Acura 3.5 RL Manual Download Page 1201 | Manualshive

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Wake-up Function Test

Description:

• When the ignition switch is turned ON (II), all of the multiplex control units wake up at the same time. In this case, the

wake up lines and communication lines are not involved in the wake up function.

• When a switch related to the multiplex control unit (door) is operated:

First, the door multiplex control unit wakes up, then the control unit starts to communicate to the driver's control unit.
By this communication, the driver's control unit wakes up. The driver's control unit wakes the passenger's control unit
up by the wake up line, and all the control units start to function.

• When a switch related to the multiplex control unit (driver's or passenger's) is operated:

The control unit related to the operated switch wakes up, then the control unit wakes up the other unit. (In this case, the
door control unit does not wake up.)

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Summary of Contents for 3.5 RL

Page 1: ...oling Fuel and Emissions Transaxle Steering Suspension Brakes Including ABS TCS and VSA Body Heating Ventilation and Air Conditioning Body Electrical Restraints 1996 04 3 5RL Main Menu As sections w include SRS components special precautions are required when servicing ...

Page 2: ... 4a Parts Marking 03 04 Models 1 5b Identification Number Locations 1 8 Warning Caution Label Locations 1 9 Under hood Emissions Control Label 97 Models 1 13 98 Models 1 14 99 Models 1 15 00 Models 1 16 01 02 Models 1 17 03 Models 1 4b 04 Models 1 4c Lift and Support Points Lift and Safety Stands 1 18 Floor Jack 1 19 Towing 1 20 Service Precautions Handling of Special Nuts and Bolts 1 21 Main Menu...

Page 3: ...dentification Number and Canadian Motor Vehicle Safety Standard Certification COLOR LABEL INT COLOR TYPE F EXT COLOR G 79P KA SZ3 A3 C Paint Code Paint Code Paint Code Color G 79P G 83P NH 585P NH 592P RP 25P YR 508M YR 511P Juniper Green Pearl Eucalyptus Green Pearl Cayman White Pearl Flamenco Black Pearl Black Currant Pearl Heather Mist Metallic Devon Slate Pearl Main Menu Table of Contents ...

Page 4: ...Pearl Eucalyptus Green Pearl 1 Cayman White Pearl Flamenco Black Pearl Black Currant Pearl 1 Heather Mist Metallic Devon Slate Pearl 1 Engine Number Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification COLORLABEL INT COLOR TYPE F EXT COLOR G 79P KA SZ3 A3 C Paint Code ...

Page 5: ...Safety Standard Certification Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification COLORLABEL INT COLOR TYPE F EXT COLOR G 79P KA SZ3 A3 C Paint Code Paint Code Paint Code Color Crystal Silver Metallic Juniper Green Pearl 1 Cayman White Pearl Flamenco Black Pearl Athlete Gray Metallic 1 Ruby Red Pearl 1 Heather Mist Metallic B 91M G 79P NH 585P NH 592P NH 611M R 5...

Page 6: ...fication Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification COLOR LABEL INT COLOR TYPE F EXT COLOR G 97P KA SZ3 A6 C Paint Code PaintCode Paint Code Color Crystal Silver Metallic Nighthawk Black Pearl Monterey Blue Pearl 1 Vermont Green Pearl Premium White Pearl Ruby Red Pearl 1 Naples Gold Metallic B 91M B 92P B 93P G 97P NH 624P R 504P YR 524M ...

Page 7: ...afety Standard Certification Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification COLOR LABEL INT COLOR TYPE F EXT COLOR G 97P KA SZ3 A6 C Paint Code Paint Code Paint Code Color B 92P B 93P G 97P NH 552M R 504P YR 524M Nighthawk Black Pearl Monterey Blue Pearl Vermont Green Pearl 1 Sebring Silver Metallic Ruby Red Pearl 1 Naples Gold Metallic 1 U S model only ...

Page 8: ...ertification Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification COLOR LABEL INT COLOR TYPE F EXT COLOR G 97P KA SZ3 A6 C Paint Code B 92P B 502P G 97P NH 623M NH 624P R 507P YR 524M Nighthawk Black Pearl Indigo Blue Pearl 1 Vermont Green Pearl 1 Satin Silver Metallic Premium White Pearl Firepepper Pearl Naples Gold Metallic Color PaintCode Paint Code ...

Page 9: ...ChassisandPaintCodes 2002 Model Vehicle Identification Number Transmission Number PaintCode Engine Number ...

Page 10: ...Chassis and Paint Codes 2003 Model Vehicle Identification Number TransmissionNumber Paint Code ...

Page 11: ...Chassis and Paint Codes 2004 Model ...

Page 12: ...omponent terms have been changed to conform with the standards in SAE docu ment J1930 If you find a term or abbreviation in a 01 manual that is unfamiliar to you check this list If a term is not listed below it did not change 00 and Earlier Models 01 and LaterModels ...

Page 13: ... 00 and Earlier Models 01 and Later Models ...

Page 14: ...have self adhesive labels Replacement body parts have generic self adhesive labels The original engine or transmission VIN plate is transferred to a replacement engine or transmission and attached with break off bolts NOTE Be careful not to damage the parts marking labels during body repair Mask the labels before repairing the part ...

Page 15: ...Identification Number Locations Vehicle Identification Number Vehicle Identification Number Transmission Number Automatic EngineNumber ...

Page 16: ...MS ALL SRS ELECTRICAL WIRING AND CONNECTORS ARECOLOREDYELLOW TAMPERING WITH DISCONNECTING OR USING ELECTRICAL TEST EQUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL FIRING OF THE INFLATOR WARNING THE AIRBAG INFLATOR IS EXPLOSIVE AND IF ACCIDENTALLYDEPLOYED CANSERIOUSLY HURT YOU FOLLOW SERVICE MANUAL INSTRUCTIONS CAREFULLY SRS WARNING HOOD 99 01 models SUPPLEMENTAL RES...

Page 17: ... FLIP VISOR OVER FRONT SEAT PASSENGER AIRBAG MODULE DANGER WARNING 96 97 models DANGER EXPLOSIVE FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS SUCH AS COPPER LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS STORAGE TEMPERATURES MUST NOT EXCEED 200 F 93 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCE DURES REFER TO THE SERVICE MANUAL SRS SUPPLEMENT POISON CONTAIN...

Page 18: ...URY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS STORAGE TEMPERATURES MUST NOT EXCEED 200 F 93 C FOR PROPER HANDLING STORAGE AND DISPOSAL PROCE DURES REFER TO SERVICE MANUAL SRS SUPPLEMENT POISON CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE FIRST AID IF CONTENTS ARE SWALLOWED INDUCE VOMIT ING FOR EYE CONTACT FLUSH EYES WITH WATER FOR 15 MINUTES IF GASES FROM ACID OR WAT...

Page 19: ...s Control Label HEADLIGHT AIMING INFORMATION 96 99 models See page 1 11 This caution is also labeled on passenger doorjamb AIR CONDITIONING INFORMATION TIREINFORMATION SIDEAIRBAGCAUTION TIRE INFORMATION RADIATOR CAP CAUTION 00 01 models BATTERY CAUTION COOLANT INFORMATION ...

Page 20: ...p Identification 1997 model Example VACUUM HOSE ROUTING DIAGRAM 50ST 50 State THIS VEHICLE CONFORMS TO THE U S EPA AND THE STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1997 MODEL YEAR NEW MOTOR VEHICLES Engine and Evaporative Families Engine Family ...

Page 21: ...cation 1998 model Example VACUUM HOSE ROUTING DIAGRAM 50ST 50 States THIS VEHICLE CONFORMS TO THE U S EPA AND THE STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHICLES Engine and Evaporative Families Engine Family Evaporative Family ...

Page 22: ... Example VACUUM HOSE ROUTING DIAGRAM 50ST 50 States THIS VEHICLE CONFORMS TO THE U S EPA AND THE STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 MODEL YEAR NEW MOTOR VEHICLES Engine and Evaporative Families Engine Family Evaporative Family ...

Page 23: ...T 50 States THIS VEHICLE CONFORMS TO U S EPA NLEV REGULA TIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSEN GERCARS Engine and Evaporative Families Engine Family Evaporative Family VACUUM HOSE ROUTING DIAGRAM ...

Page 24: ...U S EPA NLEV REGULA TIONS APPLICABLE TO 2001 MODEL YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW LEV PASSEN GER CARS CANADIAN TIER 1 THIS VEHICLE CONFORMS CANADIAN TIER 1 STAN DARDS FOR 2001 MODEL YEAR NEW PASSENGER CARS Engine and Evaporative Families Engine Family Evaporative Family ...

Page 25: ...Emission Group Identification 2003 model Under hood Emissions Control Label Engine and Evaporative Families ...

Page 26: ...Under hood Emissions Control Label Emission Group Identification 2004 model ...

Page 27: ...he hoist a few inches centimeters and rock the vehicle to be sure it is firmly supported 3 Raise the hoist to full height and inspect the lift points for solid support NOTE Use the same support points to support the vehicle on safety stands FRONT SUPPORT POINT REAR SUPPORT POINT LIFT BLOCKS ...

Page 28: ...t and place the safety stands so the vehicle will be approximately level then lower the vehicle onto them Always use safety stands when working on or under any vehicle that is supported by only a jack Never attempt to use a bumper jack for lifting or supporting the vehicle Front Center the jack bracket in the middle ofthe jack lift platform JACK LIFT PLATFORM Rear Center the jack bracket in the mi...

Page 29: ...dy can be seriously damaged if this method of towing is attempted If the vehicle cannot be transported by flat bed it should be towed with the front wheels off the ground If due to damage the vehicle must be towed with the front wheels on the ground do the following Releasethe parking brake Start the engine Shift to position then position Turn off the engine Leave the ignition switch in Accessory ...

Page 30: ...er types of nuts and bolts may cause elec trolysis and corrosion which in turn could cause the bolt to loosen Gray plating Green coating on the threads of some bolts Gray plating Dacro type Gray plating Green coating on the threads Torquer type 1 When replacing nuts and bolts use only the same type 2 Tighten the nuts and bolts with a torque wrench to the specifications provided in this manual 3 Cl...

Page 31: ...ls 2 4 02 Model 2 4a 03 Model 2 4b 04 Model 2 4c Automatic Transmission 96 01 Models 2 4 02 Model 2 4a 03 Model 2 4b 04 Model 2 4c Differential 96 01 Models 2 8 02 Model 2 8a 03 Model 2 8b 04 Model 2 8c Steering 96 01 Models 2 9 02 Model 2 9a 03 Model 2 9b 04 Model 2 9c Suspension 96 01 Models 2 9 02 Model 2 9a 03 Model 2 9b 04 Model 2 9c Brakes 96 01 Models 2 9 02 Model 2 9a 03 Model 2 9b 04 Mode...

Page 32: ...ion to new value Run the engine for 5 minutes then turn it off Readjust deflection to used belt value 2 Do not adjust the gap replace the spark plug if it is out of service limit 1 NIHON HATSUJO manufactured valve spring 2 CHUO HATSUJO manufactured valve spring Cylinder Head Valve Train Section 6 ...

Page 33: ...ion to new value Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt value 2 Do not adjust the gap replace the spark plug if it is out of service limit Cylinder Head Valve Train Section 6 1 NIHON HATSUJO manufactured valve spring 2 CHUO HATSUJO manufactured valve spring ...

Page 34: ...Standards and Service Limits Engine Electrical Section 4 Cylinder Head Valve Train Section 6 ...

Page 35: ... Head Valve Train Section 6 1 When using a new belt adjust deflection or tension to new value Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt value 2 Do not adjust the gap replace the spark plug if it is out of service limit ...

Page 36: ...Engine Lubrication Section 8 Engine Block Section 7 ...

Page 37: ... Engine Block Section 7 Engine Lubrication Section 8 ...

Page 38: ...Engine Block Section 7 Engine Lubrication Section 8 1 RIKEN manufactured piston ring 2 TEIKOKU PISTON RING manufactured piston ring ...

Page 39: ...Engine Block Section 7 Engine Lubrication Section 8 ...

Page 40: ...Standards and Service Limits Cooling Section 10 Fuel and Emissions Section 11 ...

Page 41: ...Standards and Service Limits Cooling Section 10 Fuel and Emissions Section 11 ...

Page 42: ...Fuel and Emissions Section 11 Standards and Service Limits Cooling Section 10 ...

Page 43: ...Standards and Service Limits Cooling Section 10 Fuel and Emissions Section 11 ...

Page 44: ...Standards and Service Limits Automatic Transmission Section 14 ...

Page 45: ...Automatic Transmission cont d Section 14 ...

Page 46: ...Standards and Service Limits Automatic Transmission cont d Section 14 ...

Page 47: ...Automatic Transmission cont d Section 14 ...

Page 48: ...Standards and Service Limits Automatic Transmission cont d Section 14 ...

Page 49: ...Standards and Service Limits Automatic Transmission Section 14 ...

Page 50: ...Automatic Transmission cont d Section 14 ...

Page 51: ...Standards and Service Limits Automatic Transmission cont d Section 14 ...

Page 52: ...Automatic Transmission cont d Section 14 ...

Page 53: ...Standards and Service Limits Automatic Transmission cont d Section 14 ...

Page 54: ...Standards and Service Limits Differential Section 15 ...

Page 55: ...Standards and Service Limits Differential Section 15 ...

Page 56: ...Standards and Service Limits Differential Section 15 ...

Page 57: ...Standards and Service Limits Differential Section 15 ...

Page 58: ...Steering Section 17 Suspension Section 18 Brakes Section 19 ...

Page 59: ...Steering Section 17 Suspension Section 18 Brakes Section 19 ...

Page 60: ...Steering Section 17 Suspension Section 18 Brakes Section 19 ...

Page 61: ...Brakes Section 19 Suspension Section 18 Steering Section 17 ...

Page 62: ...Standards and Service Limits AirConditioning Section22 ...

Page 63: ...Standards and Service Limits Air Conditioning Section 22 ...

Page 64: ...ds and Service Limits Air Conditioning Section 22 When using a new belt adjust deflection or tension to new value Run the engine for 5 minutes then turn it off Readjust deflection or tension to used belt value ...

Page 65: ...Standards and Service Limits Air Conditioning Section 22 ...

Page 66: ...Design Specifications ...

Page 67: ...Design Specifications cont d ...

Page 68: ...Design Specifications ...

Page 69: ...Design Specifications cont d ...

Page 70: ...Design Specifications ...

Page 71: ...Design Specifications ...

Page 72: ...Design Specifications ...

Page 73: ...Design Specifications cont d ...

Page 74: ...Body Specifications ...

Page 75: ...Body Specifications ...

Page 76: ...Body Specifications ...

Page 77: ...Body Specifications ...

Page 78: ...oints 3 2 Maintenance Schedule Normal Conditions 96 97 models 3 4 98 00 models 3 8 01 model 3 12 02 03 models 3 2a 04 model 3 2c Severe Conditions 96 97 models 3 6 98 00 models 3 10 01 model 3 14 02 03 models 3 4a 04 model 3 4c ...

Page 79: ... LUBRICANT API Service Grade Use SJ Energy Conserving grade oil The oil container may also display the API Certification seal shown below Make sure it says For Gasoline Engines SAE Viscosity See chart below HondaATF Z1 ATF 1 Genuine Honda DOT3 brake fluid 2 Steering grease P N 08733 B070E Multi purpose grease Honda White Lithium Grease Rust preventive Silicone grease Genuine Honda power steering f...

Page 80: ...NOTE Lubricate all hinges latches and locks once a year In corrosive areas more frequent lubrication is necessary We recommend Honda White Lithium Grease ...

Page 81: ...he severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages 3 6 and 3 7 do not apply 8 4 8 5 8 4 10 5 11 153 4 22 6 8 to 6 13 10 10 4 33 17 15 22 85 11 124 10 5 14 108 15 4 19 10 19 11 12 17 18 19 19 19 23 19 8 19 6 22 68 ...

Page 82: ...emission warranties However Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long term reliability For Canadian models This Maintenance Schedule outlines the minimum required maintenance 17 14 17 23 18 3 18 21 18 22 16 3 19 28 8 4 10 5 14 108 15 4 17 16 19 8 10 2 9 5 11 126 ...

Page 83: ... is out of service limit 2 Replace the tinning belt and timing balancer belt at 60 000 miles U S 100 000 km Canada if the vehicle regularly is driven in one or more of these conditions In very high temperatures over 110 F 43 C In very low temperatures under 20 F 29 C 3 Replace every 15 000 miles 24 000 km if the vehicle is driven primarily in urban areas that have high concentrations of soot in th...

Page 84: ... 8 km per trip or in freezing temperatures driving less than 10 miles 16 km per trip Driving in hot over 90 F 32 C conditions Extensive idling or long periods of stop and go driving Trailer towing driving with a roof top carrier or driving in mountainous conditions Driving on muddy dusty or de iced roads NOTE If the vehicle is driven OCCASIONALLY under a 3 4 and 3 5 severe condition you should fol...

Page 85: ...e severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages 3 10 and 3 11 do not apply 8 4 8 5 8 4 10 5 11 153 4 22 6 8 to 6 13 10 10 4 33 17 15 22 85 11 124 10 5 14 108 15 4 19 10 19 11 12 17 18 19 19 19 23 19 8 19 6 22 68 ...

Page 86: ... emission warranties However Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long term reliability ForCanadianmodels This Maintenance Schedule outlines the minimum required maintenance 17 14 17 23 18 3 18 21 18 22 16 3 19 28 8 4 10 5 14 108 15 4 17 16 19 8 10 3 9 5 11 126 ...

Page 87: ...ule if the vehicle is driven in Canada or MAINLY under one or more of the Severe Driving Conditions page 3 11 8 4 8 5 8 4 10 5 11 153 4 22 6 8 to 6 13 10 10 4 33 17 15 22 85 11 124 10 5 14 108 15 4 19 10 19 11 12 17 18 19 23 19 8 19 6 22 68 3 2 3 3 ...

Page 88: ...les 8 km per trip or in freezing temperatures driving less than 10 miles 16 km per trip Driving in hot over 90 F 32 C conditions Extensive idling or long periods of stop and go driving Trailer towing driving with a roof top carrier or driving in mountainous conditions Driving on muddy dusty or de iced roads NOTE If the vehicle is driven OCCASIONALLY under a severe condition you should follow the N...

Page 89: ...e severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages 3 14 and 3 15 do not apply 8 4 8 5 8 4 10 5 11 153 4 22 6 8 to 6 13 10 10 4 33 17 15 22 85 11 124 10 5 14 108 15 4 19 10 19 11 12 17 18 19 19 19 23 19 8 19 6 22 68 ...

Page 90: ...emission warranties However Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long term reliability For Canadian models This Maintenance Schedule outlines the minimum required maintenance 17 14 17 23 18 3 18 21 18 22 16 3 19 28 8 4 10 5 14 108 15 4 17 16 19 8 10 2 9 5 11 126 ...

Page 91: ... service limit 2 Replace the timing belt and timing balancer belt at 60 000 miles U S 100 000 km Canada if the vehicle regularly is driven in one or more of these conditions In very high temperatures over 110 F 43 C In very low temperatures under 20 F 29 C 3 Replace every 15 000 miles 24 000 km if the vehicle is driven primarily in urban areas that have high concentrations of soot in the air from ...

Page 92: ...8 km per trip or in freezing temperatures driving less than 10 miles 16 km per trip Driving in hot over 90 F 32 C conditions Extensive idling or long periods of stop and go driving Trailer towing driving with a roof top carrier or driving in mountainous conditions Driving on muddy dusty or de iced roads NOTE If the vehicle is driven OCCASIONALLY under a severe condition you should follow the Norma...

Page 93: ...evere driving conditions specified in the Severe Conditions Maintenance Schedule on pages 3 4 and 3 5 do not apply 8 4 8 5 8 4 10 5 11 153 4 22 6 8 to 6 13 10 10 4 33 17 15 22 85 11 124 10 5 14 108 15 4 19 10 19 11 19 12 19 17 19 18 19 19 19 23 19 8 19 6 22 68 ...

Page 94: ...emission warranties However Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long term reliability For Canadian models Follow the Severe Conditions Maintenance Schedule on page 3 4 and 3 5 17 14 17 23 18 3 18 21 18 22 16 3 19 28 8 4 10 5 14 108 15 4 17 16 19 8 10 2 9 5 11 126 ...

Page 95: ...evere driving conditions specified in the Severe Conditions Maintenance Schedule on pages 3 4 and 3 5 do not apply 8 4 8 5 8 4 10 5 11 150 4 22 6 8 to 6 13 10 10 4 33 17 15 22 85 11 121 10 5 14 108 15 4 19 10 19 11 19 12 19 17 19 18 19 19 19 23 19 8 19 7 22 68 ...

Page 96: ...For Canadian models Follow the Severe Conditions Maintenance Schedule on page 3 4 and 3 5 17 14 17 23 18 3 18 21 18 22 16 3 19 28 8 4 10 5 14 108 15 4 17 16 19 8 9 5 11 123 ...

Page 97: ...gh temperatures over 110 F 43 C In very low temperatures under 20 F 29 C 2 Replace every 15 000 miles 24 000 km if the vehicle is driven primarily in urban areas that have high concentrations of soot in the air from industry and diesel powered vehi Follow the Severe Conditions Maintenance Schedule if the vehicle is driven in Canada or MAINLY under one or more of the Severe Driving Conditions page ...

Page 98: ...eage period to ensure long term reliability Severe Driving Conditions Driving less than 5 miles 8 km per trip or in freezing temperatures driving less than 10 miles 16 km per trip Driving in hot over 90 F 32 C conditions Extensive idling or long periods of stop and go driving Trailer towing driving with a roof top carrier or driving in mountainous conditions Driving on muddy dusty or de iced roads...

Page 99: ...the vehicle is driven in Canada or MAINLY under one or more of the Severe Driving Conditions page 3 5 8 4 8 5 8 4 10 5 11 150 4 22 6 8 to 6 13 10 10 4 33 17 15 22 85 11 121 10 5 14 108 15 4 19 10 19 11 19 12 19 17 19 18 19 19 19 23 19 8 19 7 22 68 3 2 3 3 ...

Page 100: ... is driven OCCASIONALLY under a severe condition you should follow the Normal Conditions Maintenance Schedule on pages 3 2 and 3 3 17 14 17 23 18 3 18 21 18 22 16 3 19 28 8 4 10 5 14 108 15 4 17 16 19 8 9 5 11 123 23 123 ...

Page 101: ...on Timing Inspection 4 18 Idle Speed Check 4 19 Noise Condenser Capacity Test 4 19 Ignition Control Module Input Test 4 20 Ignition Coil Test 4 21 Spark Plug Inspection 4 22 Charging System Component Location Index 4 23 Troubleshooting 4 25 Alternator Replacement 4 29 Overhaul 4 30 Rectifier Test 4 31 Brush Inspection 4 31 Rotor Slip Ring Test 4 32 Stator Test 4 32 Belt Inspection and Adjustment 4...

Page 102: ...f No Tool Number Description Qty Page Reference A973X 041 XXXXX 07JGG 001010A 07PAZ 0010100 Vacuum Pump Gauge Belt Tension Gauge SCS Service Connector 4 43 4 33 4 18 Included in Belt Tension Gauge Set T N 07TGG 001000A ...

Page 103: ...omponentLocation Index STARTER CUT RELAY Wire colors BLK WHT BLK WHT BLK WHT and WHT RED UNDER DASH FUSE RELAY BOX STARTER Test page 4 5 Replacement page 4 6 Overhaul page 4 8 Solenoid Test page 4 9 Reassembly page 4 14 ...

Page 104: ... crank the engine If the starter does not crank the engine go to step 3 If it cranks the engine erratically or too slowly go to Check for Wear and Damage on the next page Check the battery battery positive cable ground starter cut relay and the wire connections for loose ness and corrosion Test again If the starter still does not crank the engine go to step 4 Unplug the connector BLK WHT wire from...

Page 105: ...gh check for Dead or low battery Open circuit in starter armature commutator segments Starter armature dragging Shorted armature winding Excessive drag in engine Check Cranking rpm Engine speed during cranking should be above 100 rpm If speed is too low check for Loose battery or starter terminals Excessively worn starter brushes Open circuit in commutator segments Dirty or damaged helical spline ...

Page 106: ... Remove the left driveshaft see section 16 Starter Replacement 1 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s pre set buttons 2 Disconnect the battery negative terminal first then the positive terminal NOTE The PCM memory setting is needed after reconnecting the battery see page 11 123 3 Raise the coolant reservoir then remove the battery and...

Page 107: ... mm 54 N m 5 5 kgf m 40 Ibf ft 13 Disconnect the starter cable and BLK WHT wire then remove the starter 8 x 1 25 mm 8 8 N m 0 9 kgf m 6 5 Ibf ft 10 x 1 25 mm STARTER 44 N m 4 5 kgf m 33 Ibf ft CABLE BLK WHT WIRE 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft STARTER 14 Install in the reverse order of removal NOTE When installing the starter cable make sure that the crimped side of the ring terminal is fa...

Page 108: ...ge 4 12 END COVER RING GEAR ARMATURE HOUSING Test page 4 9 MOLYBDENUM DISULFIDE OVERRUNNING CLUTCH ASSEMBLY GEAR SHAFT PLANETARY GEAR Inspection page 4 13 PLATE MOLYBDENUM DISULFIDE ARMATURE Inspection and Test page 4 10 MOLYBDENUM DISULFIDE OVERRUNNING CLUTCH ASSEMBLY Inspection page 4 13 SOLENOID LEVER STARTER SOLENOID Test page 4 9 RINGGEAR PINION STOP SPRING CLIP Replace MOLYBDENUM DISULFIDE G...

Page 109: ...osition according to the table PLUNGER SOLENOID HOUSING GROUND Starter Field Winding Test 1 Check for continuity between the brushes If there s no continuity replace the armature housing 2 Check for continuity between each brush and the armature housing ground If continuity exists replace the armature housing BRUSHES ARMATURE HOUSING GROUND GROUND PULL IN COIL HOLD IN COIL ...

Page 110: ...600 sandpaper COMMUTATOR SANDPAPER If commutator diameter is below the service limit replace the armature Commutator Diameter Standard NEW 31 9 32 1 mm 1 256 1 264 in Service Limit 31 5 mm 1 240 in VERNIER CALIPER COMMUTATOR 3 Measure the commutator runout If the commutator runout is within the service limit check the commutator for carbon dust or brass chips between the segments If the commutator...

Page 111: ...open circuit exists between any segments replace the armature COMMUTATOR SEGMENT 6 Place the armature on an armature tester Hold a hacksaw blade on the armature core If the blade is attracted to the core or vibrates while the core is turned the armature is shorted Replace the arma ture ARMATURE TESTER HACKSAW BLADE ARMATURE 7 With an ohmmeter check that no continuity exists between the commutator ...

Page 112: ...s off the brush SPRING SCALE Commercially available SPRING BRUSH SpringTension 29 1 37 8 N 2 97 3 85 kgf 6 548 8 488 Ibf Starter Brush Inspection Measure the brush length If the length not within the service limit replace the brush holder assembly Brush Length Standard NEW 18 mm 0 71in Service Limit 10 mm 0 39 in BRUSH NOTE To seat new brushes after installing them in their holders slip a strip of...

Page 113: ...aft Does it move freely If not replace it 1 2 Rotate the overrunning clutch both ways Does it lock in one direction and rotate smoothly in reverse If it does not lock in either direction or it locks in both directions replace it SHAFT 3 4 DRIVE GEAR If the starter drive gear is worn or damaged replace the overrunning clutch assembly the gear is not avail able separately Check the condition of the ...

Page 114: ...l the pinion stop and overrunning clutch off the shaft SPRING CLIP PINION STOP Starter Reassembly NOTE Use the illustration on page 4 8 as reference for reassembly 1 Pry back each brush spring with a screwdriver then position the brush about halfway out of its holder and release the spring to hold it there 2 Install the armature in the housing Next pry back each brush spring again and push the bru...

Page 115: ...ot leave the battery connected for more than 10 seconds RetractingTest Disconnect the battery also from the body If the pinion retracts immediately it is working properly CAUTION Do not leave the battery connected for more than 10 seconds NOTE The PCM memory must be reset after reconnect ing the battery see page 11 125 Starter No load Test 1 Clamp the starter firmly in a vise 2 Connect the starter...

Page 116: ...Ignition System Component Location Index IGNITION COILS Test page 4 21 SPARKPLUGS Inspection page 4 22 NOISE CONDENSER Test page 4 19 IGNITION CONTROL MODULE ICM Input Test page 4 20 ...

Page 117: ...TE Located under the glove box SCS SERVICE CONNECTOR 07PAZ 0010100 3 Check the idle speed see page 4 19 4 Remove the engine cover see section 5 5 Connect a timing light to the No 1 ignition coil wires while the engine idles point the timing light toward the pointer on the timing belt cover No 1 IGNITION COIL WIRES TIMING LIGHT CRANKSHAFTPULLEY 6 Inspect ignition timing at idle speed Ignition Timin...

Page 118: ...systemsturned off 3 Adjust the idle speed if necessary see section 11 Noise Condenser Capacity Test 1 Use a commercially available condenser tester Con nect the condenser tester probes and measure the condenser capacity Condenser capacity 0 47 0 09 microfarads F POSITIVE TERMINAL BODY GROUND Negative NOTE The noise condenser is intended to reduce ignition noise However condenser failure may cause ...

Page 119: ...f any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the ICM must be faulty replace it Wire side of female terminals ICM 8P CONNECTOR Trml Wire Test condition Test Desired result Possible cause if result is not obtained 2 7 4 3 1 8 6 5 BLK3 BLK4 WHT1 WHT GRN WHT BLK WHT BLU RED GRN WHT RED Under all conditions Ignition switch ON ID Check...

Page 120: ...e coil tempera ture specification is at 77 F 25 C Primary Winding Resistance between the No 1 and No 2 terminals 0 9 1 1 ohms If the resistance is not within specification replace the coil If the resistance is OK but other troubleshooting doesn t reveal the cause of the problem substi tute a known good ignition coil and check engine operation again If the engine then runs OK replace the original c...

Page 121: ...orated ignition coil or ignition wires 2 Do not adjust the gap of platinum tip plugs replace the spark plug if the gap is out of specification or if the center electrode is rounded Electrode Gap Standard Service Limit 1 1 mm 0 043 in 1 3 mm 0 051 in Platinum tip plug Do not adjust the gap replace the spark plug if the gap is out of specification or if the center electrode is rounded 3 Replace the ...

Page 122: ...Charging System Component Location Index ALTERNATOR BELT Inspection and Adjustment page 4 33 ALTERNATOR Alternator and Regulator Test page 4 27 Replacement page 4 29 Overhaul page 4 30 ...

Page 123: ...y ground in the L circuit 1 Turn the ignition switch OFF 2 Disconnect the ABS control unit C447 and passenger s multiplex control unit C401 as applicable 3 Turn the ignition switch ON II Does the charging system light stay off Check for short in control unit s 1 Turn the ignition switch OFF 2 Reconnect the ABS control unit connector 3 Turn the ignition switch ON II and check the charging system li...

Page 124: ... OFF 2 Connect the 4P connector to the alternator 3 Turn the ignition switch ON II Does the charging system lightcome on 4 Start the engine Does the charging system light go off The charging system light circuit is OK Turn the ignition switch OFF and repair the open circuit in the BLK YELwire ALTERNATOR 4PCONNECTOR Wire side of female terminals Check the alternator regulator see page 4 27 Check th...

Page 125: ...OLT 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft ADJUSTING ROD ALTERNATOR BELT MOUNTING BOLT 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft 5 Remove the alternator bracket ALTERNATOR BRACKET 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft 6 Disconnect the 4P connector and harness clip bracket then remove the terminal nut and the BLK wire from the B terminal Take out the alternato...

Page 126: ...ASSEMBLY Inspection page 4 31 22 mm BOX WRENCH 10 mm BOX WRENCH PULLEY LOCKNUT 110 N m 11 3 kgf m 81 7 Ibf ft VOLTAGE REGULATOR RECTIFIER ASSEMBLY Test page 4 31 TERMINAL INSULATOR INSULATOR SLEEVE REAR HOUSING SPACER CAUTION Do not get grease or oil on the slip rings ROTOR Test page 4 32 PULLEY LOCKNUT 110 N m 11 3 kgf m 81 7 Ibf ft STATOR THROUGH BOLT STATOR DRIVE END HOUSING Test page 4 32 PULL...

Page 127: ...nd P and between the E ground and P termi nals of each diode pair All diodes should have con tinuity in only one direction 2 If any of the eight diodes fails replace the rectifier assembly Diodes are not available separately Alternator Brush Inspection 1 Remove the end cover then take out the brush holder by removing its two screws 2 Measure the length of the brushes with a vernier caliper Alterna...

Page 128: ...ternator ROTOR SHAFT SLIP RINGS ROTOR 2 Check that there is no continuity between the slip rings and the rotor or rotor shaft 3 If the rotor fails either continuity check replace the alternator Stator Test 1 Check that there is continuity between each pair of leads LEADS COIL CORE 2 Check that there is no continuity between each lead and the coil core 3 If the coil fails either continuity check re...

Page 129: ...d measure the deflection between the alternator and crankshaft pulley Deflection Used Belt 9 5 11 5 mm 0 37 0 45 in New Belt 7 0 8 0 mm 0 28 0 31 in NOTE If the belt is worn or damaged replace it Belt tension gauge method Attach the belt tension gauge to the belt and measure the tension Follow the gauge manufacturer s instructions Tension Used Belt 390 590 N 40 60 kgf 88 130 Ibf New Belt 780 980 N...

Page 130: ...g the adjusting rod to obtain the proper belt tension then retighten the bolts Looser Tighter ADJUSTING ROD MOUNTING BOLT 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft LOCK BOLT 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft 3 Recheck the deflection or tension of the belt NOTE For the power steering pump belt and A C compressor belt adjustments refer to section 17 and section 22 ...

Page 131: ... INDICATOR LIGHT Bulb Locations page 23 76 MAIN SWITCH Test Replacement page 4 41 SET RESUME CANCEL SWITCH Test Replacement page 4 39 CRUISE CONTROL UNIT Input Test page 4 37 VEHICLE SPEED SENSOR VSS Troubleshooting page 23 86 TRANSMISSION RANGE SWITCH Test section 14 ACTUATOR CABLE Adjustment page 4 45 ACTUATOR Test page 4 43 Replacement page 4 44 Solenoid Test page 4 42 BRAKE PEDAL POSITION SWIT...

Page 132: ...ector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it CRUISE...

Page 133: ...terminals There should be cycle 0 5 V or battery voltage Check for voltage to ground There should be 0 V with the pedal pressed and battery voltage with the pedal released Check for voltage to ground There should be battery voltage with the pedal pressed and 0 V with the pedalreleased Attach to ground The cruise light in the gauge assembly should come on Check for resistance to ground There should...

Page 134: ...memory must be reset after recon necting the battery see page 11 125 3 Disconnect the airbag connectors Driver s Side Remove the access panel from the steering wheel then disconnect the 2P connector between the driver s airbag and cable reel CABLE REEL CONNECTOR DRIVER S AIRBAG 2P CONNECTOR ACCESS PANEL Front Passenger s Side Remove the glove box see section 20 Disconnect the front passenger s 2P ...

Page 135: ...the switch in the sequence shown SET RESUME CANCEL SWITCH SET RESUME CANCEL SWITCH COVER 8 Remove the two screws and disconnect the 4P con nector Then remove the switch SET RESUME CANCEL SWITCH SCREWS 9 Check for continuity between the terminals in each switch position according to the table If there is continuity and it matches the table replace the cable reel If there is no continuity in any pos...

Page 136: ...nel 3 Check for continuity between the terminals in each switch position according to the table If there is no continuity replace the switch BrakePedalPositionSwitchTest 1 Disconnect the 4P connector from the switch Terminal side of male terminals 4P CONNECTOR BRAKE PEDAL 2 Check for continuity between the terminals accord ing to the table 3 If necessary replace the switch or adjust pedal height s...

Page 137: ...m the actuator Terminal side of male terminals 2 Check for resistance between the terminals accord ing to the table NOTE Resistance will vary slightly with tempera ture specified resistance is at 70 F 20 C VENT VALVE From VENT HOSE To VACUUM TANK VACUUM VALVE SAFETY VALVE ...

Page 138: ...not be able to pull it out If you can it is defective Disconnect ground from the No 3 terminal The actuator rod should return If it does not return and the vent hose and filter are not plugged the solenoid valve assembly is defective Repeat steps 2 through 5 and disconnect ground from the No 1 terminal The actuator rod should return If it does not return and the vent hose and filter are not plugge...

Page 139: ...or cable from the actuator rod by releasing the clip from the rod with a screwdriver as shown CLIP ACTUATOR ROD ACTUATOR CABLE NUTS 6 Loosen the locknut then disconnect the actuator cable from the throttle linkage ADJUSTING NUT LOCKNUT ACTUATOR CABLE CABLE BRACKET THROTTLE LINKAGE 7 Install in the reverse order of removal and adjust free play at the throttle linkage after connecting the actuatorca...

Page 140: ...OUTPUT LINKAGE ADJUSTING NUT FREE PLAY 5 0 5 mm 0 20 0 02 in ACTUATOR CABLE 3 If the free play is not within specs move the cable to the point where the engine speed starts to increase and tighten the locknut and adjusting nut CABLE BRACKET ADJUSTING NUT LOCKNUT ACTUATOR CABLE 4 Turn the adjusting nut until it is 5 0 5 mm 0 20 0 02 in away from the bracket 5 0 5 mm 0 20 0 02 in CABLE BRACKET ADJUS...

Page 141: ...Engine Removal Installation Special Tools 5 2 Engine Removal 5 3 Installation 5 14 Engine Mount Control System Component Location Index 5 18 Troubleshooting 5 20 Diaphragm Actuator Test 5 22 ...

Page 142: ...SpecialTools Ref No Tool Number Description Qty PageReference A973X 041 XXXXX Vacuum Pump Gauge 0 30 in Hg 5 21 5 22 ...

Page 143: ... reconnecting the battery see section 11 1 Move the front passenger s seat forward 2 96 98 models Remove the support struts from the hood Fix the hood in a vertical position then rein stall the support struts by using 6 x 1 0 mm bolts 99 01 models Remove the hood see page 20 73 6 x 1 0 mm bolt SUPPORT STRUT 3 Make sure you have the anti theft code for the radio then write down the frequencies for ...

Page 144: ...cables when removing them Always replace any kinked cable with a new one Adjust the throttle cable when installing see section 11 Adjust the cruise control cable when installing see section 4 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft THROTTLE COVER THROTTLE CABLE CRUISE CONTROL CABLE LOCKNUTS ADJUSTING NUTS 10 Raise the coolant reservoir then remove the battery and battery base 11 Remove the relay bo...

Page 145: ... the engine compartment 15 Remove the connector and engine wire harness clamp CONNECTOR ENGINE WIRE HARNESS CONNECTOR CLAMP 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 16 Relieve fuel pressure by loosening the service bolt on the fuel filter about one turn see section 11 Do not smoke while working on the fuel system Keep open flame and sparks away from the work area Drain fuel only into an approved con...

Page 146: ...19 Disconnect the transmission sub harness connec tor and remove the wire harness clamp WIRE HARNESS CLAMP TRANSMISSION SUB HARNESS CONNECTOR CONNECTOR CONTROL BOX 21 Disconnect the engine wire harness connectors on the right side of the engine compartment ENGINE WIRE HARNESS CONNECTOR 20 Disconnect the connector then remove the control box 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft ...

Page 147: ...OSES 24 Loosen the mounting bolt lock bolt and adjusting rod then remove the alternator belt ADJUSTING ROD LOCK BOLT 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft ALTERNATOR BELT MOUNTING BOLT 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft 25 Loosen the idler pulley center nut and adjusting bolt then remove the air conditioning A C com pressor belt ADJUSTING BOLT IDLER PULLEY CENTER NUT 10 x 1 25 mm 44 N m 4 5 ...

Page 148: ... the radiator cap to avoid scalding by hot coolant or steam 30 Raise the hoist to full height 31 Remove the front tires wheels and splash shield SPLASH SHIELD 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 32 Drain the engine coolant see page 10 5 Loosen the drain plug in the radiator 33 Drain the automatic transmission fluid ATF Reinstall the drain plug using a new washer see section 14 34 Drain the dif...

Page 149: ...1 Remove the transmission stop collars 42 Remove exhaust pipe A GASKETS Replace GASKET Replace EXHAUST PIPE A SELF LOCKING NUT 10 x 1 25 mm 54 N m 5 5 kgf m 40 Ibf ft Replace 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft SELF LOCKING NUT 10 x 1 25 mm 54 N m 5 5 kgf m 40 Ibf ft Replace TRANSMISSION STOP COLLAR 43 Remove the wire harness cover and grommet then remove the three way catalytic converter TWC ...

Page 150: ... Ibf ft ATF COOLER HOSES 46 Remove the shift cable cover mounting bolts then remove the shift control solenoid valve linear sole noid harness connector from the shift cable cover 47 Remove the shift cable cover from the transmission housing 48 Remove the shift cable with shift cable holder from the shift cable holder base 49 Remove the control lever from the control shaft 50 Lower the hoist 51 Rem...

Page 151: ...54 Attach the chain hoist to the engine FUEL PRESSURE REGULATOR 29 N m 3 0 kgf m 22 Ibf ft NOTE Loosen the locknut on the fuel pressure regulator then turn the fuel pressure regulator 180 ...

Page 152: ... 14 57 Remove the transmission beam TRANSMISSION BEAM 58 Remove the transmission mount and transmission mount bracket TRANSMISSION MOUNT TRANSMISSION MOUNT BRACKET 59 Lower the hoist 60 Separate the left front mount bracket from the left front mount LEFT FRONT MOUNT 61 Separate the right front mount bracket from the right front mount RIGHT FRONT MOUNT ...

Page 153: ...uum hose LEFT ENGINE MOUNT BRACKET LEFT ENGINE MOUNT VACUUM HOSE 64 Raise the chain hoist to remove all slack from the chain 65 Check that the engine transmission is completely free of vacuum hoses fuel and coolant hoses and electrical wiring 66 Slowly raise the engine approximately 150 mm 6 in Check once again that all hoses and wires are discon nected from the engine transmission 67 Raise the en...

Page 154: ...Ibf ft 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft 12 x 1 25 mm 74 N m 7 5 kgf m 54 Ibf ft LEFT FRONT MOUNT BRACKET ENGINE STIFFENER 12 x 1 25 mm 54 N m 5 5 kgf m 40 Ibf ft LEFT ENGINE MOUNT BRACKET FRONT ENGINE HANGER 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft 12 x 1 25 mm 64 N m 6 5 kg...

Page 155: ...he engine so that the rear beam does not hit the transmission 1 Install the transmission mount bracket then tighten the mounting bolts TRANSMISSION MOUNT BRACKET TRANSMISSION MOUNT 2 Install the transmission mount Do not tighten the bolt 3 Tighten the nut on the right engine mount bracket then install the vacuum hose 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft VACUUM HOSE 4 Tighten the nut on the left...

Page 156: ... 11 Adjust the cruise control cable see section 4 Refill the engine with engine oil see page 8 4 Refill the transmission with ATF see section 14 Refill the differential with differential oil see section15 Refill the radiator with engine coolant see page 10 5 Bleed air from the cooling system at the bleed bolt with the heater valve open see page 10 5 Clean the battery posts and cable terminals with...

Page 157: ...Mount and Bracket Bolts Nuts Torque Value Specifications 10 x 1 25 mm bolts nuts 38 N m 3 9 kgf m 28 Ibf ft RIGHT ENGINE MOUNT LEFT ENGINE MOUNT RIGHT FRONT MOUNT LEFT FRONT MOUNT ...

Page 158: ...ount Control System Component Location Index ENGINE MOUNT CONTROL SOLENOID VALVE Troubleshooting page 5 20 POWERTRAIN CONTROL MODULE PCM Troubleshooting page 5 20 ENGINE MOUNT DIAPHRAGM ACTUATOR Test page 5 22 ...

Page 159: ...mbly 6P con nector is disconnected Reconnect the IMRC engine mount control solenoid valve assembly 6P connector The engine mount control system is OK IMRC ENGINE MOUNT CONTROLSOLENOID VALVEASSEMBLY6P CONNECTOR Test the Engine Mount Control Solenoid Valve Wire 1 Shift to or position 2 Disconnect the IMRC engine mount control solenoid valve assembly 6P connector 3 Measure voltage between the No 3 te...

Page 160: ... trol solenoid valve and connect a vacuum pump gauge to the hose Apply vacuum for 20 seconds Does the engine mount hold vacuum Inspect the vacuum hose Replace the left and or right engine mount VACUUM PUMP GAUGE 0 30 in Hg A973X 041 XXXXX UPPER VACUUM HOSE Test the Engine Mount Release the vacuum then apply vacuum again ENGINE MOUNT CONTROLSOLENOID VALVE Is there a noticeable change in idle smooth...

Page 161: ...cover 6 x 1 0 mm 13 N m 1 3 kgf m 9 4 Ibf ft ACTUATOR COVER 3 Clean and oil the diaphragm actuator rod 4 With a vacuum pump gauge apply vacuum of about 30 7 kPa 230 mmHg 9 1 in Hg and check that the actuator rod moves smoothly Replace the engine mount if the actuator rod does not operate DIAPHRAGM ACTUATOR VACUUM PUMP GAUGE 0 30 in Hg A973X 041 XXXXX ENGINE MOUNT ...

Page 162: ...CYP Sensor Replacement 6 14 Cylinder Head Component Location Index 6 15 Removal 6 18 Warpage 6 30 Installation 6 37 Rocker Arm Assembly Disassembly Reassembly 6 25 Removal 6 26 Camshaft Inspection 6 26 Rocker Arms and Shafts Clearance Inspection 6 28 Valves Valve Springs and Valve Seals Removal 6 29 Installation 6 35 Valve Guides Valve Movement 6 31 Replacement 6 33 Reaming 6 34 Valve Seats Recond...

Page 163: ...Valve Guide Reamer 5 5 mm Socket 19 mm Holder Handle Holder Attachment 50 mm Offset Valve Guide Driver 5 5 mm Valve Spring Compressor Attachment 6 34 6 3 6 3 6 3 6 33 6 34 6 29 6 35 07HAH PJ7010B 07JAA 001020A 07JAB 001020A 07MAB PY3010A 07742 0010100 07757 PJ1010A ...

Page 164: ...l Lubricate WASHER PULLEY BOLT CRANKSHAFT PULLEY TIMING BELT DRIVE PULLEY CRANKSHAFT BALANCER BELT DRIVE PULLEY TIMING BELT GUIDE PLATE Crankshaft pulley bolt size and torque value 16 x 1 5 mm 245 N m 25 0 kgf m 181 Ibf ft HOLDER HANDLE 07JAB 001020A HOLDER ATTACHMENT 50 mm OFFSET 07MAB PY3010A SOCKET 19 mm 07JAA 001020A Commercially available NOTE Do not use an impact wrench when installing ...

Page 165: ...page 6 8 Installation page 6 10 BALANCER BELT Inspection page 6 6 Adjustment page 6 7 Removal page 6 8 Installation page 6 10 RIGHT UPPER COVER TIMING BELT DRIVE PULLEY Replacement page 6 3 LOWER COVER BALANCER BELT DRIVE PULLEY Replacement page 6 3 IDLER PULLEY BRACKET 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft PULLEY BOLT 16 x 1 5 mm 245 N m 25 0 kgf m 181 Ibf ft Replacement page 6 3 Do not use an i...

Page 166: ...ve the alternator belt see page 5 7 4 Loosen the idler pulley center nut and adjusting bolt then remove the air conditioning A C com pressor belt see page 5 7 5 Remove the TCS control valve upper and lower brackets NOTE Refer to section 19 when installing the brackets TCS CONTROL VALVE LOWER BRACKET 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft 6 Loosen the adjusting bolt locknut and mounting bolt then r...

Page 167: ...11 Remove the idler pulley bracket dipstick and tube 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft DIPSTICK TUBE 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft 12 Remove the crankshaft pulley see page 6 3 13 Remove the upper and lower covers NOTE Do not use the upper and lower covers for storing removed items LEFT UPPER COVER RUBBER SEAL LOWER COVER RIGHT UPPER COVER IDLER PULLEY BRACKET O RING Replace ...

Page 168: ...n retighten the adjusting bolt BALANCER BELT ADJUSTING BOLT 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft 15 Remove the balancer belt 16 Loosen the timing belt adjusting bolt 180 Push the tensioner to remove tension from the timing belt then retighten the adjusting bolt TIMING BELT ADJUSTING BOLT 10 x 1 25 mm 42 N m 4 3 kgf m 31 Ibf ft 17 Remove the timing belt ...

Page 169: ...emoved The pistons may hit the valves and cause damage NOTE When installing only the balancer belt go to step 12 1 Remove the spark plugs 2 Remove the balancer belt drive pulley and timing belt guide plate see page 6 4 3 Set the tinning belt drive pulley so that the No 1 pis ton is at top dead center TDC Align the TDC mark on the timing belt drive pulley with the pointer on the oil pump POINTER TD...

Page 170: ...ghtcamshaftpulley NOTE For easier installation turn the right camshaft pul ley clockwise about a half tooth from the TDC posi tion Make sure the timing belt drive pulley and cam shaftpulleysareatTDC 6 Loosen and retighten the timing belt adjusting bolt to tension the timing belt 7 Install the lower cover and crankshaft pulley see page 6 3 8 Rotate the crankshaft pulley about 5 or 6 turns clock wis...

Page 171: ...e page 6 10 15 Install the balancer belt drive pulley then install the balancerbelt 16 Loosen and retighten the balancer belt adjusting bolt to tension the balancer belt 17 Remove the 6 mm bolt Install the sealing bolt in the maintenance hole Use a newwasher 18 Install the crankshaft pulley then rotate the crank shaft pulley about 5 or 6 turns clockwise so that the balancer belt positions on the p...

Page 172: ...ubber cap 23 If the camshaft and crankshaft pulleys are not posi tioned at TDC remove the timing belt and adjust the positioning following the procedure on page 6 10 then reinstall the timing belt 24 After installation adjust the tension of each belt See section 4 for alternator belt tension adjust ment See section 22 for A C compressor belt tension adjustment See section 17 for P S pump belt tens...

Page 173: ...king the following adjust ment Inspect the timing belt before adjusting the belt ten sion Always rotate the crankshaft clockwise when viewed from the pulley side Rotating it counter clockwise may result in improper adjustment of the belt tension 1 Remove the left upper cover 2 Set the No 1 piston at TDC see page 6 13 3 Rotate the crankshaft clockwise ten teeth on the camshaft pulley The blue mark ...

Page 174: ...isconnect the TCS throttle sensor connector and TCS throttle actuator connector then remove the TCS control valve assembly see page 6 8 8 Disconnect the vehicle speed sensor VSS sub har ness connector then remove the wire harness holder see page 6 8 9 Remove the breather hose and vacuum hoses see page 6 9 10 Remove the vacuum hoses and ignition control module ICM bracket see page 6 9 11 Remove the...

Page 175: ...ing A C com pressor belt see page 5 7 5 Loosen the adjusting bolt locknut and mounting bolt then remove the power steering P S pump belt see page 6 6 6 Remove the TCS control valve upper and lower brackets see page 6 8 7 Disconnect the TCS throttle sensor connector and TCS throttle actuator connector then remove the TCS control valve assembly see page 6 8 8 Disconnect the vehicle speed sensor VSS ...

Page 176: ...he left camshaft pulley 7 Remove the left back cover 8 Remove the CKP CYP sensor from the left cylinder head 9 Install the CKP CYP sensor in the reverse order of removal Refer to page 6 10 when installing the timing belt 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft RIGHT UPPER COVER LEFT UPPER COVER 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft LEFT CAMSHAFT PULLEY 8 x 1 25 mm 31 N m 3 2 kgf m 23 Ibf ft 6 x 1 ...

Page 177: ...lace when leaking damaged or deteriorated Apply liquid gasket at the four corners of the recesses page 6 38 CYLINDER HEAD COVER Refer to page 6 38 when installing 8 x 1 25 mm 31 N m 3 2 kgf m 23 Ibf ft RUBBER SEALS Replace when damaged or deteriorated 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft LEFT BACK COVER LEFT CAMSHAFT PULLEY 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft CKP CYP SENSOR RIGHT CAMSHAFT PUL...

Page 178: ...R HEAD BOLT 11 x 1 5 mm 76 N m 7 8 kgf m 56 Ibf ft Apply engine oil to the bolt threads EXHAUST GAS RECIRCULATION EGR PASSAGE 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft OIL CONTROL ORIFICES Removewith6x1 0mm bolt and clean RIGHT CYLINDER HEAD GASKET Replace OIL CONTROL ORIFICES Remove with 6 x 1 0 mm bolt and clean 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft LEFT CYLINDER HEAD GASKET Replace 8 x 1 25 mm 2...

Page 179: ...mm 22 N m 2 2 kgf m 16 Ibf ft 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft RUBBERPLUG Apply liquid gasket VALVE GUIDE Inspection page 6 31 Replacement page 6 33 Reaming page 6 34 CAMSHAFT Inspection page 6 26 INTAKE VALVE Removal page 6 29 Installation page 6 35 OILSEAL Replace CYLINDERHEAD Removal page 6 18 Installation page 6 37 Warpage page 6 30 Valve seat reconditioning page 6 32 EXHAUST VALVE SPRIN...

Page 180: ...tion then reinstall the sup port struts by using 6 x 1 0 mm bolts see page 5 3 2 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s pre set buttons 3 Disconnect the battery negative terminal first then the positive terminal 4 Drain the engine coolant see page 10 5 5 Remove the strut brace see page 5 3 6 Remove the engine cover see page 5 3 7 Remove...

Page 181: ...el system Keep open flame and sparks awayfrom the work area Drain fuel only into an approved container 15 Remove the fuel feed hose and fuel return hose FUEL RETURN HOSE FUEL FEED HOSE FUEL PULSATION DAMPER 22 N m 2 2 kgf m 16 Ibf ft WASHERS Replace 16 Remove the evaporative emission EVAP canister hose and brake booster vacuum hose BRAKE BOOSTER VACUUM HOSE EVAP CONTROL CANISTER HOSE 17 Disconnect...

Page 182: ...ather hose 22 Remove the vacuum hoses then remove the igni tion control module ICM bracket see page 6 9 23 Remove the engine wire harness connectors and wire harness clamps from the cylinder heads and intake manifold Six injector connectors Six ignition coil connectors Throttle position sensor connector CKP CYPsensorconnector Intake air temperature IAT sensor connector Exhaust gas recirculation EG...

Page 183: ...nd intake manifold 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft VACUUM LINE 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 26 Remove the EGR pipe GASKET Replace EGR PIPE 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft GASKET Replace 27 Remove the vacuum hoses then remove the Intake Manifold Runner Control IMRC solenoid valve mount control solenoid valve assembly bracket BRACKET VACUUM HOSES 6 x 1 0 mm 12 N m 1 2 kgf m 8...

Page 184: ... N m 1 2 kgf m 8 7 Ibf ft HEATER HOSE 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 31 Remove the vacuum line mounting bolts wire har ness holder and positive crankcase ventilation PCV hose PCV HOSE VACUUM LINE 32 Remove the EVAP canister hose EVAP purge solenoid valve and vacuum hose EVAP CONTROL CANISTER HOSE EVAP PURGE CONTROL SOLENOID VALVE 6 x 1 0mm 12 N m 1 2 kgf m 8 7 Ibf ft VACUUM HOSE 6 x 1 0 mm...

Page 185: ...ls to prevent foreign materials from get ting into the cylinders INTAKE MANIFOLD WATER PASSAGE GASKETS Replace 36 Remove the covers then remove the left and right exhaust manifolds see page 9 4 37 Remove the balancer belt and timing belt see page 6 8 38 Remove the three bolts securing the alternator bracket ALTERNATOR BRACKET 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 39 Remove the two bolts securing ...

Page 186: ...1 25 mm 31 N m 3 2 kgf m 23 Ibf ft BACK COVER BACK COVER 41 Remove the left and right cylinder head covers 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft CYLINDER HEAD COVER 42 Remove the cylinder head bolts then remove the cylinder heads CAUTION To prevent warpage unscrew the bolts in sequence 1 3 turn at a time repeat the sequence until all bolts are loose CYLINDER HEAD BOLTS LOOSENING SEQUENCE ...

Page 187: ...ge is less than 0 05 mm 0 002 in cylinder head resurfacing is not required If warpage is between 0 05 mm 0 002 in and 0 2 mm 0 008 in resurface the cylinder head Maximum resurface limit is 0 2 mm 0 008 in based on a height of 100 mm 3 94 in Measure along edges and three ways across the center Cylinder Head Height Standard New 99 95 100 05 mm 3 935 3 939 in CYLINDER HEAD HEIGHT Measure the cylinder...

Page 188: ...10 Clean the oil control orifices before installing Do not use the upper and lower covers to store removed items Clean the upper and lower covers before installation 1 Install the cylinder head dowel pins 2 Install the oil control orifices and cylinder head gas kets RIGHT CYLINDER HEAD GASKET R MARK OIL CONTROL ORIFICES Remove with 6 x 1 0 mm bolt and clean OIL CONTROL ORIFICE Clean O RINGS Replac...

Page 189: ...hen work it into the groove around the outside edges NOTE Before installing the cylinder head cover gasket thoroughly clean the seal and the groove When installing make sure the head cover gasket is seated securely in the corners of the recesses with no gap CORNERS OF THE RECESS HEAD COVER GASKET Clean CORNERS OF THE RECESS CYLINDER HEAD COVER 7 Apply liquid gasket to the head cover gasket at the ...

Page 190: ...s applied Replace the washer when damaged or deterio rated WASHER CYLINDER HEAD COVER 9 Tighten the nuts in 2 or 3 steps In the final step tight en all nuts in sequence to 12 N m 1 2 kgf m 8 7 Ibf ft NOTE After assembly wait at least 30 minutes before filling the engine with oil 10 Install the left and right back covers then install the left and right camshaft pulleys LEFT CAMSHAFT PULLEY BACK COV...

Page 191: ...7 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft GASKETS Replace 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft WATER PASSAGE EGR PIPE GASKETS Replace O RING Replace 14 Install the exhaust manifolds Tighten the nuts in a crisscross pattern in 2 or 3 steps beginning with the inner nut see page 9 4 NOTE Always use new exhaust manifold gaskets 15 After installation check that all tubes hoses and connectors ar...

Page 192: ... places WAVEWASHER 4places CAMSHAFT HOLDER L 5 is similar to R 1 CAMSHAFT HOLDER L 1 is similar to R 5 EXHAUST ROCKER SHAFT HYDRAULIC TAPPET EXHAUST ROCKER ARM B 3 places ROCKER ARM O RING Replace INTAKE ROCKER ARM A INTAKE ROCKER ARM B EXHAUST ROCKER ARM A EXHAUST ROCKER ARM B Letter A is stamped on rocker arm Letter B is stamped on rocker arm Letter A is stamped on rocker arm Letter B is stamped...

Page 193: ...haft holder bolts two turns at a time in a crisscross pattern When removing the rocker arm assembly do not remove the camshaft holder bolts The bolts will keep the camshaft holders the springs and the rocker arms on the shafts CAMSHAFT HOLDER BOLTS LOOSENING SEQUENCE NOTE Refer to page 6 36 when installing ...

Page 194: ... specified torque Specified torque 8 mm bolts 22 N m 2 2 kgf m 16 Ibf ft 6 mm bolts 12 N m 1 2 kgf m 8 7 Ibf ft 8 mm bolts 2 Seat the camshaft by pushing it toward the rear of the cylinder head 3 Zero the dial indicator against the rear of the cam shaft Push the camshaft back and forth and read the end play Camshaft End Play Standard New 0 05 0 15 mm 0 002 0 006 in Service Limit 0 15 mm 0 006 in C...

Page 195: ... clearance is out of toler ance And the camshaft has already been replaced you must replace the cylinder head If the camshaft has not been replaced first check the total runout with the camshaft supported on V blocks Rotate camshaft while measuring If the total runout of the camshaft is within toler ance replace the cylinder head If the total runout is out of tolerance replace the camshaft and rec...

Page 196: ... Zero the gauge to the shaft diameter MICROMETER CYLINDER BORE GAUGE 3 Measure the inside diameter of each rocker arm and check for an out of round condition Rocker Arm to Shaft Clearance Standard NEW 0 018 0 054 mm 0 0007 0 0021 in Service Limit 0 08 mm 0 003 in Inspect rocker arm face for wear 4 Repeat for all rockers If over the service limit replace the rocker shaft and all overtolerance rocke...

Page 197: ... keepers before installing the valve spring compres sor PLASTIC MALLET SOCKET 2 Install the valve spring compressor Compress the spring and remove the valve keepers VALVE SPRING COMPRESSOR ATTACHMENT 07757 PJ1010A VALVE KEEPERS VALVESPRINGCOMPRESSOR Snap on CF711 or EQUIVALENT Commercially available 3 Install the valve guide seal remover VALVE SEAL SEAL REMOVER VALVE GUIDE SEALREMOVER LISLE P N 57...

Page 198: ...m 1 295 1 303 in 113 58 113 88 mm 4 472 4 483 in 5 48 5 49 mm 0 2157 0 2161 in 5 45 mm 0 215 in 0 85 1 15 mm 0 033 0 045 in 0 65 mm 0 026 in Exhaust Valve Dimensions A Standard New B Standard New C Standard New C Service Limit D Standard New D Service Limit 27 90 28 10 mm 1 098 1 106 in 116 03 116 33 mm 4 568 4 580 in 5 45 5 46 mm 0 2146 0 2150 in 5 42 mm 0 213 in 1 35 1 65 mm 0 053 0 065 in 1 15 ...

Page 199: ... 2899 Commercially available NOTE Use small ID end of tool VALVESEAL Replace 4 Install the valve spring and valve retainer then install the valve spring compressor Compress the spring and install the valve keepers NOTE Place the end of the valve spring with closely wound coils toward the cylinder head VALVE SPRING COMPRESSOR ATTACHMENT 07757 PJ1010A VALVE SPRING COMPRESSOR Snap on CF711 or EQUIVAL...

