
signs ol boing dtopped or improperly handled, such
as dents, crack3or deformation.
Always kgp tho short connector on the aitbag connector when ths harneggi9 disconnected.
Do not disassembleor tamper with the airbag assombly.
TORX6BOLT
10 N.m {1.0 kgf.m, 7lbf.ft)
HORNCONTACTPI-ATE
STEERINGWHEEL
LID
\s
SPACER
@
CRUISECONTROLSET/
NESUMESWITCHES
CRUISECONTROLSET/
RESUMESWITCHESCOVER
17-25
vnx.su
SteeringWheel
Installation
Airbag installation
2.
CAUTION:
. Bfore inrtalling the stooring wheel, align tho front
who6l3 etraight ahead.
. Bo sure to install the harness wires so that thGy are
not pinched or intorfsring with othor car parts.
. Do not roplace thc original stsoring wheel with any
othor design. since it will maks it impo$ibla to properly install the airbag. {Only use genuine HONDA
replscomont parts)
. After rols3embly. confirm thai the whoels are still
straight ahoad 8nd that steoring wheel spoke anglo
is correct. lf minor spoke anglo adiustment is nocssrry, do so qnly by adlustment ol th tie-rods, not by
romoving and repositioning the steering wh|.
Installthe steeringwheel.
NOTE: Be sure the steeringwheel shaft engages
the cablereeland cancelingsleeve.
contirm ihat the airbag assombly is

@
socurely attachsd to the stooring wheel; othrwise,
scvoro porsonal iniury could rsult during airbag
doploym6nt.
1.
B e f o r e i n s t a l l i n gt h e s t e e r i n gw h e e l , c e n t e r t h e
cablereel.
Do this by tirst rotating the cable reel clockwise
until it stoos.
Then rotate it counterclockwise(approximatelytwo
turnsl until:
- The yellow gear tooth linesup with the mark on
the cover.
- The arrow on the cablereel label pointsstraight
UD.
a9 N.m (5.0 ksf'm,36 lbf.ftl
Attach the cruise control sevresume switchs connectorto the steeringwheelclip.

Connectihe horn connector.
YELI-OWGEAR
CRUISE
CONTROL
SET/NESUME
SWITCHES
CONNECTOR
ALIGNMENTMARK
17-26
vnx.su
5.
Installthe airbagassemblywith new TORXobolts.
Connectthe battery positive terminal and thn connectthe nsgativeterminal.
1 0 . After installing the sirbag assembly,confirm proper

system opera(on:
. Turn the ignitionto ll: the instrumntpan6l SRS
indicatorlight should come on for about 6 seconds and then go off,
. Confirm operation of horn buttons.
. Confirm oDerationof cruise control sevresume
switches.
a Turn the steering wheel countetclockwiseand
make su.e the yellow gear tooth still lines up
with the alignmentmark.
YELLOWGEARTOOTH
BOLTS
TORXO
10N.m{1.0kgf'm.7lbfftl
the shortconnectortrom the airbagconDisconnect

nector.
7.
Connectthe airbag3-Pconnectorand cablereel3-P

connector.
ALIGNMENTMARK
Attachthe short connectoron the accesspanel.and

installthe accesspanelon the steeringlowercover.
CABLEREEICONNECTOR
17-27
vnx.su
Steering Golumn
Removal
CAUTION:
. All SRS elctrical wiring hlrnesses are coversd with
yollow insuhtion.
. Bctore dieconnocting any part ol tho SRS wiro h!rnesa,connoct the thort connector (s).
. Roplacetho ontire aftected SRS harness asrmbly if
it has !n open circuit or d!mlgod wiring.
5.
Removethe connectorholder and disconnectthe

SRSmain harnessfrom the cablereel wire ha.ness
at the underside ot the column bracket.
Removethe airbag assemblyand steering wheel

page 17-25).
.(see
Removethe lower cover.
Removethe driver'skneebolster.
HARNESS
R e m o v et h e c a b l e r e e l a n d t u r n s i g n a lc a n c e l i n g
steeve.
7.
LOWER
COVER
R e m o v et h e c o l u m n c o v e r s b y r e m o v i n g t h e
screws.
Removethe combinationswitch from the steering

columnby disconnecting
the connectors,
TURNSIGNALCANCELING
SlTEVE
COMA|NANON SW]TCH
STEERING
COLUMN
scREws
17-2A
vnx.su
CABI..E
REEL
8.
1 0 . Disconnoctthe ignition switch connectorsfrom th6
Removthe stesringioint cover.
undor-dashfuse/relavbox.
'l1.
R e m o v et h o 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 8nd bolts.
JOIMTOOVER
STEERINGCOLUMN
BOITS
Removetho steering joint bolts, and move the ioint

towardths column.
17-29
vnx.su
SteeringColumn
lnspection
Checkthe steeringcolumn ball bearingand steering
joint bearingsfor play and propermovement.
lf there is noiseor excessiveplay,replacethe joint or
columnassembly.
Checkthe tilt mechanismfor proper movementand

oamage.
-
Checkthe retainingcollarfor damage.

lf it is damaged,replacethe retainingcollar.
COI-UMNBALL
EEARING
Attacha springscaleto the knob of the tilt lever.

Measurethe preloadrequiredto move the lever.
Pr6load:70 - 90 N 17- 9 kgt, 15 - 20 tbf)
STEERINGJOINT
BEARINGS
RETAININGCOLLAR
lf the preloadmeasuredis not within the sDecification. removethe 6 mm bolt and stoDDer.
Adjustthe preloadby retighteningthe rilt tockbolt
untilthe correctforcecan be obtained.
Reinstallthe stopperand 6 mm bolt and recheck
the Dreload.
TILT LOCKBOLT
Checkthe absorbingplates,absorbingplate guides

and slidingcapsulesfor distonionor breakage.
Replacethem as an assemblyif they are distonedor
broken.
ABSONBING
9.8 N'm {1.0kgt.m,7.2lbt'ftl
SLIDINGCAPSULE
This part is attached
to the columnbracket
with the plasticinjections.
17-30
vnx.su
lnstallation
STEERINGCOLUMNASSEMBLY
RETAININGOOLLAR
STEERING
JOINTBOLIS
22 N.m{2.2tst m, 16lbf.ftl
FLANGEBOLT
22 N m 12,2kgl.m, 16lbf.ftl
FLAMiE NUT
13 N.rn {1.3kgt m, 9 lbt ftl
17-31
vnx.su
SteeringColumn
CAUTION:
. All SRS electrical wiring hrrnossos are covgrod wilh
yellow insulation,
. When disconnctingthe SRS wire harness,install
the short connector on the airbag. thn dbconnoct
the wire harness.
. Replacathe entire alfected SRS harness assembly if
there is an open circuit or damage to tho wiring.
1.
I n s t a l lt h e s t e e r i n gc o l u m n w i t h t h e f l a n g e n u t s ,
then installthecolumnholderand flangebolts.
Tighten the upper and lower steering joint bolts
looselyinstalledin steD2,
Slip the upperend of the steeringjoint onto the column shaft {line up the bolt hole with the flat on the
shaft),and loosely install the upper steeringjoint
bolt.
Finaltorque:
22 N.m
{2.2kgf.m, 16lbt.ftl
UPPERSTEERING
JOINT BOLT
Bolt must line up with
flat on shaft.
FLANGEBOLTS
22 N.m
12.2ksi.m,16tbtftl
STEERING
JOINT
Installthe steeringjoint cover with the clampsand

clip.
Slip the lower end of the steeringjoint onto the pini o n s h a f t .L i n e u p t h e b o l t h o l e w i t h t h e g r o o v e

aroundthe shaft)and looselyjnstallthelower bolt.
NOTE:
. B e s u r e t h a t t h e l o w e r s t e e r i n gj o i n t b o l t . i s
securelyin the groove in the steering gearbox
pinion.
. Beforetighteningthe steeringjoint bolts,pull on
the sleeringjoint to make sure that the steering
joint is fully seated.
LOWERSTEERINGJOINT BOLT
Fin6ltoroue:
22 N.m {2.2kgt m. 15 lbf.ftl
CLIP
1 7 -3 2
vnx.su
Connectthe ignition switch wire connectorsto the

under-dashfuse/relavbox.
7.
Installthe combinationswitch and turn signalcancelingsleeveonto the steeringcolumn.
9. Installthecolumncovers.
UPPER
COLUMNCOVER
NOTE:Be sure the wires are not caughtor pinched

by any parts when installingthe combination
switch.
coMatNATroN
swncH
scREws
TURNSIGNALCANCELING
SLEEVE
1 0 . lnstallthe driver'skneebolster.
1 1 . lnstallthe lowercover.
Installthe cablereel onto the steeringcolumn,then
connectthe SRS main harnessand cable reel wiro
harnessand installthe connectorholder.
't2. Installthesteeringwheel
'17-26).
{seepage
NOTE:Align the slot in the cablereel with the projectionon the cancelingsleeve.
17-33
vnx.su
PowerSteeringHoses,Pipes
Replacement
CAUTION: Chock all clampsfor doterioration 8nd dstormation, and rsplacGwith new onss if n6co33!ry,
NOTE:
. Connecteachhosgto the correspondingpipe securgly until it stopsat the stoppron the pipe.
Installthe clamp or ad,ustableclamp at the specified
distancsfrom the hoseend as shown in the drawing.
. Add the power steeringfluid to the speciliedlevelon
the reservoirand checkfo. leaks(seepage17-23).
<HOSECLAMP:>
<AIUUSTABII HOSECLAMP:>
Putoverthe pipe untilthe

hose stops at the stopper.
Putov6rthe pipe untilthehosestopsat the

$opper.
2.5 - 5.5 mm
{0.01- 0.22 inl
2.5 - 5.5 mm
10.01- 0.22 in)
2.0 - 4.0 mm
- 0.16inl
10.08
OUYI.fT HOSE
11 N.m
{1.1 kgl.m, 8 lbl.ftl
ABLECLAMP
INI."ETHOSE
RETURNHOSE
CLAMPS
coot"ER
CLAMPS
17 -34
vnx.su
PowerSteeringPump
Disassembly
Removal
NOTE: Before disconnectingthe hoses from the pump,
placea suitablecontainsrunderthe car.
Pulley Removal
1.
Drainthe fluid from the pump.
2,
2.
Removethe belt by looseningthe pump adjusting

bolt and mountingbolts.
Holdthe stee.ingpump in a visewith soft iaws, and

hold the pulleywith the specialtooland removethe
pulleynut and pulley.
3.
D i s c o n n e c t h e i n l e t a n d o u t l e t h o s e sf r o m t h e
pump and plug the hoses.
CAUTION: Bo clrstul not to damage the pump

ho$ing with thr iaw3 of ths vise.
NOTE;Take care not to spill ths tluid on the body

or parts.Wipe off spillodfluid at once.
NOTE:Pullevnut has left-handthreads.
1.
Drain the power steeringfluid from the rsservoir.
4.
Removethe pump mountingbolt, then removeth

pump
N O T E : D o n o t t u r n t h e s t e e r i n gw h e s l w i t h t h e
pump removeo
5.
Wrap the opening of th pump with a piece of taps

to provent any foreign matrial. Se6 pags 17-44for
oumDinstsllstion,
OUTI.TTHOSE
tNt.THOSE
PULLEYNUT {Left-handthread)
(cont'dl
17-35
vnx.su
PowerSteeringPump
(cont'dl
Disassembly
Flow GontrolValveRemoval/lnspoction
l.
2.
Rsmovethe control valve covr by romoving the

threeflangebolts.
il.
Inspectthe bore for the flow control valvs for scratches or wear.
5.
Slip the valve back in the pump and chockthat it

movesin and out smoothly.
Removethe spring, flow control valve and O-rings.
FLOW
CONTROL
VALVE
lf OK, go on step 6, if not replace th6 valve and

rochsckthe valve movsment.
NOTE: The original valve was selectedfor a precise

fit in the pump housingbore,so makesureths nw
on6 has the same identificationmark.
OutsidOiamter
Checkthe flow control valvg for wgar, burrs, and

other damage to the edges of th groovos in tho
Mark
Part Name
FLOWCONTROL
VALVEA
FLOWCONTROL
VALVEB
FLOW
OONTROLVALVE
6.
Outside Diameter
mm (in)
17.991- 17.996
(0.7083- 0.7085)
17.996- 18.001
{0.7085- 0.7087}
lf the valve movement still incorrct, replacothe

pump as an assembly.
Attach a hose to the end of the valve as shown.

HOSE
Ch6ckfor
damags to dgos.
FLOW CONTROLVALVE
17-36
vnx.su
7 . Submergethe valve in a containerof power steering fluid or solvent,and blow in the hose.lf air bubb l e s l e a kt h r o u g h t h e v a l v e a t l e s s t h a n 1 0 0 k P a
11.0kgf/cm,,14.2psi),replaceor repairit as follows.
Pump Rotor Removal

CAUTION: Tho pump components are made ot aluminum. B car6ful not to damagethem when servicing.
1.
Removethe inletjoint and O-rjng.
AIR PRESSURE
i-
POWERSTEEBING
FLUIDor SOLVENT
13x 1.9mm
O.RING
Replac.
'\)4.
8, Hold the bottom end of th valve with a oDenend

wrencn.
nlll
9. Unscrewthe seat in the top end of the valve, and

removeany shims,the reliefcheckball, reliefvalve
and reliefvalvespring,
REUEFVALVE
RELIEFCHECKBALL
sHrM(sl
lf usd.
SEAT
13 N.m
11.3ks[.m, I lbf.tt]
2.
Removethe pump coverand O-ring.
PUMPCOVER
Clampthisend in
a vise with sott iaws.
FLOWCONTROL
VALVE
REUEFvALvE
SPBING
58.5x 1.5mm
O.RING
Feplace.
10. Clean all the parts in solvent, dry them off, then
reassembleand retestthe valve.Sge page 17-43for
f low controlvalve installation.
NOTE: lf necessary,relief pressureis adiustedat
the facto.y by adding shims under the check ball
seat.lf you found shims in your valve,be sure you
reinstallas many as you took out,
(cont'd)
17-37
vnx.su
Power Steering Pump

Disassembly{cont'd}
3.
Removethe two rollersfrom the side plate.
Removethe pump cam ring from the pump housIng.
Removethe side piateand preloadspring.

N O T E :R e p l a c et h e p u m p a s a n a s s e m b l y i. f t h e
cam ring must be replaced.
N O T E : R e p l a c et h e p u m p a s a n a s s e m b l y i, f t h e
side platemust be replaced.
PUMPCAM RING
Checkfor damageor wear.
ROLI..ER
5 x 26.8 mm
SIDEPLATE
Checkfor damageor wear.
ROLLER
4,5 x 119.8
mm
Removethe pump rotorand vanes.

N O T E :R e p l a c et h e p u m p a s a n a s s e m b l y ,i f t h e
pump rotor or vanesmust be replaced.
7.
Remove the O-rings from the side plate.
PUMPROTOR
Checklor damageor wear.
16.8x 1.9mm
O.RING
Replace.
54 x 1.9 mm
O-RING
Replace.
1734
vnx.su
R e m o v t h e c i r c l i p ,t h e n r e m o v et h e d r i v e s h a f t
assemblyfrom the pump housing using a plastic
nammr.
Removeand discardthe bearingusing the special

tool and a gress.
Pra3s
Removethe sealspacerand oil seal.

Inspectthe pump housingfor damageon the sealing surfaces.
/-clRcLlP
ra-,"
Q'/
DRIVESHAFT
for bend,
damageor wear,
I{UB DIS/ASSEMBLYBASE
07GAF- SD40700
1 3 . Installthe new bearingusing the
special tool and a
press.
Press
PUMPHOUSING
11. lnspectthe bearingby rotatingthe outar raceslowly. lf any play or roughnessis felt, replacethe bearing.
Installwiththe
red shieldedside
lacingdown.
07GAF- SDis)700
NOTE:Supportthe innerrace
with the tool securely.
17-39
vnx.su
PowerSteeringPump
Reassembly
CAUTION: The power steering componsnts are mado of sluminum. Avoid dsmaging th componcnts during assombly,
NOTE:
. Cleanthe disassembledpans with a solventand dry them with compressedair. Do not dip the rubber parts in a sof
vent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply recommendedpower steeringfluid or steeringgrease(HondaP/N:08733- B070E)to the parts indicatedin the
assemblvprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe powersteeringsystem.
. Replacethepump asan assemblyifthe partsindicatedwith asterisk(*) are worn or damaged.
ROLLER
5 x 26.8 mm
PUMPcovEn
."'MP cAM RING

/
.",orr*r,
-eûrrae
vrues
sirx1.smm
\
^ /
/
/
pratesl
{ro
{ro
Platesl
o_nrNc
o-ntNG
\Al
\A
I
/
I
Replace.
d A - h 1 / / E Z i l * l / / / ' ^ e e ' a c e
,h$;@:",n1
i'"otr
16.8x 1.9mm O-RING
.PUMP HOUSING
xf:.i'/pp@6{fr;ry
tt.m,1a|t t.fti//
/-V#m
/
ROLLER
RoLLER
/
1.5
a.5 x 49.8
ag.amm /
68.5x 1.9 mm
O-R|NG
o-RING
Replace.
Reptace.
DRIVESHAFT
\E
PUMPSEAL
SPACER
|
I
//
>ei
INLETJO-INT
I
'PUMP
ROTOR
iiij:f:,ll-T;-,",,,,ll;il'- g--lblY""."*";
Replace.
$+--E
22.r x r.9 mm o-RfNG ------t@-<'t
Replace.
srntnc
-5.8x1.9mm
o^::t:\-G
Replace.
FLANGEBOLT
'11N.m
11.1kg-m,8lb-ftI
CONTROLVALVECOVEN
17-40
vnx.su
Pump Rotor Installation

L
6. Install the preload spring in the pump housing.
Coatthe lip of the new oil sealwith steeringgrease

(HondaP/N08733- 8070E).
7. Set the 4.5 x 49.8 mm roller in the 4.5 mm hole in

t h e p u m ph o u s i n g .
I n s t a l lt h e n e w o i l s e a l i n t h e p u m p h o u s i n gb y
hand,then installthe pump sealspacer.
8. Setthe side plateover the rollerand installit on the

p u m ph o u s r n g .
NOTE:Insertthe oil seal with its groovedside facingin.
9. Set the 5 x 26.8mm roller in the 5 mm hole in the

side plate.
5 x 26.8 mm
ROLLER
3. Installthe pump drive shaftassemblywith the specialtool.

4.
Installthe 38 mm circlipwith its taperedsidefacing

out,
DRIVERATTACHMENT
07947 - 6:1io500
5 mm HOLE
38 mm
SIDEPLATE
crncuP
-
PRELOAD
SPRING
DRIVE
fu'/'i,Er
t\=zl4
PUMPSEAL
I"J
If /sprcen
x,
tY
,1.5mm
-ot seal
-Gll
ATTACHMENT,
37 x ,r0
07t,16- dt102d,
1 0 . Assemblepump rotorto the drive shaftwith the "o"

markon the rotorfacingupward.
1 1 . Setthe 10 vanesin the groovesin the rotor.
5.
Coatthe side plate grooveswith the recommended

p o w e r s t e e r i n gf l u i d , t h e n p o s i t i o nt h e 1 6 . 8x
1.9 mm and 54 x 1,9mm O-ringson the side plate.
NOTE:8e surethat the round ends of the vanesare

in contactwith the slidingsurfaceof the cam ring.
PUMPROTOR
16.8x 1.9mm
O.RING
5a x 1,9
O.RING
l
(cont'd)
SIDEPLATE
17-41
vnx.su
PowerSteeringPump
(cont'dl
Reassembly
Set the pump cam ring over the two rollerswith the
"8" markon the cam ring upward.
1 7 . Setthe 13 x 1.9mm O-ringon the inletjoint.

1 8 . Installthe inletjoint on the pump housing.
1 3 . Apply clean power steeringfluid to the vanes and

cam ring.
11.1kgt.m. t lbf.ftl
INLETJOINT
PUMPCAM RING
1 3x 1 . 9
O.RING
T9
1 4 . Installthe 68.5x 1,9mm O-ringon the pump cover.
1 5 . Align the rollerset holesin the pump coverwith the
rollers.
'16. Align
the projectionon the pump housingand the

projectionon the pump cover,and tighten the four
bolts.
20N.m
{2.0 kg .m, lil lbf.ftl
PUMPCOVER
PROJECTIONS
17 -42
vnx.su
PulleyInstallation
Flow Gontrol Valve Installation

1.
Apply steeringgrease(HondaP/N08733- B070E)to

new O-rings.
2.
Coatthe flow controlvalvewith clean power steeri n gf l u i d .
3.
Install the flow control valve, spring and control

valvecoveron the pump housing.
4.
Tightenthe threecontrolcover bolts.
1.
Holdthe steeringpump in a visewith softjaws.

CAUTION: Be careful not to damago the pump
hou3ing with the laws ol th vise.
2.
Installthe pump pulley as shown. Then installthe

pulleynut.
PULLEYNUT
FLOWCONTROL
VALVE
E;W
SPRING
11 N.m {1.1kgl.m,8lbtftl
Holdthe pulleywith the specialtool and tightenthe

pulleynut.
PULLEY
PULLEY
NUT
6irN.m(6.5kgt.m,47lbt tt)
Checkthat the pump turns smoothlyby turningthe
pulrey.
17-43
vnx.su
Power Steering Pump

lnstallation
1.
Adjustthe pump belt (seepage 17-201.
C o n n e c tt h e i n l e t a n d o u t l e t h o s e s .T i g h t e nt h e
pump fiftingssecurely.
5.
Looselyinstallthe pump in the pump bracketwith
mountingbolts.
11N.m
11.rkgf.m,8lbf.ftl
OUTIIT HOUSE
O-RING
Replaco.
INI.TTHOSE
Fillthe reservoirto the uoDerlevelline.

NOTE;Takecare not to spill the fluid on the body
and parts.Wipe off the spilledfluid at once.
GAUTION: Uro only Ganuino Honda Powor Stsor.
ing Fluid-V. Using othor tlui& 3uch a3 ATF or oiher
manutacturor's powor steering tluid will drm89e
the rystgm.
SYSTEM CAPACITY:
1.06litor(1.12US.qt,0.93lmp.qt)
RESERVOIR
CAPACIW:
0.79 litor (0.1|:|US.qt, 0.?0 lmp.qtl
ADJUSTING
BOLT
UP?ERI.fVEL LINE
IEVEI LINE
Start the engine,let it run at idle, then turn the

steering wheel lock-to-lockseveraltimes to bleed
air from the system.
Recheckthe fluid level and add some if necess8ry.
PUMPMOUNTINGBOLTS
2,r N.m {2.4 kgl.m. 17 lbf'ft}
Installthe DumDbelt.
CAUTION:
. Make surs that thg powor gtooring bslt i!
securglyon the grooyos of ths pulloy!.
. Do not get powor stggring fluid o. groaso in thg
power steering bclt or pulley trc6. Cloanoft 8ny
tluid or groa36belore installation.
BELT
POWER
STEERING
PULI..EY
17 -44
vnx.su
CAUTIONTDo not fill tha .63ervoir boyond th6

uppr lcvol lino.
SteeringGearbox
Removal
R e m o v et h e c o t t e r p i n t r o m t h e c a s t l e n u t a n d
removo the nut.
NOTE:Usingsolventand a brush,wash any oil and dirt

off the valve body unit, its lines, and the end if the gearbox. Blow dry with compressedair.
1.
Drain the power steering fluid as describedon page

1 7- 2 1 .
2.
Rsisethe front of car, and support on safety stands

in the propsr locations(seesection 1).
3.
Removethe front wheels.
il.
Removsthe steringjoint cove.,
Installthe10 mm hex nut on the balljoint.

Be surethat ths 10 mm hex nut is flush with the ball
ioint pin end, or the threaded section of the ball
i o i n t p i n m i g h t b e d a m a g e db y t h e b a l l i o i n t
remover.
NOTE: Removethe ball joint using the Ball Joint
Remover,28 mm {07MAC- 5100200}.Referto page
l8-11 fot how to use the ball joint rcmover,
8. Separatthe tie-rodball joint and knuckleusingthe

soscialtool.
CAUTION: Avold d.maging th. blllloint boot.
SIEERINGJOIi{TCOVEB
28 mm
BALLJOlt{T REMOVER.
07MAC- SLqt2|X)
Removethe steering joint lower bolt, and move the
joint towardthe column.
Disconnectthe shift linkage {MfI model: see section

13,A/[ model see section 14).
NOTE: Lock the steering shaft with the ignition key

to retain the steering shaft position.
1 0 . Disconnectthe heatedoxygen sensor (H02S)conngctor, and separatethe three way catalyticconverter by removing the slf-lockingnuts.
NOTE: Always replacethe gasketswith new ones.
HEATEDOXycEt{SNSOnOONNECTOR SELF.LOCKINGNUT
{cont'd)
Replacs.
IHREE WAY
CA?ALYTICCONVERTEN
17-45
vnx.su
SteeringGearbox
Removal(cont'dl
1 1 . Removethe return pipe clamp from the left side of
the rear beam.and move the returnpiDeabovethe
steeringgearbox.
14. Disconnectthe two linesfrom th valve bodv unit

on the steering gea.box.
CAUTION: Aftor dkconnccting tho ho3o and pip.,
plug or r.d thc ho3. rnd pipc whh I pioco of tapo
or .quivll.nt to prcvont torcign m!tori!|3 f.om
ritrdng thc vdv. body unit.
12. Removethe rearbeambrace.
RETURNPIPECLAMP
NOTE:
. Placethe pipe disconnectedin the previous step
at the rear side of the gearboxso that they do
not hinderin the gearboxremoval.
. Do not loosen the cylinder pipes A and B betweenthe valvebody unit and cylinder,
RETUR]T
HOSE
1 3 . Removethe left tie-rod end, then slide the rack

the way to the right.
I.TFTTIE-ROD
END
15. Removethe steeringgearboxmountingbolts.
GEARBOXMOU NNG BOLTS
17-46
vnx.su
Pull the steeringgearboxall the way down to clear

the pinion shaftfrom the bulkhead,and removethe
pinionshaftgrommet.
1 1 . Move the steeringgearboxto the right so the left
rackgnd clearsthe rearbeam.
1 8 . Hold the steeringgearboxand slidethe rackall the
way to the left, then placethe left rack end below
the rearbeam.
1 9 . Move the steeringgearboxto the left. and tilr the
left side down to remove it from the car.
PINIONSHAFTGROMMET
STEEBINGGEARBOX
17-47
vnx.su
Steering Gearbox
Disassembly
Stssring RackDisassembly
5.
Hold the steeringrack with a wrench and unscrew

the rackend with a wrench.
NOTE:
. Before disassemblingthe gearbox,wash it off with
solventand a brush.
. Do not dip sealsand O-ringsin solvent.
1.
Removethe steeringgearbox(seepage 17-45).
2.
Removethe air hoseand clips.
3.
Removethe tie-rodend and locknut.
L o o s e nt h 6 l o c k n u t a n d r e m o v e t h a r a c k g u i d e
screw.
7.
CLIP
4.
Ramovethe spring and rack guide from the gear

housing.
Removethe boot bands and tube clamps.Pull the

bootsawayfrom the endsof the gearbox.
TUBECLAMP
LOCKNUT
BOOT
17-48,
vnx.su
RACKGUIDE
Removethe cylinder pipe A and B from the gearbox.
1 1 . Drill a 3 mm {0.12in) diameterhole approximately

2.5 - 3.5 mm (0.10- 0.14in) in depth in the stakedpoint on the cylinder.
Drainthe fluid from the cylinderfittings by moving

the steeringrackbackand forth,
NOTE: Do not allow metal shavingsto enter the

cylinderhousing.
CYLINDERPIPEB
STAKEOPOINT
- 0.12inl
D.prh:2.5- 3,0mm 10.10
CYUNDER
END
12. Installa pulleryoke to the stesringgearbox.Clamp

the puller yoke in a vise with soft iaws as shown,
then loosenand removethe cvlinderend.
Removethe two flangebolts,then removethe valve
body unit from the gearbox. {See page 17-51for
valvebody unit disassembly.)
PULLER
YOKE:
Commercirlly
Avrilablo
Sn.p-OnoT/N qrie'-1
oTcloT/N 7372
VALVEBODYUNIT
FLANGEBOLT
(cont'd)
17-49
vnx.su
SteeringGearbox
Disassemblylcont'd)
13, Setthe gearboxin a pressso the gearhousingpoints
upward.
1 7 . Removethe 12 mm bolt and nut from the steering
rack,then installa 24"long.3/8"driveextension,and

the specialtool into the cylinderfrom the gearbox
side.
14. Installtheflangeboltintothe endofthe steeringrack

until it bottomsin the hole,then backthe flangebolt
out 1/4 turn. Hold the tlange bolt and tighten the
flangenut againstthe rackby hand.
CAUTION: Be caretul not to damagc th in3idr

surfaceot ths housing with tho tool3.
1 8 . Setthe gearboxin a press,then pressout the cylinder
end sealand backupring trom the gearbox.
15. Pressthe cylinderend sealand steeringrackout of

the gearbox,
NOTE: Holdthe sreeringrackto keepit from talling
when pressedclear.
CAUTION:
Ksepthe tool straight to avoid damagingthacYlind.r
wall. Chscktis tool angls, and corrst if nrcolrary,
whsn rsmoving the cylinder end seal.
Use ! prors to r6movo tho cylinder end rgal. Do not
try to remove the soal by 3triking ths tool. h will
break the brckup ring and tho cylindr end leal will
romain in ths gsarbox.
Pre$
VINYL TAPE
2it" LONG3/8" DRIVEEXTENSION:

CommrcirllyAvailobl.
12 mm
FLANGENUT
STEERING
GEARBOX
1 6 . Removethe soecialtool and cylinderend seallrom

the steeringrack.
ENDSEAL
CYLINDER
REMOVERATTACHME?ST
CYLINDERENO
SEAL
19. Carefullypry the pistonseal ring and O-iing off the

pistonof the rack.
CAUTION: Be careful not to damags th insidc ot
seal ring groove whgn romoving th seal ring.
Replace.
17-50
vnx.su
20. Apply vinyl tape to the pinionshaft.
2 3 . C h e c kf o . 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.
2 1 . Separatethe valve housingfrom the pinion shafv

valveusinga press.
VALVEHOUSING
NOTE:The pinion shaft and sleeveare a precision

matched set. It either the pinion shaft or sleeve
must be replaced,replacethe both partsas a set.
SLEEVESEALRINGS
Ch6ckfor oeel off or
oamag0,
Vinyl t.p.
22. Checkthe innerwall of the valve housingwherethe

seal ring slideswith your finger.lf there is a step in
t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e
valvehousing.
24. Removethe circlipand pinionshaft sleevefrom the

oinionshaft.
NOTE:
There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valvehousingonly the wall is stepped.
When the valve housingis replaced,installnew
3 2 m m s h i m ( s )o n t h e b e a r i n gs u r f a c eo f t h e
housingto adjustthe thickness.
(cont'd)
17-51
vnx.su
SteeringGearbox
Disassembly(cont'dl
25. Using a cutter or an equivalenttool, cut and remove
the four seal rings from the sl6eve.
Removathe valve oil seal 8nd backup ring from the

pinionshaft.
CAUTION: Bc clroful not to drmrg. ths .dgc. ot

thc alcava g1oov6 whan rcmoving the 3cd rings
lnd O.ring.
NOTE:
. Inspectthe ball bearing by rotating the outer
race slowly. lf thsre is excessiveplay, replacethe
pinionshaftand sleeveas an assembly.
. The pinion shaft and sleeve are a precisefiu do
not intermix old and new pinion shaftsand
steev8s,
SI-EEVE
26. Using a cutter or an gquivalenttool, cut the valve

seal ring and O-ring Et the groove the pinion shaft.
Removethe valv saal ring 8nd O-ring,
28, Pressth6 valve oil sal and roller besring out ofthe
valve housing using a hydraulicpress and special
tool shown below.
CAUTION: Br crrltul not to drm.gr thc cdgct of

thc plnion rhdt grooya whcn rcmoving the vllvc
!.!l ring rnd O-ring.
Cutting slot position.
17.52
vnx.su
PILOTCOLLAR
O?GAF- PHTO1OO
Reassembly
NOTE:
. Cleanthe disassembledpartswith a solventand dry them with compressedair. Do not dip the rubberparts in a solvent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply power steering fluid or steering grease{HONDAP/N: 08733- 8070E)to the parts indicated in the assembly procedures.
. Do not allow dust,dirt. or otherforeignmaterialsto enterthe powersteeringsystem.
. Usethe appropriatespecialtoolswhere necessary.
FLANGCBOLT
20 N.m 12.0kg{.m, lil lbt'ftl
VALVEI{OUSING
CYLINDERPIPEA
26 N'm (2.7 kgf.m, 20 lbf.ftl
BOLI..ERBEARING
Replace.
VALVE SEAL RING
Replace.
+-cncl|P
SITEVE
S1IEVE SEAI RINGS

Reolace.
BACKUPRIM}
VALVE SEAL RING
Raplacs.
RACKGUIDESCREW
O.RING
Replac.
LOCKNUT
PINIONSHAFT
CYLINDERHOUSING
BACKUPRING
SHIMS
O-RING
Replace.
O-RING
Replace.
CYUNDERENDSEAL
Reolace.
CYLINDEREND SEAL
Replaco.
GEARHOUSING
O.RING
Replace.
x$ Ynd#
PISTONSEALRING
Replace.
STEERINGRACK
(cont'd)
17-53
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SteeringGearbox
Reassembly
lcont'd)
Vllvc Body Rea3sombly
1.
2.
3.
4.
Apply vinyl tape to the steppedportion of the pinion shaft,and coat the surfaceof the vinyl tape with
the power steeringtluid,
I n s t a l lt h e b a c k u p r i n g w i t h i t s t a p e r e d s i d e a s
shown below.
Coat the inside surface of the new valve oil seal
with powersteeringfluid.
Slide the valve oil seal over the pinion shaft.being
carefulnot to damagethe sealinglip.
CAUTION: ln3tall the valve oil ssal with hs groovad
3idetacing opposits the besring.
Vinyl trpo
lst.ppcd ponion,
7. 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.
8. Apply power steeringfluid to the insideof the special tool. Set the largerdiameterend of the special
tool over the valvesealring.
9. Move the specialtool up and down severaltimes to
makethe valvesealring Jit in the pinionshaft.
10. Removethe specialtool.
. 1 1 . T u r nt h e s p e c i atlo o l o v e ra n d s e t t h es m a l l e r d i a m eter end of the specialtool over the valveseal ring.
Move the sDecialtool uD and down severaitimes to
m a k et h e v a l v e s e a l r i n g s n u g l yf i t i n t h e p i n i o n
shaft.
Taperedposition.
Groove side.
VALVESEALRING
VALVEOIL SEAL
Salinglip
E
Fit the new O-ringin the grooveof the pinion shaft.
Then slide the new valve seal ring over the shaft
and groovein on the pinionshaft.
Removethe vinyl tapefrom the pinionshaft.
NOTE:Do not over - expandthe valvesaalring.
PINION SHAFT
VALVESEALRING
17-54
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(H(ffi
Usethe widerdiameter
end ot the special
tool first to make
the valvesealring
fit in the pinion
shaft.
Make the valve seal ring

snuglyfit in the.pinion
shaftusingthe otherend
(smallerdiameterend)of
the specialtool.
Apply powersteeringfluid to the surfaceof the specialtool. Set the new sealrings overthe specialtool
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l , a n d
expandthe seal rings.Do two rings at a time from
eachend of the sleeve,
NOTE:
. Do not over-expand
the seal ring.Installthe resin
seal rings with care so as not to damagethem.
After installation,be sure to contract the seal
rings usingthe specialtool{sizingtool}.
. There are two types of sleeve seal rings: black
a n d b r o w n . D o n o t m i x t h e d i f f e r e n tt y p e s o f
sleevesealringsas they are not compatible.
't7. Apply power steeringfluid to the surfaceol the pinion shaft,then assemblethe sleeveover the pinion
shaft,aligningthe locatingpin on the insideof the
sleevewith the cutoutin the shaft,
NOTE:Be carefulnot to damagethe valveseal ring
when insertingthe sleeve.
1 8 . Installthe circlipsecurelyin the pinionshaftgroove.
NOTE:Installrh circlipwith its taperedside facing
OUI.
Cutout,
1 3 . Setthe specialtool in the groovesin the sleeve.and

set eachring in eachgroovesecurely.
NOTE: After installation,compressthe seal rings
with your fingerstemporarily.
BALLJOINT BOOTCLIPGUIDE
o?MAG - SL001d)
19. Apply power steeringfluid to the seal ring lip of the

v a l v e o i l s e a l .T h e n i n s t a l lt h e s e a l i n t h e v a l v e
housingusinga hydraulicpressand specialtools as
shown.
14. Apply power steeringfluid to the seal rings on the

sleeveand to the entireinsidesurfaceof the special
tool.
15. Insertthe sleeveinto the specialtoolslowly.
1 6 . M o v e t h e s l e v ee a c h d i r e c t i o ns e v e r a lt i m e s t o
makethe sealringssnuglyfit in the sleeve.
ATTACHMENT,
32x35mm
077{6 - 0010100
NOTE:Be surethat the sealringsare not turnedup.

SLEEVESEALRING
SIZINGTOOL
07974- 5450200
VALVEOIL SEAL
{cont'd)
17-55
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ir
SteeringGearbox
(cont'd)
Reassembly
20. Pressthe new roller bearinginto the valve housing
usinga hydraulicpressand specialtool as shown.
NOTE:Placeths roller bearingon the valve housing with its letter stamped facing up towards the
valveside.
Pr.33,
2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
Dressas shown.
CAUTION: Before irserting the pinion 3haft, bo
suro that the backup ring is csntored with the pin.
ion shaft bearing,
ATTACHMENT,
32x35mm
- (x)1010O
077/aO
BACKUPBING
ROLLERBEARING
Letterstampedface
2 1 . Apply vinyl tape to the pinion shaft,then coat the

vinyl tape with powersteeringfluid.
Insertthe pinionshaftinto the valvehousing.
CAUTION: Be carotul not to damage tho valvs soal
rings.
23. Removethe vinyltapefrom the pinionshaft.
Soalinglip frc..
VALVEOIL SEAL
VALVCHOUSING
PINION
E
SI,-EEVESEAL RINGS
Be surethat the
searings are not
turnedup,then
install.
17-56
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25. Coatthe pistonseal ring guide with power steering

fluid, and slideit onto the rack,big end first.
3 1 . Coatthe sliding surfaceof the specialtool and new

cylinderend sealwith powersteeringfluid.
26. Positionthe new O-ringand new pistonseal ring on

the specialtool, then slide them down towards big
end of the tool.
32. Placethe seal on the specialtool with its grooved
NOTE:
. Do not over expand resin seal rings. Installthe
resin seal ring with care so as not to damage
them. After installation,be sure to contractthe
sealring usingthe specialtool (sizingtool).
. Replacepiston'sO-ringand sealring as a set.
sidefacingoppositethe specialtool.
Groovedside.
Pull the O-ringoff into the pistongroove,then pull

the pistonsealring off into the pistongrooveon top
of the O-ring.
PISTON
CYLINDEREND SEAL
PISTONSEALRING
GUIDE
07GAG- SD,OI00
CYLINDEREND
SEALSLIDER
0797a - 6890801
Apply a thin coat of greaseto the insideof the special tool, and installit on the steeringrack.
CAUTION:Make sure the rack teeth do not tace
the slot in the specialtool.
O.RING
PISTONSEALRING
CYLINOERENDSEAL
28. Coat the piston seal ring and inside of the special
toolwith power steeringfluid.
Carefullyslide the tool onto the rack and over the
pistonsealring.
30. Move the specialtool back and forth severaltimes
to makethe pistonsealring fit snuglyin the piston.
PISTON
E
SEALSLIDER
0t974 - 6890801
(cont'd)
17-57
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SteeringGearbox
Reassembly
lcont'dl
34. Separatethe cylinderend sealfrom the spscialtool,
then remove the tool from the steering .ack.
CYUNDERENDSEAL
3 7 . Setlhe gearboxin a presswith the cylindorhousing

facing upward.
Installthe flangebolt intothe end of the steeringrack
until it bottomsin the hole,then backthe flangbolt
out 1/il turn. Hold the flange bolt and tighten the
flangenut againstthe rackby hand.
'to
Installthe cylinderend seal into the bottom of the
cylinder by pressingon the bolt with a press as
shown.
CAUTION: Do not push on ihc bolt with excelcivr
forcc; 83 it may dEmagothr cylindor ond 3o!1.
Pr9!t
I
12 x 170 mm FLANGEBOLT
12 mm FLANGENUT
lnstall the backup ring on the steering rack, then
placethe cylinderend sealto piston.
STEERINGRACK
BACKUPRING
CYUNDERENDSEAL
Removethe flangebolt and centerthe steeringrack.

4 1 . Installthe specialtool or vinyl tape onto the end of
CYLINDERENDSCAL
Greasethe steering rack teeth, then insert the steering rackinto the gear housing.
CAUTION: Be clrs{ul not to d.mage to inn9r !urftca of thc goar housing with th rsck cdg6.
the steering rack, then coat the specialtool or vinyl

tapewith powersteeringfluid.
Coatthe insidesurfaceof the new cylinderend seal
with power steeringfluid.
Installthe cylinderend seal onto the steringrack
with its grooved side toward the piston.
Removethe specialtool. Push in the cylinder end
sealwith finger.
NOTE: Take care not to damagethe cylinder end
seal with the threads and burrs at the stakod oosition of the gearbox.
St k d po3ition.
c.oov.d3id...--#
<r|'
---_-EE]TmIrnTr--------EJl Li IL ll
CYUNDERENDSEAL
17-58
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Installa puller yoke to the steeringgearbox,then

clamp the puller yoke in a vise with soft jaws as
shown.
YOXE:
PULLER
CommcrcirllyAvrihblo
Sn.p-OnoT/N Cr123-l
orco T/N 7372
or aquivrlani
,t8. Selectthe 32 mm shim(s).

N O T E :O n l y r e i n s t a ltl h e o r i g i n a l3 2 m m s h i m ( s )
when the steering gearbox is reassembledwithout
replacingthe pinion shaft,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 folrows.
Shim rlection:
-'1. Set the four 32 mm shimson the baringsurfaceof
the gearbox housing. Total thicknessof the four
shimsshouldeoualno more than 0.70mm.
0.10 mm,
Shim set: tour 32 mm shims (Thickness:
0.15mm, 0.20,0.25mm respectivelyl
CAUTION: The tour 32 mm shimr do not hlva
thlckn$s idcntitication mukt. Mo!3ur. tho thicloa33 of rach 3him using a miclomctrl, and mlrk
tho shim lor id6ntific8tion.
Greasethe insidesurfaceof the cylinderend, then

installthe cylinderend by screwingit into the cylind e rh o u s i n g .
4 1 . After tighteningthe cylinderend, stakethe point of
the cylinderhousingshown below.
NOTE:Stakein the cylinderin the positionopposite
from where the stake was removed during disassemblv.
Strke point, D.pth: 1.0 mm (0.04inl
CYLINDERHOUSING
- 2 . 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
tighten the flange bolts to the specitiedtorque
VALVEBODYUNIT
FLANGEBOLT
20 N.m {2.okgtm, 14lbt'ftl
SHIM SET
{foul thim.)
4.0 mm 10.15inl
CYLINDEREND
Measurethe clearancebetween the gearbox and

valvebody unit usinga feelergaugeas shown.
NOTE:Measurethe clearanceat the point midway
betweenthe two mounting bolts.
CYLINOER
69 N.m 17.0kgf.m, 51 lbtft)
(cont'd)
17-59
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SteeringGearbox
Reassembly
lcont'd)
- 4 . D e t e r m i n et h e r e q u i f e dt h i c k n e s so f t h e 3 2 m m
shims by subtractingthe clearanceobtainedin the
step-3 from the total thicknessof the four shims.
( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( C l e a r a n c e=)
Requiredthicknessof the shims
54. Installthecylind6rpipesA and B.

NOTE:
. Cleanthe jointsofthe cylinderpipeA and B tho.oughly. The joints must be free of foreign mat.iat,
o Installthe cylinderpipe A and B by tighting the
flare nuts by hand first, then tighten the flare
nuts to the specified torque starting with the
cylinderside nuts.
NOTE:Selectthe shims so that th6 total thickness

is closeto, but lessthan the requiredthickness.
Exampls:
Measu.ementis 0.28mm (0.011in):
0.70- 0.28= 0.42mm (0.028- 0.011= 0.0't7in)
CYLINDER
PIPEB
26 N.m (2.7kg{.m,20lbtft)
The selectedshims should be 0.25 mm (O.O1O

in) and
0.15mm (0.005in) in thickness.
l f t h e r e q u i r e ds h i m t h i c k n e s si s 0 . l O m m o r l e s s ,n o
shims are necessary.
i[9. Set the selected32 mm shims on the bearingsurfaceof the garboxhousing.
50, Coatthe new O-ringwith gresseand installit in the
groovein the gearboxhousing.
c t . Apply greaseto the needlebearingin the gearbox
housing.
Installthe valve body unit on the gearboxhousing
by engagingthe gears.
Greasethe sliding surface of the rack guide and

installit onto the gear housing.
Apply a thin coat of greaseto the nw O-ring and
installit on the rackguidescrew.
Installthe spring, rack guide screw and locknuton
the gear housing.
Adjustthe rackguide screw(seepage l7-21).
NOTE: Note the valve body unit installationposition (directionof pipe connection).
Tightenthe flangeboltsto the specifiedtorque.
NOTE:After adjusting,checkthat the rack moves

smoothlyby slidingto rackright and left.
FLANGEBOLT
20 N.m (2.0 kgt m, 14lbf.ft)
VALVEBODYUNIT
-6t
O-RING
-ffiti
LOCKNUT
NEEOLEBEARING
_#{
BACKGUIDESCREW
17-60
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Install the new lock washor in the groov in the

steering rack.
62. Apply steering groass to the circumferenc6 of tho

rackend housing.
60. Hold the steering rack with I wrsnch and tighten

the rackend.
Coat the rack end groove and inside of the boot

with siliconegreas.
After tightening th rack end, stskethe four sections

of lock washer with a commerciallyavailableroll
Dindrift and a mallet.
64. l n s t s l l t h e b o o t s i n t h s r a c k e n d w i t h t h e t u b e
clamos.
o l
ROLL PIN DRIFT

Comm.rcl.lly Av|il.bl.
lsnrp-On No. PPR8or .rquiv.lenll
NOTE: Installthe boots with the rack in the straight

ahsad position (i.6. right and lft tis-rods ar squal
in length).
NOTE: Wipe ths gro.se off

the thread sction.
NOTE: This drift has a fl8t,

to prevent puncturing
of motal washer.
TUEE CLAJTIP
(cont'dl
17-61
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SteeringGearbox
Reassembly(cont'dl
65. Adjust the air hose fitting position of the boots by
turning it as shown below.
6 7 . Install new boot bands on the boot and bend both

sets of locking tabs.
Lightlytap on the doubled-overportionsto reduce
their height.
GAUTION: Stake tho band locking tabs firmly.
Front
Slide the rack right and left to be certainthat the

boots are not detormed or twisted.
AIR HOSEFITTING
70. Install the right and left tie-rod ends on the rack
ends.
C o n n e c t h e a i r h o s e b e t w e e nt h e r i g h t a n d l e f t
boot.then installthe clips on the cylinderpipe B as
snown.
Install
therightclip
in thisposition.
CLIP
17-62
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lnstallation
CAUTION; BGGlrc{ul not io bcnd or drm8go tho piping
whcn in3tllling tho gea.box.
1.
Beforeinstallingthe gearbox,slide the rack all the

way to right.
2.
Passthe right side of the steeringgearbox above

and throughthe right sideof the rearbeam.
3.
Hold the steeringgearboxand slidethe rackall the

wav to the left.
4.
Raisethe left side of the steeringgearbox above

and throughthe leftside of the rearbeam.
5.
Installthe pinion shaft grommet and insertthe pinion shaft up throughthe bulkhead.
7.
Centerthe steering rackwithin its stroke.

Makesurethat the cablereelof the SRSis centered
as follows:
Turn the steeringwheel left approx.150degrees,
to checkthe cablereelpositionwith indicator.
. lfthe cablereelis centered.the yellowgeartooth
linesup with the alignmentmarkon the cover.
. R e t u r n t h e s t e e r i n gw h e e l r i g h t a p p r o x . 1 5 0
degrees to position the steering wheel in the
straightaheadposition.
.
YELLOWGEARTOOTH
NOTE:Align the tab on the pinion shaft grommet

with the slot in the valvebodv.
TAA
MARK
ALIGNMEi'IT
Slip the lower end of the steeringjoint onto the pinion shaft(line up the bolt hole with the groove
aroundthe shaft),and tightenthe lower bolt.
NOTE:
. Connectthe steeringshaft and pinion with the
cablereeland steeringrackcentered.
. Be sure that the lower steeringioint bolt is securelyin the groove in the steeringgearboxpinion.
. lf the steeringwheel and rack are not centeted,
r e p o s i t i o nt h e s e r r a l i o n sa t l o w e r e n d o f t h e
steeringjoint.
6.
Installand tightenthe gearboxmountingbolts.

NOTE: After installingthe gearbox,check the air
h o s e c o n n a c t i o n sf o r i n t e r f e r e n c ew i t h a d j a c e n t
pans.
58 N.m 15.9kg[.m, $ lbl.ftl
LOWERBOLT
22 N.m 12.2kgi.m, 16lbf.ftl
(cont'dl
38 N m 13.9kgl.m, 28 lbt.ftl
17-63
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SteeringGearbox
10. Installthe steeringjoint cover with the clampsand
cliDs.
1 2 . I n s t a l lt h e r e a r b e a m b r a c e r o d a n d r e t u r n p i p e
clampon the rearbeam.
N O T E : I n s t a l lt h e r e a r b e a m b r a c et o w a r d t h e
returnpipeclamp.
STEERINGJOINTCOVER
38 N.m 13.9kg{.m,28 lbf.ft)
CLIP
13. Install the three way catalyticconverter with the

new gasketsand new self-lockingnuts,and connect
the heatedoxygensensor(H02S)connector,
11. Connectthe fluid linesto the valvebodv unit.

RETURNHOSE
HEATED
OXYGEN
SENSOR
CONNECTOF
SELF.LOCKING
NUT
33 N.m 13.4
SELF.LOCKING
NUT
22 N.m (2.2 kgt m, 16 lbt.ftl
14. Connectthe shift linkage (M/T model: see section

13,A/T model:seesection14).
17-64
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BallJoint Boot Replacement

1 5 . Threadthe right and lefi tie-rodends onto the rack
an eoualnumberof turns.
TIE.RODLOCKNUT
TIE-ROOEND
Removethe boot set ring and the boot.

CAUTION:Do not contaminateihe boot in3tallstion section with graso.
Packthe interiorof the boot and lip with grease.
Wipe the greaseoff the sliding surfaceof the ball
pin,then packthe lower areawith freshgrease.
CAUTION:
. Kep g;eass off the boot in3tallation section and
tho laperad section of the ball pin.
. Do not altow dust, di.t, or other toreign mat6tials to enter tho boot,
LIP
BALLPIN TAPERED
SECTION
Wipe off the grease.
the tie-rodends to the steeringknuckles,

Rconnect
tighten the castle nut to the specifiedtorque, and
installnew cotterpins.
CAUTION:Iorquo tho castle nut to tho lower torque lpocification, thsn tighton it only far cnough to
align thc slot with tho pin hole. Do not align tho
nut by loosoning.
NE.RODEND
BOOTINSTALLATION
SECTION
wiDe off the grease.
BOOTINSTALLATION
SECTION
Wipe off the grease.
Installthe boot in the grooveot the boot installation

sectionsecurely,then bleedair.
SALLJOINTBOOT
CLIPGUIDE
07MAG- SL(x)l00
Adiust the depth by
turningthe tool.
CASILE NUT
39 - 47 N.m
14.0- a.8 kgf.m. 29 - 35 lbf ftl
COTTERPIN
On reassembly,bend
the cotterpin as shown.
17. lnstallthe front wheels.
18. Fill the systemwith pgwer steeringfluid and bleed

air from the system(seepage 17-21).
performthe followingchecks.
19. After installation.
. Checkthe gearboxJor leaks(seepage 17-231
. Adjustthe front toe (seesection18).
o Checkthe steeringwheel spokeangle.Adjust by
turningthe right and lefttie-rods,if necessary.
SET RING
Insertthe specialtool into the threadsin the ball pin

and align the end of the tool with the groovein the
boot.
Slidethe clip overthe tool and into position
CAUTION: After installing the boot, check th. b.ll
pin taperod section tor grease contamiration and
wipe it if nocossary.
Turn the right and lefttie-rodsequally.
17-65
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-3 Loosenthe locknutssecuringthe centerglass

guide,and adjustthe glassfore and aft by moving the center glassguide.
R6ar Door:
'13.
Adjust clearance"H" as follows.
"H"
NOTE: Hold the adjusting bolts with a hex

wrench or tlat tip screwdriverwhen loosening
the locknuts.
lsos page 20-421
- 1 Loosenthe nut securingthe stopperplates.

2 Loosenthe nut securingthe rollerguide, and
move the guide up or down to alignthe glass
with the body at the rear and center pillars.
GLASS
I
-4 Repeatsteps-2 and -3 until clearance"H" is
within the specifiedlimits.then fasten the center
glass guide and rollerguide.
Pressthe stopperplatesagainstthe glassstoppers, then fasten the stopper plates.
ROLLERGUIDE
NOTE: Checkthat the stopperplatescontact

the glassstoppersevenly.
STOPPERPLAYE
lF ontl
204s
vnx.su
Doors
GlassAdjustment(cont'dl
14. Adjust clearance"8" as follows.
-3 Loosenthe upper locknut on the center glass

guide, and turn the adiustingbolt until cleatance
"B" is within the soecifiedvalue.
ADJUSTING
EOLT
"8" (see page 20-421
-l
Lower the glass 1O mm {0.39 in).
- 2 Pushthe glassoutward 1Omm (O.39inl. then
LOCKNUT
1 2 x 1 . 2 5m m
22 N.m 12.2kgf.m,
16 tbt.ft)
pushthe insidestabilizers
againstthe glssslightly. Fastenthe insidestabilizers.
NOTE: Checkthat the glassmoves smoothly.
*
GLASS
NOTE: Do not adjustthe lower adjustingbolts

on the center glass guide.
-4 Move the glass up and down to seat it, then
measureclearance"8" at the designatedlocattons.
- 5 Measureclea.ance"H" againto make sure it
is still wilhin the specifiedlimits at the designated locations.
NOTE: Repeatthe above steps until the correct
clearancesafe obtained.
20-46
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15. After the clearanceshave been adjusledproperly.

reinstallthe weatherstrip.
1 7 . Check for water leaks.

NOTE; Do not use high pressurewater.
16. Check that the glass contacts the weatherstrip

evenly.
NOTE: Measuringpoints are describedon page
20-42.
18. Routethe door harnessand connectors,and fasten

them to the door (see pages 20-22, 331.
WEATHERSTRIP
19. Disconnectthe oowef window switchfrom the doo.

harness,then installthe power window switch on
the door panel (see page 20-41).
Conter Pillar soction:
2O. Attach the plasticcover,then installthe door panel

(see pages 2O-2O, 321.
2047
vnx.su
Doors
Striker Adjustment
PositionAdjustment
NOTE: Placethe vehicleon a tirm, levelsurfacewhen
adjustingthe doors.
Make surethe door latchessecurelywithout slamming.

lf it needs adjustment;
After installingthe door, check for a flush fit with the

body, then checkfor equalgapsbetweenthe front, rear,
and bottom door edges and the body.
The door and body edgesshouldalso be parallel.Adiust
at the hingesas shown.
1 . Draw a line aroundthe st.iker for reJerence.

Loosenthe screws,and move the strikerlN or OUT
to make the latch tit tighter or looser.Move the striker UP or DOWN to align it with the latch opening.
Then liqhtly tighten the screws and recheck.
CAUTION: Plac a shop towsl on tho jack to prevent damage to the door when loosening the dool
and hingo mounting bolts for adjustmont.
BOLTS
DOORMOUNTING
8 x 1.25 mm 29 N.m l3.Okgl m, 22lbftrl
Loosen lhe door mo!nting bolts
slightlyto move the door lN or OUT
until ir's flush waththe body. It
necessary,you can installa shim behind one hingeto make the door
edgesPAFALLELwith the body.
DOOR
scREws
HIIGE xrruceMouNTTNG
BoLTs
I x 1.25mm
18 N.m ('1.8kgt.m, 13lbf.ttl
I x 1.25mm
29 N.m l3.O kgt'm,22 lbl'ft)
Loosenthe hingemounting
bolts, and move the door
BACKWARDoI FORWARD,
UP or DOWN as necessary
to equalizethe gaps.
NOTE: Holdrhe outerhandleout, andpushthe door

againstthe body to be sure the striker allows a flush
fit.
lf the door latchesproperly,tightenthe screwsand
recheck.
Lower the glass,
SHOPTOWEL
The door and body edges should be parallel.
NOTE: Check tor water leaks.
20-48
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Mirrors
PowerDoor Mirror Replacement
Hstchback
Sedan
1. Pry out the cover panelwith a flat tip screwdriver,

then removeit.
1. Removethe door panel (seepage 20-201and disconnect the connector.
CAUTION: When prying with a flat tip screwdriver.

w'ap it whh protoctiva tapo to pravont damage.
2.
Pry the cover panelout with a flat tip screwdriver,

then remove the cover panel.
CAUTION: Whsn prying with a flat tip scrowd.lvl,
wrap it with protectiv taps to p.svont damag6.
HOOKS
2.
Disconnectthe connector.Removethe nuts, then

removethe door mirror while holdinoit.
3.
< i Scrow locations
< : Nut locltion3,3
^^
Removethe screws while holdingthe door mirror.
, A< : Scrow, 2
sxo.8mm
| l m-t uto.+
.+rg
r.m, I
rst..
l$9| +111
i
3 lbl'lrl
,"",''@
.I s ' 0 . 4(0.4
- ---J'/
4 N.m
, B< : Scr6w, I
I 66
|
kst.m, \
\3_!!t.rrr__
sro.'"e-.
+ w.m (0.4 kgt.m,
\!Lbllq
cot{t{EcToB
(Doo. mirror ddol
DOOR MIRROR
CONNECTOR
lDoor harnoss
.ide)
CONNECTOR
3.
CONNECTOR
Installation is the reverse o{ the removal procedure.
4.
Installation is the reverse of the removal procedure,
20-49
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Mirrors
Mirror Holder Replacement
1.
Carefullypry out the mirror holder with a tlat tip

screwdriveras shown.
CAUTION: To p.evnt damage to tha mirlor, wrap
ths end ot a tlat tip screwdrivr with a shop towel.
Mirror Visor and Mirror Covel Replacement

Hatchback
1.
Removethe mirror holder.
2.
Turnthe actuatorforward.then removethe screws.
< : Scrawlocation3,4
MIRRORHOLDER
2.
Installationis the reverseof the removalorocedure.

NOTE: Apply greaseto the locationsindicatedby
the arrows.
Hatchback
3.
Detachthe hooks, then removethe mirror visor.
JOINT PIN
Sedan
MIRRORVISOR
JOINT PIN
20-50
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4.
Turn the actuatorto the originalposition.

Removethe screws,then removethe mirrorcover.
Sedan
1,
Removethe mirror holder.
2.
Turn the mirror base forward, then remove the

screws.
< : Scrowlocttions,3
< : Sciow location!

A< : Sc.ew, 4
8<: Screw, I
ACTUATOR
@
_ J
4E0 l
. _ J
MIRRORBASE
5,
Installationis the reverseol the removalDrocedure,

3.
Detach the hook. then removethe mirror visor.
{cont'd)
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20-51
Mirrors
Mirror Visor and Mirrol Covel
Replacement{cont'd)
4.
RearviewMirror Replacement
1 . Pry the cover off using the end ot a flat tip screwdriver.
Removethe actuator,then removethe screws.
<: Scraw locations

A < : S c r w ,3
B { : S c r e w ,2
CAUTION: To provent damage to tho miror and

covl, wrap tho end of the screwdriver with I shop
towol.
C < : S c . e w ,1
Remove the screws, then remove the rearview

mtrror.
SCREW
5x0.8mm
4 N.m {0.4 kgf.m,
3 tbf.ftl
ACTUATOR
REARVIEW
MIRROR
Turn the mirror base as shown, then removethe mirror cover
SHOP TOWEL
3.
MIRRORCOVER
lnstallationis the reverseof the removalprocedure.
20-52
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Installation is the reverse of the removal procedure.
Windshield,RearWindow, OuarterGlass
lndex
NOTE: The numbersafter the part names show the quantitiesof the parts used.
Hatchback
UPPERMOLOING
UPPERRUBBERDAM
RIGHTSIDE
CLIP E. 2 Whir
Cl-lP F, 2 Loft. Whito
Right. Bluo
CLIP A, I Rod
RETAINER,6 Orengo
CLIP B, 2 O.an96
CLIPC, 2 Black
LEFTSIDEMOLDING
Removal,page 20-55
e.'.
CLIP D. 2 G.6en
RETAINER, 2 Ysllow
REARWINDOWMOLOING
page 2O-65
Replacement,
UPPERSEAL
UPPERFASTENER,2
(Slt-adh.sive-type,glass sid6l
UPPERFASTENER,2
(Self-6dhosiv6-type,hatch sidel
SIDERUAAER
DAM. 2
SIOESPACER.2
REARWINDOW
Removal,page 20'6'1
Instaflataon,page 20-62
f ? *
""'î^r.{"'/\
LOWERFASTENER.2
{Self-adh6siv-type,
glass sidel
LOWERFASTENER,2
{Selt-adhosive-1ype,
hatch sid6)
ADHESIVETAPEB, 2
20-53
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Windshield,RearWindow
lndex
NOTE: The numbersafter the part names show the quantitiesof the parts used.
Sodan
UPPER
MOLDII{G
UPPERRUEBEROAM
RIGHT SIDE MOLDING
cLtP E, 2 Whir6
CLIP F, 2 L6ft. Whlto
Righl. Bluo
CLIP A, I Rod
&...
e
WINDSHIELD
Removal,page20-55
Installation,page20-56
*aro,nr*. 6 o'!.gc
CLIP B, 2 B?own
bq
,@
A
\
/ '
GLASSBRACKET,
2
RET
AINER. 2
Yollow
REARWINDOWMOLOING
2
UPPERFASTENER,
{S.ll-.dho!lvo-typo,gh$ .ldcl
g
.qB.....--
REARWINDOW
Removal, page 20-68
Installation,
page 20-69
urra" FAslEr{ER,2
(Cllp-typo, body .ld.l
&'.....- r,o, sPAcER,

4
R.-.......-"-.owER
FA'TENER.
2
lsolf-.dhe3ivo-type, sla$ sidol
LOWERCOVER
LOWERFASTENER,
2
(Solt-rdhe.lvo-typo.
body sidol
20-54
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Windshield
Removal
CAUTION:
a Woar glovos to lmov and install the windshiold,
a Us saat covers to avoid damaging any surfaces.
3.
Removethe right and left glass brackels.
4.
Peeloft the upper molding.
1. To removethe windshield,first removethe:

a Front pillartrim (seepage 20-911
. Headliner(seepages 20-98. 1OO)
a Front wipers and air scoop (seesection 23)
2.
Detach the clips trom the retainers,then remove

both side moldingsas shown.
NOTE: lf necessary,replaceany dsmagedclips.
NOTE: Whenthe uppermoldingremovalis ditticult,

cut the upper rubber portion O off, then cut the side
rubber portion@.
UPPER
MOLDII{G
ADHESIVE
WINDSHIELD
f-CLIPC, D
5.
>
Removethe other retainerstrom the bodv.
lcont'd)
20-55
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Windshield
Removal(cont'd)
6.
lnstallation
Apply protective tape to along the edge ot the dashboard and body as shown.
Usingan awl, make a hole throughthe rubberd8m
and adhesivefrom insidethe car. Pushthe pianowire
th.ought the hole, 8nd wrap each end arounda paece
of wood.
w|l{osHlELo
1.
ScraDethe old adhesivesmooth with a knife, to a

thickness of about 2 mm (O.O8in) on ths bonding
surtace aroundthe entite windshieldopeningflange,
NOTE:
a Do not scrapedown to the paintsd surfaco ot the
body; damaged paint will interfere with proper
bonding.
a Remove the rubber dam from the bodv.
a Mask off surrounding surfaces betore painting.
2.
Cleanthe body bondingsurtacewith a spongedampened in alcohol.

NOTE: Atter clesning,keep oil, greaseand water
from getting on the surface.
3.
WII{DSHIELD
PIANOWIRE
lf the old windshildis to be reinstalled,use a putty

knife to scrape df{ all iraces oJ old adhesive, then
cleanthe windshieldsurfacewith alcoholwhere new
adhesiveis to bs applied.
NOTE: Make su.e the bonding surface is kept {ree
of water, oil and grease.
CAUTION: Avoid sotllng thE wlndshiold on hs
edges; small chips may latct dcvelop into crack3'
ADHESIVE
DAM
Wilh a helperon the outside.pullthe pianowire back

and forth in a sawing motion. and carefully cut
through the rubberdam and adhesivearoundthe entire windshield.
a Cleanthe shadowedarea.
a Cleanthe area@ as shown.
InCd.
CAUTION: Hold tho dano vyi]oas clos6to tho windshield as possible to prvsnt damag to ths body and
dashboard.
vn77777ri_
t
wtt{DsHtELo
WINDSHIELD
8.
Carefullyremovethe windshield.
20-56
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.--
4.
Center and glue the upper moldingto the upper edge

of the windshield.
6.
Installthe glsss bracketsand retainersas shown.

NOTE: The numbersatterthe pan namesshow the
quantitiesof the psrts used.
ALIGNMENTMARK
BRACKET,2
GIuethe uDDerand lower rubberdamsto the inside

face ot the windshield,as shown, to contain the
adhesiveduring installation,
7.
NOTE: Be careful not to touch the windshieldwhere

adhesivewill be applied.
12 mm {0.47 inl
Set the windshieldon the glassbrackets,then center

it in the opening.Make alignmentmarksacrossthe
windshieldand body with a greasepencilatthe four
points shown.
ALIGNMENTMARK
RUBBER UPPERMOLDING
UPPER
DAM
1O mm 10.39ln)
8.
Removethe windshield.
20-57
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Windshield
With a sponge.apply a light coal oJ glass primer
aroundthe edgeot the windshieldas shown, then
lightly wipe it olt with gauzeor cheesecloth.
NOTE:
a Do not apply body primerto the windshield,and
do not get body and glassprimerspongesmlxed
up.
a Nevertouch the primedsurfaceswith your hands.
ll you do, the adhesivemay not bondto the windshieldproperly,causinga leakafterthewindshield
is installed.
o Keep water, dust, and abrasivematerialsawaY
from the primed surface.
10. With a sponge,apply a light coat of body primerto

the originaladhesiveremainingaround the windshieldopeningflange. Let the bodY primerdry tor
at least 1O minutes.
NOTE:
a Do not apply glass primerto the body, and be
careful not to mix up glass and body primer
sponges,
a Mask otl the dashboard before painting the
flange.
//////, I Aeely bodv Primerh6te.
16mm
{0.63in)
V//f, : apptv stassptimer hors.
5 mm {0.19 inl
UPPER
UPPERRUBBER
WINDSHIELD
6 mm (0.23 in)
16 mm
1O.63inl
5mm
( O . 1 9i n l
RUBBER
-
DAM .YJ * o
16 mm
10.63inl
>\ast,
/
WINDSHIELD
\
UPPERMOLOING
1 1 . Thoroughlymix the adhesiveand hardenertogether

on a glass or metal plate with a putty knife.
NOTE:
a Cleanthe platewith a spongeand alcoholbefore
mixlng.
a Follow the instructions that come with the
adhesive.
12. Beforefilling a cartridge,cut the end ol the nozzle,
as shown.
Cut nozzleend,
10 mm (O.39inl
7 mm 10.27in)
20-58
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,*-
13. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the canridge
in a caulkinggun, and run a beadot adhesivearound
the edge ot the windshieldas shown.
15. Installthe clips on both side moldings.

>: Clip localione
A> : Clip A, I
NOTE: Apply the adhesivewithin 30 minutesafter
applying the glass primer.

12 mm (0.47 in,
T-/
l_/
f f i l
UPPER
RUBBER
: roxesrve
B < : C l i pB , 2
"___)
_)
C<: Clip C lHatchback,2l

lsodan,4l
D<: Cllp D {Hatchback,2l
8 m m lO.3'l inl
Make a slightlythicker
2mfi
lO.O7 inl
E V : C l i pE , 2
MOLDING
LOWER
RUBBEB
DAM
F)
F llelt. Whitel
lRight. Bluel
E lwhite)
A lRodl
'14.
Use suction cups to hold the windshieldover the

opening,alignit with the alignmentmarks made in
step 7, and set it down on the adhesive.Lightly push
on the windshielduntil its edgeis fully seatedon the
adhesiveall the way around.
SIDE
MOLDING
A (Rod)
It
B lHatchback, Orangel
lsedan, B.own)
NOTE: Do not close or open the doors until adhesive is dry.
C (Hstchback, Elack)
(Sodan, Orangel
SUCTION
D lHatchback, Green)
C (Sodan, O.ange)
16. Sc.apeor wipe the excessadhesiveoff with a Dutty knife or towel.

NOTE: To removeadhesivetrom a paintedsurface
or the windshield,wipe with a solt shoptowel dampened with alcohol.
vnx.su
20-59
Windshield
lnstallation(cont'd)
18. Let the adhesivedry tor at least one hour. then spray
water overthe windshieldand checkfor leaks.Mark
leakingareas,and let the windshielddry, then seal
with sealant.
17. lnstall both side moldings.
NOTE:
a Let the car stand tor at leastfour hoursafter windshieldinstallation,lf the car hasto be used within the first four hours,it must be drivenslowly
a KeeDthe windshielddry for the first hour after
installation.
a Check that the ends of the side moldingare set
under the air scooP.
CLIPE
19. Reassembleall removedPans.
SIDEMOLOING
RETAINER
CLIP B
CLIP C, D
20-60
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RearWindow
Removal
Hatchback
CAUTION;
a Use covsrs to avoid damaging tho interior.
a Wear gloves to romove and install the glass.
a Do not damags the defroster grid linss.
a Tako care not scratch th raar window molding,
4.
CAUTION: Hold ths piano wire as clos to the roat

window as possibleto prevont damageto the body
and molding.
1. To removethe rear window. first removethe:

a Rearshelt (seepage 20-91)
a Hatch side trim and hatch trim panel (seepage
20-146)
. High mount brake light (see section 23)
a Rearwiper and wiper motor (seesection 231
2.
With a helperon the outside,pullthe pianowire back

and forth in a sawing motion, and carefully cut
through the adhesivethe along the top and the sides
oJ the rear window.
Removethe rear window trim and disconnectthe

connectors.
PROTECTIVETAPE
PROTECTIVE
TAPE
CONNECTOR
3.
Cut the adhesivewith a knife at the bottom of the

aearwindow.
Apply protectivetape to the innerand outer edges

of the hatch.
Usingan awl. make a hole th.ough the adhesivetrom
the inside.at the top ot the hatch. Pushpiano wire
through the hole, and wrap each end a.ound a piece
of wood.
NOTE: Do not use piano wire in this area.

6.
Carefullyremovethe rear window.
MOLOING
NOTE: Replace the fasteners with new ones

wheneverthe rear window has been removed.
20-61
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-r
RearWndow
lnstallation
4.
Scrapethe old adhesivesmooth with a knife to a

thicknessof about 2 mm (O.O8in) on the bonding
surface around the entire rear window opening
flange.
Apply the upper sealto the insideface of glassas

snown.
Gluethe uppertasteners,lower fastenersand side
spacers,to the insidetace ot the rear window on
each side.
NOTE:
a Do not scrapedown to the painted surface of the
body; damagedpaint will interferewith proper
bonding.
UPPERSEAL
a Removethe upperand lower fastenerstrom the

hatch.
a Mask otf surroundingsurtacesbefore applying
primer.
Clean the hatch bonding surface with a sponge
dampenedin alcohol.
NOTE: After cleaning,keepoil, greaseor water trom
getting on the surface.
lI the old rearwindow is to be reinstalled,usea putty knile to scrapeott all tracesot old adhesive,then
cleanthe rear window surfacewith alcoholwhere
new adhesiveis to be applied.
NOTE: Make sure the bondingsurfaceis kept tree
F A S T E N E' R , 2
FASTENER,2
/
ALIGNMENT
CAUTION: Avoid stting ths rear window on its

edges; small chips may lator devalop into cracks,
sroE
SPACER,2
G||lethe lower fastenersand upperJastenersto the

hatch, as shown.
NOTE: Cleanthe shadowedarea,
REARWINDOW
20-62
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7 . Set the rear window upright on the hatch, then

center it in the opening. Make alignmentmarks
acrossthe rearwindow and body with a greasepencil at the tour points shown.
1O. Installthe rear window trim.
ALIGNMENT
MARKS
1 1. With a sponge, apply a light coat of glass primer

around the edge of the rear window, then lightly
wipe it ott with gauzeor cheesecloth.
8 . Removethe rear window.

cl
NOTE:
a Do not applybodyprimerto the rearwindow,and
do not get body and glassprimerspongesmixed
up.
lf you do, the adhesivemav not bondto the rear
window properly,causinga leak after the rear
window is installed.
a Keep water, dust. and abrasivematerialsawav
from the primed surlace.
Centerand glue the side rubbe.dams to the inside

face of the rearwindow, as shown, to containthe
adhesiveduring installation.
NOTE:
a Gluethe siderubberdams,usingthe printeddots
as a guidea Be carefulnot to touch the rear window, where
a Mask off surroundingsurfacesbefore applying
pnmeI.
REARWINDOW
////
, appV glass primor hero.
NOTE: Apply the glass primer, UPPER

using the printeddots as a
(0.0ainl
guroe.
15 mm
10.6inl
MOLOING 1 5 m m
{0.6 in}
REARWINDOW
MOLDING
(cont'd)
20-63
vnx.su
RearWindow
1 2 .With a sponge,apply a light coat ol body primerto
the originaladhesiveremainingaroundthe rearwindow openingflange.Let the body primerdry tor at
least 10 minutes.
NOTE:
a Do not apply glass primer to the body, and be
sponges.
a Nevertouch the primedsurfaceswith your hands
7//,
15. Pack adhesiveinto the cartridgewilhout air pockets to ensurecontinousdelivery.Put the cartridge
in a caulkinggun, and run a beadof adhesivearound
the edge of ihe rear window, as shown.
it.E\,",1/: ADHESTVE
UPPER 5 m m
SEAL
1 0 . 1 9I n l
8mm
10.31inl
I Applv body p.lmor h.]o.