Page 200: ...surement still exceeds the limit recheck using the alternate method then replace the valve and guide if necessary Alternate Method An alternate method of checking guide to stem clear ance is to subtract the O D of the valve stem measured with a micrometer from the I D of the valve guide mea sured with an inside micrometer or ball gauge Take the measurements in 3 places along the valve stem and thr...

Page 201: ...der head 4 Working from the camshaft side use the driver and an air hammer to drive the guide about 2 mm 0 1 in towards the combustion chamber This will knock off some of the carbon and make removal easier CAUTION Always wear safety goggles or a face shield when driving valve guides Hold the air hammer directly in line with the valve guide to prevent damaging the driver 5 Turn the head over and dr...

Page 202: ...ft side of the head use the special tool to drive the guide in to the specified installed height If you have all 12 guides to do you may have to reheat the head VALVE GUIDE DRIVER 5 5 mm 07742 0010100 Valve Guide Installed Height Intake 15 75 16 25 mm 0 620 0 640 in Exhaust 15 75 16 25 mm 0 620 0 640 in VALVE GUIDE Measure here CYLINDER HEAD ...

Page 203: ...ore REAMERHANDLE VALVE GUIDE REAMER 5 5 mm 07HAH PJ7010B Turn reamer in clockwise direction only 3 Continue to rotate the reamer clockwise while removing it from the bore 4 Thoroughly wash the guide in detergent and water to remove any cutting residue 5 Check the clearance with a valve see page 6 31 Verify that the valve slides in the valve guide with out exerting pressure ...

Page 204: ...und should be centered on the seat If it is too high closer to the valve stem you must make a second cut with the 60 cutter to move it down then one more cut with the 45 cutter to restore seat width If it is too low closer to the valve edge you must make a second cut with the 30 cutter to move it up then one more cut with the 45 cutter to restore seat width NOTE The final cut should always be made...

Page 205: ...in wire Bleed the tappet of air by pumping the plunger slowly until no bubbles come out of the hydraulic tappet WIRE HYDRAULIC TAPPET PLUNGER 5W 30or 10W 30 ENGINE OIL CHECK BALL 2 Install the hydraulic tappet to the rocker arm NOTE Use a new O ring when reassembling Apply oil to the O ring before installation ROCKER ARM O RING Replace HYDRAULIC TAPPET ...

Page 206: ... come out of the hydraulic tappets 1 Install the camshaft and rubber cap then install the camshaft seal with the open side spring facing in NOTE Position the camshaft with pin hole at the top Do not apply oil to the camshaft holder mating surface of the camshaft seal Apply liquid gasket Part No 08718 0001 or 08718 0003 around the rubber cap RUBBER CAP Replace if there was oil leakage OIL SEAL Repl...

Page 207: ...t holders Apply liquid gasket to the shaded areas No 5 No 1 3 Tighten each bolt 2 turns at a time in the sequence shown below to ensure that the rockers do not bind on the valves Specified torque 8 mm bolts 22 N m 2 2 kgf m 16 Ibf ft 6 mm bolts 12 N m 1 2 kgf m 8 7 Ibf ft 8 mm bolts ...

Page 208: ...tons and Crankshaft Removal 7 10 Crankshaft Inspection 7 13 Installation 7 24 Pistons Inspection 7 14 Installation 7 23 Cylinder Block Inspection 7 15 Bore Honing 7 16 Piston Pins Removal 7 16 Inspection 7 18 Installation 7 19 Connecting Rods Selection 7 17 Piston Rings End Gap 7 20 Replacement 7 20 Ring to Groove Clearance 7 21 Alignment 7 21 Crankshaft Oil Seal Installation 7 22 Installation eng...

Page 209: ...07GAD PH70201 07LAB PV00100 07749 0010000 07948 SB00101 07965 SD90200 7 30 7 7 7 22 7 30 7 22 7 30 7 30 Special Tools ...

Page 210: ...y liquid gasketaround the oil hole to the block mating surface O RING Replace 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft BALANCER SHAFT REAR COVER 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 8 x 1 25 mm 25 N m 2 5 kgf m 18 Ibf ft REARBALANCER WEIGHT O RING Replace OUTER PIPE O RING Replace ENGINE OIL PRESSURE SWITCH 18 N m 1 8 kgf m 13 Ibf ft 1 8 in BSPT British Standard Pipe Taper 28threads inch Use prope...

Page 211: ...l with open side facing up 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft TORQUE CONVERTER COVER 12 x 1 0 mm 74 N m 7 5 kgf m 54 Ibf ft WASHER DRIVE PLATE Check for cracks CRANKSHAFT OIL SEAL Installation page 7 22 Replace 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft REAR COVER Apply liquid gasket to block mating surface O RING Replace DOWEL PIN 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft CRANKSHAFT OIL SEAL Install...

Page 212: ... for binding CRANKSHAFT End play page 7 7 Runout Taper and Out of Round page 7 13 Installation page 7 24 MAIN BEARING CAP MAIN BEARINGS Clearance page 7 8 Selection page 7 8 NOTE New main bearings must be selected by matching crank and block identification markings RUBBER CAP DOWEL PIN 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft OIL BREATHER COVER THRUSTWASHERS Grooved sides face outward NOTE Thrust wa...

Page 213: ...ge7 17 Inspect the top of each cylinder bore for carbon build up or a ridge before removing the piston Remove ridge if necessary page 7 11 CYLINDER BORE SIZES NOTE To maintain proper piston clearance match these letters with the letters on the pistons The letters on the block read from front to rear No 1 through No 3 cylinders on the first line and No 4 through No 6 cylinders on the second line On...

Page 214: ... install a new connecting rod If still out of tolerance replace the crankshaft see pages 7 10 and 7 24 Push the crankshaft firmly away from the dial indicator and zero the dial against the end of the crankshaft Then pull the crankshaft firmly back toward the indicator the dial reading should not exceed service limit SCREWDRIVER CrankshaftEndPlay Standard New 0 10 0 29 mm 0 004 0 011 in Service Lim...

Page 215: ... them only with solvent or detergent Crankshaft Bore Code Locations Letters or bars have been stamped on the end of the cylinder block as a code for the size of each of the four main journal bores Use them and the numbers or bars stamped on the crankshaft codes for main journal size to choosethecorrectbearings No 4 JOURNAL DRIVE PLATE END No 1 JOURNAL PULLEY END MainJournalCode Locations Numbers o...

Page 216: ...Reinstall the bearing half and cap and torque the nuts to 44 N m 4 5 kgf m 33 Ibf ft NOTE Do not rotate the crankshaft during inspec tion 5 Remove the rod cap and bearing half and measure the widest part of the plastigage Connecting Rod Bearing to Journal Oil Clearance Standard New 0 022 0 046 mm 0 0009 0 0018 in Service Limit 0 05 mm 0 002 in PLASTIGAGE STRIP Selection CAUTION If the codes are in...

Page 217: ...ft as shown below then remove the rear balancer weight REAR BALANCER WEIGHT 4 Pull out the balancer shaft NOTE Take care not to damage the journals when removing the balancer shaft BALANCER GEAR CASE DOWEL PIN 2 Remove the balancer shaft rear cover BALANCER SHAFT REARCOVER O RING Replace BALANCER SHAFT ...

Page 218: ...ns CAUTION If the ridge is not removed it may damage the pistons as they are pushed out 10 Remove the connecting rod caps after setting the crank pin at BDC for each cylinder Remove the pis ton assembly by pushing on the connecting rod CAUTION Take care not to damage the crank pin or cylinder with the connecting rod CORRECT RIDGE REAMER Commercially available PISTON INCORRECT PISTON OIL PUMP DOWEL...

Page 219: ...rod assembly with its cylinder num ber NOTE The existing number on the connecting rod does not indicate its position in the engine it indicates the rod bore size 15 Remove the bearing cap bolts and bearing cap side bolts then remove the bearing cap RUBBER CAP MAINBEARING CAP To help with removal of the caps install the cap bolts in the outside bolt holes CAP BOLT MAINBEARINGCAPS 16 Lift the cranks...

Page 220: ...plete revolutions Support with lathe type tool or V blocks Out of Round and Taper Measure out of round at the middle of each rod and main journal in two places The difference between measurements on each journal must not be more than the service limit Journal Out of Round Standard New 0 004 mm 0 0002 in max Service Limit 0 010 mm 0 0004 in Measure taper at edges Measure out of round at middle Meas...

Page 221: ...aft into the block 4 Install the bearings and caps Tighten the cap bolts only enough to seat the bearing caps TIMING BELT SIDE BEARING CAPS JOURNAL NUMBER CAP BOLT 9 x 1 25 mm CAP BOLT 11 x 1 5 mm BEARING CAP MAIN BEARING LONG BOLT SHORT BOLTS LONG BOLT SIDE CAP BOLT 10 x 1 25 mm RUBBER CAP THRUST WASHERS Grooved sides face outward 3 Install the thrust washers on the No 3 journal Oil the thrust wa...

Page 222: ... torque Torque 39 N m 4 0 kgf m 29 Ibf ft Apply engine oil to the bolt threads 8 Tighten the 11 x 1 5 mm cap bolts to the specified torque Torque 76 N m 7 8 kgf m 56 Ibf ft Apply engine oil to the bolt threads 9 Tighten the 10 x 1 25 mm cap side bolts to the spec ified torque Torque 49 N m 5 0 kgf m 36 Ibf ft 9 x 1 25 mm 39 N m 4 0 kgf m 29 Ibf ft 11 x 1 5 mm 76 N m 7 8 kgf m 56 Ibf ft 10 x 1 25 m...

Page 223: ... inner threads of the bolt holes Do not apply liquid gasket to O ring grooves Do not install the parts if five minutes or more have elapsed since applying liquid gasket Instead reapply liquid gasket after removing old residue After assembly wait at least 30 minutes before filling the engine with oil Apply liquid gasket along the broken line O RING GROOVE NOTE Apply a light coat of oil to the crank...

Page 224: ...hem DOWEL PIN O RINGS Replace OIL PUMP DOWEL PIN 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft DOWEL PIN DOWEL PIN OIL PAN ASSEMBLY NOTE Do not apply liquid gasket to the O ring grooves 13 Apply liquid gasket to the cylinder block then install the oil pan CYLINDER BLOCK Apply liquid gasket along the broken line O RING GROOVE cont d ...

Page 225: ... not to damage the journals when installing the balancer shaft 16 Install the balancer shaft holder see page 7 3 NOTE Apply liquid gasket around the oil hole to the block mating surface 17 Install the rear balancer weight 18 Hold the balancer shaft as shown below then tighten the bolt 8 x 1 25 mm 25 N m 2 5 kgf m 18 Ibf ft 19 Install the balancer shaft rear cover BALANCER SHAFT REAR COVER 6 x 1 0 ...

Page 226: ...the oil pump mating surface of the balancer gear case BALANCER GEAR CASE O RING GROOVE Apply liquid gasket along the broken line 24 Remove the 6 mm bolt Install the sealing bolt in the maintenance hole Use a new washer 22 Install the balancer gear case 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft BALANCER GEAR CASE DOWEL PIN O RING Replace 23 Check alignment of the pointers after installing the balancer...

Page 227: ...e sizes Standard Piston Diameter Oversize Piston Diameter 0 25 90 230 90 240 mm 3 5524 3 5527 in 0 50 90 480 90 490 mm 3 5622 3 5626 in SKIRT DIAMETER 14 0 mm 0 55in 89 980 89 990 mm 3 5425 3 5429 in 89 970 89 980 mm 3 5421 3 5425 in B No Letter A 89 970 mm 3 5421 in Service Limit 89 960 mm 3 5417 in 3 Calculate the difference between cylinder bore diame ter see page 7 15 and piston diameter Pisto...

Page 228: ...f a hammer 2 Install the piston connecting rod assemblies in the cylinder block Guide the piston carefully to prevent damage Fit long rubber hoses about 30 cm 12 in long to the connecting rod bolts to protect the crank shaft Install the pistons after setting the crankshaft to BDC for each cylinder INCORRECT The arrow must face the timing belt side of the engine and the connecting rod oil hole must...

Page 229: ...0 90 010 mm 3 5433 3 5437 in B or Il A or I Oversize 0 25 90 250 90 270 mm 3 5531 3 5539 in 0 50 90 500 90 520 mm 3 5630 3 5638 in BoreTaper Limit Difference between first and third measure ment 0 05 mm 0 002 in Reboring Limit 0 5 mm 0 02 in If measurements in any cylinder are beyond the oversize bore service limit replace the cylinder block If the block is to be rebored refer to Piston Clear ance...

Page 230: ...f all metal particles Wash the cylin der bores with hot soapy water then dry and oil them immediately to prevent rusting NOTE Never use solvent it will only redistribute the grit on the cylinder walls 4 If scoring or scratches are still present in the cylin der bores after honing to the service limit rebore the cylinder block NOTE Some light vertical scoring and scratching is acceptable if it is n...

Page 231: ... gaps are lined up with the cutouts in the piston pin bores NOTE Take care not to damage the ring grooves SNAP RING Cutout in the piston pin bore 2 Remove both snap rings Start at the cutout in the piston pin bore NOTE Remove the snap rings carefully so they do not go flying or get lost Wear eye protection SNAP RING ...

Page 232: ...n and connecting rod assembly to approximately 158 F 70 C then remove the piston pin Work carefully to prevent getting burned NOTE Inspect the piston piston pin and connecting rod when they are at the room temperature ...

Page 233: ...dial indicator to the piston pin diameter 4 Measure the piston pin to connecting rod clearance PistonPin to ConnectingRodClearance Standard New 0 005 0 015 mm 0 0002 0 0006 in Service Limit 0 02 mm 0 0008 in 3 Check the difference between the piston pin diame ter and piston pin hole diameter on the piston NOTE Check the piston for distortion or cracks PistonPin to PistonClearance Standard New 0 00...

Page 234: ... NOTE Install the piston with its offset mark and the oil hole in the connecting rod on the same side OFFSET MARK OIL HOLE The arrow must face the timing belt side of the engine and the connecting rod oil hole must face the right side of the engine Assemble the rod and the piston with the off set mark and oil hole on the same side PISTON PISTONPIN 2 Heat the piston to approximately 158 F 70 C Work...

Page 235: ...g the range You may find any combination of 1 2 3 or 4 I Il IIl or IIIl in any engine Normal Bore Size 57 0 mm 2 24 in NOTE Reference numbers or bars are for big end bore size and do not indicate the position of the rod in the engine Inspect each connecting rod for cracks and heat dam age CONNECTING ROD BORE REFERENCE NUMBER or BAR Half of number is stamped on bearing cap the other half on connect...

Page 236: ...6 0 022 in Service Limit 0 85 mm 0 033 in Oil Ring Standard New 0 20 0 70 mm 0 008 0 028 in 1 0 20 0 50 mm 0 008 0 020 in 2 Service Limit 0 80 mm 0 031 in Replacement 1 Using a ring expander remove the old piston rings 2 Clean all the ring grooves thoroughly NOTE Use a squared off broken ring or ring groove cleaner with a blade to fit the piston grooves File down the blade if necessary Top ring gr...

Page 237: ... of rings measure the ring to groove clearance Top Ring Clearance Standard New 0 055 0 080 mm 0 0022 0 0031 in Service Limit 0 13 mm 0 005 in Second Ring Clearance Standard New 0 030 0 055 mm 0 0012 0 0022 in Service Limit 0 13 mm 0 005 in FEELER GAUGE ...

Page 238: ...hrome SECOND RING Dark Piston Ring Dimensions Top Ring Standard A 3 3 mm 0 13 in B 1 5 mm 0 06 in Second Ring Standard A 3 5 mm 0 14 in B 1 2 mm 0 05 in NOTE The manufacturing marks must be facing upward OIL RING MARK SPACER TOP RING SECOND RING MARK ...

Page 239: ...rooves to make sure they do not bind 3 Position the ring end gaps as shown SECOND RING GAP DO NOT position any ring gap atpistonthrustsurfaces Approx 90 TOP RING GAP DO NOT position any ring gap in line with piston pin hole OIL RING GAP SPACER GAP OIL RING GAP ...

Page 240: ...l seal into the rear cover REAR COVER DRIVER ATTACHMENT 07948 SB00101 Install oil seal with the part number side facing out 2 Confirm that the clearance is equal all the way around with a feeler gauge Clearance 0 2 0 5 mm 0 01 0 02 in 0 2 0 5 mm 0 01 0 02 in REAR COVER REAR COVER CRANKSHAFT OIL SEAL NOTE Refer to pages 7 30 and 8 15 for installation of the oil pump side oil seal DRIVER 07749 00100...

Page 241: ...p is not distorted Installsealwiththe part number side facing out Tape tools together SEAL DRIVER 07GAD PH70201 SUPPORT COLLAR 07965 SD90200 2 Measure the crankshaft oil seal thickness and the oil seal housing depth Using the special tool drive the crankshaft oil seal into the rear cover to the point where the clearance between the bottom of the oil seal and the rear cover is 0 2 0 5 mm 0 01 0 02 ...

Page 242: ...nt Location Index 8 3 Engine Oil Inspection 8 4 Replacement 8 4 Oil Filter Replacement 8 5 Oil Pressure Switch Testing 8 7 Oil Pressure Testing 8 7 Oil Pan Removal 8 8 Installation 8 10 Oil Pump Overhaul 8 12 Removal Inspection Installation 8 13 ...

Page 243: ...Special Tools 07LAC PW50101 07MAF PY40101 07746 0010500 07749 0010000 07912 6110001 Tool Number 8 9 8 11 8 15 8 15 8 6 ...

Page 244: ...x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft OIL CONTROL ORIFICE HYDRAULICTAPPET Remove with 6 x 1 0 mm bolt and clean O RINGS Replace 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft BAFFLE PLATE 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft SNAP RING Install with open side facing up 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft LOWERBAFFLE PLATE DOWEL PIN OIL PAN Apply liquid gasket to ma...

Page 245: ...pan so the dipstick will show the actual level 2 Make certain that the oil level indicated on the dip stick is between the upper and lower marks DIPSTICK UPPER LOWER 3 If the level has dropped close to the lower mark add oil until it reaches the upper mark CAUTION Insert the dipstick carefully to avoid bend ing it Inspection ...

Page 246: ... or Energy Con serving II SH grade oil SAE 5 W 30 preferred You can also use an oil that bears the API CERTIFICATION mark Capacity 4 3 4 5 US qt 3 8 Imp qt at oil change 4 6 4 9 US qt 4 0 Imp qt at oil change including filter 5 3 5 6 US qt 4 7 Imp qt after engine overhaul Change interval Every 7 500 miles 12 000 km or 12 months Normal conditions Every 3 750 miles 6 000 km or 6 months Severe condit...

Page 247: ...to this chart Ambient Temperature An oil with a viscosity of 5W 30 is preferred for improved fuel economy and year round protection in the vehicle You may use a 10W 30 oil if the climate in your area is limited to the temperature range shown on the chart APISERVICELABEL 4 Run the engine for more than 3 minutes then check for oil leakage ...

Page 248: ...oil filter with the special oil filter wrench 2 Inspect the threads and rubber seal on the new fil ter Wipe off the seat on the engine block then apply a light coat of oil to the filter rubber seal NOTE Use only filters with a built in bypass sys tem Inspect threads and rubber seal surface Apply oil to rubber seal before installing cont d ...

Page 249: ... at the bottom of the filter when the rubber seal is seated 2 Tighten the filter by turning it clockwise seven num bers from the marked point For example if a mark is made under the number 2 when the rubber seal is seated the filter should be tightened until the number 1 comes up to the marked point Number when rubber Number after tightening seal is seated CAUTION Using any procedure other than th...

Page 250: ... oil pressure indicator light stays on with the engine running check the engine oil level If the oil level is correct 1 Connect a tachometer 2 Remove the engine oil pressure switch and install an oil pressure gauge ADAPTER 1 8 28 BSPT ENGINE OIL PRESSURE SWITCH MOUNTING HOLE OIL PRESSURE GAUGE Commercially available 3 Start the engine Shut it off immediately if the gauge registers no oil pressure ...

Page 251: ...the front tires wheels and splash shield see page 5 8 6 Remove the damper forks see section 18 7 Disconnect the suspension lower arm ball joints with the special tool Refer to section 18 for the proper procedure 8 Remove the driveshafts and intermediate shaft see section 16 9 Drain the differential oil Reinstall the drain plug using a new washer see section 15 10 Drain the engine oil Reinstall the...

Page 252: ...sition to lock the secondary VACUUM HOSE 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft 17 Disconnect the vacuum hose then remove the right engine mount 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft RIGHT ENGINE MOUNT 21 Remove the differential mounting bolts and 26 mm shim then remove the differential assembly 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft 22 Remove the stiffener see page 5 14 23 Remove the drive pl...

Page 253: ...t to O ring grooves To prevent oil leakage apply liquid gasket to the inner threads of the bolt holes Do not install the parts if 5 minutes or more have elapsed since applying liquid gasket Instead reapply liquid gasket after removing old residue After assembly wait at least 30 minutes before fill ing the engine with oil CYLINDER BLOCK O RING GROOVE Apply liquid gasket along the broken line NOTE U...

Page 254: ... Apply liquid gasket P N 08718 0001 to the sealing bolt threads 11 5 0 3 mm 0 45 0 01 in 12 14g 0 4 0 5oz 36 mm SEALING BOLT 78 N m 8 0 kgf m 58 Ibf ft 8 Check the following after reassembly Refill the differential with differential oil Refill the engine with engine oil Make sure the set rings on the driveshafts are completely inserted into the grooves of the dif ferential or intermediate shaft Ad...

Page 255: ... 6 Ibf ft PUMP COVER INNER ROTOR Inspection page 8 14 PUMP HOUSING Inspection page 8 14 Apply liquid gasket to mating surface of the cylinder block when installing 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft OILSEAL Installation page 8 15 Replace SPRING O RING Replace SPRING SEAT COTTER PIN Replace RELIEF VALVE Valve must slide freely in housing bore Replace if sc...

Page 256: ...lancer gear case O RING Replace BALANCER GEAR CASE DOWEL PIN 2 Remove the balancer shaft rear cover BALANCER SHAFT REAR COVER O RING Replace BALANCER SHAFT 3 Hold the balancer shaft as shown below then remove the rear balancer weight 4 Pull out the balancer shaft NOTE Take care not to damage the journals when removing the balancer shaft REARBALANCER WEIGHT ...

Page 257: ...earance on the pump rotor If the housing to rotor axial clearance exceeds the service limit replace the set of inner and outer rotors and or the pump housing 8 Remove the screws from the pump housing then separate the housing and cover 9 Check the inner to outer rotor radial clearance on the pump rotor If the inner to outer rotor clearance exceeds the service limit replace the inner and outer roto...

Page 258: ...IL PUMP HOUSING 15 Reassemble the oil pump applying liquid thread lock to the pump housing screws 16 Check that the oil pump turns freely 17 Apply a light coat of oil to the seal lip 18 Install the two dowel pins and new O ring on the cylinder block 19 Apply liquid gasket to the cylinder block mating sur face of the oil pump NOTE Use liquid gasket Part No 08718 0001 or 08718 0003 Check that the ma...

Page 259: ...n insert the balancer shaft NOTE Take care not to damage the journals when installing the balancer shaft BALANCER SHAFT O RING Replace BALANCER SHAFT REAR COVER 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 23 Install the balancer shaft holder see page 7 3 NOTE Apply liquid gasket around the oil hole to the block mating surface 24 Install the rear balancer weight 25 Hold the balancer shaft as shown below...

Page 260: ...ncer shaft 6 mm BOLT 45 mm 1 8 in or longer BALANCER SHAFT 12 mm SEALING BOLT 20 N m 2 0 kgf m 14 Ibf ft WASHER Replace 28 Apply liquid gasket to the oil pump mating surface of the balancer gear case BALANCER GEAR CASE 29 Install the balancer gear case 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft BALANCER GEAR CASE DOWEL PIN O RING Replace 30 Check alignment of the pointers after installing the balancer...

Page 261: ...Intake Manifold Exhaust System Special Tools 9 2 Intake Manifold Replacement 9 3 Exhaust Manifold Replacement 9 4 Exhaust Pipe and Muffler Replacement 9 5 TWC Inspection 9 6 HO2S Replacement 9 6 ...

Page 262: ...Special Tools Ref No Tool Number Description Qty Page Reference 07LAA PT50101 02 Sensor Socket Wrench 9 6 ...

Page 263: ...kgf m 16 Ibf ft FAST IDLE THERMO VALVE THROTTLE BODY BASE THROTTLE BODY 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft IDLE AIR CONTROL IAC VALVE 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft INTAKE AIR BYPASS VALVE BODY Replace if cracked or if mating surfaces are damaged 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft EXHAUST GAS RECIRCULATION EGR PIPE INTAKE MANIFOLD CHAMBER Replace if cracked or if mating surfaces ar...

Page 264: ...eads Replace LEFT PRIMARY HEATED OXYGEN SENSOR LEFT PRIMARY HO2S BANK 2 SENSOR 1 44 N m 4 5 kgf m 33 Ibf ft Replacement page 9 6 LEFT EXHAUST MANIFOLD COVER 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft RIGHT 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft HEAT SHIELD RIGHT PRIMARY HEATED OXYGEN SENSOR RIGHT PRIMARY HO2S BANK 1 SENSOR 1 44 N m 4 5 kgf m 33 Ibf ft Replacement page 9 6 RIGHT EXHAUST MANIFOLD COVER ...

Page 265: ...bf ft Replace SELF LOCKING NUT 8 x 1 25 mm 23 N m 2 3 kgf m 17 Ibf ft Replace SELF LOCKING NUT 10 x 1 25 mm 33 N m 3 4 kgf m 25 Ibf ft Replace SECONDARY HEATED OXYGEN SENSOR SECONDARY HO2S SENSOR 2 44 N m 4 5 kgf m 33 Ibf ft Replacement page 9 7 GASKET Replace THREE WAY CATALYTIC CONVERTER TWC Inspection page 9 6 SELF LOCKING NUT 10 x 1 25 mm 54 N m 5 5 kgf m 40 Ibf ft Replace EXHAUST PIPE A SELF ...

Page 266: ...TWC Inspection Using a flashlight make a visual check for plugging melting or cracking of the catalyst TWC FLASHLIGHT ...

Page 267: ...e left and or right primary H02S LEFT LEFT PRIMARY HO2S CONNECTOR O2 SENSOR SOCKET WRENCH 07LAA PT50101 44 N m 4 5 kgf m 33 Ibf ft RIGHT O2 SENSOR SOCKET WRENCH 07LAA PT50101 44 N m 4 5 kgf m 33 Ibf ft RIGHT PRIMARY H02SCONNECTOR 2 Install the left and or right primary HO2S in reverse order of removal T ...

Page 268: ...tor SECONDARY HO2S CONNECTOR 3 Remove the wire harness cover then remove the grommet WIRE HARNESS GROMMET COVER HEAT SHIELD 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 4 Remove the heat shields 5 Remove the secondary HO2S SECONDARY HO2S 44 N m 4 5 kgf m 33 Ibf ft O2 SENSOR WRENCH Commercially available 6 Install the secondary HO2S in reverse order of removal ...

Page 269: ...ostat Replacement 10 8 Testing 10 9 Water Pump Component Location Index 10 10 Inspection 10 11 Replacement 10 11 Fan Control Component Location Index 10 12 Troubleshooting 10 14 Fan Control Module Terminals 10 14 Fan Motor Testing 10 15 Radiator Fan Control Sensor Testing 10 15 Engine Coolant Temperature ECT Gauge 96 02 models Gauge Testing 10 16 Sending Unit Testing 10 16 ...

Page 270: ...essary Check all hose clamps and retighten if necessary Use new O rings when reassembling AUTOMATIC TRANSMISSION FLUID ATF COOLER HOSES Refer to section 14 when installing RADIATOR CAP Pressure testing page 10 7 6 x 1 0 mm 9 N m 0 9 kgf m 7 Ibf ft RADIATOR Engine coolant Refilling and bleeding page 10 6 Leak test page 10 7 Inspect soldered joints and seams for leaks Blow out dirt from between core...

Page 271: ...tions HEATER HOSES FAST IDLE THERMO VALVE HEATER VALVE WATER BYPASS HOSES IDLE AIR CONTROL VALVE THERMOSTAT HOUSING REAR WATER OUTLET ATF COOLER HOSES Refer to section 14 wheninstalling ATF COOLER LINES COOLANT RESERVOIR ...

Page 272: ...OTE Set the upper and lower cushions securely Fill the radiator with engine coolant and bleed the air 6 x 1 0 mm 9 N m 0 9 kgf m 7 Ibf ft CONDENSER FAN SHROUD 6 x 1 0 mm 7 N m 0 7 kgf m 5 Ibf ft FAN MOTOR CONNECTOR ATFCOOLER HOSES Refer to section 14 when installing UPPER RADIATOR HOSE RADIATOR CAP UPPER BRACKET AND CUSHION RADIATOR O RING Replace LOWER CUSHION RADIATORFAN CONTROL SENSOR 27 N m 2 ...

Page 273: ...r NOTE Always use only genuine Honda antifreeze coolant For best corrosion protection the coolant con centration must be maintained year round at 50 minimum Coolant concentrations less than 50 may not provide sufficient protection against corrosion or freezing Coolant concentrations greater than 60 will impair cooling efficiency and are not recom mended CAUTION Do not mix different brands ofantifr...

Page 274: ...Type 2 6 Remove the engine cover see page 5 3 7 Loosen the air bleed bolt in the thermostat housing then pour Honda All Season Antifreeze Coolant Type 2 into the radiator to the bottom of the filler neck Do not let coolant spill on any electrical parts or the paint If any coolant spills rinse it off immedi ately NOTE Always use Honda All Season Antifreeze Coolant Type 2 Using a non Honda coolant c...

Page 275: ...nd fill the radiator with engine coolant to the top of the filler neck 2 Attach the pressure tester to the radiator and apply a pressure of 93 123 kPa 0 95 1 25 kgf cm2 14 18 psi RADIATORPRESSURE TESTER Commercially available 3 Inspect for engine coolant leaks and a drop in pres sure 4 Remove the tester and reinstall the radiator cap NOTE Check for engine oil in the coolant and or coolant in the e...

Page 276: ...1 0 kgf m 7 2 Ibf ft ENGINE COOLANT TEMPERATURE ECT GAUGE SENDING UNIT 9 N m 0 9 kgf m 7 Ibf ft ENGINE COOLANT TEMPERATURE ECT SENSOR 18 N m 1 8 kgf m 13 Ibf ft THERMOSTAT COVER O RING Replace THERMOSTAT Install with pin up RUBBER SEAL Replace 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft ...

Page 277: ...e water and check the temperature with a thermometer Check the temperature at which the thermostat first opens and at which it is fully open CAUTION Do not let the thermometer touch the bottom of the hot container 3 Measure lift height of the thermostat when it is fully open STANDARD THERMOSTAT Lift height above 10 0 mm 0 39 in Starts opening 169 176 F 76 80 C Fully open 194 F 90 C ...

Page 278: ...m 1 2 kgf m 8 7 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft WATER PASSAGE INTAKE MANIFOLD THROTTLE BODY O RINGS Replace WATER BYPASS PIPE O RING Replace THERMOSTAT HOUSING ASSEMBLY 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft REAR WATER OUTLET Apply liquid gasket to the cylinder head mating surface CONNECTING PIPE 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft DOWEL PIN ...

Page 279: ...ove the left camshaft pulley and back cover see page 6 24 3 Remove the water pump NOTE Inspect and clean the O ring groove and mating surface with the cylinder block O RING Replace 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft DOWEL PIN DOWEL PIN 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft 4 Install the water pump in the reverse order of removal NOTE Keep the O ring in p...

Page 280: ...AY Wire colors BLK YEL YEL LT GRN BLK and BLU FAN CONTROL MODULE CONDENSER FAN RELAY Wirecolors BLK YEL WHT BLU and BLU ORN RADIATOR FAN MAIN RELAY Wire colors BLK YEL RED LT GRN BLK BLK and BLU RADIATOR FAN RADIATOR FAN CONTROL SENSOR Testing page 10 14 ...

Page 281: ...ls FANCONTROL MODULE Terminal Wire Connects to 1 2 3 4 5 6 7 8 9 10 11 12 GRN RED BLK RED WHT LT GRN BLK GRN BLK BLK YEL PNK BLU ORN BLU GRN A C pressure switch Not used Ground A C pressure switch Radiator fan relay Coil Radiator fan control sensor IG2 Main power supply PCM Not used Condenser fan relay Coil Not used Radiator fan control sensor PCM ...

Page 282: ...olsensor NOTE Bleed air from the cooling system after installing the radiator fan control sensor see page 10 5 1 Remove the radiator fan control sensor from the radiator see page 10 2 2 Suspend the radiator fan control sensor in a con tainer of water as shown THERMOMETER RADIATOR FAN CONTROL SENSOR WATER 3 Heat the water and check the temperature with a thermometer CAUTION Do not let the thermomet...

Page 283: ...r of the gauge does not move at all check for an open in the YEL GRN wire If the wires are OK replace the ECT gauge If the ECT gauge works test the ECT sending unit ECT Sending Unit Testing 1 Remove the engine cover see page 5 3 2 Disconnect the YEL GRN wire from the ECT sending unit YEL GRN WIRE Covered with insulation POSITIVE TERMINAL ECTSENDING UNIT 3 Using an ohmmeter measure the change in re...

Page 284: ...ed Setting 11 124 PCM Memory Setting 11 125 Fuel Supply System Fuel Lines 11 126 Fuel Tube Quick Connect Fittings 11 129 System Description 11 132 Fuel Pressure 11 132 Fuel Injectors 11 133 Fuel Pressure Regulator 11 135 Troubleshooting 11 137 Fuel Pump Relay 11 139 Fuel Pump Resistor 11 141 Fuel Filter 11 142 Fuel Pump 11 142 Fuel Gauge 11 143 Fuel Gauge Sending Unit 11 144 Low Fuel Indicator Sys...

Page 285: ... 004000A Vacuum Pressure Gauge 0 4 in Hg SCS Service Connector Backprobe Set Fuel Pressure Gauge 11 137 11 139 11 155 11 158 11 159 11 162 11 163 11 168 11 169 11 182 11 184 11 185 11 187 11 189 11 190 11 193 11 194 11 195 11 197 11 198 11 199 11 200 11 203 11 204 11 205 11 205 11 40 11 45 11 132 11 135 For additional 2004 information refer to page 11 2c ...

Page 286: ...TP SENSOR VEHICLE SPEED SENSOR VSS Troubleshooting see section 14 IDLE AIR CONTROL IAC VALVE RIGHT KNOCK SENSOR RIGHT KS BANK 1 ENGINE COOLANT TEMPERATURE ECT SENSOR CRANKSHAFT POSITION CYLINDER POSITION CKP CYP SENSOR EVAPORATIVE EMISSION EVAP PURGE CONTROL SOLENOID VALVE LEFT PRIMARY HEATED OXYGEN SENSOR LEFT PRIMARY HO2S BANK 2 SENSOR 1 POWER STEERING PRESSURE PSP SWITCH Troubleshooting page 11...

Page 287: ...L Assy LEFT PRIMARY HEATED OXYGEN SENSOR LEFTPRIMARYHO2S BANK 2 SENSOR 1 THROTTLE POSITION TP SENSOR EVAPORATIVE EMISSION EVAP CANISTER PURGE VALVE CRANKSHAFT POSITION CYLINDER POSITION CKP CYP SENSOR ENGINE COOLANT TEMPERATURE ECT SENSOR IDLE AIR CONTROL IAC VALVE RIGHT KNOCK SENSOR BANK 1 VEHICLESPEEDSENSOR VSS Troubleshooting see section 14 LEFT KNOCK SENSOR BANK 2 INTAKE AIR TEMPERATURE IAT SE...

Page 288: ...g page 11 146 Troubleshooting page 11 147 DATA LINK CONNECTOR DLC Troubleshooting procedures page 11 40 SERVICE CHECK CONNECTOR Troubleshooting procedures page 11 40 POWERTRAIN CONTROL MODULE PCM Troubleshooting page 11 63 For Troubleshooting of DTC related components see chart on page 11 53 00 03 models 11 41 04 model ...

Page 289: ...ubleshooting page 11 141 FUEL PUMP RELAY Troubleshooting page 11 139 IDLE AIR CONTROL IAC THERMAL VALVE Inspection page 11 123 THROTTLECABLE Inspection Adjustment page 11 154 Installation page 11 154 POSITIVE CRANKCASE VENTILATION PCV VALVE Inspection page 11 174 INTAKE MANIFOLD RUNNDER CONTROL IMRC DIAPHRAGM 2 Testing page 11 162 For Troubleshooting of DTC related components see chart on page 11 ...

Page 290: ...EL FILL CAP FUEL TUBE QUICK CONNECT FITTINGS Precautions page 11 129 Disconnection page 11 129 Connection page 11 130 INJECTORS Replacement page 11 133 EVAPORATIVE EMISSION EVAP CONTROL CANISTER VENT SHUT VALVE Replacement page 11 201 EVAPORATIVE EMISSION EVAP CONTROL CANISTER FUEL FEED PIPE FUEL RETURN PIPE FUEL VAPOR PIPE FUEL TANK Replacement page 11 150 FUEL TANK EVAPORATIVE EMISSION EVAP VALV...

Page 291: ...ent page 11 143 FUEL FILL CAP EVAPORATIVE EMISSION EVAP CANISTER FILTER FUEL TUBE QUICK CONNECT FITTINGS Precautions page 11 129 Disconnection page 11 129 Connection page 11 130 EVAPORATIVE EMISSION EVAP CANISTER VENT SHUT VALVE Replacement page 11 201 FUEL VAPOR PIPE EVAPORATIVE EMISSION EVAP TWO WAY VALVE Testing page 11 205 FUEL TANK PRESSURE FTP SENSOR FUEL RETURN PIPE EVAPORATIVE EMISSION EVA...

Page 292: ...NTROL SOLENOID VALVE ENGINE MOUNT CONTROL SOLENOID VALVE INTAKE AIR BYPASS IAB CHECK VALVE FRONT OF VEHICLE EVAPORATIVE EMISSION EVAP CONTROL CANISTER VENT SHUT VALVE EVAPORATIVE EMISSION EVAP CONTROL CANISTER INTAKE AIR BYPASS IAB LOW CONTROL DIAPHRAGM VALVE Vacuum hose No To RIGHT ENGINE MOUNT EVAPORATIVE EMISSION EVAP PURGE CONTROL SOLENOID VALVE To LEFT ENGINE MOUNT TANK CRUISE CONTROL To VACU...

Page 293: ...RVOIR INTAKE MANIFOLD RUNNER CONTROL IMRC CHECKVALVE INTAKE MANIFOLD RUNNER CONTROL IMRC SOLENOID VALVE 1 ENGINE MOUNT CONTROL SOLENOID VALVE INTAKE MANIFOLD RUNNER CONTROL IMRC DIAPHRAGM 2 INTAKE MANIFOLD RUNNER CONTROL IMRC DIAPHRAGM 1 FUEL PRESSURE REGULATOR To EVAPORATIVE EMISSION EVAP CANISTER FRONT OF VEHICLE To RIGHT ENGINE MOUNT To LEFT ENGINE MOUNT EVAPORATIVE EMISSION EVAP CANISTER PURGE...

Page 294: ...TION EGR VALVE VACUUM CONTROL SOLENOID VALVE EXHAUST GAS RECIRCULATION EGR VALVE VACUUM CONTROL VALVE PRESSURE REGULATOR VACUUM CONTROL SOLENOID VALVE Vacuum hose No For Troubleshooting of DTC related components see chart on page 11 53 ...

Page 295: ...ER RESONATOR INTAKE AIR BYPASS IAB CHECK VALVE INTAKE AIR BYPASS IAB VACUUM TANK INTAKE AIR BYPASS IAB LOW CONTROL SOLENOID VALVE INTAKE AIR BYPASS IAB LOW CONTROL DIAPHRAGM VALVE INTAKE AIR BYPASS IAB HIGH CONTROL SOLENOID VALVE INTAKE AIR BYPASS IAB HIGH CONTROL DIAPHRAGM VALVE EXHAUST GAS RECIRCULATION EGR VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION EGR CONTROL SOLENOID VALVE EXHAUST GAS REC...

Page 296: ...FOLD RUNNER CONTROL IMRC CHECK VALVE INTAKE MANIFOLD RUNNER CONTROL IMRC VACUUM RESERVOIR INTAKE MANIFOLD RUNNER CONTROL IMRC SOLENOID VALVE 1 INTAKE MANIFOLD RUNNER CONTROL IMRC DIAPHRAGM 1 INTAKE MANIFOLD RUNNER CONTROL IMRC SOLENOID VALVE 2 INTAKE MANIFOLD RUNNER CONTROL IMRC DIAPHRAGM 2 EXHAUST GAS RECIRCULATION EGR VALVE VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION EGR VALVE VACUUM CONTROL ...

Page 297: ...s FUSES BACK UP RADIO 7 5A STOP HORN 15A BATTERY 120A FUSE BOX 50A IG SW 50A in the under hood fuse relay box No 6 ECU PCM 20A No 25 IG COIL 30A No 22 FUEL PUMP 20A No 20 ECU PCM 20A No 14 STARTER SIGNAL 7 5A 2 00 01 models ToIMMOBILIZER UNIT ...

Page 298: ... 1 96 99 models 2 00 01 models IGNCOIL1 A11 IGNCOIL2 A24 IGNCOI B12 IGNCCHL4 B11 IGNCOIL5 B10 IGNCOIL6 B2 PHRSTL F7 PHRSTR F3 MFPLSLF8 MFPLSR F4 ILU E22 ...

Page 299: ...System Description Electrical Connections cont d TERMINAL LOCATIONS ...

Page 300: ...LEFT PRIMARY HO2S BANK 2 SENSOR 1 RIGHT PRIMARY HO2S BANK 1 SENSOR 1 ...

Page 301: ...System Description Electrical Connections cont d To page 11 19 JUNCTION CONNECTOR JUNCTION CONNECTOR JUNCTION CONNECTOR ...

Page 302: ... From page 11 18 To IMMOBILIZER UNIT TACHOMETER CONNECTOR To MFCS UNIT JUNCTION CONNECTOR ENGINE MOUNT CONTROL SOLENOID VALVE C254 C101 G101 JUNCTION CONNECTOR ...

Page 303: ...System Description Electrical Connections cont d ...

Page 304: ...JUNCTION CONNECTOR ...

Page 305: ...System Description Electrical Connections cont d 1 96 99 models ...

Page 306: ... 2 00 01 models ...

Page 307: ...System Description Electrical Connections cont d To A C PRESSURE SWITCH 1 96 99 models ...

Page 308: ... To page 11 26 ...

Page 309: ...System Description Electrical Connections cont d From page 11 25 To page 11 27 ...

Page 310: ... From page 11 26 2 00 01 models ...

Page 311: ...System Description Electrical Connections ...

Page 312: ......

Page 313: ...System Description Electrical Connections cont d ...

Page 314: ...System Description Electrical Connections ...

Page 315: ... cont d ...

Page 316: ...Electrical Connections cont d System Description ...

Page 317: ... cont d ...

Page 318: ...System Description Electrical Connections cont d ...

Page 319: ... cont d ...

Page 320: ...System Description Electrical Connections cont d ...

Page 321: ... cont d ...

Page 322: ...Electrical Connections cont d System Description ...

Page 323: ... cont d ...

Page 324: ...System Description Electrical Connections cont d ...

Page 325: ... cont d ...

Page 326: ...System Description Electrical Connections cont d ...

Page 327: ... cont d ...

Page 328: ...tment A T SUB HARNESS C144 C143 C163 G101 C129 C110 C161 C162 C106 C137 C127 C344 LEFT ENGINE COMPARTMENT WIRE HARNESS C125 C316 1 96 99 models C131 C308 C124 C301 C303 C130 C128 C126 ENGINE WIRE HARNESS C145 C109 C108 C138 C139 C323 C171 C320 1 C319 1 ...

Page 329: ...om terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System Different wires with the same color have been given a number suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same ...

Page 330: ... HARNESS C257 C107 C142 C251 C103 C113 C256 C123 C151 C115 VEHICLE SPEED SENSOR SUB HARNESS ENGINE WIRE HARNESS C121 C175 C214 LEFT ENGINE COMPARTMENT WIREHARNESS C173 C174 C172 C252 C104 C120 C119 C152 C116 C114 C140 C141 111 C255 C105 C254 C101 C253 C102 C136 C135 C134 ...

Page 331: ...a number suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System ...

Page 332: ...loor DASHBOARD WIRE HARNESS C430 C503 MAIN WIRE HARNESS C428 LEFT ENGINE COMPARTMENT WIRE HARNESS C417 C327 C432 C418 C325 C419 C326 LEFT SIDE WIRE HARNESS 2 00 01 models C420 C328 C416 C324 C421 C433 C651 C329 C406 C404 C405 C414 2 C656 2 C413 C654 ...

Page 333: ...n given a number suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System ...

Page 334: ...System Description System Connectors Dash and Floor cont d C509 DASHBOARD WIRE HARNESS C508 MAIN WIRE HARNESS LEFT ENGINE COMPARTMENT WIRE HARNESS LEFT SIDE WIRE HARNESS C501 C502 ...

Page 335: ...en given a number suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System ...

Page 336: ... DASHBOARD WIRE HARNESS RIGHT ENGINE COMPARTMENT WIRE HARNESS C469 C442 C601 C461 PCM B MAIN WIRE HARNESS C459 PCM A C457 C611 RIGHT SIDE WIRE HARNESS 2 00 01 models C470 C460 PCM C C463 PCM D C450 2 C448 VSA CONVERTER UNIT 2 C451 C201 C456 C454 C458 PCM E C464 C476 C517 ...

Page 337: ...the same color have been given a number suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System ...

Page 338: ...ctors Dash and Floor cont d TCS CONTROL UNIT 1 C624 1 REAR WIRE HARNESS C667 C704 RIGHT SIDE WIRE HARNESS C675 2 FUEL UNIT WIRE HARNESS LEFTSIDEWIRE HARNESS 1 96 99 models 2 00 01 models C669 C721 C722 C673 2 C674 2 C670 C701 C623 1 ...

Page 339: ...ave been given a number suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System ...

Page 340: ...System Description System Connectors Engine Compartment ...

Page 341: ...mber suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System cont d ...

Page 342: ...System Connectors Engine Compartment cont d System Description ...

Page 343: ...a number suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System ...

Page 344: ...System Description System Connectors Dash and Floor ...

Page 345: ...mber suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side cont d Related to Fuel and Emissions System ...

Page 346: ...System Description System Connectors Dash and Floor cont d ...

Page 347: ...mber suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System cont d ...

Page 348: ...System Connectors Dash and Floor cont d System Description ...

Page 349: ...stinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side cont d Connector with female terminals single outline View from wire side Related to Fuel and Emissions System Terminal side of female terminals ...

Page 350: ...System Description System Connectors Dash and Floor cont d ...

Page 351: ...a number suffix to distinguish them for example YEL BLK1 and YEL BLK2 are not the same Connector with male terminals double outline View from terminal side Connector with female terminals single outline View from wire side Related to Fuel and Emissions System ...

Page 352: ... PGM Tester user s manuals for specific operating instructions The scan tool or tester can read the DTC freeze frame data current data and other Powertrain Control Module PCM data Freeze frame data indicates the engine conditions when the first malfunction misfire or fuel trim malfunction was detected It can be useful information when troubleshooting B When the MIL has not come on but there is a d...

Page 353: ...od fuse relay box for 10 seconds NOTE If the BACK UP RADIO 7 5 A fuse is removed and the ignition switch ON II MIL will report on and BACK UP RADIO 7 5 A FUSE PCM will store the DTC P0560 UNDER HOOD FUSE RELAY BOX III Final Procedure this procedure must be done after any troubleshooting 1 Remove the SCS service connector if it is connected NOTE If the SCS service connector is connected and there a...

Page 354: ...ocedures cont d IV Known Good PCM Substitution Use the following procedure if you need a known good PCM to test a vehicle It allows you to swap an PCM from a donor vehicle without having to program it to the test vehicle s ignition key 1 Cut a temporary ignition key for the test vehicle with a non immobilizer key blank 2 Remove the PCM from the test vehicle 3 Write the test vehicle s VIN on the PC...

Page 355: ...of the wire Backprobe Adapter DIGITAL MULTIMETER Commercially available or KS AHM 32 003 Stacking Patch Cord BACKPROBE SET 07SAZ 001000A Two required CAUTION Puncturing the insulation on a wire can cause poor or intermittent electrical connections Bring the tester probe into contact with the terminal from the terminal side of wire harness connectors in the engine compartment For female connectors ...

Page 356: ... 00 01 models 2 3 21 13 1 2 10 12 20 21 5 6 7 4 5 6 7 9 8 5 14 15 6 7 9 8 Troubleshoot for misfire on pages 11 96 11 100 2 8 9 11 18 17 19 10 2 5 10 21 7 3 16 20 22 20 22 Other Probable Causes for an engine that will not start Compression PGM FI main relay Engine locked up Timing belt Starting system Ignition system Overheating Battery Probable Cause List For the DTC Chart see page 11 53 00 01 mod...

Page 357: ...early the same as tachometer indication at idle speed 650 50 rpm YES VehicleSpeed The PCM converts pulse signals from the Vehicle Speed Sensor VSS into speed data Nearly the same as speedometer indication YES Manifold Absolute Pressure MAP The absolute pressure created in the intake manifold by engine load and speed With engine stopped Nearly the same as atmo spheric pressure At idle speed 24 37 k...

Page 358: ...chiometric ratio when in closed loop status 30 43 YES Long Term Fuel Trim Bank 1 Right Bank 2 Left Long term fuel trim in computed from short term fuel trim and indicates changes occuring in the fuel supply system over a long period If long term fuel trim is higher than 1 00 the amount of injected fuel must be increased If it is lower than 1 00 the amount of injected fuel must be reduced 20 YES In...

Page 359: ...m Engine locked up Overheating Timing belt Battery Probable Cause 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Page 11 66 see DTC chart see DTC chart see DTC chart Section 14 11 81 see DTC chart 11 106 System Powertrain Control Module PCM Fuel pressure Crankshaft Position Camshaft Position CKP CMP Crankshaft Position Cylinder Position CKP CYP sensorcircuit Intake Air Temperature IAT se...

Page 360: ...Powertrain Control Module Terminal Arrangement PCM CONNECTOR A 26P PCM CONNECTOR A 26P Wire side of female terminals NOTE Standard battery voltage is 12 V 96 99 models 1 00 01 models ...

Page 361: ...Troubleshooting Powertrain Control Module Terminal Arrangement cont d PCM CONNECTOR B 16P Wire side of female terminals NOTE Standard battery voltage is 12 V PCM CONNECTOR B 16P ...

Page 362: ...PCM CONNECTOR C 12P Wire side of female terminals PCM CONNECTOR C 12P NOTE Standard battery voltage is 12 V withTCS 1 with VSA cont d 11 49 ...

Page 363: ...Troubleshooting Powertrain Control Module Terminal Arrangement cont d PCM CONNECTOR D 22P Wire side of female terminals withTCS 1 with VSA NOTE Standard battery voltage is 12 V PCM CONNECTOR D 22P ...

Page 364: ...PCM CONNECTOR E 26P PCM CONNECTOR E 26P Wire side of female terminals NOTE Standard battery voltage is 12 V withTCS 1 withVSA ...

Page 365: ...Troubleshooting Powertrain Control Module Terminal Arrangement cont d PCM CONNECTOR F 8P Wire side of female terminals NOTE Standard battery voltage is 12 V PCM CONNECTOR F 8P ...

Page 366: ...Troubleshooting Powertrain Control Module Terminal Arrangement PCM CONNECTOR A 26P ...

Page 367: ...Troubleshooting Powertrain Control Module Terminal Arrangement cont d PCM CONNECTOR B 16P ...

Page 368: ...PCM CONNECTOR C 12P ...

Page 369: ...PCM CONNECTOR D 22P Powertrain Control Module Terminal Arrangement cont d Troubleshooting ...

Page 370: ...PCM CONNECTOR E 26P ...

Page 371: ...PCM CONNECTOR F 8P Powertrain Control Module Terminal Arrangement cont d Troubleshooting ...

Page 372: ...alfunction Indicator Lamp MIL with the SCS service connector connected 2 These DTCs require two trips or two driving cycles unless the SCS service connector is connected 3 96 model only 4 97 model only 11 91 11 87 11 86 11 84 11 82 11 80 11 79 11 78 11 77 11 76 11 75 11 74 11 72 11 71 11 69 ...

Page 373: ...ng Diagnostic Trouble Code DTC Chart cont d 11 88 11 89 11 90 11 91 11 84 11 86 11 87 11 91 11 93 11 93 11 93 11 93 2 These DTCs require two trips or two driving cycles unless the SCS service connector is connected ...

Page 374: ...ice connector is connected 5 The indicator light and the Malfunction Indicator Lamp MIL may come on simultaneously 7 97 01 models 9 98 01 models 10 00 01 models 11 109 11 109 11 108 Section 14 11 101 11 113 11 180 11 178 11 177 11 100 11 95 11 95 11 106 11 106 11 167 11 165 ...

Page 375: ...Troubleshooting Diagnostic Trouble Code DTC Chart cont d 11 83 11 83 11 73 11 73 11 96 11 100 11 96 11 102 11 102 11 104 11 104 11 106 11 106 7 97 01 models 8 96 97 models 9 98 01 models ...

Page 376: ...9 Section 19 Section 19 Section 14 2 These DTCs require two trips or two driving cycles unless the SCS service connector is connected 5 The indicator light and the Malfunction Indicator Lamp MIL may come on simultaneously 6 withTCS VSA 11 187 00 03 96 99 11 192 11 196 00 03 96 99 ...

Page 377: ...ndary Heated Oxygen Sensor Secondary H02S Circuit Low Voltage Sensor 2 Secondary Heated Oxygen Sensor Secondary H02S Circuit High Voltage Sensor 2 Probable Cause Open or short in MAP sensor circuit MAP sensor PCM Open in MAP sensor circuit MAP sensor PCM Short in IAT sensor circuit IAT sensor PCM Open in IAT sensor circuit IAT sensor PCM ECT sensor Cooling system Short in ECT sensor circuit ECT se...

Page 378: ...H02S Sensor 2 Open or short in Secondary H02S Sensor 2 heater circuit PCM Left Primary H02S Bank 2 Sensor 1 Exhaust system Open in Left Primary H02S Bank 2 Sensor 1 circuit Left Primary H02S Bank 2 Sensor 1 PCM Open or short in Left Primary HO2S Bank 2 Sensor 1 heater circuit PCM Fuel supply system Right Primary H02S Bank 1 Sensor 1 MAP sensor Contaminated fuel Valve clearance Exhaust leakage Fuel...

Page 379: ...m Low Purge Flow Idle Control System RPM Lower Than Expected Idle Control System RPM Higher Than Expected Probable Cause CKP 1 Sensor CKP 1 Sensor circuit PCM CKP 1 Sensor Timing belt skipped teeth CMP CYP 1 Sensor CMP CYP 1 Sensor circuit PCM CMP CYP 1 Sensor EGR valve EGRline EGR valve with position sensor EGR valve position sensor circuit EGR valve vacuum control solenoid valve EGR valve vacuum...

Page 380: ...Voltage Detection Module Reset Circuit Malfunction Left Bank Bank 2 Spark Plug Voltage Detection Module Reset Circuit Malfunction Right Bank Bank 1 CrankshaftPosition CKP 2 Sensor Circuit Intermittent Interruption CrankshaftPosition CKP 2 Sensor Circuit No Signal Probable Cause IAC valve IAC valve circuit PCM PCM Back up Circuit PCM PCM TP sensor TP sensor MAP sensor MAP sensor Injector Injector c...

Page 381: ...t High Voltage Probable Cause CMP CYP 2 Sensor CMP CYP 2 Sensor CMP CYP 2 Sensor circuit PCM Vacuum connection Fuel tank FTP sensor Fuel fill cap EVAP bypass solenoid valve EVAP two way valve EVAP canister vent shut valve EVAP canister EVAP canister purge valve Vacuum connection EVAP canister FTP sensor EVAP bypass solenoid valve EVAP two way valve EVAP canister vent shut valve Fuel tank EVAP cani...

Page 382: ...t High Voltage Bank 1 Sensor 1 Left Primary Heated Oxygen Sensor Left Primary H02S Circuit High Voltage Bank 2 Sensor 1 Probable Cause Right Primary H02S Bank 2 Sensor 1 Short in Right Primary H02S Bank 2 Sensor 1 circuit Fuel supply system PCM Left Primary HO2S Bank 2 Sensor 1 Short in Left Primary H02S Bank 2 Sensor 1 circuit Fuel supply system PCM Page 11 56 11 56 ...

Page 383: ... had a failure but it checks out OK at this time If the Malfunction Indicator Lamp MIL on the dash does not come on check for poor connections or loose wires at all connectors related to the circuit that you are troubleshooting see illustration below Most of the troubleshooting flowcharts have you reset the Powertrain Control Module PCM and try to duplicate the Diagnostic Trouble Code DTC If the p...

Page 384: ...Timing and Duration The PCM contains memories for the basic discharge durations at various engine speeds and manifold pressures The basic discharge duration after being read out from the memory is further modified by signals sent from various sensors to obtain the final discharge duration Idle Air Control Idle Air Control Valve IAC Valve When the engine is cold the A C compressor is on the transmi...

Page 385: ...inue to run 2 Back up Function When an abnormality occurs in the PCM itself the fuel injectors are controlled by a back up circuit independent of the system in order to permit minimal driving 3 Self diagnosis Function Malfunction Indicator Lamp MIL When an abnormality occurs in a signal from a sensor the PCM supplies ground for the MIL and stores the DTC in erasable memory When the ignition is ini...

Page 386: ...gine is stopped during this procedure go to step 3 and do the procedure again 5 Check for the readiness code with the scan tool EVAP Leak Monitor NOTE When the battery negative cable is disconnected all readiness codes are cleared If the engine is stopped while doing the procedure between stops 6 and 16 do this procedure from step 1 again 1 Make sure the gasoline level is 60 90 of fuel tank capaci...

Page 387: ...k or neutral until the radiator fan comes on 3 Let the engine idle for 5 seconds 4 Drive at a steady speed between 50 62 mph 80 100 km h for about 2 minutes 5 With the A T in D4 position decelerate from 62 mph 100 km h by completely releasing the throttle for at least 5 seconds If the engine is stopped during this procedure go to step 4 and do the procedure again 6 Check for the readiness code wit...

Page 388: ... under dash fuse relay box PGM FI main relay The MIL stays on or comes on after 2 seconds with the ignition switch turned ON II An intermittent short in the wire between the PCM C5 and the service check con nector data link connector An intermittent open in the wires between the PCM D22 and the service check connec tor An intermittent short in the wire between the PCM A7 and the gauge assembly See...

Page 389: ...in relay Repair short in the wire between PGM FI main relay and the PCM fuel injectors or IAC valve Repair short in the wire between fuel injectors and IACvalve Replace No 6 ECU PCM 20 A fuse Repair short in the wire between No 25 IG COIL 30 A fuse and PGM FI main relay Replace No 25 IG COIL 30 A fuse PCM CONNECTORS A 26P Repair open in the wire s between the PCM A13 B9 and PGM FI main relay Check...

Page 390: ...nd and the PCM con nector terminals D10 and D21 individually disconnect the 3P connector of each sensor one at a time MAP sensor TP sensor EGR valve liftsensor Fuel tank pressure sensor TCS VSA control valve angle sensor with TCS VSA Is there approx 5 V NO Check for a short in the wires VCC1 VCC2 lines 1 Turn the ignition switch OFF 2 Disconnect the ECM connec tor D 22P 3 Check for continuity betw...

Page 391: ...ound Is there approx 5 V or battery voltage YES Go to the DTC Troubleshooting Index see page 11 53 PCM CONNECTOR C 12P Wire side of female terminals Repair short in the wire between the service check connector data link connector and PCM C5 DATA LINK CONNECTOR DLC 16P Wire side of female terminals Is there continuity Repair short in the wire between the DLC and PCM D4 00 01 models To page 11 67 NO...

Page 392: ...CTOR D 22P Wire side of female terminals Is there continuity Repair open in the wire between the DLC and PCM D4 YES Check for a short in the wire MIL line Turn the ignition switch ON II Does the MIL come on NO Repair short in the wire between the gauge assembly and PCM A7 Substitute a known good PCM and recheck see page 11 41 for immobilizer information If symptom indication goes away replace the ...

Page 393: ...jumper wire 3 Turn the ignition switch ON II PCM CONNECTOR A 26P Wire side of female terminals Does the MIL come on YES Repair open in the wires between the PCM A7 and gauge assembly Replace the MIL bulb Substitute a known good PCM and recheck see page 11 42 for immobilizer information If symptom indication goes away replace the original PCM NO MIL LT GRN RED JUMPER WIRE From page 11 63 ...

Page 394: ... on after 2 seconds with the ignition switch turned ON II An intermittent short in the wire between the PCM C5 and the service check con nector data link connector An intermittent open in the wire between the PCM D22 and the service check connec tor An intermittent short in the wire between the PCM A7 and the gauge assembly See the HDS or the scan tool user s manuals for specific operating instruc...

Page 395: ... relay and the PCM fuel injectors or IAC valve Repair short in the wire between fuel injectors and IACvalve Replace No 6 ECU PCM 20 A fuse Repair short in the wire between No 25 IG COIL 30 A fuse and PGM FI main relay Replace No 25 IG COIL 30 A fuse Repair open in the wire s between the PCM A13 B9 and PGM FI main relay Check for a poor connection or loose wires at the PGM FI main relay Test the PG...

Page 396: ... Check for a short in a sensor While measuring voltage between body ground and the PCM con nector terminals D10 and D21 individually disconnect the 3P connector of each sensor one at a time MAP sensor TP sensor EGR valve lift sensor Fuel tank pressure sensor VSA control valve angle sensor Is there about 5 V NO Check for a short in the wires VCC1 VCC2 lines 1 Turn the ignition switch OFF 2 Disconne...

Page 397: ...tor terminal C5 and body ground PCM CONNECTOR C 12P SCS RED Wire side of female terminals Is there about 5 V or battery voltage Repair short in the wire between the service check connector data link connector and PCM C5 YES DATA LINK CONNECTOR DLC Terminal side of female terminals Is there continuity Repair short in the wire between the DLC and PCM D4 NO To page 11 74 cont d From page 11 70 Check ...

Page 398: ... continuity Repair open in the wire between the DLC and PCM D4 YES Check for a short in the wire MIL line Turn the ignition switch ON II Does the MIL come on NO Repair short in the wire between the gauge assembly and PCM A7 Substitute a known good PCM and recheck If symptom indica tion goes away replace the origi nal PCM MIL Circuit Troubleshooting cont d ...

Page 399: ...ter minal A7 and body ground with a jumper wire 3 Turn the ignition switch ON II Does the MIL come on YES Repair open in the wires between the PCM A7 and gauge assembly Replace the MIL bulb Substitute a known good PCM and recheck If symptom indica tion goes away replace the origi nal PCM From page 11 70 ...

Page 400: ...ation and the scan tool does not indicate Diagnostic Trouble Code DTC P0505 or P1508 check the following items Adjust the idle speed see page 11 124 Air conditioning signal see page 11 116 ALT FR signal see page 11 118 Starter switch signal see page 11 119 Transmission range signal see section 14 PSP switch signal see page 11 120 Brake pedal position switch signal see page 11 122 Idle air control ...

Page 401: ...FF 2 Reconnect the radiator fan control unit 12P connector 3 Turn the ignition switch ON II 4 Momentarily connect PCM connector terminals A8 and A26 with a jumper wire sever al times ACS PNK YES Repair short in the wire between the PCM C2 and the radiator fan control unit PCMCONNECTORA 26P Topage 11 117 Wire side of female terminals Substitute a known good PCM and recheck see page 11 42 for immobi...

Page 402: ...n the PCM A8 and the A C clutch relay PCM CONNECTORS Check the A C operation 1 Start the engine 2 Turn the blower switch ON 3 Turn the A C switch ON Does the A C operate YES Check for an open in the wire ACSline Measure voltage between PCM connector terminals A26 and C2 Air conditioning signal is OK Wire side of female terminals Is voltage less than 1 0 V YES Repair open in the wire between the PC...

Page 403: ...r terminal D5 Is there continuity YES See the ALT inspection see section 4 NO Wire side of female terminals Check for a short in the wire ALT Fline 1 Turn the ignition switch OFF 2 Disconnect the negative bat tery cable from the battery 3 Disconnect the PCM connector D 22P 4 Check for continuity between body ground and PCM con nector terminal D5 Is there continuity Repair short in the wire between...

Page 404: ...ween the PCM C6 and the No 14 STARTER SIGNAL 7 5 A fuse YES Inspect the No 14 STARTER SIG NAL 7 5 A fuse in the under dash fuse relay box NO YES Starter switch signal is OK Check for an open or short in the wire STS line Measure voltage between PCM connector terminals C6 and A26 with the ignition switch in the start position III NOTE Transmission in or position Inspection of Starter Switch Sig nal...

Page 405: ...and A26 Is there battery voltage NO PCMCONNECTORS Checkfor an open in the wire PSP SW Iine 1 Turn the ignition switch OFF 2 Disconnect the PSP switch connector 3 Turn the ignition switch ON II 4 At the wire side connect the PSP switch connector termi nals No 1 and No 2 with a jumper wire 5 Measure voltage between PCM connectorterminals B3 and A26 Wire side of female terminals PSPSWITCHCONNECTOR C1...

Page 406: ...age between PCM connector terminals B3 and A26 Is there battery voltage NO PCMCONNECTORS Wire side of female terminals Is there continuity Repair short in the wire between the PCM B3 and the PSP switch NO Substitute a known good PCM and recheck see page 11 42 for immobilizer information If pre scribed voltage is now available replace the original PCM YES Replace the PSP switch YES ...

Page 407: ...e be tween the brake pedal posi tion switch and the STOP HORN 15 A fuse Replace the STOP HORN 15 A fuse Wire side of female terminals Is there battery voltage Repair open in the wire between the PCM E2 and the brake pedal position switch Brake pedal position switch sig nal is OK YES NO Repair open in the wire be tween the brake pedal posi tion switch and the STOP HORN 15A fuse Inspect the brake pe...

Page 408: ...1 Remove the cover of the idle air control thermal valve 2 Start the engine 3 Put your finger on the valve seat area and make sure that there is air flow with the engine cold engine coolant temperature below 86 F 30 C and idling O RINGS Replace 12 N m 1 2 kgf m 8 7 Ibf ft 4 Start the engine Hold the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on then let it idl...

Page 409: ...e engine Hold the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on then let it idle 3 Disconnect the IAC valve connector IAC VALVE 4 If the engine stalls start the engine with the acceler ator pedal slightly depressed Stabilize the rpm at 1 000 then slowly release the pedal until the engine idles 5 Check idling under the following conditions head lights Hi and re...

Page 410: ...ter resetting the PCM 8 Restart and idle the engine with no load conditions for one minute then check the idle speed NOTE Canada Pull the parking brake lever up Start the engine then check that the headlights are off Idle speed should be 650 50 rpm in Park or neutral NOTE If the idle speed is not within specification see Symptom Chart on page 11 44 ...

Page 411: ...ure is needed after the PCM reset procedure and reconnect ing the battery or the BACK UP RADIO 7 5 A fuse 1 Start the engine Hold the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on 2 Let the engine idle for approx 5 minutes under the following conditions Transmission in Park or neutral A C switch OFF Headlights OFF Rear defogger OFF ...

Page 412: ...er and other components for damage leaks or deterioration and replace if neces sary 96 99 models 22 N m 2 2 kgf m 16 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 00 01 models 37 N m 3 8 kgf m 27 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 37 N m 3 8 kgf m 27 Ibf ft ...

Page 413: ...WAY VALVE EVAPORATIVE EMISSION EVAP CONTROL CANISTER 10 15mm 0 39 0 59in Clamp in the middle Clamp in the middle FUEL TANK FUEL FILTER To FUEL PRESSURE REGULATOR BASE GASKET Replace BASE GASKET Replace FUEL PUMP ASSEMBLY FUEL GAUGE SENDING UNITASSEMBLY FUEL TANK EVAPORATIVE EMISSION EVAP VALVE ...

Page 414: ...ont d 00 01 models Check all hose clamps and retighten if necessary A Do not disconnect To FUEL FILTER FUEL TANK VAPOR CONTROL VALVE FUEL GAUGE SENDING UNITASSEMBLY Clamp in the middle Clamp in the middle FUEL TANK FUEL PUMP ASSEMBLY ...

Page 415: ...t fitting can be reconnected but the retainer on the mating pipe cannot be reused once it has been removed from the pipe Replace the retainer when Replacing the fuel pump Replacing the fuel feed pipe It has been removed from the pipe It is damaged ACCESS PANEL RETAINER Disconnection Do not smoke while working on the fuel system Keep open flames away from your work area 1 Relieve fuel pressure see ...

Page 416: ... pump replacing the fuel feed pipe it has been removed from the pipe it is damaged Connection Do not smoke while working on the fuel system Keep open flames away from your work area 1 Check the pipe contact area for dirt and damage and clean if necessary CONTACT AREA PIPE 2 Insert a new retainer into the connector if the retainer is damaged or after replacing the fuel pump replacing the fuel feed ...

Page 417: ...ith a click ing sound NOTE If it is hard to connect put a small amount of new engine oil on the pipe end Connection with new retainer CONNECTOR RETAINER RETAINER PIPE 4 Make sure the connection is secure and the pawls are firmly locked into place check visually and by pulling the connector Pull apart CONNECTOR RETAINER PIPE 5 Reconnect the battery negative cable and turn the ignition switch ON II ...

Page 418: ...t for two sec onds turn it OFF then back on again and read the fuel pressure Pressureshouldbe 299 348 kPa 3 05 3 55 kgf cm2 43 4 50 5 psi 4 Reconnect vacuum hose to the fuel pressure regula tor Pressureshould be 240 289 kPa 2 45 2 95 kgf cm2 34 8 41 9 psi If the fuel pressure is not as specified first check the fuel pump see page 11 142 If the fuel pump is OK check the following If the fuel pressu...

Page 419: ... pressure regulator NOTE Place a rag or shop towel over the hoses before disconnecting them 7 Disconnect the fuel hose from the fuel rail 8 Remove the vacuum pipe 9 Loosen the retainer nuts on the fuel rail and harness holder 10 Disconnect the 3P connector from the MAP sensor 11 Disconnect the fuel rail 12 Remove the injectors from the intake manifold HARNESS HOLDER SEAL RING Replace FUEL PRESSURE...

Page 420: ...fold FUEL RAILS 18 Install and tighten the retainer nuts 19 Connect the 3P connector to the MAP sensor 20 Connect the fuel hose to the fuel rail 21 Connect the vacuum pipe 22 Connect the vacuum hose and fuel return hose to the fuel pressure regulator 23 Install the connectors on the injectors 24 Connect the PCV valve 25 Turn the ignition switch ON II but do not operate the starter After the fuel p...

Page 421: ...g the test Keep open flames away from your work area 1 Attach a fuel pressure gauge to the service port of the fuel filter see page 11 132 2 Start the engine Pressureshould be 299 348 kPa 3 05 3 55 kgf cm2 43 50 psi with the fuel pressure regulator vacuum hose dis connected and pinched FUEL PRESSURE GAUGE 07406 0040001 FUEL PRESSURE REGULATOR FUELFILTER 3 Reconnect the vacuum hose to the fuel pres...

Page 422: ...nut and remove the fuel pres sure regulator WASHER O RING Replace LOCKING NUT 29 N m 3 0 kgf m 22 Ibf ft Reassembly 1 Install the fuel pressure regulator in the fuel rail Turn it by hand until it stops 2 Turn the fuel pressure regulator counterclockwise to set the angle as shown 3 Tighten the locking nut FUEL RAIL NOTE Replace the O ring When assembling the fuel pressure regulator apply clean engi...

Page 423: ...ce the fuel pressure regulator con trolsolenoidvalve Inspect for a short to ground in wire between PCM A10 and the 4P connector If the wire is OK substitute a known good PCM and recheck see page 11 42 for immobilizer information If symp tom goes away replace the orig inal PCM CONTROL BOX 4PCONNECTOR Is there manifold vacuum Replace the fuel pressure regula tor control solenoid valve Terminal side ...

Page 424: ...er dash fuse relay box andthe4Pconnector Wire side of female terminals PCMCONNECTORA 26P Wire side of female terminals Is there manifold vacuum Repair open in wire between PCM A10 and the 4P connector NO Fuel Pressure Regulator Control Solenoid Valve is OK YES FPRCS RED GRN JUMPER WIRE Check for an open in the wire FPRCS line 1 Turn the ignition switch OFF 2 Reconnect the 4P connector to the contr...

Page 425: ... the radiator fan comes on then let it idle for at least one minute 2 Turn the ignition switch OFF 3 Disconnect No 21 hose from the install pipe and connect a vacuum pump to the hose 4 Apply vacuum 27 to 40 kpa 200 to SOOmmHg 8 to 12 in Hg 5 Start the engine 6 Hold engine speed at 6 500 rpm transmission in or position 7 Measure voltage between PCM connector terminal C4 and body ground Is there les...

Page 426: ...al C4 and body ground CAUTION the PCM connector C 12P must be disconnected for this test or the PCM will be damaged Wire side of female terminals Is there battery voltage Replace the fuel pump relay NO Wire side of female terminals Check for an open in the wire 1 Remove the jumper wire 2 Measure voltage between the fuel pump relay 4P connector terminal No 2 and body ground Is there battery voltage...

Page 427: ...CONNECTOR C704 Wire side of female terminals Inspect the PGM FI main relay see page 11 146 Replace the fuel pump resistor FUEL UNIT SUB HARNESS CONNECTOR C669 BLK YEL Inspect the fuel pump see page 11 142 Terminal side of male terminals Repair open in wire between the fuel pump resistor and the fuel pump YES NO YES JUMPER WIRE NO YES Check the operation of the PGM FI main relay 1 Disconnect the fu...

Page 428: ...el pressure regulator are OK 1 Place a shop towel under and around the fuel filter 2 Relieve fuel pressure see page 11 132 3 Remove the special bolt and the fuel feed pipe while supporting the fuel filter with another wrench as shown 4 Remove the fuel filter bracket 5 Remove the fuel filter stay and fuel filter 6 Install the new fuel filter in the reverse order of removal and note these items When...

Page 429: ...ct the 10P connector CAUTION Be sure to turn the ignition switch OFF before disconnecting the wires 3 Disconnect the PGM FI main relay connector and connect the No 2 terminal and No 5 terminal with a jumper wire 8P connector PGM FI MAIN RELAY CONNECTORS 4P 8P YEL JUMPER WIRE Wire side of female terminals 4 Check that battery voltage is available between the fuel unit sub harness connector terminal...

Page 430: ...ve the rear seat cushion see section 20 2 Remove the access panel from the floor 3 Disconnect the 2P connector from the fuel pump 4 Remove the fuel pump mounting nuts 5 9 N m 0 6 kgf m 4 3 Ibf ft 5 Remove the fuel pump from the fuel tank 6 Install parts in the reverse order of removal BASE GASKET Replace ...

Page 431: ... the access panel from the floor ACCESS PANEL FUEL GAUGE SENDING UNIT 4 Disconnect the 3P connector from the fuel gauge sending unit 5 Measure voltage between the 3P connector termi nals No 1 and No 2 with the ignition switch ON II There should be between 5 and 8 V FUEL GAUGE SENDING UNIT CONNECTOR C723 Wire side of female terminals If the voltage is as specified go to step 6 If the voltage is not...

Page 432: ...ION Turn the ignition switch OFF before the pointer reaches F on the gauge dial Failure to do so may damage the fuel gauge NOTE The fuel gauge is a bobbin cross coil type hence the fuel level is continuously indicated even when the ignition switch is OFF and the pointer moves more slowly than that of a bimetal type If the pointer of the fuel gauge does not move at all replace the gauge If the gaug...

Page 433: ...n see section 20 2 Remove the access panel 3 With the ignition switch OFF disconnect the 3P con nector from the fuel gauge sending unit 4 Remove the fuel gauge sending unit 5 9 N m 0 6 kgf m 4 3 Ibf ft BASE GASKET Replace Fuel Gauge Sending Unit Testing Do not smoke while working on the fuel ...

Page 434: ... the No 1 and No 2 terminals at E EMPTY 1 2 HALF FULL and F FULL by moving the float Terminal side of male terminals Top of the workbench Bottom of the fuel tank If you do not get the above readings replace the fuel gaugesending unit ...

Page 435: ...6 Remove the fuel tank access panel from the floor and disconnect the 3P connector from the fuel gauge sending unit 7 Connect the No 1 and No 3 terminals with a jumper wire if the light comes on check the sending unit If the light does not come on check for an open in the BLU RED wire between the fuel unit and fuel gauge assembly blown bulb poor ground G652 FUEL GAUGE SENDING UNIT CONNECTOR IC723 ...

Page 436: ...al of the PGM FI main relay If there is continuity go on to step 3 If there is no continuity replace the relay and retest 8P CONNECTOR To FUEL PUMP 3 Attach the battery positive terminal to the No 4 ter minal and the battery negative terminal to the No 7 terminal of the PGM FI main relay Then check that there is continuity between the No 3 terminal and No 1 terminal of the PGM FI main relay If the...

Page 437: ...1 located at middle of engine NO Repair open or short in the wire between the PGM FI main relay and the No 6 ECU PCM 20A fuse Replace the No 6 ECU PCM 20 A fuse in the under dash fuse relaybox PGM FIMAINRELAY4PCONNECTOR C432 Wire side of female terminals NO Repair open or short in the wire between the PGM FI main relay and the No 22 FUEL PUMP 20A fuse ReplacetheNo 22FUELPUMP 20 A fuse in the under...

Page 438: ...or A 26 P from the PCM 3 Check for continuity between the PGM FI main relay 8P connector terminal No 2 and PCM connector terminal A4 PGM FI MAIN RELAY4PCONNECTOR C432 IGSW BLK YEL NO Repair open or short in the wire between the PGM FI main relay and the No 25 IG COIL 30A fuse Replace the No 25 IG COIL 30 A fuse in the under dash fuse relay box Wire side of female terminals PGM FI MAIN RELAY 8P CON...

Page 439: ...voltage YES Repair open in the wire between the PCM A13 B1 and the PGM FI main relay Replace the PGM FI main relay Check for an open in the PCM 1 Turn the ignition switch OFF 2 Measure voltage between PCM connector terminals A4 and A12 when the ignition switch is first turned on for 2 seconds Is there 1 0V or less YES Substitute a known good PCM and recheck see page 11 42 for immobilizer informati...

Page 440: ...el into an approved container 10 Disconnect the hoses see page 11 129 Slide back the clamps then twist hoses as you pull to avoid damaging them 11 Place a jack or other support under the tank 12 Remove the strap nuts and let the straps fall free 13 Remove the fuel tank If it sticks on the undercoat applied to its mount carefully pry it off the mount 14 Install the drain bolt with a new washer then...

Page 441: ...eat shield 12 Remove the fuel tank covers 13 Remove the drain bolt and drain the fuel into an approved container 14 Disconnect the hoses see page 11 129 Slide back the clamps then twist hoses as you pull to avoid damaging them 15 Place a jack or other support under the tank 16 Remove the strap nuts and let the straps fall free 17 Remove the fuel tank If it sticks on the undercoat applied to its mo...

Page 442: ...ator in the intake air pipe provides additional silencing as air is drawn into the system IMRC SOLENOID VALVE 2 IMRC SOLENOID VALVE 1 IMRC VACUUM TANK From No 20 ECU PCM 20 A FUSE in the under dash fuse relay box IMRC DIAPHRAGM VALVE 1 VARIOUS SENSORS THROTTLE BODY INTAKE AIR DUCT INTAKE MANIFOLD IDLE ADJUSTING SCREW With TCS IDLEAIR CONTROL THERMAL VALVE IAC VALVE From PGM FI MAIN RELAY IMRC DIAP...

Page 443: ...ir cleaner element every 30 000 miles 48 000 km or 24 months whichever comes first Severe conditions Clean air cleaner element every 15 000 miles 24 000 km or 12 months and replace every 30 000 miles 48 000 km or 24 months whichever comes first AIR CLEANER HOUSING COVER AIR CLEANER HOUSING ...

Page 444: ...re it opens fully when you push the accelerator pedal to the floor Also check the throttle valve to be sure it returns to the idle position whenev eryou release the accelerator pedal Installation 1 Open the throttle valve fully then install the throttle cable in the throttle linkage and install the cable housing in the cable bracket LOCKNUT INNER CABLE ADJUSTING NUT THROTTLE LINKAGE CABLE BRACKET ...

Page 445: ...ates no vacuum If there is vacuum check the throttle cable see page 11 154 3 Check that vacuum is indicated on the gauge when the throttle is opened slightly from idle If the gauge indicates no vacuum check the throttle body port If the throttle body port is clogged clean it with carburetor cleaner 4 Stop the engine and check that the throttle cable operates smoothly without binding or sticking If...

Page 446: ...DLE ADJUSTING SCREW TP SENSOR NOTE Do not adjust the throttle stop screw After reassembly adjust the throttle cable see page 11 154 and the cruise control cable see section 4 THROTTLE CABLE GASKET Replace Disassembly With TCS VSA Remove the TCS VSA control valve see section 19 Throttle Body cont d ...

Page 447: ... SOLENOID VALVE 2 OFF ENGINE SPEED IS ABOVE 3 200 rpm ENGINE SPEED IS ABOVE 3 800 rpm IMRC SOLENOID VALVE 2 IMRC SOLENOID VALVE IMRC DIAPHRAGM 1 VARIOUS SENSORS IMRC VALVE 1 CLOSED IMRC VALVE 2 CLOSED IMRC VALVE 2 IMRC DIAPHRAGM 2 IMRC VALVE 1 IMRC DIAPHRAGM 1 IMRC VALVE 1 OPEN IMRC VALVE 2 CLOSED IMRC VALVE 1 OPEN IMRC VALVE 2 OPEN From No 20 ECU PCM 20 A FUSE in the under dash fuse relay box Fro...

Page 448: ...vacuum YES Check for an open in the wire IABCS1 line 1 Turn the ignition switch OFF 2 Disconnect the 6P connector from the IMRC engine mount control solenoid valve assy 3 Start engine and allow it to idle 4 Measure voltage between 6P connector terminal No 2 and No 5 Is there battery voltage NO Check for an open in the wire IG1 line Measure voltage between 6P con nector terminal No 2 and body groun...

Page 449: ...d PCM and recheck see page 11 42 for immobilizer information If symp tom goes away replace the origi nal PCM Check for vacuum at IMRC vacu umreservoir Disconnect the No 4 hose on IMRC solenoid valve 1 and con nect a vacuum gauge to the hose VACUUM PUMP GAUGE A973X 041 XXXXX IMRC DIAPHRAGM2 No 8 VACUUM HOSE Is there vacuum YES Repair the blockage or vacuum leak between the IMRC vacuum resorvoir and...

Page 450: ...ide of female terminals NO Repair open in wire between PCM A22 andthe6Pconnector YES Replace the IMRC solenoid valve 1 To page 11 161 To page 11 161 Isthere vacuum Isthere vacuum NO YES Check the IMRC Solenoid Valve 1 Disconnect the 6P connector from the IMRC engine mount control solenoid valve assembly Substitute a known good PCM and recheck see page 11 42 for immobilizer information If symp tom ...

Page 451: ...rmation If symp tom goes away replace the origi nalPCM Wire side of female terminals Repair short to ground at wire between PCM A20 and the 4P connector YES Replace the IMRC solenoid valve 2 Repair short to ground at wire between PCM A22 and the 4P connector YES NO Check for a short in the wire IABCS2 line 1 Turn the ignition switch OFF 2 Disconnect the PCM connec torA 26P formthe PCM 3 Check for ...

Page 452: ... If the IMRC diaphragm does not hold vacuum or the IMRC diaphragm rod does not move in and out replace the IMRC diaphragm see section 9 and retest Intake Manifold Runner Control IMRC Valve 2 Testing 1 Disconnect the No 8 hose from the vacuum hose manifold and attach a vacuum pump to the vacu um hose manifold IMRC SOLENOID VALVE 2 No 8 HOSE 2 Apply vacuum and verify that the IMRC diaphragm holds va...

Page 453: ... neutral until the radiator fan comes on 2 Disconnect the vacuum hoses and connect vacuum pump to the hoses individually VACUUM PUMP GAUGE 0 30 In Hg A973X 041 XXXXX 3 Allow the engine to idle and check the vacuum If no vacuum check the vacuum hose routing of the intake air bypass control system If the vacuum check the IAC Valve see page 11 115 the Idle Air Control Thermal Valve see page 11 123 an...

Page 454: ... then let it idle 2 Connect a tachometer 3 Check and adjust the idle speed if necessary see page 11 124 4 Warm up and calibrate the CO meter according to the meter manufacturer s instructions 5 Check idle CO with the headlights heater blower rear window defogger cooling fan and air condition er off NOTE Canada Depress the parking brake pedal Start the engine then check that the headlights are off ...

Page 455: ... valve lifts for varying operating conditions The EGR valve position sensor detects the amount of EGR valve lift and sends the information to the PCM The PCM then compares it with the ideal EGR valve lift which is determined by signals sent from the other sensors If there is any difference between the two the PCM cuts current to the EGR valve vacuum control solenoid valve to reduce vacuum applied ...

Page 456: ... gas is drawn directly into the intake manifold BREATHER PIPE PCV HOSE PCV VALVE BLOW BY VAPOR FRESH AIR Inspection 1 Remove the engine cover Check the PCV hoses and connections for leaks and clogging PCV HOSE PCV VALVE BREATHER PIPE 2 At idle make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake manifold is lightly pinched with your fin gers or plie...

Page 457: ...urge valve EVAPCANISTERPURGEVALVEDUTYCONTROLLEDAFTERSTART ING ENGINE 96 99 models 1 00 01 models C Fuel Tank Vapor Control System When fuel vapor pressure in the fuel tank is higher than the set value of the EVAP two way valve the valve opens and regulates the flow of fuel vapor to the EVAP canister During refueling the fuel tank vapor control valve opens with the pressure in the fuel tank and fee...

Page 458: ...EL TANK VAPOR RECIRCULATION TUBE EVAP BYPASS SOLENOID VALVE EVAP CANISTER FILTER EVAP CANISTER FUEL TANK VAROR RECIRCULATION VALVE EVAP TWO WAY VALVE FUEL TANK EVAP CANISTER VENT SHUT VALVE EVAP CANISTER PURGE VALVE VARIOUS SENSORS INTAKE MANIFOLD FUEL TANK PRESSURE SENSOR FUEL TANK VAPOR CONTROL VALVE FUEL FILL CAP FUEL TANK VAPOR SIGNAL TUBE ...

Page 459: ... control canister EVAP CONTROL CANISTER 3 Remove the EVAP control canister vent shut valve EVAP CANISTER VENT SHUT VALVE O RING Replace 00 04 models 1 Disconnect the connector and hoses 2 Remove the EVAP canister mounting bolt and the EVAP canister MOUNTING BOLT EVAP CANISTER 3 Remove the EVAP canister vent shut valve EVAP CANISTER VENT SHUT VALVE O RING Replace COVER ...

Page 460: ...mission Control System Evaporative Emission EVAP Controls cont d Evaporative Emission EVAP Two Way Valve and EVAP Bypass Solenoid Valve Replacement 96 99 models O RING Replace 00 04 models O RING Replace ...

Page 461: ... the vacuum holds replace the Fuel Tank Vapor Control valve see page 11 204 If the vacuum does not hold the float is OK Valve Test 1 Make sure the fuel tank is less than half full 2 Remove the fuel fill cap 3 Remove the fuel hose joint pretector Disconnect the fuel tank vapor signal tube FUEL TANK VAPOR SIGNAL TUBE 4 Disconnect the vacuum hose from the EVAP canis ter and then plug the port with ca...

Page 462: ...um on the pump in step 6 If the vacuum holds replace the Fuel Tank Vapor Control valve If the vacuum is released the Fuel Tank Vapor Control valve is OK 9 Disconnect the fuel tank vapor vent tube from the EVAP canister then plug the port on the canister Reapply vacuum 80 pumps If the vacuum holds replace the Fuel Tank Vapor Control valve If the vacuum does not hold inspect the EVAP canister vent s...

Page 463: ...d Fuel Tank Vapor Control Valve Replacement 1 Remove the fuel tank see page 11 151 2 Remove the Fuel Tank Vapor Control valve from the fuel tank 3 Install parts in the reverse order of removal 4N m 0 4 kgf m 3 Ibf ft FUEL TANK VAPOR CONTROL VALVE BASE GASKET Replace ...

Page 464: ...m should stabilize momentarily at 0 8 2 1 kPa 6 16 mmHg 0 2 0 6 in Hg If the vacuum stabilizes valve opens below 0 8 kPa 6 mmHg 0 2 in Hg or above 2 1 kPa 16 mmHg 0 6 in Hg install a new valve and retest 4 Move the vacuum pump hose from the vacuum fit ting to the pressure fitting and move the vacuum gauge hose from the vacuum side to the pressure side as shown 96 99 models PRESSURE SIDE 00 04 mode...

Page 465: ...rter Housing Valve Body Removal 14 134 Valve Body Repair 14 136 Valve Assembly 14 137 Valve Caps Description 14 138 Secondary Valve Body Disassembly lnspection Reassembly 14 139 Main Valve Body Disassembly lnspection Reassembly 14 140 Regulator Valve Body Disassembly lnspection Reassembly 14 142 Accumulator Body Disassembly lnspection Reassembly 14 143 ATF Pump Body Disassembly lnspection Reassemb...

Page 466: ...lts Attachment 45 x 55 mm I D Extension Shaft Installer A T Pressure Hose 2210 mm A T Pressure Hose Adapter SCS Service Connector Backprobe Set A T Oil Pressure Gauge Set w panel A T Low Pressure Gauge w panel Adjustable Bearing Puller 25 40 mm Attachment 52 x 55 mm Attachment 62 x 68 mm Attachment 72 x 75 mm Driver I D 40 mm Driver Mainshaft Holder Driver Attachment 14 158 14 173 14 164 14 167 14...

Page 467: ...e body contains the manual valve the 1 2 shift valve the 2 3 shift valve the 3 4 shift valve the 4 3 kick down valve and the main orifice control valve The secondary valve body contains the 3 4 orifice control valve the 4 3 shift timing valve the line pressure control valve the modulator valve and the accumulator pistons The throttle valve body includes the throttle valve which is bolted onto the ...

Page 468: ...nto operation in position in 2nd 3rd and 4th gear Use for rapid acceleration at highway speeds and general driving up hill and down hill driving starts off in 1st shifts automatically to 2nd then 3rd depending on vehicle speed and throttle position Downshifts through 2nd to 1st on deceleration to stop The lock up mechanism comes into operation in 3rd speed Use for engine braking or better traction...

Page 469: ...DIPSTICK RING GEAR DRIVE PLATE TORQUE CONVERTER 4TH CLUTCH 1ST CLUTCH 2ND CLUTCH MAINSHAFT COUNTERSHAFT DIFFERENTIAL ASSEMBLY EXTENSION SHAFT SECONDARY DRIVEN GEAR REVERSE CLUTCH 1ST HOLD CLUTCH 3RD CLUTCH ...

Page 470: ...ack to back to the 1st clutch The 4th clutch is supplied hydraulic pressure by a circuit connected to the internal hydraulic cir cuit Reverse Clutch The reverse clutch engages disengages reverse gear and is located on the rear end of the countershaft The reverse clutch is supplied hydraulic pressure by its ATF feed pipe within the countershaft One way Clutch This transmission has two one way clutc...

Page 471: ...EAR DIFFERENTIAL EXTENSION SHAFT SECONDARY DRIVE GEAR 3RD CLUTCH SECONDARY DRIVEN GEAR COUNTERSHAFT 3RD GEAR COUNTERSHAFT 4TH GEAR 1ST HOLD CLUTCH 1ST GEAR ONE WAY CLUTCH COUNTERSHAFT 1ST GEAR ONE WAY CLUTCH HUB COUNTERSHAFT 2ND GEAR 2ND GEAR ONE WAY CLUTCH PARK GEAR REVERSECLUTCH COUNTERSHAFT REVERSE GEAR MAINSHAFT COUNTERSHAFT ...

Page 472: ...t clutch engages driving power is not transmitted as the 1st gear one way clutch slips 2 Although the 1st and 2nd clutches engage driving power is not transmitted as the one way clutches slip 3 The one way clutch engages when accelerating and slips when decelerating ...

Page 473: ...ressure is not applied to the clutches Power is not transmitted to the countershaft The countershaft is locked by the park pawl interlocking the park gear 4TH CLUTCH 1ST CLUTCH 2ND CLUTCH TORQUE CONVERTER MAINSHAFT COUNTERSHAFT REVERSE CLUTCH 3RD CLUTCH PARKGEAR 1ST GEAR ONE WAY CLUTCH 1ST HOLD CLUTCH 2NDGEAR ONE WAY CLUTCH ...

Page 474: ...ountershaft Power transmitted to the mainshaft 1st gear is conveyed via the countershaft 1st gear to the 1st gear one way clutch the 2nd gear one way clutch and the 1st hold clutch The one way clutches are used to drive the countershaft and the 1st hold clutch drives the counter shaft 3 Power is transmitted to the secondary drive gear which drives the secondary driven gear TORQUE CONVERTER SECONDA...

Page 475: ...disengages at this time because the application of torque is reversed 3 The counterforce conveyed to the countershaft 1st gear turns the mainshaft 1st gear At this time since hydraulic pres sure is also applied to the 1st clutch counterforce is also transmitted to the mainshaft As a result engine braking can be obtained with 1st gear TORQUE CONVERTER 1ST CLUTCH MAINSHAFT 1ST GEAR MAINSHAFT SECONDA...

Page 476: ...mainshaft 2nd gear is conveyed via the countershaft 2nd gear to the 2nd gear one way clutch on the inside of the countershaft 2nd gear The 2nd gear one way clutch is used to drive the park gear on the counter shaft 3 Power is transmitted to the secondary drive gear which drives the secondary driven gear Hydraulic pressure is applied to the 1st hold clutch but the countershaft is rotated by the 2nd...

Page 477: ...he 1st gear one way clutch is used to drive the countershaft 2nd gear 3 The 2nd gear one way clutch disengages at this time because the application of torque is reversed 4 The counterforce conveyed to the countershaft 1st gear turns the mainshaft 2nd gear At this time since hydraulic pres sure is applied to the 2nd clutch counterforce is transmitted to the mainshaft As a result engine braking can ...

Page 478: ... the mainshaft causing the mainshaft 1st gear to rotate 2 Power is transmitted to the countershaft 1st gear which drives the countershaft via the one way clutches 3 Power is transmitted to the secondary drive gear which drives the secondary driven gear NOTE In or position hydraulic pressure is not applied to the 1st hold clutch TORQUE CONVERTER MAINSHAFT 1ST GEAR 2ND GEAR ONE WAY CLUTCH 1ST GEAR O...

Page 479: ...is transmitted to the secondary drive gear which drives the secondary driven gear NOTE In or position 2nd gear hydraulic pressure is also applied to the 1st clutch but since the rotation speed of 2nd gear exceeds that of 1st gear power from 1st gear is cut off at the 1st gear one way clutch TORQUE CONVERTER SECONDARY DRIVE GEAR MAINSHAFT 2ND GEAR 2ND CLUTCH MAINSHAFT COUNTERSHAFT 2ND GEAR ONE WAY ...

Page 480: ...ven gear NOTE In or position 3rd gear hydraulic pressure is also applied to the 1st clutch and to the 2nd clutch but since the rotation speed of 3rd gear exceeds that of 2nd gear power from 2nd gear is cut off at the 2nd gear one way clutch TORQUECONVERTER SECONDARY DRIVE GEAR COUNTERSHAFT 2ND GEAR ONE WAY CLUTCH COUNTERSHAFT 2ND GEAR SECONDARYDRIVENGEAR 3RD CLUTCH COUNTERSHAFT 3RDGEAR MAINSHAFT 2...

Page 481: ... which drives the secondary driven gear NOTE In position 4th gear hydraulic pressure is also applied to the 1st clutch and to the 2nd clutch but since the rotation speed of 4th gear exceeds that of 2nd gear power from 2nd gear is cut off at the 2nd gear one way clutch TORQUE CONVERTER MAINSHAFT 4TH GEAR MAINSHAFT 2ND GEAR SECONDARY DRIVEGEAR COUNTERSHAFT 2ND GEAR SECONDARY DRIVEN GEAR COUNTERSHAFT...

Page 482: ...on direction of the countershaft reverse gear is changed via the reverse idler gear in the rear cover 3 Power is transmitted to the secondary drive gear which drives the secondary driven gear REVERSEIDLER GEAR MAINSHAFT REVERSE GEAR COUNTERSHAFT REVERSE GEAR TORQUE CONVERTER REVERSE IDLER GEAR MAINSHAFT COUNTERSHAFT SECONDARY DRIVE GEAR COUNTERSHAFT REVERSE GEAR REVERSE CLUTCH SECONDARY DRIVEN GEA...

Page 483: ...er s side PCM Throttle Position Sensor Signal Engine Coolant Temperature Sensor Signal Indicator Light Self Diagnosis Signal PGM FI Control System Shift Control Lock upControl A T Control System Self Diagnosis Function Vehicle Speed Sensor Signal Service Check Connector Shift Solenoid Valve A Shift Solenoid Valve B A T Clutch Pressure Control Solenoid Valve Torque Converter Clutch Lock upControl S...

Page 484: ...shifting in position while the vehicle is ascending or descending a slope or reducing speed See page 14 36 for reverse inhibitor control description Lock upControl From sensor input signals the PCM determines whether to turn the lock up ON or OFF and activates torque converter clutch lock up control solenoid valve A and or B accordingly The combination of driving signals to torque converter clutch...

Page 485: ...ditions memorized in the PCM based on the input from the vehicle speed sensor throttle position sensor engine coolant temperature sensor barometric pressure sensor brake pedal position switch signal and shift lever position signal to control shifting while a vehicle is ascending or descending a slope ...

Page 486: ...en the PCM determines that the vehicle is going down a hill in position the shift up speed from 3rd to 4th gear when the throttle is closed becomes faster than the set speed for flat road driving to widen the 3rd gear driving area This in combination with engine braking from the deceleration lock up achieves smooth driving when the vehicle is descending There are two descending modes with differen...

Page 487: ...Circuit Diagram and Terminal Locations ...

Page 488: ...udes the main valve body the secondary valve body the ATF pump body the regulator valve body the throttle valve body and the accumulator body The throttle valve body is joined with the A T clutch pressure control solenoid valve The shift solenoid valves A and B are bolted on the secondary valve body The torque converter clutch lock up control solenoid valves A and B are bolted on the outside ofthe...

Page 489: ...e 3 4 orifice control valve the 4 3 shift timing valve the 1st accumulator piston and the 2nd accumulator piston The shift solenoid valves A and B are assembled on the secondary valve body ThrottleValveBody A TClutchPressureControlSolenoidValve The throttle valve body is joined with the A T clutch pressure control solenoid valve which is controlled by the PCM The throttle valve body A T clutch pre...

Page 490: ...ator body is located on the torque converter housing next to the ATF pump body The accumulator body houses the 3rd accumulator piston and the 4th accumulator piston RegulatorValve Body The regulator valve body is located on the ATF pump body The regulator valve body consists of the regulator valve the cooler relief valve and the lock up shift valve REGULATOR VALVE BODY REGULATOR VALVE 4TH ACCUMULA...

Page 491: ...n be regulated a wide range by the line pressure control pressure NOTE When used left or right indicates direction on the illustration below ENGINE NOT RUNNING ENGINE RUNNING To Torque Converter LINE PRESSURE CONTROL PRESSURE REGULATOR VALVE ORIFICE ACAVITY REGULATOR VALVE To Lubricating System LINE PRESSURE from ATF PUMP Stator Reaction Hydraulic Pressure Control Hydraulic pressure increases acco...

Page 492: ...ulator Valve Manual Valve Torque Converter Pressure Lubrication Pressure To Regulate Line Pressure Modulator Valve To Select Line Pressure Clutch Pressure Clutch Pressure Shift Solenoid Valves Torque Converter Clutch Lock up Control Solenoid Valves Regulator Valve Throttle B Pressure Line Pressure Control Pressure Line Pressure Control Valve Throttle Valve 1 2 Shift Valve 2 3 Shift Valve 3 4 Shift...

Page 493: ...ter inlet pressure 92 enters 94 of the torque converter through the lock up shift valve and discharges into 90 The torque converter check valve prevents the torque converter pressure from rising Under this condition the hydraulic pressure is not applied to the clutches as the manual valve stops line pressure 1 NOTE When used left or right indicates direction on the hydraulic circuit The hydraulic ...

Page 494: ... turned ON by the PCM and the 1 2 shift valve is moved to the right side The line pressure 4 becomes the 1st clutch pressure 10 at the 1 2 shift valve The 1st clutch pressure 10 is applied to the 1st clutch and the 1st clutch is engaged The line pressure 7 becomes the 1st hold clutch pressure 70 at the 1 2 shift valve The Ist hold clutch pressure 70 is applied to the 1st hold clutch and the 1st ho...

Page 495: ...he PCM The line pressure 4 passes through the 1 2 shift valve and the 2 3 shift valve then changes to the 2nd clutch pressure 20 at the orifice The 2nd clutch pressure 20 is applied to the 2nd clutch and the 2nd clutch is engaged The 1st hold clutch pressure 70 passes through the 1 2 shift valve then goes to the 1st hold clutch The 1st hold clutch is engaged Power is transmitted only during decele...

Page 496: ...t valve because shift solenoid valve A is turned OFF and B is turned ON by the PCM The 1 2 shift valve is moved to the right side and uncovers the port to allow the 1st clutch pressure 10 to the 1st clutch The 1st clutch pressure 10 is applied to the 1st clutch consequent ly the vehicle will move as the engine power is transmitted In or position the 1st hold clutch pressure is not applied to the 1...

Page 497: ...left side and uncovers the port to allow the line pres sure 5 to the 2nd clutch The line pressure 5 becomes the 2nd clutch pressure 20 at the orifice The 2nd clutch pres sure 20 is applied to the 2nd clutch and the 2nd clutch is engaged Hydraulic pressure also flows to the 1st clutch However no power is transmitted because of the one way clutch NOTE When used left or right indicates direction on t...

Page 498: ...e 2 3 shift valve uncovers the port to allow the line pressure 5 to the 3 4 shift valve as this valve is moved to the left side The line pressure 5 becomes the 3rd clutch pressure at the 3 4 shift valve The 3rd clutch pressure 30 is applied to the 3rd clutch and the 3rd clutch is engaged Hydraulic pressure also flows to the 1st clutch and 2nd clutch However no power is transmitted because of the o...

Page 499: ...g The 3 4 shift valve is moved to the left side by modulator pressure 6B The 3 4 shift valve covers the port leading to the 3rd clutch and uncovers to the 4th clutch as this valve is moved to the left side The line pressure 5 from the 2 3 shift valve becomes the 4th clutch pressure 40 at the 3 4 shift valve The 4th clutch pressure 40 is applied to the 4th clutch and the 4th clutch is engaged Hydra...

Page 500: ...pplied to the reverse clutch and the reverse clutch is engaged Reverse Inhibitor Control When the position is selected while the vehicle is moving forward at speeds over 6 mph 10 km h the PCM outputs the 1st signal to shift solenoid valves A and B shift solenoid valve A is turned OFF shift solenoid valve B is turned ON The 1 2 shift valve is moved to the right side and covers the port to stop line...

Page 501: ... line pressure 1 is intercepted by the manual valve Hydraulic pressure is not supplied to the clutches and power is not transmitted NOTE When used left or right indicates direction on the hydraulic circuit The hydraulic circuit is for 96 98 models On 99 01 models the 2nd accumulator is different ...

Page 502: ...cover As a result the converter turbine is locked to the converter cover The effect is to bypass the converter thereby placing the vehicle in direct drive LOCK UP PISTON TORQUE CONVERTER COVER DAMPER SPRING TURBINE 2 Operation clutch off With the lock up clutch off the fluid flows in the reverse of CLUTCH ON As a result the lock up piston moves away from the converter cover and the torque converte...

Page 503: ...ng of the lock up system Under certain conditions the lock up clutch is applied during deceleration in 3rd and 4th gear The lock up system controls the range of lock up according to torque converter clutch lock up control solenoid valves A and B and the throttle valve When torque converter clutch solenoid valves A and B activate modulator pressure changes Torque converter clutch solenoid valves A ...

Page 504: ...this condition the pressures working on both ends of the lock up shift valve are equal and the shift valve is moved to the right side by the tension of the valve spring alone The fluid from the pump will flow through the left side of the lock up clutch to the torque converter that is the lock up clutch is in OFF condition NOTE When used left or right indicates direction on the hydraulic circuit ...

Page 505: ...e lock up clutch The back pressure F2 is regulated by the lock up control valve whereas the position of the lock up timing valve is deter mined by the throttle B pressure tension of the valve spring and pressure regulated by the modulator valve Also the posi tion of the lock up control valve is determined by the back pressure of the lock up control valve and torque converter pres sure regulated by...

Page 506: ...e is low However throttle B pressure is still low at this time consequently the lock up timing valve is kept on the right side by the spring force With the torque converter clutch solenoid valve B turned on the lock up control valve is moved somewhat to the left side causing the back pressure F2 to lower This allows a greater amount of the fluid F1 to work on the lock up clutch so as to engage the...

Page 507: ...ming valve and the lock up control valve and they are moved to the left side The lock up timing valve covers the port leading torque converter pressure 90 from the torque converter to the lock up control valve The lock up control valve uncovers the port to leak the torque converter pressure 94 and 96 As this takes place torque converter back pressure is released fully causing the lock up clutch to...

Page 508: ...e Converter Clutch Lock up Control Solenoid Valve B Duty Operation The PCM switches solenoid valve B on and off rapidly under certain conditions The slight lock up and half lock up regions are maintained so as to lock the torque converter properly NOTE When used left or right indicates direction on the hydraulic circuit ...

Page 509: ...the park gear Even if the end of the park pawl rides on top of the park gear teeth slight movement of the countershaft will cause the park pawl and the park gear to mesh with each other completely because the park cone receives tension from the park rod spring The park pawl receives the tension which acts to separate the park pawl from the park gear from the park pawl spring COUNTERSHAFT PARK ROD ...

Page 510: ...tem The PCM terminal voltage and measuring conditions are shown for the connector terminals the A T control system The other PCM terminal voltage and measuring conditions are described in section 11 PCM Terminal Locations PCM CONNECTOR B 16P PCMCONNECTORC 12P ...

Page 511: ...PCM CONNECTOR D 22P PCM CONNECTOR E 26P ...

Page 512: ...PCM Terminal Voltage Measuring Conditions A T Control System cont d PCM CONNECTOR E 26P cont d ...

Page 513: ...T SPEED SENSOR TORQUE CONVERTER CLUTCH LOCK UP CONTROL SOLENOID VALVES A AND B MAINSHAFT SPEED SENSOR SHIFT SOLENOID VALVES A AND B Located in transmission VEHICLE SPEED SENSOR VSS A T CLUTCH PRESSURE CONTROL SOLENOID VALVE Located in transmission TRANSMISSION RANGE SWITCH A T GEAR POSITION SWITCH ...

Page 514: ...e SAE DTC type 2 Turn the ignition switch ON II and observe the DTC on the screen 3 Record all fuel and emissions DTCs A T DTCs and freeze data 4 If there is a fuel and emissions DTC first check the fuel and emissions system as indicated by the DTC except for DTC P0700 DTC P0700 means there is one or more A T DTC and no problems were detected in the fuel and emissions circuit of the PCM 5 Get the ...

Page 515: ...he indicator light INDICATOR LIGHT Codes 1 through 9 are indicated by individual short blinks Codes 10 and above are indicated by a series of long and short blinks One long blink equals 10 short blinks Add the long and short blinks together to determine the code After deter mining the code refer to the electrical system Symptom to Component Chart on pages 14 56 and 14 57 NOTE Disconnecting the BAC...

Page 516: ...ng to the troubleshooting flowchart with the special tools and a digital multime ter as shown How to use the Backprobe Set Connect the backprobe adapters to the stacking patch cords and connect the cords to a multimeter Using the wire insulation as a guide for the contoured tip of the backprobe adapter gently slide the tip into the connector from the wire side until it comes in contact with the te...

Page 517: ... A T control system memory The PCM memory must be reset after reconnecting the battery or the BACK UP RADIO fuse see page 11 111 BACK UP RADIO 7 5A FUSE UNDER HOOD FUSE RELAY BOX Final Procedure NOTE This procedure must be done after any troubleshooting 1 Turn the ignition switch OFF 2 Disconnect the OBD II Scan Tool or Honda PGM Tester from the Data Link Connector 16P or remove the special tool f...

Page 518: ...l System 14 74 14 72 14 78 14 77 14 68 14 70 14 63 14 66 14 58 14 60 14 76 14 62 DTC The DTC in parentheses is the code the indicator light indicates when the service check connector is connected to the special tool SCS service connector ...

Page 519: ...If the self diagnostic indicator light does not blink perform an inspection according to the table below 14 79 14 81 14 82 14 84 ...

Page 520: ...l system Shift solenoid valve A Shift solenoid valve B Transmission range switch A T gear position switch short to ground Transmission range switch A T gear position switch open Torque converter clutch solenoid valve A Lock up control solenoid valve A Torque converter clutch solenoid valve B Lock up control solenoid valve B A T clutch pressure control solenoid valve Vehiclespeed sensor VSS Page 14...

Page 521: ...ator light is on constantly not blinking whenever the ignition switch is on II Shift lever cannot be moved from position with the brake pedal pressed Ignition key cannot be moved from ACC 1 position to LOCK 0 position while pushing the ignition key with the shift lever is in position Inspection Check interlock system shift lock system Check interlock system key interlock system Ref page 14 79 14 8...

Page 522: ...oid valve A of the torque converter clutch solenoid connector and body ground and between the No 1 terminal solenoid valve B and body ground STANDARD 12 25 If the resistance is OK replace the transmission sub harness If the resistance is out of specification replace the torque converter clutch solenoid valves A and B 5 If the resistance is within the standard connect the No 1 terminal of the torqu...

Page 523: ...ER CLUTCH SOLENOID VALVES A AND B FILTER GASKET Replace Install in this direction Clean mounting surface and fluid passages 2 Clean the mounting surface and fluid passages of the torque converter clutch solenoid valves A and B and install a new torque converter clutch solenoid valves A and B with a new filter gasket NOTE Install the filter gasket in the direction shown 3 Check connector for rust d...

Page 524: ...OID VALVE HARNESS CONNECTOR Terminal side of male terminals If the resistance is within specification replace the transmission sub harness If the resistance is out of specification replace the shift solenoid valves A and B 5 If the resistance is within the standard connect the No 2 terminal of the shift solenoid valve A T clutch pressure control solenoid valve harness connector to the battery posi...

Page 525: ...ale terminals If the resistance is within specification replace the transmission sub harness If the resistance is out of specification replace the A T clutch pressure control solenoid valve 5 If the resistance is within the standard connect the No 4 terminal of the shift solenoid valve A T clutch pressure control solenoid harness connector to the battery positive terminal and connect the No 3 ter ...

Page 526: ... the secondary HO2S harness cover then remove the three way catalytic converter 4 Remove the heat shields 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft HEAT SHIELD HEAT SHIELD 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 5 Place a jack under the transmission and raise the transmission just enough to take weight off of the mounts then remove the bolt securing the shift cable guide bracket and the transmission...

Page 527: ...RANSMISSION BEAM BOLTS 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft 12 Tighten the four beam bolts to the specified torque then tighten the three inner bolts to the specified torque 13 Install the shift cable guide bracket on the transmis sion beam 14 Install the heat shields 15 Install exhaust pipe A and the three way catalytic converter then install the exhaust pipe A bracket 16 Push the secondary HO...

Page 528: ...s seat 4 Remove the exhaust pipe A bracket then remove exhaust pipe A 5 Remove the secondary HO2S harness cover then remove the three way catalytic converter 6 Remove the heat shields 7 Disconnect the transmission range switch connector TRANSMISSION RANGE SWITCHCONNECTOR 10P Terminal side of male terminals 8 Check for continuity between the terminal in each switch position according to the table b...

Page 529: ...ANGE SWITCH SHIFT SOLENOID VALVE A T CLUTCH PRESSURE CONTROL SOLENOID VALVE HARNESS CONNECTOR 5 Remove the clamp from the transmission range switch harness bracket on the rear cover 6 Remove the shift cable cover mounting bolts 7 Remove the shift solenoid valve A T clutch pressure control solenoid valve harness clamp and connector from the shift cable cover 8 Disconnect the shift solenoid valve A ...

Page 530: ... install the bolts 6 x 1 0 mm BOLTS Loosely install TRANSMISSIONRANGE SWITCH CONTROL SHAFT 15 Install a new lock washer on the transmission range switch by aligning its projected tip with the posi tion mark on the transmission range switch as shown LOCK WASHER LOCK TABS LOCKNUT 12 N m 1 2 kgf m 8 7 Ibf ft TRANSMISSION RANGE SWITCH PROJECTED TIP POSITION MARK LOCK WASHER Replace CONTROL SHAFT 6 x 1...

Page 531: ...ion switch ON II Move the shift lever through all gears and check the transmission range switch synchronization with the A T gear position indicator GAUGE ASSEMBLY A T GEAR POSITION INDICATOR 23 If the transmission range switch is not synchronized with the A T gear position indicator loosen the bolts securing the transmission range switch and adjust the transmission range switch installation 24 St...

Page 532: ...auge assembly see section 23 2 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the 30P and 22P connectors If any test indicates a problem find and correct the cause then recheck the system If all the input test...

Page 533: ...ock solenoid is not avail ableseparately Shift Lock Solenoid Test 1 Remove the center console see section 20 2 Disconnect the shift lock solenoid 2P connector RELEASE LEVER SHIR LOCK SOLENOID 2P CONNECTOR Wire side of female terminals 3 Connect battery power to the No 1 terminal and to the No 2 terminal ofthe solenoid momentarily NOTE Do not connect power to the No 2 terminal reverse polarity or y...

Page 534: ... KNOB RUBBER GROMMET A T GEAR POSITION PANEL COLLAR THROUGH BOLTS LOCKNUTS 6 x 1 0 mm 8 N m 0 8 kgf m 6 Ibf ft 4 Remove the two mounting bolts then remove the shift lock solenoid 6 x 1 0 mm 8 N m 0 8 kgf m 6 Ibf ft SHIFT LOCK SOLENOID SHIFT LOCK STOP 5 Install the shift lock solenoid in the reverse order of removal NOTE Make sure there is clearance between the stop pin and base bracket when the so...

Page 535: ...the direction shown PARK PIN SWITCH PARK PIN SWITCH 2P CONNECTOR Terminal side of male terminals 3 Check for continuity between the terminals in each switch lever position according to the table 4 If necessary replace the park pin switch 5 Remove the screw then remove the park pin switch from the base bracket PARK PIN SWITCH SCREW 5 x 0 8 mm 4 N m 0 4 kgf m 3 Ibf ft ...

Page 536: ...icator light indication If the light indicates a trouble code perform the electrical troubleshooting according to the Electrical System Symptom to Component Chart If the indicator light does not indicate a trouble code and a failure is not found during electrical trou bleshooting perform hydraulic troubleshooting using the chart ...

Page 537: ......

Page 538: ...Symptom to Component Chart Hydraulic System cont d ...

Page 539: ... mainshaft if the bushings for the Island 2nd feedpipe are loose or damaged If the 1st feedpipe is damaged or out of round replace it If the 2nd feedpipe is damaged or out of round replace the rear cover 0 A worn or damaged one way sprag clutch is mostly a result of shifting the transmission in or posi tion while the wheels rotate in reverse such as rocking the vehicle in snow P Inspect the frame ...

Page 540: ...lippage NOTE Throttle position sensor voltage represents the throttle opening a Remove the PCM cover to expose the PCM for road testing refer to page 14 54 and 14 55 b Set the digital multimeter to check voltage between D6 terminal and A26 terminal of the PCM for the throttle position sensor NOTE Refer to page 14 54 How to use the Backprobe Set SRS components are located in this area Review the SR...

Page 541: ...and Positions Upshift Downshift Lock up NOTE Lock up ON Torque Converter Clutch Lock up control solenoid valve B turns on Lock up OFF Torque Converter Clutch Lock up control solenoid valve B turns off ...

Page 542: ...te from a stop at full throttle Check that there is no abnormal noise or clutch slippage b Upshifts should not occur with the shift lever in this position 2nd Gear Position a Accelerate from a stop at full throttle Check that there is no abnormal noise or clutch slippage b Upshifts and downshifts should not occur with the shift lever in this position Reverse Position Accelerate from a stop at full...

Page 543: ...e engine and start the engine 3 Make sure the A C switch is OFF 4 After the engine has warmed up to normal operating temperature the radiator fan comes on shift into position 5 Fully press the brake pedal and accelerator for 6 to 8 seconds and note engine speed 6 Allow two minutes for cooling then repeat the test in and positions NOTE Stall speed tests should be used for diagnostic purposes only S...

Page 544: ...ack in the transmission Make sure the notch fits in the dipstick guide and the dip stick is down all the way Changing 1 Bring the transmission up to normal operating tem perature the radiator fan comes on by driving the vehicle Park the vehicle on level ground turn the engine off and remove drain plug NOTE If a cooler flusher is to be used see page 14 195 and 14 196 SEALING WASHER Replace ATP PAN ...

Page 545: ...urely 3 Allow the front wheels to rotate freely 4 Warm up the engine the radiator fan comes on then stop and connect a tachometer 5 Connect the special tool to line pressure inspection hole TORQUE 18 N m 1 8 kgf m 13 Ibf ft CAUTION Connect the oil pressure gauge securely be sure not to allow dust and other foreign particles to enter the inspection hole LINE PRESSURE INSPECTION HOLE A T OIL PRESSUR...

Page 546: ...l solenoid valve terminals of the transmission sub harness connector as shown 10 Measure line pressure at the fully closed throttle condition If line pressure is out of specification check and repair probable cause in the table below 11 Stop the engine and connect the transmission sub harness connector 14P 12 Disconnect the special tool from line pressure inspection hole and connect the special to...

Page 547: ...sconnect the transmission sub harness connector 14P then measure throttle B pressure with the throttle fully opened 16 Connect battery voltage to the A T clutch pressure control solenoid valve terminals of the transmission sub harness connector as shown 17 Measure throttle B pressure at the fully closed throttle condition 18 Install the sealing bolts with new sealing washers in the inspection hole...

Page 548: ...sion housing 12 Clean the inlet opening of the ATP strainer thoroughly with compressed air then check that it is in good condition and the inlet opening is not clogged 13 Replace the ATP strainer if it is clogged or dam aged NOTE The ATP strainer can be reused if it is not clogged 14 Install the lower valve body assembly in the reverse order of removal SEALING WASHER Replace 5 Remove the shift cab...

Page 549: ...e check balls fall out of the main valve body when removing the main valve body Coat all parts with ATP before reassembly Replace the O rings and filters Install the filters in the direction shown Refer to page 14 141 when installing the check balls on the main valve body CAUTION Do not use a magnet to remove the check balls it may magnetize the balls ...

Page 550: ... the throttle valve body A T clutch pressure control solenoid valve assembly 5 If the A T clutch pressure control solenoid valve does not operate disconnect the A T clutch pres sure control solenoid valve harness from the A T clutch pressure control solenoid valve Connect the battery terminals directly to the A T clutch pressure control solenoid valve 6 If the A T clutch pressure control solenoid ...

Page 551: ...l A clicking sound should be heard Replace the shift solenoid valves A and B if no clicking sound is heard Terminal side of male terminals NOTE Shift solenoid valves A and B must be replaced as an assembly 1 Remove the shift solenoid valves A and B and A T clutch pressure control solenoid valve throttle valve body from the lower valve body assembly THROTTLE VALVE BODY A T CLUTCH PRESSURE CONTROL S...

Page 552: ...control box CAUTION Do not remove the vacuum tubes from the control box CONTROL BOX TRANSMISSION SUB HARNESS CONNECTOR ATP DIPSTICK PIPE BRACKET 9 Pull the carpet back to expose the secondary heated oxygen sensor secondary HO2S connector then disconnect the connector and push it out from inside of the vehicle NOTE The secondary HO2S connector is located under the passenger s seat CARPET SECONDARY ...

Page 553: ...leakage from the hoses and the lines SHIFT CABLE HOLDER WASHER SHIFT CABLE COVER ATF DIPSTICK TUBE O RING Replace SHIFT CABLE HOLDER BASE 15 Remove the shift cable cover mounting bolts then remove the shift solenoid valve A T clutch pressure control solenoid valve harness connector and clamp from the shift cable cover 16 Remove the shift cable cover from the transmission housing 17 Remove the shif...

Page 554: ...SMISSION REAR MOUNT BRACKET MOUNT EXHAUST PIPE BRACKET TRANSMISSION BEAM 23 Place a jack under the transmission and raise the transmission just enough to take weight off of the mounts then remove the transmission beam rear transmission bracket mount and exhaust pipe bracket 24 Make sure the transmission is in position then remove the 36 mm sealing bolt and O ring 00 model from the secondary driven...

Page 555: ...STIFFENER 26 mm SHIM TORQUE CONVERTER COVERS 28 Remove the torque converter covers 29 Remove the six drive plate bolts one at a time while rotating the crankshaft pulley NOTE If necessary remove the spark plugs while removing the drive plate bolts 30 Remove the transmission housing mounting bolts 31 Pull the transmission away from the engine until it clears the dowel pins then lower it on the tran...

Page 556: ...Transmission Reassembly NOTE Coat all parts with ATF Replace the following parts O rings Lock washers Gaskets Mainshaft and countershaft locknuts and conical disc springs Sealing washers ...

Page 557: ... to the specified torque Recheck the ATF drive gear and the ATF driven gear shaft movement CAUTION Failure to align the ATF pump driven gear shaft correctly will result in seized ATF pump gears or a seized ATF pump driven gear shaft 9 Install the regulator separator plate and two dowel pins on the ATF pump body 10 Install the Stator shaft with a new O ring and stop shaft 11 Install the regulator v...

Page 558: ...he transmission hanger harness clamp bracket and speed sensor connector bracket then tighten them in two or more steps in the sequence shown TORQUE 33 N m 3 4 kgf m 25 Ibf ft HARNESS CLAMP BRACKET TRANSMISSION HANGER SPEED SENSOR CONNECTOR BRACKET 21 Install the mainshaft and countershaft speed sen sors with the washers on the transmission housing 22 Install the countershaft 2nd gear assembly 2nd ...

Page 559: ...EAR THRUST NEEDLE BEARING NEEDLE BEARING REVERSEGEAR COLLAR O RINGS Replace REVERSE CLUTCH ASSEMBLY 24 mm WASHER BALL BEARING REVERSEGEAR REVERSE GEAR DISTANCE COLLAR CONICAL SPRING WASHER 2ND CLUTCH ASSEMBLY O RINGS Replace 29 mm THRUST WASHER MAINSHAFT THRUST NEEDLE BEARING CONICAL SPRING WASHER REVERSE CLUTCH DISTANCE COLLAR COUNTERSHAFT 29 Install the thrust needle bearing and 29 mm thrust was...

Page 560: ...n the trans mission housing 39 Install the rear cover and engage the reverse gears while rotating the mainshaft REVERSE IDLER GEAR MAINSHAFT REVERSE GEAR COUNTERSHAFT REVERSE GEAR 40 Push on the rear cover while expanding the snap ring with the snap ring pliers until the ring snaps in place around the bearing NOTE Make sure the snap ring fits in place around the bearing If not raise the countersha...