MOLDING
10 mm
{0.4 in)
40 mm 11.6 Inl
16 mln 10.63Inl
1 mm {0.04 inl
NOTE: Apply the adhesiv,

using the printed dots aa
a guide.
fu.:*1",
lO.Oainl
16 mm {0.63 inl
t|nm
(O.35 Inl
)E--lT-*
-\
MOLDING
I J.
Thoroughlymix the adhesiveand hardenertogether

on a glassor metal plate with a putty knife'
NOTE:
a Cleanthe platewith a spongeand alcoholbefole
mixing.
a Follow the instructions that came with the
adhesive.
1 4 . Beforelilling a cartridge,cut the end of the nozzle'

as shown.
1O mm {0.39 inl
7 mm (0.27 inl
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-C=
/
/
GLASS
MOLDING
RearWindow Molding
Replacement
16. Use suctioncups to hold the rear window over the
opening,align it with the alignmentmarks made in
step 7, and set it down on the adhesive.Lightly push
on the rear window until its edges are fulty seated
on the adhesiveall the way around,
1.
Remove the rear window, then remove the uppGr

seal.
2.
Placethe rear window on its surface,as shown, with

a helperholdingthe rear window.
NOTE: Do not open or close the doors until the

adhesiveis drv.
CAUTION: Avold setting the rea? ryindow on h!

odgos: small chips may latol dovolop into cracka.
ALIGNMEI{T MARKS
3.
Cut the innerside rubberportionO olf the molding,

then cut the top rubber portion @.
REAR
wtNDow
REARWINDOW
17. Scrapeor wipe the sxcessadhesiveotf with a Dutty knife or towel,
4.
Turn the rearwindow over, then cut the outer side

rubber portion@ of the motding.
NOTE: To remove adhesive lrcm a painted swface

or the rear window, use a soft shop towel damDened
with alcohol.
18. Let the adhesivsdry tor at least one hour, then spray
watgr over the raar window and check tor leaks.
Mark leakingareasand let the rear window dry, then
seal with sealant.
NOTE: Let the car stand for at least tour hours al_
ter rearwindow installation.lf the car has to be used
within the first four hours,it must be drivenslowlv.
5.
Scrapeall tracesof old moldingtrom the chamtered

edges of the glass.
NOTE: Be sure to scrapeall traces of old molding
thoroughly.
19. Reinstallall remainingremovedparts.
6.
Cleanthe rear window su.tacewith alcoholwhere

new moldingis to be installed.
NOTE: Makesurethe su.faceis kept tree of waler,
oil and grease.
{cont'dl
20-65
vnx.su
RearWindow Molding
Replacement(cont'd)
7.
With a brush. apply a light coat of glass primer

aroundthe edge of the glass.
1O. Placethe rearwindow outside-up.then alignthe joint

"T" mark at the top ot the
ot the moldingwith the
glass as shown.
NOTE: Scrapeotl excessglassprimerwith a putty

knife after installingnew molding.
JOINT
6mm
1O.23Inl
MOLOING
SUBFACE
INSIDESURFACE
6mm
(0.23inl
8 . Degrease the inner surfaces ol new molding
thoroughly,then apply a light coat ot glass primer

to the surtaces.
wtNDOW
NOTE:
a Apply glassprimeraroundthe entiregrooveof the
new molding,
a Do not apply glass primerto the outer surface.
1 1 .Pressthe molding into position around the entire

edge of the rear window.
NOTE: Checkthat the moldingis not wrinkledor lifted awav at corners.
Run a bead oJ adhesivein the groove of the molding'
MOLDING
MOLDING
20-66
vnx.su
12. Scrape o. wipe the excess adhesiveofJ with a Dutty knife or gauge.
NOTE: Cleanthe moldingand rearwindow surface
with alcoholwhere upper seal is to be apptied.
1 5. Scribe a line on the molding lip with a greaspencil

to show the cutting portion ot the molding lip, as
shown.
{Gla*r Surtacel
Surfaco to be
wiped clean.
{Gla$ Insido Surtacel
1 mm (0.04 In)
16. Cut the moldinglip off, as shown.

13. Apply the uppersealto the insideface of glass(see
page 2O-621.
14. After the adhesiveis dry, use suctioncups to hold
the rearwindow over the opening,set the rearwindow on the hatch, then center it in the opening.
SUCTION CUPS
MOLDING LIP
17. Closethe hatch, then check the gap between the

moldinglip and body.
18. lf the moldinglip contactsthe body, cut the molding lip off. keepingthe gap para el wiih the body.
20-67
vnx.su
RearWindow
Removal
4.
Sadan
Peel off the molding.

NOTE: When moldingremovalis difficult, cut the
moldingwith a knife.
CAUTION:
a Wear gloves to remove and install the leal window.
a Do not damage the delloster grid lines.
MOLOING
1. To removethe rear window, f irst remove:

. Trunk lid {see page 20-149)
a Rearseat-backside bolsters(seepage 20-11 1)
. Rearshelf (see page 2O-95)
a Rearpillartrim panel {seepage 20 95)
2.
REARWINOOW
Disconnectthe defrosterleads, and remove their

holders.
NOTE: Avoid scratchingthe rearwindow with the
cutter blade.
3.
Removethe clips, then removethe lower cover.

NOTE: Use a clip removerto removelhe clips.
REAR
wlNDow
Pull down the rear of the headliner (see page
20-101).
CAUTION: Take care not to bend the headlinerexcessively.
o.
Apply protectivetape to the edge of the body, as

shown.
Usingan awl. makea holethroughthe adhesivefrom
insidethe car. Pushthe pianowire throughthe hole
and wrap each end around a piece of wood.
PROTECTIVETAPE
ADHESIVE
/ - a,o*o*'*a
MOLDING
HEADLINER
PIANOWIRE
LOWERCOVER
LowERsPAcER/
;ru/
FASTENER
LowER
oore,srvr \3
PRorEcrtvE
rlee
20-68
vnx.su
---
Installation
7 . With a helperon the outside,pullthepianowire back
and torth in a sawing motion, and carelully cut
through the adhesivearoundthe entire rear window.
Scrapethe old adhesivesmooth with a knite, to a

thicknessof about 2 mm (O.08in) on the bonding
surface around the entire rear window opening
flange.
CAUTION: Hold tho piano wir as closo to the real

window as possibleto prevent damageto the body.
a Do not scrapedown to the painted sudace of the
body; damagedpaint will interferewith proper
bonding.
a Removethe upper and lower fastenerstrom the
body.
a Mask off surroundingsurfacesbefore applying
Dflmer.
REARWINDOW
2.
Cleanthe body bondingsurfacewith a spongedampened in alcohol.

NOTE: After cleaning,keep oil, greaseand water
from getting on the surface.
3.
PIANO wlRE
ll the old rearwindow is to be reinstalled,usea Dutty knifeto scrapeoft all tracesof old adhesive.then
cleanthe rear window surfacewith alcoholwhere
new adhesiveis to be aDolied.
NOTE: Make sure the bondingsurfaceis kept free
8.
CAUTION: Avoid setting the rear window on its

edges; small chips may later develop into cracks.
Carefullyremovethe rear window.
Cleanthe shadowedarea.
/s
\\--
t\
{cont'd)
20-69
vnx.su
RearWindow
lnstallation (cont'd)
4.
6.
Apply the double-facedadhesivetape to the inside

o{ the rear window, as shown
Install the upper fasteners and glue the lower

fastenersto the bodY,as shown.
NOTE: The numbers atter the parts names show
quantity of the Part used.
lnside
0.16 mm (0.006 inl

5 0 0 m m ( 1 9 . 7i n )
5OOmm 119.7in)
ALIGNMENT MARKS
Glue the moldingaroundthe edge oi the rear window, as shown.
7.
Gluethe sideandlower spacersand tastenersto the

inside face ot the rear window and molding, as
shown.
NOTE: The numbersafterthe part namesshow the
quantitiesof the Partsused.
5 O Om m 1 1 9 . 7
> : Spac6r,lastonellocations
SIDE
S P A C E R , 4^
lo, \./O
MOLDING
'7:^ c
rs
s-."
\\t--
MOLDING
l\ 4!9!llEN,r_r\,ry!s
q
la,Loqrcen.t
(4relycv!|I!"
l$;*
\'*'w
\ o.f9!T.nl"1"*"
ALIGNMENT
MARKS
20-70
vnx.su
8. Set the rearwindow, then centerit in the opening.

Make alignmentmarksacrossthe rearwindow and
body with a gfease pencilat the tout Dointsshown.
ALIGT{MENTMARKS
1 1. With a sponge.apptya light coat ot body primerro

the originaladhesiveremainingaroundthe rearwindow opening flange. Let the body p.imer d.y tor at
least 10 minutes.
NOTE:
a Do not apply glass primer to the body, and be
sponges.
a Nevertouch the primedsurfaceswith vour hands.
l//////1,:appv body p'imo' hero.
i"lT
;o:d:';",
16 mm 10.63inl
9. Removethe rear window.

O. With a sponge, apply a light coat of glass primer
around the edge of the rear window as shown, then
lightly wipe it otf with gauze or cheesecloth.
6 mm 10.23inl
NOTE:
a Do not apply body primerto the rear window, and
up.
a Nevertouch the primedsurfacswith your hands.
lf you do, the adhesive may not bond to the rear
window prope.ly, causing a leak after the rear
window is installed.
a Keep water. dust, and abrasive materials awav
f,om the D.imedsurtace.
72/:
Appl,t gltst onmrr sctc.
16 mm 10.63inl
12. Thoroughlymix the adhesiveand hardenertogether

on a glassor metal plate with a putty knife. Fo ow
the instructionsthat came with the adhesive.
NOTE: Cleanthe plate with a spongeand alcohol
before mixing.
All around.
10 mm lO.4 inl
13. Beforefillinga cartridge,cut the end of the nozzle,

as shown.
/.s
s
10 mm (0.39 in)
7 mm (0.27 inl
{cont'd)
20-71
vnx.su
RearWndow
14. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the cartridge
the edge oI the rear window, as shown.
NOTE: Apply the adhesivewithin 30 minutesafter
applyingthe glass Primer.
16. Scrapeor wipe the excessadhesiveoff with a putty knife or towel.

NOTE: To removeadhesivefrom a paintedsurtace
or the rear window, use a soft shop towel dampened
with alcohol.
17. Installthe lower cover.
12 mm (O.47inl
[/
, aoxesrve
t-l
ADHESIVE
^X-"--"-,
s-_T--r-
8 mm (o,31inl
REAR WINDOW
I MOLOING
cr-rss
1 5 . Use suctioncups to hold the rearwindow over the

opening,align it with the alignmentmarks made in
step8, andset it down on the adhesiveLightlypush
on the rear window until its edgesare fully seated
on the adhesiveall the way around.
'18. Let the adhesivedry for at least one hour, then spray
water over the rear window and check Jor leaks'
Mark leakingareas,let the rearwindow dry, then seal
with sealant.
NOTE: Let the car stand Jo. at leastfour hoursafter rear window installation,lf the car has to be used
within the tirst tour hours,it must be drivenslowly'
NOTE: Do not close or open the doors until the

adhesiveis drv.
SUCTION
ALIGNMENT
19. Raisethe headlinerback up into position,then install:

a Rear pillart.im Panel
a Rear shelf
a Rearseat-backside bolstels
20-72
vnx.su
OuarterGlass
Replacement
a War glovs to romove and installthe quartol glass.
a Use seat covers to avoid damaging any surfaces.
3.
NOTE: Replacethe quarter glass with new one when

removingit.
1.
2.
Pullthe piano wire back and forth in a sawing motion, and carefullycut throughthe adhesivearound
the entire quarterglass.
CAUTION: Hold th tiano wire as closoto the qurter glass as possibleto prevent damage to th6 body
and quarter pillar trim panol.
To removethe quarterglass,first removethe quarter

trim (seepage 20 93).
NOTE: Wheneachcornercut is difficult.usea knife

to cut through the adhesivefrom insidethe car.
Apply protectivetape to the edgeof the quarterpillar trim panel and body as shown.
Usingan awl. make a hole through the adhesivefrom
insidethe car. Pushthe pianowire throughtthe hole,
and wrap each end around a piece of wood.
OUARTERPILI.AR
TRIM PANEL
AOHESIVE
PROTECTIVE
TAPE
OUARTERGLASS
PIAI{O wlRE
PROTECTIVE
TAPE
OUARTERGLASS
CLIP
PROTECTIVE
TAPE
ADHESIVE
TAPE
ADHESIVE
OUARTERPILLAR
TRIM PANEL
ADHESIVE
PROTECTIVE
TAPE
4.
Carefullyremovethe quarterglass.
20-73
vnx.su
OuarterGlass
Replacement(cont'd)
Scrapethe old adhesivesmooth with a knife. to a
thicknessof about 2 mm (O.08in) on the bonding
surface around the entire quaner glass opening
flange.
8.
NOTE:
o Be careJulnot to touch the quarter glass where
a Do not peel the separatoroff the double-taced
adhesivetaPes.
NOTE:
a Do not scrape down to the painted surface of the
body: damagedpaint will interferewith proper
bonding.
a Mask oft surroundingsurfacesbefore applying
orimer.
b-
Cleanthe body bondingsurfacewith a spongedampened in alcohol.
adhesivetapesto the moldApply the double-faced

ing, as shown,
srDE
sPAcERI
\ nrolonci
NOTE: Atter cleaning,keep oil, greaseand water

from getting on the surtace.
\ /
IfR-.s
-l
3 mm (0.12 inl
ADHESIVE
TAPE8
MOLDING
_c$$l
Cleanthe new quarter glass surface with alcohol
where adhesiveis to be aDDlied.
NOTE: Make surethe bondingsurfaceis kept tree
CAUTION: Avoid setting th quartsr glass on its
edgas; small chips may later dvelop into cracks.
195 mm
(?.68 in)
150 mm
15.9 inl
CLIP
4 . 5 m m 1 O . 1 8i n l
ADHESIVE
Clean the shadowed area all

the way around.
CLIP
MOLDING
vnx.su
MOLDING
9.
With a sponge.applya light coat of glassprimerto

the insideface ot the quarterglass,as shown, then
lightly wipe it ott with gauze or cheesecloth.
1O. Installthe quartertrim.

OUARTER
NOTE:
a Do not apply body primerto the quaner glass,and
up.
a Nevertouch the primedsurlaceswith your hands.
lf you do, the adhesivemay not bond to the quaner glassproperly,causinga leakafter the quarter
glass is installed.
a Keepwater, dust. and abrasivematerialsawav
from the primedsurface.
V///
, AooV glass primer h6re1 1. With a sponge.apply a light coat of body primerto
the originaladhesiveremainingaroundthe quarte.
glass openingflange.
Let the body primer dry lor at least 1O minutes.
NOTE:
a Do not apply glass primerto the body, and be
careful no1 to mix up glass and body prime.
sponges.
a Nevertouchthe primedsurfaceswith your hands.
'////7, , aepty body p.imer here.
5 m m lO.2 inl
ffi
16 mm
6mm
10.24in) {0.63 in}
10 mm lO.4 inl
'16
mm
(0.63 inl
OUARTER
TRIM
10 mm lO,4 inl
5 mrr| 10.2inl
(cont'd )
20-75
vnx.su
OuarterGlass
(cont'd)
Replacement
12. Thoroughlymix the adhesiveand hardenertogether
on a glass or metal plate with a putty knife.
t5.
to.
NOTE:
a Cleanthe platewith a spongeand alcoholbefore
mixing.
a Follow the instructions that came with the
adhesive.
13. Beforetillinga cartridge,cut the end of the nozzle,
as shown.
Cut nozzleend,
as shown.
Installthe fastenersto the body as shown.

Use suctioncups to hold the quarterglassover the
opening,alignit with the clip settingpoints,and set
it down on the adhesive.Lightlypuch on the quarter glassuntil its edgesare tully seatedon the adhesive all the way around.
NOTE: Do not open or close the doors until the
adhesiveis dry.
10 mm 10.39in)
7 mm {0.27 inl
14. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the cartrige
the edge of the quarter glass as shown.
NOTE:
a After applyingthe adhesive,peel the separator
off the double-facedadhesivetapes.
a Apply the adhesivewithin 30 minutesafter applying the glass Primer.
t1;T,,1\
:ADt'Es'vE
17. Scrapeor wipe the excessadhesiveoff with a putty knile or towel,
I mm 10.3in)
8 mm lO.3 in)
AOHESIVETAPES 8
-1r
*-{6
2mm{0.08
IL_-_
J,
NOTE: Usea soft shoptowel dampenedwith alcohol to removeadhesivefrom a paintedsurfaceor the

quarler glass.
18. Letthe adhesivedry for at leastone hour,then spray
water over the quarter glass and check for leaks'
Markleakingareasand let the quarterglassdry, then
seal with sealant.
NOTE: Let the car stand for at least tour hoursatlf the car hasto be used
ter quarterglassinstallation.
within the f irst four hours,it must be drivenslowly.
SIOE SPACER
'19.
ADHESIVE
TAPEA
'12 mm (0.47 inl
Reinstallall remaningremovedparts.
2 mm lO.O8in)
20-76
vnx.su
Moonroof
Index
Hatchback
CABLE ASSEMBLY
Replacement,page 2O-81
SUNSHADE
page 20-79
Replacement,
MOTOR
page 20-80
Replacement,
GLASS BRACKET
page 20-81
Replacement,
SUI{SHADE
RAIL
FRONT DRAII{
CHANNEL
a'# /
DRAIN CHANNL
-4
FRAMESEAL
GUIDERAIL
page 20 8l
Replacement,
FRONTRAIL
HOLDER
,**4
REAR ORAINTUBE
\a
FRAME
20-77
vnx.su
Moonroof
Troubleshooting
Probable Cause
Symptom
Water leaks
1 Cloggeddrain tube.
Gap between glass weatherstripand roof panel.
Defectiveor improperlyinstalledglass weatherstrip.
4 GaDbetween drain seal and roof panel.
Wind noise
1. Excessiveclearancebetween glass weatherstripand roof panel.
Motor noise
1. Loosemotor.
2. Worn gear or bearing.
3. Cableassemblydeformed.
Glassdoes not move, but motor

turns
1. Clutch out of adjustment.

2. Foreignmatter stuck between guide rail and slider,
3. Inner cable loose.
4. Cableassemblynot attachedproperly.
Glassdoes not move and motor

does not turn (glasscan be moved
with moonroofwrench)
1 . B l o w nf u s e .
2. Faultyswitch.
3. Battery run down.
4. Defectivemotor.
5. Faulty realy.
GlassHeightAdiustment
The roof panelshouldbe even with the glassweathers t r i p ,t o w i t h i n l 8 t O . 5 m m ( O . O 7I 0 . O 2i n ) a l l t h e
way around. It not, slidethe sunshadeback, and:
Y : Bolt locstions, 6
1 . Tilt-up the glass.
2 . Loosenthe bolts and adjustthe glass.

Repeaton oppositeside it necessary.
1 . 8 1 0 . 5 m m l O . O 7i 0,O2 in)
ROOFPANEL
GLASS ERACKET
GLASS BRACKET
GLASS WEATI{ERSTRIP
4.
Side-to-side fit ot glass weatherstrip can be adjusted by loosening the frame mounting bolts and moving the frame right or lelt and forward or backward
by hand (see page 2O-8O).
f )
20-78
vnx.su
RearEdgeClosingAdjustment
Open the glass about a foot, then close it to check where
rear edge beginsto rise. lf it rises too soon and seats too
tightly againstthe roof panel,or too late and does not
seat tightly enough,adjust it.
1.
Removethe headliner(seepsge 20-98).
2.
Removethe glass.
3.
Removethe motor {see page 2O-8O).
4.
Align the tilt-up positionof the lifter on each side.
Glass and Sunshade Redacernent

1.
Open the sunshade.
2.
Tilt-upthe glass.
3.
Removethe bolts, then removethe glassfrom rhe

glass bracket.
V : 8oh locations,6
GLASSBRACKET
Checkthat the alignmentleft and right. then install

the motor.
4.
Removethe screw and lift the sunshaderailon each

side.
5.
Silde the sunshade forwa.d, then remove the

sunshade.
V : Scrawlocations,2
Installthe glass,then check for water leaks.
II
NOTE: Do not use high pressurewate..

lnstallthe headliner.
SUNSI{ADE
l-t
Installationis the reverseof the removalprocedure.
Check for water leaks.

NOTE: Do not use high pressurewater.
20-79
vnx.su
Moonroof
Motor, DrainTube and FrameReplacement
CAUTION: B caretul not to damag lhe seats, dashboard and other interior trim.
4.
Removethe bolts,then removethe trame from the

car.
1. Removethe glass (see page 2O-79)and headliner

(see page 20-98).
2.
Disconnectthe drain tubes.
NOTE: You may requireassistancewhen removing

the frame.
Disconnectthe motor connector,and removethe

clips securingthe ceilinglight wire harness.
: Eolt locations, I
< : CliD locations. 2
6 x 1.0 mm
9.8 N.m (1.0kgt m,
7.2 rbr.ttl
)
CEILIINGLIGHT
TUBECI-IP
FRAME
FRAME
3.
DRAIN TUBE
To install,slidethe drain
tube over the ftame nozzle
at least 10 mm {O.4 in}.
Removethe bolts and nuts,then removethe motor,

if necessarv,
NOTE: Make sureboth slidersare parallelwhen in-
6.
Pull the drain tubes out the front and rear pillars.
NOTE; Betorepullingout the draintube, tie a string
to the end of it so it can be reinstalled.
stalling the motor.

: 8olt, nut locationg
A
: Bolt, 2
B : N u t ,3
Ld
6x1.Omm
9.8 N.m
I
I
tt.o kgf.-,
,.?-", _,/I
FRONT
7 . Installationis the reverseol the removalprocedure.

NOTE:
a Cleanthe surtaceof the frame.
a Check the trame seal.
a Check for water leaks.
20-80
vnx.su
GlassBracket/Slider,
Lifter, GuideRailsand CableAssemblyReplacement
1 . Removethe frame from the car {see page 2O-8O).
5.
Removethe motor (seepage 2O-8O).
Removethe front rail holderon each side.
V : Nut, scrow locations

AV : f{ut, 2
Removethe drain channel.
BV: Screw,
NOTE: Take care not to damage,twist or lift the

seat.
SUNSHADE
V : Screwlocations,2
DRAIN
CHAI{NEL
b.
Removethe anchorspring on each side.
7.
Removethe nuts and screws, then lift and remove

both guiderailsand cableassemblyfrom the trame.
Removethe sunshadeand both sunshaderails.
V : Nut, rcrow locations

AV : Nut. 2
4.
BV : Sciow, 4
Removethe front drain channel on each side.
V : Clip locations,2
NOTE: To instalt,Iill the
gtoove rn each grommet with sealant,
GUIDERAIL
GUIDE RAIL
20-81
vnx.su
Moonroof
GlassBracket/SliderLifter GuideRailsand CableAssemblyReplacement
(cont'dl
8.
Slidethe guide rail fofward, then removeit.
1 0 .Slide the anchor rod forward, then remove it from

the guide rail.
NOTE: Take care not to bend the inner cable.
CABLE ASSEMBLY
STOPPER
To install. insort the anchor

rod by turning the stopper 9Oo.
GUIDERAIL
ROD
AIT|CHOB
Separatethe glassbracket,lifter, slidestopperlink

and slider,
11. lnstallationis the reverseol the removalprocedure.

INNERCABLE
GLASS
NOTE:
a Dsmsgedpansshouldbe replaced.
. Applygreaseto the slidingportion.
SLIOER
NOTE: To instll,apply multipurposegreaseto
the lifter and slide stooDer link.
20-82
vnx.su
Opening Drag Check

(Motor Removedl
Closing Force Check

(Motor Installedl
Betoreinstallingthe motor, measurethe etfort required

to open the glass using a spring scale as shown.
CAUTION: When using a spring scale, protoct the
leading edg6 ot th glass with a shop towel.
lf load is over 40 N (4 kgt, 9lbf). check side clearance
and glass height adjustment(see page 2O-78).
1. After installingall removedparts,havea hetperhotd

the switch to close the glass while you measure
torce requiredto stop it. Attach a spring scale as
shown. Readthe force as soon as the glasssiops
moving, then immediatelyreleasethe switch and
spnng scare.
CAUTION: When using a spring scale, protoct tho
leading odge ol th glass with a shop towel.
200-290 N
(20- 30 kgf, rt4- 66 lbf)
GLASS
lf the force is not within specification,installa new

lock washer,adjustthe tensionby turningthe motor clutch adjustingnut, and bend the lock washer
againstthe motor clutch adjustingnut.
LOCK
WASHER
Replace.
'r
coul{TERcLocKwrsE
To decrease
20-83
vnx.su
Moonroof
lndex
Ssdan
GLASS BRACKET
----/_--4
DRAIN CHANNEL
SUNSHAOE
Replacement,page
SLIDE STOPPRLINK
SUNSHADERAIL
FRONTORAIN
GUIDERAIL
REARRAIL
HOLDER
MOTOR
page20-87
Replacement,
SEAL
REAR DRAIN
('
V
\
FROi{TDRAINTUBE
FRAME
Repfacement,page 20-87
20-84
vnx.su
Symptom
Probable Cause
Water leaks
1. Cloggeddrain tube.
2. Gap between glass weatherstripand roof panel.
3. Defectiveor improperlyinstalledglass weatherstrip.
4. Gap between drain seal and roof panel.
Wind noise
1. Excessiveclearancebetween glass weatherstripand root panel.
Motor noise
1. Loosemotor.
2, Worn gear or bearing,
3. Cableassemblydeformed.
Glassdoes not move, but motor

turns
1.
2.
3.
4.
Glassdoes not move and motor

does not turn {glasscan be moved
with moonroofwrench)
1 . B l o w nf u s e .
2. Faulty switch.
3, Battery run down.
4. Defectivemotor.
5. Faulty relay.
Clutch out of adjustment.

Foreignmatter stuck between guide rail and slider.
lnner cable loose.
Cableassemblynot attachedproperly.
Glass Height Adjustment

The roof panelshouldbe even with the glassweathers t r i p t, o w i t h i n1 . 8 t O . 5 m m { O . O 71 O . O 2i n }a l l t h ew a y
around. lf not, slidethe sunshadeback, and:
V : Eolt localions, 6
I
6x LOmm
"),
9 . 8 N . m 1 1 . Ok g f m
7.2 tbf.ttt
1 . Tilt-upthe glass.
2 . Loosenthe bolts and adjust the glass.

GLASS
Repeaton oppositeside if necessary.
4'/
10.5 mm lO.O7 1O.02 inl
ROOF PANEL
GLASS BRACKET
GLASS ERACKET
GLASSWEATHERSTRIP
4.
Side-to-side
fit of glassweatherstripcan be adjusted by looseningthe frame mountingbolts and moving the frame right or lett and forward or backward
by hand (see page 20-87).
vnx.su
12
Forward
Moonroof
Rear Edge Closing Adjustment
Open the glassabout a foot, then close it to check where
rear edge beginsto rise. It it risestoo soon and seats too
tightly againstthe roof panel,or too late and does not
seat tightly enough,adjust it.
Glass and SunshadeReplacement

1.
Open the sunshade.
2.
Tilt-up the glass.
3,
Removethe bolts, then removethe glassfrom the

glass bracket.
1. Removethe headliner(seepage 20-1OO).

2.
Removethe glass.
3.
Removethe motor (see page 20-87).
4.
Align the tilt-up positionof the lifter on each side.
Using the moonroof
BOLTS
6 x 1 . Om m
9.8 N'm lt O kgf m,
7.2 tbt.ftl
GLASS BRACKET
4.
Removethe screws and lift the sunshaderails.
5.
Silde the sunshade forward. then remove the

sunsnaoe.
5 . Checkthat the alignmentlett and right, then install

the motor.
o.
SUlTSHADE
RAIL
Installthe glass.then check for water leaks.

7.
Installthe headliner.
Installationis the.everseot the removalprocedure.

Check for water leaks.
20-86
vnx.su
Motor, DrainTube and FrameReplacement

CAUTION: Be carotul not to damago th seats, dashboard and other int6rior trim,
1. Removethe glass (see page 2O-86)and headliner
(see page 20-10O).
Disconnectthe motor connector,and removethe
clips securingthe ceilinglight wire harness.
SCREW
NOTE: To removethe motor, removethe screws.

Disconnectthe drain tubes.
4.
\/
Loosenthe front bolts.

Removethe bolts,then removethe trame from the
car.
NOTE:
a You may requireassistancewhen removingthe
trame.
a Take care not to bend the sunshaderails.
TUBE
CLIP
CONNECTOR
Make sure the sliders are

parallel when installing the
motor,
FRAME
BOLT
6 x 1 . 0m m
9.8 N.m (1.Olg{.rn.
7.2 tbt.ttl
DRAINTUBE
To install,sladethe drain tube ov6r
the frame nozzleat least 10 mm lO.4 in).
Loosen the tront bohs

Fo?w!?d
SUNSHADE
RAILS
tt.
Pullthe draintubes out of the tront and rearoillars.

NOTE: Beforepullingout the draintube, tie a string
to the end of it so it can be reinstalled.
Installationis the reverseof the removalgrocedure.

FRONT
DRAIN VALVES
NOTE:
a Installthe tube clips with the ends facing the side to ease installation of the headliner.
a Cleanthe surtaceof the frame.
a Check the frame seal.
a Check for water leaks.
a Make sure the sunshademoves smoothlv.
20-87
vnx.su
Moonroof
Lifter,GuideRailsand CableAssemblyReplacement
GlassBracket/Slider,
1 . Removethe frame (seepage 20-87).

2.
3.
Removethe screws,then removethe sunshaderail

by slidingit backward.
Removethe drain channel.

SUNSHADERAIL
NOTE: Take care not to damage,twist or litt the

seal.
SCREW
4.
Removethe motor (seepage 20-87).
5.
Removethe front drain channel.
6.
Removethe nut, then removethe front rail holder.
7.
Removethe screws @ attschingthe guide rail. then litt the guide rail.
8.
Removethe nut. then removethe rear rail holder.
ITUT
6xl.Omm
9.8 t{.m {1.0 kgt.m,
7.2 tbf.ttl
NOTE: Removethe anchorspring.

AI{CHOR
REAR RAIL
HOLDER
SUB-SEAL
NUT
6 x 'l.O mm
9.8 N.m {1.O kgf.m,
7 .2 tbt-lrl
NOTE: Installthe rear rail holder, then glue

the sub-seal to the trame.
9,
Slidethe glass bracket/slider,liJterbackward,then removeit.
20-88
vnx.su
10. Separatethe glass bracket, lifter, slide stopper lank

and slider.
INNERCABLE
LIFTER
1 2 . Slidethe guide rail backward, then removeth gude

rail from the inner cable.
NOTE: To install.apply the caulkingro gurde rarl
mount faces of the frame.
GLASS
BRACKET
GUIDE RAIL
SLIDER
NOTE:To install,applymuttjpurpose
grcase
to th liftsr and slidestopperlink.
Applycaulking
before
instaing the guiderait.
1 3 .Removethe screws,then removethe cableassem1 1. Slidethe anchorrod forward, then removeit from
the guide rail.
bly from the frame.

NOTE: Take care not to bend the cable pipes.
FRAME
STOPPER
To install, inson tho anchor

rod by turning tho stopper 9Oo
NOTE:lo install,fill the groovein

eachgrommetwith sealant.
1 4 . Installationis the reverseof the .emovalprocedure.
AI{CHOR ROD
NOTE:
a Damagedpsrts should be replaced.
a Apply greaseto the slidingportion.
20-89
vnx.su
Moonroof
Closing Force Check
lMotor Installed)
OpeningDragCheck
(Motor Removed)
Beforeinstallingthe motor. measurethe effort required
to open the glass using a springscale as shown
CAUTION: Whon using a spring scalo. protoct the
lading odge ol the glass with a shop towI.
1. After installingall removedparts,havea helperhold

the switch to close the glass while you measure
force requiredto stop it. Attach a spring scale as
shown. Readthe torce as soon as the glass stops
moving, then immediatelyreleasethe switch and
spring scale.
lf load is over 40 N (4 kgl, 9lbt), check side clearance

and glass height adiustment(see page 20-85)'
CAUTION: When using a sp ng scala. protect th

leading odge ol the glass with a shop towel'
ClosingForce:200-290 N
120-30 ksf. 44-66
lbf)
GLASS
lf the lorce is not within specification,installa new

lock washer.adjustthe tensionby turnangthe motor clutch adjustingnut, and bend the lock washe.
againstthe motor clutch adjustingnut.
clocKwlsE/i 1
Toincrease
\ l,
torce,
20-90
L.
vnx.su
coutrenctocKwlsE
Io decrease
force
InteriorTrim
Replacement
a Wal glovesto removeand installth trim and panols.
a When prying with a flat tip screwd.ivor. wrap it with
protective tap to prevent damaga.
NOTE: Take care not to bend or scratchthe trim and
Danels.
Hatchback
Rear trim panet/Sidetrim panel/Ouarterpillar trim p-l
16moval:
1. Open the hatch.
2.
Kick panel/Front pillar trim removal:
Removethe .ear shelt.

REARSHELF
l.
Removethe kick Danel.

< : Clip locations
A< | Cllp,1
B< : Ctip,1
CV : C[p, 1
U ry-ry
J t l , M l *
NOTE: Removethe driver'skick panelwhile pulling

the hood releasehandle.
REARSHELF
KICK PANEL
Removethe rear seat (seepage 20-'l08).

4.
Removethe trunk mat and sparetire lid.
Pullthe door trim back,then removethe front oillar

rflm.
< : Clip locations, 4
SPARETIRELID
FRONTPILLAR
TRUNKMAT

NOTE: lf necessary,.eplaceany damagedclips.
vnx.su
ao..t dr
20-91
lnteriorTrim
(cont'd)
Replacement
5.
7.
Removethe rear trim panel.
Removethe side trim Panel.
> : Clip locations
v : Clip locations,7
1 ) P u s ht h e i n n e rc l i p . - 2 ) D e t a c ht h e c l i p b y
pulling it.
NOTE:Do not push
W-tNj
w) !)
it in too lar.
INNERCLIP
@ M)
BD : Clip, 4
A> : Clip. 4
DV : Clip, 1
CD : Clip, 3
,Ull
,,zqzz4 |
> : Boll, screw locations
A> : Bolt,2
B > : S c i o w ,2
@-,
PANEL
Removethe speakerlid and left accesspanelfrom

the side trim panel.
> : Clip locaiions
8V : CliP,2
A> : Clip, 2
,e-,ff)
ffi
i,Gffi'^*^
,Kl^\
fo
NOTE: Disconnectthe cargo area light connector

trom the left side trim Panel.
CARGO AREA
LIG}IT
SPEAKER
LID
\
LEFT
accEss
PANEL
vnx.su
8. Removethe upper anchorbolts from the front and

rear seat belts (seepages 20-1 15, 1 19).
11. Removethe quarterpillartrim panel.

> : Clip locations
9. Removethe door trim.

A>: Clip7
,
NOTE: When installingthe door trim, align it with
the door openingflange notch.
Btr: Clip3
.
S;+
)
NOTE: Removethe front seat belt lrom the belt

9UrOe.
BELT
1O. Removethe quartertiim and coat hangerfleft sidel.
: Screw locstions, 'l
'12.

NOTE:
a lf necessary,.eplaceany damagedclips.
a When installingthe side trim panel, make sure
there are no twists or kinks in the front and rear
seat belts.
a Wheninstallingthe reartrim panel,installtheclip
as follows.
Pry lhe lid.
- 1 I Pull the inner clip up as shown.
t
Q-.-INNER
cLrP
(./ilk
\c4z )
\/
tl
\#
-2) Installthe clip in the rear trim panel.then

push the inner clip until it's flush.
INNERCLIP
20-93
vnx.su
lnteriorTrim
Replacementlcont'dl
Removethe front and rear door trim
3.
Sodan
NOTE: When installingthe ffont and rear door trim,

align them with the door openingflange notch.
Center pillar lower trim/Center pillal trim removal:

Removethe belt hole cap, then slip the front seat
belt through the slit in the belt hole cap.
1.
<: Sc.ew location,1
e)
FRONT SEAT BELT
BELTHOLE
CAP
CENTERPILLAR
LOWERTRIM
2.
Removethe upperand lower anchorbolts trom the

tront seat belt, then removethe center pilla.lower
tirm.
NOTE:
a When removingthe anchorbolts, use a 17 mm
socket or box-endwrench.
a On reassembly,replacethe upperanchorbolt (* )
and use liquidthread lock.
4.
Removethe center pillartrim.
< : Cllp locations.2
A : Clip localions.2
nfa147zzn
trui
L_,)
*UPPER
EOLT
ANCHOR
7/t6-20 UNF
32 N m (3.3 kgf'm, 24 lbl ft)
ANCHOR COVER
FRONT
SEAT
EELT
CENTERPILLAR
TRIM
CENTERPILLAR
LOWERTRIM
lnstallationis the reverseoJthe removalprocedure.
ANCHOR CAP
LOWERANCHOR
BOLY
7/16-20 UNF
32 N.m 13.3 kgt.m,
24 lbt.ltl
20-94
vnx.su
NOTE:
a lf necessary,replaceany damagedclips.
a Beloreattachingthe centerpillarlower trim and
belt hole cap. make sure there are no twists or
kinks in the front seat belt.
Roar pillar tlim panel/Rearshell trim panel/Rsar she

removal:
1.
2.
4.
Bemove the rear shelf trim panel.
V : Clip locrtions, 2
Remove both seat-back side bolsters {see page

2 0 - 11 1 ) .
âffi-_--.]-"t't
Removethe upperportionof the reardoor sill molding, then pull the reardoor trim awav on each side.
Y,r\-J/
\t -
'/
-
> : Clip locations, 2
REARsHEr-F
TRIMPANEL
REAR PILLARTRIM PANEL
5.
3.
Removeboth rear pillartrim panels.
Slip the rearseat belr throughthe slit in the rearshelf.
REARSHELF
> i Cliplocalionr,12
W.,
REAR PILLAR
TRIM PANEL
NOTE: When installing,make sure

the rear window defoggerwire
harnessis .outed properly.
6.
R e m o v et h e s e a tl o c kc o v e r{ s e ep a g e2 0 1 1 1 ) a n d
high mount brake lighr (seesection 23).
(cont'd)
20-95
vnx.su
lnteriorTrim
(cont'd)
Replacement
7.
Removethe rear shelf.
NOTE:
a When installingthe rear shelf, make sure there
are no twists or kinks in the rear seat belt'
V : Clip locations
BV: Cllp,2
AV : Clip, 4
N i
==:
w "ff=
t
;
_)
8.
lnstallation is lhe reverseof the removal plocedure.
=)
lf necessary,removethe belt hole cap and speaker

cover from the rear shelf,
: Screwlocatlons,3
AELTHOLE
CAP
REARSHELF
20-96
vnx.su
Trunk Trim
Replacement
NOTE: Take care not to bend or scratchthe panels.
'1.
2.
4.
Fold the rear seat-backforwaro.
Removethe clips,then removethe trunk side panel

on each side.
NOTE: A clips on the trunk side panel can be removed in the same way as those on the rea. trim
paner.
Lift the trunk mat, then removethe sparetire lid.

TRUNK MAT
< : Cllp locationt

A{ : Cllp,6
8v : Cllp,4
FASTENERS
@q lF
--
3.
t"
Removethe clips,then removethe reartrim Danel.
V : Clip loc.tlorE
AV : Clip, 4
- I l Push the inner clip.
NOTE: Do not push it
in too Iar.
-2) Detach the clip by

pullingit.
II{NEB CLIP
ffi
5 . Installationis the reverseot the removalprocedure.
gV I Cllp, 2
- I I Loosen the inner clip.
II{NER
w
{*
,/
-21 Detach the clip by

pullingit.
(8r-ct-tp
- 1) Pull the inner clip up as shown.
hfr
)J"'J
eEdf,
..&G\
NOTE:
a When installingthe reartrim panel,installthe A
clip as follows.
t
4
Y_)
rd[h
H
tNt{ER
cLrP
-2) Installthe clip in rhe rear trim panel,rhen

push the inner clip until it,s flush.
INI{ER CLIP
20-97
vnx.su
Headliner
Replacement
CAUTION: Whon Fyhg with I flat tip sclewdrivsr, wrap
it whh protectivs tapo to prevent damaga.
NOTE:
a Take care not to bend and scratchthe headliner.
a Be caretulnot to damagethe dashboardand other interior lrim.
a Fold the front seat-backbackward.
3.
Removethe tront and rear ceilinglights, then disconnect the conneclors.

: Sc.ew, nut localions
Halchback
B : Nut, 2
: Scrcw, 2
&) ?)
CONNECTOR
1. Remove;
. Door trim (see page 20-93)
a Front Dillartirm {see page 20-91)
a Ouartertrim (see page 20-93)
a Coat hanger(see page 20-93)
a Rearviewmirror {seepage 20-52)
2.
Removethe sunvisorand holderfrom each side.

: Scrowlocation!,6
u)
LOCK WASHER
(Outside)
l
H
"^/
Aaqr+-
HOLDEB
SUNV|SOR
BRACKET
HOOK
ffi)
CONNECTOR
LENS
HOOK
NOTE:
a lf necessary,remove the sunvisor bracket as
shown.
a When installingthe sunvisorbracket,apply grease
and make sure it's installedproperly.
suNvlsoR
BRACKET
m)
H
,r--T-\
LENS
suNvrsoR
20-98
vnx.su
HOOKS
4.
Removethe grabhandle(frontpassenger.s)
and grab
hole caps (driver's),
: Scrowlocationsl2l
6.
Removethe upperanchorbolts from the front and

rear seat belts (seepages 2O-l j 5, I l9).
7.
Removethe upper ponion of the quaner pilla.trim

panel,then detach the headlinerclio on each side.
e)
A : Clip locotions,2
HEADLINER
HOOKS
_ t
8 . Removethe roof trim (moonrootmodel).

Open the hatch, then removethe rear root trim.
Removethe headliner.
ROOF TRIM
5.
socxET
Removethe socket plug (moonroofmodel).
FRAME
-@'
//Gr
HEADLII{ER
OUARTERPILLAR
TRIM PANEL
{ +=s
,
SOCKET
PLUG
(cont'dl
20-99
vnx.su
Headliner
{cont'd)
Replacement
9, Lower the headlineras shown.
NOTE: Take care not to bend and scratch the
headliner.
HEADLINER
Sodan
'1.
Remove:
a Center Dillarlower trim (seepage 20-94)
a Front and rear door trim lsee page 20-94)
a Front pillartrim (see page 2O-9 .
a Center pillartrim (seepage 20-94)
a Rear pillartrim panel (seepage 20 95)
a Rearview mirror (see Page 20-521
2 . Removethe sunvisorand holderfrom each side

: Screw locationS, 6
LEFT OUARTERPILLAR
TRIM PANEL
s,1
RIGHTOURTERPILLAR
TRIM PANEL
1O. Bemovethe headlinerthrough the hatch opening'
HOLDER
NOTE:
a When insertingthe headlinerthrough the hatch
opening,be carefulnot to fold or bend it. Also,
be carefulnot to scratchthe bodY.
a Checkthat both sidesof the headlineraresecurely attachedto the trim and Panels.
a When installingthe roof trim, install the Joint
toward the rear.
LOCKWASHER
loutsidel
$-.unu,"o"
BRACKET
/'
HEADLINER
1 1 .Installationis the reverseof the removalprocedure.
NOTE:
a lf necessary,remove the sunvisor bracket as
shown.
a Wheninstalling
the sunvisorbracket,applygrease
and make sure it's installedproperly.
, @
suNvrsoR
20-100
vnx.su
3.
Removethe tront and rear ceilinglights, then disconnect the connectors.
A : Screw,nut locations
A A : S c . 6 w 2,
4.
Remove the grab handles (tront and rear pas'

senger'sland grab hole caps (driver,s).
: Sc.sw locatioh!l2l
orlx
-A-i
B : N u r ,2
CONNECTOR
CEILING
.-L----- ----z
GRAB HOLE CAPS
CONNECTOR
REARCEILING
LIGHT
HOOKS
20-101
vnx.su
Headliner
{cont'd)
Replacement
5.
Removethe .ool trim (moonroofmodell.
6.
Detach the clips by slidingthe headlinerforward.
A : Clip locations,3
)
HEADLINER
door
Removethe headlinerthroughthe passenger's
opening.
HEADLINER
lnstallationis the reverseot the removalprocedure

NOTE:
a When insertingthe headlinerthrough the door
opening.be carefulnot to fold or bend it. Also,
be careful not to scratchthe body
a Check that both sidesot the headlinerare securely attachedto the trim and Panels.
a When installingthe roof trim, install the joint
toward the rear.
20-102
vnx.su
Seats
Front Seat Removal
NOTE: Take care not to scratch the seat covers and
bodY.
1.
3.
Remove the bolts.
V:Boh locatlong
Slidethe lront seat backward,then removeth6 bohs,
A V : Bolt, 1
> i Eolt locltlon..
I'
> : 8olt,
8 x '1.25mm
ii i.:iiil..i'xst.^.
I
16:t'ftt
-
/)
NOTE: When insralling,use--i

liquid thread lock.
Slide the front seat forward, then romove the seat

track end covers.
4.
Lift the front seat, then disconnectthe connector

(driver's).
CAUTlOltl: When prying wlth E flat tip scr.wddvor,

w.ap lt whh protactive tapo to prevont damago,
CONNECTOR
Carefullyremove the front seat through the door

opening.
vnx.su
20-103
Seats
Front Seat RePlacement
5,

body.
1.
2.
(see
Removethe front seat through the door opening
page 20-1O3).
> : Bolt location., 2
lnnrnt
v)*
Removethe screws and reclineknob, then remove

the reclinecover.
COVER
RECLINE
Foldthe seat-backcover and pad, then removethe

bolts.
I
|
l O x 1 . 2 5m m
i
47 N'm 14.8kgl ln, I
SEAT.gACK
COVER
PAO
"?"!."t_J
SCREW
6.
Removethe screws,then removethe centercover.
Removethe Pivot nut.
PIVOT WASHER
SEATBELT
BUCKLE
'1
{seepage2O'1 7)
PLAIN
WASHER
PIVOT NUT
8 r 1.25mm
22Nm12.2kgl'm,
16 lbf.ftl
CENTERCOVER
7 . Removethe seat-back.
scREws
Removethe hook and fastener,then lold the seatback cover back.
20-104
vnx.su
NOTE: Take care not to bend the hinge bracket.
sEAr-BAcK
8.
Separatethe seat cushionand seat tracks.
RECLINE
AOJUSTER
NOTE:
a B e f o r e s e p a r a t i n g ,s l i d e t h e s e a t c u s h i o n
backward.
a Take care not to bend the joint rod.
< : Bolt locations, 4
9. Separatethe seat track and reclineadiuste..

: Bolt, nut locations
A
: Bolt, I
BY : Nut,2
j @i+ilJ
A;iil;iiry-,'_o()_
_/
_].'*",
RECLINE
ADJUSTER
JOINTBOD
Disconnect
the rearseataccesscable(hatchback
passenger'sl.
REARSEAT
ACCESSCABLE
1 0 . Installationis the reverseof the removalprocedure.

NOTE:
a To preventwrinkleswhen installinga seat-back
cover,make sure the materialis stretchedeven,
ly over the pad beforesecuringall the hooks.
a Apply greaseto the moving surtaces.
20-105
vnx.su
Seats
Front Seat CoverRePlacement
CAUTION: Wear gloves to removo and install the 36at
covrs.
4.
\\
ilff-]s)
NOTE: Take care not to tear the seamsor damagethe

seat covers.
Soat-back covor lomoval:
1. Slidethe Jrontseat forwa.d and told the seat-back
forward.
2.
Removethe lumbarsupport knob.
fH".,
Removethe hooks and fasteners.then fold the seatback cover back.

FASTE]IIER
FASTENER
5.
Removethe seat-backcover by releasingthe inside

chps.
Cllp removrl:
Removethe headrestand headrestguide.

Scrw location,
,e,
c J /
6.
HEAOREST
SEAT.BACK
20-106
-
vnx.su
Pull back the edge of the seat-backcover all the way

around,then releasethe clips.
Seat cushion romoval:

1. Removethe seat cushionfrom the seat tracks (see
p a g e2 0 - 1 0 5 ) .
2.
Removeall clips from underthe seat cushion,then

loosenthe seat cushioncover
Cllp romoval:
Installationis the reverseof the removalptocadtr!.

NOTE:
a To preventwrinkleswhen installinga seatcover,
make sure the materialis stretchedevenlyover
the pad before securingall the clips.
a Replacethe.eleased clips with new ones.
CLIP
UPHOLSTERYRING PLIERS
NEW CLIP
PAD
WIRE {Pad sido}
SEAT CUSHIONCOVER
2
Pullback the edgeof the seat cushioncover all the

way arounC,then releasethe clips.
SEAT CUSHION
COVER
20-107
vnx.su
Seats
RearSeat Replacement
3.
Hatchback
body.
Removethe cliD pin on each side.

Slidethe seat-backsoutward, then removethe seatbacks from the pivot bracket.
1. Fold the seat-backs{orward.
CLIPPIN
(seepage 20-1Og)
SEAT.BACK
SEAT.BACKS
2.
Remove the clips, then fold the trunk mat.
V: Clip locations,14
v /
J
TRUNKMAT
SEAT-BACK
20-108
vnx.su
PIVOTBRACKET
4.
Removethe bolt, then removethe seat cushion.

: Bolt locations,t
LATCH COLIAR
l--): Xoot locations,2
6 r 1.0 mm
9.8Nm
SEAT-BACK
COVER
SEAT CUSHION
NOTE: When removingthe striker,removethe side

t.im panel (see page 20-91).
> : Bolt locations,2
.a\
tDt@
<Jt
STRIKER
l
I
6x1.0mm
i
9 , 8 N . ml 1 . Ok g l . m , l
1.2lbl..ttl
._
/l
CUSHION
5.
lf necessary,removethe seat latch lrom the seatback and removethe striker.

CAUTION: Wear gloves to remov and install the
soat latch and latch collar.
8 ) : S c r e w ,1
l
l
'
.,,W
Gp" II
9 . 8N . m1 1 . 0k s fm . I
7 2 tP!ft!---/'
./
REARSEATEELT
LATCH COLLAR
.otc" rtroa
Installationis the revelseof the removalprocedure.

NOTE:
a Make sure the seat,backslock securely.
a lf necessary,adjust the strikers.
a Betoreattachingthe seat-backsand seat cushion,
makesurethere are no twists or kinks in the rear
seat belts.
a When installingthe seat cushion,stipthe seat belt
bucklesthrough the slits in the seat cushion.
> : Bolt, sc.w locrtions

A > : B o l t ,2
6.
El
LATCH COVER
SEAT LATCH
t'
T-8ACK
( c o n t ' d)
20-109
vnx.su
Seats
(cont'd)
3.
Sedan
Detach the hook, then removethe trunk mat.
NOTE: Take care not to scratch the seal covers and

booy.
1.
TRUNK
MAT
a-^
Nry
Y
Fold the seat-backforward.
SEAT.BACK
I { \ t \
HOOK
TRUNK
MAT
SEAT-8ACK
2.
4.
Removethe clips.
Removethe bolts. then removethe seat-back.
V : Eolt locations,4
V : Clip locations,I
l
I
l
I E gel?"Til.*,,",
iI
7.2 tbt'trl
/-.;-\
----+tl
---M\r/ / I
,/
"
-----r"
TRUNKMAT
REARSEATLAICH/
LOCKCYLINDER
{seepage2O-'l11l
REARSEAT
PIVOTBRACKET
(seepage2O-111)
REARSEAT
PIVOT BRACKET
SEAT-BACK
SEAT.BACK
20-110
vnx.su
5.
Removethe bolt, then .emove the seat cushion.
Y: Bolt location. 1
-r
7.
lf necessary,removethe rearseat latch, lock c!ftiab

and rear seat pivot bracket.
i Hool loc.lion3. 2
Roar soat latch/Lock cylinder rmoval:

6r1.0mm i
9.8N.m
I
Pry the rear shelj up after removing the rear shelt

trim panel (seepage 2O-95)and seat lock cover.
NOTE: Take care not to bend the lock rod.
SEAT CUSHION
V i Bolt. scrow locations
AV i Boll, 2
9:
9.8 l;o--'
tt.m
EI
v_
i
tgf .m,
lr.o kgf.m,
l1.O
I
7.2 tbf.ft!____//
BV : Sc?ow, 2
4x0.7mm
4 N.rrt
{O.4 kgf'm,
3tbt.ttt
I
)
SEATLOCK
COVER
SEATLOCK
covER\-_L/-R\
w
-"1/ -
LOCK
CYLINDER
Pry here.
LOCKROD
Removethe bolts, then removethe seat-backside
bolstersby lifting them upward.
: Bolt locationr, 2
6 r 1 . om m
9.8 N.m
( 1 . 0k g l ' m ,
7.2 tbt.fti
REARSEAT
LATCH
r'): Hook locetions, 2
I
i
I
R6ar seat pivot brackol removal:

NOTE: When installingthe pivot bolt, applygrease
to it.
TOOTHED
BUSHTNGLOCKWASHER
REARSEAT
PIVOT BRAC(ET
PIVOT BOLT
8 x 1.25mm
22 N.m (2.2 kgf m,
16 tbf.ftt
WASHER
20-111
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Seats
(cont'd)
8.
lnstallationis the reverseot the removalprocedure

NOTE:
a Make sure the seat-backlocks securely.
a It necessary,adiust the rear seal latch and
seat-back.
a BeJoresttaching the seat-back,side bolstersand
seat cushion,make sure there are no twlsts or
kinks in the rear seat belts and center belt
a When installingthe seat cushion,slip the seat belt
bucklesthrough the slits in the seat cushion.
RearSeat CoverRePlacement
CAUTION: Wear glovs to lmovo and install tho seat
covgls.
NOTE:
a Take care not to tear the seamsor damagethe seat
covels,
a Removethe cliDsas shown.
SEAT-BACK
Soat-back cover romoval:
Hatchback
1 . Removethe seat-back(see page 20-108).
2.
Removethe latch cover and latch collar (seepage

20-109).
Removeallthe clipstrom the back of the seat-back,
then loosenthe seat-backcover.
SEAT.BACK
COVER
ilgF]
CLIP
4.
Pull back the edge of the seat-backcover all the way

around,then releasethe clips.
SEAT-BACK
CLIP
20-112
vnx.su
Sodan
l.
2.
Seat cushion cover lsmoval:
Removethe seat-back(seepage 2O-11O1.

Removeall the clipsfrom the backof the seat-back,
then loosenthe seat-backcover.
Harchbacr(
1.
Removethe seat cushion (see page 20-lOg).
2.
Removethe cushioncentertrim panel.
SEAT-BACKCOVER
V : Scrowlocations,2
/+r
v ,-.,)
CEITTER
J.
CLIP
Removeall :he clips from under the seat cushion.

then loosenthe seat cushioncovers.
SEAT CUSHION
covERs
3.
Pullback the edge of the seat-backcover all the way

around,then releasethe clios.
SEAT-8ACK COVER
CLIP
4.
Pullbackthe edgeof the seat cushioncoversallthe

way around,then releasethe clips.
SEAT CUSHION
covEBs
CLIPS
CLIP
lconl'dl
20-113
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Seats
Rear Seat Cover Replacement
(cont'd)
S6dan
1 . Removethe seat cushion (see page 20-1 1 1).
Removeall the clips from under the seat cushion,

then loosenthe seat cushioncover
SEAT CUSHION
COVER
)rir
ry"M
CLIP
Pullback the edge of the seat cushioncover all the

way around.then releasethe clips.
SEAT CUSHION
COVER
t)
ll
ll
CLIPS

NOTE:
a To preventwrinkleswhen installinga seat cover.
mark sure the materialis stretchedevenlYover
the pad before securingall the clips.
a Replacethe releasedclips with new ones.
UPHOLSTERYRING PLIERS
Commerciallyavailable.
{Cover sid6}
20-1 1 4
vnx.su
Seat Belts
Front Seat Belt Replacement
cAUTloN: chock tho tlont seal belts for damage and lsplace them if necessary.
B carelul not to damag then during
romoval and installation.
F.ont seat belt romoval:
Hatchback
1.
Removethe following parts, and slidethe front seat fo.ward fullv.

. Rearshelf (seepage 20-911
. Rear trim panel (see page 20-921
a Rearseat (seepage 20-1Og)

a Side trim panel (see page 2c,-92}
Removeall the anchorbolts, the retractorbolt and the retractormountrngbott, then

removethe front seat belt.
NOTE: When removingthe anchor bolts and the retractorbolt, use a l7 mm socket
or box-endwrench.
3.
Check that the retractorlockingmechanismfunctions as describedon page 20_122-
Pry the anchorcover.
UPPERANCHOR BOLT
7/16-20 UNF
32 N.m (33 kgl.m,
24 tbt.ttl
Remove the tront seat belt trom the belt ouide-
EELTGUIDE
RETRACTORMOUNTING
BOLT
6 x 1 . Om m
9.8 N.m (1.0 kgt.rn.
7.2 tbl.ftl
RETRACTOR
LOWERANCHORBOLT
7/'16-20UNF
32 N.m 13.3 kgl.m,
24 rbf.ft)
RETRACTORBOLT
7/16-20 UNF
32 ltl.m {3.3 kgl,m,
24 tbt.ftl
{cont'd)
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20-115
Seat Belts
FrontSeat Belt Replacement
{cont'dl
Sedan
4.
Removethe retractorbolt and retractormounting

bolt, then removethe front seat belt.
1. Slide the front seat tully forward.

2.
Removethe belt hole cap. then slip the front seat

belt through the slit in the belt hole cap.
NOTE: When removingthe retractorbolt, use a 17

mm socket or box-endwrench.
< : Screwlocation,1
I
FRONTSEATBEI.T
FRONTSEAT
BELT
II
MOUNTING
RETRACTOB
BOLT
'l.O
mm
6x
BELTHOLE
CAP
9.8 N.m {1.o kgl.m,
7 .2 tbt.ltl
RCTRACTOR
)
CENTERPILLAR
LOWERTRIM
3.
SLIT
Removethe upperand lower anchorbolts from the

front seat belt, then remove the center pillar lower
trim.
NOTE: When removingthe anchorbolts, use a 17
mm socket or box-endwrench.
RETRACTOFSOLT
7/16-20 UI{F
32 N.m {3.3 kgl.m.
24 tbf.ftl
A : Clip locations, 2
f '"
f
-1t'-
r _Ju i
l
*UPPERANCHORBOLT
7/16-20UNF
32 N.m (3.3 ksf'm, 24 lbf.ftl
_.|
Check that the retractorlocking mechanismfunctions as describedon page 2O-122.
6 . Removethe centerpillartrim {seepage20-94}.then

removethe shoulderanchoradjuster.
ANCHORCOVER
u-.
FRONT
SEAT
BELT
8 x 1.25mm
23 N.m 12.3 kgl.m,
17 tbt.ft)
ANCHORCAP
LOWERANCHOR
BOLT
7/16-20 UNF
32 N.m (3.3 kgt.m,
24 tbt.ftl
20-116
vnx.su
Seal b6lt buckle romoval:

1. Removethe rear console(see page 20-128).
2.
3.
> : Scrow locations, 2
Slidethe front seat until you can removethe screw.

then removethe center cover.
SEATBELT
BUCKLE
Oisconnectthe connector (driver's),remove the

center anchorbolt, then removethe seat belt buckle.
CONNECTOR
iCENTER ANCHOR BOLT

7/16-20 UNF
32 N.m (3.3 ksf.m,7.2 lbf.ftl
CENTEBCOVER
Upper and lower anchor bolt construction:

Hatchback
LOCK
WASHER
COLLAR
PLAIN
WASI{ER
PLAIN WASHER
LOWERA CHOR
BOLT
BEARING
lcont'd)
20-117
vnx.su
Seat Belts
(cont'd)
Front Seat Belt Replacement
Sodan
.UPPER
ANCHOR
BOLT
Canter anchor bolt consttuction:
Rotractor bolt conslruction:
BEARING
WAVE WASHER
Installationis the reverseot the removalprocedure.

NOTE:
a Make sure you assemblethe washersand collarson the upper and lower anchor bolts as shown.
a Beforeattachingthe sidetrim panel(Hatchbacklor centerpillarlower trim (Sedanl. makesurethe.e are no twists
or kinks in the front seat belt.
a On reassembly,replacethe upper anchor bolt {Sedanland center anchorbolt (*), and use liquid thread lock.
20-118
vnx.su
Rear Seat Belt Replacement

CAUTION: Check lhs roar saat bslts tor damago and ioplaca them it necassary. 86 careful not to damago thcm d.rhe
romoval and imtallation.
Hatchback
1. Remove:
o Rearshelf {seepage 20-911
a Reartrim panel (seepage 20-921
. Rarseat (seepage 20-1081

a Side trim panel (see page 20-921
Removeall the anchorbolts, the retractorbolt and the retractormountingbolt, then removethe rearseat belt and
center belt.
NOTE: When removingthe ancho. bolts and the retractorbolt, use a 17 mm socket or box-endwrench.
Check that the retractorlockingmechanismfunctions as describedon page 2O-122.
Pry the anchor cover.
MOUNTING
RETRACTOR
BOLT
6xl.Omm
9.8 N.m {'l.Okgf.m,
7 .2 tbt.ttl
UPPERANCHORBOLT
7/16-20Ul{F
32 N.m (3.3 kgt.m,
24 tbt.ft)
RETRACTOB
REAR SEAT
AELT
NETRACTORBOLT
7/16-20 UNF
32 N.m (3.3 kgl.m,
24 tbt.fr)
LOWERANCHOR BOLT
7 t16-20 UNF
32 N'm 13.3 kgf.m,
24 tbt.ftl
CENTERANCHOR BOLT
7/16-20 UNF
32 N.m {3.3 kgl m,
24 lbf.ft)
vnx.su
BUCKLE
(cont'd)
Seat Belts
(cont'd)
RearSeat Belt Replacement
Sodan
'I .
Remove:
a
a
a
.
Rear seat {see page 20-1 10)

Rear pillartrim panel (seepage 20-951
Rear shelf trim panel (seepage 20-95)
Rear shelf (see pag 20-96)
a Trunk mat (see page 20-97}

a Reartrim panel {see page 20-971
. Trunk side panel (seepage 20-97)
Remove all the anchor bolts, the retractor bolt and the retractor mounting bolts, then remove the rear sat belts
and center belts.
NOTE: When removingthe anchor bolts and the retractorbolt, use a 17 mm socket or box-endwrench.
Check thst the retractorlockingmchanismtunctions as describedon page 2O-122'
ANCHORBOLT
UPPER
7/16-20UNF
32 N.tn (3.3 kgf'm, 24 lbl ft)
RETRACTOR
MOUNTING
BOLT
6 x 1 . 0m m
9.8 il.m (1.0 kgt.m,
7.2 tbt.tll
RETRACTOR
BOLT
7/16-20UNF
32 .m (3.3 kgl.m,
24 tbt.ft)
RETRACTOR
REAR SEAT
BELT
AI{CHORBOLTS
CENTER
7/16-20UNF
32 N.m (3.3 ksl'm,
LOWERANCHORBOLT
7/16-20UNF
32 N.m (3.3 kgf.m,
24 tbf.ftl
24 lbl ftl
CENTERBELTS
20-120
vnx.su
Uppo. anchor bolt construction:

Hatchback
Sedan
LOCK
WASHER
ANCHOR COVER
UPPERAI{CHOR
UPPERANCHOB
BEARING
COLLAR
TOOTHED
LOCKWASHEN
COLLAR
WASHER
Lower and cantol ancho. bolt conatluction:
Rotracto. mounting bolt construclion:

RETRACTOR
BOLT
MOUNTING
\
\
/{- tr-
LOWEBAI{CHORBOLT/
ANCHORBOLT
TOOTHED
LOCKWASHER
{Sedanl
/
J
l-n(
l$t".,-,fu
tYlf-\ u tY
\
Rotractor bolt construction:

RETRACTOR
AOLT
TOOTHED
LOCKWASHER
b'ryd
TOOTHEO
LOCK WASHER

NOTE:
a Make sure you assemblethe washersand collarson the upper anchorbolt as shown.
a Beforeattachingthe side trim panel (Hatchbacklor rear shelf (Sedan),make sure there are no twists or kinks
in the rear seat belt.
a Beforeattachingthe seat-back,side bolsters{Sedan)and seat cushion,make sure there are no twisls or kinks
in the rear seat belts.
a When instsllingthe seat cushion,slip the seat belt bucklesthrough the slits in the seat cushion.
20-121
vnx.su
Seat Belts
lnspection
Retractol InsDection
1. Beforeinstallingthe retractor,check that the seat
belt can be pulledout freely.
2.
Make surethat the seat belt doesnot lock when the

retractoris leanedslowlyup to 150 from the mounted oosition. The seal belt should lock when the
retractoris leanedover 4O".
Rear:
RETRACTOR
CAUTION: Do not attempt to disassemble the

tgtractol.
Hatchback
' : Mounted Position
3.
Replacethe seat belt with a new one if there is any

abnormality.
On-the-Cal Sat Belt Inspection

1 . Checkthat the seat belt is not twisted or caughton
anythrng.
2 . After installingthe anchors,check lor free movement
RETRACTOB
Forwald
removethe anchor
on the anchorbolts.lf necessary,
boltsandcheckthat the washersand otherpans are
not damagedor improperlyinstalled.
Rear:
3 . Check the seat belts for damageor discoloration.

Cleanwith a shop towel iI necessary.
CAUTION: Use only soap and water to clean.
NOTE: Dirt build-upin the metalloopsof the upper
anchorscan causethe seat beltsto retractslowly.
WiDethe insideof the loopswith a cleanclothdampened in isopropylalcohol.
4.
Iniid6
Forward
Checkthat the seat belt does not lock when pulled

out slowly.The seatbeltis designedto lockonlyduring a suddenstop or impact.
Make sure that the seat belt will retract automatacally when released.
Sedan
Front:
Replacethe seat belt with a new one it there is any

abnormality.
Forward
lnsido
20-122
vnx.su
Child Seat Anchor Plate

Attachmentpointsare providedfor a rearseat mounted
child restraintsystem which uses a top tether,
The attachmentpointsare locatedon the reartrim panel
or rear shelf, just behindthe rear seat-back.
Whenusinga childseatwith a top tether,installthechild
seat anchor platessecurely.
Hatchback
NOTE: The reartrim panelhas perJorations
at each
attachmentpoint. Cut the reartrim panelalongthe
perforationsto make a hole,
TOOTHEDWASHER
BEAR TRIM PANEL
NOTE:
a Do not removethe toothed washer from the child
seatanchorplate.Usethe childseatanchorplate
with the toothed washer attachedto it.
a When installinga childseat on the rearseat, follow the intructionsof the manufacturerof the
child seat,
a Additionalanchor platesare available.
a Do not use the child seat anchor plate for any

other puipos; it is dosigned exclusively tor installation of a child seat.
a Mako sure tho roar seat-back is locked firmlv
whn installing a child soat.
ATTACHMENT POINTS
Sedan
NOTE: Removethe plug covers from the attachment points of the rear shelf (Canada).
Use a razor bladeor sharp knife to carefullycut a
1 inch diametercircleat the locationof the attachment point (USAI.
IOO mm
265 mm 13.94inl
( 1 0 . 4i n l
REAR SHELF
20-123
vnx.su
Garpet
Replacement
SRS wire harnessesare routed near the carpet.
1.
Remove:
Hatchback
CAUTION:
a All SRS slectrical wiring harnssosal covorod
with yollow insulation.
a Belore disconncting 8ny patt of th SRS wite
harness,connoct th short connectors {see pago
20-2721.
a ReDlacethe ntire affected SRS halnsa assambly if it has an opan cilcuit or damaged wiring.
a
a
a
a
a
a
a
.
a
a
Front seat (seepage 2O-103)

Rear seat (seepage 20-108)
R e a rs h e l l { s e ep a g e 2 O - 9 1 }
Rear trim panel {see Page 20-921
Side trim panel (see page 20-92)
Front seat belt lower anchor(seepage 20-115)
Front and rear consoles(seepage 2o-128)
Kick panel (seepage 2O-91)
Dashboardlower cover (see page 20-131)
Openercover (see page 20-154)
Sedsn
ORIVER'SAIRBAG
a
a
a
a
a
a
a
a
o
2.
Front seat (seepage 20-103)

Rearseat {seepage 2O-110)
Rear pillartrim panel (seepage 20-95)
Center pillarlower trim (seepage 20-94)
Front seat belt lower anchor{seepage 20- 1 16l
Front and rear consoles(seepage 20-128)
Kick panel (seepage 20-91)
Dashboardlower cover (seepage 20-131)
Openercover (seePage20-155)
Removethe footrest.
V : Bolt locatios,2
6 x 1 . Om m
9.8 N.m {'l.o
7 .2 tbt.ftl
FOOTREST
20-124
vnx.su
Removethe door sill moldinglrom each side.

NOTE:
a Take care not to damagethe door sill moldings.
a lf necessary.separatethe door sill moldingand
carper.
: Push nul locatlon3, 5
V : Clip locatlons
AV : Clip, 2
------l.l\-\\\).\\\1,
B< : Ctip, 'l
| /rryz)'
C < : C l i p ,1
| ru4l
O > : C t 9 .r
rA
l_ w_)
MW
i -) _)I W I
: Push nut locations, 2
DOORSILL MOLDING
Sedan
A : Clip location3,
: Push nut locations, 4
''*'N*
<l\lt.felt
EI
w /
CARPET I
I
I
I
{ NUr I
":-/
FRONTDOOR
SILL MOLDII{G
20-125
vnx.su
Carpet
(cont'd)
Replacement
4.
Removethe SRS unit covers.
Cut the carpet under the parkingbtake lever'
6.
PARKINGBRAKE
> : Clip locations,2
CARPET
Cut here.
7.
Removethe dashboardcenter bracket and center

beam bracket.
V : Bolt locatlona
B > : B o l t ,1
AV : Boll, 4
s x 1.2smm I
22 N.m
12.2ksf m,
16 tbt.ftl
SRS UNIT COVERS
Cut tne @ ana@ areasin the carpet,then pull it

back, as shown.
I
I
/,/
l:?'o'!"t
C> : goli, 2
6 x 1.0 ftm
9.8Nm
11.0kst'm,
I
I
i
'1Y"!_/
SRS MAIN
20-126
vnx.su
6x1.Omm
9.8 N'm tl.O kgl m,
-'/
I
I
8.
Removethe carpet by slidingit rearward.
a Reattachthe @ cut area of the carpet {seepage

2 0 - 1 2 6 ) .a s t o l l o w s .
V : Cllp loc6tions
AV : Clip, 3
- 1) Cleanthe back of the carpetwith a sponge

damoenedin alcohol.
Attach the fastenersto the edgeof the car,
pet with double-facedadhesivetape.
B > : C l i p ,1
:ft
r,,-,
FASTENERS
Hatchback
FASTENERS
-2) Attach the other tastener.as shown.