Page 561: ... Install the ATF pan with two dowel pins and a new gasket 14 bolts 48 Install the ATF cooler lines with new sealing wash ers then tighten the line bolts 49 Connect the transmission sub harness connector to speed sensor connectors and solenoid connectors 50 Install the transmission range switch harness clamp to the bracket on the rear cover DOWEL PIN CONNECTOR STOP DETENT LEVER LOWER VALVE BODY ASS...

Page 562: ...transmission housing bolt on the engine stiffener side 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft ENGINE STIFFENER 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft 26 mm SHIM 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft TRANSMISSION HOUSING MOUNTING BOLT 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft TORQUE CONVERTER COVERS 7 Attach the torque converter to the drive plate with six bol...

Page 563: ... transmission mount bracket bolts three bolts 14 Tighten the transmission beam center bolts three bolts installed loosely in step 11 15 Remove the transmission jack from the transmis sion 16 Install the shift cable guide bracket on the transmis sion beam SHIFT CABLE GUIDE BRACKET TRANSMISSION BEAM 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft SHIFT CABLE TRANSMISSION BEAM BOLTS 10x1 25mm REAR TRANSMISSI...

Page 564: ...stall the extension shaft using the special tool as shown NOTE Push the extension shaft in the secondary driven gear shaft until the extension shaft stops EXTENSION SHAFT INSTALLER 07MAF PY40101 SET RING EXTENSION SHAFT 20 Remove the special tool 21 Fill the opening between the secondary driven gear shaft and the extension shaft with High Temp Urea Grease P N 08798 9002 as shown SUPER HIGH TEMP UR...

Page 565: ...he sealing bolt SEALING BOLT 36 mm 78 N m 8 0 kgf m 58 Ibf ft O RING Replace 24 Remove the steering gearbox mounting bolts then install the lower plate STEERING GEARBOX STEERING GEARBOX MOUNTING BOLTS 10 x 1 25 mm LOWER 10 x 1 25 mm 38 N m PLATE 59 N m 6 0 kgf m 3 9 kgf m 28 Ibf ft 43 Ibf ft 25 Install the control lever on the control shaft CAUTION Take care not to bend the shift cable 6 x 1 0 mm ...

Page 566: ...bf ft HEAT SHIELD HEAT SHIELD 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 31 Install the exhaust pipe A and the three way catalytic converter then install the transmission stop collars 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft Replace 10 x 1 25 mm 33 N m 3 4 kgf m 25 Ibf ft Replace 10 x 1 25 mm 54 N m 5 5 kgf m 40 Ibf ft Replace GASKET Replace 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft 8 x 1 25 mm 22 N m 2 ...

Page 567: ... transmission through all gears three times Check the shift lever operation and the A T gear position indicator operation 43 Let the engine reach normal operating temperature the radiator fan comes on with the transmission in the or position then turn it off and check ATF level 44 Road test as described on pages 14 104 thru 14 106 45 Enter the anti theft radio code for the radio then enter the cus...

Page 568: ... Moore J38405 A orequivalent 7 With the water and air valves off attach the water and air supplies to the flusher Use hot water if available OFF VALVE 8 Turn on the flusher water valve so water will flow through the cooler for 10 seconds NOTE If water does not flow through the cooler it is completely plugged cannot be flushed and must be replaced 9 Depress the trigger to mix the flushing fluid int...

Page 569: ...page 14 108 TOOL MAINTENANCE 1 Empty and rinse after each use Fill the can with water and pressurize the can Flush the discharge line to ensure that the unit is clean 2 If discharge liquid does not foam the orifice may be blocked 3 To clean disconnect the plumbing from the tank at the large coupling nut FILLER CAP FILTER COUPLING NUT O RING ORIFICE 4 Remove the in line filter from the discharge si...

Page 570: ...Illustrated Index Transmission Housing Lower Valve Body ...

Page 571: ...ASSAGE ATP STRAINER SHIFT SOLENOID VALVE B SHIFT SOLENOID VALVE A T CLUTCH PRESSURE CONTROL SOLENOID VALVE HARNESS O RING Replace DETENT SPRING PIN DETENT SPRING DETENT SPRING PLATE LOCK WASHER Replace FILTER Replace FILTERS Replace CHOKE FILTER Replace O RING Replace DRAIN PLUG 18 x 1 5 mm SEALING WASHER Replace ATF PAN ATF PAN GASKET Replace DOWEL PINS DOWEL PINS TRANSMISSION RANGE SWITCH A T GE...

Page 572: ...Illustrated Index Rear Cover ...

Page 573: ...REVERSE GEAR DISTANCE COLLAR CONICAL SPRING WASHER 28 mm Replace 2ND CLUTCH ASSEMBLY O RINGS Replace THRUST WASHER 29 mm THRUST NEEDLE BEARING MAINSHAFT 2ND GEAR NEEDLEBEARING THRUST NEEDLE BEARING MAINSHAFT 2ND GEAR COLLAR COUNTERSHAFT LOCKNUT 24 x 1 25 mm Replace WASHER 24 mm Replace BALL BEARING THRUST WASHER 25 mm THRUST NEEDLE BEARING COUNTERSHAFT REVERSE GEAR THRUST NEEDLE BEARING NEEDLE BEA...

Page 574: ...Illustrated Index Transmission Housing ...

Page 575: ...BEARING COUNTERSHAFT 3RD GEAR NEEDLE BEARING THRUST NEEDLE BEARING COUNTERSHAFT 3RD GEAR COLLAR 3RD CLUTCH ASSEMBLY O RINGS Replace COUNTERSHAFT SEALING RINGS 42 mm SET RING Replace TAPEREDROLLERBEARING SECONDARY DRIVEN GEAR SHAFT TAPEREDROLLERBEARING SECONDARY DRIVEN GEAR SHAFT OIL SEAL Replace EXTENSION SHAFT PARK ROD LOCK WASHER Replace DETENT LEVER TRANSMISSION HOUSING TRANSMISSION HOUSING OIL...

Page 576: ...Illustrated Index Torque Converter Housing Valve Body ...

Page 577: ...EED PIPES 8 x 40 mm ACCUMULATOR COVER DOWEL PINS ACCUMULATOR BODY DOWEL PINS TORQUE CONVERTER HOUSING SEPARATOR PLATE TORQUE CONVERTER HOUSING TORQUE CONVERTER HOUSING COUNTERSHAFT BEARING ATF GUIDE PLATE TORQUE CONVERTER CLUTCH LOCK UP CONTROL SOLENOID VALVE CONNECTOR BRACKET TORQUE CONVERTER CLUTCH LOCK UP CONTROL SOLENOID VALVE ASSEMBLY TORQUE CONVERTER CLUTCH LOCK UP CONTROL SOLENOID FILTER GA...

Page 578: ...mbly Removal CONNECTOR STOP DOWEL PIN O RING Replace HARNESS CONNECTOR DOWEL PIN O RING Replace ATP STRAINER 6 x 1 0 mm 3 Bolts ATP PAN GASKET Replace DOWEL PIN ATP PAN 6 x 1 0 mm 14 Bolts DOWEL PIN LOWER VALVE BODY ASSEMBLY 6 x 1 0 mm 6 Bolts ...

Page 579: ...re con trol solenoid valve harness connector stop 2 Remove the ATP pan 14 bolts 3 Remove the ATP strainer three bolts 4 Remove the lower valve body assembly six bolts while pushing the connector out of the transmission housing 5 Clean the inlet opening of the ATP strainer thor oughly with compressed air then check that it is in good condition and the inlet opening is not clogged INLET OPENING ATP ...

Page 580: ...horoughly in solvent or carburetor cleaner and dry with compressed air Blow out all passages When removing the rear cover replace the following O rings Mainshaft and countershaft locknuts Conical spring washers Rear cover gasket 24 mm washers ...

Page 581: ...fety glasses LOCK TAB 8 Remove the special tool from the mainshaft after removing the locknuts 9 Remove the 24 mm washer ball bearing reverse gear reverse gear distance collar and conical spring washer from the mainshaft 10 Remove the 24 mm washer ball bearing 25 mm thrust washer thrust needle bearing reverse gear thrust needle bearing needle bearing reverse gear collar reverse clutch assembly con...

Page 582: ...g Removal NOTE Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air Blow out all passages When removing the transmission housing replace the following O rings Transmission housing gasket ...

Page 583: ...shown CAUTION Make sure you remove the mainshaft and countershaft speed sensors before removing the transmission housing from the torque converter housing HOUSING PULLER 07HAC PK4010A TRANSMISSION HOUSING HOUSING PULLER EXTENSION BOLTS 07MAC PY40100 3 Required 4 Remove the mainshaft sub assembly and counter shaft sub assembly together NOTE Remove the shafts carefully to avoid dam aging the regulat...

Page 584: ...using Valve Body Removal NOTE Clean all parts thoroughly in solvent or carburetor cleaner and dry with compressed air Blow out all passages When removing the valve body from the torque converter housing replace the O ring ...

Page 585: ...heck valve and spring 5 Remove the four bolts securing the accumulator cover then remove the accumulator cover NOTE The accumulator cover is spring loaded To prevent stripping the threads in the torque converter housing press down on the accumulator cover while unscrewing the bolts in a crisscross pattern 6 Remove the eight ATP feed pipes from the accumu lator body 7 Remove the eight 6 mm bolts an...

Page 586: ...ompressed air 4 Roll up half a sheet of ATF soaked 600 paper and insert it in the valve bore of the sticking valve Twist the paper slightly so that it unrolls and fits the bore tightly then polish the bore by twisting the paper as you push it in and out CAUTION The valve body is aluminum and doesn t require much polishing to remove any burrs ATF soaked 600abrasive paper 5 Remove the 600 paper Thor...

Page 587: ...CAP SPRING Set the spring in the valve then install them in the valve body Push the spring in with a screwdriver then install the spring seat SPRING SEAT SPRING VALVE BODY Install the valve valve spring and cap in the valve body then secure with the valve cap clip Rotate the valve cap clip until it stops against the valve body wall VALVECAP CLIP VALVECAP ROLLER VALVE BODY VALVE ...

Page 588: ...ith one projected tip and a hollow end are installed with the tip toward the inside of the valve body The tip is a spring guide TOWARD OUTSIDE OF VALVE BODY TOWARDINSIDEOFVALVEBODY Caps with hollow ends are installed with the hollow end away from the inside of the valve body Caps with notched ends are installed with the notch toward the inside of the valve body Caps with flat ends and a hole throu...

Page 589: ...ll parts thoroughly in solvent or carburetor cleaner and dry them with compressed air Blow out all passages Check all valves for free movement If any fail to slide freely see Valve Body Repair on page 14 136 Coat all parts with ATP during assembly Install the filters in the direction shown ...

Page 590: ...If any fail to slide freely see Valve Body Repair on page 14 136 Coat all parts with ATP during assembly Install the filters in the direction shown CAUTION Do not use a magnet to remove the check balls it may magnetize them 4 3 KICK DOWN VALVE 3 4 SHIFT VALVE MANUAL VALVE MAIN VALVE BODY Inspect for wear scratches and scoring FILTER Replace MAIN ORIFICE CONTROL VALVE 2 3 SHIRVALVE VALVE CAP ROLLER...

Page 591: ...NOTE Do not position the check ball in this hollow CHECK BALLS CHECK BALLS FILTERS CHOKE SPRING SPECIFICATIONS Unit mm in CHECK BALLS ...

Page 592: ...or spring cap is spring loaded Once the stop bolt is removed release the spring cap slowly so it does not pop out 2 Reassembly is the reverse of disassembly NOTE Coat all parts with ATP during assembly Align the hole in the regulator spring cap with the hole in the valve body then press the spring cap into the body and tighten the stop bolt REGULATOR VALVE BODY Inspect for wear scratches and scori...

Page 593: ...d the 4th accumulator use the same size piston The 3rd accumulator piston has the spring 3rd accumulator spring C at its bottom ATPFEEDPIPE 8 x 57 5 mm 3 pcs ATP FEED PIPE 10 x 60 mm ACCUMULATOR COVER ATFFEEDPIPE 8 x 40 mm 4 pcs ACCUMULATOR BODY Inspect for wear scratches and scoring 3RD ACCUMULATOR PISTON With spring 3rd accumulator spring at the bottom of the piston DOWEL PIN O RING Replace 4TH ...

Page 594: ...are worn or damaged Check all valves for free movement If any fail to slide freely see Valve Body Repair on page 14 136 Coat all parts with ATP during assembly Install the filter in the direction shown FILTER Replace ATPPUMP BODY Inspect for wear scratches and scoring LOCK UP TIMING VALVE VALVE CAP ROLLER TORQUE CONVERTER CHECK VALVE SLEEVE SPRING SEAT LOCK UP CONTROLVALVE SPRINGSPECIFICATIONS Uni...

Page 595: ...F pump drive and driven gears ATF Pump Gears Side Radial Clearance Standard New ATF Pump Drive Gear 0 210 0 265 mm 0 0083 0 0104 in ATF Pump Driven Gear 0 070 0 125 mm 0 0028 0 0049 in FEELER GAUGE ATFPUMP DRIVE GEAR Inspect teeth for wear or damage ATF PUMP DRIVEN GEAR Inspect teeth for wear or damage 3 Remove the ATF pump driven gear shaft Measure the thrust clearance of the ATF pump driven gear...

Page 596: ...de freely see Valve Body Repair on page 14 136 Coat all parts with ATP during assembly SNAP RING O RINGS Replace REAR COVER SEALING BOLT 8 x 1 25 mm 18 N m 1 8 kgf m 13 Ibf ft SEALING WASHER Replace O RING Replace SNAP RING 1ST HOLD ACCUMULATOR PISTON 1ST HOLD ACCUMULATOR SLEEVE REVERSEACCUMULATOR SLEEVE REVERSE ACCUMULATOR PISTON SEALING BOLT 8 x 1 25 mm 18 N m 1 8 kgf m 13 Ibf ft SEALING WASHER ...

Page 597: ...ap a shop towel around the accumulator piston and apply air pressure to the fluid passage to remove the piston Do not place your fingers in front of piston Do not use high air pressure use an OSHA approved 30 PSI nozzle REAR COVER SHOP TOWEL COMPRESSED AIR HOSE NOZZLE OSHA Approved 30 psi type only ...

Page 598: ... and dry with compressed air Blow out all passages Replace the O rings Coat all parts with ATF during assembly SNAP RING ATF FEED GUIDE O RING Replace FEED PIPE GUIDE 1ST HOLD CLUTCH FEED PIPE SNAP RING FEED PIPE GUIDE O RINGS Replace 2ND CLUTCH FEED PIPE 1ST CLUTCH FEED PIPE REAR COVER REVERSE CLUTCH FEED PIPE O RINGS Replace ...

Page 599: ...arings for galling and rough movement Coat all parts with ATF before reassembly DOWEL PIN REVERSE IDLER GEAR SHAFT THRUST WASHER 14 x 25 mm REAR COVER 8 x 1 25 mm 26 N m 2 7 kgf m 20 Ibf ft REVERSE IDLER GEAR SHAFT HOLDER REVERSE IDLER GEAR Install in this direction THRUST WASHER 14 x 30 mm ...

Page 600: ... with ATF during reassembly Inspect the thrust needle bearings and the needle bearings for galling and rough movement Before installing the O rings wrap the shaft splines with tape to prevent damage to the O rings Install the sealing ring with the mating faces as shown ...

Page 601: ...ar 4th gear and thrust washer 43 x 74 mm from the mainshaft using the special tool and a press as shown PRESS COLLAR MAINSHAFT 4TH GEAR ATTACHMENT 45 x 55 mm I D 07MAD PR90100 THRUST WASHER 43 x 74 mm 4TH GEAR 3RD GEAR ATTACHMENT 45 x 55 mm I D 07MAD PR90100 ...

Page 602: ...ing mainshaft 3rd gear and or 1st 4th clutch assembly Lubricate all parts with ATF during assembly 1 Install mainshaft 3rd gear on the mainshaft using the special tool and a press as shown PRESS COLLAR MAINSHAFT 3RD GEAR ATTACHMENT 45 x 55 mm 1 0 07MAD PR90100 3RD GEAR ATTACHMENT 45 x 55 mm I D 07MAD PR90100 cont d ...

Page 603: ...l if the gear turns freely without binding 4TH GEAR 4 Remove the mainshaft bearing from the transmis sion housing see page 14 178 5 Assemble the parts below on the mainshaft NOTE Do not install the O rings and the mainshaft 1st gear on the mainshaft during inspection 1ST 4TH CLUTCH LOCKNUT WASHER BALL BEARING REVERSE GEAR REVERSE GEAR DISTANCE COLLAR CONICAL SPRING WASHER 2ND GEAR COLLAR TRANSMISS...

Page 604: ...ER 43 x 74 mm 1ST GEAR COLLAR 1ST 4TH CLUTCH ASSEMBLY FEELER GAUGE 9 If the clearance is out of tolerance remove the 43 x 74 mm thrust washer and measure its thick ness NOTE If the 0 08 mm 0 003 in feeler gauge can be inserted perform this step Thickness 10 Select and install a new 43 x 74 mm thrust washer then recheck the clearance 11 After replacing the 43 x 74 mm thrust washer make sure that th...

Page 605: ...smission Refer to page 14 151 and 14 152 when installing the 3rd gear 4th gear and 43 x 74 mm thrust washer Assemble the parts below on the mainshaft THRUST WASHER THRUST NEEDLE BEARING THRUST WASHER 43 x 74 mm MAINSHAFT SNAP RING 1ST GEAR NEEDLE BEARINGS THRUST NEEDLE BEARING 1ST GEAR DISTANCE COLLAR 1STGEARCOLLAR 1ST 4TH CLUTCH ASSEMBLY O RINGS Replace THRUST NEEDLE BEARING 4THGEAR NEEDLE BEARIN...

Page 606: ...ate all parts with ATF during reassembly Inspect the thrust needle bearings and the needle bearings for galling and rough movement Before installing the O rings wrap the shaft splines with tape to prevent damage to the O rings The locknut has left hand threads ...

Page 607: ... Torque the countershaft locknut to 29 N m 3 0 kgf m 22 Ibf ft NOTE Countershaft locknut has left hand threads 3 Hold the 1st hold clutch assembly against the park gear Measure the clearance between the 1st hold clutch distance collar and the 1st hold clutch with a feeler gauge NOTE Take measurements in at least three places and use average as the actual clearance STANDARD 0 0 08 mm 0 0 003 in ...

Page 608: ...2ND GEAR 8 Measure 2nd gear axial clearance while pushing the 1st gear towards the reverse clutch assembly NOTE Take measurements in at least three places and use the average as the actual clearance STANDARD 0 05 0 13 mm 0 002 0 005 in 11 After replacing the 45 5 x 60 mm thrust washer make sure that the clearance is within tolerance 9 If the clearance is out of tolerance remove the 45 5 x 60 mm th...

Page 609: ...H DISTANCE COLLAR 4TH GEAR THRUST NEEDLE BEARING 3RD GEAR NEEDLE BEARING THRUST NEEDLE BEARING 3RD GEAR COLLAR 3RD CLUTCH ASSEMBLY O RINGS Replace COUNTERSHAFT Ball Bearing Replacement NOTE Lubricate all parts with ATF during assembly 1 Remove the one way clutch hub and ball bearing from the countershaft 2nd gear using the special tool and a press as shown ATTACHMENT 52 x 55mm 07746 0010400 PRESS ...

Page 610: ... follows PARK GEAR Inspect for wear and scoring ONE WAY CLUTCH Inspect for damage and faulty movement NEEDLE BEARINGS Inspect for galling and rough movement THRUST NEEDLE BEARING Inspect for galling and rough movement THRUST WASHER Inspect for wear and scoring COUNTERSHAFT 2ND GEAR Inspect for wear and scoring 4 After the parts are assembled hold the countershaft 2nd gear and turn the park gear in...

Page 611: ...ET PLATE Inspect for wear THRUST NEEDLE BEARING Inspect for galling and rough movement ONE WAY CLUTCH Inspect for damage and faulty movement COUNTERSHAFT 1ST GEAR Inspect for wear and scoring Assemble the one way clutch thrust needle bearing and set plate on the countershaft 1st gear Hold countershaft 1st gear and turn the counter shaft 2nd gear assembly in the direction shown to be sure it turns ...

Page 612: ...Standard thickness 2 6 mm 0 102 in CLUTCH END PLATE SNAP RING CLUTCH DISCS Standard thickness 1 94 mm 0 076 in CLUTCH DISCS Standard thickness 2 34 mm 0 092 in SNAP RING CLUTCH END PLATE CLUTCH PLATES Standard thickness 2 0 mm 0 079 in SNAP RING SPRING RETAINER RETURNSPRING DISC SPRING CLUTCH PISTON O RINGS Replace 1ST CLUTCH DRUM 4TH CLUTCH DRUM ...

Page 613: ... 079 in CLUTCH END PLATE SNAP RING CLUTCH DISCS Standard thickness 2 34 mm 0 092 in CLUTCH PISTON CLUTCH DISCS Standard thickness 1 94 mm 0 076 in SNAP RING CLUTCH END PLATE CLUTCHPLATES Standard thickness 2 0 mm 0 079 in SNAP RING SPRINGRETAINER RETURN SPRING CLUTCH PISTON O RINGS Replace CLUTCH DRUM DISC SPRING RETURNSPRING SPRING RETAINER SNAP RING ...

Page 614: ...LUTCH DRUM CLUTCH DISCS Standard thickness 1 94 mm 0 076 in CLUTCH DISCS Standard thickness 1 94 mm 0 076 in SNAP RING CLUTCH END PLATE CLUTCH PLATES Standard thickness 2 0 mm 0 079 in SNAP RING SPRING RETAINER RETURN SPRING DISC SPRING CLUTCH PISTON O RINGS Replace CLUTCH DRUM SNAP RING SPRING RETAINER RETURN SPRING DISC SPRING CLUTCH PISTON ...

Page 615: ...all the special tools as shown 2nd 3rd 1st hold and reverse clutches CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY 07GAE PG40200 or 07GAE PG4020A 1st and 4th clutches CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY 07GAE PG40200 or 07GAE PG4020A CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE PX40100 or 07HAE PL50100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE PX40100 CLU...

Page 616: ...L TOOL SPRING RETAINER 4 Compress the return spring with the special tool Remove the snap ring Then remove the special tools spring retainer and return spring SPECIALTOOL SNAP RING SPRING RETAINER 6 Wrap a shop rag around the clutch drum and apply air pressure to the oil passage to remove the piston Place a finger tip on the other end while applying air pressure CLUTCH DRUM PISTON OSHA APPROVED 30...

Page 617: ... O rings on the piston O RINGS PISTON PISTON O RING O RING 3 Install the piston in the clutch drum by applying pressure to the piston and rotate it to ensure proper seating NOTE Lubricate the piston O ring with ATF before installation CAUTION Do not pinch the O ring by installing the piston with too much force CLUTCH DRUM 4 Install the return spring and spring retainer and posi tion the snap ring ...

Page 618: ...TTACHMENT 07LAE PX40100 or 07HAE PL50100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE PX40100 or 07HAE PL50100 CAUTION If either end of the special tool is set over an area of the spring retainer which is unsup ported by the return spring the retainer may be damaged Be sure the special tool is adjusted to have full contact with the spring retainer SPE...

Page 619: ...SCSPRING Install in this direction CLUTCH DRUM 10 Soak the clutch discs thoroughly in ATF for a mini mum of 30 minutes 11 Starting with a clutch plate alternately install the clutch plates and discs Install the clutch end plate with the flat side toward the disc NOTE Before installing the plates and discs make sure the inside of the clutch drum is free of dirt and other foreign matter CLUTCHENDPLA...

Page 620: ...re at three locations Clutch End Plate to Top Disc Clearance DIAL INDICATOR TOP DISC 14 If the clearance is not within the service limits select a new clutch end plate from the following table NOTE If the thickest clutch end plate is installed but the clearance is still over the standard replace the clutch discs and clutch plates PLATE NUMBER 1ST HOLD CLUTCH END PLATES REVERSECLUTCHENDPLATES CLUTC...

Page 621: ...EAR SHAFT OIL SEAL Replace EXTENSION SHAFT SET RING Replace 2 Remove the extension shaft from the secondary driven gear shaft Oil Seal Replacement 1 Remove the oil seal from the secondary driven gear shaft OIL SEAL Replace SCREWDRIVER 2 Install the oil seal into the secondary driven gear shaft using the special tools as shown DRIVER 07749 0010000 ATTACHMENT 52 x 55 mm 07746 0010400 ...

Page 622: ...COLLAR SECONDARYDRIVEN GEAR SHAFT BEARING SEPARATOR 0 4 1 2 in Commercially available 2 Install the bearings using the special tool and a press asshown NOTE Press the bearings in squarely until they bot tom PRESS STEEL PLATE ATTACHMENT 45 x 55 mm I D 07MAD PR90100 TAPERED ROLLER BEARING SECONDARY DRIVEN GEAR SHAFT ATTACHMENT 45 x 55 mm I D 07MAD PR90100 55 mm Use this side for torque converter hou...

Page 623: ...torque converter housing by heating the housingto about 212 F 100 C CAUTION Do not heat the housing in excess of 212 F 100 C HEAT GUN OUTER RACE 2 Install the thrust shim and outer race in the trans mission housing using the special tools as shown NOTE Install the outer race squarely in the transmis sion housing Check that there is no clearance between the outer race thrust washer and transmission...

Page 624: ...s ing using the special tools as shown NOTE Install the outer race squarely in the torque con verter housing Check that there is no clearance between the outer race and torque converter housing DRIVER 07749 0010000 BEARING DRIVER ATTACHMENT 07GAD SD40101 ...

Page 625: ...ith a heat gun CAUTION Do not heat the housing in excess of 212 F 100 C Replace the tapered roller bearing whenever the outer race is removed NOTE Let the transmission housing cool to room temperature before adjusting the bearing preload HEAT GUN OUTER RACE 3 Select the 1 98 mm 0 078 in thrust shim from the middle of the table below THRUST SHIM 75 mm 4 After installing the thrust shim install the ...

Page 626: ...ket when checking starting torque 7 Rotate the secondary driven gear shaft in both direc tions to seat the bearing 8 Measure the starting torque of the secondary driven gear shaft with a torque wrench STANDARD 3 4 4 4 N m 35 45 kgf cm 30 39 Ibf in TORQUE WRENCH NOTE Measure the starting torque at normal room tem perature in both directions Changing the shim to the next size will increase or decrea...

Page 627: ...tallation 1 Install the oil seal into the transmission housing using the special tool as shown DRIVER 07749 0010000 SEAL DRIVER ATTACHMENT 07LAD SM40100 10 5 11 5 mm 0 41 0 45 in TRANSMISSION HOUSING OIL SEAL 2 Install the oil seal into the torque converter housing using the special tools as shown DRIVER 07749 0010000 TORQUE CONVERTER HOUSING 5 7 6 7mm 0 22 0 26in ATTACHMENT 72 x 75 mm 07746 00106...

Page 628: ... 07947 6340500 SLIDE HAMMER 3 8 16 Commercially available ADJUSTABLE BEARING PULLER 25 40mm 07736 A01000B or 07736 A01000A 2 Drive in the new mainshaft bearing until it bottoms in the housing using the special tools as shown DRIVER 07749 0010000 ATTACHMENT 62 x 68 mm 07746 0010500 3 Install the new oil seal flush with the housing using the special tools as shown DRIVER 07749 0010000 ATTACHMENT 72 ...

Page 629: ...T 62 x 68 mm 07746 0010500 0 0 1 mm 0 0 003 in ATF GUIDE PLATE Replacement 1 To remove the mainshaft bearing from the trans mission housing expand the snap ring with the snap ring pliers then push the bearing out NOTE Do not remove the snap ring unless it s nec essary to clean the groove in the housing Remove MAINSHAFT BEARING 2 Expand the snap ring with the snap ring pliers insert the new bearing...

Page 630: ... assembly from the transmission housing 5 Assemble the park mechanism in the reverse order of disassembly NOTE See page 14 180 and 14 181 when installing the transmission range switch PARK PAWL SHAFT SLEEVE PARK PAWL PARK PAWL SPRING PARK PAWL SHAFT TRANSMISSION HOUSING CONTROL SHAFT DETENT SPRING PLATE PARK ROD ASSEMBLY 6 x 1 0 mm 14 N m 1 4 kgf m 10 Ibf ft PARK ROD LOCK WASHER Replace DETENT LEV...

Page 631: ...lever to the position TRANSMISSION RANGESWITCH LOCKNUT LOCK WASHER Replace DETENT LEVER CONTROL SHAFT 2 Pry the locktabs on the lock washer then remove the locknut and lock washer 3 Remove the bolts securing the transmission range switch then remove the transmission range switch ...

Page 632: ...tallation 1 Set the transmission range switch to the position as shown NOTE The transmission range switch clicks in the position POSITION MARK TRANSMISSION RANGE SWITCH CONTROL SHAFT HOLE 2 Shift the detent lever to the position CONTROL SHAFT DETENT LEVER ...

Page 633: ...h by aligning its projected tip with the posi tion mark on the transmission range switch as shown POSITION MARK TRANSMISSION RANGE SWITCH 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 Ibf ft DETENT LEVER LOCKNUT 12 N m 1 2 kgf m 8 7 Ibf ft CONTROL SHAFT 5 Tighten the locknut while holding the detent lever in the position then bend the lock tabs against the locknut 6 Tighten the 6 mm bolts to the specified torqu...

Page 634: ...onverter Drive Plate Ring Gear 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft DRIVE PLATE RING GEAR TORQUE CONVERTER ASSEMBLY 12 x 1 0 mm 74 N m 7 5 kgf m 54 Ibf ft Torque in a crisscross pattern O RING Replace WASHER ...

Page 635: ...ler Hoses Connection Connect the ATF cooler hoses to the ATF cooler lines then secure them with the clips as shown 2 4 mm 0 1 0 2 in RADIATOR TRANSMISSION 6 8 mm 0 2 0 3 in ATF COOLER HOSE CLIP ATF COOLER LINE ...

Page 636: ... solenoid and park pin switch connectors 4 Shift the transmission into the Q position 5 Remove the self locking nut and shift cable end collar then remove the shift cable from the shift lever link CAUTION Take care not to bend the shift cable 6 Remove shift lever mounting bolts four bolts 7 Remove the shift cable bracket two bolts from the shift lever assembly then remove the shift lever assembly ...

Page 637: ...6 x 1 0 mm 8 N m 0 8 kgf m 6 Ibf ft SHIFT LEVER KNOB SHIFT LOCK SOLENOID 6x 1 0 mm 8 N m 0 8 kgf m 6 Ibf ft 5 x 0 8 mm 4 N m 0 4 kgf m 3 Ibf ft A T GEAR POSITION PANEL COLLAR RUBBER LOCK PIN LINK ADJUSTER LOCKNUT 7 N m 0 7 kgf m 5 Ibf ft BRACKET BASE PARK PIN SWITCH CONTROL SEAL ...

Page 638: ... LINK ROD LINK ADJUSTER 4 Insert a 4 0 mm 0 16 in pin into the shift lever bracket through the position cutout of the shift lever CAUTION Be sure to use a 4 0 mm 0 16 in pin SHIFT LEVER POSITION A T GEAR POSITION PANEL POSITION HOLE 5 Verify that the shift position is in the position on the transmission SHIFT CABLE CONTROLLEVER A T GEAR POSITION SWITCH 6 Turn the ignition switch ON II verify that ...

Page 639: ...If you feel the lock pin binding as you reinstall it the link rod is still out of adjustment and must be readjusted 11 Make sure the lock pin is seated securely in the adjuster NOTE Replace the lock pin if it does not snap over the link adjuster securely 12 Move the shift lever to each gear and verify that the A T gear position indicator follows the transmission range switch 13 Start the engine an...

Page 640: ...F LOCKING NUT 9 8 N m 1 0 kgf m 7 2 Ibf ft SHIFT CABLE END COLLAR 7 Pull the carpet back to expose the secondary HO2S connector Disconnect the connector then push it to outside NOTE The secondary HO2S connector is located under the passenger s seat BAND EXHAUST PIPE A TRANSMISSION STOP COLLAR 10 x 1 25mm 38 N m 3 9 kgf m 28 Ibf ft SECONDARY HO2S HARNESS COVER 6x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft...

Page 641: ...OLDER BASE 14 Remove the shift solenoid valve A T clutch pressure control solenoid valve harness connector and clamp from the shift cable cover 15 Remove the shift cable cover from the transmission housing 16 Remove the shift cable holder with the shift cable from the shift cable holder base 17 Remove the control lever from the control shaft then remove the shift cable 18 Remove the shift cable ho...

Page 642: ...t Location Index 15 9 Inspection 15 10 Disassembly 15 12 Reassembly 15 16 Installation 15 26 Differential Carrier Tapered Roller Bearing Replacement 15 15 Backlash Inspection 15 15 Ring Gear Replacement 15 16 Drive Pinion Height Adjustment 15 24 Ring Gear Tooth Contact Adjustment 15 25 Ring Gear Backlash Adjustment 15 25 Main Menu ...

Page 643: ...ller B Installer Shaft Attachment 32 x 35 mm Driver 40 mm I D Attachment 35 mm I D Driver Driver Attachment 15 17 15 18 15 10 11 15 19 15 21 22 15 5 15 21 15 15 15 23 15 28 15 17 15 17 15 17 15 14 15 15 15 16 15 18 15 20 15 16 15 17 15 18 15 21 15 23 15 23 07GAD SD40101 07HAA SF10100 07LAC PW50100 or 07LAC PW50101 07LAD PW50500 07MAD PR90100 07MAD PR90200 07MAF PY40100 or 07MAF PY40101 07MAF SP001...

Page 644: ...r stuck in gears etc Improper drive pinion preload Chipped or damaged gears Improper drive pinion preload Damaged or chipped gears Cracked or damaged drive pinion bearing or side bearing Worn excessive play or damaged side bearing Damaged side gear pinion or pinion shaft Excessive backlash between ring gear and drive pinion Improper ring gear or drive pinion preload Excessive pinion backlash Worn ...

Page 645: ...al oil is dirty remove the drain plug and drain the oil DRAIN PLUG 39 N m 4 0 kgf m 29 Ibf ft WASHER Replace OIL FILLER PLUG 44 N m 4 5 kgf m 33 Ibf ft 4 Reinstall the drain plug with a new washer and refill the differential with the recommended oil to the proper level NOTE The drain plug washer should be replaced at every oilchange Clean the drain plug before reinstalling 5 Reinstall the oil fill...

Page 646: ...on the driveshaft as the inboard joint may come apart Use care when prying out the assembly and pull it straight to avoid damaging the differential oil seal or the intermediate shaft outer seal 5 Pull on the inboard joint to remove the right drive shaft from the differential and to remove the left driveshaft from the intermediate shaft see section 16 6 Remove the intermediate shaft assembly from t...

Page 647: ... 4 3 Ibf ft LOWER PLATE 11 Disconnect the vehicle speed sensor VSS connec tor then remove the VSS power steering speed sensor NOTE Do not disconnect the hoses VSS CONNECTOR VSS POWER STEERING SPEED SENSOR 12 Remove the air cleaner housing assembly AIR CLEANER HOUSING ASSEMBLY 13 Remove the power steering pump NOTE Do not disconnect the hoses POWER STEERING PUMP ...

Page 648: ...move the engine stop mount bracket bolts ENGINE STOP MOUNTS ENGINE STOP MOUNT BRACKET BOLTS 16 Attach the chain hoist to the engine see section 5 17 Remove the right and left engine mount bracket nuts then remove the right engine mount bracket ENGINE MOUNT BRACKET NUT RIGHT ENGINE MOUNT BRACKET 18 Remove the right engine mount RIGHT ENGINE MOUNT ...

Page 649: ...Differential Assembly Removal cont d 19 Remove the mounting bolts and 26 mm shim then remove the differential assembly O RING Replace DIFFERENTIAL ASSEMBLY 26 mm SHIM ...

Page 650: ...THERPLATE TAPERED ROLLER BEARING THRUST WASHER PINION SPACER Replace 79 5 mm THRUST SHIM S 1 or 2 shims Adjustment page 15 25 TAPERED ROLLER BEARING 11 x 1 0 mm 118 N m 12 kgf m 87 Ibf ft TAPERED ROLLER BEARING BREATHER TUBE BEARING OUTER RACE RING GEAR DIFFERENTIAL CARRIER 10 x 1 25 mm 44 N m 4 5 kgf m 33 Ibf ft 79 5 mm THRUST SHIM S 1 or 2 shims Adjustment page 15 25 DIFFERENTIAL CASE COVER WASH...

Page 651: ... gear inspection hole with the oil filler plug hole 4 Measure the backlash of the ring gear on the differ ential carrier using the special tools as shown After measuring remove the dial gauge and turn the dif ferential carrier one full turn then remeasure the backlash Standard 0 06 0 14 mm 0 002 0 006 in The difference between the two measurements taken must not exceed 0 06 mm 0 002 in LOCKNUT SOC...

Page 652: ...Clean and paint the ring gear teeth lightly and evenly with Prussian Blue on both sides of each tooth 9 Reinstall the differential carrier and the differential case cover then torque the bolts in a crisscross pat tern in several steps 10 Install the special tool as shown then rotate the drive pinion in both directions so that the ring gear rotate one full turn in both directions During this operat...

Page 653: ...m thrust shim s from the differential case cover by heat ing the differential case cover to about 212 F 100 C NOTE Do not heat the differential case cover in excess of 212 F 100 C If the bearing outer race was removed by heat ing allow the differential case cover to cool to room temperature Replace the tapered roller bearing with a new one whenever the bearing outer race is replaced BEARING OUTER ...

Page 654: ...h a 1 1 4 32 mm hex bit and socket as shown DRIVE PINION 1 1 4 32 mm HEX BIT and SOCKET Commercially available 8 Raise the locknut tab from the groove of the drive pinion and remove the locknut thrust washer and pinion hub NOTE Be sure the tab of the locknut is completely clear of the groove or damage to the threads can occur TAB LOCKNUT Replace THRUST WASHER PINION HUB ...

Page 655: ...fferential case by heating the differential caseto about 212 F 100 C NOTE Do not heat the differential case in excess of 212 F 100 C If the bearing outer race was removed by heating allow the differential case to cool to room tem perature Replace the tapered roller bearing with a new one whenever the bearing outer race is replaced BEARING OUTER RACES THRUST WASHERS 79 5 mm THRUST SHIM S 1 or 2 shi...

Page 656: ...TOR 0 4 1 2 in Commercially available 2 Install the both tapered roller bearings using the special tool and a press as shown PRESS STEEL BLOCK ATTACHMENT 45 x 55 mm I D 07MAD PR90100 TAPEREDROLLER BEARING 1 Remove the tapered roller bearings see tapered roller bearing replacement 2 Install the left driveshaft and the intermediate shaft in the side gears 3 Measure the backlash of both pinion gears ...

Page 657: ...s and remove the ring gear 11 x 1 0 mm 118 N m 12 0 kgf m 87 Ibf ft DIFFERENTIAL CARRIER RING GEAR 2 Install the ring gear by tightening the bolts in a crisscross pattern in several steps If the bolts are difficult to tighten make sure that the ring gear is going onto the differential carrier correctly ...

Page 658: ...l carrier is required use the same make bearings and replace both bearings at the same time DRIVE PINION ETCHED MARK eg A1 20 set number RING GEAR SETNUMBER 1 Install the 43 mm thrust shim and tapered roller bearing using the special tools and a press as shown NOTE Use a used pinion spacer with the special tool for bearing installation and then discard the used pinion spacer PRESS DRIVER 40 mm I D...

Page 659: ...P0011A MARK B BEARING OUTER RACE INSTALLER SHAFT 07MAF SP0013A MARK B TAPERED BEARING RACE INSTALLER B 07MAF SP0012A b Next install the inboard bearing outer race TAPERED BEARING RACE INSTALLER A 07MAF SP0011A THRUST WASHER MARKB MARKB TAPERED BEARINGRACE BEARING INSTALLER B OUTER 07MAF SP0012A RACE 3 Install the 79 5 mm thrust shim s and bearing outer race using the special tools as shown NOTE In...

Page 660: ...apered roller bearing then install the drive pinion into the differential case as shown NOTE Do not install the pinion spacer and thrust washers at this time DRIVE PINION DIFFERENTIAL CASE 6 Apply lubricant to the tapered roller bearing then install it using the special tool while holding the drive pinion as shown DRIVER 40 mm I D 07746 0030100 TAPERED ROLLER BEARING DRIVE PINION 7 Install the lar...

Page 661: ...T 36 x 41 mm 07HAA SF10100 CORRECT TOOTH CONTACT 13 Remove the differential case cover and check the tooth contact pattern heel and toe Adjust the ring geartooth contactas needed see page 15 25 14 After adjusting the ring gear tooth contact remove the drive pinion then install a new pinion spacer and thrust washers on the drive pinion PINION SPACER THRUST WASHERS DRIVE PINION 9 Clean the ring gear...

Page 662: ... 32 mm HEX BIT and SOCKET Commercially available 18 Tighten the locknut to 216 N m 22 kgf m 159 Ibf ft and measure the tapered roller bearing preload Tp NOTE Rotate the drive pinion several times to assure proper tapered roller bearing contact Standard New Bearing 1 82 2 49 N m 18 6 25 4 kgf cm 16 1 22 0 Ibf in Reused Bearing 1 42 1 91 N m 14 5 19 5 kgf cm 12 6 16 9 Ibf in If the tapered roller be...

Page 663: ...times to ensure proper bearing contact 0 94 1 07 N m 9 6 10 9 kgf cm 8 33 9 46 Ibf in If the total bearing preload is not within the standard correct it by increasing or decreasing the preload on the carrier bearings as needed If there is too much preload decrease the shim thickness equal amounts on both sides If there is not enough preload increase the shim thickness equal amounts on both sides N...

Page 664: ... 0 06 0 14 mm 0 002 0 006 in The difference between the two measurements taken must not exceed 0 06 mm 0 002 in LOCKNUT SOCKET 36 x 41 mm 07HAA SF10100 28 If the backlash is less than the standard adjust the ring gearbacklash see page 15 25 29 Remove the differential case cover and check the tooth contact pattern face and flank If the tooth contact is not correct adjust ring gear contact see page ...

Page 665: ...Stake the locknut tab into the groove 1 0 mm 0 04 in 3 5 mm 0 14 in 33 Install the differential case cover and tighten the bolts in a crisscross pattern in several steps NOTE Use liquid gasket P N 08718 0001 Remove any dirt and oil from the sealing surface If 20 minutes have passed after applying liquid gasket reapply it assemble the housings and allow it to cure at least 20 minutes after assembly...

Page 666: ... Old pinion 20 0 02mm New pinion 10 0 01 mm 2 00 0 02 0 01 2 03 Select the 2 03 mm 0 0799 in new shim Example 2 Old shim 1 70 mm thickness Old pinion 10 0 01 mm New pinion 20 0 02 mm 1 70 0 01 0 02 1 71 Select the 1 70 mm 0 0669 in new shim 43 mm THRUSTSHIM A B C D E F G H I J K L M N 0 P Q R S T U V Part Number 41410 PSD 000 41411 P5D 000 41412 P5D 000 41413 P5D 000 41414 P5D 000 41415 P5D 000 41...

Page 667: ... shim the same amount NOTE The total thickness of both shims must still equal the total thickness of the original shims If there is too much backlash move the ring gear toward the drive pinion If there is not enough backlash move the ring gear away from the drive pinion 2 After adjustment recheck backlash see page 15 10 Standard 0 06 0 14 mm 0 002 0 006 in 79 5 mm THRUST SHIM AA AB AC AD AE AF AG ...

Page 668: ...Y4 000 41442 PY4 000 41443 PY4 000 Thickness 1 9 mm 0 0748 in 2 0 mm 0 0787 in 2 1 mm 0 0827 in 2 2 mm 0 0866 in 2 3 mm 0 0906 in 2 4 mm 0 0945 in 2 5 mm 0 0984 in 2 6 mm 0 1024 in 2 7 mm 0 1063 in 2 8 mm 0 1 102 in 2 9 mm 0 1 142 in 3 0 mm 0 1 181 in Measurement Value 1 99 1 9 mm 2 09 2 0 mm 2 19 2 1 mm 2 29 2 2 mm 2 39 2 3 mm 2 49 2 4 mm 2 59 2 5 mm 2 69 2 6 mm 2 79 2 7 mm 2 89 2 8mm 2 99 2 9 mm...

Page 669: ... m 3 9 kgf m 28 Ibf ft 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft RIGHT ENGINE MOUNT BRACKET Apply liquid gasket P N 08718 0001 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft 9 Remove the chain hoist 10 Install the engine stop mount bracket bolts ENGINE STOP MOUNTS 12 x 1 25 mm 74 N m 7 5 kgf m 54 Ibf ft 11 Apply Super High Temp Urea Grease P N 08798 9002 to the splines of the extension shaft then install t...

Page 670: ...6 mm SEALING BOLT 78 N m 8 0 kgf m 58 Ibf ft 14 Install the new O ring in the groove of the 36 mm sealing bolt then install the 36 mm sealing bolt NOTE Shift the transmission into the P position to lock the secondary gear 15 Install the right exhaust manifold cover then install the breather tube to the clamp 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft CLAMP BREATHER TUBE RIGHT EXHAUST MANIFOLD COVER 16...

Page 671: ... install the lower plate and the steering gearbox mounting bolts STEERINGGEARBOX MOUNTING BOLTS 59 N m 6 0 kgf m 43 Ibf ft 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft 20 Install the driveshafts and the intermediate shaft see section 16 CAUTION While installing the driveshaft and the intermediate shaft in the differential be sure not to allow dust and other foreign particles to enter into the different...

Page 672: ...Differential Assembly Installation cont d 22 Install the splash shield SPLASH SHIELD 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 23 Refill the differential with the recommended oil see page 15 4 ...

Page 673: ...eshafts Special Tools 16 2 Driveshafts Inspection 16 3 Removal 16 3 Disassembly 16 5 Reassembly 16 8 Installation 16 16 Intermediate Shaft Removal 16 17 Disassembly 16 18 Reassembly 16 19 Installation 16 21 ...

Page 674: ...07GAD PH70201 or 07GAD PH70200 07MAC SL00100 07MAD SP00100 07746 0010300 07746 0010400 07746 0030100 07749 0010000 07XAC 001020A 16 20 16 4 16 21 16 18 16 20 16 20 16 18 16 20 16 21 16 7 Special Tools ...

Page 675: ...lace the boot and boot bands Loose Splines Turn the driveshaft by hand and make sure the splines and joint are not excessively loose If damage is found replace the joints if necessary Twisting or Cracking Make sure the driveshaft is not twisted or cracked Replace it if necessary DRIVESHAFT INBOARD BOOT SPLINES OUTBOARD BOOT INBOARD JOINT BOOT BANDS ...

Page 676: ...INDLE NUT 24 x 1 5 mm Replace FRONT WHEEL 4 Drain the differential oil see section 15 NOTE It is not necessary to drain the differential oil when the left driveshaft is removed 5 Raise the locking tab on the spindle nut then remove the nut 6 Remove the self locking nut and flange bolts from the damper fork DAMPER FORK Check for damage FLANGE BOLT 10 x 1 25 mm 7 Remove the damper fork SELF LOCKING ...

Page 677: ...and remove the nut Driveshafts LOWER ARM HEX NUT CASTLE NUT 14 x 2 0 mm COTTER PIN Replace BALL JOINT REMOVER 32 mm 07MAC SL00100 9 Install a 14 mm hex nut on the ball joint Make sure the hex nut is flush with the ball joint pin end or the threaded section of the ball joint pin might be dam aged by the ball joint remover 10 Use the ball joint remover as shown on page 18 11 to separate the ball joi...

Page 678: ...ar and damage Check inside bore for wear Inspect for cracks ROLLER Marks Disassembly Inboard Joint Side 1 Carefully clamp the driveshaft in a vise with soft jaws then remove the set ring from the inboard joint 2 Remove the boot bands Take care not to damage the boot If the boot band is a locking tab type pry up the locking tabs with a screwdriver and raise the end of the band If the boot band is a...

Page 679: ... Mark Mark SPIDER Disassembly cont d 4 Mark the rollers and spider to identify the locations of the rollers on the spider then remove the rollers BEARING REMOVER Commercially available ROLLER Marks DRIVESHAFT OutboardJointSide 1 Lift up the three tabs with a screwdriver then remove the boot bands Take care not to damage the boot NOTE If the boot band is a double loop type lift up the band bend If ...

Page 680: ... Remove the vinyl tape 7 Remove the driveshaft from the vise 8 Remove the stop ring from the driveshaft DRIVESHAFT STOP RING Replace 9 Wrap the splines on the driveshaft with vinyl tape to prevent damage to the boot VINYL TAPE 5 Carefully clamp the driveshaft in a vise OUTBOARD JOINT END PAINT MARK DRIVESHAFT 3 Wipe off the grease to expose the driveshaft and the outboard joint inner race 4 Mark t...

Page 681: ...ncluded in the Grease quantity Inboard Joint 130 140g 4 6 4 9oz Left inboard joint splines A 0 5 1 0 g 0 018 0 035 oz Outboard Joint RUBBER TYPE 130 140 g 4 6 4 9 oz TPE TYPE 140 150 g 4 9 5 3 oz SETRING Replace LEFTINBOARDJOINT SPLINES A INBOARD JOINT CIRCLIP ROLLER SPIDER INBOARD BOOT Pack cavity with grease STOPRING Replace DRIVESHAFT DOUBLE LOOP BAND Replace Pack cavity with grease Packcavity ...

Page 682: ... not to damage the inboard boot and dynamic damper 3 Install the spider onto the driveshaft by aligning the mark on the spider and the end of the driveshaft 5 Fit the rollers onto the spider NOTE Reinstall the rollers in their original positions on the spider by aligning the marks Point the driveshaft upward to prevent the rollers from falling off ROLLER High shoulder faces toward the outside SPID...

Page 683: ...shafts to the specifica tions below then adjust the boots to halfway between full compression and full extension Make sure the ends of the boots seat in the groove of the driveshaft and joint Leftdriveshaft 580 585 mm 22 8 23 0 in 315 6 319 6 mm 12 4 12 6 in Right driveshaft 512 517 mm 20 2 20 4 in 9 Set the double loop band onto the boot with the band end toward the front of the vehicle 10 Pull u...

Page 684: ...ark on band 15 Unwind the boot band tool and cut off the excess free end of the band to leave a 5 10 mm 0 2 0 4 in tail protruding from the clip 16 Bend the band end by tapping it down with a ham mer NOTE Make sure the band does not move Remove any grease remaining on the surround ing surfaces 5 10 mm 0 2 0 4 in Fold over 17 Install the new set ring SET RING Replace 14 Lift up the boot band tool t...

Page 685: ...ith vinyl tape to prevent damage to the boot TPE TYPE OUTBOARD BOOT VINYL TAPE BOOT BAND Replace RUBBER TYPE OUTBOARD BOOT RUBBER VINYL TAPE 4 Insert the driveshaft into the outboard joint until the stop ring is close on the joint 5 To completely seat the outboard joint pick up the driveshaft and joint and drop them from about 10 cm 4 in onto a hard surface Do not use a hammer as excessive force m...

Page 686: ... g 4 6 4 9 oz 98 Canada and 99 01 models 140 150g 4 9 5 3oz DRIVESHAFT OUTBOARDJOINT EAR CLAMP BAND Replace 8 Fit the boot ends onto the driveshaft and outboard joint OUTBOARD BOOT TPE OUTBOARD BOOT DRIVESHAFT OUTBOARD BOOT OUTBOARD JOINT 9 Install the boot bands For 96 98 models go to step 13 For 98 Canada and 99 01 models go to step 10 10 Set the ear clamp band by threading the tab into the hole...

Page 687: ... the driveshaft and the outboard joint 14 Fit the double loop boot bands onto the boot ends 15 Pull up the slack in the band by hand 16 Mark a position on the band 10 14 mm 0 4 0 6 in from the clip 12 Check the clearance between the closed ear portion of the band If the clearance is not within the stan dard close the ear portion of the band further BOOT BAND PINCERS Kent Moore J 35910 or equivalen...

Page 688: ...d spot on the band meets the edge of the clip 19 Lift up the boot band tool to bend the free end of the band 90 to the clip Center punch the clip then fold over the remaining tail onto the clip 21 Bend the band by tapping it down with a hammer NOTE Make sure the band and the clip do not interfere with anything and the band does not move Remove any grease remaining in the sur rounding surfaces 20 U...

Page 689: ...AL 5 Install the knuckle onto the lower arm then tighten the castle nut and install a new cotter pin NOTE Wipe off the grease before tightening the nut at the ball joint CAUTION Be careful not to damage the ball joint boot Torque the castle nut to the lower torque speci fication then tighten it only far enough to align the slot with the pin hole Do not align the nut by loosening it Install a new c...

Page 690: ...o the seating surface of the new spindle nut WHEEL NUT 12 x 1 5 mm 108 N m 11 0 kgf m 80 Ibf ft SPINDLE NUT 24 x 1 5 mm 245 N m 25 0 kgf m 181 Ibf ft Replace NOTE After tightening use a drift to stake the spindle nut shoulder against the driveshaft 9 Install a new spindle nut then tighten the nut 10 Install the front wheel with the wheel nuts NOTE Before installing the wheel clean the mating surfa...

Page 691: ...emoval 1 Drain the differential oil see section 15 2 Remove the left driveshaft see page 16 3 3 Remove the three flange bolts FLANGE BOLT 8 x 1 25 mm 4 Remove the intermediate shaft from the differential INTERMEDIATE SHAFT ...

Page 692: ...er seal from the bearing support 3 Remove the external snap ring and the internal snap ring BEARING SUPPORT DRIVER ATTACHMENT 42 x 47 mm 07746 0010300 HANDLE DRIVER 07749 0010000 INTERMEDIATE SHAFT BEARING Replace 4 Press the intermediate shaft out of the shaft bearing using a press as shown Press INTERMEDIATE SHAFT Check for damage 5 Press the intermediate shaft bearing out of the bear ing suppor...

Page 693: ...6 Remove the intermediate shaft inner seal from the bearing support INNER SEAL Replace BEARING SUPPORT Check for damage O RING Replace 7 Remove the O ring ...

Page 694: ...n NOTE Clean the disassembled parts with solvent and dry them thoroughly with compressed air Do not wash the rubber parts with solvent INTERMEDIATE SHAFT BEARING SUPPORT O RING Replace SET RING Replace OUTERSEAL Replace Pack the lip of the outer seal EXTERNAL SNAP RING INNER SEAL Replace Pack the lip of the inner seal INTERMEDIATE SHAFT BEARING Replace INTERNAL SNAP RING ...

Page 695: ...rmediate shaft bearing into the bear ing support using the special tool and a press as shown OILSEALDRIVER 07GAD PH70201 or 07GAD PH70200 Press BEARING SUPPORT INTERMEDIATE SHAFT BEARING 3 Seat the internal snap ring into the groove of the bearing support BEARING SUPPORT INTERNAL SNAP RING 4 Press the intermediate shaft into the shaft bearing using the special tool and a press as shown Press INTER...

Page 696: ...sing the special tools and a press as shown NOTE Drive in the outer seal until it is 7 0 mm 0 28 in from the end of the bearing support DRIVER ATTACHMENT 07MAD SP00100 Press HANDLEDRIVER 07749 0010000 OUTERSEAL O RING 7 Install the new O ring into the bearing support groove 8 Install the new set ring into the intermediate shaft groove 7 0 0 2 mm 0 28 0 01 in ...

Page 697: ...acing down NOTE Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent or carburetor cleaner and dry with compressed air INTERMEDIATE SHAFT MARK 2 Install the three flange bolts then tighten them FLANGE BOLT 8 x 1 25 mm 22 N m 2 2 kgf m 16lbf ft ...

Page 698: ...box 17 14 Pump Belt 17 15 Rack Guide Adjustment 17 16 Fluid Replacement 17 16 Pump Pressure Check 17 17 Steering Wheel Removal 17 18 Installation 17 18 Disassembly Reassembly 17 19 Steering Column Removal Installation 17 20 Inspection 17 21 Steering Lock Replacement 17 22 Power Steering Hoses Lines Fluid Leakage Inspection 17 23 Replacement 17 23 Power Steering Pump Removal Installation 17 24 Disa...

Page 699: ...Special Tools 17 38 17 43 17 17 17 17 17 15 17 44 17 45 17 30 17 34 17 46 17 42 17 43 17 35 17 17 17 13 17 26 17 30 17 41 17 42 17 44 17 28 17 41 17 42 17 44 17 53 ...

Page 700: ...vice Component Locations RESERVOIR Fluid Replacement page 17 16 Fluid Leakage Inspection page 17 23 POWER STEERING PUMP Pump Belt Inspection and Adjustment page 17 15 Pump Pressure Check page 17 17 Removal Installation page 17 24 Disassembly page 17 25 Inspection page 17 26 Reassembly page 17 28 POWER STEERING SPEED SENSOR Replacement page 17 13 STEERING GEARBOX Rack Guide Adjustment page 17 16 Re...

Page 701: ...eck the power assist see page 17 12 If the force is over 25 N 2 6 kgf 5 7 Ibf proceed with this troubleshooting Check pump fluid pressure see page 17 17 Measure steady state fluid pres sure while idling with the both valves fully open It should be 1 500 kPa 15 kgf cm2 213 psi or less Check the flow control valve see page 17 26 Check the valve for smooth movement in the hous ing Check the relief va...

Page 702: ...ne and measure force required to turn the wheel to the right and left Difference of the force required to turn the wheel to the right and to the left should be 2 9 N 0 3 kgf 0 7 Ibf or less Adjust the rack guide see page 17 16 and recheck the pinion torque Steering effort still more than 25 N 2 6 kgf 5 7 Ibf Check the assist control valve for sticking or a clogged orifice clean the valve as necess...

Page 703: ...ist check see page17 12 A and B cylinder lines are nor mal check wheel alignment see section 18 Wheel alignment is abnormal adjust as needed A or B cylinder line is deformed replace it Check cylinder lines A and B for deformation Check the rack guide for proper adjustment see page 17 16 Check the rack guide for proper adjustment see page 17 16 Rack guide is adjusted properly Check the belt for sli...

Page 704: ... adjust idle speed see section 11 Check power steering fluid level If level is excessively low check for leaks in the system Add fluid to the specified level If fluid level is OK check O rings and seals on both ends of the pump inlet hose and the P S pump housing mating surfaces and drive shaft oil seal for suction leaks Replace parts as necessary Check if pump pressure is within the range 7 800 8...

Page 705: ...tion NOTE Pump noise in first 2 3 minutes after starting in cold weather is normal Check the rack guide for proper adjustment see page 17 16 CAUTION When inspecting do not hold the steering wheel all the way to the right or the left ...

Page 706: ...If pump noise is abnormally loud remove and inspect the pump for wear and damage see page 17 25 ...

Page 707: ...Fluid Leaks Check the gearbox assembly for oil leaks carefully Oil can leak out of various points depending on location of the faulty oil seals seal rings Check the following before removing the gearbox from the frame ...

Page 708: ...Replace front seal see page 17 25 Replace the leaking or seal see page 17 25 If the housing still leaks replace the pump ...

Page 709: ...m upthe fluid 3 Attach a spring scale to the steering wheel With the engine idling and the vehicle on a clean dry floor pull the scale as shown Rotate the steering wheel more than 90 degree angle by pulling the spring scale Read the figure on the spring scale while the steering wheel is in motion 4 The scale should read no more then 25 N 2 6 kgf 5 7 Ibf If it reads more go on to step 5 5 Stop the ...

Page 710: ...nsor inlet and outlet hoses and plug the hose fittings 4 Installation is the reverse of the removal procedure 5 After installing a new sensor turn the steering wheel lock to lock with the engine idling to bleed air from the system 6 Check the reservoir and add fluid if necessary BYPASS TUBE JOINT 07406 0010101 Included with 07406 0010001 4 Attach a spring scale to the steering wheel Start the engi...

Page 711: ...Steering LinkageandGearbox Inspection and Adjustment ...

Page 712: ...l times then stop the engine and recheck the deflection of the belt 5 Install the air cleaner ACL Adjustment 1 Remove the air cleaner ACL 2 Loosen the power steering pump mounting nut and bolt Pump Belt NOTE When using a new belt first adjust the deflection or tension to the values for the new belt then readjust the deflection or tension to the values for the used belt after running engine for 5 m...

Page 713: ...se on the reservoir 5 Fill the reservoir to the upper level line 6 Start the engine and run it at fast idle then turn the steering from lock to lock several times to bleed air from the system 7 Recheck the fluid level and add more if necessary CAUTION Do not fill the reservoir beyond the upper level line Inspection and Adjustment Rack Guide Adjustment NOTE Perform rack guide adjustment with the wh...

Page 714: ...alve fully 6 Open the pressure control valve fully P SPRESSUREGAUGE 07406 0010001 7 Start the engine and let it idle 8 Turn the steering wheel from lock to lock several times to warm the fluid to operating temperature 9 Measure steady state fluid pressure while idling with the shut off valve fully open If the pump is in good condition the gauge should read less than 1500 kPa 15 kgf cm2 213 psi If ...

Page 715: ...E Be sure the steering wheel shaft engages with the cable reel and canceling sleeve Removal SRS components are located in this area Review the SRS component locations precautions and procedures in the SRS section 24 before performing repairs or ser vice NOTE Before removing the steering wheel align the front wheels straight ahead 1 Remove the driver s airbag assembly from the steer ing wheel see s...

Page 716: ...ls HORN SWITCH Test see section 23 CRUISE CONTROL SET RESUME CANCEL SWITCH Test see section 23 RADIO REMOTE SWITCH Test see section 23 RADIO REMOTE SWITCH Test see section 23 CRUISE CONTROL SET RESUME CANCEL SWITCH Test see section 23 ...

Page 717: ...teering wheel see page 17 18 2 Remove the driver s side dashboard lower cover and knee bolster see section 20 3 Remove the column covers 4 Remove the combination switch assembly from the steering column shaft by disconnecting the connec tors and removing the screws 5 Disconnect the ignition switch connectors the tilt extend retract motor connectors and the sensor connectors 6 Remove the steering j...

Page 718: ... on the steering joint to make sure that the steer ing joint is fully seated Then tighten the joint bolts Be sure the wires are not caught or pinched by any parts when installing the column Make sure the wire harness is routed and fastened properly Make sure the connectors are properly connected 00 01 Models After installing the steering column perform the steering angle sensor neutral position me...

Page 719: ...an assembly Check the retaining collars for damage If they are dam aged replace the retaining collars Check the absorbing plates absorbing plate guides and sliding capsules for distortion and breakage Replace the steering column as an assembly if they are distorted or broken ABSORBING PLATES COLUMN BALL BEARING ABSORBING PLATE GUIDES STEERINGJOINT BEARINGS PLASTIC INJECTIONS IGNITION SWITCH Seesec...

Page 720: ... clicks into place 9 Loosely install the new shear bolt 10 Make sure the steering wheel lock operates smoothly and that the ignition key turns freely 11 Tighten the shear bolt until the hex head twists off 3 Set the tip of a chisel in the notch and loosen the bolt by tapping on the chisel 4 Remove the shear bolt from the switch body 5 Insert the ignition key and turn it to ACC I posi tion 6 Push t...

Page 721: ...with the clamps new ones of necessary until it contacts the stop on the line Install the clamp or adjustable clamp at the specified distance from the hose end as shown Add the recommended power steering fluid to the specified level on the reservoir and check for leaks ADJUSTABLEHOSECLAMP a HOSE CLAMP b Position the adjustable hose clamps at the points indi Position hose clamps at the points indica...

Page 722: ...ypositionedonthepulleys Do not get power steering fluid or grease on the power steering belt or pulley faces Clean off any fluidorgreasebeforeinstallation 8 Adjust the pump belt see page 17 15 9 Install the air cleaner ACL and intake air duct 10 Fill the reservoir to the upper level line see page 17 16 3 Disconnect the inlet and outlet hoses from the pump and plug the hoses NOTE Take care not to s...

Page 723: ...ways replace the O rings and rubber seals with new ones before assembly Apply recommended power steering fluid to the parts indicated in the assembly procedures Do not allow dust dirt or other foreign materials to enter the power steering system Replace the pump as an assembly if the parts indicated with asterisk are worn or damaged BALL BEARING Inspection and Replacement see page 17 27 FLOWCONTRO...

Page 724: ...ide plate and O rings 8 Remove the snap ring then remove the pump drive shaft by tapping the shaft end with the plastic ham mer 9 Remove the pump seal spacer and pump seal Disassembly cont d 1 Drain the fluid from the pump 2 Hold the steering pump in a vise with soft jaws hold the pulley with the special tool and remove the pulley nut and pulley CAUTION Becareful notto damagethepumphous ing with t...

Page 725: ... the grooves in the valve 2 Inspect the bore and the flow control valve for scratches and wear 3 Slip the valve back in the pump and check that it moves in and out smoothly If OK go to step 4 if not replace the pump as an assembly The flow control valve is not available separately 4 Attach a hose to the end of the valve as shown ...

Page 726: ...f the flow control valve tests OK reinstall it in the pump If the flow con trol valve still leaks air replace the pump as an assem bly The flow control valve is not available separately NOTE If necessary relief pressure is adjusted at the factory by adding shims under the check ball seat If you found shims in your valve be sure you reinstall as many as you took out 3 Install the new ball bearing u...

Page 727: ...e pump cover 8 Set the 10 vanes in the grooves in the rotor NOTE Be sure that the round ends of the vanes are in contact with the sliding surface of the cam ring 2 Position the pump drive shaft in the pump housing then drive it in using a special tool as shown 3 Install the 40 mm snap ring with its radiused side facing out 4 Coat the pump cover seal and the cover bushing with the power steering fl...

Page 728: ...6 Install the flow control valve cap on the pump hous ing and tighten it 17 Coat the O ring with power steering fluid and install it into the grooves in the inlet joint 18 Install the inlet joint on the pump housing 12 Install the pump cover assembly in the pump housing 13 Coat the flow control valve with power steering fluid 14 Install the flow control valve and spring on the pump housing 9 Coat ...

Page 729: ...cial tool and tighten the pulley nut UNIVERSAL HOLDER 07725 0030000 Reassembly cont d 19 Install the pulley as shown below then loosely install the pulley nut Hold the steering pump in a vise with soft jaws CAUTION Be careful not to damage the pump hous ing with the jaws of the vise PowerSteeringPump ...

Page 730: ...steering wheel see page 17 18 5 Remove the cotter pin from the tie rod ball joint nut and remove the nut PowerSteeringGearbox 6 Install the 12 mm hex nut on the ball joint Be sure that the 12 mm hex nut is flush with the ball joint pin end or the threaded section of the ball joint pin might be damaged by the special tool NOTE Remove the ball joint using the special tool Refer to section 18 for how...

Page 731: ...ine from the valve body unit upper side CAUTION After disconnecting the feed line plug or seal the line fitting with a piece of tape or equivalent to prevent foreign materials from entering the valve body unit 11 Remove the clamps from the line mounting cush ions then remove the feed line from the cushions 9 Remove the splash guard ...

Page 732: ... hoses CAUTION After disconnecting the line plug or seal the line with a piece of tape or equivalent 13 Remove the mounting brackets and steering gear box NOTE Before removing the steering gearbox place a jack stand under the gearbox to support it CAUTION Be careful not to bend or damage fluid lines when removing the steering gearbox ...

Page 733: ...ent and a brush Do not dip seals and 0 rings in solvent 1 Remove the steering gearbox see page 17 30 2 Remove the both tie rod ends 3 Remove the three lines sensor inlet line 10 mm return line and 6 mm return line from the valve body unit 4 Remove the line mounting cushions Power Steering Gearbox ...

Page 734: ...anotherwrench NOTE 96 98 models shown CAUTION Be careful not to damage the rack sur facewith thewrench 7 Loosen the locknut then remove the rack guide screw and O ring 96 98 models only 8 Remove the spring and rack guide from the gearbox housing 9 Remove cylinder lines A and B from the gearbox 10 Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth ...

Page 735: ...o enter the cylinder After removing the cylinder end remove any burrs at the stake point 14 Clamp the tool in a vise with soft jaws as shown then loosen and remove the cylinder end 15 Remove the gearbox housing from the vise and set it in a press so the gearbox points upward 16 Insert a 6 long 3 8 drive extension into the spe cial tool 17 Press the cylinder end seal and steering rack out of the ge...

Page 736: ...he cylinder wall Check the tool angle and correct it if necessary when removing the cylinder end seal Use a press to remove the cylinder end seal Do not try to remove the seal by striking the tool It will break the backup ring and the cylinder end seal will remain in the gearbox housing 19 Turn the special tool so it will fit through the end of the gearbox housing then position special tool on the...

Page 737: ...e gearbox housing with shop towel Valve Body Unit Disassembly Valve body unit 24 Remove the pinion dust cover Power Steering Gearbox 25 Before removing the valve housing apply vinyl tape to splines of the pinion shaft 26 Separate the valve housing from the pinion shaft valve using a press 23 Carefully pry the piston seal ring and O ring off the rack piston CAUTION Be careful not to damage the insi...

Page 738: ...w 44 mm shim s on the bear ing surface of the housing to adjust the thick ness 29 Remove the snap ring and pinion shaft sleeve from the pinion shaft 30 Using a cutter or an equivalent tool cut and remove the five seal rings from the sleeve CAUTION Be careful not to damage the edges of the sleeve grooves and outer surface when remov ing the seal rings 28 Check for wear burrs and other damage to the...

Page 739: ... out of the valve housing using a hydraulic press and the spe cial tool shown below PILOT COLLAR 07GAF PH70100 32 Remove the valve oil seal and backup ring 96 98 models or wave washer 99 01 models from the pinion shaft NOTE Inspect the ball bearing by rotating the outer race slowly If there is any excessive play re place the pinion shaft and sleeve as an assem bly The pinion shaft and sleeve are a...

Page 740: ...ke sure it slides smoothly without drag or side play 38 Separate the valve body and valve housing 39 Remove the housing seal and dowel pins from the valve body unit Pressure Control Valve Inspect its surface for scoring and scratches Slip it back into the valve body unit and make sure it slides smoothly without drag or side play 36 Remove the pressure control valve assist control valve and springs...

Page 741: ... vent Always replace the O rings and rubber seals with new ones before assembly Apply the recommended power steering fluid to the parts indicated in the assembly procedures Do not allow dust dirt or other foreign materials to enter the power steering system Use the appropriate special tools where necessary Power Steering Gearbox ...

Page 742: ...lve oil seal then install the seal in the valve hous ing using a hydraulic press and the special tools as shown CAUTION Install the valve oil seal with its grooved sidefacingthetool 4 Coat the cap seal with power steering fluid and install the it in the groove of the cap 5 Install the cap on the valve body ValveBodyUnitReassembly Assist control valve unit 1 Coat the housing seal with power steerin...

Page 743: ...ng fit snugly in the pinion shaft 13 Fit the new O ring in the groove of the pinion shaft Then slide the new valve seal ring over the shaft and the groove in on the pinion shaft 14 Remove the vinyl tape from the pinion shaft 15 Apply power steering fluid to the surface of the valve seal ring that was installed on the pinion shaft PISTON SEAL RING SIZING TOOL 07NAG SR30900 or 07NAG SR3090A 8 Apply ...

Page 744: ...D4020A 24 Insert the sleeve into the special tool slowly 25 Move the sleeve each direction several times to make the seal rings snugly fit in the sleeve NOTE Be sure that the seal rings are not turned up 26 Apply vinyl tape to the pinion shaft then coat the vinyl tape with power steering fluid 21 Apply power steering fluid to the surface of the spe cial tool Set the new seal rings over the special...

Page 745: ...ING GUIDE 07LAG SM40100 or 07LAG SM4010A 32 Coat the piston seal ring guide with power steering fluid and slide it onto the rack big end first 30 Apply steering grease on the valve oil seal and install the pinion dust cover on the valve body unit Steering Rack Installation 31 If the rubber stop was removed position the new rubber stop in the gearbox housing then press it in using a hydraulic press...

Page 746: ...6 Carefully slide the tool onto the rack and over the piston seal ring 37 Move the special tool back and forth several times to make the piston seal ring fit snugly in the piston 38 Wrap vinyl tape around the rack teeth and rack end edges then coat the surface of the tape with the power steering fluid NOTE Make sure that the vinyl tape is wrapped carefully so that there is no stepped portion PISTO...

Page 747: ...the steering rack then push in the cylinder end seal with your finger NOTE Remove any residue of tape adhesive Take care not to damage the cylinder end seal with the threads and burrs at the staked position of the gearbox housing 50 Install the special tool to the gearbox housing then clamp the tool in a vise with soft jaws as shown CAUTION Do not clamp the cylinder CYLINDER END SEAL REMOVER ATTAC...

Page 748: ...g with new ones If the pinion shaft valve housing and gearbox housing are replaced select the new shim s as follows Shim selection a Set the four 44 mm shims on the bearing surface of the gearbox housing Total thickness of the four shims should equal no more than 0 70 mm Shim set four 44 mm shims Thickness 0 10 mm 0 15 mm 0 20 mm 0 25 mm respectively CAUTION The four 44 mm shims do not have thickn...

Page 749: ...erial Install cylinder lines A and B by lighting the flare nuts by hand first then tighten the flare nuts to the specified torque Power Steering Gearbox 61 Grease the sliding surface of the rack guide and install it onto the gearbox housing 62 For 96 98 models Apply a thin coat of grease to the new 0 ring and install it on the rack guide screw For 99 01 models Apply sealant to the all around threa...

Page 750: ...rease to the boot grooves on the rack ends 71 Install the boots in the rack end with the tube clamps NOTE Install the boots with the rack in the straight ahead position right and left tie rods are equal in length 68 After tightening the rack ends stake the four section of lock washer with a commercially available roll pin drift and mallet Place the wood block then set the lock washer section of ra...

Page 751: ... tap on the doubled over portions to reduce their height CAUTION Stakethe band lockingtabsfirmly 76 Install the three lines 6 mm return line 10 mm return line and sensor inlet line to the valve body unit as shown 77 Install the line mounting cushions by aligning the marks on the 10 mm return line large diameter line Reassembly cont d 72 Install the new boot bands on the boots as shown Power Steeri...

Page 752: ...two line clamps on the line mounting cushions as shown below Installation CAUTION Be careful not to bend or damage cylinder lines A and B or the four fluid lines when installing the gearbox 1 Assemble the mounting bracket over the mount cushion then loosely install the gearbox on the rear beam with two gearbox mounting bolts NOTE Move the feed line over the gearbox so that it does not interfere wi...

Page 753: ...to the pinion shaft line up the bolt hole with the groove around the shaft and loosely install the lower joint bolt Be sure that the lower joint bolt is securely in the groove in the pinion shaft c Pull on the steering joint to make sure that the steering joint is fully seated Then tighten the joint bolts Power Steering Gearbox 7 Tighten the two gearbox mounting bolts on the mounting bracket that ...

Page 754: ...he steering wheel spoke angle Adjust by turning the right and left tie rods if necessary NOTE Turn the right and left tie rods equally 11 Reconnect the tie rod ends to the steering knuckles tighten the castle nut 96 98 models or hex nut 99 01 models to the specified torque and install new cotter pins NOTE Before connecting the tie rod ends wipe off any grease contamination from the ball joint tape...

Page 755: ...d lip with fresh grease CAUTION Keep grease off the boot installation section and the tapered section of the ball pin Do not allow dust dirt or other foreign materials to enter the boot 4 Install the new boot using the special tool as shown below NOTE The boot must not be a gap at the boot instal lation sections CAUTION After installing the boot check the ball pin tapered section for grease contam...

Page 756: ...ront Suspension Knuckle Hub Replacement 18 8 Ball Joint Boot Replacement 18 14 Suspension Arms Removal Inspection 18 15 Installation 18 16 Front Damper Removal 18 17 Disassembly Inspection 18 17 Reassembly 18 18 Installation 18 18 Rear Suspension Hub Bearing Unit Replacement 18 19 Suspension Arms Removal Inspection 18 21 Installation 18 22 Ball Joint Boot Replacement 18 23 Rear Damper Removal 18 2...

Page 757: ...l Joint Remover 32 mm Ball Joint Remover 28 mm Attachment 42 x 47 mm Attachment 72 x 75 mm Driver Support Base Support Base 18 13 18 12 18 12 18 14 18 23 18 11 18 10 18 11 18 21 18 13 18 12 18 13 18 12 18 13 18 13 07GAD SD40101 07GAF SE00100 07GAF SD40700 07GAG SD40700 07MAC SLO0100 07MAC SL00200 07746 0010300 07746 0010600 07749 0010000 07965 SD90100 07965 6920201 ...

Page 758: ...Removal Inspection page 18 15 Installation page 18 16 Rear Suspension UPPER ARM Removal Inspection page 18 21 Installation page 18 22 STABILIZER BAR Removal Inspection page 18 21 LOWER ARM A Removal Inspection page 18 21 Installation page 18 22 TRAILING ARM Removal Inspection page 18 21 Installation page 18 22 REAR DAMPER Removal page 18 23 Disassembly Inspection page 18 24 Reassembly page 18 24 I...

Page 759: ... and or turning angle Follow the equipment manufacturer s instructions 1 Check the steering wheel angle if significantly off center it may be necessary to remove the steering wheel and reposition it on the splines Turn the steering wheel to the straight ahead position 2 Check the caster angle Caster angle 2 50 1 3 If out of specification check for damaged suspen sion components Camber Inspection N...

Page 760: ...justing tighten the tie rod locknuts and reposition the tie rod boot if it is twisted or dis placed Rear Toe Inspection Adjustment NOTE Use commercially available computerized four wheel alignment equipment to measure wheel align ment caster camber toe and or turning angle Follow the equipment manufacturer s instructions 1 Release the parking brake NOTE Measure the difference in toe measurements w...

Page 761: ...ce Bearing End Play 2 If the turning angle is not within the specifications check for bent or damaged suspension compo nents 1 Raise the vehicle off the ground and support it with safety stands in the proper locations see section 1 2 Remove the wheels then reinstall the wheel nuts 3 Attach the dial gauge as shown Front Rear Standard 0 0 05 mm 0 0 002 in Front Measure the end play at the hub flange...

Page 762: ...or deformed wheels 3 Attach the dial gauge as shown AxialRunout Standard Aluminum Wheel 0 0 7 mm 0 0 03 in Service Limit 2 0 mm 0 08 in RadialRunout Standard Aluminum Wheel 0 0 7 mm 0 0 03 in Service Limit 1 5 mm 0 06 in 4 Measure the wheel runout by turning the wheel 5 If the wheel runout is more than the service limit replace the wheel ...

Page 763: ... x 2 0 mm FRONT HUB Check for damage and cracks BRAKEDISC Check for wear and rust Removal page 18 10 Inspection section 19 6 mm SCREW 5 N m 0 5 kgf m 4 Ibf ft WHEEL NUT 12 x 1 5 mm 108 N m 11 kgf m 80 Ibf ft CENTER CAP SPINDLE NUT 24 x 1 5 mm 245 N m 25 kgf m 181 Ibf ft Replace NOTE Before installing the spindle nut apply engine oil to the seating surface of the nut After tightening use a drift to...

Page 764: ... Raise the locking tab on the spindle nut then remove the nut 5 Remove the brake hose mounting bolts BRAKE HOSE 9 8 N m 1 0 kgf m 7 2 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 6 Remove the wheel sensor from the knuckle NOTE Do not disconnect the wheel sensor connec tor 9 8 N m 1 0 kgf m 7 2 Ibf ft SENSOR MOUNTING BOLTS 9 8 N m 1 0 kgf m 7 2 Ibf ft WHEEL SENSOR 7 Remove the caliper bracket mounting bolts a...

Page 765: ...he adjustment to the adjusting bolt make sure the head of the adjusting bolt is in this position to allow the jaw to pivot 16 With a wrench tighten the pressure bolt until the ball joint shaft pops loose from the steering arm Wear eye protection The ball joint can break loose suddenly and scatter dirt or other debris in your eyes Remove the tool then remove the nut from the end of the ball joint a...

Page 766: ...haft end with a plastic hammer then remove the knuckle KNUCKLE OUTBOARD JOINT Wheel Bearing Replacement NOTE Replace the bearing with a new one after removal 25 Carefully clamp the caliper bracket mount section of the knuckle in a vise with soft jaws SLIDE HAMMER Commercially available WHEEL NUT FRONT HUB 26 Separate the hub from the knuckle using a commer cially available hub puller CAUTION Hold ...

Page 767: ... the knuckle using the special tools and a press DRIVER 07749 0010000 Press ATTACHMENT 72 x 75 mm 07746 0010600 WHEEL BEARING HUB DIS ASSEMBLY BASE 07GAF SD40700 30 Remove the outboard bearing inner race from the hub using the special tools and a commercially available bearing separator Press HUB DIS ASSEMBLY TOOL 07GAF SE00100 INNER RACE BEARING SEPARATOR 0 4 1 2 in Commercially available ...

Page 768: ...32 Install the snap ring securely in the knuckle groove KNUCKLE SNAP RING 33 Install the splash guard and tighten the screws 6 mm SCREW 4 9 N m 0 5 kgf m 4 Ibf ft SPLASH GUARD 34 Place the front hub in the special tool fixture then set the knuckle in position and apply downward pressure using the special tools and a press Press ATTACHMENT 42 x 47 mm 07746 0010300 FRONT HUB ATTACHMENT 72 x 75 mm 07...

Page 769: ...r the boot 4 Install the boot in the groove of the boot installation section securely then bleed air 5 Install the upper and lower ball joint boot set rings using the special tools as follows Adjust the special tool with the adjusting bolt until the end of the tool aligns with the groove on the boot Slide the set ring over the tool and into posi tion BALL JOINT BOOT CLIP GUIDE 07GAG SD40700 ADJUST...

Page 770: ...d damage KNUCKLE Check for damage LOWER ARM RUBBER BUSHING Check for deterioration and damage BALLJOINT Inspect for faulty movement and wear BALLJOINTBOOT Check for deterioration and damage COMPLIANCE BUSHING Do not contaminate the tapered section with oil and grease DAMPER FORK RUBBER BUSHING Check for deterioration and damage LOWER ARM ASSEMBLY Check for damage Do not disassemble as it might def...

Page 771: ...2 Ibf ft Replace Hold the ball joint pin using a hex wrench and tighten the self locking nut SELF LOCKING NUT 12 x 1 25 mm 103 N m 10 5 kgf m 76 Ibf ft Replace FLANGE BOLT 12 x 1 25 mm 113 N m 11 5 kgf m 83 Ibf ft FLANGE NUT 10 x 1 25 mm 29 N m 3 0 kgf m 22 Ibf ft Before tightening the flange nut position the ball joint pin in the middle of its range of travel with the suspension under vehicle loa...

Page 772: ...cturer s instructions then remove the self locking nut CAUTION Do not compress the spring more than necessary to remove the nut SELF LOCKING NUT 10 x 1 25 mm Replace STRUT SPRING COMPRESSOR Commercially available BRANICK T N MST 580A T N 7200 or equivalent 2 Remove the damper from the spring compressor then disassemble the damper as shown on the next page Inspection 1 Reassemble all parts except t...

Page 773: ... MOUNTING WASHER Installation 1 Loosely install the damper on the frame with the aligning tab facing inside then loosely install the five flange nuts DAMPER FLANGE NUTS 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft Tighten these nuts in step 6 ALIGNINGTAB 2 Install the damper fork over the driveshaft and onto the lower arm Install the damper in the damper fork so the aligning tab is aligned with the slo...

Page 774: ...E ASSEMBLY Do not disassemble HUB BEARING UNIT Inspect for faulty movement and wear SPINDLE WASHER SPINDLE NUT 24 x 1 5 mm Replace 245 N m 25 0 kgf m 181 Ibf ft NOTE After tightening use a drift to stake the spindle nut shoulder against the spindle WHEEL NUT 12 x 1 5 mm 108 N m 11 kgf m 80 Ibf ft FLANGE NUT 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft BRAKE DISC Check for wear and rust Inspection Secti...

Page 775: ...hang the caliper assembly from the under carriage CALIPERASSEMBLY 22 N m 2 2 kgf m 16 Ibf ft 5 CALIPER BRACKET MOUNTING BOLTS 55 N m 5 6 kgf m 41 Ibf ft Remove the caliper bracket mounting bolts and hang the caliper assembly to one side 6 Remove the 6 mm brake disc retaining screws 9 8 N m 1 0 kgf m 7 2 Ibf ft BRAKEDISC 8 x 12 mm BOLTS 7 Screw two 8 x 12 mm bolts into the disc to push it away from...

Page 776: ...and damage Check the bushing for deterioration anddamage LOWER ARM B Check for bending and damage Check the bushing for deterioration and damage BALLJOINT REMOVER 28 mm 07MAC SL00200 See page 18 10 for how to use the ball joint remover TRAILING ARM BRACKET Check for damage TRAILING ARM Check for bending and damage Check the bushing for deterioration and damage LOWER ARM A Check for bending and dam...

Page 777: ...ls FLANGE BOLT 10 x 1 25 mm 3 51 N m 5 2 kgf m 38 Ibf ft FLANGE BOLT 12 x 1 25mm 108 N m 11 kgf m 80 Ibf ft SELF LOCKING NUT 10 x 1 25 mm 96 98 models 37 N m 3 8 kgf m 27 Ibf ft 99 01 models 34 N m 3 5 kgf m 25 Ibf ft Replace Hold the ball joint pin using a hex wrench and tighten the self locking nut FLANGE BOLT 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft FLANGE BOLTS 12 x 1 25 mm 108 N m 11 kgf m 80 ...

Page 778: ...e depth by turning the bolt SET RING BOOT CAUTION After installing the boot check the ball pin tapered section for grease contamination and wipe it if necessary Removal 1 Raise the rear of the vehicle and support it with safety stands in the proper locations see section 1 2 Remove the rear speaker and damper cap DAMPERCAP DAMPER MOUNTING NUTS 10 x 1 25 mm 3 Use a floor jack to compress the damper ...

Page 779: ...r no extension the gas is leaking and the damper should be replaced 4 Check for oil leaks abnormal noises or binding dur ing these tests Reassembly 1 Install the damper unit on a spring compressor NOTE Follow the manufacturer s instructions STRUT SPRING COMPRESSOR Commercially available BRANICK T N MST 580A T N 7200 or equivalent SPRING LOWER SEAT 2 Assemble the damper in the reverse order of disa...

Page 780: ... with the damper under vehicle load Do not interchange the right and left dampers CAUTION Carefully install the damper assembly on the damper bracket making sure the speed sen sor wire does not get caught between the damper and the bracket REAR DAMPER DAMPER MOUNTING BOLT 103 N m 10 5 kgf m 76 Ibf ft 4 Install and tighten the damper mounting nuts 5 Tighten the damper mounting bolt 6 Install the da...

Page 781: ...03 ABS Anti lock Brake System 98 99 models Special Tools 19 105 Component Location Index 19 106 Anti lock Brake System Features Construction 19 107 ABS Control Unit Terminal Arrangement 19 114 Troubleshooting Precautions 19 117 Diagnostic Trouble Code DTC DTC Indication 19 119 DTC Erasure 19 120 Troubleshooting Index 19 121 Modulator Unit Removal Installation 19 143 ABS Control Unit Removal Instal...

Page 782: ...SpecialTools Ref No Tool Number Description Qty Page Reference 07JAG SD40100 Pushrod Adjustment Gauge 19 15 ...

Page 783: ...assembled Master Cylinder Cup and Dust Seal Check brake operation by applying the brakes Visually check for damage or signs of fluid leakage Replace the master cylinder as an assembly if the pedal does not work properly or if there is damage or signs of fluid leakage Check for a difference in brake pedal stroke between quick and slow brake applications Replace the master cylinder if there is a dif...

Page 784: ...ht with the pushrod pressed Lower the pedal PUSHROD LOCKNUT 15 N m 1 5 kgf m 11 Ibf ft 4 Screw in the brake pedal position switch until its plunger is fully pressed threaded end touching the pad on the pedal arm Then back off the switch 1 4 turn to make 0 3 mm 0 01 in of clearance between the threaded end and pad Tighten the locknut firm ly Connect the brake pedal position switch connec tor CAUTIO...

Page 785: ...eplacing the linings make sure you drive the vehicle for break in purposes Refer to page 19 27 for the lining break in procedure Minor adjustment 1 Raise the rear wheels off the ground and support the vehicle on safety stands Block the front wheels before jacking up the rear of the vehicle 2 Remove the rear console end cover 3 Press the parking brake pedal one click PARKING BRAKE PEDAL 4 Tighten t...

Page 786: ...tands Block the front wheels before jacking up the rear of the vehicle 2 Remove the rear wheels 3 Remove the rear console end cover 4 Release the parking brake pedal and back off the adjusting nut in the equalizer EQUALIZER ADJUSTING NUT 5 Turn the brake shoe adjuster up with a flat blade screwdriver until the shoes lock then back off 8 stops FLAT BLADE SCREW DRIVER BRAKE SHOE ADJUSTER ACCESS PLUG...

Page 787: ...rake caliper Add fluid as required 1 Make sure the brake fluid level in the reservoir is at the MAX upper level line 96 97 models 98 01 models MAX UPPER LEVEL LINE MASTER CYLINDER 2 Have someone slowly pump the brake pedal several times then apply steady pressure 3 Loosen the brake bleed screw to allow air to escape from the system Then tighten the bleed screw securely 4 Repeat the procedure for e...

Page 788: ... system indicator does not function do the input test for the daytime running lights control unit see section 23 Brake Fluid Level Switch Test 1 Remove the reservoir cap Check that the float moves up and down freely if it doesn t replace the reservoir cap assembly 2 Check for continuity between the terminals in each switch position according to the table RESERVOIR CAP DOWN POSITION FLOAT Switch co...

Page 789: ...emove the pad shims pad retainers and pads NOTE 96 97 99 00 and 01 models shown PAD RETAINERS INNER PAD SHIMS Check for weakness OUTER PAD Check for wear OUTER PAD SHIM Check for weakness NOTE Replace the shims together with the pads as a set 5 Using vernier calipers measure the thickness of each brake pad lining Brake Pad Thickness Standard 10 5 11 5 mm 0 41 0 45 in Service Limit 1 6 mm 0 06 in 9...

Page 790: ...s or pads reduce stop ping ability Keep grease off the discs and pads NOTE Install the pad with the wear indicator on the inside 12 Push in the piston so the caliper will fit over the pads Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down CALIPER BOLT 49 N m 5 0 kgf m 36 Ibf ft PISTON 13 Pivot the caliper down into position Hold the caliper pin with a w...

Page 791: ...ter than 0 10 mm 0 004 in Disc Thickness and Parallelism Inspection 1 Loosen the front wheel nuts slightly then raise the vehicle and make sure it is securely supported Remove the front wheels 2 Remove the brake pads see page 19 10 3 4 Using a micrometer measure disc thickness at eight points approximately 45 apart and 10 mm 0 4 in in from the outer edge of the disc MICROMETER Brake Disc Thickness...

Page 792: ... a non Honda brake fluid can cause corrosion and decrease the life of the system INNER PAD SHIM A INNER PAD SHIM B STAINLESS 96 97 99 00 and 01 models INNER PAD WEAR INDICATOR Install inner pad with its wear indicator downward PISTON SEAL Replace OUTER PAD PIN BOOTS Replace 98 model only CALIPER PIN A CALIPER PIN B CALIPER BRACKET CALIPER PIN PIN BOOT Replace PISTON BOOT Replace PAD RETAINERS OUTE...

Page 793: ... before installing the brake booster see page 19 16 NOTE 96 97 models shown 9 Remove the four brake booster mounting nuts 10 Pull the brake booster forward until the clevis is clear of the bulkhead 11 Remove the brake booster from the engine com partment 12 Install the brake booster and master cylinder in the reverse order of removal CAUTION When connecting the brake lines make sure there is no in...

Page 794: ... try to disassemble the master cylinder assem bly Replace the master cylinder assembly with a new one if necessary Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid NOTE 96 97 models shown RESERVOIR SEAL Check for damage and deterioration RESERVOIR CAP Check for blockage and vent holes STRAINER Remove accumulated sediment ROD SEAL Check for damage and deterioratio...

Page 795: ...ADJUSTMENT GAUGE 07JAG SD40100 ADJUSTING NUT 2 Without disturbing the center shaft s position install the special tool upside down on the booster 3 Install the master cylinder nuts and tighten them to the specified torque 4 Connect the booster in line with a vacuum gauge 0 101 kPa 0 760 mmHg 30 in Hg to the booster s engine vacuum supply and maintain an engine speed that will deliver 66 kPa 500 mm...

Page 796: ... 0 008 in or more Therefore it must be adjusted and rechecked 6 If the clearance is incorrect remove the tool and adjust the clearance by holding the pushrod and turning the adjuster in or out CAUTION Do not pull the pushrod out of the brake booster NOTE Adjust the clearance while the specified vac uum is applied to the booster ADJUSTER PUSHROD 7 Adjust the pushrod length as shown if the booster i...

Page 797: ...slight change in pedal height when the A C compressor cycles on and off is nor mal The A C compressor load changes the vacuum available to the booster LeakTest 1 Press the brake pedal with the engine running then stop the engine If the pedal height does not vary while pressed for 30 seconds the vacuum booster is OK If the pedal rises the booster is faulty 2 With the engine stopped press the brake ...

Page 798: ...he way CAUTION Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside Support the caliper with a piece of wire so it does not hang from the brake hose NOTE Check the hoses and pin boots for damage and deterioration 4 Remove the pad shims pad retainers and pads INNER PAD SHIMS Check for weakness BRAKEPADS Check for wear OUTER PAD SHIM Check for weakness 5 Using ve...

Page 799: ...y Keep grease off the discs and pads NOTE Install the pad with the wear indicator on the inside 12 Push in the piston so that the caliper will fit over the pads Make sure the piston boot is in position to prevent damaging it when pivoting the caliper down 13 Pivot the caliper down into position then install the caliper bolt and tighten it 99 01 models only Hold the caliper pin with a wrench being ...

Page 800: ...hould be refinished if its runout is greater than 0 15 mm 0 006 in Disc Thickness and Parallelism Inspection 1 Loosen the rear wheel nuts slightly then raise the vehicle and make sure it is securely supported Remove the rear wheels 2 Remove the brake pads see page 19 17 3 Using a micrometer measure disc thickness at eight points approximately 45 apart and 10 mm 0 4 in in from the outer edge of the...

Page 801: ...wels Clean all parts in brake fluid and air dry blow out all passages with compressed air Before reassembling check that all parts are free of dust and other foreign particles Replace parts with new ones whenever specified to do so Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid Always use Genuine Honda DOT 3 Brake Fluid Using a non Honda brake fluid can cause c...

Page 802: ...Y Check for scoring on cylinder wall PISTON CALIPER BOLTS 23 N m 2 3 kgf m 17 Ibf ft INNER PAD CALIPER PIN B PAD SPRING PISTON SEAL Replace INNER PAD SHIM A CALIPER BRACKET MOUNTING BOLT 38 N m 3 9 kgf m 28 Ibf ft WEAR INDICATOR Install inner pad with its wear indicator downward PISTON BOOT Replace OUTER PAD SHIM OUTER PAD PAD RETAINERS CALIPERBRACKET Check for cracks CALIPER PIN CALIPER BRACKET P...

Page 803: ... kgf m 101 Ibf ft ADJUSTER ASSEMBLY Check ratchet teeth for wear and damage LOWER RETURN SPRING Check for weakness and damage PARKINGBRAKELEVER PARKING BRAKE SHOE Check for wear RETAINER SPRING Install securely on tension pin ROD SPRING Check for weakness and damage 98 01 models BACKING PLATE UPPER RETURN SPRINGS Check for weakness and damage CONNECTING ROD LOWER RETURN SPRING Check for weakness a...

Page 804: ... replace the brake shoes as a set 6 Check the bearings in the hub unit for smooth oper ation If the bearings require servicing refer to section 18 7 Measure the inside diameter of the disc drum using inside vernier calipers Drum Inside Diameter Standard 169 9 170 0 mm 6 689 6 693 in Service Limit 171 0 mm 6 732 in INSIDEVERNIERCALIPERS BRAKE DISC DRUM 8 If the inside diameter of the brake disc dru...

Page 805: ...NSPRINGS Check for weakness and damage 96 97 models 3 Remove the tension pins by pushing and turning the retainer spring TENSION PINS RETAINERSPRING 4 Disconnect the rod spring and remove the connect ing rod RODSPRING Check for weakness and damage CONNECTING ROD 5 Lower the parking brake shoe assembly 6 Separate the brake shoes by removing the lower return spring and adjuster assembly LOWERRETURNS...

Page 806: ...kote 44 MA grease to the sliding surface of the pivot pin and insert the pin into the parking brake shoe 10 Install the parking brake lever and wave washer on the pivot pin and secure them with a new U clip NOTE Pinch the new U clip securely to prevent the pivot pin from coming out of the parking brake shoe Apply Molykote 44 MA grease to sliding surface PARKING BRAKE SHOE PIVOT PIN PARKING BRAKE L...

Page 807: ...B Coat the threads of the clevises with Molykote 44 MA grease To shorten the clevises turn the adjuster bolt LOWER RETURN SPRING ADJUSTER ASSEMBLY 14 Install the adjuster assembly and the lower return spring on the parking brake shoes 15 Connect the rod spring to the connecting rod and parking brake shoe as shown NOTE Hook the rod spring to the connecting rod with the spring end pointing downward ...

Page 808: ...17 Install the upper return springs 18 Install the brake disc drum and rear brake caliper see section 18 19 Adjust the parking brake see page 19 6 ...

Page 809: ...ing surface see page 19 6 Do this operation in a safe area 1 Park the vehicle on a firm level surface 2 Keep the parking brake release lever pulled up 3 Press the parking brake pedal with 294 N 30 kgf 66 Ibf of pressure while you drive the vehicle at about 31 mph 50 km h for 400 m 1 4 mile 4 Park the vehicle for 5 10 minutes to allow the drums to cool Repeat step 3 5 Check the parking brake pedal ...

Page 810: ...L Service Manual see page 19 6 Do this operation in a safe area 1 Park the vehicle on a firm level surface 2 Keep the parking brake release lever pulled up 3 Press the parking brake pedal with 118 N 12 kgf 26 Ibf of pressure while you drive the vehicle at about 31 mph 50 km h for 400 m 1 4 mile 4 Park the vehicle for 5 10 minutes to allow the drums to cool Repeat step 3 5 Check the parking brake p...

Page 811: ...is serviced 00 01 models VSA BRAKE LINE to MODULATOR UNIT 15 N m 1 5 kgf m 11 Ibf ft MASTER CYLINDER to BRAKE LINE 15 N m 1 5 kgf m 11 Ibf ft BRAKE LINE to PUMP 15 N m 1 5 kgf m 11 Ibf ft BRAKE LINE to BRAKE HOSE 15 N m 1 5 kgf m 11 Ibf ft MASTER CYLINDER to BRAKE LINE 15 N m 1 5 kgf m 11 Ibf ft 96 99 models BRAKE LINE to MODULATOR UNIT 15 N m 1 5 kgf m 11 Ibf ft BRAKE HOSE to CALIPER BANJO BOLT 3...

Page 812: ... BRAKE HOSE MOUNTING BOLT BRAKE HOSE BANJOBOLT 4 Remove the banjo bolt and disconnect the brake hose from the caliper 5 Install the brake hose on the knuckle and damper first then connect the brake hose to the caliper with the banjo bolt and new sealing washers BRAKE HOSE MOUNTING BOLT 9 8 N m 1 0 kgf m 7 Ibf ft BRAKE HOSE BRAKE HOSE MOUNTING BOLT 8 mm 22 N m 2 2 kgf m 16 Ibf ft BANJO BOLT 34 N m ...

Page 813: ... Remove the parking brake cable from the backing plate using a 12 mm offset wrench as shown 6 Install the cable in the reverse of removal BACKINGPLATE 12mm OFFSET WRENCH PARKING BRAKE CABLE PARKING BRAKE CABLE Check for binding ADJUSTING NUT PARKING BRAKE CABLE Check for binding EQUALIZER 1 Disconnect the parking brake switch connector 2 Release the parking brake pedal and disconnect the parking b...

Page 814: ...SpecialTools Ref No Tool Number Description Qty Page Reference 07HAJ SG0010Aor 07HAJ SG0010B 07PAZ 0010100 ALB Checker SCS Service Connector 19 95 19 40 ...

Page 815: ... BOX B UNDER HOOD FUSE RELAY BOX UNDER DASH FUSE RELAY BOX LEFT FRONT WHEEL SENSOR LEFT FRONT WHEEL SENSOR CONNECTOR GAUGE ASSEMBLY ABS INDICATOR LIGHT UNDER DASH FUSE RELAY BOX METER 7 5 A FUSE ABS B2 15 A FUSE ABS B1 20 A FUSE METER 15 A FUSE BATTERY 120 A FUSE ABS MOTOR 40 A FUSE IG SW 50 A FUSE UNDER HOOD RELAY BOX C REAR FAIL SAFE RELAY METERRELAY FRONT FAIL SAFE RELAY ABS UNIT 7 5 A FUSE STO...

Page 816: ...ABS Control UnitTerminal Arrangement 26P CONNECTOR Terminal side of male terminals 26P CONNECTOR NOTE Standard voltage is 12 V ...

Page 817: ...22P CONNECTOR 22PCONNECTOR Terminal side of male terminals NOTE Standard voltage is 12 V ...

Page 818: ...rs or the same problem occurs again the control unit moves the first DTC to the next memory register and stores the second DTC in the first register If there s a third problem occurrence the two existing DTCs are moved up one register and the third DTC is stored in the first register If problems continue to occur the oldest problem is moved out of the last register and lost and the most recent pro...

Page 819: ...e pressure switch signal regardless of the vehicle speed Troubleshooting When 2 or 3 DTCs are stored in the control unit perform troubleshooting for the DTC that appears first When a customer s reported problem cannot be verified on the vehicle ask the customer about the conditions when the ABS indicator light came ON and test drive the vehicle under those conditions if possible When the ABS indic...

Page 820: ...ECTOR 07PAZ 0010100 2 Turn the ignition switch ON II but do not start the engine 3 Record the blinking frequency of the ABS indicator light The blinking frequency indicates the diagnostic trouble code DTC NOTE Check the DTC carefully and record it The memory of the DTC is erased if the connector is disconnected from theABScontrol unit GAUGE ASSEMBLY ABS INDICATOR LIGHT ...

Page 821: ...unt the blinking frequency or if you recheck the blinking frequency turn the ignition switch OFF then turn it ON II to cycle the ABS indicator light again 4 Remove the SCS service connector NOTE The Malfunction Indicator Lamp MIL will stay on after the engine is started if the SCS service connector is connected 5 Remove the ABS B2 15 A fuse in the under hood fuse relay box for at least 3 seconds t...

Page 822: ...e system Parkingbrake Pulser Different diameter tire Wheel sensor Rear wheel lock Fail safe relay Solenoid ABS function CPUcomparison IC Integrated Circuit DIAGNOSTIC PERIOD INITIAL DIAGNOSIS O O O O INDIVIDUAL DIAGNOSIS O O REGULAR DIAGNOSIS O O O O O O O O O O PROBLEM LOCATION Right front Left front Right rear Left rear Right front Left front Right rear Left rear Right Left Right Left Front Rear...

Page 823: ...Selector 8 Push the Start Test switch The ABS indicator light should not come on while the Test in Progress light is on If the ABS indicator light comes on confirm the DTC and perform the appropriate troubleshooting for the code NOTE Do not turn the Mode Selector switch when the Test in Progress light is on Damage to the ALB checker can result 9 Turn the Mode Selector switch to 2 10 Depress the br...

Page 824: ...em under right rear wheel lock There should be kickback SIMULATED DRIVING SIGNAL Inspection Points If the ABS indicator light comes on and the system stops during the inspection confirm the DTC and perform the appro priate troubleshooting for the code If there is no kickback in modes 2 through 5 and the ABS indicator light does not come on the following items are proba blecauses Pressure switch st...

Page 825: ...plug on the accumulator 1 Remove the bleeder cap from the maintenance bleeder on the modulator unit MAINTENANCE BLEEDER 11 N m 1 1 kgf m 8 Ibf ft CAP TUBE 2 Attach a wrench to the maintenance bleeder 3 Connect a tube of the appropriate diameter to the maintenance bleeder and set the other end of the rubber tube in a suitable container 4 While holding the tube with your hand slowly loosen the maint...

Page 826: ...er level with fresh brake fluid NOTE Pour the brake fluid slowly so that it does not foam and wait for a few minutes 5 Repeat steps 1 and 2 twice and refill the reservoir to the MAX upper level with fresh brake fluid 6 Tighten the maintenance bleeder to the specified torque 7 Start the engine and make sure that the ABS indica tor light goes off Bleeding When the brake fluid is completely drained f...

Page 827: ...high pressure brake fluid If the pump motor operates for 40 seconds or more the indicator light comes on and the pump motor stops Stop and restart the engine to operate the pump motor again If the ABS indicator light comes on remove the ABS B2 15 A fuse for 3 seconds or more to erase the DTC after servicing 5 After the pump motor stops refill the reservoir to the MAX line 6 After servicing make su...

Page 828: ...he high pressure brake fluid then remove the ABS B2 15 A fuse for 3 seconds or more to erase the DTC If modulator removal installation is for some other reason than repairing or replacing the modulator the pump motor may not operate In this case step 4 and 5 are not necessary 5 After the pump motor stops refill the reservoir to the MAX line 6 Make sure the ABS indicator light goes off 7 Bleed the ...

Page 829: ... 3 Replace the pump motor MODULATOR UNIT O RING Replace PUMP MOTOR 8 mm FLANGE BOLT Replace NOTE Use 8 mm bolts inthe pump motorset 15 N m 1 5 kgf m 11 Ibf ft 4 Perform modulator unit installation see page 19 100 Reservoir Replacement 1 Remove the modulator unit see page 19 99 2 Replace the reservoir O RING Replace RESERVOIR Replace O RING Replace O RING Replace JOINT Replace 3 Perform modulator u...

Page 830: ...ver 3 Remove the right front door trim 4 Remove the right kick panel 5 Turn up the floor mat 6 Remove the PCM cover 7 Remove the connectors inside of the right kick panel 8 Remove the harness clip A from the ABS control unit then remove the bolt at lower side of the ABS control unit 9 Remove the multiplex control unit passenger s 10 Remove the harness clip B and C 11 Remove the bolt at the rear of...

Page 831: ...e to other one Installation Chipped pulser Air gap 0 4 1 0 mm 0 02 0 04 in Front Rear Remove the rear brake disc to inspect the rear wheel sensor air grip WheelSensorReplacement NOTE Be careful when installing the sensors to avoid twist ing the wires The torque value of the bolts is at 9 8 N m 1 0 kgf m 7 Ibf ft Front FRONT WHEEL SENSOR Rear REAR WHEEL SENSOR ...

Page 832: ...SpecialTools Ref No Tool Number Description Qty Page Reference 07PAZ 0010100 SCS Service Connector 19 119 ...

Page 833: ...SH FUSE RELAY BOX LEFT FRONT WHEEL SENSOR GAUGE ASSEMBLY UNDER HOOD FUSE RELAY BOX ABS INDICATOR UNDER DASH FUSE RELAY BOX R C MIRROR 7 5 A FUSE METER 7 5 A FUSE STOP HORN 15 A FUSE ABSUNIT 7 5 A FUSE ABS 20 A FUSE ABSPUMP MOTOR RELAY METER 15 A FUSE BATTERY 120 A FUSE ABS MOTOR 40 A FUSE IG SW 50 A FUSE UNDER HOOD RELAY BOX C GAUGE RELAY FAIL SAFE RELAY UNDER HOOD FUSE RELAY BOX ...

Page 834: ...the slip rate of the wheels to ensure maximum grip force from the tires and it thereby ensures maneuverability and stability of the vehicle The ABS calculates the slip rate of the wheels based on the vehicle speed and the wheel speed then it controls the brake fluid pressure to attain the target slip rate Grip Force of Tire and Road Surface Slip Rate COEFFICIENT OF FRICTION TARGET SLIP RATE SLIP R...

Page 835: ...the detected wheel speed The control unit detects the vehicle speed during deceleration based on the rate of deceleration The ABS control unit calculates the slip rate of each wheel and it transmits the control signal to the modulator unit solenoid valve when the slip rate is high The pressure reduction control has 3 modes pressure reduction pressure retaining and pressure intensifying ABSCONTROLU...

Page 836: ...nd L A and L S B B S S Operation Mode Table Operation Mode Regular operation Fail safe mode S Fail safe mode A Fail safe mode L Fail safe mode B Description Operation in normal condition The ABS control unit turns the system off when the control unit detects a problem If the ABS control unit detects a malfunction during an emergency stop it will turn off the malfunc tioning component and continue ...

Page 837: ...ur channel type one channel for each wheel SOLENOIDVALVE PUMP MOTOR IN INLET VALVE NORMALLY OPEN Pressure intensifying mode Inlet valve open outlet valve closed OUT OUTLET VALVE NORMALLY CLOSED Master cylinder fluid is pumped out to the caliper Pressure retaining mode Inlet valve closed outlet valve closed Caliper fluid is retained by the inlet valve and outlet valve Pressure reduction mode Inlet ...

Page 838: ...uce the caliper fluid pressure The pump motor starts at this time As the wheel speed is restored the inlet valve opens momentarily to increase the caliper fluid pressure Wheel Sensor The wheel sensors are the magnetic contactless type As the gear pulser teeth rotate past the wheel sensor s magnetic coil AC current is generated The AC frequency changes in accordance with the wheel speed The ABS con...

Page 839: ...al Detects parking brake switch signal Outputs right front wheel sensor signal Detects left front wheel sensor signal Detects right front wheel sensor signal Detects brake pedal posi tion switch signal Power source for activating the system Measurement Terminal 1 GND 3 GND 4 GND 5 GND 6 7 8 9 10 GND 11 GND Conditions Ignition switch ON ID Spin wheel slowly Parking brake Pressed pedal Released Spin...

Page 840: ...ignal Detects pump motor drive signal Detects left rear wheel sensor signal Detects right rear wheel sensor signal Drives fail safe relay Fail safe relay is turned OFF to shut off the power source to the solenoid and pump motor relay when problem occurs Communicates with the Honda PGM Tester Measurement Terminal 12 GND 13 GND 14 GND 15 GND 16 GND 17 18 19 20 21 GND 22 GND Conditions Ignition switc...

Page 841: ...ator Turns the indicator drive transistor to ON then turns off the indicator Ground Drives right rear outlet solenoid valve Drives left front outlet solenoid valve Drives left rear outlet solenoid valve Drives right front outlet solenoid valve Ground Drives right rear inlet solenoid valve Drives left front inlet solenoid valve Drives left rear inlet solenoid valve Drives right front inlet solenoid...

Page 842: ...urned OFF 4 For DTCs 12 14 16 18 21 22 23 24 51 52 and 53 the indicator goes off when the vehicle is driven again and the sys tem is OK after the ignition switch is turned from OFF to ON II However if the DTC is erased the CPU is reset and the indicator goes off right after the engine is started if the system is OK DiagnosticTroubleCode DTC 1 If the CPU cannot be activated and the indicator comes ...

Page 843: ... problem is still present and the ABS indicator is still on Following the flowchart when the ABS indicator does not come on can result in incorrect diagnosis 2 Question the customer about the conditions when the problem occurred and try to reproduce the same conditions for troubleshooting Find out when the ABS indicator came on such as during initial diagnosis during ABS control after ABS control ...

Page 844: ...The blinking frequency indicates the DTC NOTE If the DTC is not memorized the ABS indicator will go off for 3 6 seconds and then come back on 4 Turn the ignition switch OFF and remove the SCS service connector NOTE The Malfunction Indicator Lamp MIL will stay on after the engine is started if the SCS service connector is con nected Conditions for DTC indication Vehicle speed is 6 mph 10 km h or le...

Page 845: ... goes off release the brake pedal again 7 After a few seconds the ABS indicator blinks twice and the DTC is erased If the indicator does not blink twice repeat steps 1 through 6 If the indicator stays ON after the indicator blinks twice check the DTC because a problem was detected during initial diagnosis before shifting to DTC Erasure mode 8 Turn the ignition switch OFF and remove the SCS service...

Page 846: ...rmittent interrup tion Pulser Solenoid short to body ground short to wire Wheel lock Motor lock Motor stuck OFF Motor stuck ON Fail safe relay Ignition voltage Different diameter tire Central Processing Unit CPU diagnosis and ROM RAM diagnosis DETECTION TIMING O 0 O O O O 0 O 0 O O 0 O O O PROBLEM LOCATION FR FL RR RL FR FL RR RL FR FL RR RL FR IN FR OUT FL IN FL OUT RR IN RR OUT RL IN RL OUT FR F...

Page 847: ... control valve 3 Remove the modulator unit Installation 1 Install the modulator unit 2 Install the proportioning control valve then connect the brake lines Tighten the flare nuts to 15 N m 1 5 kgf m 11 Ibf ft 3 Connect the modulator unit and pump motor connectors 4 Bleed the brake system starting with the front wheels 5 Start the engine and check that the ABS indicator goes off 6 Test drive the ve...

Page 848: ... s 10 Remove the harness clip B and C 11 Remove the bolt at rear of the ABS control unit then pull out the ABS control unit HARNESS CLIP B CONNECTORS Inside the right kick panel ABSCONTROLUNIT HARNESS CLIP A HARNESS CLIP C MULTIPLEX CONTROL UNIT PASSENGER S 12 Install the ABS control unit in the reverse order of removal Inspection 1 Check the front and rear pulser for chipped or dam aged teeth 2 M...

Page 849: ...Wheel Sensor Replacement Install the sensors carefully to avoid twisting wires Front 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 Ibf ft WHEEL SENSOR Rear 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 Ibf ft WHEEL SENSOR ...

Page 850: ...Special Tools Ref No Tool Number Description Qty Page Reference 07PAZ 0010100 SCS Service Connector 19 159 ...

Page 851: ...TTERY 120 A FUSE UNDER HOOD RELAY BOX C FAIL SAFERELAY IG SW 50 A FUSE METER 15 A FUSE METERRELAY TCS 15 A FUSE STOP HORN 96 98 models 15 A FUSE 99 model 20 A FUSE UNDER HOOD FUSE RELAY BOX UNDER HOOD RELAY BOX C LEFT FRONT WHEEL SENSOR POWERTRAIN CONTROL MODULE PCM STEERING ANGLE SENSOR RIGHT REAR WHEEL SENSOR TCS CONTROL UNIT TCS CRUISE SWITCH UNDER DASH FUSE RELAY BOX UNDER DASH FUSE RELAY BOX ...

Page 852: ...t of wheel spin best suited to the driver s needs and if necessary will then signal the TCS control valve actuator and Powertrain Control Module PCM to reduce engine power The system is automatically ready whenever the engine is started but can be manually canceled with the TCS switch However once activated the system cannot be canceled until it is once again in the ready state Components Wheel se...

Page 853: ... expected yaw rates is substantial that is if the direction of the vehicle s body will exceed the driver s expected line the control unit signals the TCS control valve actu ator and PCM thus reducing engine power and maintaining the expected line RoughRoadControl Based on signals from the wheel sensors the control unit detects a rough road based on frequency of wheel rotational vibration The contr...

Page 854: ...light receiving part photo transistor As the disc rotates it interrupts the light from the LED The light which passes through a slit is converted into the electric current by the photo transistor and the waveform of this electric cur rent is shaped by the comparator to output the disc rota tion as a rectangular signal The analysis performance of the system is improved by providing the fixed slit i...

Page 855: ...gs Although the throttle valve is still within the driver s control the engine output is relaxed by the TCS control valve and PCM to achieve optimum traction TCS CONTROL VALVE SENSOR TCS CONTROL VALVE TCS CONTROL VALVE RETURN SPRINGS TCS CONTROL VALVE ACTUATOR DC MOTOR DURING NORMAL DRIVING DURING TCS ACTUATION TCS CONTROL VALVE TCS CONTROL VALVE ACTUATOR DC MOTOR TCS CONTROL VALVE RETURN SPRINGS ...

Page 856: ...l TCS TCSopera tion permission signal Detects steering angle sensorsignal B TCS Fl TCSopera tion start signal Detects TCS switch signal Reference voltage for the sensors of the PGM FI system Detectssteeringangle sensor signal A Detects throttle position sensor signal Voltage Measurement terminals 1 GND 2 GND 3 GND 4 GND 5 GND 6 GND 7 GND 8 GND 9 GND 10 GND 11 GND 12 GND 13 GND 14 GND Conditions Ig...

Page 857: ...position switch signal Detects engine speed signal Detects barometric sensor signal TCS Fl Fuel cut torque down signal Ground for the logic circuit Power source for the steering angle sensor Drives TCS indicator light The indicator light comes on by the self bias ShieldfortheTCScon trol valve actuator motor Drives TCS control valve actuator motor DrivesTCScontrol valve actuator motor Measurement t...

Page 858: ...atmospheric pressure sensor system of the PGM FI system is faulty 2 TCS does not function when the TCS indicator light is ON 3 When both the TCS indicator light and the MIL are ON troubleshoot the PGM FI system first 4 When both the TCS indicator light and the ABS indicator light are ON troubleshoot the ABS first 5 The DTC 4 9 ABS down is memorized when the ABS control unit cannot output the wheel...

Page 859: ...ne is started if the SCS service connector is con nected 5 Perform the DTC erasure SERVICE CHECK CONNECTOR 2P SCSSERVICECONNECTOR 07PAZ 0010100 DTC Indication Pattern TCS INDICATOR LIGHT Turn the ignition switch ON II The TCS indicator light comes on to check the bulb Do not count it as DTC The TCS control unit can memorize up to 3 DTCs A new DTC is not memorized when the TCS control unit has alre...

Page 860: ...conds the TCS indicator light should go off and blink 2 times then stay on This means that the DTC is erased NOTE Always follow these steps exactly If you connect the SCS service connector and or release the parking brake pedal dur ing these steps the DTC will not be erased If the TCS indicator light blinks repeatedly replace the TCS control unit Standard Indication Pattern Abnormal Indication Pat...

Page 861: ...NEP signal 3 4 Reference voltage VREF signal 3 5 Barometric pressure BARO signal 3 6 Throttle position sensor TPS signal 3 7 TCS control valve sensor TCV signal 4 1 Right front wheel sensor FRP signal 4 2 Left front wheel sensor FLP signal 4 4 Right rear wheel sensor RRP signal 4 8 Left rear wheel sensor RLP signal 4 9 ABS down 5 1 Fail safe relay stuck on 5 2 Ignition switch IG1 signal 5 3 5 4 In...

Page 862: ...angle sensor SteeringAngleSensorSystemCheck 1 Start the engine 2 Push the TCS switch 3 times within 3 seconds 3 Slowly turn the steering wheel clockwise more than 1 5 turns NOTE Start checking after the steering wheel moves at least 1 5 turns Turn the steering wheel slowly no faster than 1 turn in 4 seconds 4 Push the TCS switch twice within 3 seconds 5 Slowly turn the steering wheel counterclockw...

Page 863: ...arks NOTE When installing the duct align the cutout with mark VACUUM TUBE INTAKE AIR DUCT BANDSCREW INTAKE AIR DUCT 3 Disconnect the TCS control valve angle sensor connector and actuator connector 4 Remove the TCS control valve assembly and bracket 5 Install the TCS control valve assembly in the reverse order of removal TCS CONTROLVALVEANGLE SENSOR CONNECTOR 6 x 1 0 mm BOLT 12 N m 1 2 kgf m 9 Ibf ...

Page 864: ...n light circuit and between termi nal No 3 and No 4 switch circuit There should be continuity when the switch is pushed and there should be no continuity when the switch is released 1 Remove the rear seat back see section 20 2 Disconnect the connectors from TCS control unit TCS CONTROL UNIT 3 Remove the three bolts and the TCS control unit 4 Install in the reverse order of removal ...

Page 865: ...Special Tools Ref No Tool Number Description Qty PageReference 07PAZ 0010100 SCS Service Connector 19 206 ...

Page 866: ...Special Tools 19 7 ...

Page 867: ... C UNDER HOOD FUSE RELAY BOX VSA OFF SWITCH UNDER DASH FUSE RELAY BOX LEFT FRONT WHEEL SENSOR LEFT REAR WHEEL SENSOR GAUGE ASSEMBLY ABS INDICATOR VSA SYSTEM INDICATOR UNDER HOOD FUSE RELAY BOX STOP HORN 20 A FUSE BRAKE SYSTEM INDICATOR VSA ACTIVATION INDICATOR UNDER DASH FUSE RELAY BOX TCS 15 A FUSE VSA 20 A FUSE METER 15 A FUSE ECU 20 A FUSE METER 7 5 A FUSE BATTERY 120 A FUSE VSA MOTOR 40 A FUSE...

Page 868: ...Terminal Arrangement VSA CONTROL UNIT 42P CONNECTOR Wire side of female terminals ...

Page 869: ...es VSA system indicator Detects brake fluid level switch signal Detects parking brake switch signal Power source for the yaw rate lateral acceleration sensor Communication signal Detects yaw rate sensor signal Power source for the pressure sensor Measurement WiththeVSAcontrol unit42P connector disconnected Terminals 23 GND 27 GND 28 13 29 14 30 31 32 GND 33 GND 36 GND 38 GND Conditions Ignition sw...

Page 870: ...Terminal Arrangement VSA CONVERTER UNIT 26P CONNECTOR Wire side of female terminals ...

Page 871: ...Terminal number Wire color Terminal sign Description Measurement With the VSA converter unit 26P connectorconnected Terminals Conditions Voltage ...

Page 872: ...gnition switch is turned from OFF to ON II However if the DTC is cleared the CPU resets and the indicator goes off right after the engine is started if the system is OK The ABS is not operational when the ABS indicator is ON the VSA is not operational when the VSA indicator is ON When the VSA indicator and MIL are both ON troubleshoot the PGM FI system first DiagnosticTroubleCode DTC The memory ca...

Page 873: ...ion the customer about the conditions when the problem occurs and try to reproduce the same conditions for troubleshooting Find out when the ABS indicator and or VSA system indicator came on such as during ABS control after ABS control when vehicle speed was at a certain speed etc 2 When the ABS indicator or VSA system indicator does not come on during the test drive but troubleshooting is per for...

Page 874: ...o off for 3 6 seconds and then come back on If the ABS indicator stays on troubleshoot for ABS indicator does not go off see page 19 213 4 Turn the ignition switch OFF and remove the SCS service connector NOTE The Malfunction Indicator Lamp MIL will stay on after the engine is started if the SCS service connector is con nected ConditionsforDTCindication Vehicle speed is 6 mph 10 km h or less The S...

Page 875: ...N II 3 Hold the VSA off switch for 3 to 5 seconds then release the VSA off switch 4 After 3 seconds the VSA activation indicator blinks 4 times It means that the DTC is cleared 5 If the VSA activation indicator stays on replace the VSA modulator control unit Standard Indication Pattern Abnormal Indication Pattern ...

Page 876: ...11 13 15 17 12 14 16 18 25 26 27 31 32 33 34 35 36 37 38 45 46 47 48 51 52 53 54 55 58 REFER TO PAGE 19 210 19 211 19 213 19 215 19 217 19 219 19 220 19 221 19 222 19 223 19 226 19 228 19 230 19 231 19 232 19 233 19 234 See page 19 236 00 01 or 19 3a 02 04 ...

Page 877: ... 84 86 88 92 93 94 95 96 97 98 REFER TO PAGE 19 237 19 238 19 239 19 240 19 241 19 243 19 244 19 245 19 246 19 251 19 252 19 254 19 255 19 257 19 258 19 260 19 262 See page 19 247 00 01 or 19 5a 02 04 See page 19 265 00 01 or 19 6a 02 04 ...