FASTENERS
CARPET
CARPET
Ssdan
-3) Align the carpet with the fastener, then
pressthe carpet down securely.
FASTENERS
FASTENER
REARCONSOLE
BRACKET
CARPET
SILL MOLDING
SILL MOLDING
Reattachthe cut area under the parking brake

leverand(9 cut area(seepage20-126)with wire
ties, as shown.
NOTE:
a Take care not to damage,wrinkle or twist the
carpet.
a Make sure the seat harnessis routed correctly.
a Slip the slits in the carpetover the rear console
bracket.
REARCONSOLE
BRACKET
Cut otf.
WIRETIE
SLIT
20-127
vnx.su
Frontand RearConsoles
Replacement
SRS wire harnessesare routed near the front console.
CAUTION:
a All SFS electrical wiring harnessesaro coverod
with y6llow insulalion.
a Betore disconnecting any part of lho SRS wire
harness,connect th short connoctorc (so pago
20-272t.
a Replacotho sntilo aftocted SRS halness assombly it it has an opon circuit or damaged wlring.
NOTE: Take care not to scratch the tront and rear consoles,and dashboard.
1.
Removethe accesscap.
CAUTION: liYhenprying with a flat tip scrwd.lvr,
wrap it with protoctivo tape to provent damag.
ACCESSCAP
FBONT
PASSENGER'SAIRBAG
2.
Remove the sctews.
v : Scraw loctlona
At : Scr.w, 2
E)
20-128
vnx.su
Bv : Scrow, 2
w)
3 . Removethe rear console,
5.
NOTE:
a Lift up the parking brake lever.
a Oetach the hooks by lifting the front ot the rear
consoleand slidingit rearward.
Remove the trim ring, then remov th console

panel.
NOTE:
a Take cafe not to scratch the selecter l6ver 8nd
A/T gear positionindicatorpanel.
a Removethe shiJtlever knob (M/T).
A : Cllp,hook loc.tions
AA : Clip,2
BA : Cllp,2
CA : Hook,2
SHIFTI.EVER
KNOB
CONSOLEPANEL
IM/TI
TRIM RI'{G
\ r
"onroar
,"Hr"tz{o$
co soLE
4.
SELECTER
POStTtON LEVEB
INDICATOR
PANEL
Removethe sshtrsy and front consolepanel.

> : Scrowlocatlon3,2
6.
Removethe screws.
> : Screwlocationr,4
Diaconnct the connector.
6bo''
I
: . /
20-129
vnx.su
Front and RearConsoles

(cont'd)
Replacement
7.
Removethe Jront consoleas shown.
It necessary, disassemble the Jront and rear

consoles.
8.
NOTE: Wrsp the selecterlever and A/T gear position indicator psnel with a shop towel to prevent
damage.
: Scrowlocations,5
A
i
_Y_)
CONSOLEPANEL (MTI
SHIFT LEVER
BOOT (M/TI
CONSOLE
: Scraw locations, I
A
I
Y,/
ARMREST
REAR CONSOLE
PARKINGBRAKE
COVER
COVERSET
PLATE
cof{solE Box
9.
20-130
vnx.su
Dashboard
Component Removal/lnstallation
SRSwire harnessesare routednear the dashboardand
steeringcolumn.
CAUTION:
a All SRS olectrical wiring harnessesar6 covolod
with yallow insulation.
a Betoro disconnecting any paft ot th6 SRS wiro
harnss,connoct th shoi connectots (s66page
23-2721.
a Replacoth entire Itlocted SRS hsrness asaembly il h has an open circuh or damagod wiring.
CAUTION: Whan prying with a flat tip scrowdiv... wrap

it with protoctiv tape, and apply protectivo tapo a.ound
th felatsd parts. to provent damag.
Instiumont p8n6l, Dashboad lower covor. Knec bobtcf
ramoval:
l.
Lower the steeringcolumn.
2.
Remove the screws and detach the cliDs, then remove the instrumentpanel.
3.
Removethe coin oocket.
4.
Removethe screws and detach the clips, then remove the dashboardlower cover.
Disconnectthe connector.
: Scraw
location3, 5
A
\ g
A i Clip locationg
AA: Cllp, 2
_:n
,,4<
-ft
B> : Clip, 2
I
|
,-__-,
l-l
L'l
itrvi
) 4Z)
INSTRUMENTPAI{EL
COIN POCKET
(cont'd)
20-131
vnx.su
Dashboard
Component Removal/lnstallation(cont'dl
5.
Removethe knee bolster.

: Bolt locations, 3
fi
CONNECTOR
6rt.omm
i Bolt locations. 2
6 x 1.0 mm
9.8 N.m {1.0kgl.m,
6 i;i'i#.,
7.2 tbr.ftl
CASSETTE
KNEE
6.
Installationis the reverseof the removalDrocedure.
3,
Stolo radio/cassette, Heater control panal removal:

1.
Removethe rearconsole,then removethe front cons o l e ( s e ep a g e 2 0 - 1 2 8 ) .
Carefullypry the hazardwarning switch and rear

window defoggerswitch out of the heatercontrol
Daner.
Disconnectthe connectors.
HAZARD WARNING
swtTcH
Loosen the bolts, then remove the stereo radio/

cassetteby pullingit out.
Disconnectthe connectorand antennalead.
NOTE: The originalradiohas a codedtheft protection circuit,Besureto get the customer'scodenumber belore
removingthe No. 32 17.5A)fuse from the underhood fuse/relaybox.
After service,reconnectpower to the radioand turn
i1 on. When the word "CODE" is displayed.enter
the customer's 5-digit code to restore radio
operation.
20-132
vnx.su
REARWINOOW
DEFOGGERSWITCH
4.
Removethe screws.
Detachthe harnessclip and connectorclip.
Pullthe heatercontrol panelout, then disco.rEt rhG

conneclors.
> : Screwlocations,2
NOTE: Take care not to bend the atr mtx control

cable.
AIR MIX COI{TROL
CABLE
HEATER
CONTROI
PANEL
7,
lnstallationis the reverseo{ the removalprocedure.

NOTE: Make sure the connectorand air mix control cable are connected properly.
CONNECTORCLIP
Disconnectthe air mix control cablefrom the heater unrt.

AIR MIX CONTROL
CABLE
HEATERCONTROL
AIR MIX CONTROL

CABLE
(cont'd)
20-133
vnx.su
Dashboard
(cont'd
ComponentRemoval/lnstallation
Side air vent .emoval:
Front passsngr's
Drivsi's
Careiullypry the side air vent at the lower edge, then

pull it out.
1. Remove the dashboard lower cover (see page

2 0 - 13 1 ) .
2.
A : Clip,hook locationg
AA : Clip, 1
Caretullypry the moonroofswitch out of the side

air vent, then disconnectthe connector.
BV : Hook, 2
Hi
MOONROOF
swrTcH
1.''
CONI{ECTOR
11,/
SIDE AIR
VENT
SIDE AIR
VENT
PROTECTIVE
TAPE
3,
Removethe screw, then removethe side air vent.

< : Clip, hook locatlont
> : Sc.6w location,
I
o@)
Sido detoggor t m romoval:
A< : Clip, 1
BV : Hook, 3
Carefullypry the side detoggertrim at the rearedge,then

remove rt.
A : Cllp,hook location!
AA : Clip,l
B A: Hook, 1
PROTECTIVE
SIDEAIR
VENT
4.

NOTE: Make sure the connector is connected
properly.
20-134
vnx.su
Clock rsmoval:
4.
Caretullypry the clock at the left edge.then pull it out.

Disconnectthe connector.
Remove the damper and striker.
>: Nut, icrgw locations

A> : l{ut, 1
CLOCK
B
\
: Scrow, 2
'
o
\ +t ] ! } l l aE l l
CONNECTOR
__,/
*'
,/
tl
@
Glove box removal:

'1.
Open the glove box.

DAMPER
2.
Removethe screw, then removethe damperfrom

the glove box.
3.
Removethe screw, then removethe glove box.
5.
Installationis the reverseo{ the removalorocedure.
: Bolt, scr6wlocstions
A
: Bolt, 2
B < : S c r o w 1,
6)P)
20-135
vnx.su
Dashboard
Precautions
Replacement
2 . lnstallthe short connectors(RED)
SRSwife harnessesare routed nearthe dashboardand

steeringcolumn.
Ddvar's:
Removethe accesspanel,then disconnectthe connector betweenthe cable reel and driver's airbag'
Connectthe short connector(RED)to the driver's
airbag connector lsee page 23-27 2l'
CAUTION:
a Alt SRS olectrical wiling harnesssale covorad
with Yollow insulation.
a Botore disconnecting any part ot the SRS wiro
harness,connect ths short connscto6 (seepage
23-2721.
a Roplac6ih entiro aflectod SRS halnoss assembly il it has an opon cilcuit or damagod wiling'
DRIVER'SAIRBAG
CABLEREEL
CONNECTOR
DRIVER'S
AIRBAG CONNECTOB
DRIVER'SAIREAG
SHORT
CONNECTOR
(RED)
ACCESSPAI{EL
Front passongor's:
Removethe glove box {seepage20-135},then disconnect the connector between the tront pas'
senger'sairbagand SRSmainharness Connectthe
short connector(RED)to the front passenger'sairbag connector(seePage 23-273).
SRS UNIT
LEFT DASH
SENSOR
Bstora lomoving the dashboaid:
FROf{T PASSENGER'S
AIRBAG
To avord accioenlal dsployment and

!@@
""iUU inir.v, always install the plotoctive short
;onnectors on the driver's and tlont passngel'sairbag connectorsbolors working near any SRSwiring'
1.
FRONT PASSET{GER'S
AIRBAG CONNECTON
Disconnectthe batterynegativecable,then disconnecl the positivecable.

NOTE: The originalradiohas a codedtheft protec
tion circuit.Be sureto get the customer'scodenumber before
- removingthe No 32 (7.5A) Iuse from the underhood fuse/relaYbox'
After service,reconnectpower to the radioandturn
"CODE" is displayed,enter
it on. When the word
the customer's 5 digit code to restore radlo
ooeration.
20-136
vnx.su
SHORT
CONNECTOR
(REDI
SBS MAIN HARNESS

CONNECTOR
Replacement
To removethe dashboard,first removethe:
a
a
a
a
a
.
a
a
3.
Front seats (seepage 2O-103)

Front and rear consoles(seepage 20-128)
Dashboardlower cover (seepage 2O-131)
Knee bolster (seepage 2O-132)
Glove box lsee page 2O-135)
Clock (seepage 20-135)
Moonrootswitch (seepage 20-1341
Stereo radio/cassette{seepage 20-132)
Removethe nuts, then removethe front passsnger,s

airbagbracket,
To avoid accidantar daploym.nr ",'d
@
possibls iniury, always install th protoctiv. 3hqt
connoctor on tho ,ront passongor'aairbag conncctor whon tha SRS main ha.na$ is disconncctod llcr
pago 20-136).
: Nut locatlons,4
Lower the steeringcolumn (seesection 17).
FRONTPASSENGER'S
ro avoid accidentat dedoyment and

@@
possiblo in ury, always install the protctive short
connector on tho drivsr's airbag connector bgtor
lowering tho stooring column (so page 20-1361.
NOTE: To preventdamageto the steeringcolumn,
wrap it with a shoDtowel.
: 8olt, nul locations
A
: Bolt, 2
8 x 1 . 2 5m m
22 N-m 12.2ksl.m,
16 lbt.frl
: u t ,2
8 x 1.25mm
gill$"'l
FRONTPASSENGER'S
AIRBAG BRACKET
SRS MAIN
HARNESS
4.
STEERINGCOLUMN
Disconnect the air mix controlcable and connectors.

AIR MIX CONTROL
CAELE
CONNECTORS
(cont'dl
20-137
vnx.su
Dashboard
(cont'd)
Replacement
8 . Remove the bolts, then lift and remove the
Disconnectthe antennalead.
5.
dashboard.
CAUTION: Use protoctive tspe on the bottom ol tha
lront tillar trim;
NOTE:
a Take care not to scratchthe dashboard.
a To prevent damageto the shift lever (M/T) or
selecter lever and A/T gear position indicator
panel (A/T), wrap them with a shop towel.
V : Bolt locations,6
6.
Disconnectthe connectorsfrom the under-dash

fuse/relaybox.
6 x 1 . 0m m
9.8 N.m (1.0 kgt'm, I
7.2 tbt.ftt
____/
PROTECTIVE
CONNECTOR
(A/T only)
CONNECTORS
SHOPTOWEL
Removethe accesspanelson both sides.

GAUTION: When prying with 8 tlat tip scrowdrivor'
wrap it with protective tapo to plvent damaga'
DASHBOARD
accEss
PANEL
HooK\
lcCesS Plnel /
___E--
ffiL
9.
lnstallationis the reverseof the removalprocedure

NOTE:
a Make surethe dashboardfits onto the body correctly.
a Beforetighteningthe bolts, make surethe dashboard wire harnessesare not pinched,and thal
the dashboardis not interferingwith the air mix
control cable.
RE=-cLrP
20-138
vnx.su
Bumpers
Front Bumper Replacement
NOTE:
a An assistantis helpfulwhen removingthe front bumper and lront bumper beam.
a Take care not to scratchthe front bumper.
a Open the hood.
3.
Removethe bolts, then removethe front bumoer.
V : Bolt locations
: Clip locadrn., 2
A A
B V : B o l r ,2
A V : B o h ,I
+Et=
-+EP_
1. Removethe tront turn signallight, then disconnect

the connectorson each side.
< : Sci6w locatlons,2
CONNECTORS
FNONTTURN
SIGNAL LIGHT
2.
FRONTBUMPER
Pull the inner fender down. then remove the screws

from the front bumper and lower bumper on each
5rcte.
: Scrow, 2
> : Boll, screwlocations

A > : 8 o l t ,2
: Scr6w locations
A
NOTE: lf necessary,disassemble
the tront bumper.
8>: Bolr5
,
C V : B o l r I,
D < : S c r e w8,
q-l -ry-l_9, =g
BA: Scrow, 2
_A_,
__s_,
A : Clip locarions
AA : Clip, 2
/H\
-<L9'a-
BA : Ctip,4
i
I
/
FRONT
BUMPERr
{-r-*=\
__tr:i!uF&,
FRONTTURN
SIGNALLIGHT
HOLOER
nolt
Et2"
'l-eo
sroe
stoE
SEAL
CLIPS
fr:**M
INNERFEl{DER
BUMPER
LOWERBUMPER
20-139
vnx.su
Bumpers
Front Bumper RePlacement(cont'd)
4.
Removethe absorberand bumperbeamgusset on

each side. then removethe front bumperbeam.
NOTE:
o Installthe holesin the front bumperbeamover
the hookson the bodY.
: Eolt locotions. 4
of the removalprocedure.
is the reverse
Installation
rcr
8 r 1.25mm
22 N.m (2.2 kgt'm,I

't6 tbt fti
_/
FRONTBUMPERBEAM
FrBo*sidor
HOLE
(Frontbumperbamsidel
Align the front bumperside clips with the tront

fender properly,then installthe front bumper.
FRONTFEiIDER
FRONT
BUMPER
ABSORBER
a Make surethe connectoris connectedproperly.
20-140
vnx.su
Rear Bumper Replacement

NOTE:
a An assjstantis helpfulwhen femovingthe rearbumper and rear bumperbeam.
a Take care not to scratch the rear bumper.
4.
Removethe bolts, then removethe rear bumper.

: Bolt locations,2
Hatchback
1.
Removethe screw from each side.
: Scrow I
A
A\
REARBUMPER
REARBUMPER
5.
Openthe hatch, then removethe reartrim panel (see
page 20-921-
lf necessary,removethe bumperupperbeam from

the rear bumper.
: Screwlocotions
J.
Removethe nuts, and disconnectthe licenseplate

light connectorand grommet.
: Scrw,4
> : Nut locotions, 4
/\
--E-
6x1.OmmI
Q) i;L'i$-.l
_':'y:) ,/
LEFTS|DE
B <: Sc.ow,4
@ s l
I
V: Cliplocations,
_ ' /
BIGHTSIDE
TRIM PANEL
.--r-Fl^
--lEr_\"., J
LICENSEPI-ATE
LIGHT HARNESS
L|CENSEPLATELtcHT
REARBUMPER
To remove the nuts, remove the rear

portionof the side trim panelon
each slde {see page 20-921.
(cont'd)
20-141
vnx.su
Bumpers
(cont'dl
RearBumperReplacement
6.
Sadan
Removethe absorber,bumper beam gusset and rear

bumper beam.
1. Removethe screw from each side
y: Boltlocalions,
4
: Sciow locations,2
I
1 2x 1 . 2 5m m
64Nm{65kgfm,I
* "r:,
)
ACCESSCAP
REARBUMPER
2.
ODenthe trunk lid, then removethe reartrim panel

(see page 20-97).
3.
Disconnectthe license plate light connector and

grommet from the rear trunk atea. Removethe clips
and bolts, then removethe rear bumper'
v: Cllploc.tions,5
\\rLlF/d,rft
#.,1
2
: 8ok locations,
6 x 1.0mm I
9 . 8N . m
l 1 . Ok g l m ,
7.2 rbr.ft)
REAREUMPER
BEAM
BEAM
EUMPER
GUSSET
lnstallationis the reverseof the removalprcedure.
NOTE: Make surethe licenseplate light connector
is connected,and the grommetis installedproperly,
GBOMMET
20-142
vnx.su
i
I
J
4.
5.
lf necessary,removethe licenseplate light harness,

bracket and lens from the rear bumper (see page
20-1411.
Removethe absorbr,bumper beam gusset and fear
bumper beam.
V i Bolt locatlons,4
12 x 1.25mm
64 .m (6.5 kgf. m ,
47 tbt.ftl
6.
Installationis the .everseof the removalprocedure.

NOTE:
a Make sure the licenseplate light connectoris connected, and the grommet is installedproperly.
a Make sure the rear bumper engagesthe side clips
securelv.
I
j
)
REARBUMPER
REAR BUMPER
BEAM
BUMPERBEAM
GUSSET
20-143
vnx.su
Hood
Replacement
NOTE:
a An assistantis helplul when removingthe hood.
a Take care not to damagethe hood and body.
a When removingthe clips, use a clip remover.
a Open the hood.
1. It necessary,removethe hood edge protector.
NOTE: It necessary,removethe hood hinge.

V : Boh locationa,4
I3;;,iH"-,,.,
I
.rtor"t
j
: Cliploc.tions,16
- )
HOOD HINGE
HOODEDGE
PROTECTOR
\
HOOD
2.
Removethe bolts. then removethe hood.

: Boltlocalions,
4
lnstallStionis the reverseof the removalprocedure.

NOTE:
a Make su.e the hood locks securely.
a Make sure the hood opens properly.
a Adjust the hood alignment(seepage 20-1451.
6x1.0mm
9.8 N'm
{l.O kgl m,
7.2 lbl.fr)
n
r)
HOOD
20-144
vnx.su
Adjustment
NOTE: Beforeadjustingthe hood, looseneach bolt slightly.
1. Adjust the hood hingesright and left as well as tore and att by using the elongatedholes.
2.
Turn the hood edge cushions,as necessary,to make the hood lit flush with the body at front and side edges.
3.
Adjust the hood latch to obtain the proper height at the forward edge.
NOTE: Move the hood latch right or left until the striker
is centeredin the hood latch, as shown.
HOOD LATCH
HOOD LATCH
6 r 1 . om m
4.
After adiustment,tighten each bolt securely.
20-145
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Hatch
Replacement
NOTE:
a An assistantis helpfulwhen removingthe hatch.
a Take care not to damagethe hatch and body.
a Take care not to scratchthe hatch sidetrims and hatch
tnm paner.
a Open the hatch.
a Removethe high mount brakelight {seesection23).
1.
NOTE: Detachthe clips by slidingthe hatch trim panel

forward, then remove it.
Removethe hatch side trim on each side.

< : Clip locations, 8
HATCH
3.
Remove the hatch spoiler as describedon page

2 0 - 1 5 9 ( f o r s o m et y p e ) .
4.
Disconnectthe connectors,then removethe wire

harnessesfrom the hatch.
V : Clip locations
Av : Clip, 3
: Speclal bolt
locetlons,2
A
2.
A : Clip localions
::::/
l
)
NOTE: Before pulling out the wire harness,tre a

strinqto the end of it so you can pull it backin when
the hatch is reinstalled.
BV : Clip, 3
W',dtri
R@t
@ ,/l ' L,/
Remove the hatch trim panel.
AA : Clip, 11
BA: CliP,6
HATCI{
WIRE I{ARNESSES
_:_/
HATCH TRIM PANEL
CONNECTORS
CONNECTOR
WIRE
HARNESS
5.
20-146
vnx.su
Removethe rear wiper motor (seesection 23).
o.
Removethe uDDeranchorbolts from the tront and

rear seat belts {seepages 20-1 15, 'l 19), then remove the upperportionof the quarterpillartrim panel
(see page 20-991.
NOTE:
a lf necessary,replacethe supportstrut.
a When scrappingthe suppon $rut, dispose ir as
describedon page 20-149.
7 . Removethe rearroof trim, then pull the rearof the

headlinerdown (see page 2O-99).
NOTE: Take care not to bend the headliner,
8 . Removethe supportstfut on each side while holding the hatch.

HATCH
I x 1 . 2 5m m
22Nm
12,2kgt'm,
16 tbt.ftl
SUPPORT
STRUT
a lf necessary,removethe hatch hinge.

V : Solt locdlions,4
9.
Removethe nuts, then removethe hatch.

8 x 1 . 2 5m m
22 N.rn
12.2kgt.m,
16 tbf.ft)
a : Nut locations,4
12.2kgl.m, I
HATCH
HINGE
HATCH
,6'y!:t ,/
HATCH
1O. Installationis the reverseot the removalprocedure.

NOTE:
a Make surethe connectorsare connectedproperly.
a Make sure the hatch locks securely.
a Make sure the hatch opens properly.
a Adjust the hatch alignment(seepage 20-148).
20-147
vnx.su
Hatch
Adjustment
NOTE:
a Beforead,usting
the hatch.looseneachbolt andnut slightly.
a Do not installthe suDDort
struts.
1 . Adjust the hatch hingesright and left as well as fore and aft by using the elongatedholes.
Turn the hatch edge cushions,as necessary.to make the hatch tit flush with the body at each side.
Adjust the hatch fit to the hatch openingby moving the striker,
4.
Use shims, as necessary,to make the hatch tit flush with the body at the rear edge.
HATCH
8 x 1.25mm
HATCH
EDGECUSHION
HATCH
NOTE: Move the striker right or left until it's centered

in the hatch latch, as shown.
HATCH
LATCH
+Q.
6x1.0mm
9.8 N m (1.0 kgl m,
7 .2 tbt.trl
5.
Atter adjustment,tighten each bolt and nut securely,
vnx.su
Trunk Lid
SupportStrut Disposal
Replacement
Tha support strut contains nitrog.n gas and

@
oil unde. prssul.
The pressuremust be relievedbsfo.e disposalto prevant
explosion and possible injury whn sc.apping.
NOTE:
a An assistantis helpfulwhen removingthe trunk lid.
a Take care not to damagethe t.unk lid and body.
a Open the trunk lid.
Placethe support strut on a level surface with its rod extended,and drilla hole 2-3 mm (3/32"1diameterin the
body to releasethe gas.
1.
Disconnectthe connectorsand trunk lid openercable.Removethe wire harnessandt.unk lid opnercable from the trunk lid.
NOTE: Before pullingout the wire harness,tie a
stringto the end ot it so you can pull it backin when
the trunk lid is reinstalled.
> : Clip locationg

AD : Clip, 3
B< : Clip, 1
CA : Clip, 5
e-i
20 mm (O.79inl
_rP
,/
WIRE HARNESS
TRUNKLID
OPENR
CABLE
CONNECTOR
CONIIECTOR
TRUNKLID
LATCH
{seepage20-157}
SUPPORTSTRUT
always war ye prot6ction to avoid get@

ting motal shavings in your eyea when roloasingth gas
fiom the support st.ut.
TRUNK LIO
OPENER
CABLE
A
A
(cont'd)
20-149
vnx.su
Trunk Lid
(cont'dl
Replacement
2.
a Remove the bolts, then remove the trunk lid

hinge.
Removethe bolts. then removethe trunk lid.
> : Bolt loc.rlons.4
V : Bolt locaitons,4
NOTE: Take care not

to hit the rear window
when removing the bolts.
TRUNKLID
removethe trunklid hinge

lf necessary.
4.
lnstallationis the reverseot the removalprocedure.

NOTE:
a Make surethe connectorsare connectedproperly.
a Adjust the torsion bars tore or aft with the torsion bar assemblvtool as shown.
NOTE:
a Removethe rearshelf{seepage20-95).
a Removethe torsionbarswith the torsionbar assembly tool.
TRUNKLID
HINGE
O =NormalPosition
O = Highertension
a Make sure the trunk lid locks securely.

a Make sure the trunk lid opens properly.
O Adjustthe trunk lid alignment(seepage20-151).
TORSION8AB
ASSEMBLYTOOL
20-150
vnx.su
Adjustment
NOTE: Beto.e adjustingthe trunk lid, looseneach bolt slightly.
1. Adjust the trunk lid hingesright and left as well as fore and aft by using rhe etongatedholes.
2.
Turnthe trunk lid edgecushions,as necessary,to makethe trunk lid fit flush with the body at the rearand sideedges.
3.
Adjust the lit betweenthe trunk lid and the trunk lid openingby moving the striker.
TRUNKLID EDGE
CUSHION
/21
ft(M
Y4Y
TRUNK LID
HINGE
TRUNI(LID
6r1.Omm
9.8 N.m 11.0 ksl m, 7.2 lbt'ft|
NOTE: Move the st.iker right or left until it's centered

in the trunk lid lalch, as shown,
6 x '1.0mrn
9.8 N m 11.0 lo,f.m,
7.2 tbt.hl
STRIKER
STRIKER
4.
Atter adjuslment,tighten each bolt securelv.
20-151
vnx.su
OpenerCables
Replacement
NOTE:
a Whenremoving
the clips,usea clip remover.
a Takecarenot to bendthe openercables.
HOODOPENER
CABLE
Hood Opener Cable:

v : Clip location.
> : Scrow locrtions, 6
Av:CllP,5
M)
Bv:Clip.6
E \ I
:=r
,/
____lEt-
HOODRELEASE
HAI{DLE
(sepage20-154)
Otr" I
:_
_)
HOOD LATCH
(seepage 20"154)
-\-
NOTE: Loosen the screw, then remove

the clip using a clip remover.
INNER FENDER
Hatch/Fuol Lid Oponer Cabls lHatchback):

(seepage2O-91),then pull thecarNOTE: Removethe rearseat (seepage 20-108), reartrim panland sidetrim panel
Det back. as necessarylsee page 20-124).
A : Clip,csblocushionlocation3
AA : Clip,
i
r
8A : Clip,
2 ,
CA : CliP,
7 ,
DD : Cllp,
1 ,
Etr : Cllp,
I ,
FA : Cllp,
GA : Clip,
HA : C.bl6 cushlon, 5
s-,$, g, e&r@)s,l Wt9)

Right sids:
HATCH LATCH
lsee page 2O-156)
Loft 3ido:
FUEL LID LATCH

lsse page 2O-155)
HATCH
OPENERCABLE
HATCH
LID
HATCH/FUEL
OPENER
{seepage2O-'l54)
20-152
vnx.su
Trunk Lid/Fuol Lid Opan.. Cablo (Sodanl:

NOTE: Removethe rearseat {seepage 2O-110) and centerpillarlowertrim (seepage20-94}, then pullthe carDetback.
as necessa.y(see page 2O-1241.Removerhe left trunk side panel (see page 20-97).
> : CliD, c.bla cu.hion locstlon!
A > : C l l p ,1
BV:Clip,2
C A: Clip,,t
D >: Clip,3
E A r C l l p ,1
ws@:ffi;6,1
F < : C.ble culhlon, 1
7--
TRUITIKLID LAICH
(sep6ge20-157)
FUEL LID
OPENER
{se6page 20-155)
FUEI.LID LATCH
(soopago20_'|55)
Installationis the reverseof the removalorocedure.
NOTE:
a Make sure each openercable is routed and connectedproperly.
a Make sure the hood, hatch. trunk lid and fuel lid open properlt.
20-153
vnx.su
Openerand Latch
Replacement
NOTE: Take care not to bend the openercables.
Hood Latch:
Hood RelsaseHandle:
< : Bolt locations
< i Bolt locations,2

6 x 1.0 mm
9.8Nm
(1.0kgl m,
7.2 tbl.lrl
6 x 'l.O mm
9.8Nm
1 1 . 0k g l m ,
7 .2 tbt ftl
HOODOPENER
CABLE
(seepage20'152)
HANDLE
,/
HOOD
LATCH
HOOD RELEASE
HANOLE
Removethe kick
panel (seepage
20-91).
HOOD
LATCH
Removethe bolt while

pullingthe handle.
HOOD
OPENER
CABLE
I
Hatch/FuelLid OpenerlHatchback):
< : Bolt, sclow locations
A<rBolt.2
HATCHiFUELLID
OPENER
the
6 x 1.0 mm
9.8 N m 11.0kgl'm,
7.2 tbl.fr)
OPENER
COVER
BV:Sc.sw, 1
6'\ I
v l
/
FUEL LID
OPENERCAELE
HATCH
OPENERCABLE
(seepage 20-152)
lnstallationis the reverseof the removalprocedure'

NOTE:
a Make sure each openercable is connectedproperly
a Make sure the hood locks securely
a Make sure the hood, hatch and fuel lid open properly.
20-154
vnx.su
J't
o
@
t-
NOTE: Take care not to bend the openercables.

Trunk Lid/Fuel Lid Oponer {Sodan}:
Pry the ljd.
OPENER
COVER
< : Bolt, scrowlocatlon!
A<:Bolr,2
OPENERLOCK
CYLINDER
*rr*@
6 r 1 . 0m m
9 . 8 N m 1 1 . Ok g l m ,
TRUNKLID/FUEL
LID OPENER
B V: Scrow, 1
A
-}{H.
II
_:_)
()t
FUELLID
OPNERCABLE
(seopage 2O-153)
TRUNKLID
OPENER
CABLE
(seepage20-153)
Fuol Lid Lstch:

< : Boh,locotions,2
6r1.0mm
9 . 8 N m 1 1 . 0k s l ' m , i
7 '2 tbt'''l
------,//
FUELLIDOPNER
CAALE
( s e ep a g e s2 0 - 1 5 2 1, 5 3 )
FUEL LIO LATCH
Removethe fuel lid latch
by turning it 90o.
FUEL LID
LIO LATCH
Hatchbock: Remove the rear shelf and rear trim oanel.
then pull the rear edge ot the lett side
trim panelback (soepage 2O-91).
Sodan:Removethe rear trim panel,
then pull the rear edge of the left trunk side
panelback {seepage 2O-971.
lnstallationis the reverseof the removalorocedure.

NOTE:
a Make sure each openercableis connectedproperly.
a Make sure the fuel lid fits flush with the body.
a Make sure the tuel lid locks securelv.
a Make sure the trunk lid and fuel lid open properly.
20-155
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Hatch Latch and Lock CYlindet

Replacement
NOTE: Takecarenot 10 bendthe cylinderrod and hatch
openercable.
1.
Removethe rear trim panel (see page 20-921.
2.
Disconnectthe cylinderrod and connector.
4.
Disconnectthe hatch openercable.
HATCH LATCH
5.
Removethe lock cylinderby turning it 45o
>: Bolt localion,1
CYLINDERROD
3.
Remove the hatch latch.
>: Screw locatiois, 3
^
{-D m
6x1.omm
I
s . e N m ( 1 . 0k s l m ,
,?tb:tn
__/
o.
lnstallalionis the reverseof the removalprocedure.

NOTE:
a Apply greaseto the hatch latch.
HATCH LATCH
a Make sure the hatch locks securely.

a Make sure the hatch opens properly.
a Make surethe connectoris connectedproperly.
20-156
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Trunk Lid Latch and Lock Cylinder

Replacement
NOTE: Takecarenot to bendthe cylinderrod and trunk
lid openercable.
4.
Removethe lock cylindercover.

HOOKS
l.
CLIP
Disconnect
the connectorand trunk lid openercable.
CONNECTOR
LID
CABLE
LOCKCYLINDER
COVER
CLIPS
5.
Removethe bolt, then pullthe lock cylinderout. Re,

move the lock cylindertrom the cylinderrod, then
take them out.
: Boltlocation,'l
2.
Disconnectthe cylinderrod.
F 6xl.Omm
q;i!!"jy
LOCK
CYLINDER
CYLINDER
ROD
Removethe bolts, then removethe trunk lid latch.

CYLINDER
ROD
A : Bolt locations,3
6.
Installationis the reverseol the removatproceoure.

NOTE:
a Apply greaseto the trunk lid latch,
./,.,
,/'e4
a Make sure the trunk lid locks securelV.

a Make sure the trunk lid opens properly.
a Make sure the connectoris connectedproperly.
20-157
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Retainersand WeatherstriP
Replacement
CAUTION: Wear gloves to lemov and install tho itainrs'
NOTE: Take care not to bend the retarners.
< : Screwlocalions,19
< : Clip locations,I
!9
REAR CLIP
.\
!:
RETAINER
q
l{
SHOPTOWEL
CENTERPILLAR
MOLDING
WEATHERSTRIP
Boot side section:

RETAINER
Center oillar section:

PILLAR
FRONT CENTER
I
CENTERPILI-AR
MOLDING
NOTE: The numbers atter the part names
show the quantities ot the parts used
WEATHERSTRIP
RETAINER

NOTE:
a Check the weatherstriplor damageor deterioration,and replaceif necessary'
a After installingthe weatherstrip,check for water leaks'
a lf necessary,adjust the positionof the door glass (see page 20-40)
a It necessarv,replaceany damagedclips.
20-158
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FenderWell Trim and
Hatch Spoiler
WheelhouseProtector
Replacement
Replacement
a Take care not to scratch the hatch.

a Open the hatch.
1.
Removethe hatchsidetrim and hatchtrim panel(see

p a g e2 O - 1 4 6 ) .
2.
Removethe nuts and disconnectthe connector.
: Nut locations,4
6 x 1 . 0m m
Ch 9.8 N.m
(J
(1.0 ksl m,
__.
7,4b1!t
a Take care not to bend the tender well trim.

a Beforeinstallingthe lender well trim, cleanthe bodv
bondingsurfacewith a spongedampenedin alcohol.
a After cleaning,keepoil, g.easeor wafer lrom getling
on the surface.
> i Scrwlocations.
I
,/
coI{t{EcroR
Removethe hatch spoilerby turningthe clip nut on

the left side counterclockwise.
HATCH SPOILER
ADHESIVE
3.
FENDERWELL
TRIM
20-159
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Hatch Weatherstdp/TrunkLid Weatherstrip

Replacement
HatchWeatherstrip:
NOTE:
a Beforeinstalling
applyclearsealantinto its channelat the > locations.
the hatchweatherstrip,
a After applyingthe sealant,installthe hatchweatherstrip.
ALIGNMENT MARK
ff6llowl
HATCH
WEATHERSTRIP
Trunk Lid Wathorstrip:
MAE(
ALIGI{MENT
(Whitol
TRUNKLID
WEATHERSTRIP
HATCH/TRUNKLID
WEATHERSTRIP
When installingthe hatchor ttunk lid weatherstrip.align
it with the alignmentmark on the hatch or trunk lid
openrng.
NOTE:
a Make surethere are no wrinklesin the weatherstrip.
a Check tor water leaks.
ALIGNMET{'
MARK
Forward
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Roof Molding
Replacement
CAUTION: When prying with I flat tlp scrowddvr, wrap
it with protoctivo tapo to pravent damag6.
Pullthe roof molding up and detach the bracket lrom

the pin, then removethe roof molding.
NOTE: Take care not to scratch the bodv and root

molding.
1.
Pry the rool molding with a flat tip screwdriver as

snown.
CAUTlOfil: Use protoctivo rape on tho body.
ROOF MOLDING
SIDEMOLOII{G
BRACKET
Pull and slide the root molding, then detach the

bracket on the end of the roof molding from the pin.
4.
Installation
is the reverse
of the removalorocedure.
NOTE:
a Takecare not to damagethe windshieldside
ROOF MOLDING
molding.
a Make sure the roof molding is installed securely.
R(X)F MOLDING
PIN
{Body ddq)
ROOF MOLDING
20-161
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Door and Side Moldings

Replacement
protective tape to prvont damag'
CAUTION: When prying with 8 flal tip screwdriver, wrap it with
NOTE:
pages 2O-4' 2O' 32],'
a To remove the doot moldlng, temove the door panel and plastic cover {see
(see
page 20-91)
a To removethe rear side molding,removethe side trim panel
a Take care not to bend the door moldings.
is bent. Replacethe door molding
a The steel core in the door moldingcann-otbe restoredto its originalshapeonce it
if the steel core is bent.
V : Clip locations
av : cllp (Hatchb6ck, 5)
Dv: Cliplsodan,1)
CV: Cllp (Halchback,1l

{Sodan,2l
BV: clip (Hatchback' 3)
STEEL
CLIP
V: Plastic nui locatlon

(Hatchback, 1)
(Sedan,1)
Hatchbsck
l r >
r9
O '
NOTE:
a BeJoreinstatlingthe rear door molding,
scrapethe adhesivetape from the molding and body.
a Cleanthe motdingand door bondingsurJaceswith a spongedampenedin alcohol'
a Atter cleaning,keepoil, greaseand water
Jrom getting on the surface.
a Gluethe new adhesivetape to the molding as shown.
30mm
6mm
ls 2f 61 . t.l.18inl
REAR DOOR
MOLDING
30 mm
( 1 . 1 8i n l
lnstallationis the reverseoJ the removalProcedure.
NEW ADHESIVETAPE
Thicknoss:1.2 mm lo.o5 inl
NOTE: It necessary,replaceany damagedcliP.
20-162
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Forward
Side Sill Panel

Replacement
V : Clip locations
AV: Ctip {Harchbsck,8)
{Sodan. 8 l
> : Screw locations, 4
q,
BA : Clip (Harchback,7)
{sodan,7l
SIDECLIP
Removethe side clips from rhe body
by turning them 45o
NOTE: Loosenthe screw,

then .emovethe lower clip
using a clip remover.
Remove the lower clips, then removethe side sill panel

by sliding it forward.
Hatchback
\y':
NOTEj When removing the side

sill panel, lhe side clips will
SIDE SILL PANEL
To installthe side sill panel,removethe side clips from

the body, installthem on the side sallpanel,then instatl
the side sill panel on the car.
FENDER
NOTE:
a Take care not to twist the side sill panet.
a lf necessary,replaceany damagedside and lower
clips,
20-163
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RearEmblems
lnstallation
Align the applicaliontape with the rearturn signallight and the gap betweenthe taillightand
tape'
the emblem into place. Removethe applicataon
body, as shown, then press
NOTE:
a Beforeapplying,clean the body surlace with a spongedampenedin alcohol'
a After cleaning,keep oil, greaseand water from getting on the surface'
a When applying,make sure there are no wrinklesin the emblem'
Attachment Point:
REARTURN
SIGNALLIGHT
Hatchback
REARTURN
SIGNAL LIGHT
!---_-----------,-i-J
TAILLIGHT
20-164
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Sub-frame
Sub-t.ame Torque Sequence:
cAUTloN: After rooseningtho rsar beam mounting borts be sura to repracothom with new onea.
6 x 'l.O mm
9,8 N.m (1.0 kgt.rn,
7.2 tbt-fll
REABBEAM BBACE
1 0 x 1 . 2 5m m
44 N.m {4.5 kgt.m,
33 rbr.ftl
FEAR BEAM
COLLAR
REAR BEAM
REARBEAM
14 x 1.5 mm
89 tt.m (9.1 kst.m,
66 lbf.ftl
Beplace.
20-165
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FrameRepairGhart
-!
ar"tr*,,,ua
\
Model
Dls6ft-\
M/T
514.5
120.261
5 0 1. 5
(19.7)
U-)
2.5
(0.10)
25
{o.98)
(J
\---!e!s!
Distance
{10.53) 112.03)
Sedan
2150
2100
(84.6t
lE2.71
2642
2632
{103.6) {105.6}
J5
2 6 11
(102.8)
2657
2607
(102.6) (104.6)
t22.Ol
(104.8)
674
(26.5)
B A S EL I N E
d11.5
I cir (o-36;E;\ry+
Poinr
d l 1 . 5t O _
011.5
c r 1 . 5( 0 .
Aoad
9rl
lv
Front Osmpsr Lowsr Bush
20-166
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POINT w
d 2 5 l l . o l L o c a r eH o l e g
20-167
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Heater and Air Conditioning

Heater
A i r C o n d i t i o n i n .g. . . . . . . . .
. . . . . . . .2 1 - 1
..22-1
RESTRAINTSYSTEM{SRS}
SUPPLEMENTAL
The IntegraSRS includesa driver'sairbag,locatedin the steeringwheel hub. In addition.all modelsexcept the
RS model for Canadahave a front passenge.'sairbaglocatedin the dashboardabove the glovs box. Information
necessaryto safely servicethe SRSis includedin this ServiceManual.ltems msrkd with an asterisk(') on the
conlents page include,or are locatednear, SRS components.Servicing,disassemblingor,eplacing thes items
will requirespecialprecautionsand tools, and shouldthereforebe done by an authorizedAcura dealer.
a To avoid r6nd6dng tho SRS inoporativo. which could lead to personal injury or dealh in tho svont ot a sevele
frontal collision, all SRS servica work musl b portormed by an authorized Acura dealer.
a lmpropor sorvico procaduro3,including incorrect romoval and installatlon of tho SRS,could load to porsonaliniury causod by uninlonlional activation of tho ailbag8.
a All SRS eloctdcal widng harnossosare covored with yollow in3ulation. Relatsd compononts a.o locatod in tha
stsering column, flont console, daehboard,and dashboafd low6r pan6l, and in lhe dsshboa.d above lh glove
box. Do not uao electdcal tost equipmont on theae circuhs.
NOTE: The originalradiohas a coded theft protectioncircuit. Be sureto get the customer'scode numberbeto.e
- disconnecting the battery.
- removingthe No. 32 (7.5 A) luse from the under-hoodfuse/relaybox.
"CODE" is displayed,enter the cusAfter service,reconnectpower to the radioand turn it on. When the word
tomer's 5-digit code to restore radio operation.
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Heater
l f l u s t r a t eIdn d e x . . . . . . . . . . . . .
.........21-2
HeaterDoor Positions
.........,..,.21-3
C i r c u i tD i a g r a m
. . . . . . . . . . . . . . . . . . . .2. .1.- 6
Troubleshooting
S y m p t o mC h a r t . . . . . . . . . . . . .
......21-8
Flowcharts
B l o w e rM o t o rS p e e d. . . . . . . . . . . . . . . . . . . . . . . . . . 2. .1. -. .9
B f o w e rM o t o r
. . . . . . . . . , . . , , , , ,2. 1
. -11
M o d eC o n t r o M
l o t o . . . . . . . . . . ...... . . . . . . . . . . . . . .2. 1. - 1 4
Recircufation
ControlMotor ......,...,.,,,.,....
21 -17
Heater Control PanelInput/
O u t p u tS i g n a l s
..............21-19
Blower Unit
Repfacoment
. . . . . . . . . . . . . . . . . . . .2. .1.- 2 0
Overhaul
.......21-21
+HeaterUnit
Repfacement
. . . . . . . . . . . . . . . . . . . .2. .1. - 2 2
Overhaul
.......21-24
DefrosterDoor Adjustment ...,.............
......,, 21 -25
Heatel Control Panel
Repfacoment
. . . . . . . . . . . . . . . . . . . .2. .1. - 2 5
Overhaul
.......21-26
Heater Valve Cable
Adjustment
...21-27
Air Mix Control Cable
Adjustment
... 21-27
Mode Control Motol
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1.-. 2 e
Repfacement
. . , . . . . . . . . . . . . . . , , ,2, .1. - 2 8
Recirculation Control Motor
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1. -. 2 9
Repfacement
. . . . . . . . . . . . . . . . . . . .2. .1. - 2 9
Relay
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1. -. 3 0
Heater Fan Switch
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1.-. 3 0
Mode Control Switch
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1. -. 3 1
Recilculation Control Switch
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1.-.3 1
*: Read SRS precautionsbefore working in this area.
vnx.su
lllustratedIndex
CAUTION:
a All SRS electrical wiling harnessesare covered with
yllow insulation.
a Bafore disconnecting any pan of the SRS wile harness. connect the sholt connectorlsl.
a Replacethe sntire aflected SRS halness assembly if
NOTE: The originalradio has a coded thelt protection
circuit. Be sure to get the customer'scode numberbefore
- removingthe No. 32 (7.5 Al fuse lrom the underhood fuse/relavbox.
After service,reconnectpower to the radio and turn it
"CODE" is displayed,enterthe cuson. when the word
5-digit
code
to restoreradio operation.
tomer's
SRS MAIN HARNESS
BLOWERUNIT
Replacement,page 21-2O
O v e r h a u lp, a g e2 1 - 2 1
I{EATERVAIVE CABLE
Adjustment,page21-27
HEATERUNIT
page2l 22
Repfacement,
page21-24
Overhaul,
RECIRCULATIONCONTROLMOTOR
Test, page 21-29
Replacement,page 21 29
BLOWENRESISTOR
Test, page 21-9
W,
AIR MIX CONTROL

CABLE
Ad,ustment,page 21-27
Replacement.page 21-26
a/c swrTcH
(wirh A/cl
Test,page22-20
RECIRCULATION
CONTROLSWITCH
T e s t ,p a g e2 1 - 3 1
HEATERFAN
swtTcH
Test, page 2'l-3O
MODE CONTROLMOTOR
Test, page 21-28
Repfacement,page 21'28
MODE CONTROLSWITCH
T e s t ,p a g e2 1 ' 3 1
HEATERCONTROLPANEL
Repfacement, page 21 -25
Overhaul,page 21-26
TEMPERATURECONTROL
LEVER
(Adjustmonl: See AIR MIX
CONTROLCABLE}
21-2
vnx.su
Heater Door Positions
*)
xor
fr
coor.
VENTOOOR
-*)
(HEAT/VENTI
(cont'd)
21-3
vnx.su
Heater Door Positions

(cont'd)
\)
IHEATI
El
IHEAT/DEF)
vnx.su
vnx.su
CircuitDiagram
- OASH
UiIDEN
FUSE/RETAY
8OX
- HOOO
FUSE/REI.AY
8OX
UNOER
(7.5A1
N0.13
WtlT/BtK.+WtfT
RECIRCUI.ATION
Moron
coMTBor-
nrot
G401
21-6
vnx.su
UGHTIG
swtTcH
RED/BI.K
I r . l .
| |
I
r t , /
I t v
A . t t A _
l t I
I
, f r r , /
I r v
A- l_t r r A- l.
|
, / t t
f
I r v
A
- f_ r r A- l.
| |
, f t t , /
I r v
A
- l -r l
, f I
HEATER
CONTROL
PANEI.
OASHIIGTTTS
EnrGFr ESS
coNTROU.IT
21-7
vnx.su
Troubleshooting
Symptom Chart
NOTE: Check the enginecoolant level and allow the engineto warm up before troubleshooting.
REMEDY
SYMPTOM
Hot air flow is low.
No hot air Jlow
Blower motor runs, but one ol more

speeds are inoperative.
Follow the tlowchart (see page 21-9).
Blower runs properly.
Check for the following:

. Cloggedheaterduct
. Cloggedheater outlet
. Incorrect door position
Blowel motor does not run at all.
F o l l o wt h e f l o w c h a r t( s e ep a g e2 l - l 1 l
Blower motor runs.
Check for the following:

. clogged heatet duct
. Cloggedblower outlet
. Cloggedheatervalve
. Faultv air mix door
. Heatervalve cable sdjustment lsee page 2'l-271
. Air mix control cable adjustment(see page 21-27)
. Faultythermostat (seesection lO)
. Cloggedevaporator(with air conditioning)
. Frozenevaporator(with air conditioning)
Mode control motor does not run, or one or more modes are Follow the flowchart (see page 21-14).
inooerative.
Recirculationcontrol door does not changebetween FRESH Follow the flowchart (see page 21- 17).
and RECIRCULATE.
21-A
vnx.su
Blower Motor Speed

Blowor motor run3, bul ono ol
mors rpoodt aro inoporotivo.
-l
Turn the ignitionswirch ON lll).

and the heater tan switch OFF.
Does the blower motor run?
|t|
To pago 21-1O
\\
\
lI
iii
I!i
Measurethe rosistancebetwoen
the No. 2 and No. 4 terminalsoI
the blowr resistor.
ls there aDorox.2-3 ohms?
Removethe heater conlrol panl

{seo page 21-25}.
Turn the ignitionswitch ON (li).
At the heater fan switch 6P connector, ground each of these

waresindividuallyin ths lollowing
order:
. BLU wire
. BLUMHT wir
. BLU/YELwire
. 8LU/BLK wi.e
T o p a g e2 1 - 1 0
(cont'd)
21-9
vnx.su
Troubleshooting
Blower Motor Speed (cont'd)
From page 21-9
Does the blower motor run at

progressively higher speeds?
Raplacatho hollar fan rwitch.
Ropair opon or cau36 ol oxcoalivt

rosbtanco in tho appaopaiato
wire(3| b6twoon thg hostct lan
switch and tho blower todstor.
View trom whe side
From page 21-9
Removethe heater control panel

(seepage 21-25).
Iilil
-l
View from wire side
BLU/U,HT
Checkeach wire for continuitybetween the heater tan switch 6P
connector and body ground.
. BLU wire
. BLUMHT wire
. BLU/YELwke
. BLU/BLKwire
!\i
Raplaca tha haater lan awltch.
Bopair shon in the wir6{s} blwon lho heatot lan switch rnd
th6 blowor ro3bto?.
21-10
vnx.su
--
BlowerMotor
Blowor motor doos noi iun at all.
check the No. 37 (4o A) fuse in

tho under-hood fuse/relay box.
View from wire side

At th blower motor 2P connector, connectthe BLU/8LKwirc terminal to body ground wath a
jumpe. wire.
Turn the ignitionswitch ON (ll).
Does the blower motor run?
To page 21-12
Disconnect the blower motor 2P

connector, and measurethe voltago between the ELU/wHT wire
terminal {+} and body ground
View from wire side
"uf"'\'
{-}.
,)
Remove the blower motor relav

from the under-hood fuse/relav
box and test it {seepage21-3O}.
Roplacotho blowor motor rolay.
Measurethe voltage betwgen the

No. 1 terminal (+) and body
g r o u n d( - ) .
T o p a g e2 l - 1 3
(cont'dl
21-11
vnx.su
Troubleshooting
Blower Motor (cont'dl
F r o mp a g e2 1 - 1 1
View trom wire side
BLU/BLK{+ }
Removethe heater control pan6l

(seepage 21-25).
Turn the ignitionswitch ON (lll.
Measurethe voltage btwsen the

8LU/BLKwire terminal l+) and
body ground {- ).
ls there battory voltage?
Rgp.lr op.n In lh. BLU/BLK wh.

batwoen lh! blowar motor lnd
tho hcolar f.n .wltch.
Check tor continuity in lhe BLK

wire between the heater lan
switch and body ground.
Ch.ck tor an opan in lhr Bl-K wiro
bdtwaan tho hortar tln lwftch
.nd body ground. lf tho wlra l.
OK, ch.ck for poor ground .t
G201 .nd /rO1.
Roplacotho hsator tan lwitch.
21-12
vnx.su
From page 21-11
Tu.n the ignition switch ON (ll).
Measuretho voltage botwoon tho

No. 4 torminal (+) 6nd bodv
ground (- l.
Ropair opan in tho BLK/YEL wir.

batworn lha undor-hood fuaa/rahy box snd tho undor-dr.h
tur./rolay box.
Turn the ignirion switch OFF.
Checkfor continuity between the

No. 2 torminal and body ground.
Ch.d( to. !n oF|rn in th6 BLK wiro
batwagn lho undar-hood luro/ralry box lnd body ground. ll th.
wlre it OK. chock tor poo. ground
at G2Ol lnd G/lol.
Rop.ir opon in th. BLU/WHT wlr.

betweon tho undsr-hood lura/l.lay box and tho blowor motoi.
vnx.su
Troubleshooting
Mode ControlMotor
Modo control motor dooa not nm,
or ono oa moto modo arc In_
oporgtivo.
Disconnectth6 mode control mo_

tor 8P connector.
Turn the ignition switch ON (ll).
Measurothvoltage btween tho

BLK/YELwire terminal (+) and
bodv ground (- ).
R.p.lr op.n In lho BLrrYEL wl..

bctw.rn lha undard!.h fuaa/rul.y box .nd ih. mod! corttol
motor.
To page 21-15
21-14
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From page 21-14
View lrom wi.e side

GRl{/YEL
Check for continuity in the BLK

wire betweon the mode control
motor and body ground.
Chock lor an op6n In tho BLK wt
botwon tho modo control motot
lnd body ground. It thr wlro i!
OK, chock for poo. grouhd ot
G2O1 8nd G/tOl.
Test the modo control motor (see
page 21-281.
ls the mode control motor OKI
Removethe heater control oanel

{soe page 21-25).
Disconnect the heater control

Danel14P connector.
Chckeach wire for continuitybotwoon the mod6 control motor

and body ground.
. YEL/BLUwire
. YL wire
. 8LU,^/VHTwire
. GRNI/EL wire
. YEL/REDwire
Romovothe mode control motor

(soo pag6 21-281.
Chck the modo control linkago

and doo.s tor smooth movoment.
Do tho mode control linkage

and doorc movs smoothlv?
Ropairth6 mod6 control

linkago or doors.
Raplace thc modo control moto..
Roprir any .hort in th. wlrol!) b.tworn tha moda control anotot
and tha holtar control pan6l.
Checkthe samewires lor vohage.
ls the.6 any voltage?

NO
Roplir rho.t to powar In tha

8LK^'EL wiro b.two.h lh. modo
conlrol hotor rnd tha haat* control p!rr.|. (Thi! damrg.. tha
hello. control p!nel.)
To psg6 2'l - 16
lconl'dl
21-15
vnx.su
Troubleshooting
Mode Control Motor (cont'd)
View from wire side
From page 21-'l 5
Checkeach wire for conlinuitybetween the mode contiol motor

and the heater control panel.
. YEL/BLUwire
. YEL wire
. BLU/WHT wire
. GRN/YELwire
. YEL/REDwire
R.psir any opon in fro wir6{.1 botwocn tho mod control motol
snd tho holtar contiol prnal.
Rsplocotho hoator conlrcl panol.
21-16
vnx.su
yEL
RecirculationControlMotor
Rocirculation control doo. dooa
not chsng botwoon FRESH6nd
RECIRCULATE.
ffi
Disconnectthe rgcirculationcontrol motor 4P connector.
Turn the ignilion switch ON l).

BLK^/ELwire rerminal {+) and
body ground (- ).
Reprir op.n In th. BIK/YEL wir.

botwoon thr und.r+rh
fu!./r.by box 6nd lha radrculdion co.rtrol motoi.
T o p a g e2 1 - 1 8
{cont'd)
21-r7
vnx.su
Troubleshooting
RecirculationControl Motor (cont'd)
F r o mp a g e2 1 - l 7
Test the recirculationcontrol mo_

tor (see page 21-29).
ls the recirculationcontrol
motor OK?
Removethe recirculationcontrol
motor (see pag. 21-291.
Check the recirculation control

linkage and door for smooth
movement.
Removethe heater control panl
{seepage 21-25).
Do the recirculation
control linkage and door
move smoothly?
Disconnect the heater control

panel 14P connector.
Ropalrtho ioclrculatioo
conirol linkaga ot dool.
No. 5 GRN/RED
o. 6 GRI{MHT
View from wire side
Check for continuity in the
GRNMHT and GRN/REDwires
between the recirculationcontrol
motor 6nd body ground.
RoDair shorl in rhs GRNMHT

and/or GRN/REDwitols) botwoen
the rocirculation conl.ol motot
and tho hoster control Panol.
Checkthe samewircs for voltage.
ls there any voltage?
Ropair 3hon lo Power in tho

BLK/YELwiro botwoon ths rocitculalion control motoi and lhe
ho6tor control Panel' {Thir
ddmagos tho hatot cont.ol
oanol.)
Check for contin!ity in the

GRN/WHTand GRN/REDwires
between the recirculationcontrol
motor and the heater control
panel.
Ropair opsn in the GRi|/WHT

and/o. GRN/REDwiro{sl botwoon
ths rocirculstion conttol motot
and tho hoator control Panol.
Reolaceth heatsr control Panal.
21-18
vnx.su
View from wire sid6

GRN/RED
ffii
HeaterControlPanelInput/OutputSignals
No. Wire Color

I
BLU/WHT
Signsl
N o . Wire Color
HEAT
INPUT
YEL
I{EAT/DEF
INPUT
YEL/BLU
DEF
BLK
GROUND
GRN/RED
RECIRCULATE
GRN/WHT
YEL/RED
2
4
Si9n8l
GRN/YEL
HEATA/ENT
INPUT
RED/BLK COMBINATION
LIGHTSWITCH INPUT
INPUT 1 0
RED
BRIGHTNESS
CONTROLLER OUTPUT
OUTPUT 1 1 BLU/RED
A/C THERMOSTAT
INPUT
INPUT
12
FRESH
INPUT
1?
VENT
INPUT
't4
GRN
HEATERFAN SWITCH
OUTPUT
BLK/YEL
tG2
INPUT
21-19
vnx.su
Blower Unit
Replacement
NOTE: The blower motor, recirculation control motor
and blower resistor can be replaced without lemoving
t h e b l o w e ru n i t ( s e ep a g e2 l - 2 1 ) .
1.
Removethe glove box (see section 2O),
2.
Removethe fou. bolts and the glove box frame.
With Air Conditioning

3-b. Removethe evaporator(see page 22-261.
CLIPS
6 x I
9.8 .ft 11.Okgt.m,
7.2 tbt.ftl
GLOVE BOX FRAME
Without Ail Conditioning

3-a. Removethe wire harnessclips trom the heatrduct.
Removethe Jour self-tapping screws 8nd the heater duct.
4.
Oisconnectthe connectors from the blower motor,

blower resistor and the recirculationcontrol motor.
Removethe wire harnessclip from the recirculation
control motor, and releasethe wire harnessfrom the
clamo on the blower unit.
Removethe two mountingbolts, mountingnut and
the blower unit,
6 x 1 . 0m m
9.8 .m (1.O kgl'm,

7.2 lbf'ft}
HEATERDUCT
6 x 1 . Om m
9.8 N'm (1.0 kgf'm.
7.2 tbt.ftl
6.
lnstall in the reverse order of removal, and make sure

there are no air leaks.
21-20
--
vnx.su
Overhaul
NOTE:
' Before reassembly, make sure that the recirculation control door and linkage
move smoothly without binding.
' When teattaching the recirculationcontrol motor, make sure its positioning
will not allow the recirculationcontrotdoo.
to be pulled too fat. Attach the recirculationcontrol motor and 8ll links, then connect power
and ground, and watch
the movement ol the reci.culation control door.
m
BLOWERRESISTOR
Test. pags 2l-9
21-21
vnx.su
HeaterUnit
Replacement
CAUTION:
a All SRS electrical witing hame$os are covoed wlth
yollow insulation.
a Before disconnecting any patt of tho SRS wito harneas, connect tha shott connoctol(s|.
a Roplacoth enlire sffacted SRS harnosr a$smbly if
it has an opon cilcult or dsmaged wiring.
3.
Disconnect the heater hoses from the heater unit'

CAUTIOII: Engino coobnt will damago paint. orickly dnse any rpilled engine coolant from paintod
surfac63.
NOTE: Enginecoolantwill tun out when the hoses
are disconnected,drain it into a clean drip pan'
CLAMFS
NOTE: The original radio h8s a coded theft protection

circuit. Be sureto get the customer'scode numberbetors
- disconnecting the bafterY.
- removingthe No. 32 (7.5 A) fuse from th underhood tuse/relavbox.
- removingthe radio
After service. teconnect power to the radio and turn it
"CODE" is displayed,enterthe cuson, when the word
1. When the engineis cool, dtain the enginecoolant
from the radiator(see section 1O).
oo not lomove tho radiator cap whan
@@
the ongine is hol; tha ongino coolant is undot
pressure and could avoralYtcald you.
HEATERHOSES
4.
Remove the mounting nut from the heater unit.

NOTE: When removingthe mounting nut, take care
not to damage or bend the fuel pipes, brake pipes,
etc.
8 r 1,25rn|n
22 N.m 12.2kgt.m, tO lbf'ftl
2. Snap open the clamp and disconnect the heater

valve cable from the heater valve arm.
HEATERVALVECABLE
21-22
vnx.su
5.
Rsmove the dashboard (see section 2O).
9.
6 . Remove the heater duct (see page 21-20) or the

evaporator lse page 22-26).
7.
Rsmovethe two bolts, nut and the passenger,sSRS

(}eam.
8 x 1,26 mln
22 N.m 12.2kgf.m, 18 tbt.ttl
Install in the reverse order of removal, and:

a apply sealant to the grommets.
a do not int6rchange the inlet and outlt hoses.
Make sure that the hose clamps are secure.
a loosen th ble6d bolt on th6 engine and rfillthe
tadiator and coolant rservoirwith the propsr en_
gine coolant mixture (sse section 1O).
Tightenthe blsed boh when all the trappedair has
6sc8p6dand engine coolant begins to flow from
it (seesection 1O).
a connect all csblesand make surethey 8re properly
adiusted (see pdge 21-271.
PASSEIVGER'S
SRSEEAM
8 . Disconnect the mode control motor conngctor, and

remove the wire harness clip from the h8ter unit.
Removethe two mounting nuts and the haater unit.
6 r 1 . 0m m
9.8 .m (l.O kgt.m,7.2 tbt.frl
MODE COI{TROLI,IOTOR
col{t{cToF
vnx.su
21-23
HeaterUnit
Overhaul
1 . Remove the screw and the damper arm cover.
Pull out the heater core.
Disconnect the link from the dampar arm, and remove the screw and the damper arm.
NOTE: Be careful not to bend the inlet and outlet

pipes during heater core removal.
Removs the two screws and the heater core cover.
Assemble in the revrse older of disassembly.
4.
Remove the screw and the pipe clamp.

HEATERCORECOVER
DAMPERARM COVER
HEATERCORE
DAMPEFARM
21-24
vnx.su
HeaterControlPanel
DefrosterDoor Adjustment
Replacement
Set the mode control switch on HEAT.
Disconned the air mix control cable from the heater unit lsee page 21-271.
Loosen the adiusting screw.
Remove the rear window defogger switch and the

hazardwarning switch.
Turn the adjusting arm to the left, as shown, so that

there will be no heat leakagefrom the defrosterdoor,
4.
Remove the two self-tapping screws, then pull out

the heater control panel and the center air vent. Disconnect the connectots,and removethe heatercontrol panel and the center air vent.
Tighten the sdjusting screw.
AD.'USTII{G ARM
NOTE: The locking tabs of the hazard warning

switch and heater control panel connectors are on
the bottom.
CE]TTER
AIR VEI{T
REARWITIDOW
DEFOGGER
swtTcH
ADJUSTI G SCREW
AIR MIX CONTROLCABLE
4.
Removethe four self-tappingscrews and the center

air vnt.
CENTEBAIR VE T
Installin the reverseorder of removal.and adjust the

air mix control cable at the heater unit lsee page
21-27). lf necessary,adjustthe heatervalve cable
l s e ep a g e 2 1 - 2 7 ) .
21-25
vnx.su
HeaterControlPanel
Overhaul
HEATERFAN SWITCH
Test, page 21-30
AIR MIX CONTROLCABLE

Adjustment, page 21-27
Air Mix Control Cable Replacomni

1. Removethe ait mix control caDle'
2.
lever, and push the cable housinguntil it

Hook the tip of the new air maxcontrol cableto the temperaturecontrol
is locked.
AIR MIX CO]IITROLCABLE
NoTE:Alterassemb|y,checkthatthetemperaturecontro||eve's|idessmooth|ythroughthe'u||strokefromright
to left.
21-26
vnx.su
Heater Valve Gable
Air Mix ControlCable
Adjustment
Adjustment
Disconnectthe heatervalve cablefrom the heater

valve arm and the clamp,and from the heatercontrol arm and the clamp.
'l
Disconnectthe air mix control cable from the air max

control arm and the clamp.
2.
Set the temperaturecontrol lever to MAX, HEAT.
3,
Turnthe air mix controlarm as shown. and connect

the end of the air mix cont.ol cable to the air mix
control arm.
4.
Gently slidethe air mix control cable housingback

trom the end enoughto take up any slack in the air
mix controlcable,but not enoughto makethe tempe.aturecontrol lever move, then snap the air mix
control cable housinginto the clamp.
2 . Set the temperaturecontrol leverto MAX. HEAT.

Turn the heatercontrolarm as shown. and connect
the end of the heatervalvecableto the heatercontrol arm.
Gentlyslidethe heatervalve cablehousingback from
the end enoughto take up any slack in the heater
valve cable,but not enoughto make the temperature controllever move. Holdthe end of the heater
valvecablehousingagainstthe stop, then snapthe
heatervalve cable housinginto the clamp.
NOTE: The heatervalvecableshouldalwaysbe adjusted wheneverthe air mix controlcablehas been

disconnected.
AIR MIX CONTROL
CABLE
HEATERCOIITBOL
ARM
5.
AIB MIX CONTROL

ARM
HEATEBVALVE
CABLE
Turn the heate.valve arm as shown, and connect

the end of the heatervalvecableto the heatervalve
arm.
Gentlyslidethe heatervalve cablehousingback from
the end enoughto take up any slack in the heater
valve cable, but not enoughto make the temperature control levermove,then snapthe heatervalve
cable housinginto the clamp,
NOTE: The air mix controlcableshouldalways be
adjustedwheneverthe heatervalvecablehas been
disconnected.
CLAMP
21-27
vnx.su
Mode Control Motor

Replacement
Test
Disconnoct ths mode control motot 8P connector,

and remove it from lhe heater unit.
ConnectbatterYpower to the No. 4 terminslof the

modecontrol motor and connectgroundto the No'
8 terminal.
Remove the two sclsws, mode control motot, and

flango coll8,.
Using a jumper wire, short the No. 8 terminsl individuallyto the No. 1, 2, 3. 6 and 7 terminals,in
that order.
MODECONTROL
iioroR
a Eachtime the short circuit is mad,the mode control motor should run smoothly and stop.
NOTE: ll the modecontrolmotordoesnot run when
shortingthe tirst terminsl,short that trminalagain
after shortingthe other terminals.
The mode control motor is no.mal it it runs when
shortingthe tirst terminalagain.
3.
lf the modecontrolmotor doesnot run in step 2, re'

move it, and check ths mode control linkage8nd
doors for smooth movement.It the mod control
linkageand doors move smoothly, replaceth mod
control motor.
21-28
vnx.su
lnst8ll in tho rsvsrse order of removal. After inst8llstion, make sur the modo control motor runs
smoothlv.
Recirculation
ControlMotor
Test
Replacement
Connectbafterypower to the No. 1 terminalof the

recirculation control motor, and connect ground to
the No. 2 and No. 4 terminals;the recirculation
control motor should run smoothly.
Disconnectthe 4P connector from the recirculation

control motor, and removethe wire harnessclio from
it.
Removethe two screws, recirculationcont.ol mo,
tor and flange collar.
Disconnectthe groundfrom the No. 2 or No. 4 terminals; the recirculation control motor should stoo
at FRESHor RECTRCULATE.
4P CONNECTOR
CAUTION: N6vr connct the batt6ry in ths oppoaite direction.

NOTE: Don't cycle the recirculationcontrol motor
for a long time.
SCREWS
3.
REC|RCULAT|OII
CONTROL
MOTOR
Instsllin the reverseorderof removal.After installation, make sure tha tecirculationcontrol motor runs
smoothlv.
It the recirculationconttol motot does not run in steD

'1,
removeit, and check the recirculationcontrol linkage and door for smooth movement.lf the recirculation control linkage and doo. move smoothly,
replacethe recirculationcontrol motor.
21-29
vnx.su
Heater Fan Switch
Relay
There should be continuity btween the A and C terminals when Dower and ground are connectedto the B and
D terminals.
There should be no continuity when power is disconnected.
Check for continuitv bstween the terminalsaccordingto

the table below.
Terminal
Position
OFF
,l
3
4
rl
r?
I
I
21-30
vnx.su
ooo-
-o
-o
-o
-o
RecirculationControl
Switch
Mode Control Switch
Test
Check for continuity between the terminalsaccordingto
the table below.
Terminal
Position
Heat/Def
o --o
--o
o-
Def
Vent
o-
Heat/Vent
G-
Heat
Check for continuity between the terminalsaccordingto

the table below.
Terminal
Position
Fresh
Recirculate
-O
oo-
--o
-- -o
--o
--o
21-31
vnx.su
Air Conditioning
*Evaporator
Repfacement
Overhauf
Compressor
.........22-26
................
22-27
Description
............
22-28
fffustratedfndex ...............................
22-29
Replacement
.........22-30
Cfutch lnspection .......................
......22-32
Cfutch Overhaul...............................
22-33
Refief Vafve Replacement...............
22-34
A/C Compressor Belt
Repfacement
.........22-35
Adiustment
............22-36
Condenser
Replacement
.........22-37
A/C System Service
Evacuation
....,.......,22-38
Charging
................
22-39
LeakTest
...............22-40
+: Read SRS precautionsbefore working in
this area.
vnx.su
SpecialTools
Ref. No.
Tool Numbel
OTLAJ- PT3O1OA
07JGG- 001010A
Test Harness
BeltTensionGauge
I
22-2
vnx.su
lllustratedIndex
CAUTION:
. All SRS electrical wiring harnossosare coverd with
yellow insulation.
. Bfors disconnacting any part of the SRS wire harness,connsct the 3hort connsctor(s).
. Replacethe entirs affscted SRS harness assembly it
NOTE;The original radio has a coded theft protection
c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
before
- disconnecting
the battery.
- r e m o v i n gt h e N o . 3 2 ( 7 . 5A ) f u s e f r o m t h e u n d e r hood fuse/relaybox.
After service,reconnectDowerto the radio and turn it
on. When the word "CODE"is displayed,enter the customer's5-digitcodeto restoreradiooperation.
SRSMAIN HARNESS
lcoverd with yellow insulationl
EVAPORATOR
page22-26
Replacement,
Ovethaul.Oase22.27
SERVICE
VALVE
IHIGHPRESSURE
SIDE)
SERVICEVALVE
(LOWPRESSURE
SIDEI
RECEIVER/DRYER
CONDENSER
Replacement,
page22,37
A/C PRESSURE
SWITCH
W h e n t h e r e f r i g e r a n tp r e s s u r ei s b e l o w 2 0 0 k p a ( 2 . 0
kqflcm,,28 psi) due to refrigerantleakageor above3]OO
kPa (32 kgf/cm,, 460 psi) due to coolant btockage,the A,/C
pressureswitch opens the circuit to the A"/Cswitch and
stopsthe air conditionang
to protectthe compressor.
vnx.su
COMPRESSOR
page22-30
Replacement,
22-3
Wiring/ConnectorLocations
A/C DIODE
CONNECTOR
(Loc.ted .bovo tho.ight kick p.n.ll
RADIA'OR FAN RELAY

{Localedin the undel-hoodfu3o/reltY box)
A/CTHERMOSTAT
CONNECTOR
CONDENSERFAN
CONNECTOR
MAIN WIREHARNESS
A/C WIREHARNESS
CONNECTOR
RADIATORFAN
CONNECTOR
A/C WIREHARNESS
CLUTCH
COMPRESSOR
CONNECTOR
22-4
vnx.su
A/C PRSSURESWTTCH
CONNECTOR
Circuit Diagram
N0.41l10oAl No.39{5OAl
No.1317,5A)
MOIATOR
REI.AY
22-5
vnx.su
Description
Outline
refrigerantthroughthe sysThe air conditionersystemdeliverscooledair into the passengercompartmentby circulating
tem as shown below.
Hightemperature/ Trapsdebris Hightemperature/

Hightemperature/
hilh pressureliquid and removes high pressureliquid
gas
high pressure
molsture
heat
of
Radiation
SuctionandcomPression
RECEIVER/DRYER
coMpRESsoR
-coNDENSER
Moreliquidified
vaPor
low Pressure
Absorptionof heat
VALVE
EXPANSION
EVAPORATOR
<-'----------.-
Less moisturized
low pressurevaPor
EVAFORATOR
CONDENSOR
to the following
{R-134a)refrigerantwhich does not containchlorofluorocarbonsPay attention
This car uses HFC-134a
service items:
(R-134a)They are not compatible'
Do not mix refrigerantsCFC-I2(R-l21and HFC-134a
designedfor the Rrefrigerantoil (ND-OIL8: P/N38899-PR7-A01)
potyatkytenegtycol
{PAG)
Use onty the recommended
oil
will resultin comrefrigerant
134acompressor.Intermixingthe recommended(PAG)refrigerantoil with any other
pressortailure.
.A||lvcsystemparts(compressor.dischargeIine,suotionIine,evaporator,condenser.receiver/dryer,expansionva|ve.
o-ringsforioints}havetobeproperforre'rigerantR-l34a.DonotconfusewithR.l2parts.
. Usea halogengas leakdetectordesignedfor refrigerantR-134a'
Only use a Recovery/Recyclins/Charging
. R-.12and C-l34a refrigerantservicingequipmentare not interchangeable.
J2210
to serviceR-134aair conditioningsyssAE
of
requirements
the
to
meet
and is certifLd
Systemthat is U.L.-listed
rems.
any
Systembeforedisconnecting
. Always recoverthe refrigerantR-134awith an approvedRecover/Recycling/Charging
A,/Cfitting.
.
.
22-6
vnx.su
Troubleshooting
Reference
Ghart
.
.
Any abnormality must be correctsd before continuing the test.

Becauseof the precisemeasurgmentsneeded,use a multimeter when testing.
Before performing any troubleshooting procedurescheck:

. Fuss.r No. 35120A), *1 No. 33 (20A), ), No. 13(7.5A)
. G r o u n d sN o . G 4 0 1 G
, 2 0 1G
, ' 1 5 1G, 1 0 1
. Cleanliness
and tightnessof all connectors
*1:In the under-hoodfuse/relaybox
*2:In the under-dashfuse/relaybox
SYMPTOM
REMEDY
Radiatorfan does not run 8t all.
Performthe proceduresin the flowchan(seepage22-8).
Condenserfan does not run at all.
Performthe proceduresin the flowchart(seepage22-10).
Both fans (radiatorand condenser)do not

run for engine cooling, but they both run
with the Ay'Con.
Performthe proceduresin the flowchan(seepage22-12).
Eothfansdo not run at all.
Compressorclutchdoes not engage.
Ay'Csystem does not come on

{compressorand both fans}.
22-7
vnx.su
Troubleshooting
RadiatorFan
Redi.to. fan doo3 not run at all.
check rhe No. 33 {20 A) fuse in
the under-hoodluse/relaybox.
R e m o v et h e r a d i a t o rl a n r l a y
from the under-hoodIuse/relay
box and test it (seepage 22-19).
Raplacatha radiator tln rahy.

ground{-}.
ls therg batteryvoltag?
Connectthe No. 1 and No. 3 terminalswith a jumperwire.

Doesthe radiatorIan run?
To p3ge 22-9
Chockfor continuityin the BLK./

REDwire between the No. 1 terminaland the radiatorfan.
R.p.ir opdr in th. 8LK/RED wir.
batwaon th. unda.-hood fut./
ralay box rnd tha radirtor f.n.
Checkfor continuity in th BLK
w i r e b e t w e e nt h e r a d i a t o r{ a n
and body ground.
Ch.ck to..n op.n in th. BLK
wirc batwaan th. rldirtor hn
lnd body ground, lf tha wita i!
OK, chack tor poor gtound rt
G2ol lnd GiOl.
Rephco tho radi.tor frn motor.
22-A
vnx.su
Fromprge 22
Disconn.ct the iump.r wirc lnd

tu.n th6 ignition gwitch ON (fD.
Mo66u,otho voltlgs botwoontho

No. 4 torminll (+) 6nd bodv
ground {-}.
Rap.lr o9.|| ln th. GRN wlr. b+,
twaan tha ondar.hood tuaa/
rtLy box .nd thr A/C diod..
B.p.lr olrn h th. BLX.IYEL

wlrr
batw..n th. undar.hoodtu../
rcl.y bor aDd iha undar.darh
fur/r.Ly box.
22-9
vnx.su
Troubleshooting
CondenserFan
BLK/WHTl+l
Removethe condenserfan relay
and test it (seepage22-19).
Replacothe condan3arfrn rclay.
Measurethe voltag betwenthe

WHT wire terminal(+) and body
ground(-).
Replir opcn in tho WHT wiro botwoen tha undor-hoodfura/Jolay
box rnd tha condonr.rlan rclay.
BLU/YEL
Viewlrom wireside
Connoctthe WHT and BLU/BLK

w i r e t e r m i n a l sw i t h a j u m P e r
Doesthe condenserfan run?
10 page 22-11
View from wire side

Checkfor continuityin the BLU/
BLK wire betweenthe condenser
fan
Ian relayandthe condenser
BLU/BLK
Reprir opn in th. BLU/BLKwiro
batwcen the condenrai lan rolay
and the condcntor ftn
Checkfor continuity in the BLK

wire between the condenser fan
and body ground.
C h e c kf o t . n o p . n i n t h o B L K
wire botween the condental trn
and bodv g.ound. It the wiro i3
OK, chock lor Poo. ground rt
G151.
Raplaco the condon36r fan motor.
22-10
vnx.su
Frompage22-10
Disconnectthe iumper wire and

turn the ignitionswitchON (ll).

BLK/WHTwire terminal (+) and
body ground(-).
Reptir open in tha BLK/WHT o.
BLK/YELwire betwoon tho conden3o. f.n rel.y and tho unde.dash tus6/rel.y box.
Remove the iay'Cdiode from the
Ay'Cdiode 3P connector.
ls the A,/Cdiode OK?
Reprir op6n in th. BLU/YELwire

betwocn tho conden3ertsn reltv
.nd tho A/C diod.
22-11
vnx.su
Troubleshooting
Bolh tanr lradiltor and condan.arl do not run fot angina
cooling. bul th.y bolh tun whh
th. A/C on.
Disconnecttho engino coolanl

temporsture(ECT)switch 2P conn6ctor.
Turnrhe ignitionswitchON (ll).
Measureth voltago botwenth6

cRN wire terminal(+) and body
ground{-}.
R.p.ir op.n in ih. GRN wir. b.tw..n th. ECT .wilch .nd th.
undrr.hood ful./t l.y box.
Turn the ignition switch OFFand

check lor continuity in the BLK
wire beMeen the ECTswitch and
body ground.
Ch.ck tor.n op.n in th. BLK
wir. b.lw.!n th. ECT .witch
.nd body ground. It th. wit. i.
OK, chacl lor poor Oround tt
G10r.
Dos it road above normal?
22-12
vnx.su
Both Fans
Both tans do not run at all.
Remove the A,/Cdiode from the

A,/Cdiode 3P connector.
ls the !y'Cdiode OK?
Rep.ir opn in tho 8LU/REDwirc

belwoen tho A/C diod. lnd th.
A/C o.$sure lwitch.
22-13
vnx.su
Troubleshooting
Gompressor
R6movethe comPressorclutch
refayand test it (see Page22-19l..
BLK/YEL{+l
WHTl+l
Measurothe voltage bgtlveenth

WHT wire terminal{+) and body
ground{-}.
Rap.ir op.n in ih. WHT wit.
batwaan tha undar-hood fuaa/
ralay box and thg comptaalol
clutch r.l.y.
Connect tho WHT and 8D wire
terminalswith a jumPerwire.
BLK/RED
Viewfromwirside
View lrom wire side
Disconnect the comPressor

clutch1Pconnsctor.
To page22-15
Checkfor continuityin the RED

w i r o b o t w e e nt h e c o m P r e s s o r
clutch relay and the comPressor
clutch.
Replir op.n in th. REO wi.c
batwaan tho comPrdaor clutch
rol.y and the compr.33oi clulch.
Inapact tha compter3oa clutch

clelranca !nd ihc comPacaaor
ctutch fild coil {!.. P.9.22'32}.
22-14
vnx.su
Frcm page22-11
Turn the ignition switch ON (lI).
Masurethe voltage betweonth6

BLK/YELwire terminsl {+) and
body ground (-).
R.p.i. opcn in th. 3LX/YEL wirr

balwarn tha undar.da3h tuaa/
.clay box and iha como.aaao.
clutch rahy.

i n s t a l l t h e c o m p r o s s o rc l u t c h
relay.
Bdt ry vohro.?
Connectthe test harness"A" and
"8"
conoectorsto th6 main wire
harnessonly, not to the ECM(s6g
section11).
_@_____-l
Blttary vohago?
r_--@_
Bs {+)
Turn th6 ignition switch ON (II).

TESTHARNESS
07t4, - PT3010a
Measurethe voltagGbetweenthe
A15 terminal (+) and body
ground(-1.
R.prir op.n in th. BLK/REDwirt

b.twran the compraa.or clotch
..1.y .nd th. ECM.
Make sure the A/C and heate. ten
switch6sare OFF.
Measuretho voltage btweenthe

85 terminsl(+) and body ground
(-).
R.p.ir op.n in th. BI-U/REDwir.

b.tw.rn th. A/C diod. .nd th.
CCM.
Sub.titute r known-good ECM
and rocheck. lt lymptom/indicrtion go3rwry, rapbca th. originrl ECM.
22-15
vnx.su
"
-1llltf,'tfrSfiiwiafi
Troubleshooting
A/G System
A/C ay3t6m doe3 not como on
(compro!3orand both f.ns).
D i s c o n n e c tt h e A / C p r e s s u r e
switch 2P connector.
Turnthe ignitionswitchON (II).
Measurethe voltage beoveenthe

w i r e t e r m i n a l( + ) a n d
BLU/RED
bodv ground1-).
View from wire side
Reprir opon in thc 8LU/REDwire

batwoan tho A/c prossute
rwitch rnd th. A/C diod..
Turnthe ignitionswitchOFF.
Checklor continuity betwoenthe

No. 1 and No. 2 terminalsof the
A,/Cpressureswitch.
Checkfor NC system Pressure.
R e c on n e c t t h e A / C p r e s s u r e
switch2P connector.
10 page22-17
22-16
Rophcetha A/C pre3!u.6 awitch.
vnx.su
YEL/WHT
BLU/RED{+l
Frompage22-15
Turnthe ignitionswitchON (IIl.
YEL/WHTl+l
Measuretho voltage betweonthe
BLK/YELwire terminal (+) and
body ground(-).
R.p.i. op.n ir th. BLX/YEL wiro

batwc.n tha unda.-darh fuao/
r.l.y box .rd rh. A/C th.rmo.t!r.
Measureth voltage betweenthe
YEL/WHTwire terminal {+} and
body ground (-).
ls there battoryvoltage?
R.prir op.n in th. YEL/WHT

wiro bctwaan tha A/C praaau.c
rwhch .nd th. A/C th..mo.ht.
T!rn the ignition switch OFF.
Rconnectthe Ay'Cthermostat 3P
connctorand connectthe BLU/
REDwire terminalto groundwith
a l!mper wire,
View from wir side
Do the radiator and cond o n s e rf a n s r u n a n d t h e

compressorclutchengage?

disconn6ct
the jumperwire.
To page 22-18
(cont'd)
22-17
vnx.su
Troubleshooting
A/C System(cont'dl
Frcm page22'17
Removethe heatercontrolPanel
(seepage21 25)
D i s c o n n e c t h e h e a t e rc o n t r o l
panel14Pconnector'
No. 11 BLU/REDl+l
View lrom wire side
Turnthe ignitionswitchON (lI).
w i r e t e r m i n a l( + ) a n d
BLU/RED
body ground{ }
Rop.i. opon in tho BLU/BEDwir.
b.twoon tha A/C thermort.t lnd
the haat.r control Panal
ls the A/C switch OK?
Checkfor continuitYin the GRN

wire betweenthe heatercontrol
paneland the heaterfan switch
R.prir op.n in the GRN wiro be'
twoen thc hartet contlol Panal
and tho h.rtor fln switch.
Checkfor continuity in the BLK

wire between the heater{an
switchand body ground.
Chock fol an opon in the BLK
wi.a b.tween th. hotte. hn
lwitch tnd bodY ground. ll tho
wiro it OK, chock for Poor
g.ound .t G4ol .nd G402.
Replace the heater lan switch.
22-18
vnx.su
A/C Thermostat
Relays
Test
Connectbatterypower to terminalC and ground terminal B, and connecta test light betweenterminalsA and
N O T E :U s ea 1 2V , 3 W - 1 8 W t e s tl i g h t .
Thereshould be continuitybetweenthe A and C term!

n a l s w h e n p o w e r a n d g r o u n da r e c o n n e c t e dt o t h e B
and D terminals.
There should be no continuitywhen power is disconnected.
Dip the A-/Cthermostat into a cup filled with ice water,

and checkthe test light.
,r I
The light should go off at 37"F(3"C)or less.and should

come on at 39"F(4"C1or more.
.I I
lf the light doesn't come on and go off as specified,

replacethe Ay'Cthermostat.
.
b
P
Radiatorfan relay
12V.3W-18W
a Condenser
fan relay
a Compressor
clutchrelay
22-19
vnx.su
A/C Switch
Diode
Test
Test
NOTE: The diode is designedto pass current in one
directionwhile blockingit in the oppositedirection.
U s e a n a n a l o g o h m m e t e r ,o r a d i g i t a l o h m m e t e r
equippedwith a diodetester.
Checkfor currentflow in both directionsbetweenthe A
and B. and B and C terminals.There should be current
flow in onlv one direction.
NOTE:The Ay'Cswitch containsa diode. Use an analog

ohmmeter,or a digitalohmmeterequippedwith a diode
tester.
Checkfor current flow in both directions betweentermi
nals 11 and 12.Thereshouldbe currentflow in only one
direction.
Terminal
Position
ON
OFF
22-20
vnx.su
11
A/C ServiceTips and Precautions

(R-134a)
The air conditionersystemusesHFC-134a
(PAG)retrigerantoil (ND-OILg: p/N
.efrigerantand polyalkyleneglycol
38899- PR7- A0l ), which are not compatiblewith CFC-12
refrigerantand mineraloil. Do not use R-12refrigerantor
\R-'12)
mineraloil in this system,and do not attemptto use R-'12servicingequipment;damageto the air conditionersystemor
your servicingequipmentwill result.
only use serviceequipmentthat is u.L,-listedand is certifiedto meet the requirementsof sAE J2210to removeR-134a
from the air conditionersvstem.
CAUTION: Exposurelo air conditioner refrigorant and lubricanl vapor or mi3t cln irritato gyos, nose and throat. Avoid
breathing lhe air conditioner refrigerant and lubricant vapor or mist.
lf accidentalsystemdischargeoccurs,ventilatework areabeforresumingservice.
R-134aserviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed
air.
some mirtures of air and R-l3ifa have been 3hown to be combu3tible at slsvated prossurosand can relult
@
in fire or explosion causing inlury or property damage. Never use complessod ai. to prgssuret|st R-134aservice equipment or vehicle air conditiongr systems.
Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricantmanufacturers.
'1. Alwaysdisconnect
the negativecablefrom the batterywheneverreplacingair conditioningpans.
2. Keepmoistureand dust out of the system.When disconnecting
any lines,plug or cap the fittingsimmediately;don't
removethe capsor plugsuntil just beforeyou reconnecteachline.
3. Beforeconnectingany hoseor line,applya few dropsof refrigerantoil (ND-OIL8: P/N38899- PR7- AO1)to the O-ring.
4. Whentighteningor looseninga fitting,usea secondwrenchto supportthe matchingfitting.
5. When recoveringthe system,use a R-134arefrigerantRecovery/Recycling/Charging
System;don't releaserefrigerant
into the atmosDhere.
6. Add refrigerantoil (ND-OlL8: P/N38899- PR7- A01)after replacingthe followingparts:
NOTE:
. To avoidcontamination,
do not returnthe oil to the containeroncedispensed,and nevermix it with other refriqerant orls.
. lmmediatelyafterusingthe oil, replacethe cap on the containerand sealittoavoid moistureabsorption,
. Do not spill the refrigerantoil on the car; it may damagethe paint;if the re{rigerantoil contactsthe paint,wash it
off immediately.
Condenser.....................
25 m/ (5/6fl.oz,0.9 lmp.oz)
ilo mf 17113fl.oz,1.4lmp.oz)
Evaporator.................
Line or hose
10 ml (1/3 fl.oz. o.il lmp'ozl
Receiver/Dryer
.....,.,,....,
10 m{ l1l3 tl.oz,0.4 lmp.ozl
Leakagerepair ..............
25 mf (5/6fl.oz,0.9 lmp.ozl
Compressor
For compressor .eplacomnt, subtract the volumo of oil drained from tho
removed compressor trom 140 ml 11 213 ll.oz, 1,9
imp.ozl, and drain the calculalgdvolume of oil from
t h o n e w c o m p r e s s o r :1 4 0 m f 1 1 2 1 3 l l . o z , 1 . 9
imp.ozl- Volume ot removod compressor= Volume
to drain from nw compressor.
NOTE:Even if no oil is drainedfrom the removed
c o m p i e s s o rd, o n ' t d r a i n m o r e t h a n 5 0 m l 1 1 2 1 3
fl.oz,1.8lmp .oz)from the new comDressor.
hoseto the compresso.(6 x 1.0mml

O Dischargo
(, Dischargehosato ths condenser(6 x 1.0mm)
pipeto tho condenser(6 x 1.0mml
@ Condenser
pipeto the receiver/dryer
(6 x 1.0mm)
@ Condenser
pipeA to tho receiver/dryer
@ Receiver
16x 1.0mm)
..............................
9.8N.m {1.0kgt.m,7.2lbf.ft)
. 9.8 N.m {1.0kgf.m,j.Z lbl.ftl
9.8N.m n.O kaf.m,t-2tbl.ftl
.........................
9.8N.m (1.0katm,7.2lbf.ft)
.........................
9.8N.m(1.0kttm. 7.2lbt.ft)
@ Receiverpipe A to th6 receiverpipe B ......................................
........13N.m {1.3kgt.m.9.4lbt'ft)
O Receiverpipe B to the receiverpipe C ......................................
@ Receiverpipe C to the evaporator(6 x 1.0mm)

@Suaion pipB to the evaporator{6x 1.0mm) ................
@ SustionpipeA to the suctionpipeB ..................
(, Suctionhoselo the suctionpipeA ................
OASuctionhoseto the compressor
{5x 1.0mm} ................
13 N.m {1.3 kgf.m.9.4 lbf'ft)
9.8 N.m {1.0kgf.m, j.Zlbl.ftl

................
9.8N.m tt.Ot!f.-, r.Z tUttt}
3t N.m (3.2klnm,23 lbf.ft)
......31 N.m (3.2kgf.m,23 tbf.ftl
.................
9.8N.m11.0kgt.m,7.2lbf.ft)
22-21
vnx.su
A/C System Service

Recovery
and is cerOnlv use serviceequipmentthat is U.L.-listed
tified to meetthe requirementsof SAEJ2210to remove
(R-134a)
from the air conditionersystem.
HFC-134a
CAUTION: Expo3ute to air conditioner rcfrigelant rnd
lubricant vapor or mist can irritatc oyo!, no3o and
throat. Avoid bresthing the lir condhionot rofrigorlnt
and lubricant vapor or misl.
R.cov.rylR.cycling/Ch.rging
lf accidentalsystem dischargeoccuts, ventilate work

areabeforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak tested with
comoressedair.
some mixturos ot Eir and R'134. hsvc
!!@
bsen shown to be combu3tible st elavllcd prs33urc3
and can result in fire or oxplosion cau3ing iniurY or
property damage,Nsvor u36 comprg3Sodlir to P|'3turl
test R-134aservic equipmont o. vohiclc rir condhioncr
3ystems.
A d d i t i o n a lh e a l t h a n d s a f e t y i n f o r m a t i o nm a y b e
obtained from the refrigerantand lubricant manufacrures.
'1. Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystem to the car, as shown, following
instructions.
the equipmentmanufacturer's
2.
M e a s u r et h e a m o u n t o f r e f r i g e r a n to i l r e m o v e d
from the A/C system after the recovery process is
comoleted.
NOTE:Be sure to installthe same amount of new
r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o t e
charging.
22-22
vnx.su
Pf,ESSUFE
sy.t m.
PressureTest Chart
NOTE: PerformanceTest on page 22-24.
TESTRESULTS
RELATED
SYMPTOMS
Dischsrge
AftErstoppingcompressor,pressure
(high)pressure dropsto about200kPa(2.0kof/cmr.28
psi)quickly,andthenfallsgr;dua y.
abnormally
nrgn
PROAABLE
CAUSE
Air in system
No bubbles in sight g16sswhen condenser is cooled bv water.

Reducedor no air flow through conoenser.
E-\cessive
refrigerantin sys-
Lineto condenseris excessivelvhot.
Restrictedflow of refrigerant In syslem
Cloggedcondenseror
radiato. fins
Condenser o. radiator fan
not working properly
Dischargepres- Excossive
bubblesin sightglass;
sure abnormal- condenser
is not hot.
Highand low pressures
arebalanced
soonafterstoppingcompressor.
Low
sideis higherthannormal,
Outletof expansionvslve is not frosted,low pressure
gaugeindicates
vacuum,
Suction(lowl
Excessive
bubblesin sightglass;
pressure
conqenser
rsnot hot_
abnormally
low
Insufficient refrigerant in
syslem
FaultycompressordiscnargevaNs
Faultycompressorseal
. Faultyexpansionvalve
. Moisturein sysiem
Insufficientrefrigerant
Expansion
valveis nottrostedandlow
pressurline is not cold. Low pressure
gaugeInorcates
vacuum.
. Restricted
lines
Checkfor leak
Charge system
Replacethe compressor.
. Replace
. Recover,evacuateand recharoe
with specifiedamount.
Reoairthe leaks.
Reaover,evacuateand recharoe
with sDecifisd
amount.
Charqeas required.
Replacethe expansion valve.
Discharge temperaturg is low and the

air flow from vents is restricted.
Frorenevaporator
Expansionvalveis frostd.
Receiver/dryer
outlet is cool and inlet
isrryarm(shouldbe warm duringoper-
Runthe tan with comoressoroft

then checkAy'Cthermostat.
Clogged expansion valve
Cloggedrceiver/dryr
Clanor replace.
Replace
'
Repairor replace.
SuctionpresLow pressurehose and checkjoint are

sure abnormal- coolerthan the temDeraturoaround
ly high
evaDorator.
Suctionpressure
is loweredwhencondenseris cooledby water,
Highandlow pressure
areequalized
as soon as the compressoris stopped,
andbothgaugesfluctuatewhilerunnrng.
Suctionand
discharg pressufes aonormally high
Frozen expansion valve

Faulty expansion valve
REMEDY
Recover,evacuate and recharqo
with sDecifiedamount.
Evacuation:see Daqe22-38
Charoino:se6 D;op--2?-?q
Recover,evacuate and recharqe
with specitiedamount.
Clean
Checkvoltage and fan rpm
unecKlan ofeclton
Reducedair flow through condenser.
No bubblesin sight glasswhen conclnser is cooled bv water.

Suctionsnd
Low pressure hose and metal end
dischargepres- afeas are cooler than evaDorator.
sur abnormal- Temperaturearound
expansionvalve
is too low compared with that around
recerver/orver.
Refrigrant
Compressorclutchis dirty.
leaks
Compressorbolt(s)are dirty.
Compressorgasketis wet with oil.
u"lu"oD"ntoo
ffin"nsion
. Looseexpansioncapillary
Excessive
refrigerantin sysrem
Recover,evacuateand recharqe
with sDecifidamount.
Faultv oasket
FaultyFigh pressurevalve
Foreign particle stuck in
high pressure valve
. Cloggedcondenseror
radiatorfins
. Condenseror radiatorfan
not working properly.
Excessive
refrigerantin sysrem
Rgcover,vacuate and recharoe

with spcified amount.
Fepair or replace.
Cloggedor kinkedtow presure nos pans

Cloggedhigh pressureline
Cleancondenserand radiator
Checkvoltageand fan rpm
Checkfan direcrion
Repairor replace.
Compressorshaftsealleak-
Replacethe comDressor.
Leaking around bolt(s)
Tightenbolt(slor replace
compressor.
Ing
I Gasketleaking
22-23
vnx.su
A/G System Service

PerformanceTest
The performancetest will help determineif the air conditionersystemis operatingwithin specitications.
and is cerOnly use serviceequipmentthat is U.L.-listed
tified to meet the requirementsof SAE J2210to remove
HFC-134a
{R-134a)
Rocov.rylB.cycling/Ch!lging SFtrm.
CAUTION: Exposure to air conditioner relrigrant and

lubricant vapor ot mist can irritate eyes, nose and
throat. Avoid breathing the air conditioner rstrigerant
and lubricant vapor or mi3t.
It accidentalsystem dischargeoccurs,ventilate work
R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak testedwith
atr.
comPressed
some mixtures ot air and R'1344 hrv6
!@
been shown to be combustibls at elovatod prsssurel
and can result in firg or explosion causing iniury 01
property damage.Ngvor usg compregsedail to prossuro
tst R-134assrvice equipment or vohicl air conditioner
systms.
A d d i t i o n a lh e a l t h a n d s a f e t y i n f o r m a t i o nm a y b e
obtainedfrom the refrigerantand lubricantmanufacturers.
1.
Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystem to the car, as shown, iollowing
instructions.
2.
Inserta thermometerin the centervent outlet.

Determinethe relativehumidityand air temperature
by callingthe localweatherinformationline,
3.
Testconditions:
. Avoid directsunlight.
. Open hood.
. Openfront doors
. Set the temperaturecontrol leverto MAX COOL,
the mode control switch on VENTand the recirculationcontrolswitchon RECIRCULATE.
. Slidethe heaterfan switchon MAX
. Runthe engineat 1,500rPm
in vehicle.
. No driveror passengers
4.
A f t e r r u n n i n gt h e a i r c o n d i t i o n i n gf o r 1 0 m i n u t e s
under the above test conditions.read the delivery
temperaturefrom the thermometerin the dash vent
and the high and low systempressurefrom the A,/C
gauges.
22-24
vnx.su
LOWPRESSURE
To completethe chans:
. Markthe deliverytemperaiurealongth venicalline.
o Mark the intaketemperature (ambient air temperature)8long the bottom line.
o Drsw a line strsightup from the air temperatureto the humidity.
. Mark I point one line above and one line below the humidity l6vel (10 % above and 10 % below the humidity
l6vsl).
. Fromeachpoint,drawa horizontalline acrossthe deliverytemparaturs.
. The deliverytemperatureshouldfall betweenthe two lines,
. Completethe low side pressuretest and high side pressurtest in the sameway.
o Any measurementsoutside the line may indicatethe need for further inspection.
29q)
(301
Ii(t0l
kp.
lksf/cm')
lpril
at%
2stx'
t25)
t360l
kpr
lkgflclrfl
lpril
2qx)
t20l
t2q)l
500
15{Xt
{151
12r0t
,o0
OEUVERY
PRESSURE
9BO
t10l
t1()l
T'EUVERY
PRESSUNE
ts)
171!
{4)
tsTl
86
t30)
3q,
{3t
II
71
l25l
ax)
68
120,
l2l
t28t
INTAKE
PRESSUBE
30%
100
t1l
n4l
59
t15l
50
(101
11
ts)
DEUVERY
TEMPEMTURE
77
{25t
6
t30t
95
(35}
104
laltl
"F
fc}
INTAKETEMPERATURE
22-25
vnx.su
Evaporator
Replacement
CATION:
. All SRS eloctrical wiring harnessesare coverod with
yollow in3ulation.
. Btore disconnocting 8ny part of tho SRS wire harnsss,conngqtth 3hort connestor{sl.
. Roplacaths entire aftected SRS harness a$embly if
3.
Removethe glove box (seesection20).

Removethe four boltsand the glove box frame.
Disconnectthe connector from the Ay'Cthermostat,

and removethe wire harnessclips from the evaporator.
lcove.edwith yellowinsulation)
L
Recoverthe refrigerant with a Recovery/Recycling/

ChargingSystem lsee page 22-22]-.
2.
Femovethe bolts,and disconnectthe receiverline

and the suctionline from the evaporator.
Removethe four self-tappingscrews,mountingbolt

and the mountingnut.
1.
Disconnectthe drain hose,and removethe evaporator.
NOTE:Plug or cap the lines immediatelyafter disconnectingto avoid moistureand dust contamination into the svstem.
SUCTIONLINE
6x1.0mm
9.8 N.m {1.019f.m,
1.2 tbl.ttl
6x1.0mm
9.8Nm{1.0kg{.m,
7.2 tbtft)
8.
RECEIVEB
LINE
APORATOR
Installin the reverseorderof removal.and:

it you're installinga new evaporator,add refrigerant oil (ND-OIL8: P/N 38899- PR7- A01) (see
page22-2'll.
replacethe O-ringswith new ones at eachfitting.
and apply a thin coatof refrigerantoil (ND-OlL8:
P/N38899- PR7- A01l beforeinstallingthem.
NOTE:Be sure to use the right o-rings for HFC134a{R-134a}
to avoid leakage.
applysealantto the grommets.
a makesurethat there is no air leakage.
a chargethe system (see page 22-39)and test its
performance(see page 22-241.
22-26
vnx.su
Overhaul
L
Pull out the Ay'Cthermostat sensor from the evaporatorfins.
2.
Removethe self-tappingscrews and clamps from

the housing.
3.
C a r e f u l l ys e p a r a t et h e h o u s i n g sa n d r e m o v et h e
evaporator.
5.
Assemblein the reverseorderof disassembly,

and:
.
4.
lf necessary,
removethe expansionvalve.
.
NOTE:When looseningthe expansionvalve nuts.
usea secondwrenchto hold the expansionvalveor
evaporatorpipe.Otherwise,they can be damaged.
feplacethe O-ringswith new ones at eachfitting,

and applya thin coat of refrigerantoil (ND-OIL8:
P/N38899- PR7- A01)beforeinstallingthem.
NOTE:Be sure to use the right O-ringsfor HFC134a{R-134a)
to avoidleakage.
i n s t a l lt h e e x p a n s i o nv a l v e c a p i l l a r yt u b e w i t h
the capillarytube in contactwith the suctionline
di.ectly,and wrap it with tape.
reinstallthe Ay'Cthermostatsensorto its original
location.
6 th fin trom inlet 3id6
1 2 0 1 5m m
14.72! 0.2 inl
EVAPOAATOR
blow dirt out of fins
with compressedair.
A/C THERMOSTAT
Test.page22-19
16 N,m 11.6kgl.m,
12 tbt.ttl
8 N.m (0.8 kgf'm, 6 lbf.ftl
24 N.m (2.i1kg{.m,
17 rbt.ftl
EXPANSIONVALVE
LOWERHOUSING
CAPILLARY
TUBE
TAPE
Replace.
Make sure there is no foreign matter stuck between
the capillarytube and outletline.
22-27
vnx.su
Gompressor
Description
(R-' |34a).
A revolvinginclineddiscdrivesthe surThis compressoris a Nippondensopistontype compressorfor HFC-134a
protectedby a ceramicshoe,thus
pistons,
pushes
the
it
revolves.
disc
inclined
prstons.
As
the
rounding10 reciprocating
compressingthe refrigerant
/al
?-*:-=3
22-28
vnx.su
lllustrated lndex
CENTER
BOLT
CLUTCH
SET
Inspoc!on,
page 22-32
SNAPRINGA
Replace.
colL
Inspection, pag6 22 32
-t
f--
COMPRESSOR
COMPLETE
lDo nor disassemble)
RELIEFVALVE
R e p l a c e m e n t ,p a g e 2 2 - 3 4
22-29
'-f
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Compressor
GlutchInspection
Checkthe platedpartsot the pressureplatetor color
changes.peelingor other damage.lf there is dam8ge,replacethe clutchset.
of the tield coil.

Checkresistance
Checkthe pulley bearing play and drag by rotating

the pulleyby hand.Replacethe clutchset with a new
one if it is noisvor hasexcessiveplay/drag
replacethe
lf resistanceis not within specifications,
field coil.
Fisld Coil Rosistance:3.6 t 0.2 ohm at 68"F {20'C)
Measurethe clearancebetlveenthe pulley and the

pressureplate all the way around.lf the clearanceis
not within specifiedlimits,the pressureplatemust be
removedand shims added or removed as required.
Jollowingthe procedureon page22-33.
Clearrnce:0.50t 0.15mm {0.02i 0.01inl
NOTE:The shims are availablein three thicknesses:
0 . 1m m , 0 . 3m m a n d0 . 5m m .
22-32
vnx.su
GlutchOverhaul
l.
Removethe centerbolt while holdingthe pressure

ptate.
A/C CLUTCHHOLDER
commorciallyavailsble
Robinair: P/N 10204
Kont.Moore:P/N J37872
CENTERBOLT
13.2N.m (1.35kgt.m,9.76lbf.ftl
R e m o v et h e s n a p r i n g B w i t h a s n a p r i n g p l i e r s ,
then removethe pulley.
NOTE:
. B e c a r e f u ln o t t o d a m a g et h e p u l l e ya n d c o m presso.during removal/installation.
a Oncethe snap ring B is removed,replaceit with
a new one,
SNAPRINGB
Replace.
Removethe pressureplateand shim(s),takingcare

not to losethe shims.
sHrM{s)
(cont'd)
22-33
vnx.su
Compressor
ClutchOverhaul(cont'dl
Removethe screwfrom the field coil ground termanal. Removesnap ring A with snap rjng pliers,then
removethe field coil.
1.
NOTE:
. Do not let the compressoroil run out.
. Make sure there is no foreign matter in the system.
NOTE:
. Be carefulnot to damagethe field coil a n d c o m
pressorduring removal/installation.
. Once snap ring A is removed,replaceit with a
new one.
SNAPRINGA
Replace.
FIELD
corL
Removethe reliefvalveand the O-ring.
4t-N r-l\
\
-l/
RELIEFVALVE
13.2N.m {1.35kgtm,9.76lbtftl
2.
5.
lnstall and tighten the relief valve.

a Cleanthe matingsurfaces.
a Replacethe O-ringwith a new one at the relief
lnstallin the reverseorderof removal,and:
t al
v a l v e ,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 no
(ND-OIL8: P/N38899- PR7- A01) beforeinstalling it.
NOTE:
. To avoid contamination,do not returnthe oil
t o t h e c o n t a i n e ro n c e d i s p e n s e da, n d n e v e r
mix it with other refrigerantoils.
. l m m e d i a t e l ya f t e r u s i n gt h e o i l , r e p l a c et h e
c a p o n t h e c o n t a i n e r ,a n d s e a l i t t o a v o i d
moistureabsorption.
. D o n o t s p i l l t h e r e f r i g e r a not i l o n t h e c a r ; l t
may damage the painu if the refrigerantoil
contactsthe paint,wash it off immediately.
Checkfor leaks,and insertthe cap in the top of
the valve.
install the field coil with the wire side facing

down (see above).
clean the pulley and compressor sliding surfaces
with non-petroleum solvent.
a check the pulley bearings for excessive play.
a make sure the snap rings are in the groove propefly.
apply locking agent to the threads of the center
bolt, and tighten it securelY
make sure that the pulley turns smoothly after
it's reassembled.
22-34
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A/C CompressorBelt
Replacement
Automatic TransmissionType
1. Loosenthe adjust pulley bracketpivot bolt and the
adjusting bolt, then remove the A/C compressor
beltfrom the oullevs.
Manual TransmissionType
1. Loosenthe adjust pulley bracketpivot bolt and the
adjusting bolt, then remove the A/C compressor
beltfrom the pullevs.
2,
2.
Removethe two mounting bolts from the left front

engine mount, then pass the A,/Ccompressorbelt
through the gap betweenthe body and left front
en9rnemount.
ADJUSTINGBOLT
ADJUSTPULLEYBRACKET
PIVOTBOLT
Removethe two mounting bolts from the left front

enganemount.
Removethe enginemount nut, washer,bolt and the
leftfront enginemount.
Removethe A,./C
comoressorbelt.
ADJUSTINGBOLT
ADJUSTPULLEYBRACKET
PIVOTEOLT
l!l',
14x 1.25mm
83 N.m 18.5kgl.m.
61 tbf.ft)
LEFTFRONT
ENGINEMOUNT
l
a ar10 x 1.25mm
54 N.m (5.5 kgf.m,
4(' rbr.ft)
WASHER
Installin the reverseorder of removal,and adjust

the A,/Ccompressorbelt (seepage22-36).
1 2x ' 1 . 2 5m m
69 N.m {7.0 kgf.m,
51 tbf.ftt
10 x 1.25mm
54 N.m (5.5 kgtm, irc lbf.ft)
Installin the reverseorder of removal,and adjust

the Ay'Ccompressorbelt (seepage22-36).
N O T E : W h e n t i g h t e n i n gt h e e n g i n e m o u n t n u t ,
make sure the washer is set properly on the left
front enginemount as shown.
22-35
"t.M'
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A/C CompressorBelt
Adjustment
Dstlsqtion Method
1. Apply a force of 98 N (10 kgf, 22 lbf), and measure
the deflection between the A,/Ccompressor and the
crankshaftDullev.
Tonsion Gauge Method

1. Attach the belt tension gaugeto the Ay'Ccompressor belt as shown below, and measurethe tension
of the belt.
A/C CompressotBelt
Used 8lt: Bl8Bl engine 390 - 540 N
(40 - s5 kgf, 88 - 120 lbfl
Bl8Cl ongine 3il0 - il90 N
(35 - s0 kgf, 77 - 110 lbfl
Nw Belt 7,10- 880 N {75 - 90 kgf, 170-200lbl}
A/C CompressorBelt
UsdEelt:81881engine7.5- 9.5 mm (0.3- 0.4 in)
Bl8Cl engine8.5- 10.5mm (0.3-0.11 inl
New Belt: 5.0- 7.0 mm (0.2- 0.3 inl
Power Stesring Pump Belt
'l1.5- 13.5mm (0.,[5- 0.53inl
UsedBeli:
New 8lt: 8.0- 10.0mm (0 3 - 0.39inl
Powor Steoring Pump Belt

Used Belt: 390 - 5,{l N (40 - 55 kgf, 88 - 120 lbll
N6w Bolt: 74O- 880 N 175- 90 kgf, 170-200lbt)
NOTE:
. 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.
NOTE:
. lf there are cracksor any damageevidenton the
belt, replaceit with a new one.
. F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n sf o r t h e
belttensiongauge.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
tor lessthan five minutes,
2.
Loosenthe adjust pulley bracketpivot bolt and the

adjustingbolt locknut of the Ay'Ccompressorbelt.
3.
Turn the adiustingbolt to get proper belt tension,

then retightenthe adjust pulley bracketpivot bolt
and the adjustingbolt locknut.
2.
Loosenthe adjust pulley bracketpivot bolt and the

adjustingbolt locknut of the AVCcompressorbelt.
Recheck
the deflectionof the lvc compressorbelt
3,
Turn the adjustingbolt to get proper belt tension,

then retightenthe adjust pulley bracketpivot bolt
and the adjustingbolt locknut.
4.
Recheckthe tensionof the A{/Ccompressorbelt.
4.
22-36
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Condenser
Replacement
Recoverthe relrigerantwith a Becovery/Recycling/
ChargingSystem (see page 22-221.
Removethe coolantreservoir,
NOTE: Do not disconnectthe reservoirhose from
the coolantreservoirand the radiator.
Removethe bolts.and disconnectthe dischargeline

and the condenserlinefrom the condenser.
NOTE:Plug or cap the lines immediatelyafter disconnectingto avoid moistureand dust contamination into the system.
DISCHARGE
LINE
COOLANT
RESERVOIR
6x1.0mm
9.8 N.m (1.0kgl.m,7.2 lbt.ft)
......-.....
CONOENSER
LINE
Removethe two mounting bolts, then lift out the

condenseras shown.
NOTE: Do not damagethe radiatorand condenser
fins when removingthe condenser.
6x1.0mm
9.8N.m(1.0kgf.m,7.2lbl.tt)
R e m o . v teh e b o l t s a n d t h e r a d i a t o ru p p e r m o u n t
brackets,and removethe bolt from thg suctionhose
bracket.
9.8 N.m {1.0 kgf.m.7.2 lbtftl
Installin the reverseorderof removal.and:

. if you'reinstallinga new condenser,add refrigerant oil (ND-OIL8: P/N 38899- PR7- A01) (see
page 22-21t,.
. replacethe O-ringswith new onesat eachfitting,
and apply a thin coat of refrigerantoil {ND-OIL8:
P/N38899- PR7- A01)beforeinstallingthem.
NOTE:Be sure to use the right O-ringsfor HFC1 3 4 a( R - 1 3 4 at o) a v o i dl e a k a g e .
a do not damagethe radiatorand condenserfins
when installingthe condenser,
. be sure to installthe condensermount cushions
securelyinto the holes.
. chargethe system (see page 22-39)and test its
performance(see page 22 24!.
RAOIATORUPPEN
MOUNT BRACKETS
22-37
'1Iffi
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A/G System Service

Evacuation
and is cerOnly use serviceequipmentthat is U.L.-listed
tified to meet the roquirementsof SAE J2210 to remove
(R-134a)
lrom the 8ir conditionersystem.
HFC-134a
R.cov.ry/R.cycling/Chtroing
CAUTION: Exposulo to 6ir conditioner refligorrnt and

lubricani vapor or mi3t crn i.ritato 9y33, noaa and
thrort. Avoid bratthing ths .ir conditionor rsfrigorrnt
snd lubricsnt vtpor or mist.
lf accidentalsystem dischargeoccurs,ventilate work
area before resuming service.
R-134aserviceequipmentor vehicle8ir conditionersystems should not be pressuretested or leak tested with
compressedait.
somo mixtuto3 ot ril and R'134! hav.
!@
been shown to bo combustible at olevltad prossulo3
and can re3ult in fire or explosion crusing inlurY or
property damago,Navor us! comprossodair to prgsauro
test R-13/aa3orvicr quipmlnl or vohiclo air conditionol
sy3lems.
Additional health and safety information may be obtainedfrom the retrigerantand lubricantmanufactures.
1. When an Ay'CSystemhas beenopenedto the atmosDhere,suchas during installationor repair,it must
be evacuated using a R-134arefrigerant Recovery/
Recycling/ChargingSystem. {lf the system has been
open for several days, the receiver/dryershould be
replaced.l
2.
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 y / R e c y c l ing/ChargingSystemto the car, as shown, followinstructions.

ing the equipmentmanufacturer's
NOTE; lf tow pressuredoes not reach more than
9 3 . 3 k P a ( 7 0 0m m H g , 2 7 . 6 i n ' H g )i n 1 5 m i n u t e s ,
t h e r e i s p r o b a b l ya l e a k i n t h e s y s t e m .P a r t i a l l y
charge the system and check tor leaks {see Leak
Test).
2234
vnx.su
aotnPRESSURE
SIDE
Syttom
Charging
Only use serviceequipmentthat is U.L.-listed
and is certified to meet the requirementsof SAE J2210 to remove
(R-134a)
HFC-134a
from the air conditionersvstsm.
R.cov.rylRccacling/Ch.rging Syrtom
CAUTION: Exporuro to rir conditionor .etrigorant and

lubric8nt yapor or misl can irritats cyos, no36 and
throlt. Avoid broathing tho lir conditionor rofrig6rant
lnd lubricant vlpor or mbt,
It accidentalsystem discha.ge occurs, ventilate work
a r e a b e f o r e r e s u m i n gs e r v i c e .A d d i t i o n a lh e a l t ha n d
safety information may be obtained from the refrigerant
and lubricantmanufactures.
Rofrigerantcapacity:f00:3n g (24.7:l,oz)
CAUTION: Do not ovorchlrgo thc syrtem; tho compr6ssor will be damagad.
C o n n e c t a R - 1 3 4 ar e f r i g e r a n t R e c o v e . y / R e c y c l i n g /
Charging System to the car, as shown, following the
equipmentmanufacturer's
instructions.
22-39
vnx.su
A/C System Service

LeakTest
and is cerOnly useserviceequipmentthat is U.L.-listed
tified to meetthe requirementsof SAEJ2210to remove
(R-134a)
HFC-134a
Rocov.ry/R.cycling/Ch.tging Sy3tcm
CAUTION: Exposura to air condition ratrigerant and

lubaicant vapor or mist can irritato oyes. nose and
throat. Avoid brathing tho sir conditionsr reftigolant
and lubricant vapor or mist.
lf accidentalsvstem dischargeoccurs,ventilate work
R-134aserviceequipmentor vehicleair conditionersystems should not be pressure tested or leak tested with
comoressedair.
some mixturos ot air and R'13'la have
@
b.6n shown to b combustible at glsvated pressurs
and can result in firo or sxplo3ion causing iniury or
proporty damage. Ngvar uso compressdtir to pro33ure
tost R-134a$rvics oquipmont or vohicl air Gonditionsr
systcms.
Additional health and satetYinformation may be obtainedfrom the refrigerantand lubricantmanufactures'
1.
LOW PRESSURE
SIDE
Connecta R-134aretrigerantRecovery/Recycling/
ChargingSystem to the car. as shown, following
instructions.
NOTE:Be sure to installthe same amount of new
r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o r e
chargtng.
2.
Open high pressurevalve to chargethe system to

about 98 kPa (1.0 kgf/cm' , 14 psi), then close the
supplyvalve.
3.
Checkthe systemfor leaksusing a R-134arefriger'!4 g

{0.5 oz)
ant leak detectorwith an accuracyof
per year or better.
4.
l f y o u f i n d l e a k st h a t r e q u i r e t h e s y s t e m t o b e
opened (to repair or replacehouses,fittings,etc.),
recoverthe system accordingto the Recover
Procedureon page22-22.
5.
Aiter checkingand repairingleaks,the systemmust

be evacuated (see System Evacuationgn page 2238).
22-40
vnx.su
HIGH
SIDE
Electrical
Special Tools
Troubleshooting
T i p s a n d P r e c a u t i o n .s. . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3.-. 3
Five-stop
T l o u b l e s h o o t i n.g. . . . . . . . . . . . . , . . . - . . -Z. .3. - s
S c h e m a t i cS y m b o l s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. .3. _- 6.
w i r e C o l o rC o d s. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. -. 6
....
Relay and Control Unit Locations
E n g i n eC o m p a r t m e n .t . . . . . . . . , . . . . . . . . . . . .- - .2 3 - 7
Dsshboard
a n d D o o r . . , , . . . . . . . . . . . . . . . . . . . . . 2. .3. .- g
D a s h b o a ra
d n d F l o o r. . . . . . . . . . . . . . . . . . . . . . . . . 2. .3. .- t O
O u a n e rP a n e l
.....-.....23-12
Connector ldentification and Wire
HarnessRouting
........ 23-i 3
Index to Circuits and Systems

Airbag ...............
...-..-..2
. g-26s
Air Conditioning
....,.. Section2l
Altelnator
. . . . . . _ . . . . . . . . . . .2. .3. - 9 9
Anti-lock Brake Systsm (ABS)
Section 19
Section 14
Battery..............
. . . . . . . . . .2 3 - 6 6
C h a f g i n gS y s t e m
..........2
. 3-98
r C i g a l s t t eL i g h t e r. . . . . . . . . . . . . . . . . . . . . - . . . - . . . . . . - . . - . .
Z3-2O4
C f o c k. . . . . . . . . . . . . . . . .
..........23-197
rcruise Controf
.......--..-...23-242
Distributor
. . . . . . . . . . . . . . . . . .2. .3 - 8 7
F a nC o n t r o l s
. . . . . . . . . . . . . . .2
. .3 - 1 o g
Fuel and Emissions
... Section 1i
*Fuses
U n d e r - d a sFhu s e / R e l aByo x . . . . . . . . . . . . . . . . .2. .3 - 4 8
Undor-hoodABS Fuse/Retay
Box ............23-51
U n d e r - h o oF
d u s e / R e l aByo x , . . . . . . . . . . . . . . . . 2
. .3 - 5 2
rGauges
Engine Coolant Temperature {ECT)
G a u g e. . . . . . . . . . . . . . . .
..23-126
F u e fc a u g e
. . . . . . . . . . . . . .2. g - 1 2 3
' G a u g eA s s e m b l y
....--.23-113
Speedometer
. . . . . - . . . , , 2. 3 - 1 1 4
Tachometer
. . . . . , . . . . . - .2. 3 - 1 1 4
GroundDistribution
........ 23-60
H e a t e r, , , . . . . . . . . , . . . .
. . . . . S e c t i o n2 l
r H o r n. . . . . . . . . . . . . . . . .
.........2
. .3 - 1 9 9
* f g n i t i o nS w i t c h
. . . . . . . . . . . .2. 3 - 7 0
fgnitionSyst6m
.......-..-..23-A7
l g n i t i o nT i m i n g
. . . . . . . . . . . . .2. 3 - 8 9
Indicator Lights
" A / T G e a rP o s i t i o n. . . . . . . . . . . ...... . . . . . . . . . . . . . . . .
2 3 - 13 2
B 1 a k 6S y s t e m
...,..,..-.23-127
E n g i n eO i l P r e s s u r .a. . . . . . . . . . . . . . . . . . . . . . . . _
. .2. .3. - 15 1
L o w F u e l. . . . . . . . . . . .
......23-125
MalfunctionIndicatorLamp {MlL} ...,,. Section I l
tfnteglated Control Unit

...29-144
* l n t e r l o c kS y s t e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 3 - 13 g
Lights, Exteriol
B a c k - u pL i g h t s
..........2
. 3-179
B r a k eL i g h t s
. . . . . . . . . . . . .2. 3 - t 8 l
tDaytime RunningLights
{Csnada}........... 23-156
F r o n tP a l k i n gL i g h t s . . . . . . . . . . . . . . . . . . . . . . . . . 2
. .3. .- 16 5
F l o n t S i d e M a r k e rL i g h t s. . . . . . . . . . . . . . . . . . . . 2
. .3. - 1 6 5
F r o n tT u r n S i g n a lL i g h t s. . . . . . . . . . . . . . . . . . . . .2. .3. - 16 5
* H a z a r dW a r n i n gL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . 2g-1A4
Headlights
. . . . . . . . . . . . . . .2
. .3 - t 6 t
L i c e n s eP l a t eL i g h t s. . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. .- 16 9
Taillights
(Harchback)
. . . . . . . . . .2 3 - 1 6 6
{ S e d a n.). . . . . . . . . . . . .
.. 23-167
Lights. Inteliol
Cargo Area Light {Hatchback)......-..-..-... 23-177
C e i f i n gL i g h t
........-..-.23-175
Dash Lights BlightnessControt ..............23-t70
G l o v eB o x L i g h r. . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .-.1.6. 9.
S p o t f i g h r. . . . . . . . . . . .
....-.23-174
T r u n kL i g h t ( S e d a n l. . . . . . . . . . . . ...... . . . . . . . . .-. .2 3 . - 1 7 7
*LightingSysrem
.......-.-...23-152
:Moonroof
,,.,.......,..,,,,,.-.23-211
PGM-FISystom
........ Scrion 11
Power Distribution
.,.-..--..23-54
P o w e rD o o r L o c k s . . . . . . . . . . . . . , , . . . . . . . . . . . . . . . .2. .3. .- .2 3 3
P o w e rM i r o r s
. . , . . , . . . . - . . .2- 3 - 2 1 6
P o w e rR e l a y s
. . . . . . . . . . . , . . . 2. .3 - 6 8
Power Windows
............ 29-222
* R e a rW i n d o w D e f o g g e r. . . . . . . . , . . . . . . . . . . . , . . . . .
- 23-20,6
Reminder Systems
K e y - i nR e m i n d eS
l y s t e m . . . . , . . . . . . . . . . . . . , .2
. .3. - 15 0
L i g h t s - o nR e m i n d eS
r y s t e m . . . . . . . . . . . . . . . . .2. .3 - l 5 f
*MaintenanceRemindersystem ..,,....-..--.
23-.12g
S e a t B e l t R e m i n d eS
r y s t e m . . . . . . . . . . . . . . . . . 2. -3 - 1 2 5
*Side Markel/Turn Signal/Hazard
F f a s h eS
r ystem
.,..,..-.23.-1A4
S p a r kP f u g s
. . . . . . . . . - . . . - . . .2. .3 - 9 7
Starting System
....,,.....-.23-73
* S t e r e oS o u n dS y s t e m . . . , . . . . . . . . . . . . . . . . . . . . . . . , , . . g g
23-l
SupplementalRestraintSystem {SRS}......... 23-265
V e h i c f eS p e e dS e n s o r{ V S S ). . . . . . . . . . . . . - - . . - . 2. .3. - 1 2 2
* W i p e r / W a s h eSr y s t o m . . . . . . . . . . . . . . . - - . . . . . . . . . - . . Zg 254
rRead SRSpicautions on Page23-271
betore working
in these areas.
vnx.su
SpecialTools
Rel. No.
Tool Numbol
Description
o
o
DeploymentTool
07HAZ-SG00400
Antenna Nut Wrench
07JAA-001000c
0 7 J G G - 0 0 1 0 1 0 A Belt TensionGauge
@
Test HarnessC
07LAZ-S140300
@.'
Test HarnessD
oTLAZ-S140400
@'
Test HarnessA
oTMAZ-S100500
@'
Test HarnessB
oTMAZ-SP00500
o T N A C - S R 2 0 1 0 0 Fuel Senderwrench
@
SCS Short Connecto.
oTPAZ-0010100
@
lncludedin SRSToolSet oTHAz-SGoOooA
Included
in SRSToolSet OTMAZ-SLOo10A
o--
Oty.
I Pago R6toronce
23-300
23-195
23-108
23-201,248,285
23-247
23-241
23-244
23-124
23-89
o
@
z3-2
vnx.su
Troubleshooting
Tips and Precautions
Before Troubloshooting
a Check applicablefuses in the appropriatefuse/relay
DOX.
a Check the batteryfor damage,state of charge,and

clean and tight connections.
a Check the alternatorbelt tension.
a Nevertry to disconnectconnectorsby pullingon thei.

wires; pull on the connectorhalvesinstead.
a Always reinstallplastic covers.
CAUTION:
a Do not quick-charg a battery unless the battery
ground cabla has ben disconnoctsd. othrwiso
you will damage the alternator diodss.
a Do not att6mpt to crank the engine with the battery ground cable looselyconnectsd or you will sevorsly damag tho widng.
a The original radio has a codod thatt plotection ci.cuit. Be sul to got tho customor's code numbet
before
- disconnecting th battery.
- lomoving tho No. 32 (7.5 Al tuso f.om the
under-hood tuse/lelay box.
- removing tho radio.
Aflor slvic. reconnct powet to tho radio and
turn it on. Whon the word "CODE" is displayed,
ntl the customer'E s-digit codo to .astore ladio
operation.
Handling Connectors
a Makesurethe connectorsarecleanand haveno loose
wire terminals.
a Make sure multiple cavity connectots are packedwith
grease(exceptwatertight connectors).
a All connectorshave push-downreleasetype locks.
Beloreconnectingconnectors,make sure the lerminals are in Dlaceand not bent.
a Check tor loose retainerand rubberseals.
LOCKII{GTAA
RETAINER
LOCKING
TAB
a Someconnectorshavea clio on their sideusedto attach them to a mount bracket on the body or on
anothercomponent.This clip has a pull type lock.
a Some mountedconnectorscannot be disconnected
unlessyou first releasethe lock and removethe connector from its bracket.
LOCKING
PAWL ON
OTHER
HALF OF
Pull to
CONNECTOR orsengage
a The backs of some connectors are oacked with

grease.Add greaseif needed.It the greaseis contaminated, reDlaceit.
BRACKET
(cont'd)
23-3
vnx.su
Troubleshooting
Tips and Precautions(cont'dl
a Seat grommets in theil grooves properly.
a lnsert the connector all the way and make sure it is

securelylocked.
a Positionwires so that the open end of the cover taces
down.
GOOD
Faca
opon and
cown
]TOTGOOD
n
ll
,
,,'
r
ll
,,
s*j
-:ut*/
--ry\
-.w-,
Tosting and Ropails

a Do not us wires or harnessswith broken insulation.
Replacethem or repair them by wrapping th break
with electricaltape.
a After installing pans, make sure that no wirs are
Dinchedundsr them.
a When using electrical test quipment, follow the
manufacturer's instructiona and those dsscribed in
this manual,
a It possible,insert the probe of the toster from the wire
side {except waterproof connector).
Handling Wirs and Hamorao8

a Secure wires and wile harnessesto the frame with
their respectivewire ties at the designatedlocations'
a Removeclips carefully;don't damagetheir locks'
a Use a probe with a tapered tip.
Stip pliers under the clip base and through the hole at an
angle,then squeezethe expansiontabs to releasethe
clio.
SI'IAP-ANG PLIERS
a After installingharnessclips, make su. the hatness

doesn't interfe.e with any moving parts.
a Keeo wire hatnessesaway from exhaust pipes and
other hot parts, ftom sharp edges of brackets and
holes, and from exposed screws and bolts.
Referto the instructionsin the HondaTerminsl Kit for

identificationand .eplacemento{ connectortelminals'
23-4
vnx.su
Five-stepTroubleshooting
1.
Verify The Complaint

Turn on all the componentsin the problemcircuitto
verifythe customercomplaint.Notethe symptoms.
Do not begindisassemblyor testing until you have
narroweddown the Droblemarea.
2.
Analyze The Schomatic

Look up the schematicfor the problemcircuit. Determine how the circuit is supposedto work by tracing the current paths from the power leed through
the circuitcomponentsto ground.It severalcircuits
fail at the same time, the luse or ground is a likely
cause.
4.
Fix The Problem

Once the specilic problemis identified,make the
repair. Be sure to use proper tools and safe
proceoures.
5.
Mak6 Suro The Circuit Wolks

Turn on all componentsin the repairedcircuit in all
modes to make sure you've fixed the entire problem.
It the problemwas a blown Juse,be sureto test all
of the circuits on thst tuse. Make sure no new
problemsturn up and the originalproblemdoes not
recuf.
Basedon the symptomsand your understandingof

the circuitoperation,identity one or more possible
causesof the Droblem.
3.
lsolato The Problom By Testing The Circuit

Make circuittests to checkthe diagnosisyou made
in step 2. Keepin mind that a logical,simpleprocedure is the key to etticienttroubleshooting.
Test for
the most likely cause of failure first. T.y to make
tests at points that are easilvaccessible.
23-5
vnx.su
Troubleshooting
ym
Schematic Symbols
le @l
l
l
e-
LIGHTER
COIL,SOLENOID CIGANETTE
FUSE
GROI,ltD
Componontground
Ground terminal
BATTERY
H t+j
A
+ ilHe
e H
+ + D
a 0
Y II
VARIABLERESISTOR
RESISTOR
THERMISTOR
tcNtTtol{
swTcH
-1o
MOTOR
PUMP
CIRCUITBREA(ER
BULB
HEATER
DIODE
SPEATER,BUZZER
oF
HORI'
TRA SISTORlTrl
ANTI INNA
Wire GolorCodes
Mast
RELAY {ln no rmal poritionl

Normallyopen relay Normally closed relay
*G
t-i- |
l l l
l'*^f
SWITCH (ln ngrmal position)

'
Normally closod
Normally open
I
switch
switch
@
l
CONNECTION
Output
Inpur
f7
I
CO'IDENSER
I
T
LIGHTEMITTING
DIODE(LEDI
The tollowing abbreviationsare used to identity wire

colors in th circuit schematics:
w H T . . . . . . . . . . .W
. hite
Y E L . . . . . . . . . . . . .Y. 6 l l o w
B L K . . . . . . . . . . . . .B. l a c k
B L U . . . . . . . . . . . . .B. l u e
. reen
G R N . . . . . . . . . . . .G
R E D . . . . . . . . . . .R
. . e. d
. range
O R N . . . . . . . . . . . .O
P N K . . . . . . . . . . . . .P. i n k
B R N. . . . . . . . . . . . .B. r o w n
. ray
G R Y . . . . . . . . . . . .G
P U R. . . . . . . . . . . . .P. u r p l e
L T B L U . . . . . . . . .L i g h tB l u e
L T G R N . . . . . . . . .L i g h tG r e n
A[,
@
T T
l
CONNECTON
--+>-
tl' l
BEEDSWITCH
lril
23-6
vnx.su
The wi.e insulation has one color or one color with

another color stripe. The scond color is the stripe.
WHT/ALK
, / t
, / l
/ l
--</
.

EngineCompartment
ABS PUMP MOTOR
RELAY
ELECTRICALLOAD DETECTOR(ELD)
UNDER.HOOD
FUSE/RELAY
BOX
UNOER-HOOD
ABS
FUSE/BELAY
BOX
. ABS FRONTFAILSAFERELAY
I Wirc colors:WHT/GRN,BRN/BLK,
I
snd BLK
IYEL/GRN
I
. ABS REARFAILSAFERELAY
I Wire colors:WHT, BLU/BLK,
I
and BLK
I YEL/GRN
I
. CONDENSER
FAN RELAY
I Wi]o colors: WHT, BLUiBLK, I
I BLKMHT and 8LU/YEL
I
. A/C COMPRESSORCLUTCH RELAY
I Wiro colors: WHT, RED,I
I BLK/YELand BLK/RED I
23-7
vnx.su

Dashboardand Door
CUTRELAYIMIT)
STARTER
I wir. colo]s:BLKMHT,BLU/BLKI
I BLKMHT ANdBLK/RED
I
REARwlNDOW DEFOGGER
FELAY
I Wirocolo6:
I
I BLKA'EL,BLK/GBN, I
I BLUffEL8nd BLK^^THT
I
MOONROOFRELAY
Wirs colors:
WHT,GBN/BLK,
GRN 6nd BLK
CRUISECONTROLUNIT
PGM-FI
MAIN RELAY
POWERWINDOW
RELAY
INTEGRATEO
CONTROLUNIT
TURN SIGI{AL/
HAZARDRELAY
23-8
vnx.su
IIORNRELAY
J wi.o color3:WHT/GRN,BLx,l
and BLU/RED I
I BLU/GBN,
UNDEB-OASH
FUSE/RELAY8OX
POWERDOOR LOCK
COI{TROLUNIT
ENGINECONTROLMODULE
(ECM}
23-9
vnx.su

Dashboardand Floor
INTRLOCKCONTROL
UNIT IA/T)
23-10
vnx.su
MAINTENANCE
REMINOERUNIT
TRANSMISSIONCONTBOL
MODULEITCMI
23-11
vnx.su
Relay and Gontrol Unit Locations

OuarterPanel
ABS CONTROLUNIT
23-12
vnx.su
Connectorldentificationand Wire HarnessRouting

How to ldentity ConnoctolS:
ldentification numbers have been assignedto all connectors. The number is preceded by the letter ,,C,, for connecrors,
"G" for
singleground terminalsot "f" hr singlenon-groundterminals.
Location
Hamess
Starter cables
Engino Compartmont
Darhboard
Othors (Floor, Door,

Trunk, Rootl
T1, T2, and (E
Battery ground cable
G1 and O
Engineground cable A
T3
Engineground cable B
T4
G3
Under-hoodABS fuse/relavbox cable
T5 and (D
Enginewire harness
C 1 0 1 t h r o u g hC 1 3 4
Tl Ol andT102
G1 0 1
A/C wire harness
C l 5 ' l t h r o u g hC 1 5 6
G151
ABS modulator unit wir harness
C 1 6 1 t h r o u g hC 1 6 8
Engine companment wire ha.ness
C3O'l through C32O

G301
Main wire hatness
C2O1 through C223

G2Ol and G2O2
C4O1 through C449

G401
Rear wire harness
C501 through C536

G 5 0 1 ,G 5 0 2a n dG 5 O 3
DashboSrdwire harness
C551 through C569

G551
Driver's door wire harness
C 6 0 1 t h r o u g hC 6 1 2
Front passenger's door wire harness
C626 through C634
Left rear door wire harness(Sedan)
C651 through C654
Right rear door wire harness(Sedan)
C656 through C659
Roof wire harness
C661 through C667
Heater sub-harnessA
C671 through C677
Heatersub-hatnessB
C681 through C684
ABS sub-harness
C7O1 through C7O6

G7O1,G702 and G703
(Sedan)
Tailgatewire harness(Hatchback)
C751 through C756
Spoilersub-ha.ness(Hatchback)
C761 through C763
Rearwindow defoggerground wire

(Hatchback)
c77'l
G771
SRS main harness
C8O1 through C8O7

G801
23-13
vnx.su
Gonnectorldentificationand Wire HarnessRouting

Startol cablos
Connector or
Terminal
Numbsr of
Cavities
Connects to
Location
Notos
Right side of enginecompartment Under-hoodfuse/relaybox

Right side of enginecompartment Starter motor
Battery positive terminal
Battery
T1
r2
@
B8ttory Ground Cable
Connctor or
Trminal
Numborof
Csvities
G1
\l
Connects to
Location
Right front shock tower
Body ground,via battery ground

cable
Battery
Battery negative tetminal
Notos
Engine Ground Cable A

Connoctor or
Tolminal
Number of
Cavities
Connocta to
Location
T3
Left side of engine
Valve cover
G2
Left side of engine compartment
Body ground. via engineground

wire A
Notes
Engine Ground Cable B

Connoctor or
Torminal
Number ol
Cavitios
Connocts to
Location
Nots
Right side of enginecompartment Transmissionhousing

Body ground, via engineground
Right side of front frame
wire B
r4
G3
A/C Wiro H81n6ss

Connoctor 01
Terminal
Numbor of
Cavities
cl51
cl52
c153
c154
c155
c156
I
4
4
Connects to
Location
Right side ol enginecomPartment
Left side of enginecompartment
Left side of engine comPartment
Lett side ot enginecompartment
Left side of enginecomPanment
Notes
Main wire harness(C2O7)

Condenserfan relay
A/C compressorclutch relay
A/C pressure switch
Condenserfan motor
A/C compressorclutch
Right side of tront Jrame
G151
Under-hood ABS Fus/RelavBox Cablo

Conngctor or
Terminal
T5
Numbor ot
Cavitis
Connects lo
Localion
Right side of enginecomPartment Under-hoodABS fuse/relaybox

Right side of enginecompartment Battery positive terminal
23-14
vnx.su
Notes
UNOER.HOOD
A8S
FUSE/RELAY
BOX CABLE
BATTEBYGROUND
CABLE
ENGIT{E
GROUND
CABLEB
EI{GINEGROUND
CABLEA
A/C WIRE HAFNESS
23-15
vnx.su

EngineWire Harness{B1881 engine)
Connector 01
Terminal
Numberof
Cavities
c10'l
c102
c103
c104
c105
c106
10
14
6
1
c107
c108
c108
c109
c110
c111
c113
c114
c115
L t t o
2
8
c117
c118
c119
c't 20
c121
c122
c123
cl24
c125
c't26
c127
c128
c129
c130
T1 0 1
r102
G1 0 1
2
)
2
8
14
2
2
Connectsio
Location
M a i n w i r e h a r n e s s( C 2 2 1 )
Main wire harness{C222}
Main wire harness(C223)
Main wire harness{C220)
Startersolenoid
Enginecoolanttemperature{ECT)
sensor
Enginecoolant temperature(ECT)
Right side ol engine
gauge sendingunit
Back'up light switch
Transmission
Lock-upcontrolsolenoidvalveA and B
Transmission
lgnitioncoil
Middle of engine
Top dead center/Crankshaft
lvliddleof engine
position
position/Cylinder
(TDC/CKP/CYP)
sensor
Enginecoolanttemperature(ECT)
Right side ot engine
switch
Right side of enginecompartment Vehiclespeedsensor (VSS)
ldiddlerearof enginecompartment Heatedoxygen sensor (HO2S)
MAP sensor
Middle of engine
Throttle position (TP)sensor
Middle ol engine
ldle air control (lAC) valve
Middleof engine
Evaporativeemission(EVAPIpurge
o
f
e
n
g
i
n
e
Middle
control solenoidvalve
Engineoil pressureswitch
Middle ot engine
Alternator
Left side of engine
Intake air temperature{lAT} sensor
engine
lvliddleof
'l
No. fuel injector
M i d d l eo f e n g i n e
No. 2 tuel injector
Middle of engine
No. 3 fuel injector
Middle ot engine
No. 4 fuel injector
ol
engine
Middle
Junction connector
Enginecompartmentwire harness
(c304)
Enginecompartmenlwire harness
compartment
of
engine
Left side
(c305)
Shift control solenoidvalve A and B
Transmission
Countershaitspeed sensor
Transmission
Mainshaftspeed sensor
Transmission
Right side of
Right side of
Right side of
Right side ol
Right side of
Right side of
Notes
enginecompartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment
engine
Alternator
Lelt side oI engine
Right side of enginecompartment Under-hoodtuse/relaybox
Engine ground, via engine wire
harness
Right side of engine
23-16
vnx.su
M/T
NT
NT
NT
ENGINEWIRE HARNESS
(B188i snginel
cl19
c126
clla
c121
c122
c123
c124
cl13
23-17
vnx.su

Engine Wire Harnoss (B18Cl enginol
Connoctor 01
Totminal
umbor ol
Cavitio8
c101
cl 02
c103
c104
c105
c106
4
10
14
,l
2
Right side of
Right side of
Right side ot
Right side of
Right side of
Righrside ot
enginecompartment
engine compartment
engine comPanment
engine compartmsnt
engine compartment
engine
c107
c108
c109
c110
2
8
Transmission
Middle ol engine
MiddleoJ engine
c111
cl12
c113
c114
c115
c116
c117
Connecla to
Location
4
3
'I
Right side ot engine comPartment

Middl reat of enginecompartment
Middle of engine
Middle of engine
Middle ol engine
Middleo{ engine

Main wire harness(C22O)
Starter solenoid
Engine coolant temperature (ECT)
sensor
Enginecoolant temperature{ECTI
gauge sendingunit
Back-up light switch
lgnition coil
Top dead center/Crankshaft
position/Cylindr Position
(TDC/CKP/CYP)
sensor
Enginecoolanttemperature{ECT)
switch
Vehiclespeed sensor (VSS)
Hsated oxygen sensor{HO2S}
MAP sensor
Throttle position {TPl sensor
ldle air control (lAC) valve
Evaporativeemission{EVAPIpurge
control solenoid valve
Engineoil pressureswitch
Altrnatot
Intake 8ir temperature(lAT) ssnsor
No. 1 fuel injector
No. 2 fuel iniector
No. 3 fuel injeclor
No. 4 fuel injector
Junction connector
Enginecompartmentwareharness
I
2
Middle of engine
Lelt side ot engine
Middle of engine
Middle of engine
Middle ol engine
Middle ot engine
Middle of engine
Left side of engine companment
Lelt side ot engine compartment
't4
EnginecomPanmentwire harness
Right side ot engine

Right sid of engine
Middle ot engine
Middle of engine
VTEC solenoid valve

VTEC oil pressureswitch
Knock sensor (KS)
Intaka air bypass (lAB) control solenoid valve
T101
r102
Left side of engine

Right sid6 ot engine compartment
Alternator
Under-hood fuse/relay box
G1 0 1
Engineground, via enginewire

harness
c1r8
c119
c120
cl2'l
c122
c123
c124
c125
c't26
c'127
c131
c132
c133
c134
{c304)
23-18
vnx.su
(c305)
f{orc!
EI{GINEWIRE HARNESS
lBl8C'l onginel
c126
c119
'13
crrs
cl17
cl14
23-19
vnx.su
Connector ldentificationand Wire HarnessRouting

ABS Modulatol Unit Wile Harness
Connoctor or
Torminal
L t o l
c162
c163
c164
c165
c166
c't 67
c168
Numbor ot
CaviiieE
't4
2
2
Connocta to
Location
Right side of enginecomPartment
ABS modulatorunit
ABS modulatorunit
ABS modulatorunit
ABS modulatorunit
ABS modulatorunit
ABS modulatorunit
ABS modulatorunat
oies
Main wire harness(c21 1)

ABS Dressureswitch
ABS right Jront solenoid(OUT)
ABS right front solenoid(lN)
ABS rear solenoid(OUT)
ABS rear solenoidllN)
ABS le{t front solenoid {OUT)
ABS left tront solenoid(lNl
Engine Compartmont Wile Hatnaaa

Connector or
Tolminal
c301
c302
c303
c304
c305
c306
c307
c308
c309
c310
c311
c312
c313
c314
c315
c316
c317
Numbd of
Cavilies
20
20
1
2
14
2
1
1
2
4
2
2
1
2
c318
c319
c320
G301
Connocta to
Location
Behindleft kick Panel
Behindleft kick panel
Behindlett kick Panel
Left side of enginecomPartment
Left side o{ engine comPartment
Lelt side oJ engine comPartment
Middle of engine comPartment
Left side of engine comPartment
Left side oJ enginecomPafiment
BehindleJt headlight
Behindleft headlight
Behindleft headlight
Behind left corner ot front
bumper
Behind lett corner ot front
DUmper
Behindleft corner of ftont
DUmper
Behindleft cornet of front
DUmper
Lett side of enginecomPartment
23-20
vnx.su
t{oioE
Main wire harness(C4231

Option
Front fog light sYstem
Enginewire harness(C126)
Enginewire harness(C127)
Test tachometer connector
Canada
Daytime running lights resistor
Windshild wiper motot
Brake fluid level sensor ( + |
Brakefluid level sensor (- )
Power steering pressure (PSPI switch USA
ABS
Lett front wheel sensor
Cruise control actuator
Left headlight(Low beam)
LeJ-theadlight(High beam)
Option
Front fog light system
Windshieldwasher motor
Rearwindow washer motor
Left front side matker light
Left front tu.n signal/parking lights
Body ground,via enginecomPartment wire harness
ABS MODULATOR
UI{IT
WIREHARI{ESS
Et{GI1{ECOMPARTMET{T
WIRE HARI{ESS
23-21
vnx.su

{Undor-hood
c201
c202
c203
Behindright side of tront bumper

Behindright corner of tront
bumper
Behindright corner of front
bumpet
Behindright headlight
Behindright headlight
Right side ot enginecomPartment
Right side oJ enginecomPartment
Right side oJ enginecomPartment
Horn
Right tront turn signal/Parking
light
Right Iront side marker light
c213
Right headlight(Low beam)