Page 878: ...the combination switch 3 Install in the reverse order of removal CAUTION Do not apply any grease or oil to the steering angle sensor 4 Perform the steering angle sensor neutral position memorizing procedure see page 19 268 SCREWS STEERING ANGLE SENSOR COMBINATION SWITCH CANCEL CAM WAVE WASHER SPRING JOINT LOWERCOVER CIRCLIP NOTE When reassembling align the tabs of the joint and cancel cam to the s...

Page 879: ... The VSA activation indicator comes on for 0 3 seconds then the indicator goes off 0 2 seconds and comes on 5 Turn the steering wheel from the straight ahead position to the right until the VSA activation indicator goes off within 8 seconds after the VSA activation indicator comes on 6 Turn the steering wheel from the straight ahead position then to the left until the VSA activation indicator goes...

Page 880: ...en goes off 3 Press the VSA off switch one time before the VSA activation indicator comes on again 4 Check that the VSA activation indicator comes on when the steering wheel is in the straight ahead position neutral position and the indicator goes off when the steering wheel turns to the right or left more than 2 5 degrees 5 If the VSA activation indicator does not come on or go off perform the ne...

Page 881: ...onds goes off for 0 2 seconds then come back on The ABS indicator blinks DTC 84 This code will clear after the steering angle sensor neutralization has been success fully completed NOTE Do steps 4 7 in less than 7 seconds 4 Turn the steering wheel from the straight ahead position to the right about 20 degrees until the VSA activation indica tor goes off Return the steering wheel to the straight ah...

Page 882: ...VSA modulator control unit then tighten the two 8 mm nuts 2 Align the connecting surfaces of the VSA control unit 42P connector 3 Push the locking lever of the VSA control unit 42P connec tor down until you hear a click 4 Connect the pressure sensor 3P connector 5 Connect the six brake lines 6 Perform the precharge brake line bleeding see page 19 271 7 Bleed the brake system starting with the fron...

Page 883: ...isconnect the six brake lines 4 Remove the two 8 mm nuts 5 Remove the VSA modulator control unit Installation 1 Install the VSA modulator control unit then tighten the two 8 mm nuts 2 Align the connecting surfaces of the VSA control unit 42P connector 3 Push the locking lever of the VSA control unit 42P con nector down until you hear a click 4 Connect the pressure sensor 3P connector 5 Connect the...

Page 884: ...acket 4 Remove the two 6 mm bolts and 8 mm nut then remove the precharge pump motor Installation 1 Install the precharge pump motor on the bracket then tighten the two 6 mm bolts and the 8 mm nut 2 Install the precharge pump motor with bracket then tighten the three 6 mm bolts 3 Connect the brake line and the brake hose on the precharge pump motor 4 Perform the precharge brake line bleeding see pa...

Page 885: ...VSA off switch after the VSA activation indicator goes off twice 6 Press the VSA off switch after the VSA activation indicator comes on 7 Release the VSA off switch after the VSA activation indicator goes off 8 Press the VSA off switch after the VSA activation indicator starts blinking 9 Release the VSA off switch after the VSA activation indicator stops blinking 10 Turn the ignition switch OFF th...

Page 886: ...se the VSA off switch after the VSA activation indicator goes off twice 6 Press the VSA off switch after the VSA activation indicator comes on 7 Release the VSA off switch after the VSA activation indicator goes off 8 Press the VSA off switch after the VSA activation indicator starts blinking 9 Release the VSA off switch after the precharge pump motor stops running 10 Turn the ignition switch OFF ...

Page 887: ...s NOTE When installing the duct align the cutout with the mark VACUUMTUBE INTAKEAIRDUCT BAND SCREW INTAKE AIR DUCT 3 Disconnect the TCS control valve angle sensor connector and actuator connector 4 Remove the TCS control valve assembly and bracket 5 Install the TCS control valve assembly in the reverse order of removal TCS CONTROL VALVE ANGLE SENSOR CONNECTOR 6 x 1 0 mm BOLT 12 N m 1 2 kgf m 9 Ibf...

Page 888: ...ox back cover 3 Remove the right front door trim 4 Remove the right kick panel 5 Lift up the floor mat 6 Remove the PCM cover 7 Remove the connectors inside of the right kick panel 8 Remove the harness clip A from the VSA converter unit then remove the bolt on the lower side of the VSA converter unit 9 Remove the multiplex control unit passenger s 10 Remove the harness clip B and C 11 Remove the b...

Page 889: ...er of removal 6 mm NUT 9 8 N m 1 0 kgf m 7 2 Ibf ft 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 Ibf ft YAW RATE LATERAL ACCELERATION SENSOR SENSORCOVER Inspection 1 Check the front and rear pulser for chipped or dam aged teeth 2 Measure the air gap between the wheel sensor and pulser all the way around while rotating the pulser If the gap exceeds 1 0 mm 0 04 in check for a bent suspension arm Standard Front R...

Page 890: ...Wheel Sensor Replacement Install the sensors carefully to avoid twisting wires Front 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 Ibf ft WHEEL SENSOR Rear 6 mm BOLT 9 8 N m 1 0 kgf m 7 2 Ibf ft WHEEL SENSOR ...

Page 891: ...s 20 45 04 Model 20 2c Carpet Removal 20 46 Console Panel Rear Console Removal 96 98 Models 20 48 99 04 Models 20 49 Dashboard Component Removal Installation 20 50 Removal 20 54 Seats Component Location Index 20 56 Front Seat Removal 20 57 Disassembly Driver s 96 03 Models 20 58 04 Model 20 4c Passenger s 20 59 Seat Cover Replacement 96 03 Models 20 60 04 Model 20 6c Seat Linkage Disassembly 20 63...

Page 892: ... POWER WINDOW SWITCH POWER WINDOW SWITCH DOOR POCKET LOWER PAD ARMREST PAD SWITCH TRIM POWER SEAT MEMORY SWITCH driver s POWER MIRROR SWITCH driver s TRUNK LID OPENER SWITCH driver s Passenger s SWITCH PANEL SWITCH PANEL DOOR POCKET DOOR PANEL Removal page 20 4 DOOR PROTECTOR TWEETER GRILLE TWEETER for some models STOP LOCK KNOB COVER DYNAMIC DAMPER SWITCH BRACKET SPEAKER SPACER ADAPTER DETENT ROD...

Page 893: ...age 20 18 GLASS RUN CHANNEL FRONT CHANNEL OUTER HANDLE COVER OUTER HANDLE Removal page 20 5 POWER DOOR LOCK SWITCH LATCH Removal page 20 5 REGULATOR Removal page 20 7 CYLINDER SWITCH OUTER HANDLE BASE SEAT B SEAT A LOCKCYLINDER INNER HANDLE CABLE INNER HANDLE TRIM PLATE LATCH PROTECTOR ...

Page 894: ...or breaking it TRIM PAD REMOVER Commercially available Snap on A177 or equivalent 12 mm 0 47 in 1 mm 0 04 in 45 mm 1 77 in Clip locations DOOR PANEL TRIMPAD REMOVER DOOR PANEL STOP 3 Disconnect the connectors and inner handle cable SECURITY INDICATOR CONNECTOR driver s POWERSEAT MEMORY SWITCH CONNECTOR driver s COURTESY LIGHT CONNECTOR TWEETER CONNECTOR for some models POWER WINDOW SWITCH CONNECTO...

Page 895: ...SS RUN CHANNEL REAR LOWER CHANNEL 3 Remove the outer handle cover then remove the lock cylinder NOTE Take care not to drop the bolt inside the door Remove in numbered sequence Bolt locations 4 x 0 8 mm 3 N m 0 3 kgf m 2 Ibf ft CYLINDER ROD Disconnect COLLAR 5 x 0 8 mm 5 N m 0 5 kgf m 4 Ibf ft OUTER HANDLE BASE HOLE SEAL OUTER HANDLE COVER OUTER HANDLE BASE CLIPS CYLINDER SWITCH CONNECTOR Disconnec...

Page 896: ...er handle base using diagonal cutters NOTE To ease reassembly note location of the outer handle rod on the joint before disconnecting it Take care not to bend the rods Screw locations 6 x 1 0 mm 5 N m 0 5 kgf m 4 Ibf ft Nut location 1 OUTER HANDLE ROD DIAGONAL CUTTERS 6 x 1 0 mm 8 N m 0 8 kgf m 6 Ibf ft CYLINDER ROD OUTER HANDLE ROD BUSHING Replace OUTER HANDLE BASE CLIP LATCH CLIP CONNECTOR 7 Ins...

Page 897: ...t the connector then remove the regula tor through the hole in the door Bolt locations 7 6 x 1 0 mm 8 N m 0 8 kgf m 6 Ibf ft CONNECTOR Loosen REGULATOR POWER WINDOW MOTOR 4 Grease all the sliding surfaces of the regulator where shown 5 Installation is the reverse of the removal procedure NOTE Roll the glass up and down to see if it moves freely without binding Also make sure that there is no clear...

Page 898: ... SASH TRIM GLASS RUN CHANNEL Loosen 3 Installation is the reverse of the removal procedure NOTE Make sure the glass run channel and outer weatherstrip are installed securely Inner Sash Trim Removal NOTE Lower the glass fully Take care not to scratch the inner sash trim Remove the door panel see page 20 4 Clip locations INNER SASH TRIM Installation is the reverse of the removal procedure NOTE If ne...

Page 899: ...ulator mount ing bolts 4 Push the glass rearward front door glass or for ward rear door glass Front GLASS REGULATOR Rear GLASS REGULATOR 5 Tighten the glass mounting bolts and regulator mounting bolts 6 Loosen the front channel mounting bolts or rear channel mounting bolts 7 Lower the glass 8 Push the front channel or rear channel against the glass then tighten each mounting bolt Front GLASS FRONT...

Page 900: ...glass contacts the glass run channel evenly OUTER WEATHERSTRIP GLASS RUN CHANNEL GLASS 12 Check for water leaks Spray water over the roof and on the sealing area as shown NOTE Adjust the water pressure as shown Do not squeeze the tip of the hose HOSE HOSE 300 mm 11 8 in 13 Reinstall all removed parts in the reverse order of removal ...

Page 901: ...DOOR MOUNTING BOLTS 8 x 1 25 mm 29 N m 3 0 kgf m 22 Ibf ft Loosen the door mounting bolts slightly to move the door in or out until it s flush with the body If necessary you can install a shim behind one hinge to make the door edges parallel with the body HINGE MOUNTING BOLTS 8 x 1 25 mm 29 N m 3 0 kgf m 22 Ibf ft Remove the inner fender loosen the hinge mounting bolts and move the door backward o...

Page 902: ...ld the outer handle out and push the door against the body to be sure the striker allows a flash fit If the door latches properly tighten the screws and recheck Power Mirror Removal NOTE Take care not to scratch the mirror and door 1 Raise the glass fully 2 Remove the door panel see page 20 4 then remove the plastic cover as needed 3 Disconnect the connector and detach the clip Remove the nuts det...

Page 903: ...RSTRIP INNER WEATHERSTRIP OUTER MOLDING COURTESY LIGHT DOOR PROTECTOR DOOR PANEL Removal page 20 11 LOWER PAD POWER WINDOW SWITCH ASHTRAY SPEAKER COVER ARMREST PAD SWITCH PANEL STOP SPEAKER DOOR Adjustment page 20 17 ADAPTER DETENT ROD LOCK KNOB COVER SPACER PLASTIC COVER INNER MOLDINGS HINGE ...

Page 904: ... 20 13 Adjustment page 20 16 GLASS RUN CHANNEL LATCH Removal page 20 12 FRONT LOWER CHANNEL OUTER HANDLE COVER OUTER HANDLE Removal page 20 12 LOCK CRANK TRIM PLATE INNER HANDLE REAR CHANNEL REGULATOR Removal page 20 13 OUTER HANDLE HOLDER OUTER HANDLE BASE ROD PROTECTOR INNER HANDLE CABLE LOCK ROD SEAT A SEATB ...

Page 905: ...sconnect the connectors and inner handle cable NOTE Remove the door panel with as little bend ing as possible to avoid creasing or breaking it 95 mm 3 74 in TRIM PAD REMOVER Commercially available Snap on A177 or equivalent 12 mm 0 47 in 1 mm 0 04 in 45 45 mm 1 77 in Clip locations DOOR PANEL CLIP POWER WINDOW SWITCH CONNECTOR INNER HANDLE CABLE STOP DOOR PANEL ASHTRAY LIGHT COURTESY LIGHT CONNECT...

Page 906: ...emove the outer handle holder NOTE Take care not to drop the bolt inside the door Remove in numbered sequence Bolt locations COLLAR 4 x 0 8 mm 3 N m 0 3 kgf m 2 Ibf ft OUTER HANDLE COVER OUTER HANDLE BASE OUTER HANDLE HOLDER HOLE SEAL 4 Remove the outer handle as shown OUTER HANDLE BASE LEVER SEAT B 5 Remove the seat A then loosen the bolt OUTER HANDLE BASE SEAT A 5 x 0 8 mm 5 N m 0 5 kgf m 4 Ibf ...

Page 907: ...outer handle base through the hole in the door Pry the outer handle rod out from the outer handle base using diagonal cutters NOTE To ease reassembly note location of the outer handle rod on the joint before disconnecting it Take care not to bend the rods 7 Installation is the reverse of the removal procedure NOTE Make sure the door locks and opens properly ...

Page 908: ... cover see page 20 9 Inner molding see page 20 9 Inner sash trim see page 20 15 Sash trim see page 20 15 2 Carefully move the glass until you can see the bolts then remove them Carefully pull the glass out through the window slot NOTE Take care not to drop the glass inside the door ...

Page 909: ... remove the regula tor through the hole in the door Bolt locations 7 6 x 1 0 mm 8 N m 0 8 kgf m 6 Ibf ft CONNECTOR Loosen POWER WINDOW MOTOR 6 Grease all the sliding surfaces of the regulator where shown 7 Installation is the reverse of the removal procedure NOTE Roll the glass up and down to see if it moves freely without binding Also make sure that there is no clearance between the glass and gla...

Page 910: ...SH TRIM GROMMET GLASS RUN CHANNEL Loosen 3 Installation is the reverse of the removal procedure NOTE Make sure the glass run channel and outer weatherstrip are installed securely Inner Sash Trim Removal NOTE Lower the glass fully Take care not to scratch the inner sash trim Remove the door panel see page 20 11 Clip locations INNER WEATHERSTRIP CLIP GLASS RUN CHANNEL INNER SASH TRIM INNER SASH TRIM...

Page 911: ...ulator mount ing bolts 4 Push the glass rearward front door glass or for ward rear door glass Front GLASS REGULATOR Rear GLASS REGULATOR 5 Tighten the glass mounting bolts and regulator mounting bolts 6 Loosen the front channel mounting bolts or rear channel mounting bolts 7 Lower the glass 8 Push the front channel or rear channel against the glass then tighten each mounting bolt Front GLASS FRONT...

Page 912: ...glass contacts the glass run channel evenly OUTER WEATHERSTRIP GLASS RUN CHANNEL GLASS 12 Check for water leaks Spray water over the roof and on the sealing area as shown NOTE Adjust the water pressure as shown Do not squeeze the tip of the hose HOSE HOSE 300 mm 11 8 in 13 Reinstall all removed parts in the reverse order of removal ...

Page 913: ...DOOR MOUNTING BOLTS 8 x 1 25 mm 29 N m 3 0 kgf m 22 Ibf ft Loosen the door mounting bolts slightly to move the door in or out until it s flush with the body If necessary you can install a shim behind one hinge to make the door edges parallel with the body HINGE MOUNTING BOLTS 8 x 1 25 mm 29 N m 3 0 kgf m 22 Ibf ft Remove the inner fender loosen the hinge mounting bolts and move the door backward o...

Page 914: ...ld the outer handle out and push the door against the body to be sure the striker allows a flash fit If the door latches properly tighten the screws and recheck Power Mirror Removal NOTE Take care not to scratch the mirror and door 1 Raise the glass fully 2 Remove the door panel see page 20 4 then remove the plastic cover as needed 3 Disconnect the connector and detach the clip Remove the nuts det...

Page 915: ...p screwdriver CAUTION When prying with a flat tip screwdriver wrap it with a shop towel to prevent damage ADHESIVE TAPE HOOKS MIRROR HOUSING SHOP TOWEL MIRROR HOLDER 2 Detach the hooks disconnect the defogger connec tor if so equipped then remove the mirror holder from the actuator ACTUATOR HOOK DEFOGGER CONNECTOR MIRROR HOLDER 3 Installation is the reverse of the removal procedure ...

Page 916: ...nt damage 2 Loosen the lock bolt then slide the mirror stay from the lug LUG REARVIEW MIRROR MIRROR STAY LOCK BOLT Counterclockwise to loosen COVER 3 Remove the lock bolt then remove the toothed lock washer and hold spring from the mirror stay LOCK BOLT Left hand threads TOOTHED LOCK WASHER HOLD SPRING HOOK PLATE MIRROR STAY 4 Installation is the reverse of the removal procedure ...

Page 917: ...irror bracket with a flat tip screwdriver and a plastic hammer Remove the mirror from the lug LUG SPRING REARVIEW MIRROR 4 Remove the wire cover from the mirror bracket by releasing the hooks in the sequence shown HOOK MIRROR BRACKET WIRE COVER HOOK 5 Install the rearview mirror by sliding it over the lug until its spring contacts the lug Gently tap the mir ror bracket with a flat tip screwdriver ...

Page 918: ...en prying with a flat tip screwdriver wrap it with protective tape to prevent damage HARNESS COVER CLIP HOOK HOOK UPPER COVER REARVIEW MIRROR HARNESS UPPER COVER REARVIEWMIRROR HARNESS COVER CLIP 3 Disconnect the connector and loosen the screw with a Torx T20 bit then slide the rearview mirror rearward and off the lug LUG CONNECTOR SCREW 5 x 0 8 mm 2 8 N m 0 29 kgf m 2 1 Ibf ft Loosen REARVIEWMIRR...

Page 919: ...BBER DAM SIDESPACER 4 SIDESPACER 4 Required for replacement or reinstallation SIDE FASTENER 2 Clip type body side Required for replacement or reinstallation SIDEFASTENER 2 Self adhesive type glass side Required for replacement or reinstallation DEFOGGER SEAL MOLDING SEAL 2 MOLDING CORNER SEAL 2 97 01 models LOWER RUBBER DAM Required for replacement or reinstallation SIDE RUBBER DAM 2 Required for ...

Page 920: ...ake care not to bend the headliner excessively 4 Apply protective tape along the edge of the dash board and body as shown Using an awl make a hole through the rubber dam and adhesive from inside the vehicle Push the piano wire through the hole and wrap each end around a piece of wood PROTECTIVE TAPE PIANO WIRE WINDSHIELD PROTECTIVE TAPE PIANO WIRE DASHBOARD ADHESIVE LOWER RUBBER DAM 5 With a helpe...

Page 921: ...ce with alcohol where new adhesive is to be applied NOTE Make sure the bonding surface is kept free of water oil and grease CAUTION Avoid setting the windshield on its edges small chips may later develop into cracks NOTE Clean the shadowed area Cleanarea as shown WINDSHIELD lnside WINDSHIELD 4 Glue the rubber dams defogger seal and fasteners to the inside face of the windshield as shown NOTE Be ca...

Page 922: ...teners to the body as shown Fastener locations 2 8 Set the windshield then center it in the opening Make alignment marks across the windshield and body with a grease pencil at the four points shown NOTE Be careful not to touch the windshield where adhesivewill be applied ALIGNMENT MARK WINDSHIELD 9 Remove the windshield 2 5 mm 0 98in MOLDING CORNER SEAL Apply primer 3M N 200 or equivalent to edge ...

Page 923: ...1166 Canada Model JH4KA9656TC800364 11 With a sponge apply a light coat of body primer to the original adhesive remaining around the wind shield opening flange Let the body primer dry for at least 10 minutes NOTE Do not apply glass primer to the body and be care ful not to mix up glass and body primer sponges Never touch the primed surfaces with your hands Mask off the dashboard before painting th...

Page 924: ...K 15 SUCTION CUPS WINDSHIELD Scrape or wipe the excess adhesive off with a putty knife or towel NOTE To remove adhesive from a painted surface or the windshield wipe with a soft shop towel dampened with alcohol 16 Let the adhesive dry for at least 1 hour then spray water over the windshield and check for leaks Mark the leaking areas let the windshield dry then seal with sealant NOTE Let the vehicl...

Page 925: ...20 45 CAUTION Take care not to bend the headliner exces sively 3 Disconnect the rear window defogger connectors and window antenna connectors TERMINAL BASE COVER REAR WINDOW DEFOGGER CONNECTORS 4 Remove the lower molding then remove the remain ing molding NOTE If necessary replace any damaged molding holders and clips Molding holder locations 7 MOLDING REAR WINDOW MOLDING LOWER MOLDING Molding hol...

Page 926: ...sh the piano wire through the hole and wrap each end around a piece of wood 6 With a helper on the outside pull the piano wire back and forth in a sawing motion and carefully cut through the adhesive around the entire rear win dow CAUTION Hold the piano wire as close to the rear window as possibleto prevent damagetothe body 7 Carefully remove the rear window ...

Page 927: ... and spacers from the body 2 Clean the body bonding surface with a sponge dampened in alcohol NOTE After cleaning keep oil grease and water from getting on the surface 3 If the old rear window is to be reinstalled use a putty knife to scrape off all traces of old adhesive and the rubber dam then clean the rear window surface with alcohol where new adhesive is to be applied NOTE Make sure the bondi...

Page 928: ...window NOTE Be careful not to touch the rear window where adhesive will be applied GLASS MOLDING ADHESIVE TAPE MOLDING REAR WINDOW 50 mm 2 in Apply primer 3M N 200 or equivalent to edge of the windshield 6 Install the fasteners to the body as shown ALIGNMENT MARKS TERMINAL BASE COVER 13 mm 0 51 in ALIGNMENT MARKS LOWER SPACER SIDE FASTENER 13 mm 0 51 in 13 mm 0 51 in UPPER FASTENER ALIGNMENT MARKS...

Page 929: ...dhesive may not bond to the rear window properly causing a leak after the rear window is installed Keep water dust and abrasive materials away from the primed surface Apply glass primer here REAR WINDOW 10 With a sponge apply a light coat of body primer to the original adhesive remaining around the rear window opening flange Let the body primer dry for at least 10 minutes NOTE Do not apply glass p...

Page 930: ...REAR WINDOW SUCTION CUPS 14 Scrape or wipe the excess adhesive off with a putty knife or towel NOTE To remove adhesive from a painted surface or the rear window use a soft shop towel damp ened with alcohol 15 Install the lower molding Molding holder locations 7 Before installing push the screw grommet LOWER MOLDING 16 Let the adhesive dry for at least 1 hour then spray water over the rear window a...

Page 931: ... B Adjustment page 20 40 GROUND PLATE RAIL HOLDER A FRAME SEAL TUBE CLIP CLIP Right side FRAME Removal page 20 36 REAR DRAIN VALVE FRONT DRAIN VALVE FRONT DRAIN TUBE REAR DRAIN TUBE TUBE CLIP GUIDE RAIL Replacement page 20 37 MOTOR Removal page 20 36 INNER CABLE HOLDER COVER RAIL HOLDER B GLASSBRACKET Removal page 20 34 SHIMS DRAIN CHANNEL SWITCH PLATE A Adjustment page 20 39 ...

Page 932: ...ed Control unit connector not connected properly Defective limit switch Defective control unit Clutch out of adjustment Foreign matter stuck between guide rail and slider Inner cable loose Cable assembly not attached properly Blown fuse Faulty switch Battery run down Defective motor Faulty relay Glass Height Adjustment The roof panel should be even with the glass weather strip to within 1 7 mm 0 0...

Page 933: ...ass brackets GLASS BRACKET 6 x 1 0 mm 9 N m 0 9 kgf m 7 Ibf ft 5 Remove the glass by lifting up and pulling forward as shown NOTE Do not damage the roof panel GLASS SCREW 7 Remove the holder cover then remove the rail holder B 6 x 1 0 mm 9 N m 0 9 kgf m 7 Ibf ft COVER GUIDE PIN 8 Using the moonroof wrench move the glass bracket to the position where the moonroof normally pivots down and remove the...

Page 934: ...ing the cable slider forward using the moonroof wrench 11 Detach the drain channel rod stop from the cutout of the guide rail as shown 12 Slide the sunshade forward then remove it SUNSHADE 13 Installation is the reverse of the removal procedure NOTE Checkthe glass height see page 20 33 14 Check for water leaks NOTE Do not use high pressure water DRAIN CHANNEL ROD DRAIN CHANNEL ROD SLIDER GLASS BRA...

Page 935: ...emove the motor 3 Remove the glass see page 20 34 4 Disconnect the drain tubes 5 Remove the frame mounting bolts NOTE An assistant is helpful when removing the bolts Remove the front bolts last 6 Detach the rear hooks by moving the frame forward then remove the frame Bolt locations Nut locations 3 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 6 x 1 0 mm 9 8 N m 1 ...

Page 936: ...ure NOTE Before installing the frame clear the drain tubes and drain valves by using compressed air Check the frame seal Clean the surface of the frame When installing the frame first attach the rear hooks into the body holes When connecting the drain tube slide it over the frame nozzle at least 10 mm 0 39 in Install the tube clip as shown 9 Check for water leaks NOTE Do not use high pressure wate...

Page 937: ...t CAUTION Put on gloves to protect your hands 1 Remove the frame see page 20 36 2 Disconnect the connectors detach the harness clips and remove the adhesive tapes from the frame 3 Remove the motor glass bracket and sunshade see page 20 34 ...

Page 938: ...0 9 kgf m 7 Ibf ft SLIDER GUIDE RAIL FRAMESEAL FRAME GROMMET FRAME GROUND PLATE CABLE TUBES CABLE ASSEMBLY MOTOR SEALANT 5 Installation is the reverse of the removal procedure NOTE Damaged parts should be replaced Grease the sliding portion with Super High Temp Urea Grease P N 08758 9002 Fill the groove in each grommet with sealant Install the frame seal securely Before installing the motor make s...

Page 939: ...4 Adjust position of switch plate A switch cam as shown NOTE Move switch plate A a little at a time then secure switch plate A at the position where the switch cam contacts the closed position switch a faint click is heard Check that switch plate A contacts the cable bracket CABLE BRACKET CLOSED POSITION SWITCH OPEN END WRENCH SWITCH PLATE A Forward SLIDER SWITCH PLATEA INNER CABLE END SWITCH CAM ...

Page 940: ...position where the switch cam contacts the auto stop position switch a faint click is heard Check that switch plate B contacts the cable bracket SWITCH CAM INNER CABLE END SWITCH PLATE B AUTO STOP POSITION SWITCH OPEN END WRENCH SWITCH PLATE B Forward CABLE BRACKET CABLE BRACKET BOLTS GLASS 130 mm 5 1 in 8 Check the operation of the glass from the tilt up position to the fully closed position from...

Page 941: ...lass while you mea sure the force required to stop it Attach a spring scale as shown Read the force as soon as the glass stops moving then immediately release the switch and spring scale CAUTION When using a spring scale protect the leading edge of the glass with a shop towel Closing Force 200 290 N 20 30 kgf 44 66 Ibf SHOP TOWEL 2 SPRING SCALE If the force in not within specification install a ne...

Page 942: ...LF see page 20 43 TRUNK SIDE TRIM see page 20 44 FRONT SIDE TRIM see page 20 43 CONSOLE PANEL Removal page 20 48 REAR TRIM PANEL see page 20 44 REAR SIDE TRIM see page 20 43 TRUNK FRONT TRIM see page 20 44 REAR CONSOLE Removal 96 98 Models page 20 48 Removal 99 01 Models page 20 49 CARPET Removal page 20 46 SPARETIRE LID REAR PILLAR TRIM see page 20 43 ROOF SIDE TRIM see page 20 43 CENTER PILLAR T...

Page 943: ...ee section 24 REAR SHELF Remove the rear seat cushion and rear seat back see page 20 65 98 01 models Remove the center seat belt lower anchor bolt see section 24 00 01 models Remove the child seat tether anchors see section 24 SLIDER SHOULDER ANCHOR ADJUSTER Installation is the reverse of the removal procedure NOTE If necessary replace any damaged clips Before installing the center pillar trim low...

Page 944: ...Screw locations 2 TRUNK SIDE BOX TRUNK HOOK RIGHT TRUNK SIDE TRIM NOTE Do not push the inner clip in too far CLIP REARTRIM PANEL CDCHANGER COVER for some models LEFTTRUNK SIDE TRIM TRUNK FRONT TRIM Installation is the reverse of the removal procedure NOTE If necessary replace any damaged clips To install the F clips pull the inner clip up install the clip then push the inner clip until it s flush ...

Page 945: ...t and rear side trim see page 20 43 Front and rear door trim see page 20 43 Center pillar trim see page 20 43 Front pillar trim see page 20 43 Rear pillar trim see page 20 43 Roof side trim see page 20 43 Ceiling lights see section 23 Window antenna terminal cover see page 20 27 Moonroof switch see section 23 3 Remove the sunvisor and holder from each side Disconnect both positive terminals or 2P ...

Page 946: ...headliner through the passenger s door opening 7 Installation is the reverse of the removal procedure NOTE When inserting the headliner through the door opening be careful not to fold or bend it Also be careful not to scratch the body Check that both sides of the headliner are securely attached to the trim When installing the roof trim install the joint toward the rear ...

Page 947: ... side trim Front and rear door trim Center pillar trim Front pillar trim Rear pillar trim Roof side trim Window antenna terminal cover Remove these items Refer to the 96 01 Acura 3 5 RL Service Manual P N 61SZ305 see section 23 Ceiling lights Moonroof switch 4 Remove the sunvisor and holder from each side Disconnect both positive terminals 5 Detach the clips and hooks then remove the homelink and ...

Page 948: ...tallation is the reverse of the removal procedure and note these items When inserting the headliner through the door opening be careful not to fold or bend it Also be careful not to scratch the body Check that both sides of the headliner are securely attached to the trim When installing the roof trim install the joint toward the rear Make sure each connector is plugged in properly ...

Page 949: ...m see page 20 43 Front seat belt lower anchor see section 24 Center pillar trim see page 20 43 Rear heater cover see page 20 48 Console panel and rear console 96 98 models see page 20 48 Console panel and rear console 99 01 models see page 20 49 Dashboard lower cover passenger s see page 20 53 Glove box see page 20 53 Opener cover see page 20 89 2 Remove the accelerator pedal stop and footrest Bol...

Page 950: ...NERS RETAINERS SEAT CUSHION CLIP SEAT CUSHION CLIP SEAT HARNESS 5 Installation is the reverse of the removal procedure NOTE Take care not to damage wrinkle or twist the carpet Make sure the seat harness is routed correctly If necessary replace any damaged clips Reattach the cut area in the carpet with a wire tie as follows a Tie a string to the end of the carpet then slip the carpet under the heat...

Page 951: ...OR TRIM Disconnect the seat heater switch connectors and indicator light bulb socket CONSOLE PANEL Disconnect the cigarette lighter connector Clip locations SEAT HEATER SWITCH driver s SEATHEATER SWITCH passenger s BEVERAGE HOLDER CIGARETTE LIGHTER CONNECTOR REAR CONSOLE REAR HEATER COVER Installation is the reverse of the removal procedure NOTE If necessary replace any damaged clips Make sure the...

Page 952: ... removal procedure NOTE If necessary replace any damaged clips Make sure the wire harnesses are not pinched Make sure the connectors and bulb socket are connected properly BEVERAGE HOLDER TRAY Disconnect the beverage holder bulb socket BEVERAGE HOLDER REAR CONSOLE Disconnect the accessory power socket and detach theharnessclip REAR HEATER COVER CONSOLE PANEL Disconnect the cigarette lighter connec...

Page 953: ...ve left side by rolling upward Pull top down SELECT RESET SWITCH CONNECTOR HOOK Pull right side straight out HOOK SIDE AIR VENT Push the clip from driver sswitchtrim opening 5 Installation is the reverse of the removal procedure NOTE Make sure the connectors are connected properly Dashboardlowercover Detach the clips then remove the dashboard lower cover DASHBOARD LOWER COVER Installation is the r...

Page 954: ...the radio s preset buttons Remove the bolts then pull out the climate control unit and audio unit as an assembly Disconnect the connectors and antenna leads then remove it Bolt locations 4 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft CLIMATE CONTROL UNIT CONNECTORS CLIMATE CONTROL UNIT HAZARD WARNING SWITCH CONNECTOR CLOCK CONNECTOR AUDIO UNIT FRONT FOG LIGHT SWITCH CONNECTOR ANTENNA LEADS AUDIO UNIT C...

Page 955: ...the climate control unit audio unit and center air vent as an assembly and carefully detach the clip at the center air vent Disconnect the connectors and antenna leads then remove it Bolt locations 4 6 x 1 0 mm 9 8 N m 1 0kgf m 7 2 Ibf ft Clip locations 4 CLIP CENTER AIR VENT CLIMATE CONTROL UNIT HAZARD WARNING CLIMATE SWITCH CONTROL UNIT CONNECTOR CONNECTORS CLOCK CONNECTOR AUDIO UNIT FRONT FOG L...

Page 956: ...glove box and disconnect the connector 4 Remove the bolts then remove the glove box 5 Remove the glove box back cover Clip locations 4 GLOVE BOX BACK COVER 6 Installation is the reverse of the removal procedure Passenger s dashboard panel 1 Remove the side air vent 2 Carefully detach the clips then pull out the passen ger s dashboard panel PASSENGER S DASHBOARDPANEL 3 Installation is the reverse o...

Page 957: ...vent passenger s Insert a flat metal plate under the clips then detach the clips by prying up Pull the side air vent backward while prying the clips Side defogger trim Carefully pry the side defogger trim at the rear edge then remove it Dashboard ...

Page 958: ... page 20 51 Climate control unit and audio unit 96 98 models seepage20 51 Climate control unit audio unit and center air vent 99 01 models see page 20 52 Dashboard lower cover passenger s glove box and glove box back cover see page 20 53 Console lower carpet see page 20 47 Dashboard lower cover driver s see page 20 50 Kick panel see page 20 43 4 Lower the steering column see section 17 To avoid ac...

Page 959: ...INS PROTECTIVE PLATE ACCESS CAP IN CAR TEMPERATURE SENSOR 7 Installation is the reverse of the removal procedure NOTE Make sure the dashboard fits onto the guide pins correctly Before tightening the bolts make sure the dashboard wire harnesses are not pinched Make sure the connectors and air hose are connected properly Enter the anti theft code for the radio then enter the customer s radio station...

Page 960: ...he Restraints section 24 before performing repairs or service FRONT SEATS Removal page 20 57 Disassembly pages 20 58 20 59 Seat Cover Replacement page 20 60 Seat Linkage Disassembly page 20 63 20 64 Seat Wire Harness Installation page 20 65 REAR SEAT Removal page 20 67 Trunk pass through cover Key Cylinder Replacement page 20 68 Seat Cover Replacement page 20 69 ...

Page 961: ...rack end cover removal Bolt locations 4 10 x 1 25 mm 37 N m 3 8 kgf m 27 Ibf ft SEAT TRACK END COVER SEAT TRACK END COVER SEAT TRACK ENDCOVERS FRONT SEAT 4 Lift the front seat then disconnect the connectors Driver s seat SIDE AIRBAG CONNECTOR 99 01 models SEAT HEATER CONNECTOR for some models SEAT BELT SWITCH CONNECTOR Passenger s seat SIDE AIRBAG CONNECTOR 99 01 models Clip location POWER SEAT CO...

Page 962: ...NTER COVER 10 x 1 25 mm 47 N m 4 8 kgf m 35 Ibf ft CLIP To seat cushion cover SEAT LINKAGE Disassembly page 20 63 Installation is the reverse of the removal procedure KNOBS CAP NOTE Make sure the bushing and pivot washer are installed properly To prevent wrinkles when installing the seat back cover make sure the material is stretched evenly over the pad Grease the sliding portion POWER SEAT SWITCH...

Page 963: ...re installed properly To prevent wrinkles when installing the seat back cover make sure the material is stretched evenly over the pad Grease the sliding portion SEAT BACK HEATER CONNECTOR SEAT CUSHION CLIPS PIVOT NUT 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft SEAT HEATER CONNECTOR PIVOT WASHER SIDE AIRBAG CONNECTOR 99 01 models OPDS UNIT CONNECTOR 99 01 models BUSHING CLIP To seat cushion cover 10 x 1...

Page 964: ... flat tip screwdriver wrap it with protective tape to prevent damage 8 way power adjustable with power lumbar support and seat heater NOTE Take care not to tear the seams or damage the seat covers Refer to page 20 8 for the seat harness wiring locations Route the seat wire harness correctly Make sure the bushing and pivot washer are installed correctly Apply multipurpose grease to the moving porti...

Page 965: ...re installed properly To prevent wrinkles when installing the seat back cover make sure the material is stretched evenly over the pad Grease the sliding portion SEAT BACK HEATER CONNECTOR SEAT CUSHION CLIPS PIVOT NUT 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft SEAT HEATER CONNECTOR PIVOT WASHER SIDE AIRBAG CONNECTOR 99 01 models OPDS UNIT CONNECTOR 99 01 models BUSHING CLIP To seat cushion cover 10 x 1...

Page 966: ... component locations precautions and procedures in the Restraints section 24 before performing repairs or service CAUTION Put on gloves to protect your hands NOTE Seats with airbags are marked SIDE AIRBAG on the seat back Because the component parts seat back cover cushion etc of seats with and without airbags are different make sure you install only the correct replacement parts Do not repair tor...

Page 967: ...99 01 models CLIP SEAT BACK COVER 7 Installation is the reverse of the removal procedure NOTE To prevent wrinkles when installing a seat back cover make sure the material is stretched evenly over the pad before securing the hooks and clips Replace the released clips with new ones Use only original Acura replacement seat back covers 99 01 models ...

Page 968: ...ME 3 Pull back the edge of the seat cushion cover all the way around release the clips and remove the seat cushion cover CLIP SEAT CUSHION COVER 4 Installation is the reverse of the removal procedure NOTE To prevent wrinkles when installing a seat cush ion cover make sure the material is stretched evenly over the pad before securing the clips and hooks Replace the released clips with new ones SEAT...

Page 969: ...to protect your hands NOTE Take care not to tear the seams or damage the seat covers On the passenger s seat with side airbag do not touch the OPDS sensor in the seat back pad and keep it away from oil Oil can corrode the sensor causing it to fail Seat back cover removal 1 Slide the front seat forward and fold the seat back forward 2 Remove the back cover see page 20 4 3 Release the hook strips th...

Page 970: ...e HOOK REINFORCEING CLOTH SEAT BACK FRAME 5 Remove the headrest and headrest guides HEADREST GUIDE KNOB SEAT BACK 6 Pull back the edge of the seat back cover all the way around and release the clips then remove the seat back cover CLIP WIRE Padside SEAT BACK COVER cont d ...

Page 971: ...hooks and hook strips Replace any clips you removed with new ones Install them with commercially available uphol stery ring pliers Reinstall the hooks of the reinforceing cloth securely Use only original Honda or Acura replacement seat back covers Passenger s seat Reinitialize the OPDS control unit Refer to the 99 01 Acura 3 5 RL Service Manual P N 61SZ305 see section 24 CLIP UPHOLSTERY RING PLIER...

Page 972: ...k POWER SEAT HARNESS SLIDE GEARBOX 3 7 N m 0 38 kgf m 2 7 Ibf ft Installation is the reverse of the removal procedure SLIDE MOTOR NOTE Replace the bushings with new ones Before installing the slide motor and slide gearbox align portion A as shown Grease each lead screw and gear portion of the recline motor Check the slide motor slide gearbox up down motor and recline motor operations SLIDE JOINT C...

Page 973: ...m 25 N m 2 5 kgf m 18 Ibf ft SLIDE GEARBOX 6 x 1 0 mm 9 N m 0 9 kgf m 7 Ibf ft Apply liquid thread lock 3 7 N m 0 38 kgf m 2 7 Ibf ft Installation is the reverse of the removal procedure SLIDE MOTOR NOTE Before installing the slide motor and slide gearbox align portion as shown Grease the slide lead screws and gear portion of the recline motor Check the slide motor slide gearbox and recline motor ...

Page 974: ...er seat switch HOOK SEAT CUSHION COVER WIRE TIES Power seat wire harness location View from under REAR UP DOWN SENSOR CONNECTOR FRONT UP DOWN SENSOR CONNECTOR View from top FRONT UP DOWN MOTOR CONNECTOR HARNESS HOLDER REAR UP DOWN MOTOR CONNECTOR SEAT LINKAGE SEAT LINKAGE SLIDE SENSOR CONNECTOR SLIDE MOTOR CONNECTOR SLIDE MOTOR CONNECTOR To power seat switch To power seat switch SLIDE POWER SEAT S...

Page 975: ...Screw location Clip locations SEAT BACK SIDE AIRBAG 99 00 models WIRE TIES OPDS UNIT 99 00 models SEAT BACK HEATER HARNESS HOOKS SLIDE MOTOR CONNECTOR To power seat switch SEAT BACK HEATER CONNECTOR To seat belt buckle To seat cushion heater SEAT CUSHION COVER WIRE TIES WIRE TIES A B D C WIRE TIES A C D B ...

Page 976: ...r adjustable with power lumbar support and seat heater SEAT BACK WIRE TIES SIDE AIRBAG HARNESS POWER LUMBAR SUPPORT MOTOR SEAT BACK HEATER HARNESS C A B D POWER LUMBAR SUPPORT SUBHARNESS HOOK SEAT CUSHION COVER To seat belt buckle To power seat switch HOOK POWER LUMBAR SUPPORT CONNECTOR To seat cushion heater 20 8 SEAT BACK HEATER CONNECTOR ...

Page 977: ...ake care not to tear the seams or damage the seat covers 1 Remove the back cover see page 20 4 2 Release the hook strip on the right inside of the seat back HOOK STRIP LUMBAR SUPPORT MOTOR SEAT BACK COVER 3 Disconnect the lumbar support motor connector and remove the bolts securing the lumbar support motor LUMBAR SUPPORT MOTOR 6x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft LUMBAR SUPPORT MOTOR CONNECTOR 4...

Page 978: ...ort in the reverse order of removal and note these items Replace the wire ties as news ones To prevent wrinkles when installing a seat back cover make sure the material is stretched evenly over the pad before securing the hook strip Replace the back panel clips as new ones 20 6 ...

Page 979: ...T A Remove the clips from the trunk area SLITS SEAT CUSHION Armrest removal Installation is the reverse of the removal procedure NOTE Before attaching the seat back and seat cushion make sure there are no twists or kinks in the rear seat belts and center belt When installing the seat cushion slip the seat belt buckles through the slits in the seat cushion SEAT BACK TRUNK HOOKS PASS THROUGH COVER A...

Page 980: ...the inside hook down through the access hole TRUNK HANDLE ACCESS HOLE 3 HOOK While pressing the hook pry the trunk handle up with a flat tip screwdriver 4 Remove the trunk handle and rear seat handle together at the same time REAR SEAT HANDLE TRUNK PASS THROUGH COVER KEY CYLINDER Forward TRUNK HANDLE TRUNK PASS THROUGH COVER RETAINER CLIP 5 Remove the retainer clip then remove the trunk pass throu...

Page 981: ...EAT BELT GUIDE 5 Loosen the seat back cover by releasing all the clips hooks and inside springs CLIPS HOOKS SEAT BACK COVER INSIDE SPRINGS INSIDE SPRINGS 6 Pull back the edge of the seat back cover all the way around release the clips and remove the seat back cover CLIPS SEAT BACK COVER 7 Installation is the reverse of the removal procedure NOTE To prevent wrinkles when installing a seat back cove...

Page 982: ...ll the way around release the clips and remove the seat cushion cover CLIPS SEAT CUSHION COVER 4 Installation is the reverse of the removal procedure NOTE To prevent wrinkles when installing a seat cush ion cover make sure the material is stretched evenly over the pad before securing the clips Replace the released clips with new ones SEAT COVER NEW CLIP UPHOLSTERY RING PLIERS Commercially availabl...

Page 983: ...sion Bar Removal page 20 77 HOOD Adjustment page 20 75 FRONTGRILLE Removal page 20 77 LICENSE PLATE TRIM Removal page 20 78 REARBUMPER Removal page 20 74 REAR AIR OUTLET Removal page 20 85 REARFENDER COVER Removal page 20 85 FENDERWELL TRIM Removal page 20 85 FRONT BUMPER Removal 96 98 Models page 20 72 Removal 99 01 Models page 20 73 SIDE SILL PANEL Removal page 20 84 INNER FENDER Removal page 20...

Page 984: ...ive tape Thickness 1 2 mm 0 05 in Width 6 mm 0 24 in FRONT BUMPER BEAM FRONT BUMPER Bolt screw locations 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft Clip locations 7 Installation is the reverse of the removal procedure NOTE Make sure the front bumper engages the front bumper upper beam and side clips securely If necessary adjust the front bumper beam to obtain th...

Page 985: ...NNECTOR FRONT BUMPER BEAM FRONT BUMPER RIGHT SIDE FRONT BUMPER MOLDING LEFT FRONT FOG LIGHT CONNECTOR LICENSE PLATE BRACKET LEFT SIDE FRONT BUMPER MOLDING FRONT SPOILER Installation is the reverse of the removal procedure NOTE Make sure the front bumper engages the front bumper upper beam and side clips securely If necessary adjust the front bumper beam to obtain the proper gap ABSORBER ABSORBERBO...

Page 986: ...l Adhesivetape Thickness 1 2 mm 0 05 in Width 6 mm 0 24 in ACCESS CAPS 96 99 models 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft 00 01 models 12 x 1 25 mm 54 N m 5 5 kgf m 40 Ibf ft Nut locations 4 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft Clip locations REAR BUMPER GROMMET REAR FENDER COVER RIGHT SIDE REAR BUMPER MOLDING 99 01 models REAR BUMPER CENTER REARBUMPER MOLDING 99 01 models LEFT SIDE REAR BUMP...

Page 987: ...hood latch to obtain the proper height at the forward edge 4 After adjustment tighten each bolt securely 5 Apply touch up paint to the hinge mounting bolts and around the hinges SUPPORT STRUT HOOD EDGE I CUSHION HOOD HOOD HINGE 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft NOTE Move the hood latch right or left until the stri...

Page 988: ...fter adjustment tighten each bolt securely TRUNK LID HINGE TRUNK LID NOTE Take care not to hit the rear window when loosening the bolts 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft NOTE Remove the rear shelf see page 20 43 NOTE Move the striker right or left until it s centered in the trunk lid latch as shown STRIKER TRUNK LID LATCH TRUNK LID EDGE CUSHION TRUNK LID HINGE STRIKER TRUNK LID EDGE CUSHION ...

Page 989: ... any damaged clips Removal CAUTION Put on gloves to protect your hands NOTE Take care not to damage the body Remove the torsion bars with the torsion bar assembly tool while holding the trunk lid as shown TRUNK LID TRUNK LID HINGE TORSION BARS TORSION BAR CENTERCLIP TORSIONBAR ASSEMBLYTOOL TORSION BARS Installation is the reverse of the removal procedure NOTE Adjust the torsion bars fore or aft wi...

Page 990: ...id Weatherstrip Installation When installing the trunk lid weatherstrip align it with the alignment mark on the trunk lid opening NOTE Make sure there are no wrinkles in the weatherstrip Check for water leaks ...

Page 991: ...over HOOK TRUNK LID TRIM COVER 2 Using a clip remover remove the clips then remove the trunk lid trim TRUNK LID TRIM 3 Pull out on the top of the trunk lid hinge cover to detach the clip and pull the cover away from the trunk lid hinge TRUNK LID HINGE TRUNK LID HINGE COVER 4 Install the hinge cover in the reverse order of removal and replace any damaged clips ...

Page 992: ...o tective tape on the body NOTE Take care not to scratch the body ROOF MOLDING BRACKET PIN Body side ROOF MOLDING PIN BRACKET Installation is the reverse of the removal procedure NOTE Take care not to damage the windshield molding Make sure the roof molding is installed securely ROOF MOLDING PROTECTIVE TAPE WINDSHIELD MOLDING ...

Page 993: ... 11 and plastic cover see pages 20 2 20 9 To remove the rear side molding insert a flat tip screwdriver between the body and molding then detach the clip Take care not to bend the door moldings Plasticnutlocation 1 Adhesive area FRONT SIDE FRONT DOOR MOLDING MOLDING REAR SIDE MOLDING Adhesive areas REAR DOOR MOLDING Adhesive area CLIP CLIP ADHESIVE TAPE CLIP PROTECTIVE TAPE Adhesive area Clip loca...

Page 994: ...d plastic cover see pages 20 2 20 9 To remove the rear side molding insert a flat tip screwdriver between the body and molding then detach the clip Take care not to bend the door moldings Plastic nut location 1 FRONT DOOR MOLDING Adhesive area FRONT SIDE MOLDING REARSIDE MOLDING REAR DOOR MOLDING Adhesive areas Adhesive area CLIP CLIP ADHESIVE TAPE FRONT SIDE MOLDING ADHESIVE TAPE REAR SIDE MOLDIN...

Page 995: ...e tape residue follow up with stripe adhesive remover then scrape the adhesive tape with a putty knife 6 Remove the protective tape then clean the bonding surface with a sponge dampened in alcohol NOTE Make sure the bonding surface is kept free of water oil and grease 7 Glue the new adhesive tape to the moldings as shown Adhesive tape locations Width 5 mm 0 2 in Thickness 1 2 mm 0 05 in Forward FR...

Page 996: ...R CLIP SIDE SILL PANEL SIDE CLIPS Forward NOTE When removing the side sill panel the side clips will stay in the body SIDE SILL PANEL Remove the lower clips then remove the side sill panel by sliding it forward To install the side sill panel remove the side clips from the body install them on the side sill panel then install the side sill panel on the body NOTE Take care not to twist the side sill...

Page 997: ...sponge dampened in alcohol After cleaning keep oil grease or water from getting on the surface To remove the rear fender cover first remove the rear wheel see section 18 To remove the rear fender cover first pull out the front edge of the rear bumper see page 20 74 To remove the rear air outlet first remove the rear bumper see page 20 74 STEEL CORE Bolt screw locations Left 3 Right 2 6 x 1 0 mm 9 ...

Page 998: ... OPENER MAIN SWITCH Test page 23 274 TRUNK LID LATCH see page 20 90 FUEL FILL DOOR LATCH see page 20 89 FUEL FILL DOOR OPENER CABLE see page 20 87 HOOD LATCH see page 20 88 HOOD OPENER CABLE see page 20 87 TRUNK LID OPENER SWITCH Test page 23 274 FUEL FILL DOOR OPENER see page 20 89 WASHER RESERVOIR 00 01models Removal page 20 92 WASHER RESERVOIR 96 99 models Removal page 20 92 WINDSHIELD WASHER T...

Page 999: ...et and rear carpet back as necessary see page 20 46 Front and rear side trim see page 20 43 Front and rear door trim see page 20 43 Front seat belt lower anchor see section 24 Center pillar trim see page 20 43 Rear seat cushion and rear seat back see page 20 67 Trunk front trim see page 20 44 Spare tire lid see page 20 44 Rear trim panel and trunk side trim see page 20 44 FUEL FILL DOOR LATCH see ...

Page 1000: ...ke sure the opener cable is connected properly Make sure the hood opens properly and locks securely Hood latch Bolt locations 3 COVER HOOD OPENER CABLE Detach the clip HOOD LATCH SWITCH CONNECTOR Installation is the reverse of the removal procedure NOTE Make sure the opener cable is connected properly Make sure the hood opens properly and locks securely Grease each location of the hood latch indic...

Page 1001: ...NOTE Remove the following parts Rear trim panel see page 20 44 Rear edge of the trunk side trim left side see page 20 44 Bolt locations 2 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft FUEL FILL DOOR After installing check for aflushfitwiththe body FUEL FILL DOOR OPENER CABLE see page 20 87 FUEL FILL DOOR LATCH Removethefuelfilldoorlatch byturning it 90 Installation is the reverse of the removal procedur...

Page 1002: ...m 7 2 Ibf ft LOCK CYLINDER SWITCH CONNECTOR LOCK CYLINDER TRUNK LID LATCH CONNECTOR Installation is the reverse of the removal procedure NOTE Grease the trunk latch Make sure the trunk lid opens properly and locks securely Make sure the connector is connected properly Bolt locations 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft CYLINDER ROD ...

Page 1003: ... clip then remove the windshield wiper linkage assembly WINDSHIELD WIPER LINKAGE ASSEMBLY Bolt locations 3 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft PIN Body side HARNESS CLIP 5 Separate the windshield wiper linkage and wind shield wiper motor NOTE When installing align the alignment marks on the link and windshield wiper linkage 6 x 1 0 mm 8 N m 0 8 kgf m 5 8 Ibf ft ALIGNMENT MARKS LINK LINK WINDSH...

Page 1004: ...RESERVOIR CONNECTOR WASHER WINDSHIELD TUBE WASHER MOTOR 4 Remove the bolt then remove the washer reservoir 5 Installation is the reverse of the removal procedure NOTE Make sure the washer motor connector and washer tube is connected properly Check the washer motor operation HOOK HOOK CONNECTOR WINDSHIELD WASHER MOTOR WASHER TUBE WASHER RESERVOIR 2 Pull away the inner fender as necessary see page 2...

Page 1005: ...E WASHER RESERVOIR HOOD OPENER CABLE WASHER TUBE 00 01 models WINDSHIELD WASHER NOZZLE Installation is the reverse of the removal procedure NOTE Take care not to pinch the washer tube If necessary replace any damaged clips After installing adjust the aim of the windshield washer nozzles WINDSHIELD WASHER TUBE WASHER RESERVOIR WINDSHIELD WASHER TUBE ...

Page 1006: ...stra tion 96 99 models Installation Apply the emblems where shown NOTE Before applying clean the trunk lid surface with a sponge dampened in alcohol After cleaning keep oil grease and water from getting on the surface Attachment Points Reference ACURA EMBLEM 3 5RL EMBLEM Unit mm in COWL COVER WINDSHIELD WIPER ARMS HINGE COVER from upper edge of hinge cover Summer position 21 mm 0 8 in from upper e...

Page 1007: ...lace 12 x 1 25 mm 74 N m 7 5 kgf m 54 Ibf ft 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft REAR BEAM DAMPER REAR BEAM To body 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft FRONT BEAM DAMPER To body 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft FRONT BEAM 12 x 1 25 mm 64 N m 6 5 kgf m 47 Ibf ft SPECIAL BOLTS 12 x 1 25 mm 64 N m 5 5 kgf m 47 Ibf ft Replace REAR BEAM STIFFENER 10 x 1 25 mm 38 N m 3 9 kgf m 28 Ibf ft REA...

Page 1008: ...Frame Repair Chart Top view Unit mm in Inner diameter Left side Right side ...

Page 1009: ...POINT m ...

Page 1010: ...Frame Repair Chart cont d Side view Unit mm in Inner diameter Left side Right side ...

Page 1011: ...012 0 47 Fuel tank strap point ...

Page 1012: ... 59 In car Temperature Sensor Replacement 22 60 Test 22 60 Outside Air Temperature Sensor Replacement 22 61 Test 22 61 Sunlight Sensor Replacement 22 62 Test 22 62 Evaporator Temperature Sensor Test 22 63 Power Transistor Test 22 63 Relays Test 22 64 Evaporator Blower Unit Replacement 22 65 Overhaul 22 67 Dust and Pollen Filters Replacement 22 68 Heater Unit Replacement 22 69 Overhaul 22 71 Temper...

Page 1013: ...Special Tools Ref No Tool Number Description Qty Page Reference 07JGG 001010A 07SAZ 001000A Belt Tension Gauge BackprobeSet 22 85 22 52 Included in the Belt Tension Gauge Set 07TGG 001000A ...

Page 1014: ... C PRESSURE SWITCH SERVICE VALVE LOW PRESSURE SIDE SERVICE VALVE HIGH PRESSURE SIDE RECEIVER DRYER CONDENSER Replacement page 22 86 COMPRESSOR Replacement page 22 79 Clutch Inspection page 22 82 Clutch Overhaul page 22 83 Relief Valve Replacement page 22 84 EVAPORATOR PRESSURE REGULATOR ...

Page 1015: ...IT Replacement page 22 69 Overhaul page 22 71 RECIRCULATION CONTROL MOTOR Replacement page 22 59 Test page 22 59 HEATERVALVECABLE Adjustment page 22 72 MODE CONTROL MOTOR Replacement page 22 58 Test page 22 58 DUST AND POLLEN FILTER ASSEMBLIES Replacement page 22 68 IN CAR TEMPERATURE SENSOR Replacement page 22 60 Test page 22 60 CLIMATE CONTROL UNIT Replacement page 22 55 Bulb Replacement page 22...

Page 1016: ...RELAY Located in the under hood relay box A Test page 22 64 RIGHT ENGINE COMPARTMENT WIRE HARNESS A C PRESSURE SWITCH CONNECTOR RADIATOR FAN CONNECTOR OUTSIDE AIR TEMPERATURE SENSOR Replacement page 22 61 Test page 22 61 FAN CONTROL UNIT Located behind the PCM cover PCM COVER LEFT ENGINE COMPARTMENT WIREHARNESS COMPRESSOR CLUTCH CONNECTOR CONDENSER FAN CONNECTOR ...

Page 1017: ...SENSOR Test page 22 63 RECIRCULATION CONTROL MOTOR CONNECTOR SUNLIGHT SENSOR CONNECTOR BLOWER MOTOR RELAY Wire colors BLK YEL WHT RED BLK and BLK Test page 22 64 BLOWER MOTOR HIGH RELAY Wire colors BLK YEL BLU RED LT GRN and BLK Test page 22 64 POWER TRANSISTOR Test page 22 63 AIR MIX CONTROL MOTOR Replacement page 22 57 Test page 22 57 MODE CONTROL MOTOR CONNECTOR IN CAR TEMPERATURE SENSOR CONNEC...

Page 1018: ...or Intermixing the recommended PAG refrigerant oil with any other refrigerant oil will result in compressor failure All A C system parts compressor discharge line suction line evaporator condenser receiver dryer expansion valve O rings for joints have to be proper for refrigerant R 134a Do not confuse with R 12 parts Use a halogen gas leak detector designed for refrigerant R 134a R 12 and R 134a r...

Page 1019: ...e fan control unit turns Tr1 ON and the radiator fan Low and condenser fan runs Low ON OFF 183 F 84 C When engine coolant temperature is above 194 F 90 C the fan control unit turns Tr2 ON and the radiator fan High runs and the condenser fan High goes on 194 F 90 C ON OFF 225 F 107 C When engine coolant temperature is above 228 F 109 C the fan control unitturnsTr3 OFF and stops the A C com pressor ...

Page 1020: ...pressure switch sends a signal to the fan control unit to prevent the compressor from operating ON OFF Middle pressure switch If the refrigerant pressure goes above or below 1 520 kPa 15 5 kgf cm2 220 psi the A C pressure switch sends a signal to the fan control unit to change the speed of the condenser fan and radiator fan High Low 290 kPa 3 0 kgf cm2 42 psi ON OFF 1 230 kPa 12 5 kgf cm2 178 psi ...

Page 1021: ...aporator pressure drops below about 196 kPa 2 0 kgf cm2 28 4 psi the piston closes to keep the pressure in the evaporator above 196 kPa 2 0 kgf cm2 28 4 psi Consequently the EPR keeps the evaporator temperature and the delivery temperature constant Open PISTON Close 177 202 kPa 1 80 2 06 kgf cm2 25 6 29 3 psi PRESSURE BELLOWS PISTON Compressor side Evaporator side SPRING Evaporator Pressure Regula...

Page 1022: ...erature control dial must be set between 61 F 18 C and 89 F 32 C No heater and A C in either manual or AUTO modes Both fans do not run for engine cooling but they both run with the A C on Both fans always run at high speed for engine cooling Both fans always run at high speed with the A C on Radiator fan does not run at high speed but condenser fan runs at high speed and both fans run at low speed...

Page 1023: ...motor Blower motor Possible cause Open or short circuit faulty sensor Open or short circuit faulty sensor Open or short circuit faulty sensor Open or short circuit faulty sensor Open or short circuit obstructed door faulty motor Open or short circuit obstructed door faulty motor Open or short circuit faulty motor See page 22 16 22 18 22 20 22 22 22 24 22 26 22 28 22 30 NOTE In case of multiple pro...

Page 1024: ...T OUTPUT INPUT 20P CONNECTOR Terminal No 1 2 3 4 5 6 7 9 10 Wire Color ORN BRN BRN WHT BRN BLK BLU LT GRN RED RED YEL RED Signal POWERTRANSISTOR BASE EVAPORATOR TEMPER ATURESENSOR OUTSIDE AIR TEMPER ATURESENSOR IN CAR TEMPERATURE SENSOR MODE DEF MODE VENT AIR MIX HOT AIR MIX COOL OUTPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT Terminal No 11 12 14 15 16 17 18 19 20 Wire Color LT GRN LT GRN BL...

Page 1025: ... by touching the door striker or other body parts Do not touch the electronic components on the printed circuit board in the climate control unit 1 Remove the climate control unit see previous column 2 Carefully remove the self tapping screws and the rearcover REAR COVER 3 Remove the bulb s with a flat tip screwdriver BULB 4 Install in the reverse order of removal Make note of the following items ...

Page 1026: ...l knobs TEMPERATURE CONTROL KNOB FAN CONTROL KNOB 3 Carefully remove the self tapping screws and the rear cover REAR COVER 4 Remove the self tapping screws then remove the clock and the display from the face panel DISPLAY CLOCK 5 If necessary remove the buttons sequentially from left to right BUTTON 6 Install in the reverse order of removal Make note of the following items NOTE Do not kink or pull...

Page 1027: ... the air mix con trol motor 2 Connect battery power to the No 1 terminal of the air mix control motor and ground the No 5 termi nal the air mix control motor should run and stop at MAX COOL If it doesn t reverse the connections the air mix control motor should run and stop at MAX HOT NOTE If the air mix control motor does not run remove it then check the air mix control linkage and doors for smoot...

Page 1028: ...om the mode control motor 2 Connect battery power to the No 1 terminal of the mode control motor and ground the No 5 terminal the mode control motor should run and stop at VENT If it doesn t reverse the connections the mode control motor should run and stop at DEF NOTE If the mode control motor does not run remove it then check the mode control linkage and doors for smooth movement If they move sm...

Page 1029: ...onnector from the recirculation control motor 2 Connect battery power to the No 1 terminal and ground the No 2 and No 4 terminals the recircula tion control motor should run smoothly CAUTION Never connect the battery in the oppo site direction RECIRCULATION CONTROL MOTOR 4P CONNECTOR 3 Disconnect the No 2 or No 4 terminals from ground the recirculation control motor should stop at FRESH or RECIRCU...

Page 1030: ...ecurely Test Compare the resistance reading between the No 1 and No 2 terminals of the in car temperature sensor with the specifications shown in following graph resistance should be within specifications NOTE Check for change in resistance by heating or cooling the sensor with a hair drier etc CAUTION The sensor uses a thermistor which can be damaged if high current is applied during testing Ther...

Page 1031: ...e air temperature sensor with the specifications shown in following graph resistance should bewithin specifications NOTE Dip the sensor in ice water and measure resis tance Then pour hot water on the sensor and check for change in resistance CAUTION The sensor uses a thermistor which can be damaged if high current is applied during testing Therefore use a circuit tester with an output of 1 mA or l...

Page 1032: ...NLIGHT SENSOR AUTOMATIC LIGHTING SENSOR 2 Install in the reverse order of removal Test Turn the ignition switch ON II Measure the voltage between the terminals with the probe on the No 2 terminal and the probe on the No 1 terminal with the 2P connector connected Voltage should be 3 5 to 3 9 V or more with the sensor out of direct sun light 3 8 to 3 4 V or less with the sensor in direct sunlight NO...

Page 1033: ...e use a circuit tester with an output of 1 mA or less at the 20 k range EVAPORATORTEMPERATURESENSOR 2P CONNECTOR Test Terminal side of male terminals RESISTANCE k 1 Disconnect the 3P connector from the power tran sistor 2 Pull out the No 2 ORN terminal from the connec tor 3 Connect a 1 2 3 4 watt bulb as shown then recon nect the 3P connector to the power transistor 12V 1 2 3 4 W BULB No 3 BLU RED...

Page 1034: ...hen power is disconnected Radiator fan relay Condenserfan relay Compressor clutch relay Blower motor relay Blower motor high relay There should be continuity between the No 4 and No 5 terminals when power and ground are connected to the No 1 and No 3 terminals and there should be continu ity between the No 2 and No 5 terminals when power is disconnected Radiator fan main relay ...

Page 1035: ...INE SUCTION LINE 3 Turn the ignition switch ON II and set the recircu lation control switch on RECIRCULATE 4 Remove the glove box see section 20 5 Remove the trunk opener main switch connector the self tapping screws and the glove box back cover GLOVE BOX BACK COVER TRUNK OPENER MAIN SWITCH CONNECTOR 6 Remove the service check connector the screws and the bolt then remove the blower under cover wi...

Page 1036: ... unit NOTE Be careful not to damage or bend the capil lary tube 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft DRAIN HOSE EVAPORATOR BLOWERUNIT 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft 11 Install in the reverse order of removal Make note of the following items If you re installing a new evaporator add refrig erant oil ND OIL 8 see page 22 73 Replace the O rings with new ones at each fitting and apply a th...

Page 1037: ...r 97 4 mm 3 83 in Core center 32 7 mm 1 29 in EVAPORATOR TEMPERATURE SENSOR Test page 22 63 LOWER HOUSING EXPANSION VALVE POWER TRANSISTOR Test page 22 63 5 Assemble in the reverse order of disassembly Make note of following items Replace the O rings with new ones at each fitting and apply a thin coat of refrigerant oil before installing them NOTE Be sure to use the right O rings for HFC 134a R 13...

Page 1038: ...shown Separate the first filter assembly from the second filter assembly then remove the first filter assembly DUST AND POLLEN FILTER ASSEMBLIES FIRST DUST AND POLLEN FILTER ASSEMBLY SECOND DUST AND POLLEN FILTER ASSEMBLY 6 Remove the second dust and pollen filter assembly from the recirculation housing as shown SECOND DUST AND POLLEN FILTER ASSEMBLY 7 Remove the dust and pollen filter from the fi...

Page 1039: ...LVE ARM CABLE CLAMP HEATERVALVE CABLE 4 When the engine is cool drain the engine coolant from the radiator see section 10 Do not remove the radiator cap when the engine is hot the engine coolant is under pres sure and could severely scald you 5 Disconnect the heater hoses from the heater unit CAUTION Engine coolant will damage paint Quickly rinse any spilled engine coolant from painted sur faces N...

Page 1040: ...nd the A C wire harness Remove the mounting bolt the mounting nuts and the heater unit CRUISE CONTROL UNIT HEATER UNIT 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft A C WIRE HARNESS 12 Install in the reverse order of removal Make note of the following items Apply sealant to the grommets Do not interchange the inlet and outlet heater hoses Make sure that the clamps are secure Refill the cooling system wi...

Page 1041: ...ping screws and the pipe clamps 3 Remove the self tapping screws and the core clamp 4 Pull out the heater core NOTE Be careful not to bend the inlet and outlet pipes during heater core removal 5 Assemble in the reverse order of disassembly VENT DEFROSTER DUCT CORECLAMP HEATER CORE PIPE CLAMPS ...

Page 1042: ...the closed position and gently pull on the heater valve cable housing to take up any slack then install the heater valve cable housing into the cable clamp Heater unit side 1 At the heater unit disconnect the heater valve cable housing from the cable clamp then disconnect the heater valve cable from the temperature control arm HEATER VALVE CABLE TEMPERATURE CONTROL ARM CABLE CLAMP STOP 2 Set the a...

Page 1043: ...ng any lines plug or cap the fittings immediately don t remove the caps or plugs until just before you reconnect each line 3 Before connecting any hose or line apply a few drops of refrigerant oil to the O ring 4 When tightening or loosening a fitting use a second wrench to support the matching fitting 5 When discharging the system use a R 134a refrigerant recovery recycling charging station don t...

Page 1044: ...r line A to the condenser 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft Receiver line B to the condenser 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft Receiver line B to the evaporator 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft Suction line to the evaporator 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft Suction line to the evaporator pressure regulator 31 N m 3 2 kgf m 23 Ibf ft Suction hose to the evaporator pressure...

Page 1045: ...ixtures of air and R 134a have been shown to be combustible at elevated pressures and can result in fire or explosion causing injury or property dam age Never use compressed air to pressure test R 134a service equipment or vehicle air conditioner systems Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 Connect a R 134a refrigerant recovery...

Page 1046: ... damage Never use compressed air to pressure test R 134a service equipment or vehicle air conditioner sys tems Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 Connect a R 134a refrigerant recover recycling charging station to the vehicle as shown following the equipment manufacturer s instructions 2 Insert a thermometer in the center air ...

Page 1047: ...0 above and 10 below the humidity level From each point draw a horizontal line across the delivery temperature The delivery temperature should fall between the two lines Complete the low side pressure test and high side pressure test in the same way Any measurements outside the line may indicate the need for further inspection DELIVERY PRESSURE DELIVERY PRESSURE DELIVERY TEMPERATURE HUMIDITY LEVEL...

Page 1048: ...nd expansion valve is too low compared with that around receiver dryer Compressor clutch is dirty Compressor bolt s are dirty Compressor gasket is wet with oil Probable cause Air in system Clogged condenser or radiator fins Condenser or radiator fan not working properly Restricted flow of refriger ant in system Faulty compressor dis chargevalve Faulty compressor seal Faulty expansion valve Moistur...

Page 1049: ...amage Never use compressed air to pressure test R 134a service equipment or vehicle air conditioner sys tems Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers 1 When an A C system has been opened to the atmo sphere such as during installation or repair it must be evacuated using a R 134a refrigerant recovery recycling charging station If the ...

Page 1050: ... If accidental system discharge occurs ventilate work area before resuming service R 134a service equipment or vehicle air conditioner sys tems should not be pressure tested or leak tested with compressed air Some mixtures of air and R 134a have been shown to be combustible at elevated pressures and can result in fire or explosion causing injury or property damage Never use compressed air to press...

Page 1051: ...g charging station see page22 75 5 Loosen the A C compressor belt see page 22 85 A C COMPRESSOR BELT 6 Remove the nuts then disconnect the suction line and the discharge line from the compressor NOTE Plug or cap the lines immediately after dis connecting them to avoid moisture and dust con tamination SUCTION LINE DISCHARGE LINE 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 Ibf ft 7 Remove the mounting bolts and ...

Page 1052: ... with new ones at each fitting and apply a thin coat of refrigerant oil before installing them NOTE Be sure to use the right O rings for HFC 134a R 134a to avoid leakage Use refrigerant oil ND OIL 8 for R 134a DENSO piston type compressors only To avoid contamination do not return the oil to the container once dispensed and never mix it with other refrigerant oils Immediately after using the oil r...

Page 1053: ...nspection page 22 82 SHIM S SNAP RING B Replace PULLEY Inspection page 22 82 SNAP RING A Replace FIELD COIL Inspection page 22 82 RELIEF VALVE Replacement page 22 84 O RING Replace SUCTION SERVICE VALVE O RING Replace COMPRESSOR Do not disassemble ...

Page 1054: ...sure the clearance between the pulley and the pressure plate all the way around If the clearance is not within specified limits the pressure plate must be removed and shims added or removed as required following the procedure on page 22 83 Clearance 0 5 0 15 mm 0 020 0 006 in NOTE The shims are available in three thicknesses 0 1 mm 0 3 mm and 0 5 mm PRESSURE PLATE PULLEY Check resistance of the fi...

Page 1055: ... P N 10204 Kent Moore P N J37872 2 Remove the pressure plate and shim s taking care not to lose the shim s PRESSURE PLATE SHIM S 3 Remove the snap ring B with snap ring pliers then remove the pulley NOTE Be careful not to damage the pulley and com pressor during removal installation Once the snap ring B is removed replace it with a new one SNAP RING B Replace PULLEY ...

Page 1056: ...l installation Once the snap ring A is removed replace it with a new one SNAP RING A Replace FIELD COIL 5 Install in the reverse order of removal Make note of the following items Install the field coil with the wire side facing down see above Clean the pulley and compressor sliding surfaces with non petroleum solvent Make sure the snap rings are fully seated in the groove Make sure that the pulley...

Page 1057: ...n coat of refrigerant oil before installing it NOTE To avoid contamination do not return the oil to the container once dispensed and never mix it with other refrigerant oils Immediately after using the oil reinstall the cap on the container and seat it to avoid moisture absorption Do not spill the refrigerant oil on the vehicle it may damage the paint if the refrigerant oil con tacts the paint was...

Page 1058: ...e center nut 4 Recheck the deflection of the A C compressor belt Tension Gauge Method 1 Attach the special tool to the A C compressor belt as shown below and measure the tension of the belt A CCompressorBelt Used Belt 440 640 N 45 65 kgf 99 143 Ibf New Belt 930 1 080 N 95 110 kgf 209 243 Ibf NOTE If there are cracks or any damage evident on the belt replace it with a new one Follow the manufacture...

Page 1059: ...OTE Plug or cap the lines immediately after dis connecting them to avoid moisture and dust con tamination RECEIVER LINE B CONDENSER LINE 6 x 1 0 mm 9 8 N m 1 0 kgf m 7 2 Ibf ft RECEIVER DRYER 4 Remove the bolts then disconnect the discharge line and the receiver line A from the condenser NOTE Plug or cap the lines immediately after dis connecting them to avoid moisture and dust con tamination RECE...

Page 1060: ...ems If you re installing a new condenser add refriger ant oil ND OIL 8 see page 22 73 Replace the O rings with new ones at each fit ting and apply a thin coat of refrigerant oil before installing them NOTE Be sure to use the right O rings for HFC 134a R 134a to avoid leakage Be careful not to damage the radiator and the condenser fins when installing the condenser Be sure to install the lower moun...

Page 1061: ...nit Removal 23 150 CD Changer Removal 23 152 Stereo Amplifier Removal 23 152 Speaker Replacement 23 153 Radio Remote Switch Test 23 154 Window Antenna Wire Test Repair 23 155 XM Radio 04 Model Receiver Terminals 23 38c Antenna Terminals 23 42c Accessory Power Socket Replacement 23 156 Cigarette Lighter Replacement 23 157 Horns Component Location Index 23 158 Horn Test 23 161 Switch Test 23 162 Sea...

Page 1062: ...Motor Test 23 328 Washer Motor Test 23 328 Switch Replacement 23 329 Security Alarm System Component Location Index 23 330 Description 23 332 Control Unit Input Test 23 346 Indicator Replacement 23 352 Hood Switch Test 23 352 Trunk Lid Latch Switch Test 23 353 Trunk Key Cylinder Switch Test 23 353 Power Mirrors Component Location Index 23 354 Function Test without memory 23 357 Switch Test 23 358 ...

Page 1063: ...Special Tools 07LAJ PT3020A 07PAZ 0010100 23 86 23 248 ...

Page 1064: ...atertight connectors All connectors have push down release type locks LOCKING TAB LOCKING TAB Some connectors have a clip on their side used to attach them to a mount bracket on the body or on another component This clip has a pull type lock Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from its mount bracket LOCKING PAWL ON OTHER HALF OF...

Page 1065: ...esn t interfere with any moving parts Keep wire harnesses away from exhaust pipes and other hot parts from sharp edges of brackets and holes and from exposed screws and bolts Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals Use a probe with a tapered tip Seat grommets in their grooves properly NOT GOOD Testing and Repairs Do not use wire...

Page 1066: ...n mind that a logical simple procedure is the key to efficient troubleshooting Test for the most likely cause of failure first Try to make tests at points that are easily accessible 4 Fix The Problem Once the specific problem is identified make the repair Be sure to use proper tools and safe procedures 5 Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to mak...

Page 1067: ...99 01 models WINDSHIELD WIPER MOTOR RELAY ABS REAR FAIL SAFE RELAY 96 97 models HORN RELAY 98 01 models FRONT FOG LIGHT RELAY ABS FRONT FAIL SAFE RELAY 96 97 models ABS FAIL SAFE RELAY 98 99 models GAUGERELAY A T REVERSE RELAY REAR WINDOW DEFOGGER RELAY WINDSHIELD WIPER INTERMITTENT RELAY RADIATOR FAN MAIN RELAY CONDENSER FAN RELAY A C COMPRESSOR CLUTCHRELAY LOW BEAM CUT RELAY Canada 96 98 models ...

Page 1068: ...TE LIGHTER RELAY FRONT SEAT HEATER RELAY 96 97 models DRIVER S POWER WINDOW MOTOR RELAY A 98 01 models SPARK PLUG VOLTAGE DETECTION MODULE DIMMER RELAY ABS PUMP MOTOR RELAY 96 99 models VSA FAIL SAFE RELAY 00 01 models HEADLIGHT RELAY 96 98 models HEADLIGHT LOW BEAM RELAY 99 01 models TAILLIGHT RELAY 96 98 models HEADLIGHT HIGH BEAM RELAY 99 01 models UNDER HOOD FUSE RELAY BOX ...

Page 1069: ...1 models HORNRELAY 96 97 models POWER WINDOW MASTER SWITCH RELAY 98 02 models SPARK PLUG VOLTAGE DETECTION MODULE HEADLIGHT RELAY 96 98 models HEADLIGHT LOW BEAM RELAY 99 02 models TAILLIGHTRELAY 96 98 models HEADLIGHT HIGH BEAM RELAY 99 02 models DIMMER RELAY UNDER HOOD FUSE RELAY BOX DRIVER S POWER WINDOW MOTOR RELAY B 98 01 models ABS PUMP MOTOR RELAY 96 99 models VSA FAIL SAFE RELAY 00 02 mode...

Page 1070: ...ns Dashboard IMMOBILIZER PGM FI MAIN CRUISE CONTROL CONTROL UNIT RELAY STEERING COLUMN CONTROL UNIT UNIT MULTIPLEX CONTROL UNIT DRIVER S UNDER DASH FUSE RELAYBOX STARTER CUT RELAY SRSUNIT POWER WINDOW RELAY TURN SIGNAL HAZARD RELAY ...

Page 1071: ...CONTROL UNIT MULTIPLEX CONTROL UNIT PASSENGER S PCM DASH LIGHTS BRIGHTNESS CONTROLLER FAN CONTROL UNIT BLOWER MOTOR RELAY Wire colors BLK YEL BLK WHT and RED BLK BLOWER MOTOR HIGH RELAY Wire colors BLK YEL LG GRN BLU REDand BLK ABS CONTROL UNIT 96 99 models VSA CONVERTER UNIT 00 01 models ...

Page 1072: ... MULTIPLEX CONTROL UNIT DOOR POWER SEAT CONTROL UNIT NAVIGATION CONTROL UNIT POWER MIRROR CONTROL UNIT AUTOMATIC LIGHTING CONTROL UNIT USA DAYTIME RUNNING LIGHTS CONTROL UNIT Canada TCS CONTROL UNIT 96 99 models FUEL PUMP RELAY Wire colors RED WHT BLK YEL GRN and YEL ...

Page 1073: ...YLESS RECEIVER UNIT 3 KEYLESS RECEIVER UNIT 4 POWER MIRROR CONTROL UNIT STEREO AMPLIFIER BOSE SOUND SYSTEM 2 ONSTAR SYSTEM INTERFACE UNIT 2 ONSTARSYSTEM RADIO FREQUENCYMODULATOR UNIT MOONROOF CONTROL UNIT MOONROOFOPEN RELAY Wirecolors YEL GRN YEL 1 GRN YEL GRN BLU and BLK MOONROOFCLOSERELAY Wirecolors YEL GRN YEL 1 GRN RED GRN RED andBLK ...

Page 1074: ... 2 Disconnect the battery negative cable then disconnect the positive cable and wait at least 3 minutes 3 Disconnect the airbag connectors see section 24 4 Disconnect the connectors from the under dash fuse relay box including the SRS main harness see section24 UNDER DASH FUSE RELAY BOX SRS MAIN HARNESS NUT Installation 1 Connect the connectors to the under dash fuse relay box then install the und...

Page 1075: ...re should be continuity between the No 1 and No 3 terminals when power and ground are connected to the No 2 and No 4 terminals There should be no continuity between the No 1 and No 3 terminals when power is disconnected Radiator fan relay Horn relay Cigarette lighter relay Power window master switch relay Condenser fan relay Seat heater relay ABS front fail safe relay ABS rear fail safe relay TCS ...

Page 1076: ...clutch relay Power window relay Condenser fan relay type 1 type 2 Normally closed type 1 Check for continuity between the terminals There should be continuity between the No 1 and No 3 terminals when power is not connected to the No 2 and No 4 terminals There should be no continuity between the No 1 and No 3 terminals when power and ground are connected to the No 2 and No 4 terminals Low beam cut ...

Page 1077: ...ay Front fog light relay Gaugerelay Horn relay Moonroof open relay Moonroof close relay Radiatorfan relay Reverse relay Seat heater relay 98 model TCSfail saferelay Windshield wiper motor relay Power window master switch relay Driver s power window motor relay A Driver s power window motor relay B Accessory power socket relay 99 01 models Taillight relay 99 01 models Five terminal type B 98 01 mod...

Page 1078: ... the radio s preset buttons 2 Disconnect the battery negative cable 3 Remove the dashboard lower cover see section 20 4 Disconnect the 7P connector from the under dash fuse relay box 7P CONNECTOR Wire side of female terminals WHT BLK YEL YEL WHT RED BLK WHT 5 Check for continuity between the terminals in each switch position according to the table 6 If the continuity checks do not agree with the t...

Page 1079: ...ervice NOTE The PCM memory must be reset after reconnecting the battery see section 11 1 Make sure you have the anti theft code for the radio and the navigation system then write down the fre quencies for the radio s preset buttons 2 Disconnect the battery negative cable 3 Remove the dashboard lower cover see section 20 4 Disconnect the 7P connector from the under dash fuse relay box 5 Remove the ...

Page 1080: ...e charger manufacturer s instructions and charge the battery at a proper rate NOTE The PCM memory must be reset after reconnecting the battery see section 11 Use either a JCI or Bear ARBST tester and follow the manufacturer s procedures If you don t have one of these computerized testers follow this conventional test procedure To get accurate results the temperature of the electrolyte must be betw...

Page 1081: ...ong the battery was charged Test Load Capacity 2 Apply 300 amp load for 15 seconds to remove surface charge Allow 15 seconds recovery period Apply test load see Test Load Chart Record voltage at the end of 15 seconds Stays above 9 6 volts battery is OK Drops below 9 6 volts battery is no good BATTERY CODE 80D26R MF TESTLOADCHART Use the test load or 1 2 the cold cranking amps CCA printed on the la...

Page 1082: ...23 85 Bulb Locations page 23 76 Select Reset Switch Test page 23 84 FUEL GAUGE SENDING UNIT See section 11 PARKING BRAKE SWITCH See section 19 BRAKE FLUID LEVEL SWITCH See section 19 ENGINECOOLANTTEMPERATURE ECT GAUGE SENDING UNIT See section 10 ENGINE OIL PRESSURE SWITCH See section 8 VEHICLESPEEDSENSOR VSS Troubleshooting page 23 86 Replacement page 23 85 OUTSIDEAIRTEMPERATURE SENSOR See section...

Page 1083: ...RE GAUGE See section 10 SAFETY INDICATOR See page 23 88 FUEL GAUGE See section 11 TRIP METER OUTSIDE AIR TEMPERATURE INDICATOR See page 23 84 SPEEDOMETER Indicates 60 mph at 1 026 rpm 60 km h at 637 rpm of the vehicle speed sensor VSS TACHOMETER Indicates 100 rpm at 300 pulses per minute of the ignition control module ICM ...

Page 1084: ...e of the ignition control module ICM SPEEDOMETER Indicates 60 mph at 1 026 rpm 60 km h at 637 rpm of the vehicle speed sensor VSS TRIP METER OUTSIDE AIR TEMPERATURE INDICATOR SAFETY INDICATOR 96 01 3 5RL service manual P N 61SZ305 page 23 84 COOLANT TEMPERATURE GAUGE See section 10 FUELGAUGE See section 11 A T GEAR POSITION INDICATOR Seesection 14 ...

Page 1085: ... 2 BRAKE SYSTEM LIGHT 1 4 W A T GEAR POSITION INDICATOR LIGHTS 1 4 W x 7 LOW FUEL INDICATOR LIGHT 2 W TCS INDICATOR LIGHT 1 4 W 1 GAUGE LIGHT 3 0 W HIGH BEAM INDICATOR LIGHT 1 4 W CRUISE CONTROL INDICATOR 1 4 W 1 VSA ACTIVATION INDICATOR LIGHT 1 4 W 2 1 96 99 models 2 00 01 models MAINTENANCE REMINDER LIGHT Blinking Pattern Miles km Maintenance Reminder Light O to about 6 000 9 600 Does not come o...

Page 1086: ...be recalibrated 3 to meet the customer s expectations 1 Turn the ignition switch ON II 2 Select the outside air temperature mode then push and hold the reset button for 10 seconds While you continue to hold the reset button the display will scroll through temperature settings from 3 to 3 as shown 3 When the desired correction value appears on the display release the reset button and the recalibrat...

Page 1087: ...om the vehicle speed sensor VSS NOTE The VSS drive link is a very small part be careful not to lose it Vehicle Speed Sensor VSS DRIVE LINK VSS 3P CONNECTOR MOUNTING BOLT MOUNTING BOLT 2 Remove the two mounting bolts then remove the VSS 3 Install in the reverse order of removal 3 Disconnect the connectors and remove the gauge assembly 4 Install in the reverse order of removal GAUGE ASSEMBLY SCREW G...

Page 1088: ... ignition switch ON II Is there battery voltage Repair open in the YEL wire between the VSS and under dash fuse relay box NO YES Test the BLU WHT wire 1 Disconnect the WHT test har ness clip 2 Connect the GRN test harness clip to the positive probe of a voltmeter Is there 5 V or more NO Repair short in the BLU WHT wire between the VSS and PCM cruise control unit steering column control unit multip...

Page 1089: ...re side of female terminals BLU WHT Repair open in the BLU WHT wire between the VSS and the speedometer Does the meter indicate pulsing voltage YES NO Replace the speedometer Speedometer Test 1 Disconnect the 22P connector A from the gauge assembly 2 Touch a probe to the BLU WHT wire and connect it to body ground through a volt meter 3 Slowly rotate one wheel with the other wheel blocked Does volt...

Page 1090: ...also test the switch by using the self diagnosis function mode 2 See page 23 252 Safety Indicator Component Location Index SRS components are located in this area Review the SRS component locations precautions and procedures in the SRS section 24 before performing repairs or service SAFETY INDICATOR Input Test page 23 94 FRONT PASSENGER S DOOR SWITCH Test page 23 264 RIGHT REAR DOOR SWITCH Test pa...

Page 1091: ...oded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input test prove OK the gauge printed circuit panel must be faulty replace it 22P CONNECTOR A C508 30P CONNECTOR B C509 WHT GRN Wire side of female terminals GRN BLU GRN RED GRN YE...

Page 1092: ...Cavity Wire Test condition Test Desired result Possible cause if result is not obtained ...

Page 1093: ...e safety indicator does not come on and stay on when the No 1 terminal of the 8P connector is grounded and the ignition switch is turned from OFF to ON II If the light does not go off check for an open in the WHT GRN wire between the safety indicator and left taillight a faulty safety indicator circuit in the gauge assembly If the light goes off go to step 5 5 Make sure the light in the safety ind...

Page 1094: ...tion switch is turned from OFF to ON II If the light does not go off replace the left or right brake light failure sensor If the light goes off check for a poor ground G701 an open in the BLK wire Wire side of female terminals GRN WHT BLK 3 Make sure the light in the safety indi cator does not come on and stay on when the left and right 6P connectors are disconnected and the ignition switch is tur...

Page 1095: ...gnals from the automatic lighting sensor which senses the lux illumination level outside the vehi cle and it controls the lights by means of the lighting relay and taillight relay NOTE The exterior lights other than the headlights circuit is included with the fog lights circuit While in the AUTO mode when the exterior lights are turned off the fog lights are turned off automatically While in the A...

Page 1096: ...cement page 23 131 HEADLIGHTRELAY Test page 23 67 SIDE MARKER LIGHT FRONT TURN SIGNAL LIGHT HEADLIGHT and FRONT PARKING LIGHT AUTOMATIC LIGHTING CONTROL UNIT USA Input Test page 23 114 DAYTIME RUNNING LIGHTS CONTROL UNIT Canada Input Test page 23 116 FOG LIGHT Adjustment page 23 127 SIDE MARKER LIGHT REARTURN SIGNAL LIGHT BACK UPLIGHT TAILLIGHT Replacement page 23 125 BRAKE LIGHT Replacement page ...

Page 1097: ...page 23 125 FOG LIGHT Adjustment page 23 127 Replacement page 23 127 TAILLIGHT RELAY Test page 23 69 UNDER HOOD RELAY BOX C AUTOMATIC LIGHTING SENSOR USA DIMMER RELAY Test page 23 69 HEADLIGHT High beam HEADLIGHT Low beam FRONT TURN SIGNAL SIDE MARKER LIGHT HEADLIGHT LOW BEAM RELAY Test page 23 68 HEADLIGHT HIGH BEAM RELAY Test page 23 67 UNDER HOOD FUSE RELAY BOX ...

Page 1098: ...DAYTIME RUNNING LIGHTS CONTROL UNIT Canada Input Test page 23 116 HIGH MOUNT BRAKE LIGHT Replacement page 23 131 LICENSE PLATE LIGHTS Replacement page 23 128 BACK UPLIGHT Replacement page 23 125 TAILLIGHT BRAKELIGHT Replacement page 23 125 REARTURN SIGNAL LIGHT ...

Page 1099: ...nt loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input test probe OK the control unit must be faulty replace it 14P CONNECTOR BLK YEL RED YEL AUTOMATIC LIGHTING CONTROL UNIT Wire side of female terminals BLK BLK W...

Page 1100: ...n open in the wire Blown No 56 7 5 A fuse in the under hood fuse relay box An open in the wire Faulty driver s door switch Poor ground G401 G402 An open in the wire Faulty combination light switch Poor ground G401 G402 An open in the wire Faulty taillight relay An open in the wire Blown No 1 15 A fuse in the under dash fuse relay box NOTE Before testing connect a voltmeter and jumper wires as show...

Page 1101: ...s necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input test prove OK the control unit must be faulty replace it DAYTIME RUNNING LIGHTS CONTROL UNIT 14PCONNECTOR YEL BLU RED BLU WHT BLU 1 RED BLK 2 WHT BLU 1 RED YEL 2 GRN WHT 3 GRN RED 4 BLK Wire s...

Page 1102: ......

Page 1103: ...cessary and recheck the system If the terminals look OK check for continuity between them in each switch position according to the table If there is no continuity between any of them check for continuity in the switch harness If there is continuity in the switch harness replace the combination light switch If there is no continuity in the switch harness replace it 14PCONNECTOR Wire side of female ...

Page 1104: ...USA With automatic lighting system USA Without automatic lighting system 96 99 Canada models 00 01 Canada models Turn signal switch 00 01 Canada models ...

Page 1105: ...2 terminal of the inverter unit 2P connector and body ground INVERTER UNIT 2P CONNECTOR Is there battery voltage YES Go to step 6 NO Repair open in the wire between the under hood fuse relay box and the inverter unit 6 Turn the combination light switch OFF YES Substitute a known good inverter and recheck If the symptom indication goes away replace the original inverter unit NO Replace the igniter ...

Page 1106: ...h them or the attaching hardware immediately afterthey have been turned off 1 Remove the front bumper and front bumper upper beam see section 20 2 Disconnect the connectors 3 Remove the four mounting bolts then remove the headlight assembly HEADLIGHT ASSEMBLY 96 98 models HEADLIGHT 60 55 W FRONT TURN SIGNAL LIGHT 21 W FRONT PARKING LIGHT 5 W x 2 FRONT FOG LIGHT 55 W SIDE MARKER LIGHT 5 W 99 01 mod...

Page 1107: ...ts Do not disassemble the inverter unit and the igniter unit Do not turn on the HID bulb by using a power source other than the battery mounted on your vehicle 1 Make sure you have the anti theft code for the radio and the navigation system then write down the fre quencies for the radio s preset buttons 2 Turn the combination light switch OFF 3 Disconnect the battery negative cable then discon nec...

Page 1108: ...Check the vertical adjustment indicator The bubble should be centered underneath the longest scribe mark on the gauge 4 If either indicator is not aligned with its O mark as described above an adjustment can be made by using a Phillips screwdriver VERTICAL INDICATOR INDICATOR Bubble 5 Adjust the headlights to local requirements by turn ing the adjusters 6 After headlight replacement it may be nece...

Page 1109: ...adlights 4 Turn the low beams on 5 Determine if the headlights are aimed properly Vertical adjustment Measure the height of the headlights A The lights should reflect 52 mm 2 1 in below B the head light height Horizontal adjustment 99 00 models The width of the refracting points C should be the same as the width of the headlight central points D E 2 Park the vehicle in front of a wall or a screen ...

Page 1110: ... them run water over the lights to make sure they do not leak Taillights Replacement 1 Open the trunk lid and pull back the trunk side panel 2 Disconnect the connector s from the taillight assembly 3 Remove the four mounting nuts and the taillight assembly GASKET CONNECTOR TAILLIGHT ASSEMBLY ...

Page 1111: ... fog light switch then disconnect the connector Without Navigation System FOG LIGHT SWITCH BULB 0 84 W 5P CONNECTOR With Navigation System 2 Check for continuity between the terminals in each switch position according to the table 99 01 models with Navigation System BULB 0 84W FOG LIGHT SWITCH CONNECTOR 96 98 models 99 01 models ...

Page 1112: ...e do not touch them or the attaching hardware immediately after they have been turned off 1 Remove the mounting bolt 2P CONNECTOR MOUNTING BOLT FOGLIGHT Bulb 55W 2 Remove the fog light assembly then disconnect the 2Pconnector 3 Install the fog light in the reverse order of removal 4 After replacement adjust the fog lights to local requirements 99 01 models ...

Page 1113: ...ls 1 Remove the two screws from the license plate light assembly 2 Pull the light out and disconnect the 2P connector from the light License Plate Light 2P CONNECTOR 99 01 models 1 Slide and pull out the license plate light 2 Disconnect the 2P connector from the light 2P CONNECTOR BULB 5W LENS BULB 3CP LENS ...

Page 1114: ...High Mount Brake Light Replacement 1 Remove the rear shelf see section 20 2 Loosen the mounting bolts HIGH MOUNT BRAKE LIGHT 3 Remove the high mount brake light 2PCONNECTOR SOCKET MOUNTING BOLT ...

Page 1115: ...nt Location Index TURN SIGNAL SWITCH Test page 23 118 TURN SIGNAL INDICATOR LIGHTS In the gauge assembly Bulb Locations page 23 76 HAZARD WARNING SWITCH Test page 23 135 TURN SIGNAL HAZARD RELAY Input Test page 23 134 UNDER DASH FUSE RELAY BOX ...

Page 1116: ...nals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the socket If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the turn signal hazard relay must be faulty replace it UNDER DASH FUSE RELAY BOX TURN SIGNAL HAZARD RELAY Cavity Test condition Test De...

Page 1117: ...TOR 3 Remove the switch from the navigation display unit 4 Check for continuity between the terminals in each switch position according to the table Without Navigation System 1 Remove the hazard warning switch 2 Disconnect the 5P connector from the switch HAZARD WARNING SWITCH 5P CONNECTOR BULB 0 84 W 3 Check for continuity between the terminals in each switch position according to the table ...

Page 1118: ...ntrol System see page 23 257 DRIVER S VANITY MIRROR LIGHT Test page 23 140 FRONT PASSENGER S VANITY MIRROR LIGHT Test page 23 140 TRUNK LIGHT Test page 23 139 GLOVE BOX LIGHT Test page 23 139 TRUNK LID LATCH SWITCH Test page 23 353 You can also test the switch by using the self diagnosis function mode 2 See page 23 252 ...

Page 1119: ...or NOTE If necessary remove the glove box BULB 3 4 W 2 Check for continuity between the terminals in each switch position according to the table 2 Pry out the light assembly 3 Disconnect the 2P connector from the housing 4 Make sure the bulb and check for continuity between the No 1 and No 2 terminals LENS BULB 5 W HOUSING 2P CONNECTOR ...

Page 1120: ... for continuity between the terminals in each switch position according to the table Without Homelink Remote Control System 1 Remove the two screws from the sunvisor bracket 2 Remove the sunvisor then disconnect the positive terminal POSITIVE TERMINAL SUNVISOR MOUNT BASE SCREWS SUNVISOR LENS BULB 2 0 W NOTE The switch is built into the vanity mirror 3 Check for continuity between the terminals in ...

Page 1121: ...Clock Removal 1 Remove the climate control unit see section 22 2 Remove the two screws then remove the clock CLIMATE CONTROL UNIT Terminals Cavity Wire Connects to CLOCK SCREWS ...

Page 1122: ...GHTTWEETER Replacement page 23 153 FRONTPASSENGERSDOORSPEAKER Replacement page 23 153 WINDOW ANTENNA Test page 23 155 Repair page 23 155 RIGHTREARDOORSPEAKER Replacement page 23 153 REAR SPEAKERS Replacement page 23 153 STEREOAMPLIFIER Terminals page 23 143 Removal page 23 152 Stereo Sound System Component Location Index SRS components are located in this area Review the SRS component locations pr...

Page 1123: ...al P N 61SZ305 page 23 153 AUDIO AMPLIFIER Terminals page 23 36 Removal 96 01 3 5RL Service manual P N 61SZ305 page 23 152 LEFT TWEETER Replacement 96 01 3 5RL service manual P N 61SZ305 page 23 153 LEFT TWIDDLER Replacement 96 01 3 5RL service manual P N 61SZ305 page 23 153 DRIVER S DOOR SPEAKER Replacement 96 01 3 5RL service manual P N 61SZ305 page 23 153 REAR SPEAKERS Replacement 96 01 3 5RL s...

Page 1124: ...Stereo Amplifier Terminals With Bose Sound System Cavity Wire Connects to Cavity Wire Connects to ...

Page 1125: ...Audio System Audio Amplifier Terminals ...

Page 1126: ...ound System Audio Unit Terminals 96 98 models Standard Sound System 99 01 models Bose Sound System without navigation system 96 98 models Bose Sound System 99 01 models Bose Sound System with navigation system ...

Page 1127: ...d C9 are not used 1 96 99 models 2 00 01 models 3 With navigation system Bose Sound System Standard Sound System Cavity Wire Connects to Cavity Wire Connects to Terminals B1 B2 B3 B4 B6 and B7 are not used With Navigation System ...

Page 1128: ...Stereo Sound System Audio Unit Terminals 02 03 Models Without Navigation System 02 03 Models With Navigation System ...

Page 1129: ...interface unit Cellular phone Dash lights brightness Radio remote switch Ground G403 Output Left rear Output Right rear 2 B2 2 B3 B5 B8 WHT BLU RED BLK BLU or GRN 1 OnStar control unit Line in OnStar control unit Line in Ground G401 G402 Multiplex control unit pas senger s Terminal B1 B4 B6 and B7 are not used C4 C7 1 C8 1 C9 C10 WHT LT GRN BLU RED WHT BLK Navigation unit Navigation unit OnStar co...

Page 1130: ...Audio Unit Terminals 04 Model Without Navigation System 04 Model With Navigation System ...

Page 1131: ... for the radio s preset buttons 2 Remove the navigation panel and audio panel assembly seesection 20 3 Remove the four mounting screws then remove the navigation monitor 4 Loosen the audio unit mounting screws 5 Remove the pins from the bracket then remove the navigation panel 7 Install in the reverse order of removal 8 After installing the audio unit enter the anti theft code for the radio and th...

Page 1132: ... enter the anti theft code for the radio then enter the customer s radio station presets Without navigation system 1 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s preset buttons 2 Remove the automatic climate control panel and audio panel assembly see section 20 SCREW AUDIO UNIT BRACKET BOLT ...

Page 1133: ...bracket Stereo Sound System CD Changer Removal 1 Open the trunk lid 2 Remove the CD changer cover Stereo Amplifier Removal 1 Remove the rear seat see section 20 2 Loosen the three amplifier mounting bolts COVER CD CHANGER CD CHANGER BRACKET STEREO AMPLIFIER MOUNTING BOLTS CONNECTORS 3 Slide the amplifier out of its three mounting slots disconnect the 12P and 18P connectors then remove the amplifie...

Page 1134: ... screws and tweeter TWEETER SPEAKER COVER 2P CONNECTOR SPEAKER SCREW Rear Speaker 1 Remove the rear seat back see section 20 2 Remove the rear shelf see section 20 3 Remove the four screws then disconnect the 2P connector from the speaker 4 Remove the speaker from the speaker adapter Rear Door Speaker 1 Remove the rear door panel see section 20 2 Remove the four screws then disconnect the 2P conne...

Page 1135: ...io remote switch RADIO REMOTE SWITCH SWITCH COVER 2P CONNECTOR 2 Remove the radio remote switch from the steering wheel by removing the two screws and disconnect the 2P connector 3 Remove the remote switch from the steering wheel seesection 17 4 Measure resistance between the No 1 and No 2 terminals in each switch position according to the table Position Resistance Approx 100 Approx 350 Approx 770...

Page 1136: ...o longer than one inch 1 Lightly rub the area around the broken section with fine steel wool then clean it with alcohol 2 Carefully mask above and below the broken portion of the window antenna wire with cellophane tape 4 Check for continuity in the repaired wire 5 Apply a second coat of paint in the same way Let it dry 3 hours before removing the tape PAINT 3 Using a small brush apply a heavy coa...

Page 1137: ...Audio System XM Receiver Terminals 03 Model With Navigation System ...

Page 1138: ...ct the connectors from the XM antenna and the cellular phone antenna 3 Remove the nuts from the XM antenna and the cel lular phone antenna 4 Remove the XM antenna and the cellular phone antenna 5 Remove from the phone antenna from the XM antenna XM ANTENNA CELLULAR PHONE ANTENNA ...

Page 1139: ...Accessory Power Socket Replacement 1 Remove the rear console see section 20 2 Remove the accessory power socket from the rear console ACCESSORY POWER SOCKET ...

Page 1140: ...e thermal protector 4 When installing the cigarette lighter align each lug on the face panel illumination ring and cigarette lighter socket with the groove in the hole then position the bulb housing on the thermal protector between the stops in the console panel ILLUMINATION RING CIGARETTE LIGHTER SOCKET FRONT ASHTRAY PANEL ASHTRAY LIGHT 1 4 W THERMAL PROTECTOR RING NUT LIGHT 1 4 W THERMOFUSE HOUS...

Page 1141: ...EEL See section 24 UNDER HOOD RELAY BOX B Wire colors WHT YEL ORN BLU RED and WHT YEL Test page 23 67 HORNRELAY 1 HORN 96 98 models Test page 23 161 SECURITY HORN 99 01 models Test page 23 161 HORNS Test page 23 161 SECURITY HORN RELAY 99 01 models Test page 23 68 Wire colors WHT YEL BLU ORN BLU RED and WHT YEL Test page 23 69 HORN RELAY 2 HORN SWITCH Test page 23 162 1 96 97 models 2 98 01 models...

Page 1142: ...OR CONNECTOR Horn Test 1 Disconnect the 2P or 1P connectors from the horns LEFT HORN 3 Test the horn by connecting battery power to one terminal and grounding the other The horn should sound 4 If the horn fails to work replace it No 2 Ground No 1 No 1 No 2 ...

Page 1143: ...00 01 USA models 3 00 01 Canada models If there is continuity go to step 9 If there is no continuity check for an open in the wire of the combination switch harness Wire side of female terminals 4P CONNECTOR Wire side of female terminals 4 Remove the steering column upper and lower covers 5 Disconnect the 4P connector from the cable reel 6 Go to step 7 for except 00 01 Canada models and go to step...

Page 1144: ...move the driver s airbag see section 24 13 Check for continuity between the horn switch positive terminal and steering wheel nut with the horn switch pressed HORN SWITCH POSITIVE TERMINAL STEERING WHEEL NUT 96 98 models 99 00 models STEERING WHEEL NUT HORN SWITCH POSITIVE TERMINAL If there is continuity checkthe cable reel see section 24 check the set resume cancel switch seesection 4 If there is ...

Page 1145: ... no voltage replace the seat belt tensioner assembly If there is battery voltage go to step 6 6 Turn the ignition switch OFF 7 Check for continuity between the No 1 and body ground with the seat belt buckled There should be continuity If there is no continuity check for poor ground G601 G651 an open in the BLU RED wire faulty seat belt switch 3 Check for voltage between the No 2 terminal and body ...

Page 1146: ...nroof system has an automatic stop function When the moonroof CLOSE switch is pressed the moonroof starts to close and stops once about 130 mm 5 1 in before the fully closed position When the CLOSE switch is released and pressed again the moonroof will close fully MOONROOF OPEN RELAY Wirecolors YEL GRN orYEL GRN YEL GRN BLU and BLK Test page 23 69 MOONROOF CLOSE RELAY Wirecolors YEL GRN orYEL GRN ...

Page 1147: ...ED YEL GRN 1 YEL 2 IgnitionswitchON II Ignition switch ON II IgnitionswitchON II Ignition switch ON II Check for voltage to ground There should be battery voltage Check for voltage to ground There should be battery voltage Attach to ground The moonroof motor should run open Attach to ground The moonroof motor should run close Blown No 51 30 A fuse in the under hood fuse relay box Blown No 23 10 A ...

Page 1148: ...GRN BLK YEL BLU Under all conditions Ignition switch ON II Under all conditions Ignition switch ON II Open switch ON pressed ignitionswitch OFF Check for continuity to ground There should be continuity Check for voltage to ground There should be battery voltage with the limit switch 4 ON Check for continuity to ground There should be continuity Check for voltage to ground There should be battery v...

Page 1149: ... less than 2 V with the limit switch 1 OFF and the limitswitch 4 ON Check for voltage to ground There should be less than 3 V Check for voltage to ground There should be battery voltage Faulty limit switch 1 An open in the wire Poor ground Faulty moonroof switch An open in the wire Poor ground Faulty limit switch 1 Faulty limit switch 4 Faulty moonroof switch An open in the wire Poor ground Faulty...

Page 1150: ... MOONROOF MOTOR 2P CONNECTOR Terminal side of male terminals 6 Test the motor by connecting power and ground according to the table If the motor runs smoothly repair the moonroof wire harness If the motor fails to run or does not run smoothly replace the motor see section 20 NOTE See closing force check in section 20 for motor clutch test If the motor fails to run or does not run smoothly go to st...

Page 1151: ...ly pry the switch out and disconnect the 5P connector from the switch 5P CONNECTOR 2 Check for continuity between the terminals in each switch position according to the table Terminal side of male terminals MOONROOF SWITCH ...

Page 1152: ...t page 23 69 UNDER HOOD RELAY BOX C SEATHEATERRELAY 3 Test page 23 67 DRIVER S SEAT HEATER SWITCH Test Replacement page 23 176 DRIVER S SEAT CUSHION HEATER Test page 23 176 DRIVER S SEAT BACK HEATER Test page 23 176 FRONT PASSENGER S SEAT HEATER SWITCH Test Replacement page 23 176 FRONT PASSENGER S SEAT CUSHION HEATER 4 Test page 23 176 FRONT PASSENGER S SEAT CUSHION HEATER Test page 23 176 UNDER ...

Page 1153: ...W x 3 6P CONNECTOR FRONT PASSENGER S SEATHEATER SWITCH 3 Check for continuity between the terminals in each switch position according to the table 2 Check for continuity between the No 1 and No 4 terminals and No 3 and No 4 terminals There should be continuity Heater Test 1 Carefully remove the driver s and front passenger s seat see section 20 Driver s seat Front passenger s seat Terminal side of...

Page 1154: ... and a control unit The control unit receives signals from each sensor Based on the difference between the two lux levels the light outside the vehicle and the light from the headlights of the other vehicle etc the control unit controls the elector chromic gel to reduce the glare This dimming function is canceled when the transmission is in reverse or when the automatic inside dimming mirror switc...

Page 1155: ...h sensor Based on the difference between the two lux levels the light outside the vehicle and the light from the headlights of the other vehicle etc the control unit controls the electro chromic gel to reduce the glare This dimming function is canceled when the transmission is in reverse or when the automatic inside dimming mir ror switch is turned OFF BACKWARD LUX LEVEL SENSOR SWITCH FORWARD LUX ...

Page 1156: ...nd body ground with the ignition switch ON II If there is battery voltage go to step 4 If there is no voltage check for an open in the wire or poorground G401 G402 4 Check for voltage between the No 2 terminal and body ground with the ignition switch ON II and A T gear position in If there is battery voltage replace the mirror by removing three screws If there is no voltage check for an open in th...

Page 1157: ...the ignition switch ON II If there is battery voltage go to step 3 If there is no voltage check for an open in the wire or poorground G401 G402 3 Check for voltage between the No 16 terminal and body ground with the ignition switch ON II and A T gear position in If there is battery voltage replace the mirror by removing torx screw If there is no voltage check for an open in the wire or faulty reve...

Page 1158: ... Component Location Index FRONT PASSENGER S SEAT RECLINE MOTOR Test page 23 181 Replacement section 20 SLIDE MOTOR Test page 23 181 Replacement section 20 SLIDE SWITCH ADJUSTMENT SWITCH Test Replacement page 23 181 RECLINE SWITCH ...

Page 1159: ...e table CAUTION When a motor stops running disconnect battery power immediately 4 If the motor does not run or fails to run smoothly replace it see section 20 Motor Test CAUTION Be careful not to damage the seat interior trim or body 1 Remove the front passenger s seat see section 20 2 Disconnect the 2P connector from each power seat motor SLIDE MOTOR RECLINE MOTOR Terminal side of male terminals ...

Page 1160: ... page 23 187 IMMOBILIZER INDICATOR LIGHT Bulb Locations page 23 76 IMMOBILIZER RECEIVER Test page 23 188 Replacement page 23 189 STARTER CUT RELAY Test page 23 68 TRANSPONDER Built into the ignition key Test page 23 188 IGNITION KEY Master and valet keys UNDER DASH FUSE RELAY BOX ...

Page 1161: ...mmobilizer sys tem NOTE This key cannot start the engine do not use it except for rewriting the system If someone tries to start the engine with the learning key all master and valet keys must be relearned When the key is inserted in the ignition and turned to the II position the immobilizer control unit sends power to the transponder through the receiver The transponder then sends a coded signal ...

Page 1162: ...ode sent by the transponder If a key has been used whose code was not received or recognized by the unit or which was not approved by Acura the indicator light will come on for about 2 seconds then it will blink continuously If the ignition switch is turned OFF the indicator will blink for about 5 seconds to signal that the unit has been set cor rectly then the indicator will go off IMMOBILIZER IN...

Page 1163: ...er equipped with an immobilizer program card Any key that is not learned during rewriting will no longer start the engine If the customer has lost his key and cannot start the engine contact Acura Customer Relations or Roadside Assistance Before Testing Due to the action of the immobilizer system the engine takes slightly more time to start than engines of vehicle without an immobilizer system Whe...

Page 1164: ...nder all conditions Check for voltage to ground There should be battery voltage Check for continuity to ground There should be continuity Check for voltage to ground There should be battery voltage Check for voltage to ground There should be battery voltage Attach to ground The immobilizer indicator light should come on Check for continuity between the A6 terminal and PCM 12P connector No 11 termi...

Page 1165: ...art ImmobilizersystemisOKnow Wire side of female terminals Is there continuity NO Short in the shielded wires between the immobilizer receiver and the immobilizer control unit Replacethewireharness Measure resistance between the B1 and B3 terminals ofthe 3P con nector Is there about 15 ohms YES Faulty receiver or open in the shielded wires between the immo bilizer receiver and immobilizer control ...

Page 1166: ...cylinder housing with pushing the lock pin NOTE The lock pin can be pushed by pulling the key in position I 4 The remaining installation is the reverse of the removal procedure NOTE This harness is shielded and serves as a communication link be careful not to damage it 7 Turn the ignition key to I 8 Push the lock pin and remove the key cylinder by pulling the ignition key NOTE Don t pull on the im...

Page 1167: ...t Test page 23 238 FRONT UP DOWN POSITION SENSOR Test page 23 229 DRIVER SPOWERSEAT REAR UP DOWN POSITION SENSOR Test page 23 229 RECLINE MOTOR Test page 23 228 Replacement section 20 RECLINE POSITION SENSOR Test page 23 229 REAR UP DOWN MOTOR Test page 23 228 Replacement section 20 POWER SEAT ADJUSTMENT SWITCH Test page 23 227 Replacement section 20 SLIDE MOTOR Test page 23 228 Replacement sectio...

Page 1168: ...OTOR Test page 23 226 TILT MOTOR Test page 23 226 EXTEND RETRACT SENSOR Test page 23 226 TILT POSITION SENSOR Test page 23 226 STEERING COLUMN SWITCH Test page 23 225 STEERING COLUMN CONTROL UNIT Input Test page 23 230 ...

Page 1169: ...OWERSEATPOSITIONSENSORS Each motor has a reed switch sensor which detects motor rotation and sends a pulse to the power seat control unit when the motor rotates The control unit stores the number of pulses in its memory and the seat position is memorized POWERMIRRORPOSITIONSENSORS By means of a Hall effect type tilt position sensor and swing position sensor the power mirror control unit detects th...

Page 1170: ...sitions can be memorized within these ranges NOTE The power mirror position can be memorized within all ranges of the mirror movements Power Seat NEUTRAL Steering Column 240 mm 9 4 in 40 mm 1 6 in RETRACT EXTEND TILT DOWN TILT UP 30 mm 1 2 in ...

Page 1171: ...roblem s Exist s ExampleshowsDTC 12 Up to five DTCs can be indicated in the order the problems occurred The first digit is indicated by the number of long 1 second blinks and the second digit is indicated by the number of short 0 26 second blinks There is a 3 second break between each DTC when there are multiple DTCs MEMO button Pos button 1 Pos button 2 Ignition switch Indicator 1 Indicator 2 Can...

Page 1172: ...y is pulled out Steering column doesn t tilt up or the steering column position cannot be retrieved with the shift lever in Possible Cause Fault in slide switch or slide switch wiring Fault in recline switch or recline switch wiring Fault in front up down switch or front up down switch wiring Fault in rear up down switch or rear up down switch wiring Fault in tilt switch or tilt switch wiring Faul...

Page 1173: ...thout turning the ignition switch ON II and the vehicle parked the steering column will return to the position it was in before mode 1 began Mode 3 When one of position buttons is pressed with the vehicle parked and the ignition key is inserted the steering column the seat and the mirrors will move to their memorized positions NOTE The priority of the automatic adjustments are shown If the ignitio...

Page 1174: ...hers Symptom The driving position cannot be stored The position button indicators do not come on or do not blink Flowchart 9 11 Page 23 220 23 224 Communication Lines NOTE There are two communication lines between the steering column control unit and the power seat control unit and two communication lines between the steering column control unit and the power mirror control unit If one communica t...

Page 1175: ...olumn control unit stands for steering column control unit mirror control unit stands for power mirror control unit seat control unit stands for power seat control unit All connector views are from wire side of female terminals Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the ...

Page 1176: ...ery voltage Check for continuity to ground There should be continuity Check for voltage to ground There should be no voltage Check for voltage to ground There should be approx 5 V Blown No 20 20 A fuse in the under dash fuse relay box An open in the wire Blown No 56 7 5 A fuse in the under hood fuse relay box An open in the wire Blown No 11 20 A fuse in the under dash fuse relay box An open in the...

Page 1177: ...Check for continuity between the terminals in each switch position according to the table 3 Check for continuity between the terminals in each switch position according to the table Steering Column Switch Test 1 Remove the steering column covers see section 20 2 Disconnect the 7P connector from the switch then remove the switch from the steering column lower cover STEERING COLUMN SWITCH STEERING C...

Page 1178: ...tor Extend retract Motor CAUTION When a motor stops running disconnect battery power immediately Tilt Extend retract Position Sensor Test 1 Remove the steering column covers see section 20 2 Disconnect the 4P connector from the sensor EXTEND RETRACT POSITION SENSOR 4P CONNECTOR Terminal side of male terminals 3 Measure resistance between the terminals in each position according to the table Positi...

Page 1179: ...y removing its two mounting screws Driver s Power Seat Switch Test 1 Remove the adjustment switch cover and pull off the adjustment switch knob see section 20 DRIVER S POWER SEAT ADJUSTMENT SWITCH 3 Check for continuity between the terminals in each switch position according to the table ...

Page 1180: ...nnect the connector from each power seat motor Terminal side of male terminals RECLINE MOTOR REAR UP DOWN MOTOR DRIVER S SEAT FRONT UP DOWN MOTOR Terminal side of male terminals SLIDE MOTOR 3 Test the motors according to the table CAUTION When a motor stops running disconnect battery power immediately 4 If the motor does not run or fails to run smoothly replace it see section 20 ...

Page 1181: ...NSOR REAR UP DOWN POSITION SENSOR FRONT UP DOWN POSITION SENSOR SLIDE POSITION SENSOR NOTE If a motor does not run reverse power and ground If the motor still does not run replace the motor 3 Test the sensor by connecting power and ground to the motor and connect an analog ohmmeter test leads to the sensor connector The needle in the ohmmeter should move from left to right CAUTION When a motor sto...

Page 1182: ...oblem find and correct the cause then recheck the system If all the input tests prove OK substitute a known good control unit and recheck the system NOTE If all the control unit steering column power seat power mirror input tests prove OK disconnect all three control units and check for opens or shorts in the communication lines All connector views are from wire side of female terminals STEERING C...

Page 1183: ...nuity Check for voltage to ground There should be 1 V or less Check for voltage to ground There should be 4 V or more Attach to ground The indicator should come on Check for voltage to ground There should be 1 V or less Check for voltage to ground There should be 4 V or more Check for voltage to ground The voltage should pulse from 0 V to about 5 V or more Blown No 20 20 A fuse in the under dashfu...

Page 1184: ...There should be no continuity Check for continuity There should be continuity Check for continuity There should be no continuity Check for continuity There should be continuity Check for continuity There should be no continuity Check for continuity There should be continuity Check for continuity There should be no continuity Check for continuity There should be continuity Check for continuity Ther...

Page 1185: ...in the wire Reconnect all connectors to the steering column control unit Cavity Wire Test condition Test Desiredresult Possible cause if result is not obtained B2 B10 B9 B10 B1 B10 GRY BRN PNK BRN BLU BRN Under all conditions with all steering column control unit connectors connected Under all conditions with all steering column control unit connectors connected Under all conditions with all steer...

Page 1186: ...ect the cause then recheck the system If all the input tests prove OK substitute a known good control unit and recheck the system NOTE If all the control unit steering column power seat power mirror input tests prove OK disconnect all three con trol units and check for opens or shorts in the communication lines All connector views are from wire side of female terminals 12P CONNECTOR A POWER SEAT C...

Page 1187: ...inuity Check for continuity between the B12 and B16 terminals There should be no continuity Check for continuity between the B 3 and B16 terminals There should be continuity Check for continuity between the B 3 andB16terminals There should be no continuity Check for continuity between the B11 and B16 terminals There should be continuity Check for continuity between the B11 and B16 terminals There ...

Page 1188: ...ontinuity Check for continuity between the B14 and B16 terminals There should be no continuity Check for continuity between the B5andB16terminals There should be continuity Check for continuity between the B5 and B16 terminals There should be no continuity Check for continuity between the B13 and B16 terminals There should be continuity Check for continuity between the B13and B16terminals There sh...

Page 1189: ...e recline motor operation The motor should run forward Check the recline motor operation The motor should run backward Faulty front up down motor An open in the wire Faulty front up down motor An open in the wire Faulty rear up down motor An open in the wire Faulty rear up down motor An open in the wire Faulty slide motor An open in the wire Faulty slide motor An open in the wire Faulty recline mo...

Page 1190: ... indicates a problem find and correct the cause then recheck the system If all the input tests prove OK substitute a known good control unit and recheck the system NOTE If all the control unit steering column power seat power mirror input tests prove OK disconnect all three control units and check for opens or shorts in the communication lines All connector views are from wire side of female termi...

Page 1191: ... to ground There should be continuity Check for voltage to ground There should be batteryvoltage Check for voltage to ground There should be battery voltage Check for voltage to ground There should be battery voltage Checkfor voltage to ground There should be battery voltage Check for voltage to ground There should be battery voltage Blown No 56 7 5A fuse in the under hood fuse relay box An open i...

Page 1192: ...trol unit Cavity Wire Test condition Test Desiredresult Possible causeifresult is notobtained B8 B16 B7 B16 B15 B16 B6 B16 B14 B16 RED BLK BRN WHT GRN BRN WHT GRY BRN WHT GRN WHT BRN WHT GRY BRN WHT Ignition switch ON II NOTE Connect all mirror control unit connectors Ignition switch ON II NOTE Connect all mirror control unit connectors Ignition switch ON II NOTE Connect all mirror control unit co...

Page 1193: ... PNK BLKand BLK MULTIPLEX CONTROL UNIT DRIVER S Description The multiplex control system is composed of three control units located in the driver s side kick panel passenger s side kick panel and driver s door These three control units send multiplex signals over shared wires reduce the number of control units and wire harness weight and improves the quality of electrical functions by means of the...

Page 1194: ...iplex control units Wire color BRN YEL Driver s Passenger s from the driver s to the passenger s multiplex control units Wire color BRN WHT Passenger s Driver s from the passenger s to the driver s multiplex control units Wire color RED YEL The control units always communicate via these lines when the system is operating and they stop communicating when the system is OFF Wake up and Sleep Function...

Page 1195: ... power and ground sys tem see page 23 245 Is the power and ground system OK Repair the power and ground system NO YES Check the self diagnosis function Mode 1 for a diagnostic trouble code DTC see page 23 248 Find and repair the cause of the DTC YES Is a DTC indicated NO Check the wake up function see page 23 249 NO Repair the wake up function Is the wake up function OK YES Troubleshoot the indivi...

Page 1196: ... MULTIPLEX CONTROL UNIT DOOR DRIVER S DOOR PANEL 2OP CONNECTOR Wire side of female terminals WHT YEL GRN WHT 1 WHT BLK 2 BLK BLK 1 Cavity Wire Test condition Test Desired result Possible cause if result is not obtained WHT YEL GRN WHT or WHT BLK BLK Under all conditions Ignition switch ON II Under all conditions Check for voltage to ground There should be battery voltage Check for voltage to groun...

Page 1197: ...TIPLEX CONTROL UNIT PASSENGER S 22P CONNECTOR Cavity Wire Test condition Test Desired result Possible cause if result is not obtained Under all conditions Under all conditions Under all conditions Ignition switch ON II Under all conditions WHT YEL BLK WHT YEL BLK Check for voltage to ground There should be battery voltage Check for continuity to ground There should be continuity Check for voltage ...

Page 1198: ...the control unit must be faulty replace it Wire side of female terminals MULTIPLEX CONTROL UNIT DRIVER S 16P CONNECTOR 26P CONNECTOR 2 Canada Cavity Wire Test condition Test Desired result Possible cause if result is not obtained Under all conditions Under all conditions Ignition switch ON II Check for voltage to ground There should be battery voltage Check for continuity to ground There should be...

Page 1199: ...ds The system is OK NO Does the ignition key light and buzzer come ON YES MULTIPLEX CONTROL INSPECTION CONNECTOR Go to self diagnosis function mode 1 see page 23 248 NOTE If no DTCs are indicated but you know the system is abnormal check these items If the light does not come on and the buzzer does not beep check the continuity between the BLK wire of the multiplex control inspection connector and...

Page 1200: ...ector on the receiver side unit C Faulty circuit in the receiver side unit If the voltage is too low A Check for short to ground or to another wire B Check for poor contact at the connector on the transmit side unit C Faulty circuit in the transmitter side unit If any control units appears to be faulty select one control unit substitute a known good control unit then recheck If the system works pr...