Right headlight(High beam)
Radiatorfan motor
A / C w i r e h a r n e s s( C 1 5 1 )
ABS front fail saJerelay
ABS rear fail sate relay
ABS pump motor
ABS modulatorunit wire harness
(c161)
Under-hoodABS fuse/relaYbox
comPartment
of
engine
Right side
(c901)
box
Right side of enginecomPartment Under-hoodABS fuse/relaY
c214
c215
c216
c217
c218
c219
c220
Bight side ot enginecomPattment

c204
c205
c206
c207
c208
c209
c210
c211
8
4
14
c212
c220
c221
c222
c223
(c902)
7
J
Under-hoodfuse/relaybox (C907)
Under-hoodtuse/relaYbox (C909)
Under-hoodfuse/relaybox (C9l Ol
Under-hoodfuse/relaYbox (C908)
Under-hoodfuse/relaYbox (C911)
Right front wheel sensor
Enginewire harness{C104)
(C'l04)
Righl side ot enginecomPartmenl Enginewire harness
(C101)
Right side of enginecompartmenl E n g i n ew i r e h a r n e s s
(Cl 02)
harness
wire
Engine
Right side of enginecomPartmen'
103)
harness
{C
wire
Engine
comPartment
wire
Right side of enginecompartment Body ground, via main
harness
wire
Right side of enginecomPartment Body ground, via main
harness
23-22
vnx.su
UNDER.HOOD
FUSE/RELAY
BOX
MAIN WIRE HARNESSlcont'dl
c222
c221
c223
c220
c212
c213
Continuos on
pago 23-25
23-23
itfltfitfi
vnx.su

Main Wire Ha.ness {Right branch}
Connactor or
Terminal
Numbsr of
Cavitis
c401
,E
c402
c403
c404
c405
c406
c407
c408
c409
c410
10
2
22
lo
22
26
Connscts to
Location
Front Passenger'sdoor
Under right side of dash
Under right side ot dash
Behindright kick panel
23-24
vnx.su
Front passenger'sdoor wire

harness(C626)
A/C diode
Heatersub-harnessA (C672)
Heatersub-harnessA {C671}
SCS short connectol
Data link connector(DLC)
ABS sub-harness(C7011
Enginecontrol module (ECM)
Enginecontrol module (ECM)
Enginecontrol module (ECMI
ttlotor
MAIN WIRE HARNESSlcont'dl
Continuos on
pago 23-27
Continuod from
pa90
23-25
vnx.su

Msin Wiie Harness (Left branch)
Connector or
Terminal
Numbel ot
Cavities
c411
c412
c413
c414
c415
c416
c4'17
c418
c419
14
8
4
I
14
20
22
Centerfloor
Centerfloor
Centerfloor
Under left side ot dash
c420
26
c42'l
10
c423
20

Under left side of dash
c424
20
c425
c426
c427
c42A
c429
c430
c431
c43l
c432
c433
c434
c435
c436
c437
c438
c439
c440
c44'l
c442
c443
c444
c445
c446
c447
c448
c449
G401
't4
4
2
10
4
7
4
o
7
I
7
22
6
4
7
4
15
to
Connects to
Notes
A/T gear positionconsolelight

Shift lock solenoid
A/T gear positionswitch
Interlockcontrol unit
Daytimerunninglights control unit
Daytimerunninglights control unil
Cruisecontrol unit
Junction connector
Transmissioncontrol module
(TCM)
Transmissioncontroi module
{TCM)
Rearwire harness(C501)
Rear wire harness{C502)
(c301)
Afi
AiT
Afi
Afi
Canada
Canada
Location
Under lett side of

Under left side ot
Under lett side of
Under lett side of
Under lett side of
Under lett side of
Under lett side ot
Arf
An
(c302)
dash
dash
dash
dash
dash
dash
dash

Under left side ol dash
Behinddashboardlower cover
Under lett side of dash
Behindunder-dashfuse/relaybox
Under left side ot dash
Roof wire harness(C663)

Securitysystem (Option)
SRS main harness(C802)
Clutch interlockswitch
Clutch switch (Cruisecontrol)
Dashboardwire harness(C552)
Brakeswitch (Without cruise
control)
Brakeswitch (With cruisecontrol)
lgnitionswitch
Combinationlight switch
Under-dashfuse/relaybox {C9131
Under-dashfuse/relaybox {C9161
Underdash tuse/relaybox (C9'l7l
Securitysystem {Option)
PGM-FImain relay
Starter cut relay
Rearwindow defoqgerrelay
Integratedcont.ol unit
Securitysystem {Option)
Horn relay
Body ground,via main wire
harness
23-26
vnx.su
Canada
M/T
M/T
Atr
Canada
Canada
Canada
M/T
Canada
MAIN WIRE HANNESS
Continuod from
poge 23-25
c418
C430 9432
c412
c41t
c440
c449
UNDER.DASH
FUSE/RELAYBOX
23-27
vnx.su

Roar wiro Harn$s (Hatchbsckl
Connector or
Torminal
Numbor of
Cavitios
Connecta to
Location
Behind dashboard lower cover
Behind dashboard lower cover
Driver's door
Center tloor
Center lloor
Left qusrter panel
Fueltank
Fueltsnk
Right quarter panel
Right quarter panel
Left quarter panel
Left quarter panel
Left quarter panel
Left quarter panel
Left side corner of cargo area
Lft side corner of cargo area
Left side corner of cargo area
Left rear corner of cargo area
Center ot cargo area bulkhead
Right rear cornor oJ cargo area
Center of cargo area bulkhsad
Right side of cargo area

Under-dashfuse/relaybox (C912)
Driver'sdoor wire harness{C6011
Driver's seat belt switch
Palkingbrakeswitch
Driver'sdoor switch
Fuel pump
Fuel gauge sendingunit
Passenger'sdoor switch
Right rear speaket
Left rear speaker
Noise condenser
ConnectorC517
ConnectorC516
Power antennamotor
Cargo area light
Traile.lightingconnector
LeJt taillight
License plate lights
Right taillight
Tailgate latch switch
Tailgatewire harness(C752)
Tailgatewire harness(C751)
G501
Behindleft kick psnel
G502
Left side of Jloor
G503
Center ot cargo area bulkhead
Body ground, via rear wire

harness
Body ground, via rear wire
harness
Body ground,via rear wire
harness
c501
c502
c503
c504
c505
c506
c507
c508
c509
LStt
c 5 11
c512
c513
c514
c515
c516
c517
c 5 r8
c519
c520
c521
c522
c523
c524
c525
c526
10
'14
10
12
25
2
1
1
2
I
2
20
20
2
6
b
2
2
2
4
23-28
vnx.su
llotos
REARWIRE HARNESS
G503
23-29
vnx.su

Rear Wire HamsEs (S6danl
Connector ol
Torminal
Number ot
Caviti6s
c501
10
c503
c504
c505
c506
c507
c508
c509
c510
10
Connocts to
Locaiion
4
6

Behinddashboardlowe, cover
Driver'sdoor
Centerfloor
Centerfloor
Left B-pillar
Fueltank
Fueltank
Right B'pillar
Above right side of trunk
Above left side ot trunk
Left quarter panel
Left quarter panel
Left quarter panel
Left side corner of trunk
Above center of trunk
Left side corner of trunk
Left rear corner of trunk
Right rear corner of trunk
Right rear corner of trunk
Left ,ear door
c52A
Right rear door

Under-dashtuse/relaybox {C912}
Driver'sdoor wire harness(C6Ol )
Driver'sseat belt switch
Parking brake switch
Driver'sdoor switch
Fuel pump
Fuelgauge sendingunil
Front passenger'sdoor switch
Right rear speaker
Left rear speaker
Noisecondenser
C o n n e c t oC
r 517
C o n n e c t oC
r 516
Power antenna motor
Trunk light
Trailerlightingconneclor
Left outer taillighr
Licenseplate lights
Right outer taillighr
Left rear door wire harness
(c651)
Right rear door wire harness
LCZY
1
,|
LeJt quarter panel

LeJtside oJ rear window
Above right side of trunk
Right quarter panel
Right side of rear window
Left side ot trunk lid
Centerot trunk lid
Right side ot trunk lid
Lett rear door switch

Rearwindow delogget (+ )
High mount btake light
Right rear door switch
Rear window defogger(- )
Left inner taillight
T,unk latch switch
Right inner taillight
G501
Behindlett kick panel
G502
Left side of floor
G503
Above center of trunk

narness
narness
narness
aEt t
c512
L9
IJ
c514
c515
c516
c517
c518
c519
c520
c521
c522
c523
c527
c530
c531
c532
c533
c534
c535
c536
12
25
'I
1
a
1
2
2
20
20
2
6
4
2
1
I
4
4
(c656)
23-30
vnx.su
Notos
c528
c532
c533
13
REARWIRE HARNESS
23-31
vnx.su

Dashboardwile Ha.n6ss
Connector ot
Trminal
Number of
Caviti6s
20
10
c553
c554
L55b
c556
c557
c558
c560
LCO
to
12
5
22
10
13
16
c563
c564
c565
c566
c567
c568
a 6ACl
10
6
to
Connects to
Location
Under lett side oJ dash
Behindgauges
Behindgauges
Behindgauges
Behindgauges
Behindmiddleof dash
Left side of dash
Behindmiddleof dash
Behindmiddleof dash
Right side of dash
Under middleof dash
Under middleof dash
Under middleof dash
Main wire harness(C43Ol
Rear wire harness{C505)
Cruisemain switch
Junction connector
Gaugeassembly
Gaugeassembly
Gaugeassembly
Gaugeassembly
Clock
Dash lights brightnesscontroller
Hazardwarning switch
Rear window defoggerswitch
Glov box light
Stereo radio/cassette PlaYer
Chime
Maintenancereminde.unit
Cigarettelighter
Under middle of dash
Body ground, via dashboardwire

harness
23-32
vnx.su
Notes
Afi
c5P3 csor
cl6a cs,aa
"ru.,
DASI{BOARD
WIRE HARNESS
UNDER-DASH
FUSE/RELAY8OX
23-33
vnx.su

Drlvar's Door Wir6 Hamors
Connectot 01
Torminal
Number of
Cavitles
c601
c602
c603
c604
c605
c605
c606
25
2
4
14
I
I
Location
Connocts to
Oriver'sdoor wire harness(C506)

Driver'sdoor speaker
Driver's power window motor
Power door lock control unit
Hatchback
Left power mirror
Left power mirror
Sedan
818C1
Lett tweeter
engrne
Driver'sdoor lock switch
Power mirror switch
Power window masterswitch
D.iver's door lock actuatorassembly
Driver'skey cylinderswitch
Power window master switch
Sedan
Driver'sdoor
Driver's door
Driver'sdoor
Driver'sdoor
Behindmirror panel
Driver'sdoor
Driver'sdoor
c607
c608
c609
c610
10
10
o
Driver'sdoor
Drivr's door
Driver's door
Driver's door
c611
c612
2
I
Oriver'sdoor
Driver'sdoor
Notos
23-34
vnx.su
Hatchback:
Sedan:
23-35
vnx.su

Flont Pasangol's Door Wire Hamosg
Conngctor or
Talminal
Numbel of
C8viti63
c626
c627
c628
25
2
2
Front passenger's door

Front passsngel's door
Front psssengr's door
c629
c629
c630
8
tt
Behind cover panel

Front passengor's door
c631
c632
Front Passonger'sdool
c633
Front passengr's door
c634
23-36
Connocts to
Locatlon
Front passngot's door
vnx.su
Main wire harness(C4O1)

Front passenger's door speaker
Front passengr's power window
motot
Right power mirror
Right power mirror
Right tweeler
Front passenger's door lock
switch
Front passengor's Power window
switch
Front passenget's door lock actuator
Front passengor's door key
cylind6r switch
Not6s
Hatchback
S6dan
8 1 8 C1
6n9ino
Hatchback:
PASSENGER'SDOOR WIRE HARNESS
Sedan:
FRONT PASSENGEB'SDOOR WIBE HARNESS
23-37
vnx.su

Left R6ar Door Wil8 Harn6ss (Sedan)
Connoctol ol
Tarminal
Number ot
Caviiies
Lbc I
c652
c653
c654
Connocta to
Locstion
Resr wira harness(C527)

Loft rsar power window motor
Left rsar gower window switch
LIt roar Powor window sctuator
Lett rear door

Left rear door
Left rear door
Left rear door
Right Rear Door Wilo Hatnosr (S6danl
Rear wira harness {C528)

Right 168r power window motor
Right 168rpower window switch
Right rear Powor window actuator
Right rear door

Right rear door
Right rar door
Right rear door
23-38.
vnx.su
l{ot.t
LEFTREARDOOR
WIRE HARNESS
WIRE HARNESS
23-39
vnx.su

Roof Wire HanesE
Connector ol
Terminal
Number ot
Cavitiss
Connccts to
Location
Under-dashfuse/relay box (C918)
Moonroot relay
c664

Left side of dashboa.d
Main wire harnoss(C425)

Moonroof switch
LOO5
Roof
Moonroof motor
LOOO
Roof
Spotlight
Roof
Ceilinglight
c661
c662
LOOJ
c667
23-40
vnx.su
Notct
with
moonroof
with
moonroof
with
moonroof
with
moonroot
with
moonroot
Hdchback:
FUSE/RELAY
BOX
Scdrn:
ROOF WIRE HABNESS

UNDEB.DASH
FUSE/RELAYBOX
23-41
vnx.su

ABS Sub-harn6ss
Connactor ol
Terminal
Number of
Cavities
c701
c702
c703
c704
c705
c705
c706
c706
22
G701
G702
20
22
2
2
Conncts to
Location
Right side of Jloor
Right quarter panel
Bighl quarter panel
Right side of trunk
LeJt side of cargo area
Left side ot trunk

ABS maintenanceconnecto.
ABS control unit
ABS control unit
ABS right wheel sensor
ABS right wheel sensor
ABS left wheel sensor
ABS left wheel sensor
Right quarter panel

Right quarter panel
Body ground, via ABS sub-harness

Body ground, via ABS sub-harness
23-42
vnx.su
Notas
Hatchback
Sedan
Hatchback
Sedan
Hatchback:
Sedan:
23-43
vnx.su

Hatch Wire Harnsss {Hatchbackl
Connector or
Torminal
Numbor ol
Cavilies
c751
c752
L/5J
c754
c755
G751
Connscts to
Location
Right side oJ cargo area
Right side of reat window
Right side of hatch
Rearwire harness(C526)
Rear wire harness(C5251
Rearwindow defogger(+ I
Spoilersub-harness(C761)
Middle of hatch
Middleof hatch
Rear window wiper motot

High mount brake light
Right side oJ hstch
Body ground, via hatch wire

naaness
l{otos
8 1 8 C1
engine
8 18 8 1
engine
Spoilor Sub-harn6ss(Hatchback with B18C snginel

Connoctor or
Terminal
c761
c762
c763
Number ot
Cavitios
I
1
Connocls to
Localion
Right side of hatch
Middle of hatch
Middle of hatch
Notos
Hatch wire harness(C754)

High mount btake light ( + )
High mount brake light ( - )
Roar Window Defoggor Ground Wire (Hatchbackl

Connoctol or
Tgrminal
Numbor of
Caviti6s
c77'l
G771
Connoctg to
Location
Lett side ot rear window
Rearwindow defogger(-)
Left side ot rear window
Body ground, via tear window

deJoggerground wi.e
23-4r'i
vnx.su
Notes
HATCH
WIRE
BEARWII{DOW
DEFOGGER
GROUND
IVIBE
c763
SPOILERSUB.HAFIIESS
23-45
'r]fi
vnx.su

Hoator Sub-harneEsA
Connoctor or
Terminal
Numbr of
Cavities
'lo
c671
c672
c673
c674
c675
c676
c677
2
4
4
14
Conn6cts to
Location
Behindglove box
Behindglove box
Behindglove box
Behindmiddleof dash
Notog

Main wire harness(C4o3)
Blower motor
Blower resistor
Recirculationcontrol motot
A/C thermostat
Heatersub-harnessB (C681)
Hoator Sub-hameEsB
connoctor 01
T6rminal
Number of
CavitioE
c681
c682
c683
c684
14
I
6
14
Connocts to
Location
Behindmiddleof dash
Middle ol floor
Behindmiddleof dash
Behindmiddle of dash
Heatersub-harnessA (C677)
Mode control motor
HeaterJan switch
Heaterconttol Panel
HEATERSUB-HARI{ESSB
23-46
vnx.su
Notos

SRS Main Harness
Connector or
Terminal
Number ol
Cavities
c801
c802
c803
c804
c805
c806
c807
2
4
G801
18
2
Location
Connocts to
I Behinddashboardlowet cover
J Under left side of dash
Middle of floor
Behindglove box
Middle of floor
l{otos
Under-dashf use/rclay box (C929)

Main wire haness 1C427)
Cable reel
SRS unit
Left dash sensor
Right dash sensor
Passenger'sairbagassembly
Body ground, via SRS main
harness
UNDER-DASH
FUSE/RELAYBOX
23-47
vnx.su
Fuses
Under-dashFuse/RelayBox
c919
lTo dashboardwire harness(C55'l)l
c918
lTo root wiro harness (C661ll
c920
.elayl
lTo lurn signal/hszard
c928
lTo SRS luso block {C931}l
cg22
lTo powor window rclayl
Auxili.ry fulo holdei
Elnnnr.'trJnnrJn
1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 22
UUIJUIJULJLILIIJ
n|:]nnnnnn
1
t4l 5
(7) 8
LIIJLIULJUUU
r: Not usod
.: Canadd
| ): S6dan
23
UIJ
r''lN11
9. 1 0 1 1
U LILI
r . - - - - - - - l
O: C923 loplion lBATll

@: C924 toption (BATll
O: C925 toption llc2)1
@r C926 loption{No.19 fusoll
@: C927 loption {ACC)I
c929
J To SRSmain I
{C8011I
I harnass
c930
I To ignitionl
i
I switch
c931
I To undrdash
I
I fuso/rolaybox {C928)I
SRS FUSE BLOCK
23-48
vnx.su
Fuse Numbr AmDs

1
30A
Wire Colol
WHT
2
3
Gomponent ls) or Circuit (s) Prot8cted

Moonroof motor
Not used
7 . 5A
WHT/RED Integratedcontrol unit, Ceilinglight, Power antennamotor. Data link connector (DLC)
20A
YEL/BLK
Right rea. power window motor (Sedan)
20A
WHT/YEL Driver'spower window motor
20A
WHT/GRN
Power door lock control unit
20A
GRNiBLK
Lelt rear power window motor (Sedan)
20A
1 0A
BLU/BLK Passenger'spower window motor

RED/BLU Right headlight{High beaml
10
1 0A
R E D / G R N Left headlight(High beam). High beam indicato.tight
11
Not used
12
Not used
13
7.5 A
BLK/YEL
Rearwindow defoggersystem, A/C system, ABS control unit, power mrrror

actuator
14
'15
20A
GRN/BLK
Wiper/washersystem, Moonroof relay, Integratedcontrol unii
1 0A
YEL
to
7.5A
YEL/BLK
17
1 0A
7.5A
WHT/YEL Daytimerunninglights control unit (Csnada)

BLU^tvHT ECM, PGM-FImain relay
1 0A
RED/BLK
'to
20
21
23
Gauges,Clock, Back-uplights, Maintenancereminderunit

Daytimerunninglights control unit (Canadal
Dash lights, Parkinglights, Taillights,Licenseplate tights

Not used
1 0A
RED/WHT
Right headlight(Low beam)
1 0A
RED/YEL
Left headlight(Low beam)
1 5A
YEL/RED
Stereo radio/cassette player, Cigarette lighter
24
REO
BLK/YEL
25
1 0A
PNK
26
1 0A
YEL/BLK
SRS unit
PGM-FImain relay, TCM, Cruisecontrot unit, VSS, ELOunit IUSA)
SRS unit
Turn signal/hazard
relay
' 1 N o . 24 115 Al: 8 1 8 8 1 e n g i n e

N o . 24 t2O At:. B 1 8 C l e n g i n e
23-49
vnx.su
Fuses
Under-dashFuse/RelayBox (cont'd)
NOTE: View from the backside of the under-dashtuse/relay box
c916
[To m.in wlro h.rnr.t lol39]l
cgt5
tTo ..r wftt hJtr.r (CsOrDl
c9r4
[To Int grrtad control unhl
c917
[To mrin wh.
c913
lTo m.in wlro hlni.rr
(qt38)l
c91
tTo r..r w|? hrt|.|t
(C6O3ll
23-50
vnx.su
Under-hoodABS Fuse/RelayBox
T5 [To undo]-hood ABS fuso/rolay box cabl.l
C9O3 ITo ABS pump molor rolayl
C9O1 [To main wiro ham6$ (C212]l

C9O2 [To moin wiro hs1n6ss(C213]l
Wire Color
ABS 81
20A
WHT/GRN
ABS 82
1 5A
WHT
ABS MOTOR 4 0 A
ABS UNIT
1 0A
Componont (s) or Circuit (sl Protectsd

Right/left ABS front solenoids
ABS control unit, ABS rear solenoid
ABS pump motor relay, ABS unit (10 A) fuse
BRN/YEL
ABS control unit
23-51
vnx.su
Fuses
Under-hoodFuse/RelayBox
n
F n nn
46 45 /t4 35 3l
ALTERI{ATOR
fTo .ngino wlto hsrno$ {Tlolll
UU U UU
n
32
U
n
42
33
r:r
n
43
[To rldidor
hn r.l.Yl
Not usod
r: l\lot u3.d
umbor Amps
Componon! (sl 01 Clrcuit 13)Protoqtod
Color
31
1 5A
YEL/WHT PGM-Flmain relay
32
7.5 A
WHT/BLU ECM, TCM. Clock, Stereo radio/cassette plsyer, Maintenance reminder unit
a2
204
BLK/RED
Radiator Jan motor

Not used
34
50A
Condenserfan motor, A/C compressorclutch

WHT/RED N o . I { 3 OA ) , N o . 3 ( 7 . 5 A ) . N o . 4 l 2 O A l , N o 5 ( 2 OA ) , N o . 7 ( 2 OA ) ,
No. I (20 A) fuses
37
38
40A
BLU/lVHT
Blower motor
30A
BLK/GRN
Rear window defogger,Noisecondenser
?q
50A
WHT/BLK
lgnitionswitch {BAT}
40
50A
WHT
41
1 0 0A
42
43
20A
WHT/GRN
Horn system, Brake system, Key interlock solenoid (Aff)
1 0A
WHT/GRN
Turn signal/hazard.elay
35
204
WHT
Combinationlight switch, No. 17 (1O Al fuse

Power distribution
44
Not used
45
Not used
46
Not used
23-52
vnx.su
NOTE; View from the backside of the under-hood fuse/relav box

c907
lTo m.ln wiro h.mo$ (C214)l
lTo mrin wiro hameq lC217ll
[To msinwlro hEmosslc215l]
lTo mlln wlr. hlmct.
(C216li
c911
lTo ftain wiro hamers(C218)l:USA
23-53
vnx.su
PowerDistribution
Gircuit ldentification
8OX
ABSFUSE/FEIAY
UNOER-HOOD
ABS81 {2OA)
WHT/GRN
f
r-
Bight
tromsotcooia
blt ) nas
A8682II5AI
ABSoumomotor
8n /YEL-
A8Scontol unit
Btx/YEL
<
tu!.
ib.l3l7.5Al
YER/RED
A&Scontrol
unit
BATTERY
Stldar motor
r BLKffEL
_o_
- HOODFUSE/RELAY
8OX
UNDER
No.43ll0Al
wHT/GRt{
Turnsi0nrl/h.z.rd|thY
WHT/GRN
tlom
llom mLy
Keyintodocklohnokl{A/Tl
ECM
Cruisocontrolunil
controlmodub(TcMl
Tran.mksion
ABScontiolunh
&6k lighl!
I
AL]ERNATOR
L"I
No.1l(100A)
no.42l20A)
.r"-
oiot
GRi{/REo
{Topsge23- 55)
G401
23-54
vnx.su
ECM
_HOODFUSE/NEUY
UNDER
8OX
{Fromp.So23- 541
YELJWHT
PGM-R mlin |rhv

TrdEmirConco rolrl|oduL
frcMt
-OASH
UI{DEF
FUSSRELAY
BOX
tTop!9c23- 581
nÔIATOR
FANREI-AY
8LK/RED
No.l317.5Al
FUSE
Radi.torfln molor
ENGII{E
COOTAMI
TEMPEMTURE
IECT)
swtTcH
*@"r;1
L swyel
oiot
BTOWER
MOTOR
RETAY
'"---G20t
G40t
8bw.r motor
8LU/WHT
8tX/GRtl-f
E
WHT-----
R!!r windowd,.to![.r
Noiacondsn..r
Cord.nrorlan motor
IJC como.a.lorclutdt
1/-
y
ut{DER-oAsH
R sE/nEL
BoX(Toprs.23- 58I
-IB>
wHTnED
*,"r^*__E>
Fl,$SlrrrrTgl,*r,
No,40l50Al
COMBIMTON
UGHTSWTTCH
{Top!! 23-59 )
- DASIIFUSAREUY
UiIDER
BOXfTop{6 23- 58 llc$.d!l
23-55
vnx.su
PowerDistribution
Circuit ldentification
- DASHFUSE/REIAY
BOX
UNDER
IGNITION
SWITCH
sRsFusE
81-0cK
No.25l10Al
l r c z
Ml
-'-
\'-
_ ÂCC
Chuging sY3l.m light

lln tho g6ugs3mblyl
Cruiscontrolunit
Cdis6 msin 3whch itdicttor light
p age23- 5 7 1
r 1 No.24115A):
81881
engin
No.24l20A):Bl8C16ngin.
PGM- Flmlin r6lry

lrrmmirdon controlmodulo[ICM)
)
Vohag6rcoulator
Vehiclosp.dsomorIVSS)
E|.l)unitIUSA)
Crubeconttolunit
No.14l20A)
GRNiEI(
GRNAt(
Moonrcofrclay
Wind.hicldwipotmotor
Wirdlhildwaah6.motor
R6arwindowws3hormotot{Hrtchblctl
Int.gGtodcontrolunit
PowerwirdowtclaY
Int6lratdcontrclunit
GRN/8I..K
R6afwindow wipor motol

(H3tchbtck)
BLKffEt
No.l5{1041
N0.40{504)
FUSE
(Frompago23- 551
-EiT"h#,H#J:r"
YEt..--
* 2 N o . 1{71 0 4 1
bor sockstl
ShittlocksolenoU{Ml
-up lights
Eack
C924
optionconnctor:
Daytimo
runninglightsconttolunit
23-56
vnx.su
IGNITION
SWTCHISTI
lFromp.! 23- 561
f7
I
.---F------l
STARTFP
Bffi,!'HT6u?'ili,iY
'|
rt-11iPt
l-+{
i
.'.io-F
l - l
l\ \ clurcr
I
inl-rhicicxswrcr
1,,,,,,
;rui8rrH
--.5
BIK/RED
BLX/!\,HT
st.dersotenoid
BLKMHT-
Starlsrsolenoki
BLK/REO
fr
r---
uxrivnSr$!gfr*,r.,
L-eumo
-------J
-DASHFUSEiRELAY
UNDER
BOX
No.l817.5A)
ELUMHT--?(From
pag623-56
)
No.23ll5Al
lG2
lFromp.!623- 56 )
PGM_ Ftmsinrctay
ECM
lntgretodcontrol unit
--E
YEURED
boxsockotl
{Fus/relay
St6r6oradio/c$rtt6 playot
Cigronelightor
Optionconnoctor:
C927
Pow6rminor *tuetols
noarwandowdologgorswitch
indicrtorlight
+ l,lo,16
{7.5A1
R6dietorfan roby
Elowormotor rclay
fuC compr$sor clutch rsl6y
A/C lhomGtst
Cond6ns&tan ml6y
Mod6controlmotor
Rocicubtion control motor
H6atrcontrolpanol
Rearwindow deloggorrelay
ABS pompmotor tolay
ABSinspctionconnoctor
ABScontrcl unit
Optionconnoctor:C925
Daytimerunninglights
controlunit
23-57
vnx.su
PowerDistribution
- OASHFUSE/REI-AY
UNOER
BOX
WHT/RED
-
TrunUcergo
.rur lght
Fbwer.nr.nn! moror
Spotlight(Wrt'hmoonmoll
C.ilin! light
Drl! link conn ctor lDLCl
WHT/REof
boxsockstl
Irtogrltad control unit
WHT/GRN
Pow6rdoor locl control unit
optionconnoclor:
C923
No,14l20l
FUSE
{lntomalconnaclionl
*G20t
G40l
WHTIYEL
*
BLU/4X+l
vnx.su
Powor
windowconttolunrt
{&ih intoDoworwindowmarloirwhchl
p,i""1" *;n6o* no1o,
l_
| l,lssrng6r'swndowmotor
GRN/BLX
-
YEUE|-K
-
r: Sedln
23-58
|
l-
Leftrerrwindowmoror
ftenroar winoowmotor
- DASHFUSE/RELAY
UNOER
8OX
DIMMEN
No.9l10A)
neontu
REo/BLU
? o *c--i| No.lolloAl
ftghtl
b.rml
lHish
I hordlishr
--E:::::l-
i
|
No.2lll0A)
REDiU,HT+REo^wHT
I
I No.22ll0Al
-TiED,TEL-L.trr
|
l"JnJ"",,**".
Rgh,I
| h.rdliohtlLowbrml
l
optioncondsclor:
C926
RED/BLK
*
o.sh hhts briohtners

co .ollr
Dlshlght!
A/T gorr pGition conloh hht

Horler control Drnellioht
l_tft
Rishn.
Iro
REDALK ..-
REDEL(+
parung
rgnr
fff')t.'..,nt
tillisht{sdanl
f#t) inner
Lic.n! pbt li0hts
Truilorliglfi ng connoclor
tGNtTloN
swtTcH
ltcl)
p36
23- 56)
lFrom
V
I
l-
FUS
HOLDER
t
BLK,ryEL
#
tt
I
m.ze
rroo
YEUBTK-
Tumdgnd/hazrrdr6i.y
l
l
23-59
vnx.su
GroundDistribution
Gircuitldentification
Blttory
_d_
:
GI
Tnnll|iltirn
houinc
_d_
:
G3
Et -
Y||tr rpoollrEor rYSq

VrECDlaaaura
rwitch
18| 8Cl.r{i|r)
Engino
coohnttomporlru|!ICCTI
!wilch
ux_r]---..o eu{l{
"-
*" ",
iTl*;,,
Dlt linl connctor lDl"Cl

I Tranamildrficontroldbduh
t (TcMt
ECM(-G
ECMILG2I
Xmct t rmr l(Sl

{VTEC}
lLatadorvo.n
!.ruor lHozsl
Cnnkd|rft Doritiont
ICKPI$nlor
t
ECM
TDC!.No. t
Cylndaroolitirn f
ICYPI!.ir.o.
1
L-----------
on[/8LU-r-.
Mdn httt !p6od

..n.or lAlTl
WHT/BI-U+
sLu/GRN-F
Co(||llanhrft !p.d
r.Bor WT)
BLUrYEL
-
Irn ry oroundcebh E , Etgi," *ir" ha."o

Enoina
0oondcrbL A E , Etgir. *rp"nn"nt *ir. han*"s
E:
|
ground
ngino
c.bL 8 E: Mdnwirbhem6r
E
E:
23-60
vnx.su
I
I
Tnnln&don codaol moduL
frcMt
l-
Cor|danlor
lan motor
-f,
:
G15l
h.ldtgh
lLow be.ml
Rbhttror pr*inoûm .ign.l lehr

Righttro li,. m|.t rhht
EtounitIUSAI
- HOOO
UI{DER
FUSE/RTAY
8OX
Elowormotorrolay
R6!r*indow dsloegrrrcby
G40t
fro p.g. 23- 62)
AB{iF np motor
au#eu
ABSpr..&r! lwltch
E , A/c*ir" tr".osr
unitwitchrrn.r
E : ABSdbduknor
:
Min
wirr
h.moB
Ul
23-61
vnx.su
GroundDistribution
lHi0hberm)
'LK
H[l[llsf#"ff'"Jfl1"'o"
Homrol.y
lgdtionkoylrvitch
8r
-;rv@.nciw*'*.,
oq_
BIK -{
t .
|-{N|
l-
4.X -7
BIK
tr
tr
E
lub - hamar! A
Engin6comprrtmonl wiro htrnds
@ :llort.|
Main wiro hftn.ss
tlt . H6!t6r lub - harara$B
Frcnt prsongor'! door wim hlmosg
23-62
vnx.su
F
L
Cftxchsvynch
{M/Twhhcruisccontroll
conlrclunit I lArt
Intorlocl
r-
Ct rch htodock swhch lM/Tl

Ra'r window wioar/washotlwitdl
l-
P!.rsong.r'!dootloct kcycylindrsYritch
doorbck 3witch
P!s!6n06r's
Windlhiald wio.r/w$h6r rwhch
G,Ol
lR!6t p.g! 23-621
cod$rionl
Porvlrwidow rlhy
Tlm demlftd.id nhy
Intaeiltadcontrolunh
*-----ilHHlifr,
JUNCtOI{
coif{EcroR
g..(
SRslidbnor loht/&dit
d{
Daahhhr Mchinalaconto{..
Clocl
Grler. .nd hdixor hhtr
Mdntandranrnlidarurlt
R.r rvlndoud.foglr r*hdr
n"K
Chino
Cigrfi.ItDt.r
Gbv! boxhhl
Crui$ contmlmin .witdr
Starao[do/clalatta pbyal
c56l
) snsu'*
G80r
E: MdnYdoh.m..!
E, ootrtoct ,lo ttetr"..
@: noor*in |trttan
E'sasnr*rtrrtu
23-63
vnx.su
GroundDistribution
Hstchbsckl
Pow6r
doorlockcontolunh
Driver'B
doorlockectrrtor
Driv6r'sdoorlockk6ycylind6lswhch
Drivor'sdoorlockswitch
Powor
mirroa
swhch
] Pow6rwindowmanorswitch
8r-K
Ddver'3seat bah 3whch
----BLK,lVHT
Fuolg&lge sodiogunil
R rl pump
nuo,
Poworsntonmmotor
Tnibr lighingconnctor
L
E
eLx -i]-
BLK-
;l:. I taillisht
Licnroph6 light3
HishrDunt br.k6tisht
BtK---------
) ABs*nuoruni
AIY_I
I_
BI.KA.VHT
Lrh
I ABScontolunh
ABScontrolunh
Rorrwirdowwipcrnotor
cirt
Ro window dfoggor
nirt
E
E
E
Roarwiroharnoss
Ddv6r's
doorwileham63s
@ :Tailgatowirc hamoss
@ : R6erwindow d6lo9grgro{nd wirc
ABSsub-hernoss
23-64
vnx.su
Sd8n:
,.-*-{.4rr-*
Powgrdoorlockcontrclunit
Drivor'sdoor lock actustor
D ve/s door lock key cylindl rwhch
Ddv6r'sdoor lock switch
] Powerwindow mrster switch
Drivor's soat bolt swhch
--E
Brx,4/vHr
*",r *n
lfr]ff;nj
G5o2
Irunk latchswhch
f l8iler lightingconnector
Licoruopl.to lights
RiohtI .
nnst rrn gnr
L-ft J
Riohr)
.... .
ran||gnr
L-ft J
Poweranlonnamotot
Highmo0ntbt'k6light
Rearwindow dotoggor
otoa
oo "onuo,unn
]
t,*----l
=,-"*-
,_^
ABscontrclunh
.:
G702
@:
@ :Ddvo/sdoorwir hemoss
E ' ABSsub- hafn6s.
23-65
vnx.su
Battery
a Battory tluid (6lectrolytl contains sulturic acid. lt may cauaa aevere burns iI it gots on your skin or in youl oyos.
Woar protoctivo clothing and I fac shield,
- ll aloctrolyt6 gots on youl skin or clothos, rimo it off with wator immediately,
- lf eloclrolyto g6ts in your oyos, tlush it out by splashingwat6r in youl eyes for at least 15 minutes; call a physiclan
immediately,
a A battery gives off hydrogon gas, lf ignit6d. tha hydrogsn will orploda and could crack tho baflory cas6 and splattor
acid on you. Koep spa*s. flames, and cigarottos away from the baftery.
a Overchargingwill raiso ths tempelature ot th electrolyte. This may force electrolyte to splay out of the battery venta.
Follow lhe chargor manutacturer's instluctions and chargo tho battory at a prop61rate.
NOTE: The originalradiohas a codedtheft protectioncircuit. lt serviceto the car requiresany of the lollowing, be sure
to get the customer'scode number before
- removingNo. 32 (7.5 Al fuse from the under-hoodfuse/relaybox
- removingthe radio,
After service,reconnectpower to the radioand turn it on. When the word "CODE" is displayed,enter the customer's
s-digir code to restore radio operation,
Use eithera JCI or BearARBSTtester, and follow the manufacturer'sprocedures.It you don'r have one of these computerized testers, follow this conventional test procedure:
To get accurateresults,the temperatureot the electrolytemust be between TOoF l21ool and IOOoF{38oCl.
lf the case is cracked or the posts are loose,

replace the battery.
lf the indicator shows low electrolvte, add

distilledwater it oossible.
Test Load Cspacity (# 1)

.
.
.
.
Apply 3OOamp losd fo. 15 secondsto remove

surJacecharge.
Allow 15 secondsrecoveryperiod.
Apply test load (see Test Load Chartl.
Recordvoltage at the end of 15 seconds.
Voltagestays above 9.6

volts: The batterv is OK.
23-66
vnx.su
Chargeon High Setting {4O ampsl

Chargeuntil EYEshows chargeis OK; plus an
additional30 minutesto assuretull charge.
NOTE:lf the battery chargeis very low, it
may be necessaryto bypassthe charger's
polarityprotectioncircuitry.
lf the EYEdoes not show chargeis OK within
three hours,the battery is no good; replaceit.
Write down how long the battery was
charged.
Test Load Capacity l#21

Apply 300 amp load for 15 secondsto removesurfacecharge.
Allow 15 secondsrecovervDeriod.
Apply test load (seeTest Load Chan).
Recordvoltaoe at the end of 15 seconds.
Voltagestays abov 9.6 volts: The Uatteryis Of. I
Voltagedrops below 9.6 volts: The battery

is no good.
For oramplo: AOD26L.MF

.-
BATTERY
ERY COOE
COOE
TEST LOAD CHART
Use the test load ot 112the cold crankingamps (CCA)printed on the labelon the top of the battery. lf neithe. is indicated, us the informationbelow:
BATTERY
CODE
COLD CRANKING
AMPS (CCA)
80
70
550
55
405
440
TESTLOAD
lamps,
270
220
200
23-67
vnx.su
Power Relays
RelayTest
t{ormally-opn Type:
1.
Remove the power relay from its sockat.
2.
Check continuity between relay terminals.
a Power window relay

a Radiator fan relay
a glower motor relav
a There should be continuity between the A and C

terminals when power and ground ar connected to the B and D trminals
a There should be no continuitv whn power is disconnected.
T6rminal
A
(B- D)
PowEr
Connactod
Di!c!nnact6d
IP
tb
I
I
a
a
a
a
a
Staner cut relay

Condenser fan .elay
A/C compressor clutch relay
ABS t.ont {ail-saferelay
ABS lear fail-saterelav
A
\
B
/
tffit
t[fT4r
\ C
23-68
vnx.su
D ,
vnx.su
23-69
lgnition Switch
CAUTION:
a All SRS electdcal wiring harnessssaro covotod whh
yollow insulation.
a Botore disconnocting any part ot th6 SRS wiro harn6ss. connoct tha shon connoctor(t).
a Replactho ontiro affected SRS hames! asllmbly It
it has an op6n circuit 01 damagod widng.
J.
Chsck tor continuity btween the terminals in each

switch position according to the table.
SRS MAIN HARI{ESS

(Cov6red with Yollow inrulltiori)
1.
Removethe dashboardlower cover and knee bolster.
Terninal
BAT
tG1
ST
P6ition
--o
oI
KNEE BOLSTER
DASHBOARDLOWERCOVER
Disconnect the 5-P connector flom the undsr-dash

fuse/relav box and the 7-P connector from the main
wire harness.
23-70
4.
lf continuity checks do not agre with the tabl6,

reolace the lectrical part of the switch lsee page
23-72t.
vnx.su
ElectricalSwitch Replacement
a All SRS lectric8l wiring hamossesar covorsd with
yellow insulation,
a Befora disconnecting any pan of tho SRS wilo harneas. connect the short connoctor(sl.
a R6placethe entire attect6d SFS harnessassombly if
it has an opon circuit 01 damaged wiling.
NOTE: The originalradio has a coded theft protection

circuit, Be sure to get the customer'scode numberbefore
- removingthe No. 32 (7.5 Al fuse from the under-hood
luse/relaybox.
- removangthe radio.
on. Whenthe word "CODE" is displayed,enterthe customer's 5-digit code to restoreradio ope.ation.
4.
Removethe steeringcolumn covers.

UPPERCOVER
Insertthe key and turn it to ,,O',.

Removethe two bolts and replacethe switch.
1. Disconnectthe negativecable from the batery.

2.
Removethe dashboardlower cover and knee bolster

{seepage 23-70).
3.
Disconnectthe 5-P connectorfrom the under-dash

fuse/relaybox and the 7-Pconnectorfrom the main
wire harness (see page 23-70).
7.
vnx.su
Installin the reve.seorde. of removat.
23-71
lgnition Switch
Steering Lock Replacement
CAUTION:
a All SRS electrical wiring harnessesale covsred with
yellow insulation.
a Belore disconnecting any parl ot the SRS wir halness, connecl the short connector{s).
a Replacethe entire alfected SRS harness a$6mbly il
NOTE: The originalradio has a coded thett protection

circuit. Be sureto get the customer'scode numberbetore
- disconnectingthe batterY.
- removingthe No. 32 (7.5 A) fuse from the under-hood
fuse/relaybox.
6. Lower the steeringcolumn sssembly.

each oJ the two shearbolts and drill
7. Center-Dunch
their heads off with a 5 mm {3/16 in) drill bit'
CAUTION: Do not dama96 tho switch body whon
rmovlng the shoar bol$.
8 . Remove the shear bolts from the switch body.
1.
Disconnectthe negativecable from the battery.
2.
Removethe dashboaldlowercoverand kneebolster

(see page 23-7'l).
3.
Disconnectthe 5-P connectorfrom the under-dash

fuse/relaybox and the 7-Pconnectortrom the main
wire harness{see page 23-71).
1 1 .Insert the ignition key and check for proper opera-
4.
Remove the steering column covers (see page

23-711.
1 2 . Tighten the shearbolts untilthe hex headstwist off.
5.
Removethe columnholdermountingboltsand nuts'
1 0 . Loosely tighten the new shear bolts.

tion of the steering wheel lock and that th ignition
key turns freely.
NUT
13 N.m
(1.3 kgf.m, 9.4 lbl'ftl
BOLT
22 N.m
12.2 kgl'm. 16 tbt.ftl
23-72
Installthe new ignitionswitch without the key inserted.
vnx.su
StartingSystem
GomponentLocationIndex
STARTERCUT RELAY {M/T}

Test, page 23,68
A/T GEAR POSITIONSWITCH

Test, page 23-136
page 23-137
Replacement,
CLUTCHINTERLOCK
SWITCH(M/T}
Test, page 23-78
Switch Adiustment.section 12
BA
Test, page23-66
Test, page 23-76

SolenoidTest, page 23 78
page 23 79
Repfacement,
Overhaul,pages23-8O
Reassembly,
page 23,85
23-73
vnx.su
Starting System
GircuitDiagram(M/Tl
tGNtTt0t{
SWTCH
UNOERHOOO
FUSE/REI.AY
BOX
+O
/.^1\tOFr
\_:/
I
I
BT.KMHT
STARTER
CUTREIAY
EUqWHT
II
t*u*
I
I
8l-K
r H l
I STARTER
G 20r
G40r
vnx.su
Circuit Diagram(A/T)
G?{rao
swncH
-HOOD
UI{DER
FUSE/NEUY
BOX
N,0.41
{l00Al
-{ 6i\ o+
Io.39160t
\_v
I
Bl-torvHT
II
,(h\
A/I GEAR
g, ffi.:11?[:#ir11,",,
II
BI.K/BED
vnx.su
Starting System
Startel Test
NOTE: The air temDeraturemust be between 59 8nd
10OoF(15 and 38oC) beforetesting.
Chock Stanr Engag6ment:

1.
Recommendsd Procodure:
Disconnectthe 2-P connector(ignitioncoil primary

lead) from the distributor.
a Use a staner svstem tester.

a Connect and operatethe equipmentin accordance
with the manutacturer'sinstructions.
a Test and troubleshootas described.
Altohato Procedure:
a Use the following equipment:
- Ammeter. 0-4OO A
- Voltmeter, O- 20 V {accuratewithin 0.1 volt)
- Tachometer,O- 120O rpm
a Hook up voltmeterand ammeteras shown'
2 . Pressthe clutch pedalallthe way in (M/T),and turn
"Start". The starter should

the ignition switch to
crank the engine.
NOTE: On cars equippedwith manualtransmission,
the enginewill not crank unlessthe clutch pedalis
fully depressed.
lf the staner does not crank the enginego to step 3.
J.
Check the baftery, battery positive cable, ground,

and the wire connections for looseness and corrosion,
Test again.lf the starterstill does not crankthe engine, go to step 4.
4.
Bvpassthe ignitionswitch citcuit as follows {make

sure the transmissionis in neutral):
Unplug the connector (BLK/WHTwire and solenoid
terminsl) trom the starter. Then connect a jumper
wire from the battery positive ( + ) terminal to the
solenoid terminal. The starter should crank the
engrne.
a lf the starter still does not crank the engine,
replace it and diagnose its internal problems.
a lf the starter cranks the engine,go to step 5.
TERMINAL
NEGATIVE
NOTE: After this test, or any subsequent repair,
resetthe ECMto clearany codes (seesection 1 1)
23-76
vnx.su
5.
Check lor 8n opn in the BLKMHT wire circuit between the staner and ignition switch, and connectors.
Chack Cranking rpm:
6.
Check the ignitionswitch (see page 23-70).
lf spe6d is too low, chck for:
7,
On cars with automatic transmission,check the A/T

gear position switch (neutral position switchl and
connector.On cars with manualtransmission,check
the staner cut relay, clutch interlock switch, and
connectors.
a
a
a
a
a
NOTE: Check the No. 39 (5O A) fuse in the under-hood

fuse/relay box for the starter cut relay.
Check tor Woar and Damago:
The starter should crank the engine smoothly and steadily. lf th startsr engages, but cranks the engine erratically, remove it. Inspect the starter, drive gear, and
flywheel ring gesr for damage.
a Check the drive gear overunning clutch for binding
or slippingwhen the armatureis rotated with the drive
gear held. Replacethe gesrs if damaged.
Enginespsod during cranking should be above 1O0rpm.
Loose battsry or starter teminals

Excessively worn starter brushes
Open circuit in commutator segments
Dirty or damaged helical spline or drive gear
Defective drive gear overrunning clutch
Chock StErtor Disongagomoni:

Pressthe clutch pedalallth way in (M/T),turn the ionition switch to "lll" and roleaseto "11".
The starter drive gear shoulddisengagefrom the tlywheel
ring gear. When you roleasethe key.
lf the drive gear hangsup on th flywheel ring gear, check
for:
a Solenoid plunger and switch malfunction
a Dirty drive gear assembly or damaged overrunning
clutch
Check Cranking Voltago 8nd Current Draw:

Cranking voltage should be no less than 8.O volts.
Current draw should be no more than 360 amperes.
lf cranking voltag is too low, or current draw too high,
check for:
a Fully charged battery
a Open circuit in starter armaturecommutatot segments
a Starter armature dragging
a Shoned armature winding
a Excessivedrag in engine
23-77
vnx.su
Starting System
Starter Solenoid Test
Clutch Interlock Switch Test

1.

(seepage 23-70), then disconnectthe 2-P connector from the switch.
2.
Check tor continuity between the terminals according to the table.
1.
Check for continuitv between the tetminals accotding to the table.
Tsrminal
Coil
HOLD-IN
Trminal
A
PULL-IN
ClutchPedal
Housing
o- ---c
o- ---.o
RELEASED
PUSHED
Pt LL- tt{ coll
lf necessary.replacethe switch or adjust the switch

oosition (seesection 12).
23-78
vnx.su
HOLD- |l{ COIL
Starter Replacement
1 . Disconnectthe negativecable from the batterv.
2.
4.
Removethe intake air duct.
Disconnect the staner csble from the B terminal on

the solenoid,then the BLK/WHTwire from the S
terminal.
Removethe two bolts holdingthe staner, then remove the startef.
UPPER
MOUI{TII{GBOLT
44 N..h (4.5 kgl.m, 33 lbt,ftl
8 TERMII{ALMOUIITTI{G
NUT
9 .ln (0.9 kgf.m, 6.5 tbf.ttl
AIR CIEANER
HOUS|L
TERMINAL
Removethe enginewire harnessand startefcables

from their brackets.
BLI(AA/HTWIRE
ENGINEWIRE HARI{ESS
6.
Installin the reverseorder of removal,
CAALES
23-79
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StartingSystem
Startel Overhaul
CAUTION: Disconneclth battery ngativecable befole
lomoving the startet.
SOLENOID
PLUNGER
STARTER
SOLENOID
Test, page 23-78

citcuit. Be sureto get the customer'scode numberbefore
- disconnectingthe batterY.
- removingthe No.3 2 (7.5 A) fusefrom the under-hood
fuse/relaybox.
- removingthe tadio.
Atter service,reconnectpower to the radio and turn at
BRUSHHOLOER
ARMATURE
PINIONGEAR
IDLERGEAR
ENOCOVER
t r . /
.' BRUSH HOLDER

Test, page 23-8'l
ERUSH
COVER
SOLENOIDHOUSING
IDLERGEAR
@*
HARNESSBRACKET
ARMATURE
lnspection and Test,
page 23-82
ROLLERBEARINGS
and CAGE
Prevenl rollers trom being scattered and lost.
MOLYBDENUMDISULFIDE
STEELBALL
installsteel ball
from clutch side.
-s@]
MOLYBDENUM
DISULFIDE
CLUTCHASSEMBLY
OVERRUNNING
Inspection,page 23_84
_R1
MOLYADENUM
DISULFIDE
GEAR HOUSING
23-80
vnx.su
Starter Brush Holder Test

1.
Starter Brush Inspection
Checkthat there is no continuity between the O and

O brush holders.lf continuity exists. replacethe
b,ush holderassembly,
G) BRUSHHOLDER
O BRUSHI{OLDER
Measurethe brush length. lf it is less than the service

limit, replacethe armaturehousingand brushholderassembly.
Brush Lngth
Standard{Now): 15.O- 15.5 mm (0.59-0.61 inl
Se.viceLimit:
10.0 mm (0.39 inl
E BRUSHHOLOER
O BRUSHHOLDER
Insertthe brushinto the brushholder,and bringthe

brush into contact with the commutator,then attach
a springscaleto the spring,Measurethe springtension at the moment the spring lifts off the brush.
SpringTension:17.7 -23.5 N {1.8-2.4 kgf,
4.O_5.3 tbfl
NOTE: To seatnew brushesafter installingthem in their

holders,slip a strip of # 5OOor # 600 sandpaper,with
the grit side up. over the commutatorand smoothlyrotate the armature.The contact surfaceof the brushes
will be sandedto the same contouras the commutato..
SPRINGSCLAE
23-81
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StartingSystem
ArmatureInspectionand Test
1.
CommutrtorRunout
Standard(Naw):0-O.O2 mm (0-O.OO08inl
SowicoLimit: 0.O5 mm (O.O02inl
Inspectthe armaturefor wear or damagedue to contact with the field coil magnets.
Inspect tor damage
COMMUTATOR
A dirtv or burnt commutator surface may be lsulfaced with emery cloth or a lathe within the following specilications.
Commutator Diametr
S t s n d a l d( N 6 w ) :2 9 . 9 - 3 O . O m m ( 1 . 1 7 - 1 . 1 8 I n l
Selvico Limit: 29 mm (1.14 lnl
3 . lf the commutator runout and diamete. are within

limits, check the commutator tor damageor for carbon dust or brass chips between the segments.
4.
VERNIEBCALIPER
23-82
vnx.su
lf the surf6c6 is dirty, recondition it with # 50O or

# 600 sandpsper.
Checkfor mica depth. It necessary,undercutmica

with a hacksaw bladeto achieveproperdepth.
Placethe armatuteon an armaturetester. Hold a

hacksawblade on the armaturecore,
ITOTGOOO
ARMATURETESTER
HACKSAW BLADE
MICA DEPTH
Commutator Mica D6pth

Stsndard{Nsw):0.5-0.8 mm (O.O2-0.03 in}
Sslvice Limit: 0.2 mm (O.OO8inl
ARMATUFE
Check tor continuity between the segments of the

commutator.lf an open circuitexists betweenanv
segments,replacethe armatute.
It the blade is attracted to the core or vibrstes while
the core is turned,the armatureis shorted.Reolace
the armature.
8.
Check with an ohmmeterthat no continuityexists

betweenthe commutatorand armatutecoilcore. and
between the commutator and armatureshaft. lf con_
tinuity exists, replacethe armature
M
SHAFT
COMMUTATOR
23-83
vnx.su
StartingSystem
Starter Field Winding Test
OverrunningClutch InsPection
1.
Check for continuity between the brushes.lf there's

no continuity, replace the armature housing.
Slidethe overrunningclutch slong the shatt.

Does it move treely? ll not, replace it.
2.
Check for continuity between each brushand the armature housing{ground) lf continuity exists, replace
the armatulehousing.
Rotate the overrunning clutch both ways.

Does it lock in one direction and rotate smoothly in
reverse? lf it does not lock in either direction or it
locks in both directions, replace it.
BRUSHES
CLUTCH GEAR
DRIVEGAR
ll the starter drive gear is worn or damaged, replsce

the ovsrrunning clutch assembly; the gea. is not
available separately.
4.
23-8,4
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Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth ale
damaged.
Solenoid PlungerInspection
StarterReassembly
Check the contact points and the face of the staner solenoid plunger for burning, pitting or any other defects. lf
surfacas are rough, recondition them with a strio of
# 500 or #600 sandpaper.
Rassemblethe starter in the reverse order of disassembly.

1.
Pry back each brush spring with a screwdriver,thon

position the brush about halfway out of its holder,
and release the spring to hold it there.
2.
Instsllthe armaturein the housing.Next pry back

each brush spring again and push the brush down
until it seats against the commutator, then release
the spring against the end of the brush.
soLEr{otD
PIUNGER
a&T&'
s..
V
3.
BRUSH
Installthe end cover on the brush holder.
23-85
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StartingSystem
PerformanceTest
NOTE: Beforestaning the tollowing checks. disconnect
the wire Jrom te.minal M, and make a connectionas
describedbelow usingas heavya wire as possible{preferably equivalentto the wire used for the car).
Rotracting Test:
Pull-in Coil Tasl:
NOTE: Do not leavethe battery connectedtor more than

1O seconds.
Disconnectthe battery negative cable. ll the pinion

retracts immediately, it is working properly.
Connectthe battervas shown. It the starterpinionpops

out, it is working properly.
GAUTION: Do not leavothe battery connectodfor mora
than 10 seconds.
Startoi Noioad Test:

1, Clamp the starte. firmly in a vise.
2,
Connectthe starterto the battery as shown and contirm that the motor starts 8nd keeps rotating.
Hold-in Coil Tost:

Disconnectthe battetv from the M terminal.lf the pinion does not retract,the hold-incoilis working properly.
CAUTION: Do not l6avetho battory Gonnectedfor moro
than 10 soconds.
It the electric current and motor speed meet the

when the batteryvoltageis at 11 V,
sDecifications
the staner is working properly.
Spacifications: 90 A or less {Eleciric curentl.
3OO0 rpm or more (Motor speodl
23-86
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lgnition System
Gomponent Location Index
IGNITIONTIMINGCONTROLSYSTEM
a Troubleshooting,
section I1
a Inspectionand setting, page 23-89
DISTRIBUTOR
Top End Inspection,page 23-91
Removal/lnstallation,
pages23-91, 92
Overhaul,page 23-93
Reassemblv,
page 23,94
lgnitionCoil Test/Replacement,
page 23-95
lgnitionControlModule {lCM} Inpur Test, page 23-96
SPARK PLUGS
fnspection, Page 23-97
WIRES
Inspection, psge 23-94
23-87
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lgnition System
Circuit Diagram
BOX
HOOO
FUSE/RELAY
UNOERECM
V
I
YEUGNiI
posilioo
sonsor
CKP:Cr6nk.halt
position
snsor
CYP|Cylindor
tG tTtoNc0NTROl(cMl
MoDUr.r
/ H8sbuilt in \
I OOrsO
I
TOC/CKP/CYP
SENSOR
-_r_1=__E
-J---L--L--Lr
U'+++
ORN
23-88
vnx.su
lgnition Timing Inspection and Setting

1 . Startthe engine.Holdthe engineat 3,00Orpm with
no load (A/T in S or E position,M/T in neutral)until
Pullout the servicecheckconnectorlocatedbehind
the rightkick panel.Connectthe BRN/WHTand BLK
terminalswith the SCS short connector.
DATA LINK
CONNECTOR{3-P}
NOTE: Do not attach
the jumper wire.
4.
Adiust ignitiontiming, if necessary,to the following specifications:

lgnition Timing:
16 t 2 BTDC (RED)at 75O 1 50 rpm in noutral
NOTE:
a Shift lever must be in neutral.
a All electricalsystemsshould be turned OFF.
POINTER
SCS SHORT CONNECTOR

{0?PAZ-O010't00t
SERVICE
CHECKCONNECTOR
I2.PI
NOTE:Locatedbehindthe right kick
oanel
Connecta timing light to the No.1 ignitionwire and

point it toward the pointeron the timing belt cover.
REOMARK
TIMINGLIGHT
lcont'd)
23-89
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lgnitionSystem
lgnition Timing lnspection and
Setting (cont'd)
5.
To adjust ignition timing, loosen the distributor

mounting bolts, and turn the distributor housing
counterclockwise to advance the timing, or clockwise to retard the timing.
ldle Speed Inspection

Shift to neutral or Ll] and start the engine. Hold the
engineat 3,OOOrpm with no load until the radiator
fan comes on, then let it idle.
2 . Connect a tachometer to the test tachometer connector.
MOUNN G BOLTS
24 N.m (2.4 kgl.m, 17 lbt'ftl
b.
Tighten the adjusting bolts and recheck the timing.

Remove the SCS short connector trom the service
check connector.
ldle sp6od
M/T: 750 t 50 rpm in neuttal
A/T: 75O t 50 rpm in @ or @
NOTE: Allelectricalsystemsshouldbe turnedOFF.
Adjustthe idlespeedil necessary(seesection 1 1).
23-90
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DistributorTop End Inspection
Distributor Removal
1 . Checkfor rough or pitted rotor and cap tefminals.
1.
2 . Scrapeor file oft the carbondeposits.

Smooth the rotor terminal with an oil stone or #600
sandpaperi{ rough.
2 . Disconnectthe ignitionwires from the distributor
Disconnectthe 2-P and 8-P connectorsfrom the distributor.
cap.
Check the distributorcap Jor cracks, wear, and

dSmage,lf necessary,clean or replaceit.
3.
Removethe distributor mounting bolts, then remove

the distributorIrom the cvlinderhead.
23-91
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lgnitionSystem
DistributorInstallation
Coat a new O-ring with engine oil, then install it.
5.
Connect the ignition wires as shown.
Slip the distributorinto position.

NOTE: The lugs on the end of the distributorand
its mating grooves in the camshaft end are both offset to eliminate the possibility ot installing the distributor 18Oo out of time.
DISTRIBUTOR
END
CAMSHAFTEND
Set the timing with a timing light (sepage23-89).

After setting the timing, tighten the mounting bolts.
24 N.m (2.4 kgf'm' 17 lbt'ft|
Install the mounting bolts and tighten them temporarily.

Connect the 2-P and 8-P connectors to the distributor.
23-92
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DistributorOverhaul
BLKTYEL
DlsTNIBUTOR
ROTORRETAII{IITGSCREW
lMust be madeof
diamagnsticmateriall
Chock tor cracks, wear, damage,

or fouling.
Clean or replace.
HOUSING
Check for cracks
oa damage.
IGNITIONCONTROLMODULE {ICM)
Troubleshooting,section 1 1
Input tost, page 23-96
23-93
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lgnition System
Distributor Reassembly
1 . When reassemblingthe dislributor, install the distributor rotor so on the shaft that it faces in the direction shown (toward the No. 1 cylindetl,
lgnition Wire lnspection and Test

CAUTION: Caretully removo the ignition wiros by pulling on tho rubbq boots. Do not bend the wilos; you might
blak tham inside.
1.
Checkthe conditionof the wire terminals.lf any te.minalis corroded,cleanit. and if it is brokenor distorted. reolacethe wire.
IGNITION
WIRE
2 . Alignthe indexmarkon the distributorhousingwith

the index mark on the end of the shaft.
2 . Connect ohmmeter probesand measureresistance.

lgnition Wile Roaistanco:
25 k0 max. at 68oF (2OoCl
INDEX MARKS
IGNITIONWIRE
3.
23-94
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lf resistanceexceeds25 kO,replacethe ignitionwire,
lgnitionCoil Test
lgnition Coil Replacement
With the ignition switch OFF, remove the distribulor cap.
1.
With the ignition switch OFF, remove the disrributor cap, rotor, and cap seal, then remove the leak
cover.
Removethe two screws to disconnect the BLK^/EL

and WHT/BLUwires from terminalsA (+ ) and B ( - )
respectively.
CAP SEAL
Removethe two screws to disconnect the BLK/YEL

and WHT/BLUwires from the coil.
3.
Using an ohmmetet, measur tesistance betwen

the terminals,Replacethe coil if the resistanceis not
within specifications.
3 . Remove the two screws and slide the ignition coil

out of the distributorhousing,
NOTE: Resistancewill vary with th coil tm9erature; spcificationsare at 68oF l20oC)

Prlmary Winding Rosistanco
(8otwo6n tho A and B torminalsl: 0.6-0.g ohms
Secondary Winding Rssistanc6
(Botwoon the A and socondary winding tomlnalsl:
1 2 . 8- 1 9 . 2 k O
A l+)
I11
t L
B{-}
l
WHT/BLUWIRE
23-95
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lgnition System
lgnition ControlModule(lCMl Input Test
NOTE:
a SeesectionI 1 if the malfunctionindicatorlamD(MlL)
blinks.
a Pertorman input test for the ignitioncontrol module
(lCM)after finishingthe fundamentaltests for the ignition system and the fuel and emissionssystems.
a The tachometershouldoperatenormally.
1.
Removethe distributorcap, the distributorrotor, and

the leak cover.
2.
Disconnectthe BLK/YEL,WHT/BLU,YEL/GRN,and
BLU wires from the lCM.
4.
Turn the ignitionswitch ON. Checkfor voltagebetween the WHT/BLUwire and body ground.
There should be battery voltage.
a lf there is no battery voltage,check:
- lgnition coil
- WHT/BLUwire betweenthe ignitioncoil and
the ICM
a lf there is battery voltage. go to step 5.
Checkthe YEL/GRNwire betweenthe ECMand the
tcM.
6 . Checkthe BLUwi.e betweenthe tachometerand the
rcM.
7 . It all tests are normal,replacethe lCM.
YEL/GRN
wlRE
3.
Turn the ignitionswitch ON. Checkfor voltagebetween the BLK/YELwire and body ground.
a lf there is no batteryvoltage,checkthe BLK^/EL
wire betweenthe ignitionswitch and the lCM.
a lf there is battery voltage,go to step 4.
23-96
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Spark Plug Inspection

1. Inspectthe electrodesand ceramicinsulatorfor:
Replacethe plug if the centerelectrodeis rounded as shown below:

ROUNDED
ELECTROOE
.
.
.
.
Damaged
gask6t
rmpropergap
Oil-touling
Carbondeposits
Crackedcenter
electrodeinsulator
Bl8Cl engine:
a Make surethat the '1.4mm (0.055 in) wire-type
pluggaugedoes not go into the gap for the platinum tip plug. lf the gaugegoes into the gap, do
not attemptto adjustthe side electrode;replace
the plugwith a new one.Useonlythe sparkplugs
listed below.
ROUNDEOELECTRODE
Electrode Gap
Standard:1 .2-'l .3 mm
{0.047-O.051 in)
ServiceLimit: 1.4 mm
{0.055 in)
Burned or worn electlodes may be caused by:

. Advancedignitiontiming
. Loose spark plug
. Plug heat rangetoo low
. Insufficientcooling
Fouledplug may be causedby:
. Retardedignitiontiming
. Oil in combustionchamber
. lncorrectspark plug gap
. Plug heat rangetoo high
. txcessive idling/lowspeed running
. Cloggedair cleanerelement
. Deterioratedignitioncoil or ignitionwires
CAUTION: Do not use a blade-type plug gaugs, it

may damagethe platinumtip of the centerolectrodo.
S p a r kp l u g sf o r t h e 8 1 8 8 1 e n g i n e :
Check the electrodegap.

Bl88l engine:
a Adjust the gap with a suitablegappingtool.
ElectrodeGap
1 . 0 - 1 . 1 m m ( O . O 3 9 - 0 . O 4 3i n )
Standard:
Z F R s F -11( N G K )
K J l 6 C R - 111
(Nippondenso)
For all normaldriving
Z F R 6 F -1 ( N G K )
KJ2OCR-11
1
(Nippondenso)
For hot climatesor continuous high speed driving
S p a r kp l u g sf o r t h e B ' l 8 C l e n g i n e :
P F R 6 G _ 1( N
3GK)
PK2OPR-113
I
I Forall normaldriving
{Nippondenso)
1 . 1m m
{0.0,$ in)
3.
Applya smallquantityol anti-seize

compoundto the
plug threads.
Screw the plugs into the cylinderheadiingef-tight,
t h e n t o r q u et h e m t o 1 8 N . m ( 1 . 8 k g f . m , 1 3 l b f . f t ) .
23-97
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ChargingSystem
ComponentLocationlndex
CHARGINGSYSTEM LIGHT
lln the gauge sssemblyl
Tst. pages23-1OO.101
Bulb Locations, page 23-1 15
BOX
UI{DER.HOOD
FUSE/BELAY
(USA:Hasbuilr-inELECTRICAL
LOADDETECTOR
{ELD)UNIT)
Troubleshooting
ot ELD,sction11
BATTERY
Tost,
ALTERNATORBELT
Inspoction and Adiustment, page 23-108
Alt6rnator/Regulator
Tosl, pags23-102, 1O3
Replacament.page 23-'l 04
Ovsrhaul, pago 23-105
23-98
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CircuitDiagram
- HOODFUS/REI.AY
UI,IDER
8OX
No.4t11004) /a\
ilo.39l50Al
*1 :USA
+2 llo.24ll SAl:81881.min
tlo.24{2041:
818C| .niin6
UNDER_OASH
FUSE/REIAY
8OX
. NTEGRATED
COMTNOL
UMT
. aBscoilTRoruNn
VI
ECM
VI
Fr|'l)
wNort'lc
AI.TERNATOR
oiot
G401
23-99
vnx.su
ChargingSystem
Troubleshooting
Bofore troubleshooting check
- tightnessof the alternatorbelt (see page 23-1Og).
- that the malfunctionindicatortamp lMlL) of the ECM does not blink. lf it blinks,refer to section 1 1.
lf the charging system light is on, or th battery is dead or low, prtorm the following tests in the order listed below:
1.
2.
3.
Baftery Test (see page 23-66)

Charging System Light Test
Alternator/RegulatorTest
ChErging Sysrom Light T6tt
Tu]n tho ignhlon srvitch on (lll.
Does th charging syslem

light come on7
o pago23-1011
Does tho charging system

light go ott?
BOX
FUSE/RELAY
(r..r tid.)
Turn the ignition switch otf.
I'{TEGRATED
CO]TTROLUI{IT
Disconnect the 4-P connoctor
lromt th altornator.
Turn the ignitionswitch on {ll),
Ramova tfto 26-P connactd trom

th. ABS control unh snd lh. intggrotad conrol unh ttoln tha tad
ol tho und..dlrh tu!a/r.l.y box.
It thr .hlrglng .yrtom lighl .l.Y.
on, rrpalr tho ahon to ground In
rhr WHT/BLU wi...
NOTE: After this test or relaled

rep6irs, roconnoct the control
units. th6n aosetth ECMto cloar
any cooos.
Does the charging system

light come on?
Sad.n:
H.tchb.ck:
UNIT
ABS COI{TROL
tlo rhon o. opon h ih. WIfT/BLU
who. Porfom dtomrtor/rogdttol
rost beo pag. 23-l02l.
2A-P CONi{ECTOR
26.P CON ECTOR

ABS CONTROL
23-100
vnx.su
lFrom page 23-10O)
' N o . 2 4 ( 1 5 A ) : 8 1 8 B ' l ongrne

N o . 2 4 ( 2 0 A ) : 8 1 8 C 1 engine
Turn the ignition switch ott.
Check fuse *No. 24 in the underdash tuse/relay bor.
Disconnect the 4-P connector

Irom the alternator.
Turn the ignitionswitch on {ll).
Ch6ckforvoltago between tho lG

terminal(BLK/YELwire) of rho il-P
connectorand body ground.
Rgp.i. op.n in th. BLK|'EL wiro.
wirg side
L IWHT/BLUI
Ground the WHT/BLUwire at the

L terminal ot the 4-P connector.
Does the charging system light

come on?
Chockfor ! blownchrrgingry3rom llghr bulb. It rh. butbi! oK,

ropairopenin lho IiYHT/BLUwiro.
(cont'd)
23-101
vnx.su
ChargingSystem
Altornator/RegulatorTest
NOTE; Mske surethe battery is sufficientlychargod(sa
page 23-66).
LOADADJUSTER
ICARBONPILE)
FULLFIELD
TESTEB
LEAD(BLUI
Connoct tho Sun VAT4O {ot

ooulvslont lgrt equipmonl) and
tum tho s6l6ctor rwitch ro posi_
tion I |rtarting).
VOLTMETER
t{EGATIVE
LEAD(8LK}
O IOAD
shift to neurralorlPland start the

engino. Hold the ;;gine at 3oO0
rpm wiih no load until the radia_
tor lan coms on. then let it idle.
Raisethe engine speed to 2OOO

rom and hold il there.
ls lhe voltageover 15.1V?
VOLT
SELECTON
TEST
swlTcH
II{DUCTIVE
FICK.I.|P
IGR '
VOLTMETER
POStTtVE
LEADIREDI
Releasethe acceleratorpedaland
let the enginoidle.
EGATIVETESTER
CABLE(BLKI
Make sure all electrical systems
are turned otf. Turn the selector
swilch to position2 (charging).
INDUCTIVE
PICK.UP
B TERMI]TAL
WIRE
Removethe inductivepick-upand
zero the ammeter.
Place the inductive pick-uP over

the B terminalwire oI the altgrnator so that the arow Dointsaway
trom the alternator.
Raisethe engins speed lo 20OO

rpm and hold it there.
ls the voltagelessthan 13.9V?
T..t itr b.ttry (.- 9|e. 8Al.
NO
tropagezJ-ruJ,
23-102
vnx.su
(Frompage 23-1021
Apply a load wirh the VA'-4O until the battery voltagedropsto bet w e e n 1 2 - 1 3 . 5V .
ls the amperage 60 A or more?
With the engine spe6d still at

2OOOrpm, full-tieldthe altemalor.
NOTE; Attach a probeto the VAT-4Ofull field test lead and insert the orobe
into the full tield sccesshole at the back of the alternator.Switch the field selector
to the "A (Ground)" positionmomentarilyand check amperagereading.
CAUTION: The voltago will ris6 quickly whon the slternator is full-fiolded. Do
not allow th voltago to oxc66d 18 V 01 it may damage the elect.ical system
REGULATOR
{Locatod
the end cover)
FULL FIELD
ACCESSHOLE
Toat rnd rooalr d|e dtomEtor {soo

psg.. 23-104 to 23-tO7).
4-P CONNECTOR
Turn the ignition switch off; then

turn aton again.
Disconnocl lhe 4-P connector

Irom the altornator.
Check lor voltage between the lG

terminal (BLK/YEL) and body
ground.
ls there battery vokage?
Rop.ii open in tho BLK/YELwiro.

IG IBLKATELI
wire side
L IWHT/BLUI
23-103
vnx.su
ChargingSystem
Alternator Replacement
- removingthe No. 32 {7.5 A) fusefrom the under-hood
fuse/relaybox.
After service,reconnectpowet to the radioand turn it on.
"CODE" is displayed,enler the cusWhen the word
1.
Disconnectthe groundcablefrom the batterynegative (- ) terminal.
2.
Disconnectthe alternatorconnectorfrom the alrernaror.
7. Removethe lower and upper mounting bracket bolts

and the mountingbrackets.
UPPERMOUNTII{G
BOLTS
BRACKET
il4 N.m {4.5 kgl'm, 33 lbl'ft}
,\\\- ( \ \
\(^
\-/ I
NUT
TERMINAL
B TERMINAL
24 N.m 12.4 kgf'm,

't 7 tbf.ftl
ALTERNATOR
CONNECTOR
Removethe terminal nut and the WHT wire from the

B terminal.
BRACKET
BOLTS
BRACKET
44 N.m (4.5 ksl.m, 33 lbt'ft1
Loosenthe adjustingnut. then removethe mountIng nul.

ADJUSTING NUT
8. Removethe adiustingnut and uppermountingbolt,

then lift out the alternator.
9. lnstall the altetnator in the reverseorder of removal.
CAUTION: Adiust tho alternalor belt tension aftor
installation (seo Page 23-1O81.
NOTE: Reconnectthe battery ground cable and turn
"CODE" is displayed,
the radioon. When the word
5-digit
code.
enter the customer's
NUT
MOUNTING
44 N.m (4.5 kgt.m, 33 lbf'ftl
5. Removethe alternatorbelt from the alternatorpulley.
6.
Removethe lower mountingbolt, then lift the alternator upward.
23-104
w
vnx.su
AlternatorOverhaul
CAUTION: Do not rmove th pulley unlEsthe t.ont
bearing needs r6placsm6nt.
PULLEY
To loosenthe pulley locknut, use 10 mm and 22 mm

wrenches.It necessary,use an impact wrench.
Test, page 23-107

SPACER RING
REAR BEARING
10 mm BOX WRENCH
PULLEYLOCKI{UT
1 ' l l N . m 1 1 1 . 3k g t . m , 8 2 t b f . t r l
rl
@n
FRONTBEARING
STATOR/DRIVEEND
HOUStt{G
CAUTION: Do not get grease

or oil on the slip rings.
BBUSHHOLDER
INSULA
TOR
ARUSH HOLOER
(@P
"
STATOR THROUGH
BOLT
VOLTAGEREGULATOR
%A
re
DIODEIRECTIFIER)ASSEMBLY
Test, page 23-106
PULLEYLOCKNUT
111 N.m (11.3 kgt.m,82 lbf.ft)
REAR HOUSING
Inspection,page 23-
TERMINALINSULATOR
qt
".,"
fu"- "o*n.r"
-
BRACKET
23-105
vnx.su
GhargingSystem
AlternatorBrushInspection
Rectifier Test
NOTE: The diodesare designedto allow currentto pass
in one directionwhile blockingit in the oppositedireclion. Each diode must be tested for continuitvin both
directionswith an ohmmeterthat has diode checking
capability.Since the alternatorrectifier is made up of
'16
checks,
eight diodes(four pairs),there are a total of
Remove the end cover, then lake oul the brush

holder by removing its two screws
Measurethe length of the brusheswith a vernier
calioer.
Aliornatol Brush Longlh:
Standard:10.5 mm (O.41 in)
Servic. Limit: 1.5 mm (O.06 in)
1. Checkfor continuityin each ditectionbetweenthe

B and P terminals,and betweenthe E (ground)and
P terminalsof each diode pair. All diodesshouldhave
continuity in only one direction,
VERI{IEBCALIPEB
lf the brushesare less than the service limit, replace

the b.ush holderassemblv.
lf any of the eight diodestails, replacethe rectifier

assembly.(Diodesare not availableseparately.)
23-106
vnx.su
RotorSlip RingTest
1.
Stator Test
Checkthst there is continuity betweenthg slip rings.
1. Chockthat there is continuitybetweeneach pair of

l6ads.
ROTORSHAFT
cotl coRE
Check th8t there is no continuity betwen the slip

rings and the rotor or rotor shaft.
Ch6ck that there is no continuity between each lead

and the coil core.
lf the rotor fails either continuity check, rsplace th

alternator.
lf th coil fsils eithercontinuitycheck. replacethe

alt6rnator.
23-107
vnx.su
ChargingSystem
AlternatorBelt Inspectionand Adjustment
Boh Tsnsion Gaug6 Mothod:
Foltowingthe gauge manuJacturer'sinstructions,attach
the belt tension gauge to the belt and measurethe
tension.
Deflection Method:
Apply a force of 100 N (1o kgt, 22 lbJ)and measurethe
deflection between the alternator and the crankshatt
pulley.
Detlsction:9-11 mm (0.35-O.43 inl
Tension:340-49O N (35-50 kgl, 77-110 lbfl
NOTE; On a brand-new belt {one that has ben run

for lessthan five minutes),the deJlectionshouldbe
6-8 mm 1O.23-O.32 in) whn first measured.lf
the belt is worn or damaged,replaceit.
NOTE: On a brand-new belt (one that has been run

for less than tive minutes), tension should be
690-880 N (70-90 kgt, 154- 198 lbJ)when tirst
measured.lf the belt is worn or damaged,replaceit.
ALTERI{ATOR ADJUSTING NUT

24 .ln 12.4 kst'm, 17lbl'ft}
NUT
ADJUSTIT{G
ALTER'{ATOR
24 N.m {2.4 kgl'm, 17 lbl'ft1
MOUt{Tlt{G
NUT
44 t{.m (4.5 kgt.m,
33 tbf.ft)
PULLEY ALTEBNA
oTJGG-0O1010A
lf adiustment is nocessarY:
lf adi$tmsnt is nscaasary:
1. Loosenthe alternatoradjustingnut and mounting

nur.
1.
Loosen the alternator adiusting nut and mounting

nut.
2.
Move the alternatorto obtain the properbelt tension,

then retighten the adjusting nut and mounting nut
to the specifiedtorques.
2.
Move ths ahernatorto obtain the properbslt tension,

then retightenthe adjustingnut and mountingnut
to the specified torques.
3.
Recheck the deflection ot the belt.
3.
Recheckthe tension of the belt,
NOTE: lt necessary,adiust the P/S pump belt (see

section 17) and A/C compressorbelt lsee section
22t.
23-108
vnx.su
NOTE: lf necessary,adjust the P/S pump belt (see

section 17) and A/C compressor belt (see section
22t.
Fan Gontrols
ComponentLocationIndex
For the A/C system, see section 22.
RADIAIOR FAN REI.AY

Test, page 23-68
CONDCNSER
FAI{ BELAY
lwir6 color3:ELKnirHT,WHTI
IBLUryEL,and BLU/BL(
I
UNDER-HOOD
FUSE/RELAY
BOX
Test, page 23-68
ENGII{E
cooLA T
TEMPERATURE
FAN MOTOR
Test, page 23-112
{ECT)
SwlTCH
Tesr,page23-'l12
BADIATORFAN MOTOR
Test,page23-112
23-109
vnx.su
FanControls
Circuit Diagram(WithoutA/Cl
- DAstl
ul{oR
GIINONSWITCH FUSC/RELAYBOX
- HOODFUS/REI.AY
BOX
UI{OER
No.4l{lmA,
No.39l50Al
.{
6r\
\-Y
ECM
Gtr{
l,*^,
($fffiHil'r"n.''
t?i'r?Tdf.ol
I
I
ffi,"'l
I
Btl(
II
:
G10l
23-110
FIIF.-
vnx.su
F'rrr^'l
-l
ots YEt{<\o*r
Gircuit Diagram(With A/Cl
- HOOO
UNOER
FUSE/REIAY
BOX
No.41l100Al
G FIONSWIICH
,5
No.39l50At
RAOIATOR
FAN
REI.AY
GRt{
| ,*n,n,
,z*r CoOtAt{T
qU llffffarunErEcrr
t?i'i."1",i:"ol
monronI
FAN
I
MOTOR
BI-K
II
:
G10l
23-111
vnx.su
Fan Controls
Engine Coolant Temperature (ECT)

Switch Test
Fan Motor Test
NOTE: Bleedair from the cooling system atter installing the enginecoolanttemperature(ECT)switch (seesection 1O).
1.
Disconnectthe 2-P connectorfrom the fan motor.
2.
Test the motot by connectingbatterypower to the

B terminal,and groundto the A terminal
3.
lf the Jan motor fails to run smoothly, replaceit.
1. Remove the ECT switch from the thermostat

housing.
NOTE: The illustrationshows the radiatorfan.
2.
Suspendthe ECT switch in a containerof coolant

as shown.
Heatthe coolantand checkenginecoolanltemperature with a thermometer.

Checkthe continuitybetweenthe A and B terminals
accordingto the table:
Terminal
B
;;,".,"---\
Above196 2O3"F
{91-95'C)
Switch
B e l o w1 8 1 - 1 8 9 o F
(83-87'C)
23-112
vnx.su
o_
-o
GaugeAssembly
CAUTION:
a All SRS electrical wiring harnossesare covrod with
yellow insulation.
a Bofore disconnecting any prn ot th SRS wire harness, connect tho short connector(sl.
a Rplaceth6 entirs affGctedSRS halne$ assembly if
it has an open circuit o? damaged wiring.
(C61'iostho SBS indicator signal)
SRS MAIN HARNESS

{Cov.r6d with yollow inrularionl
GAUGE ASSEMBLY
GaugeLocationIndex,page 23-114
IndicatorLocationIndex,page 23-114
TerminalLocationIndex,page 23-114
Bulb Location.page 23-'l 15
Disassembly.page 23-119
Removal,page 23-118
FUEL GAUGE SENDINGUNtT

Test, page 23'124
Repfacemenr,page 23-124
VEHICLESPEEOSENSOBIVSS}
Test, page 23-120
fnput Test. page 23-120
PARKITTG
BRAKESWITCH
Test, page 23-127
BRAKE FLUID LEVELSWITCH
Tesr, page 23-127
EI{GINEOIL PBESSURESWITCH
Test, page 23-122
ENGINECOOLANTTEMPERATUREIECTI GAUGE
SENOINGUNIT
Test, page 23-126
23-113
vnx.su
GaugeAssembly
LocationIndex
Gauge/lndicator/Terminal
CAUTIOI{:
a All SRS olectrical wiring harnessosaro covorod with
yellow insulation,
Belol disconnecting any part ot tho SRS wiro hatnesa. connoct the short connoctol(El.
Replacoth6 entire aff6cted SRS hamess sssombly lf
it has an open circuil or damagod widng.
"8"
CoNNECTOR (c5601
Bi ----------+
co r{EcroR"c" (c558}
B16
Cl ----+ClO
A/T GEARPOSIT|O
IIDICATOR SYSTEI
Seepags23-132
TACHOMETER:
Indicatos lOO rpm at
20O pulss per minul
of the ignition control
modulllCM).
FUEL GAUGE:
GaugeTest, page 23-123
Sending Unit Tost, page 23-124
f',. /i)
)Y
- " b
\_./ \J
\-___--
E GI[{E COOLAI{TTEIIPEFATUREIECTI
c6uge TEst, p6g6 23-126
Sending Unit Tsst, pago 23-126
a1 -----> A5
Dl-------.>D13
SPEEDOMETER:
Indicates (60 mph 6i 1025 rpml or
{60 km/h at 637 rem) of th
vhicle spe6d sonsor lVSSl.
coNNECfOR
"A" (C557)
col{]{ECTOR"D" (C5591
23,-114
rtrF
--
vnx.su
BulbLocations
HIGH BEAM INDICA
L|GHT{r.4 Wl
LEFT TURI{ SIGNAL INDICATORLIGHT II.4 WI

RIGHTTURN SIGNALINDICATORLIGHT(I.4 W}
CHARGINGSYSTEMLIGHTII.4 WI
BBAKESYSTEMLIGHT(1.4 W)
SEAT BELTREMINDER
LIGHTI1.4 WI
POSITIOIII]{DICATORLIGHT (1.12 W x 7l
OOOR-OPEN
INDICATORLIGHT{1.4 WI
LOW EI{GII{EOIL PRESSURE
TOBLIGHT11.4WI
MALFUI{CTIONINDICATORLAMP
(MrLl fi.4 wt
iSRS INDICATORLIGHT(1.4 W}
LOW FUEL INDICATORLIGHT {3.4 WI
LIGHTS
MAINTENANCE
REMINOER
LIGHTIT.4 WI
{3.4 W x 3}
cRutsE LTGHT
tl.4 Wl
ABS INDICATORLIGHT(1.4 W}
TAILGAT-OPENINDICATORI-IGHT{1.4 W): Harchback
TnUNK-OPENINDICATORLIGHT 11.4 W): Sodan
*: On the SRS printed

circuit board
23-115
vnx.su
GaugeAssembly
GircuitDiagram
r3 [o.24 ll5 ): 81E81dttr

10,24120
):B1&1.mir
ulocn-DsH
&X
RISC/RELAY
Tw'lcu I
+ 3r,4ts.
r
t_gstr
sas
tNtT
I
I
A
FUSE
l{l(
6t0l
[fffi"vv
sns
txocAloR
UGTIT
.lsffiisl
{,MT
VI
- r Gin&no
".lJ
r l
I C,afi/ilD
GMVn!O
#n
ir ll
l8flfl*';
i| \()n
I RUNIiITGI
I uGfiTs \
ht0/Git{
Gn[/Ft0
6mii'
I
-
23-116
vnx.su
r
-"
|
.
| snrxt
I Rlp
ir |ffi.
l
Itrr
r l
it A
:
r6ii G30r
N'ElGAI.EE
sExDr6 ulllT
a{G|l|
c@lat{T
Il$EiA'l il
tErcTt
SAdTG
txt
IIFT
TURt{
stcll L
DtCATOn
UGHI
fircll
EAT
lotc ToR
TIGHT
r |l{rE|Arcc
Sfn 0ER
ucfir
6tc|l| Oh.
mEssunr
[oic Toi
IIGHT
.,tlvt
stAT Et T
gIDEN
IJGHT
M Ut[CrOrl
OG TOi
txtu
nooB-oPEtl
fptc^Ton
TIGHI
I|
tt,4w)
'
B1
a2
HflHh*'F:
trtc[iE
olL
FnISSUNE
s1vlrcH
I
OFVEFS
SCAT*LT
slvtTcH
1:
G501
G502
23-117
vnx.su
GaugeAssembly
Removal
Tilt the steeringwheel down with the tilt adjustment
tevet.
CAUTION:
a All SRS electrical wiling harnessesara cover6d with
yollow insulation.
a Eofore disconnecting any part ol the SRS wiro harn6ss, connoct lhe short connector(sl.
a Roplacetho entirs affocted SRS harneasassembly if
it has an open circuit 01 damaged wi.ing.
Removethe three mountingscrews, and spreada

protectivecloth on the steeringcolumn.
lcarrio. tho SRs indicolor 8ignal)
CLOTH
PROTECTIVE
Prythe gaugeassemblyout, and disconnectallconnectorsfrom it.
SBSMAIN HARI{ESS
(Covor6dwith Yollowin.ulationl
1 . Removethe two screwslrom the instrumentpanel.

2 . Removethe instrumentpanel.
NOTE: Remove the instrument panel careJully
without damagingthe cliPs.
CLIPS
GAUGE ASSEMBLY
o.
Take out the gauge assembly as shown.
23-118
vnx.su
Disassembly
NOTE: Handlethe terminalsand printedcircuit boardscaretullyto avoid damagingthem.
TAGHOMETER
MOUI{TINGSCREW(x 3l
ENGINE
COOLA]TT
TEiIPERATURE
{ECT}
GAUGE
MOUNTING
SCREW(x 3)
SPEEDOMETER
MOUNTTNG
SCREWtx 4l
k)T
n
FUELGAUGE UNIT
Test, psge 23-123
. SPEEDOMETER
Specilication, pa96 23-1 14
Troubfeshooting. page 23-1 20
. ODOMETER
Troubleshooting,page 23-1 20
. TRIP METER
Troubfeshooting,page 23-120
23-119
vnx.su
Speedometer/TripMeter/Odometer
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence.
Item to be inspected
-9
lt)
a
; 6
+*
c.r i
. ( D
z c
*
;5
9 c
d)=
Symptom
Odometerand trip meter wotk, but speedometerdoes
not.
q)
'
qlv
'i
F
-9
(L
> g
o
o
works, but odometerand trip meter do

SDeedometer
nor,
Speedometer.odometer,and trip meter do not work.

VSS Input Test (At hamss side of 3-P connector)
Tst: Desirsdresult
Tost condition
No.
Wir6
1
BLK
Under all conditions

lgnition switch ON (ll)
BLK/YEL
ORN
lgnitionswitch ON (ll)
Possiblecause it result is not obtained
Check for continuityto ground: . An open in the wire

. P o o rg r o u n d( G 1 O 1 )
There should be continuity.
Blown *No. 24 fuse in the unde.Check tor voltageto ground:
dash tus/relay box
There should be battery
Short to ground
voltage.
An open in the wire
Check for voltageto ground:
There should be about 5 V.
. Shon to ground
. An open in the wire
NOTE:A shortto groundin the ORN wire can be causedby a short in any componentconnectedto lt.
vSS Tost
Speedometerdoes not work.
3-P CONNECTOR
Inspect'No. 24luse in the underdash tuse/relay box belore

testing.
Turn the ignitionswitch ON lll).

Measure voltage between the
BLK/YEL wire terminal and the
8LK wire terminalin the harness
side of the 3-P connector.
{To next page)
2 4 ( 1 5 A ) : 8 1 8 8 1 e n g i n e N o . 2 4 { 2 0 A ) : 8 1 8 C 1e n g i n e
23-120
vnx.su
{From previous page)
Check tor continuity between the

BLK terminaland body ground.
Measure voltage between the

ORNand the BLKwire terminals.
ls there about 5 V?
Raisethe tront of the car and support it with salety stands.
Ropair opon belwon

VSS and groundG101.
Ropairopon in tho BLKrYELwiro

botwoen VSS and undor-dssh
luse/rolay box.
Ropair op6n in th6 ORN wire or

shon to body ground.
Touch a probe to the ORN wire

and connect at to body ground
through a voltmeter.
Putthecar in neutralwithkevON.
Slowly rotate one wheel with the

other wheel blocked.
Does voltage pulse from O to

about 1O V?
Roplac. tho VSS {see page

23-1221.
Touch a probe to the ORN wire

and connect it to body ground
througha voltmeter.
Slowly rotate one wheelwith the

other wheel blocked.
Ooes the meter indicate

pulsingvoltage?
Ropairopon in th6 OBil wire botween tho VSS and th6 3p.odomolgt.
23-121
vnx.su
VehideSpeedSensor(VSSI
Replacement
Disconnectthe 3-P connectortrom the vehiclespeed
sensor{VSS).
EngineOil Pressure
IndicatorSystem
EngineOil PressureSwitch Test
1.
Removethe YEL/REDwile from the engineoil pressure switch.
Remove ihe two mounting bolts, then remove the

VSS.
ENGI'{EOIL PRESSURESWITCH
TERMII{AL
POSITIVE
Check tor continuitv between the positive torminal

and the engine{gtound)with the ignhionswhch OFF.
a lf there is continuity,go to step 3.
a lf there is no continuity, replace the switch.
InstSll in the revsrse order of removal.
Check for continuity again, this time with th engine

runnrng.
NOTE: The VSS drive link is a very small paru

caretul not to lose it.
a lf there is continuity,go to step 4,

a lf there is no continuity, the switch is OK.
Make sureengineoil levelis OK, then checkengin
oil pressure (se section 8).
a lf engineoil pressureis OK, replacethe switch'
a lf engineoil pressureis low, checkthe sngineoil
pump (seesection 8) and, if necessary,replacit.
23-122
nlmlliitl
vnx.su
FuelGauge
GaugeTest
NOTE: Referto page23-1 16 for the luelgaugesystem
circuit.
'1.
Check the No. 15 {1O A) fuse in the under-dash

fuse/relaybox beforetesting.
2.
Removethe rear seat (seesection 2Ol.
3,
Removethe protective cover and access DanelJrom

the tloor.
4.
With the ignition switch OFF, disconnectthe 3-p

connectotfrom the fuel gauge sendingunit.
PROTECTIVE
o.
Turn the ignition switch OFF. Attach 8 jumper wir

between the BLKA HT and YELMHT terminats.
then turn the ignitionswitch ON 0l).
Check that the pointer of the fuel gauge starts moving toward the "F" mark.
CAUTION: Turn th ignition switch OFFboforo the
pointer roachas "F" on tho gauge dial. Failuroto do
ao may damage tho fuel gauge.
NOTE: The fuel gaugeis a bobbin(c.oss-coitltype
gauge.hencethe tuel levelis continuouslyindicated even when the ignitionswitch is OFF, and the
pornter moves more slowly than that of a bimetal
rype gauge.
a lf the pointerof the fuel gaugedoes not move at
all, replacethe gauge.
a lf the gaugeis OK, inspectthe {uel gaugesending unit.
Connect the voltmete. positive paobe to the

YELMHT terminal and the negativeprobe to the
BLKMHT terminal,then turn the ignitionswitch ON
(ll). Thereshould be between 5 and 8 V.
a lf the voltage is as specified.go to step 5.
a It the voltage is not as specified,check for
- an open in the YEL/WHT. BLU/WHT or
BLK/WHTwire.
- poor ground (G5O2).
vnx.su
23-123
FuelGauge
SendingUnit Test/Replacement
oo not lmoke while working on tho fuol
@
system. Kaop open flamos away from your wotk aroa.
1.
Remove the rear seat (see section 2O).
2.
Removethe protective cover and accesspanel lrom

the floor.
3.
With the ignition switch OFF, disconnect the 3-P

connector from the fuel gauge sending unit.
4.
Removethe tuel gauge sndingunit.
5.
Measurethe resistancebetween the A and B terminalsat E (empty),1/2 (halffull) and F (full)by moving the tloat.
Float Position
Resistance lO)
6.
E
1 0 5 - 1 1 0 25.5-39.5 2-5
Check the change in resistanceby moving the float

uo and down.
lf unableto obtain the above readingsor it resistance

dos not change,replacethe fuelgauge sendingunit.
23-124
vnx.su
Low FuelIndicator
Seat Belt Reminder

System
IndicatorLight Test
Seat Belt Switch Test
NOTE: Reterto page 23- 1 16 tor the wiring description

of the low fuel indicatorcircuit.
1 . Slide the driver's seat to the middle position, then

disconnect the 2-P connector Jrom the back ot th
sear.
1. Park car on level ground.
2 . Check for continuity between the A and B terminals

oo not rmoko whil6 working on th
@
fuol system, Keop opn llamg3 awsy from your work
area. Drain fuel only into an approvod container,
in each conditionaccordingto the table.

Terminal
Drain tuel into an 8pplovd container. Then install

the drain bolt with a new washer.
UNEUCKLED
J.
A
C"**
Add lessthan 8.2 t (2.2 U.S.Gal,1.8 lmp.Gal)of fuel

and turn the ignitionswitch ON (ll).The low fuel indicator light shouldcom on within lour minutes,
o--
BUCKLED
a lf the light does not come on, remove the access

Daneland disconnect the 3-P connector from the
fuel gauge sending unit, Connect the A
(BLKMHT) terminal to the C (BLU/WHT)terminal with a iumper wir.
- lf the light comeson, the problemis eitherthe
sendingunit or its ground.
- lf the light does not come on, the problemis
an openin the BLU/WHTwire to the gaugeassembly, no power to the gauge, or a blown
bulb.
a l f t h e l i g h t c o m e s o n , a d d a p p r o x .4 , { 1 . 1
U.S.Gal,O.9lmp.Gal)ot tuel, the light shouldgo
ofJ within four minutes.
ANCHOR
3-P CONI{ECTOB
NOTE: Befer to page 23-146 for the seat

reminderinout test.
3.
lf necessary.replacethe seat belt switch.
View lrom wire side
23-125
vnx.su
EngineCoolantTemperature(ECTIGauge
GaugeTest
ECT Sending Unit Test

Disconnectthe YEL/GRNwire from the ECT sending unit.
NOTE: Referto page 23-116 fot the wiring description

oJ the enginecoolant temperature(ECT)gauge circuit
diagram.
With the enginecold, use an ohmmeterto measure

resistancebetween the positiveterminal and the engine (ground).
1. Check the No. 15 (10 A) fuse in the under-dash

tuse/relay box before testing.
2.
Make sure the ignitionswitch is OFF,then disconnect the YEL/GRNwire from the ECT gaugesending unit and g.ound it with a jumper wire.
TERMINAL
POSITIVE
Check the temperatureof the coolant.

Runthe engineand measurethe changein ,esistance
with the engineai operatingtemperatu.e{the radiator tan comes on).
J.
Turn the ignitionswitch ON (lll.

Check that the pointer of the ECTgaugestarts moving toward the "H" mark,
CAUTION: Tuln th6 ignition switch OFF botore th
point reaches "H" on tho gaugo dial. Failuroto do
so may damago tho gaugo.
Temperatu.e
Resistance(O)
5.
a It the pointerof the gaugedoes not move at all,

check Jor an oDenin rhe YEL or YEL/GRNwire.
lf the wires are OK, replscethe ECT gauge.
a It the ECT gauge works, test the ECT sending
untt.
23-126
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1330F(560C)
't37
185.F(850C)2 1 2 0 F( 1 0 0 0 c )
46-30
ll the obtainedreadingsare substantiallydifferent

Jromthe specificationsabove, replacethe ECTsending unit.
BrakeSystemlndicator
ParkingBrakeSwitch Test
Brake Fluid Level Switch Test

Removethe reservoircaD.
Removethe tloor console, and disconnect the connector from the switch.
Check that the tloat moves up and down freely, if

it does not, replacethe reservoircap sssembly.
Check for continuity btween the positive terminal

and body ground in each lever position accordinoto
the table.
Torminal
L6vorposition
POSITIVE
Chsck for continuitv between the terminals in each

float positionaccordingto the table.
EODY
Terminal
Floatposition
UP
NEGATIVE
POSITIVE
UP
DOWN
-o
DOWN
POStTtVE
CAP
RESERVOIR
DOWN POSITION
when float drops.
TERMINAL
Canada:
lf the parking brake switch is OK, but ths brake system indicator does not function, pertorm the input
test for the daytime running lights control unit (see
p a g e2 3 - 1 5 6 ) .
Switch contacts open at
proper fluid level.
4.
lf necessary,replacethe reservoircap assemblv.
23-127
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MaintenanceReminderS ystem
Gomponent Location Index
CAUTION:
a All SRS eloctrical wiring halnsses are coveled with
yllow insulation.
a Bsfore disconnocting any part of the SRS wire harne6a, connect tho shon connoctor(s).
a Replacethe entire affoctod SRS hsrness ass6mbly if
it has an open circuil or damagd wiring.
MAINTENAf{CEREMINDERLIGHT
(ln th6 gaugo 63.smblyl
GaugeAssembly.page 23-113
MAINT
REOD
VEHICLESPEEDSENSOR{VSS)
{On the t.ansmirsion houaingl
Test, page 23-120, 121
Input Test, page 23-120
page 23-122
Repfacement,
MAINTENANCEREMINDERUNIT
lBohind tho dashboard lowor covor)
23-128
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Description
Basedon signalsrecaivedtrom the vehiclespeedsensor (VSS),the microcomputerin the maintenanceremande,
unit,
which is located behind the dashboardlower cover, computes the distances traveled. When you turn the ignition switch
on, the reminder light in the gauge assembly will come on for two seconds (bulb check tunction).
Ar 9,650 t 160 km (6,000 t lOo miles)intervals,the reminderlight witl gtow for two secondsand then btankten
seconds attr you turn the ignitionswitch on. This will repeateverytime you turn the ignitionswitch on until the car reaches
12,O7O! 160 km (7,500 1 10O mites).
Beyondthe 12,O7O! 160 km (7,500 t IOO mite)interval,the tight will continuero gtow after the butb check until
you turn the ignition switch off or reset the unit.
To reset the unit, the car must be pa.ked and the ignition switch must be on. Pressthe reset button on the unit for mo.e
than three seconds,and the remindertight will go otf.
NOTE:
a Turn the ignitionswitch OFF bforeyou rmovethe 5-P connectorfrom the maintenancereminderunit.
otherwise
you will cancel all data in the memorv.
a The data will remainin the memoryeven when the ignitionswitch is turned ofJ, or if the unit is disconnected.
When
the ignitionswitch is turned on, and the car is driven. additionaldata will be stored.
sEt{son
tvss
-----------------l
MAINTENANCEREMINDENUN|T
23-129
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Maintenance
ReminderSystem
CircuitDiagram
UNDER-HOOD
FUSE/REIAY
8OX
MAINIET,IAT,ICE
REMINOER
UiIIT
23-130
vnx.su
MaintenanceReminderUnit Input Test

1 . With the ignition switch OFF, disconnectthe 5-P
connectorfrom the reminderunit,
Inspect the connector and socket terminals to be
sufe they are all makinggood contact.
View trom wire side
a lJ the terminalsare bent, looseorcorroded, repair

them as necessary,and recheckthe svstem.
a It the terminalslook OK, make the following inPut tests at the connecto..
- lf a test indicates a problem, tind and correct
the cause,then recheckthe system.
- It allthe input tests proveOK, the reminderunit
must be taulty; replace it.
No.
Wire
BLK
Tost condltion
Unde. all conditions
WHT/BLU
lgnitionON (lll
YEL
Possiblcause if result is not obtained
Check for continuityto ground: . P o o rg r o u n d( G 2 0 1 ,G 4 O 1 )

Thereshould be continuitv.
. B l o w nN o . 3 2 ( 7 . 5 A ) f u s e i n t h e
Check tor voltageto ground:
There should be battery voltage
under-hoodtuse/relaybox
. B l o w n N o . 1 5 ( 1 OA ) f u s e i n t h e
There should be batte.y voltage
under-dashfuse/relaybox
lgnitionON (ll)
Connectto body ground; The

reminderlight shouldgo on.
B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e
Blown bulb
An open in the wire
lgnition ON {ll), car in

neutral with lront ol
car raised,one wheel
rotated with other
wheel blocked
Check for voltageto g.ound:

Meter should indicatepulsing
voltage.
. Faulty vehiclespeed sensor (VSS)

. An oDenin the wire
PNK
ORN
Test: DaEiredrasult
23-131
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A/T GearPositionIndicator
ComponentLocationlndex
cAUTtOt{:
a All SRSolectdcalwiring harnossos
a16covarodwith
yellow insulation.
Boforo disconnocting any part ot the SRS wlr. harnoaa, conngct the short conn6ctor(sl.
Roplacotho entire aff6ct6d SRS harn$s assombly il
it has an op6n cilcuit or damagod wiling,
SRS MAIN HARI{ESS

(Cov.rod whh ygllow io.ul.tlonl
GAUGE ASSEMBLY
Bemoval,page 23-118
Disassombly,pag 23'1 19
Bulb Locations,pago 23-115
IiIIERLOCK SYSTEM
page 23-139
DGscription.
A/T GEARPOSITION
IlTDICATOR
InputTest,pago23-134
A/T GEAR P('SITIOI{ SWITCH

Test, page 23-136
ReDlacement,6ection 14
23-132
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CircuitDiagram
IGNITION
UNOER-OASH
FUSSREI-AY
8OX
swrTcH
UNOER_HOOD
FUSE
/ REI.AY
8OX
wHT/BLX
+wHT+
/-?t CH-
\ty
ftrt*l
"l
Bl.x/Yt-+<.\-o+!
No.19ll0A)
FUSE
TMI{SMrSSr0r,l
c0IJTRor
i.IODULE
ITCMI
YEL
lln thogtugo8lsmbvl
fitMritc-;-
D4
CANCEL
AN GEAR
POSITION
INDICATOR
DIMMING
CIRCUIT
lgll
YELTWHTGRN/8L|(
II
.
INTERLOCK
coMtRot
TRANSMISSION
MODU|.! [TCM}
UNJ]_
o*nn,o_yTT
GRT'IMHT
pr{x/cR1
-J
No.19
{l
FUSE
GR |-U -l
GRiITYEt
LTGNNiW{T
A/TGEAN
POStTt0N
coNsot-E
LIGHT
0.4w)
M GEAR
PosrTroN
swncH
I
DASHI-IGHTS
BRIGHTNESS
CONTROI.IER
G201
G40t
G2ol
G401
23-133
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A/T Gear PositionIndicator

Indicator Input Test
CAUTION:
a All SRS electrical widng harn6ssosara cov6r6d whh
yellow insulation.
a Before disconnecting any part ot the SRS wiro hErness. connect the shon connoctolls).
a Replacethe entire affectod SRS harnosr assombly il
Removethe gauge assemblyfrom the dashboard(see
page 23- l 18), and disconnectconnectors"8", "C" and
"D" from it. lnsoectthe connecto.terminalsto be sure
they are all makinggood contact.
a lf the terminalsare bent. looseor corroded,repairthem
as necessary,and recheckthe system.
a lf the terminalslook OK, makethe following input tests
at the connector.
- lf any test indicatesa problem,find and corect the
cause,then recheckthe system.
- lf all the input tests prove OK, the gaugeassembly must be taulty; replaceit.
"8"
CONI{ECTOR
SS
23-134
vnx.su
CONNECTOR"D": Visw from wire side ot femals

tetminals
No.
Wila
BLK
Test condition
lgnitionswitch ON {ll}
YEL
Test: Dsirod rasult

Possiblecause if result is not obtainod
, 4O1)
Check for continuityto ground: . P o o rg r o u n d( G 2 O 1 G
There should be continuitv.
. B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e
There should be battery voltage. under-dashfuse box
CONNECTOR"8": View from wire sid6 of fem.l6

i6lminals
No.
Wile
Tost condition
RED/BLK
Tost: Dsir6d result
Possiblocause if result is not obtained

. Faulty dash lights b.ightnesscontrol
Combinationlight
Check for voltage between
RED/BLK
switch ON and dash
RED/BLK
and
RED
terminals:
system
ano
lights brighlnesscontrol There should be baftery voltage. . An open in the wire
RED
dial on full bright
CONNECTOR"C": Vi3w lrom wire sido of temale

t6rminals
No.
Test condition
Shift lever in position@
GRN^^/HT NOTE:Don't pushthe
brakepedal.
GRN/RED Shift lever in position@
GRN
Shift lever in positionS
YELAA'HT
GRNA HT
Tost: Desirod r6sult

Check for continuityto ground:
Thereshould be continuitv.
NOTE:Thereshould be no
continuity in any other position.
GRNITEL
GRN/BLK
Possiblecause it result is not obtained

Faulty A/T gear positionswitch
Poor ground
An open in the wire
GRN/BLU Shitr leverin position@

GRN/YEL Shitt lever in positionf2 ]
LTShift lever in positionE

GRNMHT
GRN/BLK
and shift lever in any
positionexcept @
. Faultyt,ansmissioncontrol module
(TCM)
for two seconds after the
ignitionswitch is turned ON,
and less than 1 V two seconds
later.
3 YEL/vVHT

and shitt lever in any
positionexcept @
Check for voltage to ground:

There should be less than 'l V
tor two seconds after the
ignitionswitch is turned ON
and more than 5 V two
secondslater.
. Faultytransmissioncontrol modute
(TCMI
lgnitionswirch ON {ll}

Thereshould be mofe than 5 V
. Faulty transmission control module

ITCM) or ECM
LT.
GRN/BLK
23-135
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A/T GearPositionIndicator
gear Position
I I Gea
A/T
Fosluon Dwtrcn
I esr Switch Test
1 . Removethe console.then disconnectthe 14-Pconnector from the switch.
2 . Checkfor continuitvbetweenthe terminalsin each

positionaccordingto the table.
tgrminal
90e
a Move the lever back and forth at each position

without touchingthe pushbutton,and checktor
continuity within the rangeof free play.
a lf there is no continuitywithin the.ange of free
play, adjustthe installingpositionol the switch
as describedon the next page.
14-P CONI{ECTOR
Back-up
Ught Swhch
A/T Goar Position Swhch (Without crulso contloll

Terminal
\
P*ii-_\
tr
a
ooooooo-
E
E
N
tr
tr
Terminal
_\
--o
-.o
-o
--o
tr
a
E
E
E
E
E
o- --o
oo-
--.o
o- --o
Back-up
Llght Swltch
P*,i-
--o
A/T Goar Position Switch (With cruiss controll

\
Noutrrl
Polition Swhch
oo- --o
t{outral
Potidon Swltch
J
--o
--o
G_
oo-
--o
23-136
vnx.su
o- --o
oo- --o
A/T GearPositionSwitch
A/T Gear Position Switch

Adjustment
Replacement
Removethe console, then disconnectthe 14-P connectof from the switch.
1.
Shift to the ill position,and loosenthe nuts.
2.
Slide the switch in the direcrionof E

position
[within2.Omm (O.079in.)lso that thereis continuity
betweenthe "A" and "L" terminalsin the ranqeof
free plsy oJ the shiJt lever.
3.
Recheckfor continuity between each ot the terminals.
Remove the two console switch mounting nuts.
swtTcH
SHIFTLEVER
NOTE:
a lf adiustmentis not possible.check for damage
to the shiJt lever detent and/or the bracket. lf
there is no damage,replacethe consoleswitch.
a The engineshouldstart when the shift leveris in
position LN] in the range of free play.
LOCKPIN
Positionthe switch sliderto "Neutral" as shown

above.
4.
Move the shift lever to

switch into position.
then slip the

@ porition
Attach the switch with the two nuts.

Test the switch in the @ and E] position ot the shift
lever.The engineshouldsta.t when the shift lever
is in position p anywhere in the range of free play.
Connectthe 14-Pconnector,clampthe harnessand
installthe console.
NUTS
23-137
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Interlock System
All SRS electrical wiring harnasssare covered with
yallow insulation.
Before disconnecting any part of the SRS wire harness, connect the shon connector(sl.
Replacethe entire affected SRS halness assmbly it
it has an open circuit or damagedwiring.
SRS MAI[{ HARNESS

lcovorod with yellow insulstionl
INTERLOCK
CONTROL
UNIT
fnput Test, page 23-141
KEY INTERLOCKSOLENOID
snd KEY INTERLOCKSWITCH
(ln the steeringlock assembly)
Test, page 23-142
SHIFT LOCK SOLENOIO

Test, page 23- 143
23-138
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Descraption
The car is squippod with thq following dovlc6. to prevont inadvoft.nt shitting:
a A/T selector with shift lock
a Key cylinder with interlocked ignition key
Shift Lock Syst6m;
The shitt lock system prevents the shift lever from moving to
@ or lDil from the @ position unless the brake pedal
is depressed and the accelerator is in its rest oosition.
NOTE:
a The shift lever cannot be shifted when the brake pedsl and the accelerator are depressed on at the same time.
a In case ot system malfunction, the shift lever can be releasedby pushing a key into the releaseslot near the shift lever.
Koy Ints.lock Systsm:

The ignition key cannot be removed from the ignition switch unless the shil-t lever is in the
E position
When the shift lever is in any position other than @, a solnoid is activated, making it impossible for the key to be removed until the shift lever is moved to the llj position.
Th shift lever is in the E position.
SOLEI{OID
ON: LOCK
OFF:UNLOCK
KEY CYLINDER
The shift lever is in any position except pl .
II{TERLOCKLEVER
swtTcH
23-139
vnx.su
lnterlockSystem
CircuitDiagram
NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem (tor examplg,
GRNMHT 1 and GRNMHT 2 are not the same).
-HOODFUSE/REi.AY
BOX
UNOER
N0.41(1OCA)
No.39l50A)
W}IT/BLK+WHT
WHT/GRN
THROTTLE
POSITION
ITPI
SENSOR
,
IN/vt,H]
^'v"'
i I
I
if,f,trfi
I
l......................_GRNA,t/r{rz1
/r\ S'ftiei
f lJlT,ll*n""n,
23-140
vnx.su
ControlUnit Input Test

Oisconnectthe 8-P connector from the interlock control
unit. Check for good contact between the connectorand
socketterminals.lf the terminals8re OK, make Iollowing input tests at the connector.lf all inputtests are OK,
but the problemremains,replacethe cont.ol unit,
NOTE: lf the shilt lock solenoidclickswhen the ignition
switch is ON and the brake pedal is pushed (shift tever
is in lfl position, acceleratoris in rest position), the shift
lock system is electronically normal; test the A/T gear
positaonswitch as described on page 23- 134.
Shift Lock Sy.tem:

No,
Wlr6
'I
wn t/hEu
Tost condition
Tost: Dosiredresult
Possiblocause if rssuh is not obtainod
Brakepedal pushed

There should be bsttery voltage
lgnitionswitch ON I [ ) ,
brske pedal and
accelerator pushed at
the same time

There should be less than
battery voltage.
Blown No. 41 (15 A) fuse in the

under-hood fuse/relay box
Faulty transmission control module
(TCM}
Faulty ECM
Faultv brake switch
Faulty throftle position lTP) sensor
An oDen in the wire
Shift lever in @
Check lol continuity to ground:

Faulty A/T gear position switch

Poor ground {G201, G401}
An oDenin the wire
lgnitionwitch ON (lll

Blown No. 15 (10 A) luse in the

under-dashfuse/relay box
Faulty shift lock solenoid
An oDenin the wire
GRN^/vHT'
YEL/BLK
Koy Intodock Systam:

No. Wire
T6st condition
T6st: Desiled reault
Possible caure if rosult is not obtainsd

. Poor ground (G2O1,G4O1)
. An ooen in the wire
Check for continuity to ground:

Shift lever in position
Check for continuityto ground;

Ther should be continuity.
Faulty A/T gear position swirch

Poor ground (c2O1, G4O1)
An oDenin the wire

lgnition switch tu.ned

to ACC (ll 8nd the key
WHTAYEL pushedin
Bfown No. 42 l2O Al fuse in the

under-hood tuse/relay box
Faulty steering lock assembly
(kev interlock solonoid)
An oDenin the wire
Check tor voltage to ground:

There should be batery voltage,
lgnition switch turned

to ACC (ll and the key
WHT/BLU pushedin
Bfown No. 42 l2O Al fuse in the

under-hood fuse/relav box
Faulty steering lock assembly
(key interlock solenoid)
An oDenin the wire
BLK
23-141
vnx.su
Interlock System
I esr Interlock Dorenoro
Solenoid Test
Key
Kev IntenocK
CAUTION:
a All SRS electrical wiring harnessesar covered rYith
yollow insulation.
a 8eforc disconnecting any pan of the SRS wire harness. connecl tha short connoclol{s|.
a Raplacethe ontire affected SRS harness assembly if
it has an opon circuit or damaged wiring,
4.
Checkfor continuitvbetweenthe terminalsin each

switch positionaccordingto the table.
\______________rry
Position
lonition
S hchAcc
Koypushdin
r
KoyroleEsod
o-
--o
--o
* : l5-20ohms
5,
{Covorod with yollow inlulrtionl
Checkthat the key cannot be removedwhen the battery is connectedto the No. 6 8nd No. 7 terminals.
a It the kev cannot be removed, the key interlock
solenoidis OK.
a lf the key can be removed, replace the steering
lock assembly(key interlock solenoidis not available separately).
1 . Removethe dashboardlower cover

Removethe knee bolster.
Disconnectthe 7-P connectorfrom the main wire
narness.
23-142
vnx.su
Shift Lock Solenoid Test/Replacement

Removethe console,then disconnectthe 2-p conneclor oJ the shift lock solenoidfrom the main wire
harness.
NOTE: Do not connectpowe. to the B { - ) terminat
(reversepolarity)or you will damsgethe diode inside the solenoid.
Connect battery power to the A terminal,groundthe
B terminal momentarily. and check solenoid
oDeralron.
Replace.
9,8 N.m {1.0 kgl.m,

7.2 tbl.hl
5.
Check and, if necessary,adjust the solenoid'sposition.

a When the shift lock solenoidis ON, check that
there is a clearanceol 2.5 1 O.5 mm {O.O98I
O.O2Oin) between the toD rear corner ot the shift
lock lever 8nd the lock pin groove,then tighten
the selflocking nuts.
NOTE: Use new self-lockingnuts.
2.5 t O.5 mm
{0.098 t 0.020 inl
SHIFT LOCK
LEVEB
a lf the solenoiddoes not operate,replaceit as

describedin steps 3,4, and 5.
a lJ the solenoiddoes operate, check and, if necessary, adiust its two positionsas shown in step 5.
a
Removethe shift lock collar and the solenoidpin.

Removethe selflocking nuts and shift lock solenoid,
then installthenew solenoidin the reverseotderot
removat.
LOCKPINGROOVE
a When the shift lock solenoidis OFF,make sure
that the lock pin is blocked bv the shift lock lever.
LOCK PIN
LOCK PIN
GROOVE
23-143
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IntegratedControl Unit
Circuit Diagram
D.3c ptlon
An integratd control unit, located in the left kick panel, integratss the functions of tho keyin/seat beh r6mindr, sido
markar light {lasher, wiper/washer, lights-on r6minder, rear window dsfogger timer, brak system light bulb check, and
enging oil pressure indicator flasher circuitE,
NOTE: Difforent wires with the same color have be6n given a numbor suffix to distinguish them (for Example,
and GRN/RED'are not the same).
GRN/RED1
HOOD
FUSE/RELAY
8OX
UNOER-
- DASHFUS/RETAY
BOX
UNOER
WIPER/
WNOSHIELD
WASHER
SWITCH
IMT
OFFiINT
Ir l
I
I
I
I
I
I
I
I
I
I
I
I
I
I
t
P
r
r
r
3
8
e
l
t
i
;
t
I
t-0w
ErGrilE
0|l
PRESSI'RE
INDICATOR
LIGI{T
B
r
COI{TROI
UNIT
NTEGRATED
WINDSHIELO
WIPERAVASHER
YEUEE
swtTcH
tr-/
I
BLK/GRNBI
VOLTAGE
REGULATOR
{lnahamator,
WINDSHIELO
WIPER
MOTOR
{Asl
washef-wiproporation
lr ) : Withcombinod
23-144
vnx.su
Br-u/Brx
fr,rTrtl.*
r*r.,
+
/\
J L
r--------Y----__tfl
I moan
swtTcH
i PosrIoN
t,x*rt
BLK/RE9
-----J
- OASHFUSE/REI-AY
UNDR
8OX
ERAKE
SYSTEM
I.IGHT
ll.4wl
YEI-
SEAT8EI-T
REMIi/OER
LIGHT
t1.4Wl
a
E
t
.?
RED/BLU
I
a'u,[!
tsl
BI-K
*rt
(3CP,
QiftHl.
I
BI..K
G20r
G30l
G40l
RIGHT
FRONT
SIDE
MASKER
I,IGHT
t3cP'
23-145
vnx.su
IntegratedControlUnit
Input Test
CAUTION:
a All SRS elocttical widng hatnesssato covored with
yollow insulation.
a Botolo disconnocring any pan ot the SRS wile hal'
ness, connct tho shon connoctor(3l.
a Replaca tho ontlrg affsctod SRS hE noaa assombly if
it has an opon circuit or damag6d wifng.
Remove the dashboSrd lower cover and knee bolstar.
then disconnect the 1 5-P connector Jrom the integratsd
control unit.
Removethe integrated control unit from the under-dash
Juse/relavbox.
SRSMAII{ HARI{ESS
Inspect the connector and socket tetminals to be sure
they are all makinggood cont8ct.
a lf the terminalsare bent, looseot corrodd,repairthem
as necessary, and recheck the system
a lf the terminalslook OK, makethe tollowing input tssts
at the connector and under-dashtuse/relsy box.
- lf any test indicatesa problem,find and correct the
cause, then recheck the system.
- It all the input tests prove OK, the control unit must
be faulty; replace it.
NOTE:
a Diftorent wires with the sam color have been given
a number suffix to distinguish thn {for 6xample,
GRN/BLUIand GRN/BLU' arenot the same).
a Do not disconnect any connectors on tho under-dash
fu8e/relay box except the integratsd contlol unit.
H_____-t{
.BLK/GBI{ LT
15.P CONNECTOR
BLU/WHTI BLU/GR]{I BLU/YELI LT GB /BED

YEL/BLU
23-146
vnx.su
GRN/BLUI GRI{/RED
All Systems:
No. Tsrminal
1
Tst condition
T6st: Desired rosult
Possiblacause it result is not obtained

Check for continuityto ground: . Poor ground (G201, G4O1)
. Blown No. 3 (7.5 A) fuse in the
There should be battery voltage. under-dashfuse/relaybox
. B l o w nN o . 1 5 ( 1 0 A ) t u s e i n t h e
There should be bsttery voltage

lgnition switch ON {ll)

F
Rar Window Detogger Timer System:

No. Wire
Tost condition
I
YEL
Test: Dosiled result
Defoggerswitch
pushed
Check lor continuityto ground:

There should be continuityas
the switch is Dushed.
Faultydefoggerswitch
P o o rg r o u n d{ G 2 0 1 ,G 4 O 1 }
An open in the wire
Connectto ground:The rear

window defoggershould work
and the detoggerswitch indicator light should come on.
Blown No. 13 {7.5 Al fuse in the

Faulty defogger relay
Blown bulb
An open in the wire
BLUiYEL
Intermittent Wip6r Relay System:

Wir/
No. Terminal
Test condition
,|
TEt: Desir6d result
and windshieldwipet
YEL/BLU
switch INT

Windshieldwiper
BLU/WHT
switch OFF or INT
ano
and wiper bladesin
BLUiGRN
park position
Check for continuity between

the BLUMHT and BLU/GRNterminals:There should be
continuity.
.E
Possiblecause il rosult i8 not obtained
lgnitionswitch ON (lll
Possiblocause if rosult is not obtained

Bfown No. '14 l2O Al fuse in the
Faulty windshieldwiper switch
An oDenin the wire
Faulty windshieldwiper switch
Faultv windshieldwiDer motor
An open in the wire

lgnitionswitch ON (ll) Check for voltageto ground:

. Faulty windshieldwasher switch
* B L K / G R N and windshieldwasher There
should be battery voltage. . An open in the wire
motor switch ON
*: With combinedwasher-wiper
operation
(cont'd)
23-147
vnx.su
IntegratedControl Unit
Input Test (cont'd)
rWith combined washeFwipot operation
Engine Oil PressureIndicator Flashal System:

Wire/
Tsst condition
No. Telminal
Enginerunning
lgnitionswitch oFF
LT BLU
. Faulty charging system

There should be battery voltage . An oDenin the wire
Check for continuityto gtound: . Faulty engine oil ptessure switch
Check indicatorlight. lf the light . Blown bulb
. An open in the ware
does not come on, Sttach the
ground:
YEL/REDterminalto
The light should come on as the
ignitionswitch is turned ON.
Start the engine.

Key-in/Seat Bolt Reminder Systam:

Test condition
Wila
No.
LT GRN/
RED
Driver'sdoor open
Front passenger'sdoor
switch open
NOTE:Betoretesting,
remove No. 3 (7.5 A)
tuse from the underdash fuse/relaybox.
lgnition key inserted
into the ignitionswitch

RED/BLU and driver's seat belt
unbuckled
Test: Dosired lesuh
Insufficientoil
lmproper lubrication
Faulty engineoil pressureswitch
Possiblecauso if resuh is not obtainod
Check for continuityto ground; . Faulty driver's door switch

Check tor continuityto ground: . Faultylront passenger'sdoor switch

There should be 1 V or less.
Faulty ignition key switch

Poor ground (G201, G401)
An ooen in the wite
Check lor voltageto ground:

Faulty seat belt switch

Poor ground {G551)
An open in the wire
NOTE: Referto page 23-125 for the seat belt switch test.
23-148'
;.rqFft,
Possiblo cuse if r6rult is not obtainod
YEL/RED
GRN/BLU'
Test: Desired result
vnx.su
Bulb Check System (blake system lightl

No. Tsrminal
Test condition
Tost: Desirod resuh
Possibls caus6 it result is not obtainod
lgnitionswitch at
START
Check lor voltageto ground:

Blown No. 18 {7.5 Al fuse in the

Faulty clutch intrlock switch or
starter cut relay {M/T}
Faulty neutral position switch (A/T)
An open in the wire
lgnition switch ON (ll),

brake fluid reservoir
tull, and parkingbrake
lever down
Connectto ground: Brake

system light should come on.
Lights-on Romind6rSystom:
Wire/
No, Toiminal
T6Et condition
GRN/8LU'
Driver's door open

Combinationlight
switch ON.
Connectthe I terminal
to the J terminal.
Side Markol Light Flashar System:

Wiro/
No. Terminal
Test condition
1
Combinationlight
switch ON
lgnition switch ON {ll)

G R N / B L U 1and turn signalswitch
to "Left"
2
Tost: Dositod rosuh
Possibl6caus6 if rosuh is not obtainod

Check for continuityto ground: . Faulty driver's door switch
Check for voltage to g.ound:
Blown No. l9 (1O A) tuse in the
under-dashfuse/relav box
Faulty combination light switch
An oDenin the wire
Check chime operation:Chime . Faulty chime
should activate each time the
batterv is connected,
Tast: Desired rosult

Po$ible cause if result is not obtained

. Blown No. 19 (1O A) tuse in the

It should changefrom
O-12-O V repeatedly.
Blown No. 26 (10 A) luse in the

Faulty turn signal/hazardrelay
An oDenin the wire
Check the front side marker

light: Left (or Right) front side
markerlight shouldcome on as
the batterv is connected.
Blown bulb
P o o rg r o u n d( G 2 O 1 c, 3 O 1 , G 4 O 1 l
An open in the wire
lgnitionswitch ON {ll)
GRN/YEL and turn signalswitch
to "Right"
GRN/WHT and turn signalswitch
to "Left (or Rightl":
Connectthe H terminal
GRN/REDl to the GRNMHT
(or GRN/REDl)terminal.
. Blown brake system light

23-149
vnx.su
Key-in ReminderSystem
Door Switch Test
lgnition Key Switch Test

NOTE: Referto page 23-145fot a diagramof the keyin lemindercircuit,and to page23-148 Jorthe inputtest
ol the beepercircuit.
l.
Removethe screw, then pull out the door switch.

Disconnectthe 1-P connectorfrom the switch.
When the ignitionkey is not removed,the key-inreminder

in the integratedcontrolunit sensesgroundthroughthe
closedignitionkey switch. When you open the driver's
door, the beepercircuit sensesgroundthrough the closed
"LT BLU" and "GRN/
door switch, With groundat the
BLU" terminals,the beepersounds.
1.

(see page 23-70).
2.
Disconnectthe 7-P connectorfrom the main wire

harness.
Open the door.
BASE PLATE
4.
Check lor continuity between the positive terminal

and the baseplate (ground)in each switch position
accordingto the table.
Terminal
POSITIVE
BASEPLATE
Position
Checkfor continuitybetweenthe No. 2 and No. 4
terminalsin each conditionacco.dingto the table.
PUSHED
{doorclosedl
RELEASED
ldooro!en)
Terminal
Condition
KEYINSERTED
--o
KEYREMOVED
23-150
vnx.su
EngineOil Pressure
Indicator System
Lights-onReminder
System
Description
Description
NOTE: Reterto page 23-144 tor the circuitdiagramot

the engine oil pressureindicatorflasher,snd to page
23-148 lor the input test of the flashercircuit.
NOTE: Referto page23-145 tor a diagramof the lightson remindercircuit, and to page 23-149 for the input
tests of the circuit.
The low engine oil pressureindicator tight works in two

ways. lt will flash continuouslyfollowinga momentary
loss of oil pressure, or it will go on and stay on with a
completeloss of oil pressure.
When the ignitionkey is turnedto OFF8nd removed.with

the lights on, voltageis apptiedto the remindercircuit
in the integratdcontrol unit. When you open the driver,s
door, the circuit senses ground through the closed door
switch.
With voltage at the "H" terminal, ground at the
"GRN/BLU2"
terminaland no voltageat the ,,F,' terminal, the chime sounds to remindthe driver to turn oJf the
lights.
When the engine first starts, before oil Dressurerises

above 29.4 kP8 10.3 kgf/cmr, 4.3 psi), current flows
through the low engineoil pressureindicatorlight and
the oil pressureswitch to ground.This tests the circuit.
Wilh the enginerunning,voltageis appliedro the ftasher circuit of the integrated control unit. With normal oil
pressure,the oil pressureswitch is openandthe low engine oil pressureindicatorlight does not operate.lf the
oil pressureswitch closesmomentarily(morethan O.5
secondsl,but then opensagain,terminal"yEL/RED,'will
sensegroundthrough the switch. The integratedcontrol unit willthen provide and remove ground for th low
engine oil pressure indicator light through terminal
"YEL/RED".
The light will flash on and olf until the ignition switch is turned to "OFF".
lf engineoil pressurefalls below 29.4 kPa (O.3kgJ/cmr,
4.3 psi) and does not increase,the oil pressureswitch
willstsy closed.The low engineoilpressureindicatorlight
will go on and stav on.
ChimeTest
{see page 23-70).
Disconnect the 2-P connector t.om the dashboard
wire hamess.
CHIME
NOTE; Referto page23-122lot the engineoil pressure

switch test.
Test the chime by connecting battery power to the

"A" te.minal
and groundto the "B" terminal,and
power
cycling the
on-off repestedly.
lf the chime fails to sound every time power is cycled, reDlaceit.
23-151
vnx.su
Lighting System
ComponentLocationsIndex
All SRS elctrical wiring harnessesale covered with
yallow insulation.
Bfore disconnocting any pan of th SBS wire harness, connect the short connactor(sl.
Replacth6 entire affocted SRS harnessassembly it
it has an open circuit or damagod wiring.
HIGI{ BEAM INDICATORLIGHT

(ln the gaugeassembly)
Bulb Locations,page 23-115
COMBINATIONLIGHT SWITCH
page 23-160
Replacement,
Test, page 23- l58
OAYTIME
RESISTORlC.nodal
Test, page 23-160
HEAOLIGHTS
Adjustment, page 23-162
page 23-164
Replacement,
FRONT PARKING/FRONTTURN
SIGNAL LIGHT
page 23-165
Replacement,
FRONTSIDE
MARKERLIGHT
page 23-165
Replacement,
DAYTIME RUNNIT{GLIGHTS
CONTROLUNIT {C6nada)
23-152
-
vnx.su
Hatchback:
LICENSEPLATE LIGHTS
page 23-169
Replacement.
TAILLIGHT
. Replacement,
page 23-166
. Eulb replacement,page 23-166
Sodan:
LICENSEPLATE LIGHTS
page 23'169
Roplacement,
INI{ER TAILLIGHT
. Replacement,
page 23-167
. Bulb replacement.page 23-168
TAILLIGHT
. Repfacement,page 23-167
. Bulb replacement,page 23-168
23-153
vnx.su
LightingSystem
CircuitDiagram(USAI
- HOOD
UNOER
RJSE/NELAY
8OX
-r
DIMMER
No.lo
tloAr
'1
No,22
(0oA)
lo|
,-.
otF
I'I
''t No.g
(floAr
No.2l
|l0A]
iil;
)
REO/GNN
HEADLIGHT
HIGHEEAM
INOICATOR
LIGHT
fi.4W)
@il,", @f,*, 6il*
8LK
8tK
G 20l
G401
G301
RIGHT
HEAOUGHT
G20'|
G40l
23-154
vnx.su
6p*
DASHUGI{TS
88rGr{TESS
CONTrcUTR
DASHUGHTS
. PAR(II{C
PAR(II{G
UGHI
UGHTS
. TAItUGt{TS
TAILUGI{TS
. UCENSE
PI.ATE
UGHTS
- D SH
UtrloER
RJSE/RELAY
sox
GircuitDiagram(Canadal
UNOER_HOOD
FUSEiRETAY
8OX
BATTERY
G"*
-il
/ d \
coMBrNAtor{
rcHrswnc
BAT
'.=r"
tlL-J
l l ' L
"- l-'li'
"orr ;-\d " ;j
I I *o\."
r.r-,9
I
L
I LI
RED/BLU
t'
REO/}VHT
RED,
GRN
UNDEN-DASH
FUSEiIEI,AY
8OX
I
I
I
I
i,"#
llrrff li'rrt,I
No.2l
fl0A)
(
Jm.tr
No.l9
|l04]
BLU REOr'
TVHT
RED/
GRtI
rGNrTrot{
tG2 swITcH
\9-l
NED/B
t10A)t
No.l6
{7.54}
WHTTYEL
. DASH
LGHTS
BRIGHTNESS
COI{TROLLER
. DASH
I-IGHTS
. PARKING
I-GHIS
. TAII,LIGHTS
. UCENSE
N"ATLIGI{TS
I a-r
jllA/Vr
neonru
oI
RED/GRI{
+\{H
I r-0
1651,1/) | l55W)
HIGHBEAM
INOICATOR
UGHT
fl.4W
l"
wxrinto
DAYTIME
RUNNING
UGI{TS
RESISTOR
RED/
GRN
Hr
f#
HI
t85W)
LO
t55Wl
RIGHT
HEADLIGHT
PARKIIIG
BRAKE
sw{TcH
I
23-155
vnx.su
Lighting System
DaytimeRunningLightsControlUnit Input Test (Canada)
CAUTION:
a All SRS eloc{dcal wi ng harnssesare covelod with
yollow insulation.
a Boforo dbconnocting any psrt of the SRS wir h8rnoss, connoct tho shon connector(s).
a Roplacethe entire affected SRS harness assombly it
it has an opon Gilcuit or damagod wifng.
1.
Removethe dashboardlower cover and knee bolster.
2.
Disconnectthe connectorsfrom the daytime running

lights control unit.
3.
Insoectthe connectofand socket terminalsto be

sure they are all making good contact.
a ll the terminalsare bent, loose or coroded, repair
them as necessary. and recheck the system,
a lf the terminalslook OK, make the followinginput tests at the connector,
- lf any test indicates a problem, find and cor.ect the cause, then recheck the system.
- ll allthe input tests proveOK, the controlunit
must be taulty; replaceif
4-P CONI{ECTOR
8-P CONNECTOR
YEL/ALK
GRN/RED
WHT/RED
WHTA'EL
RED/GRI{
Vi6w from ware side
View from wire side
23-156
vnx.su
Tst condition
Check Jor voltageto ground:


Blown No. 16 (7.5 A) tuse in the

Faulty ignition switch
An open in the wire
Combinationlight
switch in "O" position

The.e should be battery voltage.
Blown No. 40 {5O A) fuse in the

Faultycombinationlight switch
An ooen in the wire
Left and right headlight(high

beaml should be on but dim, and
high beam indicatorlight should
come on.
Poor ground (G201. G401. G301)

Blown bulbs
Faulty daytime runninglights
reststor
An open in the wire
Connectto ground:The brake

system light shouldcome on.
Blown brake system light
An open in the wire
RED/WHT
Combinationlight
switch is OFF; connect
a iumper wire between
5 WHT/REOthe YEL/BLKand
WHT/REDterminals,
then turn th6 ignition
switch ON.
lgnition switch ON (ll),
brake fluid resrvoil
GRN/RED
full, and parking brake
lever down
RED/GRN
. P o o rg r o u n d{ G 2 0 1 ,G 4 0 1 )
. Blown No. 17 { 10 A} luse in the
under-dashtuse/relay box
. An ooen in the wiae

YEL/BLK
tt
Possiblacause if rosult is not obtainad
BLK
WHT/YEL
Test: Desirad losult
Parking brake lever up

The.e should be continuitv.
. Faulty brake lever switch

23-157
vnx.su
Lighting System
Combination Light/Turn Signal Switch Test
CAUTION:
a Atl SRS Oloctricslwiring harnessesar6 covered with
yellow insulation.
a Bslor disconnecting any pan ot the SRS wire harness, connact the short connsctollsl.
a Replacethe sntire aftectad SRS harne$ assembly if
it has an opon circuit or damagod wiring.
1. Remove the dashboardlower cover and steering
column covers (see page 23-71).
2.
Disconnectthe 4-P and 7-P connectorsfrom the

switch.
3.
Checkthe connector and socket tetminalsto be sure

they are all making good contact. lf the terminalsare
bent, loose, or cotroded, repair them as necessary,
and recheck the system.
4.
Checktor continuitvbetweenthe terminalsin each

SRS MAIN HAR ESS
4-P CONI{ECTOR
B
D
G
H
7.P CONNECTOR
23-158
vnx.su
ComHnrtlon llght Swhch :
TErminsl
Position
Hsrdfightstvitch
t-
OFF
1J
--o
L0w
o
o
HIGH
OFF
Passing
switch
ON
Tum Slgn.l Swhch :
/ t \
RIGHT
Tsrminal
A
Position
RIGHT
-o
NEIIIMT
uFr
(J
23-15,9
vnx.su
Lighting System
Combination Light Switch
Replacement
'1.
UPPRCOVER
Daytime RunningLights Resistor
Test lCanada)
CAUTION: The daytime running lights resistor becomas
vely hot when the daytime running lights are on; do not
touch it or the attaching hardware immediatelyaftel th
lights h8ve ben turned otf.
1.
Disconnectthe 3-P connectorfrom the resistor.
DAYTIMERUNNING
LIGHTS RESISTOR
?nd

combination lighr switch, then remove the two
screws and lift out the switch.
View trom lerminalside
Measurethe resistancebetweenthe resistorterminals (A and B) and the DowerterminalC.

Rsistance:1.4 O I O.O7O
Replacethe resistorwith a new one if any ot the

resistancesare bevond soecification.
23-160
vnx.su
Headlight
Description
The low beam lightsare proiector-typelightswhich are more compactwhile maintainingsufficientbrightness.Bundling
the light raysreducesstray light and yieldsa spotlight-effect
which improvesvisibilityduringnight or foul weatherdriving.
For easieraiming,the headlightsare equippedwith vertical and horizontalgauges.
NOTE: As the oute. lensesare made oI a resin material,don't cover the headlightswhen they a.e turned on.
OUTER LENS
coNvExLEI{S
SUB-REFLECTOR
sEcoND FOCUS
INTERRUPTER
PLATE
REFLECTOB
FIRST FOCUS
BULB
23-161
vnx.su
Headlight
Adjustment
Belol adiusting lha hoadlights:
3.
Turn the low beams on. lJ necessary,align the vertical indicator with its "O" mark by turning the vertical adiuster with a Phillipsscrewdriver, and check
aiming with the chart on page 23-163.
4.
lf necessary,alignthe horizontalindicatorwith its

"0" mark by turningthe horizontaladjusterwith a
a Parkthe car on level ground.

a Make sure the luel tank is full.
a The driveror someonewho weighsthe same should
sit in the driver's seat.
a Loadthe trunk with the items you usuallycarry (if you
usuallypull a trailer,attach it to the carl.
a Push down on the tront and rear bumDersseveral
times to make sure the car is sitting normally.
a When installinga new headlightassembly,tighten the
four mountingbolts so that.theindicatorin the verti"O" mark.
cal gauge comes to the
Phillipsscrewdriver,and check aimingwith the chart

o n p a g e2 3 - 1 6 3 .
1. Open the hood.

2.
Check that both the horizontaland verticalgauge

read " O" .
. lf the gaugesrcad "O", check headlightaiming
with the aimingchartson page 23-163. (lf aiming isn't correct,refer to the trame repairchart
in section 20.)
a lf one o. both gaugesdon't read "O". go to step
5.
Recheckthat the verticalindicatorbubbleis aligned

with "o" 1 1.
lf necsssary,adjust as describedin step 3.
Turn the high beamson and check aimingwith the
charts on page 23-163.
23-162
vnx.su
Measurements (Standardl:
A: 9 fi 10 in (3000 mm)
B: 23 in (585 mm)
C: 46.1 in (1170 mml
D: 33.5 in (85O mm)
E; 1.2 in {31 mm}
FLOOR
Headlight Aiming
Low beam:
High besm:
HEADLIGHT
HIGH BEAM
HEADLIGHT
LOW BEAM
CEt{TER
FLOOR
CAUTION: Th6 out6r lonses get very hot when tho hoadlights are on; do not cover them.
23-163
vnx.su
Headlight
Headlight Replacement
1. Removethe front bumoer.
Bulb Replacement
CAUTION:
a Halogon headlights can bocomo voly hot in usa; do
not touc$ them or tho attaching hardware imm6diatoly
arter they hava been lurnod off,
a Do not try to roplaceor cl6an the headlights with the
lights on.
I.
Oisconnectthe 2-P connector(s)from the headlight.
FRONTBUMPR
Removethe mountingbolts,then pullout the headlight, and disconnectthe connectorsfrom it.
coNlrtEcToR
2.
HEADLIGHT
Afte. replacement.the horizontaland verticalaiming must be checkedusing conventionalmethods,

Use the aimingcharts on page 23-163.
23-164
vnx.su
Turn the bulb(s)counterclockwiseand removethe

bulb(s).
Front Parking/Front
Turn
Front Side Marker
Signal Lights
Lights
Replacement
l.
Replacement
Removethe screw, and pull the front parking/front

turn signal lights out ot the tront bump6r.
Remove the screw, and pull the front side marker

light assemblyout of the tront bumper.
Disconnectthe 2-P connectorfrom the lioht.
Turn the bulb socket 45o counterclockwiseto remove it from the housing.
BULE{3 CPI
Disconnect the 2-P connctor trom the tight.

Turn the bulb sockt 45o counterclockwise to remove it from the housing.
FRONTSIDE MARKERLIGHT
23-165
vnx.su
Taillights(Hatchbackl
Bulb Replacement
Replacement
1 . Open the resr hatch.
Removethe rearpanelliningandthe sidelining{see
section 20).
R6ei tum slgnal/Rolr parking lights:

1.
Openthe rearhatch,then removethe accesspanel.
2.
Removethe bulb lrom the bulb socket.
Disconnect the 4-P connector from the taillight.

4.
ACCESS PANEL
Removethe six mounting nuts, then pull out the

taillight.
4-P CON[{ECTOR
@: REARTURN SIGNALLIGHTBULB(32 CPI

@: REARPARKINGLIGHTBULB{3 CP)
Brake/T8illight/Back-uplights:
NOTE:
a Inspect the gasket. Replaceit if it is distorted or
stavs compresseo.
a After installation. run wate. over ths lights to
make sure thev don't leak.
1. ODenthe rear hatch.

2.
Removethe rear panel lining {see section 20).
o: BACK-UPLIGHTBULB{32 CP}
BULB(32l3 CP)
@: ERAKE/TAILLIGHT
23-166
-
vnx.su
Taillights (Sedan)
Replacement
Tsillight:
1. Open the trunk lid, then removethe rar panel lining and side lining (seesection 20).
2.
Disconnect the 4-P connector from the tsillight.
3.
Removethe four mountingnuts, then pull out the

tsillight.
Innol Taillight:
1. Open the trunk lid.
2.
Disconnectthe 4-P connectorfrom the innertaillight.
3.
Remova the four mounting nuts, then pull out the

inner taillight.
INNERTAILLIGHT
4-P CONi{ECTOR
TAILLIGHT
NOTE:
a Inspect the gasket. Replaceit if it is distoned or stsys
compresseo.
a After installation, run water over the lights to make
sure thev don't leak.
23-167
vnx.su
Taillights(Sedanl
Bulb Replacement
Tsillight:
1. Open the trunk lid. then removethe rear panel lining and side lining {see section 20}.
lnnor T.illlght:
1. Open the trunk lid, then removethe bulb housing.
2.
2.
Remove the bulb from the bulb housing.
Removethe bulb from the bulb socket.
BULBHOUSII{G
BULB(32l3 CP}
@: BRAKE/TAILLIGHT
@: T U R NS I G N A LL I G H TB U L B( 3 2 C P }
O:
@: REARPARKINGLIGHTBULB{3 CP)
BULBI3213CP}
@: BRAKE/TAILLIGHT
23-168
l'r'qn'F',
vnx.su
LIGHTBULB(32 CP}
BACK-UP
LicensePlateLights
Glove Box Light
Replacement
Test
Remov the screws and pull out th6 license plate

lights.
Removethe glove box and disconnectthe 2-p conneclor.
Turn the bulb socket 45o counterclockwise to remove it from the housing.
Checkfor continuitybetweenthe A and B terminals

in each conditionaccordingto the table.
Trminal
B
Condition
PUSHED
{lidclosodl
REI"EASED
{lidoDen)
o-
/:\
\7
---o
BULB
(3.4 W)
ql
-----11
dl
cior
G4{t1
23-169
vnx.su
DashLightsBrightnessGontrol
CircuitDiagram
8OX
UNDER.HOOD
FUSE/REIAY
COMBII{ATION
LIGI{TSWTTCH
wnr-@-
UNDERDASH
8OX
FUSE/NETAY
neorenn
REO/BLK
. GATJGE
UGHTS
. CruEECOITNOL
DIMMING
CIRCUTT
. A/TGEAR
POSMON
N(ICATOR
DIMMII{G
CIRCUIT
' HAZAnD
LIG}fr
WARi{|NG
S:WltCH
. REAR
SiWTTCH
UGHT
WINOOW
OEFOGGER
. CFUISE
UGHT
COMTROT
MAINS,IVITCH
. A,ITGEAN
UGHT
POSITION
CONSO|.!
. HEATER
PANEL
UGHTS
COMTNOL
T
R D
BI.K
G201
G40t
23-170
vnx.su
Controller Input Test

NOTE: 8e carefulnot to damagethe controllerand the
instrumentpanal.
1. Removethe instrumentpanel lrom the dsshboard
{ s e ep a g e 2 3 - 1 1 8 1 .
2.
Remove the dash lights b.ightness controller {rom

the dashboard.then disconnect the 3-P connector.
Inspect the connector and socket terminals to be
sure they are all making good contact.
View from whe side
a lf the terminalsare bent. looseo. corroded,repsir

them as necessary, and recheck the system.
a It the terminalslook OK, make the tollowing inDut tests at the connector.
- lf any test indicates a problem, find and correct the cause, then recheck the system.
- lf all the input tests prove OK, the dash lights
brightnesscontrollermust be faulty; replaceit.
3-P CON[{ECTOR
OASH LIGHTS
COI{TROLIER
Wire
1
BLK
Tost condition
Check for continuity to ground:

Headlightswitch ON
Check Jor voltageto ground:

Headlightswitch ON
Connectto ground: Dash lights

shouldcome on full bright.
RED/BLK
RED
Togt: Dasired resuh
Possiblecauso it resull is not obtained

. Poor ground (G20l , G4O1)
Faulty combinationlight switch
An open in the wire
23-171
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Area Lights, Spotlights

Ceiling/Trunk/Gargo
Component Location Index
r 1: Sedan
r2: Hatchback
CEIIING LIGHT
Test/Replacmont.page 23-175
SPOTLIGHTS
Test/Rsplscement, page 23-1 74
.1 LEFT REAR
DOOR SWTCH
Test. page 23-150
FRONT
PASSEl{GER'S
DOOR
swtTcH
Test, pago23-150
*2 HATCH LATCH
11 RrcHTBEAR
DOORSWrCH
Tost. page23-150
swtTcH
Test/Replacement,
page 23-178
11 TRUNK LATCH
SWITCH
Test/Replacment,
page 23-178
'1 TRUI{K LIGHT

Test/Replacemont
Page 23-177
23-172
rII-
vnx.su
CircuitDiagram
- HOOD
UNOER
FUSE/RELAY
8OX
- - - - -Hltcnb&n
--1
CARGO
ASEA
UGHT
t3.4Wl
U DEN-DASH
FUSE/RELAY
8OX
lS.d.nl
TBUi{K
UGHT
t3.4Wl
GRI{
l**,-0,,n
I rNorcAToR
I UGHT
IY
LT
II{IEGRATED
1
cotlrnor I
I,NIT
i'
GRN
GRr{/Bt
U t-t
Iq*",,.,
d_
f-
I DOOR
I swncH
II
FROiTT
PASSEiIGEB'S
DOOf,
SWTCH
23-173
vnx.su
Area Lights, Spotlights

Ceiling/Trunk/Cargo
Spotlight Test/Replacement
1. Turn the light switch OFF.
2.
Pry off the lens.
3,
Removethe two screws,then pull out the housing.
4.
Disconnectthe connectorfrom the housing.
5.
Checkfor continuitybetweenthe terminalsin each

Hatchback:
;r,,-
CONNECTOR
tEFr
Torminal
----l
ON
BorB'
/:\
\:/
o-
OFF
ON
RIGHT
Sedan:
""li **li
BULB
23-174
vnx.su
--o
--o
o-
OFF
B'O
CorC'
Ceiling Light Test/Replacement

With moonrool:
5.

2.
Pry otJ the lens.
3.
Removethe two mountingnuts, then pull out the

housing.
Checkfor continuitybetweenthe terminalsin sch

swatchpositionaccordingto the table.
re.mrnal
Position
OFF
DOOR
ON
8or8'
oo-
za
\7
G-
/1
\7
--o
--o
--o
\:.,/
3-P CONNECTOR
F om o.3l7.5Al FUSE
(ln th. snd.. - dr.h fu!./rby boxl
4.
Disconnectthe 3-P connectorf.om the housing.
23-175
vnx.su
Area Lights' Spotlights

Geiling/Trunk/Cargo
Geiling Light Test/Replacement
Check for continuity between the terminals in each
5.
Without moonroot:
2.
Pry ofJ the lens.
3.
Removethe sctew, then pull out the housing'
T6ninsl
P"riti""
DOOR
ooLF
BorB'
OFF
ON
/:\
\:.,/
A
--o
--o
/A
3-P
CONNECTOR
4.
F om o.3l7.5Al FUSE
tln thr uid.r - ddr h|. /,.LY borl
A
Disconnectthe 3-P connectorfrom the housing.
23-176
vnx.su
--o
Trunk/CargoArea Light Test/Replacement

Pry the trunk/cargoafea light lens out of its housing.
Pry out the light assembly.
Disconnectthe 2-P connectortrom the housing.
Hatchback:
4.
Make surethat the bulbis in good condition.Check

for continuitybetweenthe A (+) and B (-lterminals. There should be continuitv (Hachback:the
switch must be Dushed).
Hatchback:
2.P CONNECTOR
Froh o.3 (7.5A1FUSE

{ln th. undor- d!.h
fur./r.hy box)
BULE13.4Wl
To HATCH
LATCH
A {+}
swtTcH
B{-)
Sedan:
2.P CONNECTOR
F om o.3 (7.5A1FUSE
{ln th. und.i- da.h
tur/r.hy box)
HOUSING
BULB{3.4 W)
To TRU K
LATCH
swtTcH
23-177
vnx.su
Area Lights,Spotlight
Ceiling/Trunk/Cargo
Latch Switch Test/Replacemsnt
Sedan:
lhtchb.ck:
1. Openthe trunk lid. and disconnectthe 2-P connector from the trunk latch switch.
1.
Op6n the hatch, and disconnect the 2-P connector

trom the hatch latch switch.
2.
There should be continuity between thg A terminal

and component ground.
2.
There should be continuity between the A and B terminals.
\j
C C
3 . lf necessary,removethe three mounting bolts to pull
out the hatch latch switch trom the latch, then disconnact the lock rod Jrom the hatch latch switch
4.
ll necessary,removethe three mounting bolts to pull
out the trunk latch switch from the trunk lid, then
disconnectthe lock rod from the trunk latch switch.
4.
Disconnect the trunk opener cable from the trunk

latch switch.
TRU'{KOPG ER
TRUNK LATCH SWITCH
23-178
vnx.su
Disconnect the hatch opener cable trom the hatch

latch switch,
Back-upLights
CircuitDiagram
UI{DER_
IIOOOFUSEiBEIAY
BOX
wHT/Bt(+WHT
A/TGEAR
Posrnotr
swrTcH
'l
f 8ek- uplioht
--------_J
L---------
23-179
vnx.su
Back-up Lights
Manual Transmigsion:
Automatic Transmission:
NOTE: Checkthe No. 1 5 { 1O A) fuse in the under-dash

fuse/relaybox befote testing.
NOTE: Checkthe No. l 5 ( 1O A) fuse in the under-dash

fuse/relay box belore testing.
'1. Test the back-uplight switch by placingthe shift

lever in reverseand turning the ignition switch to ON
( ).
1. Test the back-up light switch by shitting the shift

lever to l3l and turningthe ignitionswitch ON (ll).
2.
It the back-uplightsdo not go on, check the backup light bulbs in the taillightassembly.
3.
lf the tuseand bulbsareOK. disconnectthe connector from the back-uplight switch.
2.
lf the back-uplights do not go on, checkthe backup light bulbs in the taillightassembly.
3.
lf the tuse and bulbs are OK, disconnectthe 14-P

connector from the A/T gear position switch (backup light switch).
4.
Move the lever back and torth at the LBI position

without touching the push button, and check tor
continuitv between th C and D terminals. There
should be continuitY within the range of free plsy of
the shift lever.
terminal sade
This washer must

always be replaced
tor the switch to
lunction properlY
and to ptevent oll
teaKs.
4.
With the shift leverin reverse.checkJor continuity

betweenthe A and B terminalswith the switch installed.
a lf there is no continuity,replacethe switch {see
s e c t i o n1 3 ) .
a lf there is continuity, but the back-uplights do not
go on, check for:
- Poor ground (G5O3)
- An open in the wire
23-180
vnx.su
a lf there is no continuity within the range oJ J.ee

play, adjust the position ot the A/T gear position
switch lsee section 141.
a lt there is continuity, but the back-uplights do not
go on,check{or:
- Poor ground {G503)
- An oDen in the wire
BrakeLights
CircuitDiagram
UNDEE-HOOO
FUSE/NELAY
BOX
. HORi{
. IMTERI.OCK
SYSTEM
{u
8tK
{.
*H-i
{.
BLK
23-181
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Brake Lights
HighMount BrakeLightReplacement
(LEDtypel
Brake Switch Test
1. Removethe four screws and the high mount btake

light, then disconnectthe connectors.
lf the brakelights do not go on, check the No. 42

{2O A) fuse in the under-hoodfuse/relaybox, and
the brakelight bulbs in the taillighrassemblyand high
mount brake light.
lf the fuse and bulbsare OK. disconnectthe 2-P or
4-P connector {rom the brake switch.
'|Frt
jr'li
C
HIGHltlOUt{T BRAKELIGHT{LEDTYPEI
3.
Check fo. continuitv between the B and C terminals.

There should be continuity with the brake pedal
pushed.
a lJ there is no continuitv, replscethe switch or adjust pedal height {see section 19).
a lf there is continuity,but the brakelightsdo not
go on, inspectfor:
- Poor ground (G5O3)
- An ooen in the wire
23-1A2
vnx.su
High Mount BrakeLight Replacement

{Bulbtype)
Hatchback:
Sadan:
1. Open the hatch.
1. Openthe trunk lid, and disconnectthe 2-P connector trom the high mount brake light.
2.
Removethe two clips and the cover.
3.
Removethe two nuts and the high mount brakelight,

then disconnectthe 2-P connector.
2.
Removethe two nuts, then remove ths high mount

brake light from the rear shelt.
2-P CONt{ECTOR
4.
Turn the socket 45o counterclockwiseto removethe

bulb.
Installthe high mount brakelight in the reverseorder of removal. Cleanthe rear window glass before
installingrhe light.
Installthe high mount brakelight in the reverseorder of removal,and cleanthe rearwindow glassbetore installing.
CAUTION: Whon installing ih6 high mount brake
light. make sur6 the rubber soal fits against the real
window ev6nly.
23-183
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Side Marker/TurnSignal/HazardFlasherSystem
GAUTION:
a All SRS electrical wiring harnessosar6 covered with
yellow insulation.
a Belor disconnocting any pan of the SRS wire harngss, connoct the short connector{s).
a Rsplacetho 6ntir affectd SRS harnoss sssembly il
it has an opn cilcuit or damaged widng.
TURN SIGNAL INDICATORLIGHTS

(ln the gaugeassembly)
Bulb Locations,
23-115
COMBINATIONLIGHT SWITCH
page 23-160
Replacement,
Test, page 23-1
SRS MAIN HARI{ESS

(Cov.rod with Ysllow in3ulationl
HAZARD WARI{ING SWITCH

page 23-187
Replacement,
Test, page 23-187
UNDER-DASH
FUSE/RELAY8OX
TURN SIGNAL/HAZARORELAY
23-184
-
vnx.su
GircuitDiagram
UNDEN-HOOD
FUSE/RELAY
8OX
N0.411100A) No.40(50A)
UNDER-DASH
FUSE/RELAY
8OX
COMBINATION
LIGHTSWTCH
A.
---of-RED/GRN
IGNITION
SWITCH
WHT/BTK
+WHT+
/6i\\
\jv
+-
FUSE
HOTJER
BIK/YET
GRN/BtU
TURNSIGiIAL
swtTcH
I
| l
+
MAFKER
SIOE
LIGHT
FLASHER
CIRCUIT
controlunitl
llnthointogruted
RIGHTTURNSIGNATTIGHTS
DASHTIGHTS
BRIGHTNESS
CONTROLLER
INOICATOR
I FRONTI REAR
L|GHT
I t32CD I t32CPl
(1.4W1
2 3 -185
vnx.su
Side Marker/TurnSignal/Hazard
FlasherSystem
Turn Signal/Hazard
RelayInput Test
CAUTION:
a All SRS electrical wiring harn6ss6sar covered with
yellow insulation.
a Bforo disconn6cting any part of th SRS wire harnoss, connoct tho short connector(s).
a Replacotho ontiro sftoctod SRS harness assmbly it
it has an open circuit or damagod wiring,
I.
Removethe turn signal/hazardrelay from ths underdash Juse/relaybox.
2.
Inspectthe relayand socketterminalsto be surethey

are all makinggood contact.
a It the terminalsare bent, looseor coroded, repair
them as necessary,and recheckthe system.
a lf the terminalslook OK, make the tollowing input tests at the socket.
- lf a test indicatesa problem,find and correct
the cause, then recheck the system.
- lf all the input tests prove OK, the turn signal/hazardrelay must be taulty; replaceit.
SBS MAIN HAR ESS

{Covg.ed with yollow inrulltion)
UI{DEB-DASH
FUSE/RELAY
BOX
Telminal
,l
TeEt condition
Test: Dsired rosult
Check for continuityto ground: . Poor ground (G201, G4O1)

lgnitionswitch ON (ll) Check for voltageto ground:
Blown No. 26 (10 A) fuse in ths fuse
There should be battery voltage. holder
and hazardwarning
switch OFF
Faulty hazardwarning switch
An open in the wire
Blown No. 43 (10 Al fuse in the
lgnitionswitch OFF and Check for voltageto ground:
hazardwarning switch There should be battery voltage. under-hood fuse/relay box
ON
Faulty hazard warning switch
An ooen in the wire
Hazardwa.ning switch Hazardlights should come on.
Poor ground (G2O1,G3O1, G4O1
is ON; connect the B
G503)
terminalto the L
Faulty hazard warning switch
termrnat.
An open in the wire
. Faultyturn signalswitch
lgnition switch ON (lll
Right or left turn signallights
and turn signalswitch should come on.
in right or left; connect
the B terminalto the L
terminal.
23-186
-
Po$iblo causo it fosult is not obtainod
vnx.su
HazardWarning Switch Test
HazardWarningSwitch
Replacement
CAUTIOI{: Bo car.ful not to damag8 tho switch and conlolo panol.
1.
Prythe hazardwarning switch out of the centervent,
2.
Disconnectthe 10-P connectortrom the switch.
1 . Removethe hszardwarning switch.

2 . Check fo. continuity between the terminals in each
I"j'!ld
Position
OFF
ON
10-PCO
@ r)
o
@
ECTOR
A B C D
\ uorr
) to.uwl
23-187
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StereoSoundSystem
CAUTION:
a All SRS elctrical wlring harneaseEare covered with
yallow insulation.
a Belore dbconnscting any part of the SRS wire harnass, connect tho short connector(sl.
a Replacetho entir6 affoctod SRS harn6ss assembly if
it has an opan circuit or damag6d widng.
NOTE: The original radio has a coded theft protection
circuit. Be sureto get the customet's code numberbelore
- removingth No. 32 (7.5 A)tuse from the under-hood
fuse/relay box.
After service, reconnct power to th radio and tutn it
"CODE" is displaved,enterthe cuson. Whenthe word
tomer's 5-digit code to restore radio opelation.
Hatchback:
SBS MAII{ I{ARI{ESS

(Covord wirh y6llow in3ulationl
STEBEORADIO/CASSETTE
PTAYER
paoe23-191
Removal.
page23-192
Terminals,
RIGHTREAR
SPEAKER
Replacement.
page23-193
DOOR
SPEAKER
page23-192
Repfacement,
LEFTTWEETER
page
Replacement,
23-192
DRIVER'S
DOOR
SPEAKER
LEFT
SPEAKER
Replacemenr.page 23-193
ANTENNA MOTOR
Test, page 23-194
page 23-196
Replacement,
23-188
!iltil;s'
vnx.su
Soden:
RADIO/CASSETTE
STEREO
PLAYER
paoe23-191
Rmoval,
FBONT PASSENGER'S
Trminals.page23-192
DOOR
i FIGHT TWEETER
page 23-192
Replacement,
*: USA
SPEAKER
page 23-192
Replacement,
RIGHTREAR
SPAKER
page2 3 - 1 9 3
Replacement,
DRIVER'S
DOOB
SPEAKER
Repfacement,p8ge 23-192
POWERANTENNA MOTOR
Test, page 23-194
page 23-196
Replacement,
23-189
vnx.su
StereoSoundSystem
CircuitDiagram
tGNtTOt{
SWTTCH
FUSE
BOX
UNDER-HOOO
i RETAY
tlo.4lllo0Al
No.39l50Al
+WHT
WHT/BI"K
No.l9ll0Al
RJSE
UNDEN-DASH
FUSENEIAY
8ox
SIEROMOO
CASSETTE
N.AYER
AI{TE?{NA
MAST
AMTEI{iIA
ITAD
-L-fl
-fi1
.a'J
POWER
AITNI{AMOTOF
ntrrct d fulvl
M_nhthoantanna
| : Excoot!ad!n of Crnede
23-190
vnx.su
RIGI{T
REAR
SPEAXER
Unit Removal
CAUTION:
a All SRS oloctrical wi ng harn.$.s ara covcrrd with
yellow insulation.
a Btoro disconnocting any part ot tho SRS wirc hrrnosa, connsct tho short conn6ctol(rl.
a Raplaco the sntirs sttoctod SRS hamoas asacmbly it
it has an opon circuil 01 damagod widng.
3 . Removethe four mounting screws, then removethe

front console.
FRONTCONSOLE
SRS MAII{ HABNESS

circuit. Be sureto get the customer'scode numberblore
- removingthe No. 32 (7.5 A) fuse in the under-hood
fuse/relaybox.
After ssrvice,reconnectpower to the radioand turn it on.
When the word "CODE" is displayed,enter the customer's 5-digit code to restore radio operation.
1.
Remove the center console (see section 2O).
2,
Remove the cigarette lighter assembly {see page

23-205t.
4.
Loosen the two mounting screws, then disconnect

the 16-P connectorand the antennalead, and oull
out the stereo .adio/cassette player.
16-P COi{i{ECTOR
ANTENlTASUB-LEAD
23-191
vnx.su
Stereo Sound System

Stereo Radio/CassettePlayer
Front Speaker/Tweeter
Terminals
Replacement
Front Spoakor:
1. Carefullypry out the speakercover.
2.
Removethe three screws,then disconnectthe 2-P

connector Jrom the speaker, and remove the
speaker.
*i,.,-terlll
A
FO] ANTENNA LEAD
r^lt
T I!NM[IAL
\
2.P CONNECTOR
SPEAKER
COVER
A9---------+A16
Twootor:
1. Removethe door paneland disconnectthe tweeter
2-P connector.
Connects to
A1
RED/GRN Frontpassenger's
door speakerO
A2
BLU/GRN Driver'sdoor speaker@
A3
A4
RED/BLK Lights-onsignal
WHT/8LU Constantpower {Tuningmemory)
A5
YEL/RED ACC (Mainstereopowe. supplyl
A6
YEL/GRN Radioswitchedpower (To antenna)
A7
BLU/YEL Left rearspeakerO
A8
A9
RED/YEL Rightrearspeaker@
BRN/BLK Frontpassenger's
door speakerO
A10
GRY/BLK Driver'sdoor speakerO
A
412
lnot used)
(notused)
A13
(not usedl
A14
BLK
2.
Remove the two screws, then remove the tweeter

ano covet.
Ground(G551)
Al5
GRY/WHT Left rearspeakerO
A16
BRNAA/HT Rightrearspeakere
23-192
vnx.su
RearSpeakerReplacement
Hatchback:
1 . Removethe three screwsfrom the trunk side,then
remove the soeaker cover.
1.
Remove the sDsakercover.
2.
Removethe three screws, then disconngct the 2-P

connocter trom the rear spoakor.
LEFTREAR
SPEAKER
Removethe tour screws, then disconnectthe 2-P

connector t.om the s9eaker, and remove the
soeake,.
OUARTERTRIM PAI{EL
SPEAKERCOVER
,r--I
LEFT REAR
SPEAKEN
2-P CONNECTON
SPEAKERCOVER
REABTRAY
23-193
vnx.su
StereoSound System
Power AntennaMotor Test
Removethe quartertrim panel(Hatchback)or trunk
side trim panel (Sedan).
AI{TE T{A MAST
Disconnect the 3-P connector from the motor, and

remove the connector from its clamD.
3 . Check for power to the motor at the connector terminals:

a There should be battery voltage between the
WHT/RED(+l and BLK{-} terminalsall thetime.
a There should be battery voltage between the
YEL/GRN
{+) and BLK(-} terminalsonlvwith the
ignition and radio switched ON.
4.
AI{TEI{I{A
LEAD
Test motor oDeration:

EXTEND:Connect battery power to the "A" 8no
"B" terminals
and groundthe "C" terminal.
C
RETRACT:Then disconnectpower trom the

terminal,
ftYhh lha lnLnn.
r.tr.ci.d
t|Ilyl
"4"
Sticking Ant6nna:
The antennasticks in either the up or down position.
*ft'^to
?r*
*r'
TIFIT
1 . Usingthe antennawrench, removethe antennanut,

spacer (see page 23-195).
Cleanthe antennamast housingthreads,and reinstall the soacer.
YEL/GRN
PLASTICSLEEVE
AIITENNA MAST
Cloan mast
housing
throads.
lf the motor fails to run or does not run smoothlv,

reDtacetr.
Usethe antennanut wrench and tightenthe antenna nut to 2.3 N.m (0.23 kgf-m, 1.7 lbf-tt). lJ you
overtightenedthe nut. the antenna may stick. lf
stickingoccurs, back the nut off a little, then turn
the radioon and off to raiseand lower the antenna
again. Repeatuntil the antennamoves treely.
23-194
fmft,
vnx.su
Antenna MastReplacement
Ramoval:
Installation:
NOTE: The antennamast alone can be replacedwithout

havingto removethe power antennamoror.
1.
1.
Removethe antennanut and spacer.
2.
Carefullywithdraw the antennamast while extending it by turning the radio switch ON.
Holdthe antennaso that the teelh on the drive cable tace in the directionshown. then insen the cable into the antennahousing.
AI{TENNA I{UT
SPACER
ANTENI{A NUT WRENCH
Direction oI the
teeth
,
ANTENNA NUT
2.3 N.m 10.23kgl-m, 1.7 lbt-ft)
Checkfor engagementof the cableteeth with the

drive gear by carefully moving the cable up and
oown.
Turnthe rsdioswitch "OFF", and let the motor Dull
the drive cable into the antennahousing.
4.
Cleanthe antennahousingthreads,then insen the

antennainto the housing.Installthe bushingspacer,
and installand tighten the antennanut to 2.3 N.m
{O.23 kgl-m. 1.7 lbf-Jt).
Checkthat the antennamast retaactsand extends
fully when the radio switch is tu.ned ON and OFF
fepeatedly. It you overtightenedthe nut, the antenna may stick. lf stickingoccurs,back the nut otf a
little,then raiseand lowerthe antennaagain.Repeat
until the antennamoves treelv.
POWERANTENNA
MOTOR UNIT
23-195
vnx.su
StereoSoundSystem
PowerAntennaMotor Replacement
1 . Removetho quartr trim panel (Hatchback)or trunk
side trim panel (Sedan).
Disconnectthe 3-P connectorand antennalead trom
the motor, then remove the antenna nut and motor
bracket nut.
AI{TENNA1{UT
2.3 l{.m
AT{TEI{]{AI{UT
WBEI{CH
oTJAA-OOlo(xrc
3+CO
ECTOR
DRAI HOSE
MOTOR
BRACKET
TUT
3 . Remove the motor and antenna as an assemblv.

NOTE: Tighten the antenna nut, then tighten tha
motor bracket nut.
23-1 9 6
vnx.su
Circuit Diagram
STEREO
RADIO/
CASSTIE
PI-AYER
23-197
vnx.su
Clock
Terminals
Replacement
CAUTION:
a Pry th6 clock out at th left sido,
a Be carsful not to damage the clock and the dashboE d
whon prying the clock out.
1.
Pry the clock out from the dashboard,then disconnect the 4-P connector.
4-P COI{NECTOR
CLOCK
Torminal
A
Connecta to
Wiro
BLK
YEL
Ground
{Main clock power sup-
plv)
RED/BLK Lights-on signal

D
23-198
vnx.su
Constantpower
WHT/BLU (Time
memory)
Horn
CAUTION:
a All SRS lectricsl wiring harnessesal covered with
yellow insulation.
a Bfore disconnecting any part of the SRS wiro harneaa, connect tho short connectol(sl.
a Replacothe entire aftected SRS harnessassembly if
it haa an open circuit ot damaged wiring.
HORN
Test,page23'2O3
{Covo.ed wiih yollow insulationl
HORNSWITCHES
Test, pago23-2Ol
<------\
-\----.....=
UNDER.DASH
FUSE/RELAYBOX
CABLE REEL
HORN RELAY
I Wiro coloB: BLU/RED,BLK, I
IWHT/GRN, and BLU/GR
l
Test, page 23-68
23-199
vnx.su
Horn
CircuitDiagram
MTTERY
------------.,1
r-T-l
lll-
l1'l
()
SHORT
c0ill{EcToR
L------------J
Wrthoutcrub6conlrol,
23-200
vnx.su
Switch Test
CAUTION:
a All SRS el6ctrical wiring harnossosare covarod with
yellow inaulation.
a Beforo disconnecting any pan ot the SRS wire harneaa, connoct ths short connector(s).
a Roplacethe entil afloctod SRS harne$ a$6mbly if
it has an open circuit or dsmagad wlring.
4.
Disconnect the cable reel harness 6-P connector

from the SRSmain harness,then connect Test Harness C onlv to the cable reel harness.
CABLEREEL
HARNESS
NOTE; The originalradio has a coded theft protection

- removingthe No. 32 {7.5 A) fuse lrom the under-hood
tuse/relavbox.
After service, reconnect power to the radio and turn it
on. Whenthe word "CODE" is displayed,enterthe customer's 5-digit code to restore radio operation.
1.
Disconnectthe battery negative cable, then disconnect the positivecable.
2.
Connectthe short connector(slto the airbag(sl.

DRIVER'S
AIRBAG
TESTHAR ESSC
oTLAz- SL/l{,3OO
CABLEREEL
3.P CO NECTOR
5 . Check for continuity between the No, 3 terminal ot

the 8-P connector of Test Harness C and body
ground with the horn switch pressed.
a lf there is continuity,the horn switch is OK.
a lf there is no continuity, go to step 6.
TESTHARNESS
C
OTLAZ-SI/I()3OO
DRIVER'S
AIRBAG
3-PCO'TNECTOR COI{NECTOR
{RED}
ACCESS
PAI{EL
SHORT CONTIECTOR
{REO}
Removethe dashboatdlower cover and kne bolster

(see page 23-701.
(cont'd)
23-201
vnx.su
Horn
Switch Test (cont'd)
Check for continuity between the horn positive terminal and the steering column shaft with the horn
switch pressed, There should be no continuity.
6 . Removethe two TORX@bolt6 using a TORX@T30

bit, then removethe driver's airbagassembly.
DB|vEN'S
HORNSwlTCH
TERMIITAL
POSITIVE
AIRBAGASSEMBLY
TORXO BOLT
(U!6 s TORxo T3O bitl
a lf there is continuitv:
- With cruise control: Test the set/resume
switch. lJ the switch is OK, replacethe cable
reel.
- Without cluise control: Replacethe cable reel.
a lJ there is no continuity. remove the steering
wheel and the four screws, then remove the
steering wheel cover. Replace the faulty horn
switch.
8.
23-202
vnx.su
Reinstallthe steeringwheel {see section 17).
Horn Test
t . Removethe front bumper (seepage 23-164).
2 . Disconnct the 2-P connector from the hofn.
5.
Remove the horn.
2-P COt{t{ECTOB
MOUNTI G AOLT
4.
Test the horn by connecting battery power to one

terminsland groundingthe other, The horn should
sound.
5.
Reolacethe horn if it fails to sound.
23-203
vnx.su
CigaretteLighter
CircuitDiagtam
UNOER-HOOD
FUSE/RELAY
BOX
No.tgll0Al
FUSE
UIIOER-DASH
FUSE/N[AY
BOX
BI.K
G20t
Gilol
23-204
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Replacement
CAUTIOI{:
a All SRS sloctdcal wiring harnossasare covered whh
yollow insulatlon.
a B.tore disconnoctlng any part ot the SRS yyi16 h.rnosa, connrct tho short connoctot(al.
a Rsplaco th. onti.e !ffoct.d SRS hamoss a$ombly lf
It ha! an opon cilcuit or damagod wiring.
Disconnect the thermotuse case from the socket

no.
3 . Remove the thermal protector. and pull out the

cigarette lighter socket.
CIGARETTELIGHTEN
LTGHT(1.4 Wt
ASHTRAY LIGHT
( r . 4w l
FROI{TCO|{SOLE
THERMOFUSE
CASE
RI G NUT
THERMALPAOTECTOR
Removethe two ashtray mountingscrews. Then pull

out the ashtray from the front console, and disconnect the 4-P connctor,
SOCKET
4 . When installing the cigarette lighter, align each lug

on the face panel, illuminationring, and cigarefte
lighter socket with the groove of the hole, then position the bulb housing on the thermal protector between the stops in the console panel.
Make sure that the ground wire, bulb socket, and
thermofuse housingare seatedto the cigarette lighter assomblv.
scREws
23-205
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.--
Rear Window Defogger

CAUTION:
a All SRS olectrical wi ng ham$6s are covoled with
yllow insulation.
B6foro disconnocting any part of ths SRS wire harness. connoct tho short connector(s).
Roplacsthe ontire affectod SRS harness assombly if
it has an open circuit or damagcd wiring.
REABWINDOW
RELAY
DEFOGGER
Test,page23-68
SRS MAII{ HAR'{ESS

REARWINDOW
DEFOGGERSWITCH
Removal, page 23-209
Test, page 23-2Og
REARWINDOW DEFOGGER
Test, page 23-210
UI{DER.DASHFUSE/RELAYBOX
REARWINDOW DEFOGGERTIMER CIRCUIT
{ln the integrated control unil)
The rear window defoggeris controlledby the integratedcontrol unit, Pushingthe defoggerswitch in the instrument
panel it sends a signalto the defoggertime. in the integratedcontrol unit, and the detoggerstays on tor 25 minutes
or until the ignitionswitch is turned off. The indicatorlight in the switch comes on when the deJoggerworks.
23-206
vnx.su
UNDERHOOO
FUSE,NE[AY
80X
B[K/GRN
I
[ql
t=l
BLK/GRN
trI
;ERI
NOISE
CONDENSER
I'
8LK
I
:
H.tchback:G77
Ssdan:G50
23-207
vnx.su
RearWindow Defogger
Troubleshooting
.E
o.-
9\
c g
*o-< f
o
0to
: E
g o <E
oP
'
Symptom
Defoggerworks, but indicator
light does not go on.
Defogger does not work and
indicatorlight does not go on.
lD
o!
o5
. E 6 ('r6
z i
z )
;5
i i
9 c
5.
o
o
o
o
o
=
3
o
ED
o
o
o-
g8
o o
o5
BLKTYEL
oTBLU/YEL
1
1
Defogger does not work, but

indicstorlight goes on.
Defogger-ontime is too long or
too short (normaloperationtime
is 25 minutes).
G201
G401
'1i G771
YEL, BLUfYELor BLK/YEL

BLU|YELor BLKIYEL
3 ',: G5O3 BLK/GRNoTBLKMHT
1
'1: Hatchback
'2: Sedan
23-208
IINIilfi
vnx.su
Switch Removal
Switch Test
CAUTION: Be caroful not to damags the hoator contlol/centel ail vent.
NOTE: Be caretul not to damage the heate. control/centerair vent.
1, Carefully pry the switch out of the heater contfol/centerair vent.
1. Carefully pry the switch out of the heater control/center air vent.
2.
2.
Disconnectthe 6-P connecto,from the switch.
Checktor continuitybetweenthe terminalsacco.ding to the table.

Torminal
I
P*il*__\
PUSHED
ooo-
RETEASED
D
\../
-\
-o o-
_o
-o
/\
\:,,t
o-
/:\
\7
REARWINDOWDEFOGGER
SWITCH
Remove the indicator bulb (turn the socket 45o

counterclockwise),and removethe illuminationbulb.
REARWINDOW
DEFOGGERSWITCH
[-4
I
) ll:g'",li'T
to.a4wt
23-209
vnx.su
Rear Window Defogger

DefoggerWires Repair
Function Test
NOTE: To make an eftective repair. the broken section

must be no longerthan one inch.
CAUTION: Be carelul not to scratch 01 damago ths

defogger wires with th tsster probe.
1.
Check for voltage between the positiveterminal and

body groundwith the ignitionswitch andthe delogger switch ON. There should be battery voltage.
a lf
-
1.
Lightly rub the area around the break with line steel
wool, then clean it with alcohol.
2.
Carefullv mask above and below the broken portion

of the defoggerwire with cellophanetape.
there is no voltage,check for

laulty detoggerrelay.
faulty defoggerswitch.
faulty integratedcontrol unit.
an open in the BLK/GRNwire
OPEN
a lJ there is baftery voltage, go to step 2.
NEGATIVETERMIiIAL
TERMINAL
POSITIVE
Using a small brush,apply a heavy coat of silverconductive paint extendingabout 3 mm ( 1/8 inl on both
sides of the break. Allow 30 minutesto dry.
NOTE: Thoroughly mix the paint before use.
Turn the rearwindow detoggerswitch OFF,Check
for continuity between the negativeterminal and
body ground.
a It there is no continuity,checkto. an open in the
defoggerground wire.
a ll there is continuity,go to step 3.
Touch the voltmeter positive lead to the halfway
point of each defoggerwire, and the negativelead
to the negativeterminal.
Thereshouldbe apptoximately6 V with the ignition
switch and defoggerswitch ON.
a lf the voltageis as specified,the defoggerwire
is OK.
a lf the voltage is not as specified.repai,the defogger wire:
lf it is more than 6 V, look for the damageon
the negativehalf on the grid.
- lf it is less than 6 V. iook for the damageon
the positivehalf of the grid.
4.
Check for continuity in the repaired wire.
Apply a secondcoat of paint in the same way. Let

it drv three hours betore removing the tape.
23-210
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Moonroof
GomponentLocationlndex
a All SRS oloctrical wiring harnessesaro covared with
yellow insulation,
a Eoforo disconnocting any part of tho SRS wire harneaa, connoct th6 shon connector(sl.
a Roplaceth6 entire 8ff6cted SRS harness assombly if
it has an open circuit or damaged widng.
SRS MAIN HARI{ESS

{Covered with yellow insulation)
MOO BOOFSWTTCH
page23-214
Remov8l,
MOO ROOFMOTOR
Test,pag23-215
Replacoment,
section20
Test, page 23-215
23-211
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Moonroof
CircuitDiagram
- --------f"-----------lo
i|OoNRoOFMOf0R H.rchb.ckl
MoOnOoFttoton 6.ddl
23-212
-
vnx.su
NOTE: The numbers in the table show the troubleshooting sequence.
Itm to be insoected
es
( ! O
EE :
FE3
b 9
. o 6
; g :
'r3
oiSE
<-c
o 9
bE*
F 6
5 : 3
?t;
: - =
iE d
Symptom
-9
- . 9
:t<
o 6 6
z
c
3
9
a
9
t
c
3 E
.9
;o-
<
E-
3tr t
\ f i
3 l
.',
l
ct
z )
t5
dl=
> l
g
o
3E
o
o
o
o
o
o
o
o
o
o
o
o
.::
a-g
o 6
Moonroof does not move,

but motor tums.
Moonroof
does not
move and
motor does
not tum
lmoonroot
can be
moved with
moonroof
wrenchl.
In all switch
positions
With OPEN
switch
with closE
switch
G201
G401
WHT, GRN/BLK,
GRN,BLK
GRN/REO
GRN/YEL
23-213
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Moonroof
FunctionTest
CheckJor continuity between the No. 2 terminal and
body ground.
Removethe dashboardlower cover, and if necessarv, removethe knee bolste..
a ll
a lf
4.
there is no continuity,check for

an ooen in the BLK wire.
poor ground (G201, G4Ol).
there is continuity,go to step 4.
Check tor voltagebetweenthe No. 4 terminal( + )

and No. 2 terminsl{ - ) with the ignitionswitch ON
{ll). There should be battery voltage.
a lf there is no baftery voltage, check tot
- blown No. 1 (3o Al or No. 14 {20 A) fuse in
the under-dashtuse/relay box.
- an open in the wires (GRN/BLK,GRN,WHT)
or loose terminals.
- faulty moonroof relay.
a lf there is battery voltage, go to step 5.
Connectthe No. 4 terminalto the No. 3 terminal,
and the No. 1 terminalto the No, 2 terminalwith jumper wires. The moonrootshouldopen when the ignition switch is turned ON (ll).
KNEEBOLSTER
lf the moonroof ooens, check the moonroof

switch,
ll it doesn't open, removethe headlinetand check
the motor.
DASHBOARD
LOWER
COVER
2.
Carefullypry the switch out of the left side air vent

panel,then disconnectthe 4-P connectorto remove
the switch.
4-P CONI{ECTOR
SWITCH
MOOi{ROOF
. r - - r
l l l 2--t l
f--T
l 3 1 4 l
View from wire side
23-214
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Switch Test
Motor Test
Removethe headliner(see section 20).
1, Removethe dashboardlower cover.

2.
Carefully pry the switch out of the left side air vent
Danel, then disconnect the 4-P connector and remove the switch.
3.
Checklor continuitybetweenthe terminalsin each

switch positionsccordingto the table,
Disconnect the 2-P connector from the moonroot

moror.
Checkthe motor by connectingpower and ground
accordingto the table.
NOTE: Motor clutch test is in section 20.
Torminal
---__\
\
P"ri i-
o- --o
OPN
\
Condition
--o
G-
OFF
Te.minal
-- ---------l
OPEN
G-
CLOSE
o- --o
CLOSE
SWITCH
MOONROOF
lHatchblckl
(Scd!n)
4.
OPEiI
It the motor fails to run or doesn't run smoothly.

replaceit.
,l
Ir\./ dcLos
OFF
23-215
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PowerMirrors
POWERMIRRONS
Test, page 23'220
Repfacement,page 23'221
POWERMIRRORSWITCH
Function Test, page 23'219
Test, page 23-218
23-216
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GircuitDiagram
- HOOO
FUSE/BELAY
UNDER
8OX
*,,^.-**Q
!.,$iii.,i
LEFTT
---il;---;--------------;
ln
rI
G501
G502
23-217
vnx.su
Power Mirrors
Switch Test
Removethe driver's door panel (see section 2O).
Checktor continuitvbetweenthe terminalsin each
Mirror Switch
rermrnal
Position
OFF
G"
UP
o-
DOWN
-o
-o
-o
oo-
OFF
UP
-o
o-
DOWN
G-
tEFT
-(J_
-o
-o
-o
-o
G-
aaaaaaaa
A-------+J
o-
RIGHT
RIGHT
-<>-
o- -o
LEFT
-o
P -o
23-214
vnx.su
FunctionTest
NOTE: To test, removethe driver's door panel (seesection 20), then disconnectall of the connectorsfrom the
door oanel.
View from wire side
Loft mirror inopsrative:

Connectthe BLK/YELterminalof the 10-Pconnectorto
the YEL/RED1
terminaland the YEL/WHT(or YEL/BLKr)
terminalto body ground with jumper wires.
The left mirror should tilt down (or swing leftl when you
turn on the ignitionswitch.
a lf the mirrordoes not tilt down (or does not swing leftl,
check Jor an open in the YEL/WHT (or YEL/BLK1)
wire betweenthe left miffor and the switch. It the wir
is OK, check the left mirroractuator.
a lf the mirro. neithertilts down nor swings left, repair
the YEL/RED1wire between the left mirror and the
switch.
a lf the mirror operates properly, check the mirror
swatch.
Right mirror inoporative:

Connect the BLK/YELterminal of the 1O-Pconnector to
th BLU/WHTterminaland the YEL/WHT{or BLU/BLK)
terminalto body ground with iumper wires.
The right mirror shouldtilt down (or swing left) when you
turn on the ignitionswitch.
a lf the mirrordoes not tilt down (or does not swing left),
removethe right door paneland checkfor an open in
the YELMHT (or BLU/BLK)wire betweenthe right mirror and the switch. lf the wire is OK. checkthe right
mtrroractualor.
Miror Tost
NOTE; Checkthe No. 13 (7.5 A) tuse in the under-dash
fuse/relaybox beforetesting.
a ll the mirror neither tilts down nor swings lelt, repair

the BLUMHT wire between the right mirror and the
switch.
a lf the mirror operates properly, check the mirror
swatch.
Ono or both inoprativa:

1.
Checkfor voltagebetweenthe BLKIrEL terminal8nd

body ground with the ignitionswitch ON (ll).
a lf there is no voltage,check tor:
- Blown No. 13 {7.5 A) fuse in the under-dash
fuse/relav box
- An ooen in the BLK/YELwire
a It there is battery voltage, go to step 2.
2.
Checkfor continuitybetweenthe BLKterminaland

body ground.
There should be continuity;check Jor:
- An ooen in the BLK wire
- Poor ground (G501, G5O2)
23-219
vnx.su
Power Mirrors
Door MirrorTest
1,
Removethe mirror panel and door panel (Sed8n).

then disconnect the 8-P (Hatchback)or 3-P (Sedan)
connector from the power mirror actuator.
TILT:
Terminal
Position
Sedan:
'|(H)
2(G)
UP
DOWN
tJ
SWING:
MIRNOR
Terminal
Position
LEFT
RIGHT
Hatchback:
3.
Check actuator operation by connecting power and

ground accordingto the table.
23-220
vnx.su
2(G)
3(Ft
o
(D
lf the mirror fsils to operate properly, replace it.
PowerMirror Replacement
l.
Carefully pry out the miror panel with a llat tip

screwdrivr.
2 . Remove th door panel (see section 20).

HEtchblck:
hca! hara to
rolalaa lha conn9clor
MIRRORPA]IEL
CO
ECTOR
Disconnectthe 8-P (Hatchbck)or 3-P (Sedan)connector from thg oower mirror actuator.
4.
While holding the mirror with one hand, remove its

mounting nuts (Hatchback) or mounting screws
(Sedan) with the other.
23-221
vnx.su
PowerWindows
POWERWINDOWRELAY
Test, page23-68
FOWERWINDOW
MASTERSWITCH
{Has built-in control unitl
fnput Test, page 23-226, 228
Tost, page 23-229, 23O
Ropfacement,page 23-231
UI{DER-DASH
FUSE/RELAYBOX
WII{DOWSWITCH
FRONTPASSEI{GER'S
Test, page23-230
Repfacement. page 23-231
FRONTPASSENGER'S
WII{DOWMOTOR
fosr, page 23-232
RIGHTREARWll{DOWSWITCH(Sodrn}
Tost, page23-230
page23-231
Replacement,
RIGHT REARWII{DOW
MOTOR (Sod.nl
Test, page 23-232
DBIVER'SWINDOW MOTOR
Test, page 23-232
LEFT REARWINDOW MOTOB {S6dan)

Test. page 23-232
LEFT REAR Wlt{DOW SWITCH lsodanl

Test, page 23-230
23-222
vnx.su
CircuitDiagram(Sedanl
DASHFUSE/RELAY
BOX
UNDER_
UNOER-HOOO
FUSE/RELAY
8OX
DRiVER'S
WINOOW
MOTOR
RIGHT
REAN
WINOOW
MOTOR
LEFTREARWINDOW
MOTOR
FROI{T
PASSENGER'S
wrNoow
i,roToR
G501
G502
G20r
G401
23-223
vnx.su
PowerWindows
Circuit Diagram(Hatchback)
- HOODFUS/REI.AY
UNDER
BOX
UNOEROASHFUSE]NEI.AY
8OX
tlo.41l100Al ilo.39{50A)
8LXz
D PASSENGER'S
wrNDow
swITcH
PASSENGEN'S
wtN00wM0T0n
G50t
G502
23-224
vnx.su
G401
Troubleshooting
NOTE: The numbers in the table show the troubleshooting sequence
Item to be insoected
o
1 0 x
9 I
3E
<.i
S H
r!
Symptom
(t
o
SJ
t5
;
o-
3
I
-g
z )
9 c
.=
'
,i
E
!
F\
;
z
i
t
o
qt
i
o-
E
3
o
E
3
t
o
;
.=
;
E
3
t
=
()
I
a
o-
o-
x
.9
E
3
.E
: !
g 3
' . c
O E
All windows do not work.
G20r
G401
G50l
G502
Driver's window does not
Driver'swindow does not

work in AUTO.
Passengsr's Right tront
windows do *Lett rear
not work.
r Right rea.
WHT/YEL
BLU,
BLK/WHT
1
1
5
I
BLK/YEL
WHT/RED
BLUi BLK
GRN/BLK
YEL/BLK
23-225
vnx.su
PowerWindows
Master Switch Input Test (Sedan)
NOTE; The control unit is built into the Dowerwindow
maste. switch, and onlv controlsdriver'sdoor window
ooerations.
1. Removethe driver'sdoor paneland disconnectthe
16-P and 1-P connectorsfrom the master switch.
2.
Inspectthe connectorand socket terminalsto be

sure they are all makinggood contact.
a lf the terminalsare bent, looseor co.roded, reDair
them as necessary.and techeckthe system.
a It the terminalslook OK, make the following input tests at the connecto..
- It a test indicatesa problem,tind and correct
the cause,then recheckthe system.
- lf allthe input tests proveOK, the power window masterswitch must be faulty; replaceit.
BEDI'EL
8LU/YEL I
I GRN
YEL/BLK
View from wire side

View lrom wire side
23-226
vnx.su
Test condition
BLK2
ano
BLK3
WHT/YEL lgnitionswitch ON (lll

BLU/BLK
Tst: Desirod rosult
Possiblcause if result is not obtainad
Check for continuityto ground: . Poorground{c501, G502)

. An openin the wire
There should be continuitv,
The.e should be battery voltage.
GRN/BLK
YEL/BLK
Blown No. 14 (20 Al fuse in the

Bfown No. 5, 8, 7 ot 4 l2O Al fuse
in the under-dashfuse/relay box
Faulty power window relay
An open in the wire
Connect the WHT/YEL

and RED/YEL1
terminals,
RED/BLU1
and the RED/BLU1
and
ano
BLK3terminalswith jumREDATELl
per wires, then turn the
ignitionswitch ON (lll.
Check the driver's window

motor:
It should run (the window
moves down).
. Faulty drivea'swindow motor

Connectthe BLU/BLK
and BLU/GRNterminals,
BLU/YEL
and the BLU/YELand
and
BLK, terminalswith jumBLU/GRN
ignitionswitch ON (ll).
Check the tront passenger's

window motor:
It should run {the window
moves down).
. Faultyfront passenger'swindow
motOa
Connect the GRN/BLK

and GRN terminals,and
GRN/YEL
the GRN/YELand 8LK,
ano
terminalswith iumper
GRN
wires, then turn the ignition switch ON (ll).
Check the left fear window

motor:
moves down).
Faulty left rear window motof

Faulty lett rear window switch
An oDenin the wire
Connectthe YEL/BLK
and YEL/GRNterminals,
YEL/GRN
and the YEL and BLK,
and
terminalswith iumper
YEL
wires, then turn the ignition switch ON (ll).
Check the right rear window

motor:
moves down).
Faulty .ight rea. window motor

Faulty right rear window switch
An open in the wire
Connectthe WHT/YEL
and RED/YEL1
terminals.
BLU
and the REo/BLU1and
ano
BLK3terminalswith jumBLK/VVHT
per wires. then turn the
Conned an analogohmmeterto
te.minalsBLU and BLK/wHT:
The meter needleshould move
back and lorth alternatelvas
the driver's window motor runs.
Faulty pulser
Faultydriver's window motor
An open in the wire
23-227
vnx.su
Power Windows
MasterSwitch lnput Test (Hatchback)
NOTE: The control unit is built into the power window
master switch, and onlv controls driver's door window
operations,
1. Removethe driver'sdoor panaland disconnectthe
1O-Pconnectol from the masterswitch.
2.
lnsDect the connector and socket terminals to be

a lf the terminsls arc bent, loose or corroded,rspair
them as necessary, and recheck the system.
a lf the terminals look OK, make the following input tests at the connector terminals.
- lf a test indicates a problem, find and correct
the cause, then recheck the systsm.
- lf all the input tests proveOK, the powsr window master switch must be faulty; replace it.
Wiro
1
BLK'
Tost condition
RED/YEL
RED/BLU
BLU/GR'{
BLU/BLK
View from wirs sido
Tost: Dashodrsuh
PGslblo cluso if rosuh ir not obtalnad
Underall conditions
Chck for continuity to ground:

Poor ground (G501, G5O2)

An oDen in the wire
lgnitionswitch ON {ll)
Ch6ck for voltags to ground:

Thre should be battery voltage.
Blown No. 14 l2O Al fuse in the

under-dashfuso/relay box
Blown No. 5, or No. 8 (2O A) tuse
in the under-dashluse/relay box
Faulty power window relay
An oDen in the wire
8LK3
WHT/YEL
BLU/BLK
Connectthe WHT/YEL
and REDfYELIterminals,
RED/BLU1
and the RED/BLU1
and
ano
BLK3terminalswith jumRED/YELI
ignitionswitch ON {ll).
Check the driver's window

motor:
moves down).
. Faulty driver's window motor

. An ooen in th wire
Check ths passengor's window

motor:
moves down).
. Faulty passnger's window motor

. An oDn in the wire
Connectthe BLU/BLK
and BLU/GRNterminals,
BLU/YEL
and the BLUTYEL
and
and
BLK2terminalswith jumBLU/GRN
ignitionswitch ON {ll).
connect the WHTTYEL

and BEDrYELIterminals,
and the RED/BLU1
and
BLK3terminalswith jumpe. wires, then turn the
BLU
anq
BLKMHT
Connct an analog ohmmeter to

thE BLU ANd BLKMHT tTr
minals:
The meter needle should move
back and torth alternately as
th driver's window motor runs.
23-228
vnx.su
Faulty pulser
Faultv driver's window motor
An oDenin the wire
MasterSwitch Test (Sedan)

1.
Remove the driver's door pan6l (sse section 2O).
2.
Disconnct the 16-P and l-P connectors trom the

switch.
3.
Check for continuity btwn tho terminals in each

switch position according to the tables.
Front Paslongrr't Swltch:

Terminal
\
I Main \
Position I Swirch \
OFF
UP
DRIVER'S
SWTCH
ON
o-
OFF
G--
ON
OFF
LEFTREAR
MAtit swtTcH
DOWN
POWERwl DOW
MASTEBSW]TCH
Lcft Rear Swhch:

Terminal
\
j Main I
Position I Switch \
swtTcH
OFF
ON
OFF
RIGHT REAN SW|TCH
UP
ON
ut'f
A B C D E
DOWN
O-
o-
ON
OFF
PASSEI{GER'S
ON
OFF
o- -_o
E
r)
--o
--o
--o
o- --o
o- o --o
o- --o
--o
o--o
o--o
oo- --o
G- --o
-o
Rlght Roar Swhch:

Teminal
\
If
I Main
Position I Switch \
OFF
OFF
UP
OFF
Ddv.r't Swh.tr;
Th6 drivr's switch is combined with the cont.ol unit so
you cannot isolatethe switch to t6st it. Instead , run the
maater switch input test procedurss No. 1, 2. 3, and 7
on page 23-226. lf the tests are normal, th6 driver,s
switch must be fsulty.
DOWN
ON
OFF
o --o
o- --o
--o
--o
G_
ON
ot'l
--o
o-
---o
o-
o- --o
G-
--o
o- -o
23-229
vnx.su
Power Windows
Window Switch Test
Passenger's
Master Switch Test (Hatchbackl

1 . Removethe drivef's door panel (seesection 201.
Front:
1 . Removethe passenger'sdoor panel {seesection 20).
Oisconnectthe 1O-Pconnectorfrom the switch.

Checktor continuitybetweenthe terminalsin each
2.
3.

switch positionsccordingto the table.
pOWERWTNDOW PASSENGEB'S
MASTERSWTTCH SWITCH
Torminal
il;_\
i 1 \ i
OFF
o-
\4r-I^l,r
)rvti\
--o
o- --o
UP
G_
.Fi'ilj
Passengsl'r Switch:
Te.minsl
\
I Msin \
Position I Switch\
ON
OFF
OFF
UP
ON
OFF
ON
DOWN
OFF
Rear (Sedanl:
1. Removethe innr handle (seesection 2O)'
2,
3.

--o
o- -o
o---o
oo- -o
-o
o--o
o-o
o-
o-
--o
o- --o
DOWr.l
Drive.'s Switch:
The driver'sswitch is combinedwith the controlunit so
you cannotisolatethe switch to test it. Instead, run the
masterswitch input test proceduresNo. 1, 2, 3, and 5
on page 23-228, lf the tests are normal, the d.ivet's
switch must be faultv.
(J
Terminal
OFF
UP
DOWN
23-230
vnx.su
;;__\
G_
G_
--o
--o
o-
o-
--o
o- --o
--o
o-
Master Switch Replacement
Passenger's
Window Switch
Replacement
Hatchback:
Flont:
1. Removethe driver's door panel (seesection 20).
1.
Removethe passenger'sdoor panel (seesection 201.
2.
Disconnectthe 1O-Pconnectorlrom the switch,
2.
3,
Removethe threemountingscrewsand the switch.
3.
Removethe two mountingscrews and the switch.
swtTcl{
Roar (S6danl:
Sedan:
1.
Removethe inner handle(see section 20).
1. Removethe driver's door panel (seesection 2O).
2.
2.

switch.
3.
3.
w|I{Dow
.swtTcH
POWERMIRROR
swtTcH
INNERHANDLE
scREws
23-231
vnx.su
Power Windows
Window Motor Test
Passenger's
Driver'sWindow Motor Test
Removethe passenger'sdoor panel (seesection 20).
Motor Test:
l.
1 . R e m o v et h e driver's door panel (seesection 20).
2 . Disconnectthe 2-P connectorfrom the motor.
2.
NOTE:
a Frontpassenger'sdoor is symmetricaltodriver's
ooor.
a The illustrationshows the right reardoot, left rear
door is svmmetrical.
Disconnectthe 4-P connectortrom the motor.
. ,-,.f,/ll/
NZJI
I
..Q]qql,fiftl\ I
$e /tE \
2.P CONNECTOR
View from lerminal side
4.P CONNECTOR
3.
Test the motor in each directionby connectingbattery power and ground accordingto the table.
Terminal
(B)
Direction
B
{A}
UP
DOWN
@
3.
Test the motor in each direction by connecting battery power and ground accordingto the table.
Terminal
\
O***
UP
DOWN
{ }: Sodan
CAUTION: When the motor stops running. disconnect one lead immediately.
4.
lf the motor does not run or tails to run smoothly,

replaceit.
PulserTest:
5.
6-
CAUTION: When the motor stops tunning. disconnect on lead immdiately.
Connectthe test leadsof an analogohmmeterto the

C and D terminals.
lf the motor does not run or Jailsto run smoothly,

reDlaceit.
Runthe motor by connectingpower and groundto

theAandBterminals,
The ohmmeterneedleshouldmove back and torth
alternately.
23-232
-'
vnx.su
Power Door Locks

FRONTPASSENGER'S
DOORKEY
CYLII{DER
SWITCH
Test,page23-240
FRONTPASSENGER'SDOOR LOCK ACTUATOR
Test. pago 23-239
Reolacement.section 20
RIGHT REAR DOOR LOCK ACTUATOR lsodanl

Test,
23-239
LEFT REAR DOOR LOCK ACTUATOR {Sodan}
Test, page 23-239
FRONTPASSENGER'S
DOOR LOCK SWITCH
fest, page 23-241
1
DOOR
KEY CYLINDERSWITCH
Test. page 23-24O
DBIVER'S
LOCK ACTUATOR
Test, page 23-238
Roplacement,seclion 20
DOOR
LOCK SWITCH
'lest, page
23-241
POWEROOOR LOCK
CONTROLUNIT
fnput Tost, page 23-236
Description
For this model, a new door lock system has been adopted to improve convenienceand safety. lf the kev is insened into
the driver'sdoor key cylinder,turned to the unlock position,and pulledout immediatelythereafter,oNLy the driver.s
door will unlock. However,if the key is kept in the unlock positiontor one secondor more, ALL doors wi unlock.
23-233
vnx.su
PowerDoorLocks
CircuitDiagram
FUSE/RELAY
BOX
UiIDER-HOOD
BATTENY
No.41l100Al iJo,36l50A)
@'"t
DRIVER'S
OOOB
KEYCYI,INDER
swITcH
DRIVER'S
oooRrocK
swtTcH
o00Rtoc( KN08
L____
I
FRONT
PASSENGEN'S
DOOR
LOCK
OOOR
POWER
LOCKCONTROI.
swncH
FROMT
PASSENGER'S
oooRt-ocK
ACIUATOR
@r
I uFt REAR
000RLocK
ACTUATOR
@"
r RIGHT
REAR
000RLocK
ACTUATOR
@'
G501
G5o2
BLK
8rl(
8LK
.&
A
-l
G201
G401
GSot
G502
G501
G5o2
23-234
I
vnx.su
Troubleshooting
Item io be inspected
=
3-
-9
-.9
)x<
.=
3
o
o
:
o o
St
o o
z )
It
9 c
Symptom
Doors don't lock or

unlock with the
driver's door lock
switch.
All doors
Doors don't lock or

unlock with the
passenger'sdoot
lock switch.
All doors
O n eo r
more doors
One or
more ooors
Doo.s don't lock or

unlock with the
driver's door lock
knob.
All doors
Doo. don't lock o.

unlock with the
passenger'sdoot
key.
All doors
Doors don't unlock

wilh the driver's
door key.
One or
more ooors
o'o
;-s o
TL
(L
G501
1
- c
o-
G501
G502
WHT/GRN
GRN/REDor
GRN^/lr'HT
WHT/RED
or
YEL/RED
G 2 0 1 BLK/RED
or
G 4 0 1 BLK/WHT
WHT/REDor
YEL/RED
G501
G502
BLU/REDor
BLU/WHT
WHT/REDor
YEL/RED
O n eo r
more doors
Oriver's
ooor
'All doors
o)
O E
dl=
Power door lock system doesn't

ooerateat all.
9 E
G 2 0 1 L T G R No r
G401 LT BLU
WHT/RED
or
YEL/RED
G501
G502
BRN,WHT/RED
or YEL/RED
Gsol BRN,WHT/RED
G502 or YEL/RED
+ It the system is working normally,lldoorswill unlockwhen you

holdthe door key in the unlockposition(kev cvlinder
switch and door lock knob switch turned ON) for one secondor more.
23-235
vnx.su
Power Door Locks

Control Unit Input Test
Removethe driver's door panel {see section 2O).
Disconnectthe 1+P connectorJromthe control unit.
Inspectthe connectorand socket terminalsto be
a It the terminalsare bent. loose or corroded,repair
them as necessary.and recheckthe system.
a lf the terminalslook OK. make the following input tests at the connector.
- lf any test indicatesa problem,find and correct the cause,then recheckthe syslem.
lf all the input tests proveOK, the controlunit
must be faultv; replace it.
POWERDOORLOCK
UNIT
CONTROL
t4-P COI{NECTOR
View from wiro side
23-236
vnx.su
Disconnectthe 14-P connectorfrom the power door lock control unit.

I{o.
Wire
BLK
Tost condltlon
Connectthe YEL/RED
tarminal to the WHT/
GRN terminal,and the
WHT/REOterminalto
WHT/REDthe BLK terminsl
momentarily.
2
and
YEL/RED Connectthe WHT/RED
terminal to the WHT/
GRNterminal,and the
YEL/REDterminalto
the BLK terminal
momentarilv.
Test: Dosirsd rosult

Check tor continuity to ground:
Check door lock oDeration:
All doors should unlock.
Possibls cause if rosult is not obtainod

. Poor ground (G501, G502)
Faultv actuator
An open in the wire
Blown No. 6 (2O A) fuse in the
Check door lock ooeration:

All doors should lock.
Reconnecttho 14-Pconnectorto th6 powor door lock control unit.

t{o.
Wlro
WHT/GRN
Tost: Dolir6d r6auh
Posslblo caus6 it rosuh is not obtainod

. Blown No. 6 {2O A) fuse in the
Check tor voltage to ground:

There should be battsry voltage.
GRN/WHT
Driver's door lock

switch in LOCK
Check for voltagg to ground:

There should be I V or less.
GRN/RED
Driver's door lock

switch in UNLOCK
Faultv driver's door lock switch

An oDenin the wire
BLK/wHT
Right tront door lock

switch in LOCK
Check for voltage to ground;

There should bs 1 V or less.
BLK/RED
Right lront door lock

switch in UNLOCK
Faulty front passenger's door lock

switch
An ooen in the wire
BLUMHT
Driver'sdoor lock knob Check for voltage to ground:

in LOCK
BLU/RED
Driver'sdoor lock
knob in UNLOCK
Faulty driver'sdoor lock actuator

An ooen in the wire
Tost condition
Driver'sdoor key
cylinderin UNLOCK

There should be 1 V or less as
the switch is turned.
Faulty d,iver's door key cylinder

switch
Poor ground {G501, G5O2l
An open in the wire
LT BLU
Front passenge.'sdoot
key cylinderin LOCK
LT GRN
Front passenger'sdoor
key cylinderin UNLOCK

There should be 1 V or less as
the switch is turned.
Faulty tront passenger's door

cylinde.switch
Poo. ground (G201, G401)
An oDen in the wire
BRN
CAUTION: To provonl damago to tho molor, rpply battory voltago only momrntadly.
23-237
vnx.su
Power Door Locks

Driver'sDoor Lock Actuator Test
1 . Removethe door panel (seesection 20).
5.
Check fo. continuity between the terminals in each

Disconnectthe 6-P connectorfrom the actuator.
Terminal
LOCK
UNLOCK
DOORLOCKKI{OB
Checkactuatoroperationby connectingpower and

ground accordingto lhe table.
Terminal
---\
;;"
LOCK
UNLOCK
lJ
il;----t
CAUTION: To prevont damagolo tho actualol, apply battery voltage only momentarily.
lf the actualor fails to work properly,replaceit.
23-238
vnx.su
o
o-
-o
Passenger'sDoor Lock Actuator Test

1.
Removethe door panel (seesection

20).
s
Rear Passenger's Dool:
2.
Disconnectthe 2-P connector

r from the actuator.
NOTE: Left rear actuato, is shown, right rear actuator

is similar.
Front Passonger's Door:
terminalside

Checkactuatoroperationby connectingpower and
Terminal
B
Position
2-P
CONNECTOR
LOCK
UNLOCK
ACTUATOR
@
,-,
CAUTION: To prevent damageto the actuator, apply battery voltage only momentarily.
4.
It the actuatorfails to work properly,replaceit.
23-239
vnx.su
Power Door Locks

DoorKeyGylindet
FrontPassenger's
Switch Test
Driver's Dool Key Cylinder

Switch Test
1.
Removethe door panel (see section 20).
1. Removethe door Danel{see section 2O).
2.
2.
Disconnectthe 3-P connectortrom the switch.

FRONT
PASSENGER'S
DOOB KEY
CYLINDER
swtTcH
coN ECIOR
terminalside
3.

Terminal
Position
UNLOCK
3.
Check tor continuitv between the terminals in each

Terminal
P""ft;---l
LOCK
----o
OFF
OFF
UNLOCK
UNLOCK
UNLOCK
<
-r--O
I
I LOCK
tfil*rr
23-240
vnx.su
----o
Door Lock Switch Test

1. Removethe insidehandle.

termtnal
\
Position
LOCK
OFF
UNLOCK
23-241
vnx.su
CruiseControl
a All SRS 6l6ctrical wiring harnessosaro covorod with
yallow insulation,
a Bofo.6 disconnecting any part of th6 SRS wire harness, connoct th shon conneclor(s).
a Replacothe ontiro affected SRS halness assombly if
it has an opn circuit or damagod widng.
SRS MAIN HARNESS

(Cov.rod wilh yollow In.ulation)
MAINSWITCH
Test, page23-250
page23-250
Replacement,
CRUISELIGHT
(Builtinto gaugeassembly)
Bulb Locations,page 23-115
SET/RESUME
SWITCH
Test. page23-248
page23-248
Repfacemont,
BRAKESWITCH
Test. page 23-251
CLUTCH SWITCH (M/TI
Test, page 23-251
CRUISECONTROL
A/T GEAR POSITIOI{
swtTcH
Test, page 23-136, 252
23-242
vnx.su
ACTUATORASSEMBLY
Test,page23-253
CableAdjustment,
page23-253
23-243
vnx.su
CruiseGontrol
CircuitDiagram
+ No.24
onoine
ll5Al:81881
No.24
ensine
l20Al:818C1
_HOODFUSE/RELAY
BOX
UNOER
FUSE/RELAY
BOX
UNDER-DASH
No.4l(100A)No.39l50A)
HORN
Y
INDICATOR
TIGHT
{0,91W}
IP
I D Suur
PNK
BTK
II
I
f7
VEHICLE
SPEED
SENSOR
iVSS)
6yffi
M/r : CLUTCH
SWITCHI
A/T: A/TGEAR
I
POS|T|oN
SWTTCH
I
Bi,G#,,'.
InIEI,E)
G201
G401
G201
G401
BI-K
23-244
vnx.su
Troubleshooting
NOTE:
a The numbersin the table show the troubleshootingsequence.
a Beforetroubleshooting,
- check the No.15 {10 A) and *No. 24 fuses in the under-dashfuse/relaybox, and the No.41 (1OOA), No.39
(50 A). and No.42 (20 Al fuses in the under-hoodfuse/relavbox.
- check that the horn sounds.
check the tachometerto see if it wo.ks pfoperly.
*No.24 {15A): Bl8B1engine
N o . 2 4 { 2 OA } : 8 1 8 C 1 e n g i n e
!
F
o)
'F
c
E
c
U)
.!o
-c.
!
Symptom
oi
a
a
E
c
3
.9
:
'.E
_q
E
dl
.9
_9
E
.E
o
2
'9o1 E
l
L
og
BLU/GBN,LT GRN/RED.
Cruisecontrol cannot be set.
G301,
BLU, BLK/YEL,LT GRN,
G201,
GRY, ORN. BRN/WHT,
G401
BRN/BLK,BRN/REDor PNK
Cruisecontrol can be set, but

indicatorlight does not go on.
Cruisespeed is noticeablyhigher
or lower than what was set.
Excessiveovershootjngor
undershootingwhen trying to set
speed
Steady speed is not held even on

a flat road with cruisecontrol set.
3
2
Set sDeedis not cancelledwhen

clutch Dedalis oushed(M/Tl.
LT GRN/BLK
LT GRN/RED
,1
Set sDeed is not cancelled when

shift lever is moved to fM tnnt.
Set speed is not cancelledwhen

brake pedal is pushed.
Set speed is not cancelledwhen
main switch is pushedOFF.
Car does not decelerateor

accelerateaccordinglywhen SET
or RESUMEbutton is pushed.
G201,
YEL or RED/BLU
G401
'I
2
2
Set speed is not resumedwhen

RESUMEbutton is pushed(with
main switch on, but set speed
temporarilycancelled).
LT GRN/BLK
LT GRN/RED
23-245
vnx.su
CruiseControl
ControlUnit Input Test
CAUTION:
a All SRS olectrical wi ng harnessosare covored with
yellow insulation.
a Botore disconnecting any part of th6 SRS wire harneaa, connect the short connoctor(sl.
a Roplacethe ntir affectod SRS hamass assembly il
il has an opan circuit or damaged wifng.
1,

(see page 23-70).
2.
Disconnectthe 14-Pconnectortrom the control unit.

Insoectthe connectorand socket terminalsto be
a lf the terminalsare bent, loose or corroded,repair
them as necessary,and recheckthe system.
a It the terminalslook OK, make the following inDut tests at the connector.
- It any test indicatesa problem,find and correct the cause.then recheckthe svstem.
- lf allthe input tesls proveOK, the controlunit
must be faulty; replaceit.
SRS MAIN HARNESS
CRUISECONTROLUNIT
14-P COI{NECTOR
Viow from wire side
23-246
vnx.su
tlo.
Wlfe
BLK
BLKryEL
Tost condition

LT GRN

and main switch ON

There should be battery voltge.
GRY
lgnitionswitch ON lll),
main switch ON and
brake pedal pushed,
then released
Check for voltageto g,ound;

There should be O V with the
pedal pushedand battery
voltage with the pedal released,
Brakepedal pushd,
then rleased
Check tof voltage to ground:

with the pedal pushed,and O V
with the Dedalreleased.
Blown No. 42 l2O Al tuse in the

Faulty brake switch
An open in the wire
Connectto ground; Indicator

light in the gauge assembly
comes on.
Blown bulb
B l o w nN o . 1 5 ( 1 0 A ) f u s e i n t h e
Faulty dimmingcircuit in the gauge
assembly
An open in the wire

Faulty SET/RESUME
switch
Faultycable reel
An open in the wire
MT/: Clurch pedal

released
A/T: Shift lver in -[Zl,

NOTE:There should be no continuity when the clutch pedal is
depressed or when the shift
lever is in other positions.
Faulty or misadiustedclutch switch

(M/T)
Faulty A/T gear position switch
(A/T)
Poor ground (G201,G4O1)
An open in the wire
Start the engine.
Chsck for voltageto ground:

and main switch ON;
rsise the front of the
car, rotat one wheel
slowly.
Check Jor voltage between the

ORN @ and BLK O terminals:
There should be O- about
1 0 V - O - a b o u t 1 OV
repeatedly.
RED/BLU
LT GRN/ RESUME
button
pushed
BLK
LT GRN/
RED
11
. P o o rg r o u n d( G 2 0 1 ,G 4 0 1 1
. Blown rNo. 24 fuse in the underdash fuse/relay box
. Faulty main switch
. Faulty brakeswitch

10
Possibl6caus it losult is not obtained
GRN/wHT
Tost: Desired rosult
PNK
BLU
ORN
SET button pushed
lD:I,orlE.l
. Faulty ignitionsystem or ECM

. Faulty vehiclespeed sensor(VSSI
. An oDen in the wire
'12 8RN/WHT Connect battery power
Check the sound of the actuator

motor: You should hear the motor runningsmoothly.
. Faulty actuator
. An opsn in the wire
Connect battery power

1 4 BRN/RED to the BRN/RED
terminal.
*No. 24 (15 Al: 81881 engine
N o . 2 4 l 2 OA ) : 8 1 8 C 1e n g i n e
Check the operation of the magnetic clutch: Clutch should click

and output link should be locked.
Faulty actuator
An open in the wire
Poor ground (G3O1)
to the BRN/WHT
terminaland ground to
1 3 BRN/BLK the BRN/BLKterminal.
23-247
vnx.su
CruiseGontrol
Set/ResumeSwitch Test/Replacement
CAUTION:
a All SRS ol6ct cal widng herne$a3 err covorod with
y6llow insulation.
a Bototo disconnecting any part ot tho SRS wiro h8rn6sa, connoct tho ghort connector(sl,
a Rsplacothe antire aftected SRS harness arsombly if
it has an op6n chcuit or damagod wiring.
SRS MAIN HARNESS

circuit, Be sureto get the customer'scode numberbefor
- removingthe No. 32 (7.5 A) fuse from the under-hood
fuse/relay box.
Afte, service, reconnect power to the radio and turn it
on. Whenthe word "CODE" is displayed,enterthe customer's s-digit code to restore radio opration.
1.
Disconnectthe battery negativecable, then disconnect the Dositive cable.
2.
Connectthe short connector(s)to the airbag(s).
DRIVER'S
AIRBAG
3-P CONNECTOR
SHORT
CON]TECTON
(REDI
3.

(seepage 23-70).
4.
Oisconnectthe cable reel harness6-P connector

from the SRSmain harness,then connectTest HarnessC onlv to the cablereelside of 6-P connector.
CABLE REEL
CONNECTOR
lHlrnoa!
Eidol
ACCESS
PANEL
23-248
vnx.su
5.
Check lor continuity between the terminals of Test

HarnessC in each switch positionaccordingto the
table.
Terminal
Position
SETIONI
RESUME
{ONI
7.
Remove the two screws and remove the switch.
8.
Check lor continuitv between the terminals in each

o- ---o
---o
o-
a lf there is continuity, the switch is OK.

a lf there is no continuity, go to step 6.
6,
Remove the cover carefully by prying between the

cover and the switch in the sequenceshown.
Tominal
A'
Position
OFF
SFT(ON)
RESUME
ION)
\_r-
oo-
-o
---o
a lf there is no continuity in any position, rsplace

the switch,
CRUISE
CONTROL
SET-RESUME
swtTcHcovEF
a lf thsre is continuity in every position, replacethe

cable reel (see psge 23-302).
23-249
vnx.su
CruiseGontrol
Main Switch Test/Replacement
NOTE: Be carefulnot to damagethe switch and the instrument oanel.
1.
Removethe instrumentpaneltrom the dashboard

(see page 23-1 18).
2.
Removethe switch from the dashboard,then disconnect the 5-P connecto,.
3.
Ch6ck for continuity betwon the terminals in each

Tenninrl
A
P".ii";--\
-o o-
OFF
A
ON
/a
A
\7
-o
a lf thera is no continuity in any position, replace

th switch.
y' ucsr
rxorcaToR
UCI{T
[ ()
to.grwl \ 7 lo.grwl
A B C D E
23-250
vnx.su
BrakeSwitch Test
'1.
2.
GlutchSwitch Test (M/T)
Checkfor continuitvbetweenthe terminalsaccording to the table.

2.
Terminal
Disconnect the 2-P connectorfrom the switch,
il"*on---\
BELEASED
PUSHED
Check{or continuitvbetweenthe terminalsaccording to the table.
o-
-o
--o
| ormtnal
Clutchpodal
RELEASED
PUSHED
3.
It necessary,replacethe switch or adjust pedal

height {see section 19).
3.
lf necessary,replace the switch or adjust pedal

height (seesection 12).
23-251
vnx.su
CruiseControl
A/T GearPositionSwitch Test
1 . Removethe center console,then disconnectthe
14-P connectortrom the switch.
View trom terminal side

A

NOTE:
a Move the lever back and forth at each position
without touchingthe button, and check for continuity within the rangeof free play ot the shift
lever.
a ll there is no continuitywithin the rangeof free
play, adjustthe installationposition of the switch.
A/T Gear Position Swhch (For cruis control)

\
Terminal
il;---t
tr
a
E
lu4l
o
o
o
3.
lf necessary,replacethe switch (seesection 13).
---o
B
E
23-252
vnx.su
Actuator AssemblyTest
Actuator CableAdjustment
1 . Disconnect the 4-P connector from the actuator.
Check that the actuator cable operaressmoothtv

without bindingor sticking.
2 . Check that the output linkage moves smoothly.
Start the engineand warm it up to normaloperating

temperature(radiatorfans come on twicel,
3 . Connect battery power to the D terminaland ground

to the A terminal,
Measurehow far the output linkage moves from the

fully closedposition.Freeplay shouldbe 1 1 1 1.5
mm (O.43 I 0.06 in).
ACTUATOR
FREEPLAY:
1 1 I 1.5 mm (0.43 r 0.06 int
FULLYCLOSED
POSITION
4.
Check for I clickingsound trom the magneticclutch,

and that the output linkage is locked. lf the outDut
linkageis not locked, replacethe actuator asssmblv.
4.
Check the operation oJ the actuator motor in each

output linkago position according to the table (you
should be able to hear the motor).
Battery
polarities
Output linkage
position
lf the free play is not within specs,loosenthe locknut and turn the adjustingnut as required.
NOTE: lf necessary,checkthe throttlecontrolsystem {seesection 1 I }, then recheckthe output linkage free play.
5.
Retightenthe locknut and recheckthe free play.
FULLY M I D D L E FULLY
CLOSED POStTtON OPEN
The
B
Terminal Terminal molor
runs.
The
molor
runs.
The
molor
srops.
The
I
Terminal Terminal motor
stops.
The
motor
runs.
The
motor
runs.
FULLY CLOSED
23-253
vnx.su
Wipers/Washers
WINDOW
WII{DSHIELD/REAR
SWITCH
WIPERAA'ASHEB
Test,page23-258
Replacement,
oase23 257_..
wtNosHlELDWIPER
ARMS/BLADES ___-=4,
Repfacemont,
Page23'261 /tt'
2
/
WINOSHIELD
IVIPERMOTOR
Test, page23-260
paee23-281
Repfacement,
FUSE/RELAY
BOX
INTERMITTENTWIPER
BELAY CIRCUIT
(ln the intgral.d control onitl
REARWII{DOW WIPERMOTOR
Test, page 23-262
pago 23-263
Replacemont,
23-254
vnx.su
Circuit Diagram
UNOERDASH
FUSE/RELAY
BOX
- HOOO
UNOER
FUSENEUY
8OX
WHT/ll-X-FWHr
GRX/4X
WII{DSHIID
WIPERAIVASHER
S1VITCH
si 4.t,,1/'i;",ry)"'.,
8tK
REAR
WINOOW
WIPER
MOTOR
REARWINOOW
WIPER/WASHER
swtTcH
l*_
(ittwA!
Mor
8LK
BLK
REAR
wtN00w
WASHER
MOTOR
|-
8LK
BLK
G30l
G20r
G503
G101
G20'I
G401
G30l
. : whh comtinadwchar-wllbr olrnlirn
23-255
,r-
vnx.su
Wipers/Washers
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence
Item to be insDected
6
i
0,
(t
'96 ;5
a.P
> ;
e b
bE
: 6
rD!
otD
t 3
r!
z )
it
;E
E
ID
i 5
o .
cqt
=Y.
E P
3 3
.45
o
o
.9! O
:!
ot
E r
o c
o
o
o-
- c
o o
ln INT
YEL/BLU,8LU/GRN
In LO or Hl
BLU,BLU/YEL
ln MIST
BLU/YEL
GRN/BLK,GRN
LT GRN/BLK
Symptom
Wipers
do not
i=
o
o-;i
ln all
positions
Rear window wiper does

not work.
GRN/BLK
I
Blades do not return to

park position when the
switch is turned OFF.
Intermittent cycle is
erratic or wipers do not
work intermiftently.
Little or no washer fluid
is pumped.
G301,
G401
G503,
G751
BLU/wHT,
LT GRN/BLK
BLU/GRN
YEL/BLU.
2
G301
WiDersnd washer do not

work at the same time.
23-256
vnx.su
BLU/BLK
BLK/GRN,
BLK/GRN
Wipers/WashersSwitch Replacement
Disconnectthe 8-P and 6-p connectorsfrom the
switch.
a All SRS electrical wiring harnessesale covered with

yellow insulation.
a Belorodisconnectingthe SRSwif6 harnoss,installthe
short connector(sl.
a Rplacethe entire atlscted SRS hamess assombly il
it ha6 an open citcuii ot damaged wiring.
Removethe two sctews and the switch.

wIPERSÎITASHEBS
SWtTCl.t
A-P CONNECTOR
4.
6-P CONNECTOR
Install in the reverse order of removal.
UPPERCOVER
23-257
vnx.su
Wipers/Washers
Switch Test
Wipers/Washers
CAUTION:
a All SRS electrical wiring harn6ss6salo covered with
yellow insulation.
a Belore dkconnecting any part ot th6 SRS wire harneaa. connect the short connoctor(sl.
a Replac6the 6ntire affoctod SRS harnessassembly it
it has an open cilcuit 01 damaged wiring.
1.
2.
Disconnectthe 8-P and 6-P connectorsJrom the

swatch.
It necessary,removethe two screws and the switch.

SRS iIAIN HARNESS
{Covor.d rvilh yollow inrulation}
scREws
23-258
vnx.su
Windshield WiperAi\laEhelSwitch
D
'w*+t+*i' 4l ?u
I-
l=f,.
o"/jô-"-
_J
M|ST
M|ST
OFF/INT
E B
Terminal
il;----__\
o-
OFF
INT
o-
LO
G-
Mistswitch"ON'
Washer
switch"0N"
---o
o- *--o
---o
*-o
--o
---o
o-
HI
G--
---o
o-
R6ar Window Wipr/Washol Switch

I
,i1..___.______,x..
fr."ql|.fr
tiT
rermrnal
\
Position
L
\
Washer
switch"0N"
OFF
ON
Washer
switch"ON"
(withwiDer'0N")
o- ---o
o- -*o
--o
o---o
o-
o- ---o
o- ---o
23-259
vnx.su
Wipers/Washers
Windshield Wiper Motor Test
Open the hood and remove the cap nuts and the
wiper arms (see page 23-261).
NOTE: Removethe wiper arms carefullywithout
damagingthe hood.
A SLUTYEL}
Removethe hood seal and air scoop by prying out

their trim clips.
D IGB /BLK)
B (BLUI
Disconnectthe 5-P connectorfrom the windshield

wiper motor.
Test the motor by connectingbattery power and
\
Terminal
Pi"i,i""---\
B
D
{GRN/BLK) {8LU)
LOW SPEED
H I G HS P E E D
(BLU/YEL}
Reconnectthe 5-P connector to the wiper motor assembly.

Connect an analog voltmeter between the E
{BLU/wHT)and the C (BLK)terminals.Runthe motor by turning the wipet switch ON (LO or Hl position).
The voltmeter should alternately indicate O V and
more than 4 V.
NOTE: Use an analogtester.
lf the motor does not run or fails to run smoothly,

replacerr.
23-260
vnx.su
Windshield Wiper Motor Replacement

Openthe hood and removethe cap nuts and wipel
atms.
o.
Separatethe wiper linkageand crank arm at thejoint.

Removethe three mounting bolts and wipet motor.
NOTE: Removeth wiper arms carefullywithout

damagingthe hood.
MOUNTII{G
BOLTS
9.8 N.m
(1.0 kgm.l,7.2 lbI.ftl
Remove the hood seal and air scoop by prying out

their trim clios.
Disconnect the 5-P connector trom the windshield

wiDer motor.
8.
Installin the reverseorder of removal.
Removethe four mounting bolts and wiper linkage

assembly.
Removethe wiper harnssfrom the wipe. linkage.
23-261
vnx.su
Irflnfi]
Wipers/Washers
-Keal
I esr
wlper Motor
|Yloror Test
wlnqow Wiper
Rear Window
1.
Disconnectthe 4-P connectorfrom the wiper motor.
lf the moto. does not run or fails to tun smoothly,

replaceit.
4.
Reconnectthe 4-P connectorto the wipet motor assembly.

Connect an analog voltmeter between the D (LT
GRN/BLKIand B (BLK)terminals.Run the motor by
turning the wiper switch ON.
The voltmeter shouldslternatelyindicateO V and
more than 4 V.
NOT: Use an analogtester.
4-P
CONNECTOR
A (GBN/BLK)
C IGRNI
Viewtrom terminal
side
2.
Test the motor by connectingbatterypower to the

A (GRN/BLK)
and groundto the C (GRN)terminals.
The motor should run smoothly.
C (GRI{}
23-262
vnx.su
Rear Window Wiper Motor

Replacement
Washer Motor Test
1 . Removethe cover, mounting nut, and wiper arm.
l.
Removethe front bumper (see section 20).
Removethe rubberseal, specialnut, and washer.
2.
Disconnectthe 2-P connector lrom the washer

motor.
RESERVOIR
MOUNTINGNUT
14 N.m
11.4 kgf.m,
10 tbt.trl
WIPERARM
RUBBERSEAL
SPECIALNUT
8.8 N.m
{0.9 kgt'n,
6.5 rbt.fr)
Openthe tailgate and removethe tailgatetrim panels

(seesection 20).
Disconnectthe 4-P connectorfrom the wiper motor.
Removethe threemountingboltsand the wiper motor assembly.
MOUNTING
BOLTS
9.8 N.m
(1.O kgf.m, 7.2 lbf.ttl
6,
-4
)
WINDSHIELD
REAR
wrNDow
Test the motor by connectingbatterypower to the
A ( + ) terminaland ground to the B (- ) terminal.
a ll the motor does not run or fails to run smoothly, replaceit.
a lf the motor runssmoothly,but littleor no washer fluid is pumped.check for a disconnectedor
blockedwasherhose, or a cloggedpump outlet
in the motor.
Installin the reverseorder o{ removal.
23-263
vnx.su
Wipers/Washers
Washer Replacement
1 . Bemovethe Jront bumper (seesection 2Ol.
Removethe left lront inner fender.
Disconnectthe 2-P connectorand hose from the
washer motor.
Removethe three mountingbohs and the washer
reservorr.
5 . Removethe washer motor from the reservoir.
6.
Removethe windshieldwiper arms and air scoop

(see page 23-261). Then removethe washer nozzles and hoses.
7 . lnstall in the reverseorder of removal.

NOTE:
a Take care not to pinch the hosesduring installation.
a Installthe clips tirmly.
a After installing,adjust the aim of the washer
nozztes.
WINDSHIELD
WASHER
NOZZLE
REAR
wtt{Dow
WASHER
t{ozzLE
n
V
..,.,,@
lH (
MOUNTING
BOLTS
9.8 N.m
{1.O kgf.m, 7.2 lbf.ftl
23-264
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SupplementalRestraintSystem
(sRst
GomponentLocationIndex..................
23-266
Description
..23-267
Circuit Diagram
23-268
Wiring Locations
23-270
Precautions/Procedures
..23-271
Troubfeshooting
.............
..23-276
AirbagAssembly
Repfacement
..................
23-295
Disposal
....23-299
CableReel
Replacement
..................
23-301
DashSensor
Replacement
..................
23-305
SRSUnit
Replacement
..................
23-307
vnx.su
SupplementalRestraintSystem(SRS)
ComponentLocirtionIndex
SRSINDICATORLIGHT
(ln th6 gaug6 assembly)
page23-276
Troubleshooting,
Gaugeassembly,page23-113
CABLEREEL
Replacement,
page23-301
To CRUISECONTROL
SET/RESUMESWITCH
AIRBAG
page23.295
Beplacement,
UNDER.DASH
BOX
FUSE/RELAY
FRONTPASSENGER'S
AIRBAG
lExceptCanadsRS model)
page23-295
Replacement,
page23'299
Disposal,
RIGHTDASHSENSOR
page23-305
Replacement,
LEFTDASHSENSOR
R e p l a c e m e n t ,p a g e 2 3 - 3 0 5
SRSMAIN HARNESSFRONTPASSENGER'S
AIREAG
BRANCHlExcptCaned. RS modol)
SRSUNIT (lncludingcowl sensorl

Replacement,page23-307
23-266
vnx.su
Supplemental
RestraintSystem(SRSI
CircuitDiagram(WithoutFrontPassenger's
Airbagl
SRSINOICATOR
CIRCUIT
{lnthglugsssombv}
r---r n
r t l
ill
SADHUNOER_
HOOD
DRIVER'S
FUSE/
AIRBAG
RELAY
INFLATOR
80x
SAOC
BUC
GNO
o
a
a
@
o
a
a
@
a
@
a
@
rDc @
MI
23-268
vnx.su
a
a
GircuitDiagram(With FrontPassenger's
Airbagl
UNOE8DASH
FUSSRELAY
BOX
SRSINOICATOF
CIRCUIT
lln lh6 grugo.$.mblyl
I
I
I
I n
I ll
I tl
t U
I
SADH
UNDER
HOOD
FUSE/
REI.AY
80x
DRIVER'S
AIREAG
INFI.A]OR
o
@
o
FROI.IT
PASSENGER'S
AIREAG
INFLATOR
@
@
a
a
@
a
@
a
@
@
@
a
a
SRSUNITl8-P COI'INECTOR
23-269
vnx.su
SupplementalRestraintSystem (SRSI
Wiring Locations
CAUnON:Makesureall SRSgroundlocrtion3lrc clrln rnd ground3tra |.curalv rltachad.
NOTE:
withysllowinsulation.
arecovered
o AltSRSelectricsl
wiringharnesses
. RsDlace
the entireaffectedSRSharnessassemblyif it hasan opencircuitor damagedwiring.
CABIEREELto DdrrEFS AnaAC
3+ OOI{iECTOR
DASHBOARDWIRE HARNEi9
to INDICATOBUGHT in GAUGE ASSEMBLY
5-PCONNECTOB
aFs irA[t H^RiEss

Ana G
to FROiITPASSEMIEFS
3t coftf'Eclon
C.
SRS MAIN HARNESStO

MAIN WIREHARNESS
+P OONNECTOR
b Ra nod.ll
SRSMAINHARNESS
to UNDER-DASH
FUSE/RELAY
BOX
2"P@NNECTOR
SnS Alt{ ll^ntc8s to
MAIN WIREHARNESS
to DASHBOARDWIRE
HARNESS
lGP CONNECTOR
o sHSErson
2+ OOt{tlEcT()R
SBS MAIN HARNESSto

LEFTDASHSENSOR
2.P CONNECTOA
23-270
vnx.su
GeneralPrecautions
Airbag Handlingand Storage
Carefullyinspectany SRSpart beforeyou installit.

D o n o t i n s t a l la n y p a r t t h a t s h o w s s i g n s o f b e i n g
droppedor improperlyhandled,suchas dents,cracks
or deformation:
-
Airbagassembly{driver'sand front passenger's)

Dashsensors
Cablereel
S R Su n i t
Do not try to disassemble

the airbagassembly.lt has no
serviceableparts. Once an airbag has been operated
(deployed),
it cannotbe repairedor reuseo.
F o r t e m p o r a r ys t o r a g eo f t h e a i r b a ga s s e m b l yd u r i n g
service,pleaseobservethe followingprecautions:
.
Storethe removedairbagassemblywith the pad surfaceup.
It the airbag is impropsrty stored facs

!@
down, accidentaldeployment could propel the unit with
enough force to causesetious iniury
Use only a digital multimeterto checkthe system.lf

it's not a Hondamultimetermakesure its output is 10
mA (0.01A) or less when switchedto the smallest
value in the ohmmeterrange.A testerwith a higher
outputcould damagethe airbagcircuitor causeacci
dentaldeploymentand possibleinjury.
Do not installusedSRSpartsfrom anothercar.When
makingSRSrepai.s,useonly new pans.
E x c e p tw h e n p e r f o r m i n ge l e c t r i c a il n s p e c t i o n s ,
alwaysdisconnectboth the negativecable and positive cableat the batterybeforebeginningwork.
R e p l a c e m e n to f t h e c o m b i n a t i o n l i g h t a n d
wiper/washerswitchesand cruisecontrol switchcan
be donewithout removingthe steeringwheell
- C o m b i n a t i o nl i g h t a n d w i p e r / w a s h e rs w i t c h
(seepage23-160).
replacement
- Cruisecontrolsevresumeswitch replacement
{see
page 23-2491.
SHORTCONNECTON
{REDI
Store the removedairbagassemblyon a secureflat

suffaceaway from any high heat source(exceeding
212"Fl1OO'Cl
and free of any oil. grease,detergentor
CAUTION: lmproper handling or storage can internally

damagethe airbag assembly,making it inoperativ.
ll you suspect the airbag assembly has been damagod,
install a new unit and rgler to the Deployment/Digposal
Procedureslor disposing of the dsmaged airbag.
The originalradiohasa codedtheft protectioncircuit.

Be sure to get the customer'scode number before
disconnecting
the battery.
When reinstallingthe SRSunit cover,be sure it snaps
togetherproperly.
vnx.su
23-271
SupplementalRestraintSystem(SRSI
Wiring Precautions
o Neverattemptto modify.spliceor repairSRSwiring.
Connecting the Short Connectors
NOTE:All SRS electricalwiring harnessesare covered

with yellow insulation.
To avoid accident8l deploymont and pos@

5ibl6 iniury, slways insiall the protectiva short connector(s) on tho drivgr'3 and passengor'sairbag connec.
tor(s) be{oreworking noar any SRSwiring.
NOTE:The original radio has I coded theft protection
the batterycables.
beforedisconnecting
1.
Disconnectthe batterynegativecable.then disconnectthe Dositivecable.
2.
Connectthe shortconnector(s)
{RED):
Driver's Side:
. Removethe accesspanel from the steeringwheel.
t h e n r e m o v e t h e s h o r t c o n n e c t o r( R E D )f r o m t h e
Daner.
DRIVER'S
AIRBAG
Be sure to installthe harnesswires so that they are

not pinchedor interferingwith othercar pans.
CONNECTOR
IREDI
Disconnectthe 3-P connectorbetweenthe driver's
airbagand cablereel,then connectthe shortconnector {RED}to the airbagside oi the connector.
M a k e s u r e a l l S R S g r o u n d l o c a t i o n sa r e c l e a na n d
groundsare securelyfastenedfor optimum metal-tometal contact.Poorgroundingcan causeintermittent
problemsthat are difficultto diagnose.
23-272
vnx.su
Front Pas3enger'sSide:
. Removethe glove box damper (seesection20),and
then removethe glove box.
.
Disconnectthe 3-P connector between the front oassenger'sairbagand the SRSmain harness,then connect the short connector (RED)to the airbag side of
the connector.
SHORTCONNECTOR
(REDI
Disconnectingthe SRS Connector at the

Under-dash Fuse/relay Box:
CAUTION: Avoid br.aking the connoctor; it's doubtelocksd.
1.
First lift the connectorlid with a thin screwdriver,

then pressthe connectortab down and pull the conneclorout.
CONNECTOR
t_tD
SRSMAIN HARNESS
To reinstallthe connector.push it into positionuntil

it clicks,then closeits lid.
23-273
vnx.su
Steering-relatedPrecautions
SteeringWheel and CableReelAlignment
Steering Column Removal
NOTE:To avoid misalignmentof the steeringwheel or

airbagon reassembly,make surethe wheelsare turned
straightaheadbeforeremovingthe steeringwheel.
CAUTION:
. Bofore romoving tho 3l6oring column, first discon'
nect tha connector between ths cablo 16ol snd tho
SRSmain harness.
. lf th6 stssring column is going to be removed without dbmounting the stesring wh6el, lock the sl6sring by turning th ignition k.y to o-LOCKpo3ition or
removo tha ky llom ths ignilion so that th6 3loaring
wheel will not turn.
Rotatethe cablereelclockwiseunit it stops.

T h e n r o t a t e i t c ou n t e r c l o c k w i s e( a p p r o x i m a t e l yt w o
t u r n s lu n t i l :
- T h e y e l l o w g e a rt o o t h l i n e s u p w i t h t h e a l i g n m e n t
markon the cover.
- The arrow mark on the cablereel labelpointsstraight
up.
ARROWMARK
D o n o t r e p l a c et h e o r i g i n a ls t e e r i n gw h e e i w i t h a n y
other design,sinceit will make it impossibleto properly
instsllthe airbag(only use genuineHondareplacement
oans).
After reassemblvconfirmthat the wheelsare still turned
straightaheadand that the steeringwheel spokeangle
is correct,lf minor spokeangleadjustmentis necessary,
do so only by adjustmentof the tie-rods,not by removthe steeringwheel.
ing and repositioning
ALIGNMENTMARK
23-274
vnx.su
SensorInspection
InspectionAfter Deployment
CAUTION: Tak xtra care whon painting or doing

body work in the ara bslow th6 dalhboard.
Avoid dirost exposure ot lh6 sonsors or wiring to hest
guns, wolding, or spraying equipmont.
Di3connact both the nogativo and po3itivo b!ftery

cable3.
Connsct tho short conneclor(s) before working
bslow the da3hboardor nsar lhe dash sen3o.3.
After any degree of frontal body damage, inspect

both dash sensors.Replacea sensor if it is dented,
cracked,or deformed.
After a collision in which the airbags were deployed.

inspectthe following:
1.
Inspectthe dashsensorsfor physicaldamage.

lf the sensorsare damaged,replacethem.
2.
Inspectall the SRS wire harnesses,ReDlace,don't

repair,any damagedharnesses.
3.
Inspectthe cable reel for heat damage.lf there is

any damage.replacethe cablereel.
4.
After the car is completelyrepaired.turn the ignition switch on. lf the SRS indicatorlight comes on
for about six secondsand then goes off, the SRS
systemis OK. lf the indicatorlight does not function
properly,go to SRSTroubleshooting
(nextpage).
DASHSENSOR
a Be surethe sensorsare installedsecurelv,
BOLTS
23-275
vnx.su
Troubleshooting
Self-diagnosisFunction
Connectingthe Short Connectors
function.lf there
The SRS unit includesa self-diagnosis
is a failure in the sensors.SRSunit, inflator,or their circ u i t s ,t h e S R S i n d i c a t o rl i g h t i n t h e g a u g e s s s e m b l y
comesON.
To avoid.ccidental doploymont and pos.

@
siblo iniury. alway3 connect ths protoctive short con.
noctor to tha driver's airbag connectot and, on caf!
equippod with front passongor'sairbag, conncqt Prolactivs ghort connoctors to the d.ivsr's and tront passsngar's airbag before working nsai any SRSwiring.
NOTE:The original radio has a coded theft protection
before disconnectingthe battery cables,
1 . Disconnectthe battery negative cable, then disconnectthe oositivecable.
2.
As a system check,the SRS indicatorlight also comes

on when the ignition is first turned ON to the (ll) position. lf the light goes off after approximatelysix seconds,the systemis OK.
lf the SRSindicatorlighr remainson (or failsto come on
in the systemcheckmode),one of the SRScomponents
(or the wiring/connectors
inbetween)is laulty
Drivsr's Sido:
. R o m o v e t h e a c c o s sp a n e l t r o m t h e s t e e r i n g
wheel, then remove the shon connector(BED)
from the panel.
CABLEREL
DRIVER'S
AIRBAG
3-P
TroubleshootingPrecautions
a Always use the test harness.Do not use test probes
directlyon componentconnectorterminalsor wires;
you may damagethem or the SRSunit.
a When connectingany of the test harnessesto the
system,push the connectorsstraight-in;do not bend
the connectorterminals,
. Beforedisconnectingany part of the SRSwire harness,connectthe shon connector(RED)on the driver's airbag. On cars equippedwith a front passenger'sairbag,connectshortconnectorson the driver's
airbag.
airbagand the front passenger's
(REDI
. Disconnectthe connectorbetweenthe driver's
a i r b a g a n d c a b l e r e e l ,t h e n c o n n e c tt h e s h o r t
connector{RED}to the airbagside of the connector.
Possibloconditions:
1. SRS indicatorlight does not come on at all - see
page 23-278.
SRS indicatorlight stays on constantly- see page
23-242.
3.
SRSindicatorlight comeson in combinationwith a

failure of another electricalsystem (chargingsyst e m l i g h t ) . C h e c k f o r d a m a g e / c o r r o s i o na t t h e
under-dashtuse/relaybox connector.
ACCESS
PANEL
SHONTCONNESTOR
SRS Indicator Light Troubleshooting
2.
(RED):
Connectthe shortconnector(s)
Front Pasngo/s Sido:

. Removethe glove box damper (seesection20),
and then removethe glovebox.
. Disconnectthe connectorbetweenthe front passenger'sairbagand SRSmain harness,then connectthe short connector(RED)to the airbagside
of the connector,
SHORTCONNECTOR
NOTE:
check
. Beforestartingthe applicabletroubleshooting.
t h e c o n d i t i o no f a l l S R Sc o n n e c t o r sa n d g r o u n d
points.
. lf the fault is not found after completingthe applicable troubleshooting,substitutea known-goodSRS
unit and checkwhetherthe indicatorlight goesoff.
23-276
vnx.su
MAIN HARNESS
Test Harnesses
and AttachmentPoints
TestHsrnessA
SRSUNIT
TESTHARNESSA
07MAZ - SL|D500
2
TESTHARNESSC
07LA:Z- SL.()3(X'
to n 12 l 3
1 6 16
Tast HarnessB
TESTHARNESSB
07MAZ - SP@500
ROWA ISRSUNfT ENDI
2
I
13
12
1 5 16 17 | l
1 5 l6
17 1A
ROW B IWIREHARNESSEND)
23-277
vnx.su
Troubleshooting
The SRSIndicatorDoesNot Light
CAUTION: Uss only a digital multimeter to check the system. lf it's not a Honda multimeter, make sure its output is
10 mA {0.01Al or less when switched to the smallest value in the ohmmeter rang. A tester with a highor ouiput could
damagethe airbag circuit or causeaccidentalairbag deployment and possibleiniury
NOTE:The originalradio has a codedtheft protectioncircuit.Be sure to get the customer'scode number beforedisconnectingthe batterycables.
Dilconn6ct the battory negaiive
cable rnd thon tho positive
cable.
Connest the short connectorlsl
to tho airbaglsl (seo p6ge 23272t.
Rconnectthe batterY Positive

c a b l ea n d t h e n t h e n e g a t i v e
cable.
Turnthe ignitionswitchON (ll).
Does the brake system

light come on (in the
gaugeassembly)?
D i s c o n n e ctth e S R S m a i n h a r n e s s l 8 - P c o n n e c t o rf r o m t h e
SRSunit.
Turnthe ignitionswitchON (ll).
D o e st h e S R S i n d i c a t o r
lightcomeon?
I n s p e c tt h e N o . l 5 1 1 0A ) f u s e
(under-dash
tuse/relay
box).
ls No. 15fuseOK?
Repairopen in dashboardwir6
harnessbetween the No. 15 tus
and gauge a3sombly.
SRSMAIN HARNESS
18.PCONNECTOR
The SRSunit is faully.
Io page 23'2791
23-274
vnx.su
SRSUNIT
SRSMAIN HABNESS
(From plgr 23.27E1
Disconnocttho SRS m.in h6,ng88 {-P conn6clorf,om tho

mrin wiaoharn6$.
Tum lhq ignition switch ON (lll.
MAIN VNRE
HARNESS
D o o 3t h o S R S i n d i c . t o r
light com6 on?
Th. SRS rnlin h..n...
i.t
ulty.
Tu.n tho ignition switch OFF.
R o m o v ot h o g ! u 0 c ! s s . m b l y
th6n inrpoct ths SBS indicator
light bulb.
DASHBOARDWIFEHARNESS
5-PCONNECTOR
Raplacalh. indlc.toi llOht birlb.
Connoct ! voltmotoa bdwoln thr

No. 5 lormin.l (+) of tho 5-P connoctor rnd body ground (-).
Turn the ignition switch ON (ll).
Moaaurotha voltrgo bolwcon tha

No. 5 termin.land body g.ound.
(Top.go 2+280)
8tU{+
I
:
23-279
vnx.su
SupplementalRestraintS ystem(SRSI
Troubleshooting(cont'd)
(Frompage23-279)
ls therelesslhan8.5V ?
Short in 8LU wire ol the da.hborrd wi.o halno3s. Roplacatha

d.3hbosrd wiro ha.no$.
Turnthe ignitionswitchOFF
DASHBOARDWIREHARNESS
Connecttho voltmeter between
the No. 1 terminal(+)and the No.
3 terminal (-) of the dashbord
wire harness5-Pconnector.
YELI+,BLK{-I
Turn the ignitionswitchON (ll).
View lrom wire side.
No. 1 terminaland th No.3 termrnal,
ls there batteryvohage?
Ch6ckfor continuity betweenth6

No.3 terminaland body ground.
R.prir opcn in tho BLK wir. (No.
3 tarmin!l) batwaan th. gluga
araambly and body ground ot
look tor. poor ground 1G201,
cilol I.
{To page23-281}
Rcprir open in th. YEL wi.o lNo.

t t6rminall of the d.3hbo.rd
wir6 hamer! batwaen tho gtugo
r3s6mblv rnd tho No. 15 ll0 Al
fu36.
23-280
vnx.su
(From page 23-280)
Reconnecteach connectorto the

g a u g e a s s e m b l ya n d S R S u n i t
then connect Tgst Harness A to
the SRSunit.
Turn the ignirion ON 0l) and

moasureth voltage betwegnthe
ground (-) tor six seconds.
TEST HARNESSA
07MAZ - S!IX)s{X'
4
ls thr6 more than 8.5 V?
10 It l2
13 l 4
15 16
SBS indic.tor circqit {in th.

e.ug. r.t mblv, i. hulty,
23-2a1
vnx.su
,;l
Troubleshooting(cont'dl
SRSIndicatorLight Stayson Continuously
NOTE: Beforetroubleshooting,make sure that battery
voltageis 12 V or mo.e. Otherwiseyou'll obtain wrong
test readings.
1.
Make a photocopy of the chart on page 23-283,
2.
ConnectTestHarnessA to the SRSunit as shown.
to
ll
l2 t3
NOTE:The original .adio has a coded theft protection

before disconnectingthe battery cables.
Beforedisconnectingany pan of the SRSwire harness,connectthe short connecto(s) {RED)to the
airbag(s)(seepage23-2721.
Connect Test Harness B between the SRS unit and
SRSmain harnss18-Pconnector.
t l rt
TEST HANNESS
Tu.n the ignitionswitchON (lll.

.
"battery
Voltagesin the chart assumethe car's
voltage"is about 12 volts.Lessthan 12 volts will
result in different or possiblytalse readings.
Do not disconnectthe airbags ftom the circuit
when checkingSRSunit voltages.
7.
Checkfor continuitvbetweenthe 85 terminal and

b o d y g r o u n d , a n d t h e B l 5 t e r m i n a la n d b o d y
ground.
F i r s t , c h e c k f o r v o l t a g e b e t w e e nT e s t H a r n o s s
TerminalNo. 12 (+)and ground(-).
lf no voltageis indicated,go to step I and continue checkingall the otherterminals.
o lf vottsge is indicated,there is a poor ground at
the SRSunit.Readthe followingNOTE,and then
go on to step 5.
.
TEST HARNESSB
07MAZ - SPqrS{X)
lf there is continuityat eitherterminal,the SRS

unit is faulty. Replaceit and checkthe voltages
accordingto the chan on page23-283.
lf there is no continuity at either terminal, the
S R S u n i t g r o u n d ,t h e S R S u n i t c o m p o n e n t
g r o u n d s o r t h e S R S m a i n h a r n e s si s f a u l t y
Checkthe grounds (checkwire and control unit
mounting bolts) and, if necessary,replaceth
S R S m a i n h a r n e s s .T h e n c h e c kt h e v o l t a g e s
accordingto the charton page23-283
23-282
vnx.su
8.
Recordyou. voltagereadings.for eachterminal,in

the row of blank boxes near the top of the chart.
Compareeach readingwith the voltagerangeslisted in the column below it. lf ths readingis within a
range,circlethat range.
4.5
lf you circledall the FailureMode rangesacrossany

row. checkthe car for the ProbableFailureMode listsd at the end of the row. (Referto the letter for that
mode on the followingpages),
12,O
1/4.3
I
/
".)6r-
4.6
It youcircld
alltheranges
in thisrow,tollowthe
procedure
troubleshooting
underfailuremode,,C"on the
followingpages.
4.5
12.O
5.5 - 14.3
at'9\r t.g
5.t
4,5
r2,o
-t4.3
2.9
rl.5
-5.5
12.0
- 14.3
2 . 91 8 . 7 | 3 . 7l - r r . 2 l
lf you did not circle all the rangesacrossany row,

replacethe SRS unit with 8 known-good unit, and
retest.
- l f a l l y o u r v o l t a g e r e a d i n g sa r e n o w n o r m a l ,
replacethe originalSRSunit.
- lf your voltage readingsare still not normal but
t h e y d o n ' t f i t w i t h i n a c o m p l e t er o w o f F a i l u r e
Mode ranges,checkthe conditionof the terminals
in esch of the SRS connectorsshown in the svstom diagram on page 23-270,
l..s lr2.ol | - 5 . 8l - r a . 3 l
Circlethe rangeif your readingis within it.
NOTE:Do not disconnectthe airbagwhen checkingSRSunit voltages.

Whh tront passongor'ssirbag:
1
SAOH
a
SADC
4,3
4.3
5.4 -5.6
2.5
-3.7
2_A
4.5
12.0
-14.3
4.5
12.O
- 1rt.3
4.5
-5,5
12.0
14_3
8,6
a_6
l1_3-11.3
4,5
12.0
5.5 - 14.3
5_7
4.5
12.0
- 14.3
10
aucl
t1,5
- 14.5
GNO
t3
tDc
4.4
1 3 . 6 - 10.9
3.1
-4,9
11.5
- r4.5
11.5
14.5
2.O 8.4
4.5 - 1 0 . 9
11.2
-14.6
11.5
- 14.5
2.O
4.5
4.4
10.9
-9.7
r1,5
-14,5
2.O
4.5
8.4
to.9
2.O
-4,5
4.4
10.9
4.6
2.9
-3,7
4.5 1 2 , O
-5.5 -14.3
3,7
4.9
I1.5
l4_5
2.O
4.5
8.4
10.9
2.9
4.7
- 1 1. 2
4.5 '12.o
-5.5 -14.3
3.7
4.9
11.5
- 14.5
2.O
a_5
4.4
10.9
4,6
a_6
l1_3-t1.3
4.5
12.O
5.5 - 1 4 . 3
I t.5
- r4.5
2.O
-4,5
4.4
10.9
11.5
- t lt.5
2.O
-4.5
4.4
- 1o.9
11 . 5
- 14.5
4.3
-5,6
4.3
5.6
4.3
5,6
4_3
5.6
4.5
5.5
12.O
r4.3
-7.3
o 18.5 4.4
- 13.6 1 0 . 9
23-283
vnx.su
NOTE:Do not disconnectthe airbagwhen checkingSRSunit voltages.
Without lront Passongor'ssirbag:
l
SAOH
vcc
12.O
5.5 - 1 4 . 3
4,3
5.6
4.5
5.5
2.4
3.7
't2.o
14.3
4 . 5 12.O
5,5 - 1 4 . 3
4.6
-11.3
-5.5 - 14.3
12.O
saoc
10
BUCI
12
Gto
5,6
-7.3
11.5
- 14,5
13
t4
toc
a _ 5 8.:a
- 1 3 . 6 ro.9
11,5
-14.5
2 . O 8.4
-8.5 - r 0 . 9
11.5
-14,5
2 . O 8./a
-8.5 - r 0 . 9
11.2
- 14.6
11.5
14,5
2.O
8./t
-r0.9
8.1
-10.9
3.7
4.9
5.7
4.5
t2.o
14,3
-9.7
tt.5
- 14_5
-8.5
4.6
11.3
4.5 12.0
- 5 . 5 - 14.3
3.7
-4.9
1t.5
14.5
a.a
2.O
- 8 . 5 -r0.9
4.3
5,6
-7.3
11.5
14,5
4.3
-5.6
4.5
-5.5
12.O
- 14.3
-7.3
t1.5
- 14-5
H ll{o. 26 lo Al o.
o ta,5 E,4
- 1 3 . 0 t- 1 0 . 9
B
TESTHABT{ESS
Mods B:
. Short to driver's or Passonger'saitbag inflator body
(body groundl
. Short in dash sonsor
. Opsn in both cowl sgnsor contacts
A
B

1. Disconnectthe batterynegativecable and then the
positive cable.Then connectthe short connectots(s)
(RED)to the airbag(s)(seepage23-272).
2. ConnectTest HarnessB betweenthe SRS unit and
SRSmain harness18-Pconnector.
SRSUN]T
SRSMAIN HARNESS
18.PCONNECTOR
8.it
,r0.9
Reconnectthe drivr's airbag connector,then check

continuity betweenthe B1 terminal and body
ground, and btwesn the 87 terminsl and body
grounq,
3.
Modo A: Open in one cowl sonsor conlact

r The SRSunit is faultY.Substitutea known-goodSRS
unit and recheckthe voltagesaccordingto the chart
on page23-283.
2,O
'...
lf there is continuity at either terminal, go to step

o.
lf there is no continuity at sither terminal'

- go to step 5 (without front passonge/sairbag)'
- go to step il (with front passenger'sairbag)'
Reconnectthe front passonger'ssirbag connector,
then checkcontinuitybetwonihs 82 trminaland
body ground, and between the 88 terminal and
body ground.
lf there is continuityat eitherterminal,go to step

10.
lf there is no continuityat eitherterminal,go to
step 5.
23-284
vnx.su
Checkcontinuity between body ground and each

terminalof both dssh sensors.
7.
Checkcontinuity betweenthe No. 4 terminal and

body ground, and between the No. 5 terminal and
body ground.
TESTHARNESS
B
o?MAZ- SFmSd)
TEST HABI{ESS C
07LAiZ- SLIO:loo
lf there iscontinuityat anyof theterminals,go to

step 12.
lf thsre is no continuity at any terminal, go to

steo 13.
Disconnectthe cable reel 6-p connectorfrom the

SRS main harnss,then connect Test HarnessC
only to the cablereel sideof the 6-p connector.
lf there is continuity at either terminal, go to step

8.
SRS main harnessis faulty. Replaceit and re_
c h s c k t h e v o l t a g e sa c c o r d i n gt o t h e c h a r t o n
page 23-283.
CABLENEEL&P CONNECTOR
(cont'd)
23-285
vnx.su
Troubleshooting{cont'd}
8.
airbag3-Pconnecthe front passenger's

10. Disconnect
tor from the SRS main harness,then connectTest
HarnessC to the airbagside of the connector.
Disconnectthe drive/s airbag 3-P connectortrom

the cable reel,then connectTest HarnessC to the
driver'sairbag3-Pconnector.
FRONTPASSENGER'S
ANBAG
DRIVER'SAIRBAG
o7LAiZ- Slao:tq,
1 1 . Checkcontinuitv betweenthe No. 7 terminal and

body ground,and betweenthe No. 8 te.minal and
body ground.
Checkcontinuitv betweenthe No. 7 terminal and

body ground,and betweenthe No. 8 terminal and
body ground.
lJ there is continuityat eitherterminal,the drive r ' s a i r b a g i n f l a t o r i s f a u l t y . R e p l a c ei t a n d

recheckthe voltagesaccordingto the chart on
page z3-z6J.
lf there is continuitvat eitherterminal,the Jront

passenger'sairbag inflator is faulty. Replaceit
and recheckthe voltagesaccordingto the chart
on page 23-283.

cable reel is faulty. Replaceit and recheckthe
voltagesaccordingto the charton page23-283.
lf there is no continuitv at either terminal, the

S R S m a i n h a r n e s s i s f a u l t y . R e p l a c ei t a n d
page 23-283.
23-286
vnx.su
12. Connect Test Harness D between the dash sensor

and SRS main harness2-P connector.Checkcontinuity betweenthe No. 1 terminsland body ground,
8nd betweenthe No.2 terminaland body ground,
o lt rssistanceis 3.8 - 4.2 kO for both sensors.the

SRSunit is faulty.Substitutea known-goodSRS
unit nd recheckthe voltagesaccordingto th
chart on page 23-283.
o lf resistancsis l6ss thsn 3.8 kO for either sensor.
go to step 14.
sRs MA[{
HARNESS
2-POOTTNECTOR
1il. Connect Test Harness D between the dash sensor

and SRSinain harness2-P connector.Measurethe
resastancebetweenthe No. 1 terminal and No. 2 terminal.
SRSMAIN
HARNESS
2.PCONNECTOR
TESTHARNESS
D
o?LAiZ- SL()a(xt
TESTHARNESSD
otlA:z- sl(,(x)
rffi-l
TEST HAR ESS D

07LAZ - SL.{)a(xl
TESTXARNESS
D
otlA:z - sl4|)4tx)
t'l
lf there is continuityat eitherterminal,the dash

sensor is faulty. Replaceit and recheckthe voltagesaccordingto the chan on page23-293.

S R S m a i n h a r n e s s i s f a u l t y . R e p l a c ei t a n d
page 23-283.
Measure the resistancebetween the l6ft dash sensor terminalsB'12and Bl6, and betweenthe right
dashsensorterminalsB4 and 86.
lf resistance
is 3.8- 4.2kO,the SRSmain harness
is faulty. Replaceit and recheckthe voltages
accordingto the chan on pag23-283.
lf resistanceis lessthan 3.8 kO,the dash sensor
is faulty. Replaceit and recheckthe vottages
accordingto the charton psge 23-283.
IESTHARNESS
B
07MAZ- SPqt500
(cont'd)
23-287
vnx.su
3.
Modg C: Shon in one cowl son3ol, or open in both dash

sensors
Mode D: Open in ono da3h sensol
Measure the resistancebetween the left dash sensor terminals812 and 816, and betweenthe right
dashsensorterminals84 and 86.

the batterycables
beforedisconnecting
1.
Disconnectthe batterynegativecable and then the

positivecable.Then connectthe short connector(s)
to the airbag(s)(see page 23'2721.
2.
ConnectTest HarnessB betweenthe SRS unit and

lf resistanceis more than 5 kO for eiiher set of

terminals,go to step 4.
lf resistanceis less than 5 kOtor both sets of term i n a l s , t h e S R S u n i t i s f a u l t y . S u b s t i t u t ea
known-goodSRS unit and recheckthe voltages
accordingto the charton page23-283.
23-2AA
vnx.su
4.
Connect T6st Harness D between the dash sensor

and SRSmain harness2-Pconnector.
Measurethe resistancebetween the No. 1 terminal
and No. 2 terminal.
Mode E: Opn in driver's airbag inflator or cable reel

beforedisconnecting
the bafterycables.
1 . Disconnectthe batterynegativecableand then the
positivecable.Then connectthe short connector(s)
(RED)tothe airbag(s)(seepage23-272).
SBSMAIN
HARNESS
2-PCOI{NECTOR
2.
ConnectTest HarnessI betweenthe SRS unit and

SRSmain harnessl8-P connector.
sRsuNtt
TEST
HARNESSD
orlA:a- sl{tarx)
TESTHARI{ESSD
OTLAZ- sl/to4{lo
Reconnect the driver's airbag connector, then measure the resistance between the 81 and the 87 ter,
m rn a l s .
lf resistance
is more than 5 kO,the dash sensoris
faulty.Replacethe dash sensorand recheckthe
voltagesaccordingto the charton page23-283.
TESTHARNESSB
o?MAZ - SP00500
lf resistanceis lessthan 5 kO,the SRSmain harnessis faulty.Replacerhe SRSmain harnessand

page 23-283.
lf resistance
is more than 0.2 kO,go to step4.
lf resistanceis lessthan 0.2 kO,the SRS unit is
f a u l t y .S u b s t i t u t ea k n o w n - g o o dS R S u n i r a n d
recheckthe voltages accordingto the chan on
page23-283.
(cont'd)
23-289
vnx.su
; r.il
Troubleshooting{cont'd}
4,
Disconnectthe cable reel 6-P connectorfrom the

SRS main harness,then connect Test HarnessC
onlv to the cable reel side ot the connector.
6.
Disconnectthe driver's airbag 3-P connsctorfrom

the cabls reol harness,then connoct Test Harn6ssC
to the driver's airbag 3-P conn6ctor.
DRIVER'SAIRBAG
CAB1I REEL&P CONNECTOB
TESTHARNESS
C
07LAZ- SLIO300
Measurethe resistancebetween the No. 4 terminal

and the No, 5 terminal.
7.
Measurethe resistancebetween the No. 7 terminsl

and the No. 8 terminal.
TESTHARI{ESSC
OTLAZ- AL/|{,3OO
TEST HARI{ESS C
OTLAiZ- Sl/t{r3q)
lf resistance.ismore than 0.2 ko, go to step 6.
lf resistanceis more than 0.2 kO, ths drivsr's

a i r b a g i n f l a t o r i s f a u l t y . R e p l a c et h e a i r b s g
assmbly and recheckthe voltages according to
the chart on page 23-283,
It resistanceis less than 0.2 k0, the SRS main

harnessis faulry. Replaceit and recheckthe voltagesaccordingto the charton page23-283.
lf resistanceis lessthan 0.2 kO.the cable reel is

f a u l t y . R e p l a c ei t a n d r e c h e c kt h e v o l t a g s
accordingto the chart on page 23-283.
23-290
vnx.su
Modc F: Opon in tront pa3s6ngs/s rirbag inflstor

Disconnectthe front passenger'sairbag 3-P connector from the SRS main harness,then connectTest
HarnessC to the front passenger'sairbag sids of
the connector,
FAONT
1,
Disconnectthe batterynegativecableand then the

positivecable.Then connectthe short connoctor{sl
{RED}to the airbag(s)(seepage23-272).
2.

SRSUNIT
TESTHARNESS
C
- SL/O300
07LA,Z
a n dt h e N o .8 t e r m i n a l .
07MAZ - SP|D500
Reconnectthe front passenger'sairbag connector,

then measurethe resistancebetweenthe 82 terminal and the B8 terminal.
TEST HAB ESS C

071-Aiz- sll|{,300
TESTHARNESSB
oTMAZ - SP005(x)
lf resistanceis more than 0.2 kO,the front pass e n g e r ' sa i r b a g i n f l a t o ri s f a u l t y . R e p l a c et h e

front passenger'sairbag assemblyand rcheck
the voltagesaccordingto the chart on page 23243.
lf resistanceis more than 0.2 k0, go to step 4.
lf resistanceis lessthan 0.2 kO,the SRS unit is
faulty. Substitutea known-good SRS unit and
recheckthe voltages accordingto the chart on
page 23-283.
lf resistanceis lessthan 0.2 kO,the cable reel is

faultv. Replacethe cable reel and rcheckthe
voltages accordingto the chart on page 23-283.
(cont'd)
23-291
vnx.su
Troubleshooting{cont'dl
Modc H: Blown SRSNo. 25 fur., ol opcn in the wire
circuit. Be sure to get the customer's code number
betore disconnectingthe battery cables.
1.
Chckthe SRSNo. 25 (10 A) fuse in the under-dash

fuse/relaybox. lf it's OK, go on to step 2.
lf it's blown, replace it with a now 10 A fuse, then
turn the ignitionswitchON (ll):
.
lf the fuse doesn't blow, 90 on to step 2.
lf the fuse blows. troublsshoot as necessaryto

find th6 short.
2.
Disconnectthe battery negative cable and then the

positive cable. Then connect the short connector(sl
(RED)to the airbag(s)(see page 23-272).
3.
Connct Teat Harnsss B between the SRS unit and

the SRSmain harness18-Pconnector.
Reconnectth6 positiv 8nd negativecable to the

battery.
Measureths voltage betweenthe 813 terminal (+)
and body ground{-)with the ignitionswitchON (ll).
TESTHAN ESSB
oTMA:Z- SPOOs{X'
2
a
6
10 n
1o
ll
l3
12
1 6 1a 1 7
ra
1 6 1a 1 7 |a
lf there is battery voltage, the SRS unit is faulty.

Replaceit and rscheckthe voltages accordingto
the chan on page 23-283.
lf there is lsss than b8ttery voltage,the SRSmain
harnessis faulty. Replaceit and recheckthe voltag6s accordingto the chart on page 23-283.
SRSUNIT
23-292
vnx.su
Modc l: Short 01 opcn in SRS indicrtor whc hrrnaas

1.
Disconnectthe battery negative cable and then the

positive cable. Then connect the sho.t connector(s)
(REDltothe airbag(s)(seepage23-272).
Disconnecttho SRS main harness 4-p connector

from the main wirs harn6ss.

WIREHABNESS
2.
Turn the ignitionswitchON (ll) 8nd wait for six seconds. Measu.s the voltage betweenths No. il terminal (+) in the SFS main harness4-P connectorand
body ground,
*-
F4
5.
Reconnectthe battery positivecable and negative

caote.
6,
Checkfor continuitybetweenthe 811 terminal

body ground.
BLU
d.L
Vrowllom wi|! rftro.
lf voltage is more thsn 8.5 V, go to step 8.
It voltage is lessthan 8.5 V, go to step 3.
NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code
number before disconnectingthe banery cables.
lf there is continuity,the SRS main harnessis

s h o r t e d . R e p l a c et h e S B S m a i n n a r n e s sa n o
page23-283.
lf there is no continuity,go to step7.
(cont'dl
23-293
vnx.su
SupplementalRestraintS ystem(SRSI
Troubleshooting(cont'dl
7.
Checkfor continuity betweenthe 811 terminal of

Test HarnessB and the No. 4 terminal of the SRS
main harness4-Pconngctor,
Turn ths ignitionswitchON {ll} and wait for six seconds. Measurethe voltagebetweenthe No. 5 terminal (+)and body ground (-).
OASHSOAROIVIRE HARNESS
s.PCO ECTOR
TESTHARNESSB
07MAZ - SF|D500
Vrawfromsil! rira,
8.
l f t h e r e i s c o n t i n u i t y ,t h e S R S u n i t i s f a u l t y ,
Replaceit and recheckthe voltages according to
the charton page23-283.
lf voltage is mora than 8.5 V, the SRS indicator

circuitis faulty (in the gaugeassemblyl.Replace
the SRS indicatorcircuit assemblyand recheck
the voltsges according to the chart on page 23243.
lf there is no cootinuity.there is an open in the

SRS main harness.Replacethe SRS main h8rness and recheckthe voltagesaccordingto the
charton page23-283.
lf voltageis lessthan 8.5 V, the dashboardwire

h a r n e s s( o r t h m a i n w i r e h a r n e s s )i s f a u l t y .
Replaceit and recheckthe voltages accordingto
the chart on page 23-283.
Reconnectthe SRS main harness4-P connecto.to

the main wire ha.ness.Disconnectthe dashboard
wire ha.ness5-Pconnectorfrom the gaugeassemDtv.
DASHBOARDWIRE HARNESS
5.P OONNECTOR
23-294
vnx.su
AirbagAssemblyReplacement
storc a r.movcd
@E
p.d surfaco up, if tho lirbrg
down, accidontald.ploymert
cnough torcr lo causclariour
lirb.g rslombty with thc

is improparly 3iorad frca
could plopcl tha unit with
iniury.
CAUTION:
. Do not inst.ll urld SRS plrts trom lnothar c!1,
Whon lepairing, uss only now SRSprrt!.
o Carefully inlpcct thc airblg rlrcmbly bltorc you
install it. Do not inst.ll an airbag !$.mbly thrt
3how! sign3 of bcing droppcd or improparly hrndlod, such as dont!. crack3or dstormation.
. Alwry! koop ths rhort connactor(3l (REDI on tha
airbrg{s} whon tho hsrnca3i! dirconnastld.
. Do not diras3ombl! or tampl with tha lirbrg
a$ombly.
Fror{ P$!.ngar/3 Sida:

.
Remove th6 glove box damper, then remove the

glove box.
Disconnoctthe front psssenger'sairbag 3-p connect o r f r o m t h e S R S m a i n h a r n e s s ,a n d c o n n e c tt h e

short connoctor (RED)to the front passenger,sairbag
3-Pconnector.
FROIVTPASSNGEF'S
AIRBAG
3.PCONNECTOR
SHOBTOONNECTOR
(REDI
NOTE:The original radio has a coded th6ft protection

1.
Oisconnectthe battery nogative cabl6, then disconnect the positive cable.
2.
Connect the short connecto(s) (RD)to the aifbag

side of the connector(s);
Drivo/s Sido:
a Removethe accesspanel from the steeringwhesl,
then ramove the short connector (REDI from th6
paner.
.
Disconnectthe 3-P connectorbetwesn the driv6r's

airbagand cablereel,then connectth6 short connector {RED}to the airbagsideof the connector.
(cont'd)
23-295
vnx.su
AirbagAssemblyReplacement(cont'd)
3.
Removethe airbag(s):
Driver's Side:
.
Removethe two TORXobolts using a TORX0T30 bit,

then removethe driver'sairbagassembly.
DRIVER'S
AIRBAG ASSEMBLY
Front Palsugor'r
.
Sidc:
Removethe four mounting nuts, then lift the front

passenger's
airbagout of the dashboard.
NOTE:Oo not confusethe lower mountingnutswith
the upper mounting nuts. The upper mounting nuts
are not selt-locking.
FRONTPASSENGER'S
AIBBAGASSEMBLY
23-296
vnx.su
CAUTION: Bo 3uro to in3tsll tho SRSwiring so that it is

not pinchod or intoforing with other car parts.
Front Pa$aogsr's Sid:

.
4.
Installthe new airbag(s):

Driver's Sido: Placethe driver's airbag assembly in
the steeringwheel, and secureit with new TORX@
bolts.
TORXCBOLT
9.8 N'm 11.0kgt m.
7.2lbf.ftl Replace.
Uio a TORXOT30 bit
Placethe front passenger'sairbag assemblyin the

dashboard.
Looselyinstallall four mountingnuts.
Tighten the upper two nuts first, then the lowsr two
nuts. Adjust the lower mounting bracketif necessarV.
FRONTPASSENGER'S
AIRBAG
ASSEMALY
UPPER
MOUNTINGNUTS
TORXOBOLI
9,8 N'm l'1.0kgf.m,
7.2lbtftl Replaco.
Us. . TORX6T30 bit
LOWER
MOUNTINGNUTS
9.8 N.m (1.0lgtm, t.2lbtftl
Reolace.
CONNECTOR
IREDI
{cont'd)
23-297
vnx.su
(cont'd)
AirbagAssemblyReplacement
5.
Connect the battery positive cable, then the negative cable.
Removeand properlystore the short connector(s),

then reconnectthe airbagconnector(s).
7.
Front Passngr'sSide:
. Remove the short connector (RED)from the front
p a s s e n g e r ' sa i r b a g c o n n e c t o r ,t h e n c o n n e c tt h e
airbag 3-P connectorto the SRS main harness3-P
connector.
After installingthe airbagassembly,confirm proper

systemoperataon:
Turn the ignition ON (ll): The instrumentpanel
SRSindicatorlight shouldcome on for aboutsix
secondsand then go off.
. Make sure both horn buttons work.
a Take a test drive and make sure the cruise control sevresumswitch works.
.
SHORTCONNECTOR
FRONTPASSENGER'S ,,'
AIRBAG3.P CONNECTOR
8.
Enter the code number to restoreradio oDeration

(seepage23-191).
. Then reinstallthe glove box on the dashboard,

Driver's Side:
Removethe short connector(RED)from the driver's
airbag connector,then connectthe airbag 3-P connectorto the cablereel3-Pconnector.
CABI-EREEL
3-PCONNECTOR
SHORTCONNECTOR
IRED)
DRIVER'S
AIRBAG3.P
CONNECTOR
Attachthe short connector(RED)to the accesspanel,

then reinstallthe panelon the steeringwheel.
23-294
vnx.su
Airbag Assembly Disposal

Beforescrappingany airbag(s)(includingone in a whole
car to be scrappedl,the airbag must be deployed. t{ the
car is still within the warranty period, before you deplov
the ai.bag,the AcuraDistrictServiceManagermust give
approvaland/or specialinstructions.Onlv after the airba9 has beendeployed(asthe resultof vehiclecollision,
for example),itcan be scrapped.
lf the airbag(s)appear(s)intact (not deptoyed,treat it
{them)with extremecaution.
Followthis Drocedure:
Front Passonger'sAirbag:
4.
R e m o v et h e g l o v e b o x d a m p e r ( s e es e c t i o n2 O ) .
then removethe glove box. then disconnectthe 3-p
connectorbotweenthe front passenger,s
airbagand
SRSmain harness.
FRONT
PASSENGER'S
SHORT
CONNECTOR
AIRBAG3.PCONNECTOR IRED}
Doployingthe Airbag(sl:In-car
N O T E : l f a n S R S c a r i s t o b e e n t i r e l y s c r a p p e d .i t s
airbag(s)should be deployedwhile still in the car. The
a i r b a g ( s )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
pan(sland shouldneverbe installedin anothercar.
confirm that osch airbsg assemblyis
@
s6cursly mounted; oihorwis6. svoro parsonal iniury
could result from doployment.
1.
Disconnectthe banerynegativecable.then discon_

nectthe Dositivecable.
2.
Confirmthat the specialtool is functioningproperly

by followingthe checkprocedureon the labelof the
tool set box, or on page23-300,
SRSMAIN I{ARNESS
Driver's Airbag:
3.
Removethe accesspanel,then disconnectthe 3_p

connecto.betweenthe driver'sairbagand the cable
reel.
Cut off the airbag connector,strip the ends of the

airbagwires, and connectthe specialtool alligator
clips to the sirbag.Placethe specialtool aboutthir_
ty feet (10meters)awayfrom the airbag.
CABLEREEL
3.P CONNECTOR
DRIVER'S
AIRBAG
FRONTPASSENGER'S
AIRBAG
ALLIGATOR
CLIPS
lY.llowl
12 V BATTERV
OPERATION
swrTcH
DEPLOYMENT
TOOI
(cont,dl
07HAZ- SG00400
23-299
vnx.su
AirbagAssemblyDisposal(cont'd)
Connecta l2 volt battervto the tool:
Doploying the Airbag: Out-ot{!r.
NOTE: lf an intsct airbag assembly has been removed

from a scrappedcar, or has been found dofectiveor
damagsd during transit, storage or service, it should bs
dsployed as follows:
lf the green light on the tool comes on, th

a i r b a g i g n i t e r c i r c u i t i s d f e c t i v ea n d c a n n o t
d e p l o y t h e a i r b a g . G o t o D s m a g dA i r b a g
SpecialProcedure.
lf the red light on the tool comeson, the airbagis
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 6 s i r b a g
should deploy (deploymentis both highly audible
and visibls- a loud noiseand raDidinflationof the
bag, followed by slow deflationl.
Porition th6 lirbrg rr:.mbly t.ce up, out@

doo6 on flat ground !t lorrt thirty foot from rny ob3t..
clar or pcoplo.
lf audible/visibledeploymnt happsns and the

green light on the tool comes on, continuswith
this Drocedure.
. lf the airbag doesn't deploy, yet the green light
comes ON, its igniter is dofectiv. Go to
DamagedAirbagSpecialProcedure.
Duringdeploymnt,the airbsg assom@
bly can becomehot enoughto burn you. Wait thirty
m i n u t e s a f t e r d e p l o y m e n tb e f o r o t o u c h i n g t h e
assemblv.
Disposeof the completeairbag sssembly.No pan
of it can be reused. Place it in I sturdy plastic bag
and sealit securelv.
1.
2.
3.
Confirmthat the specialtool is functioningproperly

by followingthe checkprocedureon this pageor on
the tool box label.
Removethe short connectorfrom the airbag connector.
Folfowsteps5,6,7, and 8 of the in-cardeployment
orocequre.
Dlmlged Airbsg Sp.ci8l Procoduro.

CAUTION:
Woar a taco shiold lnd glov.s whon hlndling !
doploy.d airbag.
Waeh your hands and rin3a tham wall with
wslor aftor handling r deploycd !irb!g.
f rn lirbag crnnot be deploy.d, it rhould

E!@
not br trcltcd !s normll scrrp; ii 3hould still bc comidercd a potantillly oxplolivr dcvicc thli cln c!u3a 3ariou3 iniury.
1.
2.
3.
i[.
5.
lf instslledin a car,follow the removalprocedureon

page 23-295.
In all cases,make sure a short connector is properly
installedon the airbagconnctor.
Packagethe airbag in sxacily the same packaging
part cama in.
that the now replacement
Mark the outside 0f the box "DAMAGEDAIRBAG
NOT OEPLOYED"so it does not get confused with
your parts stock.
Contact your Acura District Service Manager for
how and where to return it for disoosal.
Dcploymont Tool: Chcck Procedure.

1.
2.
3.
Connectthe yellow clips to both switch protector

handleson the tool; connectthe tool to a battery.
Pushth operationswitch:green meansthe tool is
OK; red means the tool is faulty.
Disconnectthe battery and the yellow clips.
23-300
vnx.su
CableReelReplacement
store r rcmov.d
!!@
prd ruf.cc up. It th. .irb.g
down, sccid.ntd d.ploym.rf
rnough torca to caure a.?iour
rirbrg rsldnbty with thr

i3 impropcrly 3to.rd f.cc
could propcl th. unit with
iniury.
5.
Connectthe sho.t connector(s)

to the airbag(s).
DRIVER'S
AIRBAG
GAUTION:
o Clrdully in3pcct thc airbrg r$.mbly brtorc instll_
ling it. Do not inttrll !n lirb.g |3..mbly ihst fiow3
rignr of bring droppcd or improp.rly handled. ruch
.3 dant!, crrck3 or dafo?mation.
. Atw!$ krro th. tkroR connctot(3l on ths rtbrg\t\
connactor whan tha h|rn!|a l! dbconncstad,
. Do
dis.tlambla or tampar with thc ai.brg !rlo-t
t.mbly.
NOTE: The original radio has a codod theft Drotoction
c i r c u i t . B s s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r
bsfore disconnectingth6 battery cables.
l.
Disconnectth6 banory negstive cable and thsn the

positive cable.
2.
Makesurethe whelsare alignedstraightahoad.
3.
Removo th dashbosrd lowsr covsr and kne6 bol_

$er.
IRED}
SRSMAIN HARNESS
R e m o v et h e d r i v e r ' s a i r b a g a s s e m b l yf r o m t h e
steerangwheel (two T30 TORXObolts), then remove
the steering wheet nut.
TOR)(' BOLTS
U.. . TORX. T30 bh
DRIVER'S
AIRBAG
ASSEMBLY
DASHBOANO
LOWEROOVER
Removs tho glove box damper (s6e sction 2O),
then removethe glove box,
(cont'd)
23-301
-
vnx.su
GableReelReplacement(cont'd)
Disconnect
the connectorsfrom the horn and cruise
controlsevresumeswitches,then removethe cable
reel3-Pconnectorfrom its cliD.
10. Disconnectthe 6-P connector between the cable

reel and SRS main harness,then remove the connectorholderfrom the steeringcolumn.
CABITBEEL
CONNECTOFHOI-DER
8.
Removethe steeringwheelfrom the column.
9.
Removethe upperand lowercolumncovers.
'l l. Removethe cablereelfrom the column,
COVER
UPPER
COLUMN
23-302
vnx.su
GAUTION:
o Eatorainstdlingtho steoringwhosl,lha front whaels
lhould bo alignod straight !ho!d.

Bc auro to imtalt tho hrrnass wiros so that th6y !16
not pinchod or intsrt6ring with othor crr parts.
. Aftor rsassambly. conlirm that tho whods lre 3till
turnad straight ahead and lh.t the steering wheol
rpoko angle is corrsct {rosd tesi}. lf mino. spok
angl6 adiustmont is necols!ry, do 30 only by ldiust_
mgnt ol tho tio-rod9. not by removing and rgpositioning tho rteering whoel.
.
1 4 . Installthesteeringcolumnupperano towercovers.
t5.
Centerthe cable reel. Do this by first rotatingthe

cable reel clockwise until it stops. Then rotate it
counterclockwise
(approximately
two turns)until:
.
T h e y e l l o wg e a rt o o t h l i n e su p w i t h t h e a l i g n ment markon the cover.

a The arrow mark on the cable reel label Doints
straightup.
ABROWMARK
12. Align th cancelsleevegrooveswith the cable reel

projections.
CABLEREEL
ALIGNMENTMARK
Carefullyinstallth cable reel on the steeringcolumn shaft.Then attachthe connectorholderto the

steeringcolumn.
YELLOWGEAR
TOOTH
16. Installthe steeringwheel and attach the cable reel

3-Pconnectorto the clip.
CRUISE
CONTROL
SET/RESUME
HORNCONNECTOR
CABI.I REEL
't7.
CONNECTOR
HOLDER
vnx.su
Connectthe horn connectorand cruisecontrol sev

resumeswitchconnector.
(cont'd)
23-303
SupplementalRestraintSystem{SRSI
(cont'd)
CableReelReplacement
2 1 . Removeand properlystore the shon connector(s)
18. Installthesteeringwheel nut.
{RED},then reconnectthe airbagconnector(s}(and

reinstallthe glove box).
22. Reconnectthe battery positive cable,then the nega-
TORXOBOLTS
9.8 N.m (1.0kgf.m,7.2lbtftl
Replace.
Us6 a TORX6T30 bit
tive cable.
23. After installingthe cable reel,confirm proper syslm operalron:

Turn the ignition ON (ll); the instrument panel
SRS indicator light should go on for about six
sscondsand then go off.
a Make sure both horn buttons work.
a M a k e s u r e t h e h e a d l i g h ta n d w i p e r s w i t c h e s
work.
Go for a test drive and makesurethe cruisecontrol switcheswork.
Rotatethe steering wheel counterclockwiseto
make sure the yellow gear tooth lines up with
WHEELNUT
STEERING
,19N.m 15.0kgt m, 36 lbt ft)
Replace.
AIRBAG ASSEMBLY
1 9 . Installthe driver'sairbagassembly.
20. Connectthe cable reel 6-P connactorto the SRS
m a i n h a r n e s s ,t h e n i n s t a l lt h e k n e e b o l s t e ra n d
dashboardlower cover.
24. Enterthe code number to restore radio operation

(seepage23-191).
DASHBOARDLOWEROOVER
23-304
vnx.su
DashSensorReplacement
GAUTION:
. Oo not drmrgc the sensor wiring.
. Do not instrll used SBS part3 from anothor c!t,
When repairing an SRS:use only new part3.
o Roplaco. 3onsor it it is dented, crackod,or doform.
od.
Removethe footrestdriver,sside only and door sill

molding,then pull the carpetback,and removethe
dash sensor protector.(Left side shownj right side
is similar.)
NOTE;The original radio has a coded theft protection

c i r c u i t . 8 e s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r
before disconnectingthe bttery cabres,
1.
Oisconnectthe batterynegativecableand then the

posative
cable.
2.
Remove the glove box damper (see section 201.

then remove the glove box.
SHOBTCONNECTOR
IREDI
DASH
PROTECTOR
5.
SRS MAIN HARNESS
3. Connectthe shortconnector(s)
to the airbag(s).
Removethe two mounting bolts.then removethe

dash ssnsor.
DASH SENSOB
DRIVER'S
AIRBAG
DRNEN'S
ANAAG
3.P CONNECTOR
SHORT
CONNECTOR
IREDI
MOUNTIITGBOLTS
(cont'd)
23-305
vnx.su
(cont'dl
DashSensorReplacement
CAUTION:
. Be 3ure to install the harnesswires so that theY ars
not pinchcd or interfering with othor car parte.
o Carefully inspest the dash sensorslor signs of boing
dropped or improperlyhandled,3uchas dents,
cracksor dsformation.
. For the SRS to lunction propotly, ths right and lsft
sensorsmust be installsd on the propor sidos.
6.
Installthe sensorsecurely.
Removeand properlystore the short connector{sl,

then reconnectthe airbag connector(s)(and rsinstallthe glove box).
Reconnectthe battery positive cable,then the negative cable.
1 0 . After installingthe dash sensor,confirm proper system operation:Turn the ignition ON (ll):the instrument panel SRSindicatorlight should come on for
aboutsix secondsand then go off.
1 1 . Enter the code number to restoreradio operation
(seepage23-191)-
DASH SENSOR
MOUNTINGBOLTS
8 mm x 1.25
22 N.m (2.2kgf.m, 16lbfftl
Replace.
7.
Reinstallall other removedparts.
23-306
vnx.su
SRSUnit Replacement
CAUTION:
. 8tor6 disconneciing any part of the SRS wire harness, connect the short connectorlsl (RED)to tho
sirbagl3).
o Do nol drmsgo thc SRS unit terminal! o. connocto.s.
. Do not disassemblotho SRS unit; it ha3 no rervico.blo parts.
. Storo tho SRS unit in a cleln, dry srea.
. Do not us lny SRS unit which h.s been subisctod
to wator damag or shows sign3 ol bing droppad or
improperly handl6d, such as dents. cracki or d6tormation.
4.
Removethe left side cover from the SRSunit. then

disconnectthe SRS main harness lg-p connector
from the SRSunit.
SRSUNIT

c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r
before disconnectingthe baftery cables.
1.
Disconnect
the batterynegativecable,then the pos_
itivecable.
Connectthe short connector(s)
to the airbag(s)(see
page 23-2721.
Removethe right sidecoverfrom the SRSunit.
Removethe four TORXobolts from the SRS unit,

then pull out the SRSunit from the driver,sside.
(cont'd)
23-307
vnx.su
SupplementalRestraintSystem{SRSI
(cont'd)
SRSUnit Replacement
Remove and properly storo the short connector{s),
thgn roconnectthe sirb8g connector(s)(and reinst8ll tho glove box).
CAUTION: B suro to install tho SRS wiring ro thlt it i3

not pinched or interfeling with other car plrts.
6.
Installthe new SRSunit,
Roconnoctthe battery positivo cable,thn the n98tivo cabls.
SRS UNIT
SRSMAIN HARNESS
18.PCONNCTOR
1' l. After installing the SRS unit, confirm proper system

operation: Turn the ignition ON (ll): th instrumont
panel SRS indicator light should come on for about
six sscondsand then go off.
12. Ent6r tho code number to rostors radio operation

(seepage23-191).
TORX' BOLTS
9.8N.m11.0ksl'm.
7.2tbf.ftl
Replace.
U.. . TORX' T30bit
LEFTSIDECOVER
SRSUNIT
TOD(' BOLTS
9.8N.m(1.0tc[.m,
7.2tbf.ftl
Ur. . TORX.T30bit
COVER
Connectthe SRS main harness18-Pconnectorto

the SRSunit;push it into positionuntil it clicks.
Installthe SRSunit covers(rightand left).
NOTE: Make sure the coverssnap togther in the
middle.
23-308
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ACUrj|A

Manutactulol, Make and

81881: 1.8 f DOHCSequentiat

Vehicle Glado (Seriesl

Lift and SupportPoints

1. Placethe lift blocksas shown

Lift and Support Points

3 . Raisethe car highenoughto insenthe safetystands.

Sling-type Equipmont-The tow truck uses metal cables

NOTICE:lmpropertowing preparationwill damagethe

*: Measuredbetweenthe camshaftand rockerarm.

Unitof length:mm {in}

250rpm and wideopnthrottle Nomin6l

': Masuredbetwoonthe camshattand rcc(ersrm.

Unit of length:mm (in)

etaet engine 4.6{4.9,4.0}torengineoverhaul

3.8(4.0,3.3)for oil change,inctudin

3.7 i3.9 3 3l fdr ^il .hi

0.04- 0.16(0.002- 0.006)

,3 - 113toss- trs, r3=Jt&

Unit ot length: mm {in)

Fuel and Emissions

Caprcity , {US gal,lmp gal)

ldle sDeed with headlight and cooling fan ofi rpm

Fast idle rpm

275- 32a 12.8 -3.9,39.6 - 46.9)

Capacityf {US qt, lmp q0

Diameterof needlebearingconlact area

0.11- 0.18{0,004- 0.007)

37.984- 38.000{1.495- 1.495}

Unit of length:mm (in)

Groovewidth of shift arm contactarea

0.95r 1.68(0.037- 0.066)

- Automatic Transmission- Section

I (USqt, lmp qt)

Line pressureat 2,000rpm

Throttle fully closed

Stallspeedrpm (Checkwith car on levelground)

830- 880(8.5- 9.0,120- 130)

830- 880{8.s- 9.0.120 130)

830- 880(8.5- 9.0,120- 130)

830- 880{8.5- 9.0,120- 130}

Clutch ond plato thickn$s

Clutchond pl.t6 thicknoss

0.65- 0.85 (0.026- 0.0331

Unitol length:mm (in)

Mainshaft2nd gear thrust washer thickngss

Sealing ring contact area LD.

Reverseshift fork tinger thickness

Oil pump driveng6arI.D.

27.0- 27.r (1.063-1.067)

Unit of length: mm (in)

Differential (Automatic transmissionl

Pinionshatt contactarea l.D.

Unitof length:mm {in)

Play in strokat 200 N {20 kgf, 44 lbt)

To b lockodwhen pulled 6 -10

9.5- 10.5{0.37- 0.41}

16"r 2. -750r 50(Neurra0

Eelt tnsion N (kgf, lbf)

9.0- 11.0(0.35- 0.43)with us6db6li

Ourput l3.5 V at hot A

ShockAbsorbr,Front and Rear

API Service Grades: SF or SG

Brakeline (lncludesAnti-lockbrake linel

Brakefluid DOT3 or DOT4