Page 1201: ...x control unit wakes up then the control unit starts to communicate to the driver s control unit By this communication the driver s control unit wakes up The driver s control unit wakes the passenger s control unit up by the wake up line and all the control units start to function When a switch related to the multiplex control unit driver s or passenger s is operated The control unit related to th...

Page 1202: ...stem Wake up Function Test cont d Related Switch Input The switches and input signals that can wake up the multiplex control unit are shown below Related Switch Input Table No 17 20 A 96 97 models No 17 7 5 A 98 01 models ...

Page 1203: ...age between the wake up line PNK BLU wire between driver s and passenger s control unit There should be no voltage with the sleep mode OFF There should be battery voltage with the sleep mode ON 2 Check for voltage between each communication line and body ground while shifting to the sleep mode There should be no voltage 3 Check the parasitic draw at the battery while shifting to the sleep mode The...

Page 1204: ...ch operation but the other control units cannot wake up The control unit driver s can wake up by a switch operation related to the control unit door but the control unit passenger s cannot wake up by a switch operation All of the control units wake up by turning the ignition switch ON II Check the Wake Up Function Check the wake up lines Check for continuity of each line There should be continuity...

Page 1205: ... door switch OPEN Front passenger s key cylinder switch LOCK UNLOCK Front passenger s door lock switch LOCK UNLOCK Front passenger s door lock knob switch UNLOCK Right rear door switch OPEN Right rear door lock knob switch UNLOCK Keyless transmitter LOCK button UNLOCK button TRUNK button PANIC button Rear window defogger switch Engine oil pressure switch Multiplex Control Unit Passenger s Multiple...

Page 1206: ...Light Replacement 1 Remove the dashboard lower cover see section 20 2 Remove the column covers see section 17 3 Turn the bulb socket 45 counterclockwise to remove it from the key light housing BULB 1 4 W KEY LIGHT HOUSING BULB SOCKET ...

Page 1207: ...10 000 ohms as the dial is rotated DRIVER SSWITCH PANEL BULB 0 84 W DASH LIGHTS BRIGHTNESS CONTROLLER 3 Turn the CANCEL switch off by rotating the adjusting beyond its end position until if clicks There should be no continuity between the No 2 and No 6 termi nals NOTE The cancel switch is closed with the adjusting dial between the minimum and maximum positions 4 If necessary remove the two screws ...

Page 1208: ...2 FRONT PASSENGER S DOOR COURTESY LIGHT Replacement page 23 263 REAR CEILING LIGHT Test page 23 262 FRONT PASSENGER S DOOR SWITCH Test page 23 264 RIGHT REAR DOOR SWITCH Test page 23 264 RIGHT REAR DOOR COURTESY LIGHT Replacement page 23 263 Entry Light Control System Component Location Index IGNITION KEY SWITCH Test page 23 263 You can also test the switch by using the self diagnosis function mod...

Page 1209: ...omthepassenger s unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained B10 B21 BLU RED LT GRN BLK Turn the ceiling light switch MIDDLE and all doors closed All doors closed Connect to ground Ceiling light should come on Connect to ground Courtesy lights should come on Blown No 57 20 A fuse in the under hood fuse relay box Faulty ceiling light An open in the w...

Page 1210: ...and the fuse relay box socket If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it 2 Canada Reconnect the connectors to the unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained C9 C15 BLU WHT GRN YEL Ignitionkeyoutofthe ignition switch Ignition key insert...

Page 1211: ...e bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If a test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the power window master switch must be faulty replace it Reconnect the connector to the door unit Cavity Wire Test condition Test Desired res...

Page 1212: ... Remove the two screws from the housing 4 Disconnect the 4P connector and remove the hous ing 5 Check for continuity between the terminals in each switch position according to the table 3 Remove the two screws from the housing 4 Disconnect the 4P connector and remove the hous ing 5 Check for continuity between the terminals in each switch position according to the table HOUSING SCREW BULBS 5 W x 3...

Page 1213: ...R PLATE HOUSING DOOR PANEL BULB 3 4 W 3 Replace the courtesy light LENS 3 Check continuity between the No 2 and No 7 termi nals There should be continuity with the ignition key inserted There should be no continuity when the ignition key is removed Ignition Key Switch Test 1 Remove the dashboard lower cover see section 20 2 Disconnect the 8P connector from the main wire harness 8P CONNECTOR Wire s...

Page 1214: ...panel see section 20 2 Disconnect the 8P connector from the door lock actu ator assembly Terminal side of male terminals Rear Door Switch 1 Remove the rear door panel see section 20 2 Disconnect the 6P connector from the door lock actu ator assembly Terminal side of male terminals 3 Check continuity between the No 2 and No 6 termi nals There should be continuity with the switch released door open ...

Page 1215: ...Index You can also test the switch by using the self diagnosis function mode 2 See page 23 252 REAR WINDOW DEFOGGER RELAY Test page 23 67 UNDER HOOD RELAY BOX A REAR WINDOW DEFOGGER SWITCH Test page 23 269 REAR WINDOW DEFOGGER Function Test page 23 270 Defogger Wire Repair page 23 270 ...

Page 1216: ... Disconnect the connectors from the passenger s unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained Ignition switch ON II Ignition switch at START III and rear window defogger switch ON YEL GRN YEL BLK Under all conditions Check for continuity to ground There should be continuity Check for voltage to ground There should be battery voltage Check for voltage ...

Page 1217: ... necessary and recheck the system If the terminals look OK make the following input tests at the connector and the fuse relay box socket If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it Fuse relay box socket Cavity Wire Test condition Test Desired result Possible cause if result is not obta...

Page 1218: ...ng to the table Rear Window Defogger Coil Test 1 Open the trunk lid 2 Remove the right side panel 3 Disconnect the 1P and 2P connectors from the rear window defogger coil Terminal side of male terminals REAR WINDOW DEFOGGER COIL Terminal side of male terminals COMPONENT GROUND 4 Remove the rear window defogger coil 5 Check for continuity between the A1 and B2 terminals There should be continuity 6...

Page 1219: ...bout 6 V with the ignition switch and the defogger switch ON If the voltage is as specified the defogger wire is OK If the voltage is not as specified repair the defogger wire If it is more than 6 V there is a break in the negative half of the wire If it is less than 6 V there is a break in the positive half of the wire Defogger Wire Repair NOTE To make an effective repair the broken section must ...

Page 1220: ...cation Index TRUNK LID OPENER MAIN SWITCH Test page 23 274 TRUNK LID OPENER SWITCH Test page 23 274 TRUNK LID OPENER SOLENOID Test page 23 275 You can also test the switch by using the self diagnosis function mode 2 See page 23 252 ...

Page 1221: ... s multiplex control unit connectors Cavity Wire Test condition Test Desired result Possible cause if result is not obtained Under all conditions Trunk opener main switch ON Connect battery volt age to the B11 terminal momentarily WHT BLK YEL WHT A12 A5 B11 Check for voltage to ground There should be battery voltage Check for voltage to ground There should be less than 1 V Check trunk opener opera...

Page 1222: ... 2P connector from the switch Switch Test DRIVER S DOOR PANEL SWITCH 3 Check for continuity between the No 1 and No 2 terminals There should be continuity when the switch is pushed There should be no continuity when the switch is released 3 Check for continuity between the No 1 and No 2 terminals There should be continuity with the switch ON There should be no continuity with the switch OFF Wire s...

Page 1223: ...tion20 2 Disconnect the 6P connector from the trunk lid latch assembly TRUNK LID LATCH ASSEMBLY 6P CONNECTOR Terminal side of male terminals 3 Test the solenoid by connecting power to the No 3 terminal and ground to the No 4 terminals momen tarily The solenoid should work ...

Page 1224: ...23 295 DRIVER S DOOR LOCK ACTUATOR Test page 23 293 Replacement section 20 DRIVER S DOOR KEY CYLINDER SWITCH Test page 23 295 DRIVER S DOOR LOCK KNOB SWITCH Test page 23 293 LEFT REAR DOOR LOCK ACTUATOR Test page 23 294 Replacement section 20 LEFT REAR DOOR LOCK KNOB SWITCH Test page 23 294 You can also test the switch by using the self diagnosis function mode 2 See page 23 252 TRUNK LID OPENER SO...

Page 1225: ...R LOCK ACTUATOR Test page 23 294 Replacement section 20 RIGHT REAR DOOR LOCK KNOB SWITCH Test page 23 294 FRONT PASSENGER S DOOR LOCK ACTUATOR Test page 23 293 Replacement section 20 FRONT PASSENGER S KEY CYLINDER SWITCH Test page 23 295 Replacement section 20 FRONT PASSENGER S DOOR LOCK KNOB SWITCH Test page 23 293 FRONT PASSENGER S DOOR LOCK SWITCH Test Replacement page 23 295 ...

Page 1226: ...K SWITCH Test Replacement page 23 295 DRIVER S DOOR LOCK ACTUATOR Test page 23 293 Replacement section 20 DRIVER S DOOR KEY CYLINDER SWITCH Test page 23 295 DRIVER S DOOR LOCK KNOB SWITCH Test page 23 293 LEFT REAR DOOR LOCK ACTUATOR Test page 23 294 Replacement section 20 LEFTREARDOORLOCK KNOB SWITCH Test page 23 294 TRUNK LID OPENER SOLENOID You can also test the switches by using the self diagn...

Page 1227: ...ment section 20 FRONT PASSENGER S KEY CYLINDER SWITCH Test page 23 295 Replacement section 20 FRONT PASSENGER S DOOR LOCK KNOB SWITCH Test page 23 293 RIGHT REAR DOOR LOCK ACTUATOR Test page 23 294 Replacement section 20 RIGHT REAR DOOR LOCK KNOB SWITCH Test page 23 294 You can also test the switches by using the self diagnosis function mode 2 See page 23 252 of the 96 01 3 5RL Service Manual ...

Page 1228: ...ith the transmitter 1 Does the LED come on when the transmitter button is pushed Replace the battery CR2025 Lock unlock the doors with trans mitter NO YES NO Do the doors lock unlock Transmitter is OK YES Check with the second transmit ter Do the doors lock unlock YES Replace the original transmitter Transmitter is OK YES NO NO Reprogram the transmitter then try to lock unlock the doors see page 2...

Page 1229: ...g 02 04Models Storing transmitter codes The codes of up to three transmitters can be read into the keyless receiver unit memory If a fourth code is stored the code which was input first will be erased NOTE It is important to maintain the time limits between the steps Make sure the doors hood and tail gate are closed 1 Turn the ignition switch ON II 2 Within 1 to 4 sec push the transmitter lock or ...

Page 1230: ...hrough self diagnosis function modes 1 and 2 see pages23 248and 23 252 The numbers in the table show the troubleshooting sequence If the system is normal all doors will unlock when the door key is kept in the unlock position key cylinder switch and door lock knob switch turned ON for 1 second or more ...

Page 1231: ... test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the power window master switch must be faulty replace it 1 96 97 models 2 98 01 models Cavity Test Desired result Possible cause if result is not obtained 1 5 12 19 WHT YEL GRN BLU BLK Under all conditions Driver s door opened Driver s door closed Under all conditions Check for voltage to g...

Page 1232: ...Reconnect the connectors to the door unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained ...

Page 1233: ...s then remove the passenger s unit see page 23 245 3 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the i...

Page 1234: ...Reconnect the connectors to the passenger s unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained NOTE Refer to page 23 264 for No B3 B4 B14 and B15 terminals test ...

Page 1235: ...ox see page 23 66 2 Remove the driver s unit from the under dash fuse relay box see page 23 247 3 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector and the fuse relay box socket If any test indicate...

Page 1236: ...s unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained Reinstall the driver s unit and reconnect the connectors to the unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained ...

Page 1237: ...et terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it ...

Page 1238: ...Cavity Wire Test condition Test Desired result Possible cause if result is not obtained ...

Page 1239: ...s to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it KEYLESS RECEIVER UNIT 7P CONNEC...

Page 1240: ...d There should be battery voltage Blown No 44 20 A fuse in the under hood fuse relay box Faulty multiplex control unit passenger s Faulty horn An open in the wire Blown No 13 7 5 A fuse in the under dash fuse relay box An open in the wire Blown No 44 20 A fuse in the under hood fuse relay box Faulty multiplex control unit passenger s Faulty trunk lid opener An open in the wire Blown No 44 20 A fus...

Page 1241: ...peat step 2 11 Repeat step 3 12 Within 1 to 4 sec go to step 13 13 Repeat step 1 14 Repeat step 2 15 Confirm you can hear the sound of the door lock actu ators 16 Within 9 sec aim the first transmitter whose code you want to store at the receiver and press the trans mitter button 17 Repeat step 15 18 Within 9 sec aim the second transmitter whose code you want to store at the receiver and press the...

Page 1242: ... CAUTION To prevent damage to the actuator apply battery voltage only momentarily 4 Check for continuity between the terminals in each knob switch position according to the table 5 If the actuator fails to work properly replace it 4 Check for continuity between the terminals in each knob switch position according to the table 5 If the actuator fails to work properly replace it 3 Check actuator ope...

Page 1243: ...only momentarily Terminal side of male terminals Power Door Locks Rear Door Lock Actuator Test 1 Remove the rear door panel see section 20 2 Disconnect the 6P connector from the actuator 6PCONNECTOR 4 Check for continuity between the terminals in each knob switch position according to the table 5 If the actuator fails to work properly replace it ...

Page 1244: ...h switch position according to the table DOORLOCKSWITCH Door Lock Switch Test 1 Remove the door panel see section 20 2 Remove the two screws then remove the door lock switch Door Key Cylinder Switch Test 1 Remove the door panel see section 20 2 Disconnect the 3P connector from the key cylinder switch Terminal side of male terminals 3PCONNECTOR ...

Page 1245: ...WINDOW SWITCH Test page 23 317 Replacement page 23 316 RIGHT REAR WINDOW MOTOR Test page 23 317 POWER WINDOW MASTER SWITCH Replacement page 23 316 DRIVER S WINDOW MOTOR Test page 23 318 LEFT REAR WINDOW MOTOR Test page 23 317 LEFT REAR WINDOW SWITCH Test page 23 317 Replacement page 23 316 You can also test the switch by using the self diagnosis function mode 2 See page 23 252 For additional 02 04...

Page 1246: ...OD RELAY BOX B DRIVER S POWER WINDOW MOTOR RELAY B 2 Test page 23 69 POWER WINDOW MASTER SWITCHRELAY 2 Test page 23 69 POWERWINDOWMASTERSWITCH RELAY Test page 23 67 DRIVER S POWER WINDOW MOTOR RELAY A 2 Test page 23 69 UNDER HOOD RELAY BOXC ...

Page 1247: ...he power window control unit is required after performing the following procedures disconnecting the battery removing No 41 20 A fuse disconnecting the connector from the power window control unit removing the window regulator glass or glass run channel 1 Make sure the glass is installed properly 2 Turn the ignition switch OFF 3 Remove the No 41 20 A fuse in the under hood fuse relay box 4 Turn th...

Page 1248: ...to go through self diagnosis function modes 1 and 2 see pages 23 248 and 23 252 The numbers in the table show the troubleshooting sequence 96 97 models 98 model 99 01 models No 17 20 A No 17 7 5 A No 17 7 5 A No 18 20 A No 18 30 A No 18 20 A No 21 20 A No 21 30 A No 21 20 A No 24 20 A No 24 30 A No 24 20 A ...

Page 1249: ...page 23 247 3 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector and the fuse relay box socket If any test indicates a problem find and correct the cause then recheck the system If all the input test...

Page 1250: ...ove the driver s door panel and disconnect the 20P connector from the door unit see page 23 245 2 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct t...

Page 1251: ...sult Possible cause if result is not obtained 96 97 models 98 00 models Cavity Wire Test condition Test Desired result Possible cause if result is not obtained Reconnect the connector to the door control unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained ...

Page 1252: ...k panel see section 20 2 Disconnect the 22P and 26P connectors then remove the passenger s unit see page 23 246 3 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If a test indicates a problem find an...

Page 1253: ...red result Possible cause if result is not obtained Reconnect the connector to the passenger s control unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained 96 97 models No 18 20 A No 21 20 A 98 model No 18 30 A No 24 30 A 99 01 models No 18 20 A No 24 20 A ...

Page 1254: ...als to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If a test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it ...

Page 1255: ...nuity Check the driver s window motor It should run the window moves down Check the driver s window motor It should run the window moves up Poor ground G251 An open in the wire Blown No 41 20 A fuse in the under hood fuse relay box An open in the wire Blown No 17 7 5 A No 23 7 5 A fuse in the under dash fuse relay box Faulty power window relay An open in the wire Faulty power window master switch ...

Page 1256: ...ment 1 Remove the passenger s door panel see section 20 2 Remove the two screws then remove the switch assembly from the door panel 3 Remove the six mounting screws then remove the passenger s window switch from the panel PASSENGER S WINDOW SWITCH PANEL 4 Install in the reverse order of removal 4 Install in the reverse order of removal PANEL 3 Remove the five mounting screws then remove the master...

Page 1257: ...motor operation by connecting power and ground according to the table CAUTION When the motor stops running discon nect one lead immediately 4 If the motor does not run or fails to run smoothly replace it 3 Check for continuity between the No 4 and No 6 terminals 98 01 models There should be continuity If there is no continuity check the indicator light bulb 98 01 models 2 Check for continuity betw...

Page 1258: ... connecting bat tery power and ground according to the table CAUTION When the motor stops running discon nect one lead immediately 4 If the motor does not run or fails to run smoothly replace it Pulser Test 5 Connect the test leads of an analog ohmmeter to the No 3 and No 4 terminals 6 Run the motor by connecting power and ground to the No 1 and No 2 terminals The ohmmeter nee dle should move back...

Page 1259: ...replace it PulserTest 5 Reconnect the 6P connector to the window motor 6 Check for voltage between the terminals There should be battery voltage between the No 6 and No 4 terminals when the ignition switch is ON II Connect the an analog voltmeter between the No 5 and No 4 terminals and run the window motor down or up The voltmeter needle should move back and forth alternately Connect the an analog...

Page 1260: ...ver s Window Switch Test 1 Remove the power window master switch POWER WINDOW MASTER SWITCH 2 Check for continuity between the terminals in each switch position according to the tables Driver s window switch Main switch ...

Page 1261: ...ER WASHER SWITCH Test page 23 327 Replacement page 23 329 WINDSHIELDWIPERARMS BLADES UNDER HOOD RELAY BOX C UNDER HOOD RELAY BOX A INTERMITTENT WIPERCIRCUIT In the multiplex control unit driver s Input Test page 23 325 WINDSHIELD WIPERMOTOR RELAY Test page 23 68 You can also test the switch by using the self diagnosis function mode 2 See page 23 252 WINDSHIELD WASHER MOTOR Test page 23 328 WINDSHI...

Page 1262: ...INT TIME ring to the shortest delay the wipers will change from intermittent to low speed operation when vehicle speed exceeds 12mph 20 km h Troubleshooting NOTE Before testing go to the Troubleshooting Guide see page 23 244 Be sure to go through self daignosis function modes 1 and 2 see pages 23 248 and 23 252 The numbers in the table show the troubleshooting sequence ...

Page 1263: ...nder dash fuse relay box see page 23 247 3 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector and the fuse relay box socket If any test indicates a problem find and correct the cause then recheck the...

Page 1264: ... be less than 1 V Blown No 23 10 A fuse in the under dash fuse relay box 96 98 models Blown No 58 30 A fuse in the under hood fuse relay box 99 01 models Faulty windshield wiper motor relay 99 01 models Faulty wiper switch An open in the wire Blown No 39 15 A fuse in the under hood fuse relay box Faulty brake switch An open in the wire Blown No 23 10 A fuse in the under dash fuse relay box 96 98 m...

Page 1265: ...om the main wire harness 3 Check for continuity between the terminals in each switch position according to the table If there is continuity the switch is OK If there is no continuity check for continuity between the switch harnesses If the switch harness is OK replace the wiper washer switch Wire side of female terminals 14P CONNECTOR ...

Page 1266: ...SHER FLUID RESERVOIR Terminal side of male terminals 3 Test the washer motor by connecting battery power and ground according to the table If the motor fails to run smoothly replace it If the motor runs smoothly but little or no wash er fluid is pumped check for a disconnected or blocked washer hose or a clogged pump outlet in the motor 4 Test the motor by connecting battery power and ground accor...

Page 1267: ...cover see section 20 2 Remove the steering column covers see section 17 3 Disconnect the connectors from the wiper washer switch then remove the two screws and the switch CONNECTORS SCREWS WIPER WASHER SWITCH 4 Install in the reverse order of removal ...

Page 1268: ...OOR KEY CYLINDER SWITCH Test page 23 295 Replacement section 20 FRONT PASSENGER S DOOR LOCK KNOB SWITCH and DOOR SWITCH In the actuator assembly Test page 23 293 and 23 264 UNDER HOOD FUSE RELAY BOX TAILLIGHT RELAY 96 98 models Test page 23 68 HEADLIGHT HIGH BEAM RELAY 99 01 models Test page 23 68 HOOD SWITCH Test page 23 352 HORNS Test page 23 158 HEADLIGHT Replacement page 23 121 UNDER HOOD RELA...

Page 1269: ...SRECEIVERUNIT Input Test page 23 290 LICENSE PLATE LIGHTS Replacement page 23 128 SECURITY INDICATOR Replacement page 23 352 TRUNK KEY CYLINDER SWITCH Test page 23 353 TRUNK LID LATCH SWITCH Test page 23 353 TAILLIGHT Replacement page 23 125 LEFT REAR DOOR LOCK KNOB SWITCH and DOOR SWITCH In the actuator assembly Test page 23 294 and 23 264 DRIVER SDOORLOCKKNOB SWITCH and DOOR SWITCH In the actuat...

Page 1270: ...wing conditions occur the horns will sound the headlights will flash and the side marker lights parking lights and taillights will flash for about 2 minutes or until the system is disarmed by unlocking either door from the out side with the key NOTE When a switch is OFF input voltage is about 5 V when a switch is ON input voltage drops to less than 1 V Door is opened forcibly Trunk lid is opened w...

Page 1271: ... Engine starter circuit and battery circuit are bypassed by breaking the ignition switch or 6 Hood trunk lid opener in the vehicle is operated or 7 Panic button is pushed The horns headlights side marker lights and tail lights sound and flash repeatedly for two minutes Engine starter circuit interrupted About 2 minutes passed YES NO Want the system disarmed YES Either door unlocked by using the ke...

Page 1272: ... Remove the driver s unit from the under dash fuse relay box see page 23 247 3 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector and the fuse relay box socket If any test indicates a problem find an...

Page 1273: ...ay Faulty headlight system An open in the wire Reinstall the driver s unit and reconnect the connectors to the unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained C7 C8 C9 C15 GRY GRN ORN BLU WHT GRN YEL Left rear door lock knob unlocked Left rear door lock knob locked Trunk key cylinder switch in lock Trunk key cylinder switch in unlock Ignition key out of...

Page 1274: ...If all the input tests prove OK the control unit must be faulty replace it Disconnect the connectors from the removed passenger s unit Cavity Wire Test condition Test Desired result Possible cause if result is not obtained BLK BLU WHT YEL YEL YEL BLK Transmitter PANIC buttonON Under all conditions Under all conditions Under all conditions Ignition switch ON II Check for continuity to ground There ...

Page 1275: ...ge to ground There should be 5 V or more Check for voltage to ground There should be less than 1 V Check for voltage to ground There should be 5 V or more Check for voltage to ground There should be less than 1 V Check for voltage to ground There should be 5 V or more Check for voltage to ground There should be less than 1 V Check for voltage to ground There should be 5 V or more Check for voltage...

Page 1276: ...ed repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the power window master switch must be faulty replace it 96 97 models 98 01 models Disconnect the connectors from the unit Cavity Wire Test condition Test Desire...

Page 1277: ...han 1 V Check for voltage to ground There should be 5V or more Check for voltage to ground There should be less than 1 V Check for voltage to ground There should be 5 V or more Check for voltage to ground There should be less than 1 V Check for voltage to ground There should be 5 V or more Check for voltage to ground There should be less than 1 V Check for voltage to ground There should be 5 V or ...

Page 1278: ...onnector and remove the indicator from the door panel Hood Switch Test 1 Open the hood 2 Disconnect the 2P connector from the hood switch 3 Check for continuity between the No 1 and No 2 terminals There should be continuity with the lever released hood opened There should be no continuity with the lever pushed down hood closed SCREWS Terminal side of male terminals ...

Page 1279: ...id latch in LOCK trunk lid closed position Terminal side of male terminals TRUNKLIDLATCH Trunk Key Cylinder Switch Test 1 Open the trunk lid then remove the trunk lid inner trim see section 20 2 Disconnect the 2P connector from the trunk key cylin der switch TRUNK KEY CYLINDER Terminal side of male terminals 3 Check continuity between the No 1 and No 2 termi nals There should be continuity when th...

Page 1280: ...POWER MIRROR SWITCH Test page 23 358 Power Mirrors Component Location Index POWERMIRRORS Test page 23 359 Actuator Replacement page 23 360 ...

Page 1281: ... the left mirror and the 10P connector faulty left mirror actuator If the mirror neither tilts down nor swings left repair the BRN wire If the mirror works properly check the mirror switch Rightmirrorinoperative 1 Connect the No 6 terminal to the No 9 terminal and No 5 or No 8 terminal to body ground with jumper wires The right mirror should tilt down or swing left with the ignition switch ON II I...

Page 1282: ... in each switch position according to the table Mirror switch Power Mirrors Switch Test 1 Remove the driver s door panel see section 20 MIRROR SWITCH 10P CONNECTOR Terminal side of male terminals DEFOGGER INDICATOR 0 91 W POWER MIRROR SWITCH DEFOGGER SWITCH 2P CONNECTOR Terminal side of male terminals ...

Page 1283: ... and ground according to the table Without memory DefoggerTest 4 Check for continuity between the No 3 No 2 and No 4 No 3 terminals of the 10P 8P connector There should be continuity 5 If the mirror fails to work properly replace the mir ror actuator or mirror sub assembly see page 23 360 Without memory 98 model With memory Wire side of female terminals Withoutmemory Wire side of female terminals ...

Page 1284: ...lease the mirror holder hooks from the actuator and remove the mirror MIRROR HOLDER HOOK 2P CONNECTOR 5P CONNECTOR ACTUATOR 13 Run the actuator motor through its full range in all four directions The mirror should move smoothly 6 Without removing the center screw remove the Phillips head screws that attach the actuator to the mirror housing 7 Disconnect the four actuator wires gently pull the base...

Page 1285: ...s programmed properly see the owner s manual or call Homelink at 800 355 3515 On the internet go to www homelink jcl com If the driver s vanity mirror light does not come on check for these problems A blown No 57 20 A fuse in the under hood fuse relay box An open in the WHT BLU wire between the under hood fuse relay box and driver s vanity mirror light An open in the BLK wire between the driver s ...

Page 1286: ...23 412 23 52d 04 07PAZ 0010100 Special Tools ...

Page 1287: ...Component Locations The illustration shows 00 01 models DISPLAY UNIT VEHICLE SPEED SENSOR VSS GPS ANTENNA AUDIO UNIT NAVIGATIONUNIT ...

Page 1288: ...ceiling Replacement 2004 3 5RL Service Manual Supplement page 23 48 GPSANTENNA Located under the rear shelf Removal Installation page 23 53 DISPLAY UNIT Removal Installation page 23 54 NAVIGATION UNIT Removal Installation page 23 53 NAVIGATION SERVICE CHECK CONNECTOR Forced starting of display page 23 52 ...

Page 1289: ... system s yaw rate sensor and the vehicle speed sensor VSS enable the system to keep track of the vehicle s direction and speed of travel This hybrid system has advantages over a system that is either entirely self contained or one that relies totally on the GPS For example the self contained portion of the system can keep track of vehicle position even when satellite signals cannot be received an...

Page 1290: ... display unit FunctionDiagram 1 97 99 models Vehicle Speed Sensor VSS 2 00 01 models The vehicle speed sensor VSS is driven by the differential gear For every revolution of the sensor a four pulse signal is sent to the navigation unit The VSS outputs the distance signal by turning the navigation unit s sensor power on and off ...

Page 1291: ...ro functions by utilizing this characteristic of the piezoelectric parts and Coriolis force Coriolis force deflects moving objects as a result of the earth s rotation In the oscillation gyro this force moves the sensor element when angular velocity is applied Operation 1 The driving piezoelectric part oscillates the oscillator by repeatedly bending and returning when an AC voltage at 6 kHz is appl...

Page 1292: ...distance to each satellite and the satellite positions on their respective orbits Position detection Image with GPS satellite NOTE Four satellites on each of six orbits PrecisionofGPS The precision of the GPS varies according to the number of satellites from which electric waves are received and the con trol condition The precision is indicated by the GPS mark shown on the upper left of the displa...

Page 1293: ...cle position data If there is large difference between the two the indicated vehicle position is adjusted to the GPS vehicle position DistanceTuning The distance tuning reduces the difference between the travel distance signal from the VSS and the distance data on the map The navigation unit compares its calculated vehicle position data with the GPS vehicle position data The navigation unit then d...

Page 1294: ...cal and nine horizontal infrared rays to produce 81 sensing points The display unit transmits the signal from each operation key and the touch switches the navigation unit 00 01 models The display unit uses liquid crystal display LCD The LCD is a seven inch wide Thin Film Transistor TFT stripe type with 280 800 picture elements The color film and fluorescent light are laid out on the back of the l...

Page 1295: ... recognition that allows voice control of most of the navigation functions The TALK and BACK buttons on the steering wheel activate the voice control The illumination signal is used for two purposes The display unit uses the signal to light up the hard buttons surrounding the display In addition the signal is used by the navigation unit to automatically switch from the Day to Night display mode wh...

Page 1296: ...System Diagram ...

Page 1297: ...iption cont d Navigation Function The navigation system is composed of the navigation unit the PCM vehicle speed signal the GPS antenna microphone steering buttons audio unit and the display unit Navigation System ...

Page 1298: ...e oscillation gyro functions by utilizing this characteristic of the piezoelectric parts and Coriolis force Coriolis force deflects moving objects as a result of the earth s rotation In the oscillation gyro this force moves the sen sor element when angular velocity is applied Operation 1 The driving piezoelectric part oscillates the oscillator by repeatedly bending and returning when an AC voltage...

Page 1299: ...e satellite positions on their respective orbits Position detection Image with GPS satellite Navigation System Precision of GPS The precision of the GPS varies according to the number of satellites from which electric waves are received and the con trol condition The precision is indicated by the color of the GPS icon shown on the upper right of the display GPSAntenna The GPS antenna amplifies and...

Page 1300: ...tween the travel distance signal from the VSP and the distance data on the map The navigation unit compares its calculated vehicle position data with the GPS vehicle position data The navigation unit then decreases the tuning value when the vehicle position is always ahead of the GPS vehicle position and it increas es the tuning value when the vehicle position is always behind the GPS vehicle posi...

Page 1301: ...cent light are laid out on the back of the liquid crystal film The touch sensor on the front of the LCD is an infrared type with 20 vertical and 9 horizontal infrared rays to produce 180 sensing points The display unit transmits the signal from each operation key and the touch switches to the navigation unit Infrared rays Microphone Mic Receives voice commands and transmits them to the navigation ...

Page 1302: ...the navigation system Digital Versatile Disk The navigation program and database resides on this disk See the Navigation Owner s Manual for information on how to order a replacement or update DVD Engine Control Module Typically referred to as the PCM Frequency Asked Question See the Navigation Owner s Manual for a list of the customer FAQs and troubleshooting information Proprietary communication ...

Page 1303: ...tion for a list of the assigned colors Keyboard layout resembling the typewriter keys The keyboard layout can be changed to an alphabetical layout in the Setup mode The 2 pin connector used to put the navigation system into the diagnostic mode Code needed to activate the navigation system The security code can be obtained from the IN by entering the navigation system control serial number The seri...

Page 1304: ... front speakers See the overview for more information Vehicle Speed Pulse This pulse signal coming from the PCM is used to update the Vehicle position on the map These pulses do not indicate direction forward or back ward When in reverse the navigation receives a signal from the reverse relay and directs the VP to move backwards on the map Vehicle Speed Sensor This sensor reads the output shaft sp...

Page 1305: ... by ferry or tow truck or if the vehicle is spun on a turn table Tire slippage changes in tire rolling diameters and some driving situations may cause discrepancies in travel distances Examples of this include Continuous tire slippage on a slippery surface Driving with snow chains mounted Abnormal tire pressure Incorrect tire size Frequent lane changes across a wide highway Continuous driving on a...

Page 1306: ...ps radar detectors etc that may be hidden ServicePrecautions Before disconnecting the battery make sure you have the anti theft codes for the radio and the navigation system and write down the frequencies for the radio s preset buttons When the battery is disconnected the internal GPS clock is reset to 0 00 The clock will reset to the cor rect time after the system finishes GPS initialization Afte...

Page 1307: ...TerminalArrangement 97 99 Models NAVIGATION UNIT CONNECTOR A NAVIGATION UNIT CONNECTOR A 20P Wire side of female terminals ...

Page 1308: ...NAVIGATION UNIT CONNECTOR B 8P NAVIGATION UNIT CONNECTOR B Wire side of female terminals ...

Page 1309: ...Terminal Arrangement 97 99 Models cont d DISPLAY UNIT CONNECTOR DISPLAY UNIT CONNECTOR 20P Wire side of female terminals ...

Page 1310: ... 00 01 Models NAVIGATION UNIT CONNECTOR A 12P NAVIGATION UNIT CONNECTOR A Wire side of female terminals ...

Page 1311: ...TerminalArrangement 00 01 Models cont d NAVIGATION UNIT CONNECTOR B 16P Wire side of female terminals NAVIGATION UNIT CONNECTOR B ...

Page 1312: ...NAVIGATION UNIT CONNECTOR C 8P Wire side of female terminals NAVIGATION UNIT CONNECTOR C ...

Page 1313: ...Terminal Arrangement 00 01 Models cont d DISPLAY UNIT CONNECTOR 20P Wire side of female terminals DISPLAY UNIT CONNECTOR ...

Page 1314: ...System Description Navigation Unit Inputs and Outputs for Connector A 20P ...

Page 1315: ...NavigationSystem System Description cont d Navigation Unit Inputs and Outputs for Connector B 14P ...

Page 1316: ...Navigation Unit Inputs and Outputs for Connector C 8P cont d 23 9 Wire side of female terminals ...

Page 1317: ...Navigation System System Description cont d Navigation Unit Inputs and Outputs for Connector D 16P Not used Navigation Unit Inputs and Outputs for Connector E 2P Wire side of female terminals ...

Page 1318: ...Display Unit Inputs and Outputs for Connector A 5P Wire side of female terminals ...

Page 1319: ...Navigation System System Description cont d Display Unit Inputs and Outputs for Connector B 20P Wire side of female terminals ...

Page 1320: ......

Page 1321: ...screpancies between the actual vehicle position and the indicated vehicle position If there is a large dis crepancy and the system is receiving GPS signals the system will adjust the indicated vehicle position to the GPS vehicle position However if GPS signals cannot be received you must tune the vehicle position manually The following circumstances may cause vehicle positioning errors until the s...

Page 1322: ...lection coating When cleaning the panel wipe it gently with a soft cloth To avoid scratching the panel do not rub too hard The touch panel is an infrared system so there is no need to press hard If a touch switch does not function immediately shift your finger slightly on the switch and touch it again Symptom Duplication When the symptom can be duplicated follow the self diagnostic procedures pict...

Page 1323: ...Troubleshooting Guide NOTE Circles in the table indicate which parts to inspect 96 99 models 00 01 models 23 398 23 400 23 401 23 402 23 403 23 404 23 406 23 407 23 408 23 409 ...

Page 1324: ...Troubleshooting Guide NOTE Circles in the table indicate which parts to inspect 96 99 models 00 01 models 23 398 23 400 23 401 23 402 23 403 23 404 23 406 23 407 23 408 23 409 ...

Page 1325: ...g see page 23 30 Troubleshooting see page 23 32 Troubleshooting see page 23 33 Troubleshooting see page 23 35 Troubleshooting see page 23 35 Troubleshooting see page 23 36 Troubleshooting see page 23 36 Troubleshooting see page 23 37 Troubleshooting see page 23 37 Troubleshooting see page 23 38 Troubleshooting see page 23 38 Troubleshooting see page 23 39 ...

Page 1326: ... Check Car Status GPS Information Yaw Rate Tire Calibrate Functional Setup Version Navi System Link This diagnostic tests the cables connecting the navi gation components Ensure that the ignition switch is in the ON II position When the diagnostic begins a bong sound is heard The system is in a Detecting mode and is waiting for all items in white to be tested This includes the voice control switch...

Page 1327: ...lay unit also communicates with the climate control module to set the A C mode and fan speed These screens allow troubleshooting of the display unit Touch the menu item you want to troubleshoot and fol low the diagnostic instructions RGB Color This screen verifies that the display unit is receiving the video R G B and Composite sync signals properly The three primary colors should all be shown wit...

Page 1328: ...ay position to factory specifications Touch Panel The panel touch sensing system consists of 9 horizontal and 20 vertical infrared beams Touching the screen blocks both a horizontal and a vertical beam Every pos sible touch position is shown on this diagnostic screen Touching one of these areas should cause its color to reverse and sound a beep If any areas of the screen either don t respond or re...

Page 1329: ...X or Y values below The version represents the software version in the display The 1 following the X indicate the 20 working ver tical infrared beams receptors from left to right The Is following the Y indicate the 9 working hori zontal beams from top to bottom If any one of the 1s is a zero this indicates that these is a problem with one of the beams or receptors Check all around the inside rim o...

Page 1330: ...ion can also be found is Setup Screen 4 by touching information Serial No should be the same as the serial number found on the underside of the navigation unit This number is needed to obtain the security code from the Interactive Network IN system The Mem Clr button is for factory use and should not be used unless instructed by the factory Touching this button will erase the customer s set tings ...

Page 1331: ...er is in reverse The Back signal is used by the navigation unit to allow the map screen to show the VP moving backwards when in reverse This signal is needed because the Speed Pulse has no direction indication ILL lllumination Indication Pin 5 of navigation unit A connector a OFF 0 when parking lights or headlights are off b ON 1 when parking lights or headlights are on This signal is used by the ...

Page 1332: ...ubleshoot for GPS icon is white see page 23 32 The Current Position shows latitude longitude and elevation in meters If there are less than 3 satel lites the elevation can be grossly inaccurate The Date Time field shows the current date and also a time that includes daylight savings and other off sets entered by the customer in Setup screen 2 Adjust Time Zone Clock GPSDetail By pressing and holdin...

Page 1333: ...LOWER than the Offset voltage indicates that the vehicle is turning to the left The yaw rate offset and sensor should both indicate about 2 500 volts when stopped If either reads zero or 5 000 volts replace the navigation unit The yaw rate offset and sensor should be within 0 01 V of each other when stopped The sensor value should change relative to the offset as the car is turned while driving If...

Page 1334: ...tuning function that generates and refines this factor based on actual driving The Level indicates the status of the tuning At initializa tion it begins at 0 and increases to 10 as the navigation system is used The Auto Tuning is factory set to ON and should remain on The LEVEL indicates the tuning status If it is less than 10 the unit is still calibrating The Tire Cal Tuning and the Set button sh...

Page 1335: ...door should always be closed The screen should look like below However if the factory instructs you to insert a PC Card insert it into the card slot label side up and then slide the PC Card door shut If instructed by the factory touch the Gyro Sensor Logs ON button on the screen Follow the factory procedure for gather ing test data and properly ending the test ...

Page 1336: ...oice control switch are used to activate the voice control system The microphone is located near the map light in the ceiling It is directional and works best if the voice is coming from the drivers seat Press the TALK button on the steering wheel and in a normal voice say testing The TALK indicator on the screen should momentarily become green and the text Now Recording should appear in yellow In...

Page 1337: ...sed at Auto Shows or similar events Turning this feature on allows the navigation system to automatically follow a route to a destination when the vehicle is stationary Version This screen displays the current version of the program and allows the loading of a new version of the program either from a CD DVD or from a PC card The D Ram Program version should always be greater than or equal to the D...

Page 1338: ...AN CEL key and keep them pushed simultaneously for 5 seconds The display changes to the diagnosis menu screen SYSTEMLINKS To page 23 387 MONITOR CHECK To page 23 388 UNIT CHECK To page 23 389 TIRE CALIBRATE To page 23 387 To page 23 391 YAW RATE DIAGNOSIS MENU SCREEN Touch the item you want to check and the check starts To return to the previous screen touch the RETURN switch on the diagnosis scre...

Page 1339: ...s cycled After repairing the system turn the ignition switch OFF to reset the system then return to the Diagnosis Menu screen and run System Links again TIRE CALIBRATE The AUTO TUNING is factory set to ON and it should remain on If you find it has been turned OFF turn it back ON The TIRE CAL TUNING can be used but it is not recommended The AUTO TUNING function keeps the system in better tune When ...

Page 1340: ...red green and blue must be shown TEST PATTERN All 32 colors including black must be indi cated including the back ground color BLACK RASTER The entire display must be shown in black Each switch must be shown on the dis play and each switch must reverse and sound when touched SWITCH CHECK WHITE RASTER The entire display must be shown in white ...

Page 1341: ...SP DISPLAY UNIT RADIO AUDIO UNIT When the connection is NG Check for an open or short in the communication line If the line is OK replace the audio unit When the ROM or RAM is NG Replace the audio unit NAVI ECU NAVIGATION UNIT When an item other than GPS is NG Replace the navigation unit When GPS is NG Replace the navigation unit When GPS is NG ANT Check the GPS antenna for proper connection If th...

Page 1342: ...ck the applica ble signal line VSP vehicle speed pulse indication OFF when vehicle is not moving ON when vehicle is moving BACK reverse indication OFF when shift lever is in any position other than reverse ON when shift lever is in reverse CHG charging indication ON when engine is running and alternator is charging OFF when engine is off or alternator is not charging ILL illumination indication OF...

Page 1343: ...TE SENSOR indicates the voltage output from the yaw rate sensor It should indicate 1 500 to 3 500 V with the vehicle stopped NOTE Do not try to tune the yaw rate sensor unless instructed to by American Honda ...

Page 1344: ...in this order CAN CEL key and keep them pushed simultaneously for 5 seconds The display changes to the diagnosis menu screen To page 23 393 To page 23 394 To page 23 395 To page 23 393 To page 23 397 To page 23 393 To page 23 393 DIAGNOSIS MENU SCREEN Touch the item you want to check and the check starts To return to the previous screen touch the RETURN switch on the diagnosis screen ...

Page 1345: ...reen the screen will indicate OK and a tone will sound If there is a problem in the system the faulty communication line will change to red the screen will indicate NG and a tone will sound The indication on the screen will not change until the ignition switch is cycled After repairing the system turn the ignition switch OFF to reset the system then return to the Diagnosis Menu screen and run Syst...

Page 1346: ...arts TestPattern All 32 colors including black must be indi cated including the back ground color Black Raster The entire display must be shown in black Color Change This screen is for the manufacture s use only Switch Check Each switch must be shown on the dis play and each switch must reverse and sound when touched White Raster The entire display must be shown in white ...

Page 1347: ...or short in the communication line If the line is OK replace the display unit When the ROM or RAM is NG Replace the display unit This screen is for the manufacturer s use only NOTE Do nottouch the CLR switch Touching the CLR switch will clear the system history This screen shows the condition of the GPS reception and the vehicle position GPS Information Disp Display Unit System History ...

Page 1348: ...indication OFF when shift lever is in any position other than reverse ON when shift lever is in reverse CHG charging indication ON when engine is running and alternator is charging OFF when engine is off or alternator is not charging ILL illumination indication OFF when parking lights or headlights are off ON when parking lights or headlights are on When any item is NG replace the navigation unit ...

Page 1349: ...te SENSOR indicates the voltage output from the yaw rate sensor It should indicate 1 500 to 3 500 V with the vehicle stopped NOTE Do not try to tune the yaw rate sensor unless instructed to by American Honda ...

Page 1350: ...tion switch toACC I 4 Check that the diagnosis menu for the picture diag nosis starts up and changes to the system link screen SCS SERVICE CONNECTOR 07PAZ 0010100 00 04 Models 1 Pull back the front corner of the right trunk side trim 2 Connect the SCS service connector to the naviga tion service check connector 2P 3 Press and hold the CANCEL key press and hold the joystick up then turn the ignitio...

Page 1351: ...ay fails to light or the system link screen is not displayed refer to No picture is shown on the display DVD ROM Replacement NOTE When the DVD ROM is re inserted or replaced a map match must be done see page 23 5 1 Turn the ignition switch ON II 2 Open the front cover A of the navigation unit 3 Press the EJECT button B 4 Remove the DVD ROM 5 Insert the new DVD ROM 6 Close the front cover Do not tu...

Page 1352: ...witch ON II 2 Open the front cover of the navigation unit 3 Press the EJECT switch EJECT SWITCH FRONT COVER 4 Remove the DVD ROM 5 Insert the new DVD ROM 6 Close the front cover NOTE After servicing the front cover must be closed If you start up the navigation system with the front cover open the display will indicate Navigation unit door is open or No DVD Disk installed Please check system Do not...

Page 1353: ...tion Unit 1 Remove the navigation unit bracket from the trunk NAVIGATION UNIT 6 mm NUT 9 8 N m 1 0 kgf m 7 Ibf ft SCREW BRACKET 2 Remove the navigation unit from the bracket 3 Install in the reverse order of removal GPS Antenna 1 Remove the rear package shelf see section 20 2 Remove the GPS antenna from the package shelf GPS ANTENNA ...

Page 1354: ...racket from the trunk 2 Remove the navigation unit from the bracket 3 Install in the reverse order of removal 3 Install in the reverse order of removal GPS Antenna Removal Installation 1 Remove the rear shelf see the 96 01 3 5RL Service Manual 2 Remove the GPS antenna ...

Page 1355: ... removal Display Unit Removal Installation 96 99 Models 1 Remove the display unit audio unit and climate control unit as an assembly 2 Remove the display unit and audio unit from the frame 3 Remove the display unit from the audio unit ...

Page 1356: ...allation cont d 00 01 Models 1 Remove the center panel display unit audio unit climate control unit and bracket as an assembly see section 20 2 Remove the display unit from the bracket 3 Install in the reverse order of removal ...

Page 1357: ...ouch Display Off 5 Touch the numbers of the clock to change the clock size and location If the clock is small and in the lower right hand comer of the screen it will increase in size and move to the center of the screen If the clock is large and in the center of the screen it will decrease in size and move to the lower right hand corner of the screen 6 Push the MENU button to return to the Enter d...

Page 1358: ...nual 2 Remove the display unit from the bracket 3 Install in the reverse order of removal 3 Install in the reverse order of removal Voice Control Switch Removal Installation 1 Remove the driver s airbag assembly see 96 01 3 5RL Service Manual page 24 160 2 Remove the two screws from the voice control switch A ...

Page 1359: ...STAR CONTROL UNIT Input Test page 23 59 ONSTARSYSTEMINTERFACE UNIT Input Test page 23 62 ONSTAR SYSTEM RADIO FREQUENCY MODULATOR UNIT Input Test page 23 64 ONSTAR BUTTONS and MICROPHONE AUTOMATIC DIMMING MIRROR OnStar Buttons and Microphone Input Test Page23 66 ONSTAR BUTTON DOT BUTTON MICROPHONE EMERGENCY BUTTON ONSTAR INDICATOR ...

Page 1360: ...t Test 02 3 5RL service manual supplement P N 61SZ306 page 23 59 ONSTAR SYSTEM INTERFACE UNIT Input Test page 23 46 ONSTAR BUTTONS and MICROPHONE HOMELINK BUTTONS Input Test page 23 48 ONSTAR BUTTON ONSTAR SYSTEM RADIO FREQUENCY MODULATOR UNIT Input Test 02 3 5RL service manual supplement P N 61SZ306 page 23 64 ONSTAR INDICATOR EMERGENCY BUTTON ...

Page 1361: ...ehicle Flashes parking lights honks horn Route guidance Ride Assist Concierge services convenience Buttons and indicator DOT BUTTON ONSTAR INDICATOR Solid Green Light System OK Flashing Green Light Call in progress Solid Red Light System malfunction Flashing Red Light Call in progress but malfunction in system exist ONSTAR BUTTON EMERGENCY BUTTON Activation and termination of voice recognition VR ...

Page 1362: ...ly if forgotten or unlocked when keys are accidentally left inside the vehicle If the vehi cle is misplaced in a parking lot vehicle alert honks the horn and Flashes the parking lights can be requested remotely NOTE During normal vehicle operation the system is in high power mode After the ignition switch is turned OFF the sys tem will go into low power mode for 48 hours after that the system will...

Page 1363: ...nob Voice recognition operation Button Item Emergency button OnStar button Dot button Speaker Phone line LED indicator Audio volume Pre call status Button is pushed Waiting Green light Voice recognition mode in use Will switch over to an emergency call when pushed Will switch over to OnStar service call when pushed Voice recognition mode is activated ends the voice recognition mode when pushed a s...

Page 1364: ...ted Troubleshoot the DTCs as indi cated below DTC 1 2 3 4 5 Self Diagnostics Items GPS signal error Inter device dedicated bus malfunction Deployment com manded circuit malfunction OnStar control unit malfunction Cellular phone select service switch malfunc tion button module Note OnStar system radio frequency modulator unit com munications error SRS signal out is open Will only shows as history d...

Page 1365: ...sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it 32P CONNECTOR A red Wire side of female...

Page 1366: ... passenger s door lock key cylinder in neu tral position Front passenger s door lock key cylinder in lockedposition Front passenger s door lock key cylinder in neu tral position Front passenger s door lock key cylinder in unlocked position Under all conditions Under all conditions OnStar DOT button pushed and human advisor voice comes on OnStar DOT button pushed and human advisor voice comes on Un...

Page 1367: ...d 1 V Emergency button pushed 1 7 V Check for voltage to ground There should be about 10 V Check for voltage to ground There should be about 7 V Check for continuity to ground There should be continuity Check for voltage to ground There should be about 0 V Check for voltage to ground There should be about 3 8 V Check for voltage to ground There should be about 6 6 V Check for voltage to ground The...

Page 1368: ...inals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replace it CONNECTOR B 16P Wire side o...

Page 1369: ...e to ground Thereshould beapprox8V Check for voltage to ground DOT button pushed 280mV OnStar button pushed 1V Emergency button pushed 1 7V Check for voltage to ground Thereshouldbe4V Check for voltage to ground There should be about8V Check for voltage to ground There should be no voltage Checkforvoltageto ground Thereshould be 10V Check for voltage to ground Thereshouldbe4V Check for voltage to ...

Page 1370: ...tem interface unit 3 Inspect the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control ...

Page 1371: ...age to ground There should be approx 8V Check for voltage to ground DOT button pushed 280mV OnStar button pushed 1V Emergency button pushed 1 7V Check for voltage to ground There should be 4V Check for voltage to ground There should be about 8V Check for voltage to ground There should be no voltage Check for voltage to ground There should be 10V Check for voltage to ground There should be 4V Check...

Page 1372: ...ct the connector and socket terminals to be sure they are all making good contact If the terminals are bent loose or corroded repair them as necessary and recheck the system If the terminals look OK make the following input tests at the connector If any test indicates a problem find and correct the cause then recheck the system If all the input tests prove OK the control unit must be faulty replac...

Page 1373: ...hed Ignition switch in ACC I OnStar Emergency button pushed Ignition switch in ACC I OnStar Emergency button pushed Ignition switch in ACC I OnStar Emergency button pushed Check for voltage to ground There should be about 10 V Check for voltage to ground There should be about 7 V Check for voltage to ground There should be about 6 V Check for voltage to ground There should be about 3 V Check for v...

Page 1374: ... 11 13 14 7 15 ORN WHT GRN BLU YEL YEL GRN BLK WHT With the ignition switch OFF pressandholdthe DOT button Turn the ignition switch from OFF to ACCthreetimes and backtoACC thenrelease the DOT button Ignition switch in ACC I Ignition switch in ACC I Ignition switch in ACC I Under all conditions Ignition switch in ACC I OnStar DOT button pushed Speak into the microphone Check for voltage to ground T...

Page 1375: ...microphone Under all conditions Check for voltage to ground There should be 4V Check for continuity go ground There should be continuity An open in the wire An open in the wire B1 B2 B3 B4 B5 B6 RED BLK YEL GRN BLU YEL WHT GRN ORN BLK Under all conditions Ignition switch in ACC II Ignition switch in ACC II Ignition switch in ACC II With the ignition switch OFF pressandholdthe DOT button Turn the i...

Page 1376: ...llular Phone Antenna Replacement 1 Remove the rear ceiling light 2 Disconnect the connector from the antenna 3 Remove the nut from the antenna CELLULAR PHONE ANTENNA CONNECTOR NUT 5 N m 0 5 kgf m 4 Ibf ft ...

Page 1377: ...rom the cellular phone antenna and the XM antenna 3 Remove the nuts from the cellular phone antenna and the XM antenna 4 Remove the cellular phone antenna and the XM antenna NUT 5 N m 0 5 kgf m 4 Ibf ft 5 Remove from the cellular phone antenna from the XM antenna XM ANTENNA CELLULAR PHONE ANTENNA ...

Page 1378: ...Lumbar Support System Component Location Index LUMBAR SUPPORT MOTOR Test page 23 52 LUMBAR SUPPORT SWITCH Test Replacement page 23 52 ...

Page 1379: ...sition according to the table 4 If the continuity is not as specified replace the switch Motor Test 1 Remove the driver s seat refer to the 96 01 3 5RL Service Manual P N 61SZ305 see page 20 57 2 Disconnect the 2P connector A from the lumbar support sub harness 3 Test each motor by applying battery voltage and body ground to the terminals 4 If the motor does not run or fails to run smoothly replac...

Page 1380: ...ide Airbags 99 04 models 24 30 Backprobing Spring loaded Lock Connectors 24 31 Disconnecting the Airbag Connectors and Seat Belt Tensioner Connectors 96 98 models 24 31 Disconnecting the Airbag Connectors Side Airbag Connectors and Seat Belt Tensioner Connectors 99 04 models 24 32 Steering related Precautions 24 34 Troubleshooting Self diagnostic Procedures 96 98 Models 24 35 99 04 Models 24 84 Re...

Page 1381: ...nstallation page 24 5 Inspection page 24 8 SHOULDER ANCHOR ADJUSTER see page 24 3 FRONT SEAT BELT Removal Installation page 24 3 Inspection page 24 8 CHILD SEAT TETHER ANCHOR Installation 96 99 Models page 24 9 Removal Installation 00 01 Models page 24 10 REAR SEAT BELT BUCKLE CENTER BELT TONGUE see page 24 6 FRONT SEAT BELT BUCKLES seepage24 4 REAR CENTER SEAT BELT BUCKLE 98 01 models REAR CENTER...

Page 1382: ... TENSIONER CONNECTOR RETRACTOR BOLT 7 16 20 UNF 32 N m 3 3 kgf m 24 Ibf ft LOWER ANCHOR BOLT 7 16 20 UNF 32 N m 3 3 kgf m 24 Ibf ft 6 Remove the center pillar trim see section 20 7 Disconnect the seat belt tension reducer connector and seat belt tensioner connector To avoid accidental deployment and possible injury always disconnect the seat belt ten sioner connector before removing the retractor ...

Page 1383: ...olt construction Seat belt buckle 1 Remove the front seat see section 20 2 Remove the center cover see section 20 3 Remove the seat belt switch harness from the seat cushion NOTE Refer to pages 20 64 20 65 for 99 01 models with side airbag Driver s seat Passenger s seat ...

Page 1384: ...e the seat belt buckle Center anchor bolt construction 5 Installation is the reverse of the removal procedure NOTE Make sure you assemble the washers on the center anchor bolt as shown Make sure the seat belt switch harness is fastened properly ...

Page 1385: ...hem during removal and installation Rear seat belt 1 Remove Rear seat cushion and rear seat back see section 20 Rear side trim see section 20 Rear door trim see section 20 Rear pillar trim panel see section 20 2 Remove all the anchor bolts and retractor bolt remove the retractor mounting bolt then remove the rear seat belt and retractor ...

Page 1386: ... the rear seat belt Upper anchor bolt construction Retractor bolt construction Seat belt buckle Center belt tongue 1 Remove the rear seat cushion see section 20 2 Remove the center anchor bolts then remove the seat belt buckles and center belt tongue 3 Installation is the reverse of the removal procedure NOTE Before attaching the rear seat back and rear seat cushion make sure there are no twists o...

Page 1387: ...n 20 Rear shelf see section 20 CENTER SEAT BELT Lower center anchor bolt construction 3 Installation is the reverse of the removal procedure NOTE Check that the retractor locking mechanism func tions as described on page 24 8 Before installing the anchor bolt make sure there are no twists or kinks in the rear center seat belt 3 Remove the center seat belt anchor bolt then remove the center seat be...

Page 1388: ...pection 1 Before installing the retractor check that the seat belt can be pulled out freely 2 Make sure that the seat belt does not lock when the retractor is leaned slowly up to 15 from the mounted position The seat belt should lock when the retractor is leaned over 40 CAUTION Do not attempt to disassemble the retrac tor Front 96 98 models Mounted Position Front 99 01 models Rear center 98 01 mod...

Page 1389: ... metal loops of the upper anchors can cause the seat belts to retract slowly Wipe the inside of the loops with a clean cloth damp ened in isopropyl alcohol 4 Check that the seat belt does not lock when pulled out slowly The seat belt is designed to lock only during a sudden stop or impact 5 Make sure that the seat belt will retract automatically when released 6 For each passenger s seat belt make ...

Page 1390: ... mm 7 8 in diameter circle at the location of the attachment point USA 325 mm 12 8 in 200 mm 7 9in PLUGCOVER Canada only ATTACHMENT POINT 360 mm 14 2 in REAR SHELF ATTACHMENT POINTS 8 x 1 25 mm 22 N m 2 2 kgf m 16 Ibf ft CHILD SEAT TETHER ANCHOR TOOTHED WASHER NOTE Do not remove the toothed washer from the child seat tether anchor Use the anchor with the toothed washer attached to it When installi...

Page 1391: ...e child seat tether anchor cover and both side child seat tether anchor cover from each attachment point in the rear shelf 2 Remove the child seat tether anchors Do not remove the toothed washer from the child seat tether anchor 3 Install the tether anchors in the reverse order of removal ...

Page 1392: ...Special Tools 07HAZ SG00500 07PAZ 0010100 07SAZ TB4011A 07TAZ SZ5011A 07TAZ 001020A 07XAZ S1A0100 07XAZ S1A0200 07XAZ SZ30100 ...

Page 1393: ...Disposal page 24 168 CABLE REEL Replacement page 24 176 FRONT PASSENGER S AIRBAG Replacement page 24 160 Disposal page 24 168 DRIVER S SEAT BELT TENSIONER Replacement page 24 165 Disposal page 24 168 SRS UNIT Including safing sensor and impact sensor Replacement page 24 181 FRONT PASSENGER S SEAT BELT TENSIONER Replacement page 24 165 Disposal page 24 168 ...

Page 1394: ...76 FRONT PASSENGER SAIRBAG Replacement page 24 160 Scrapping page 24 172 Replacement page 24 164 Scrapping page 24 172 Replacement page 24 165 Scrapping page 24 172 Replacement page 24 183 Replacement page 24 181 Replacement page 24 164 Scrapping page 24 172 Replacement page 24 165 Scrapping page 24 172 Replacement page 24 183 99 01 Models ...

Page 1395: ...ircuit will keep voltage at a constant level For the SRS to operate 1 The impact sensor and safing sensor must activate and send electric signals to the microprocessor 2 The microprocessor must compute the signals and send signals to the airbag inflators and seat belt tensioners 3 The inflators must ignite and deploy the airbags and activate the tensioners Self diagnosis System A self diagnosis ci...

Page 1396: ...rts the driver that the passenger s side airbag will not deploy in a side impact Seat Belt Tensioner The seat belt tensioner is linked with the SRS airbags to further increase the effectiveness of the seat belt In a front end collision the tensioner instantly retracts the belt firmly to secure the occupants in their seats Operation The main circuit in the SRS unit senses and judges the force of im...

Page 1397: ... operating normally If the light does not come on or does not go off after 6 seconds or if it comes on while driving it indicates an abnormality in the system The system must be inspected and repaired as soon as possible For better serviceability the SRS unit memory stores the cause of the malfunction and the unit is connected to the data link connector DLC This information can be read with the Ho...

Page 1398: ...nutes be careful not to bump the SRS unit the airbags could accidentally deploy and cause damage or injury Whenever the airbags have been activated replace the seat belt tensioners and the SRS unit The original radio has a coded theft protection circuit Be sure to get the customer s code number before dis connecting the battery cables The PCM memory must be reset after reconnecting the battery see...

Page 1399: ...rs see page 24 31 24 32 After a collision in which the airbags were deployed replace the SRS unit After a collision in which the side airbag was deployed replace the side impact sensor on the side where the side airbag deployed and SRS unit After a collision in which the airbags or the side airbags did not deploy inspect for any dam age or any deformation on the SRS unit and the side impact sensor...

Page 1400: ...e SRS indicator light comes on for about 6 seconds and then goes off the SRS sys tem is OK If the indicator light does not function properly go to SRS Troubleshooting Disconnecting the SRS Connector at the Fuse Box 96 98 Models CAUTION Avoid breaking the connector it s double locked 1 First lift the connector lid with a thin screwdriver then press the connector tab down and pull the con nector out...

Page 1401: ...opposite half of the connector Then pull the connector halves apart NOTE Be sure to pull on the sleeve and not on the connector half SPRING LOADED SLEEVE Connecting 1 Hold the pawl side connector half and press on the back of the sleeve side connector half in the direction shown As the two connector halves are pressed together the sleeve is pushed back by the pawl NOTE Do not touch the sleeve 2 Wh...

Page 1402: ... back cover cushion etc of seats with and without airbags are different make sure you install only the correct replacement parts When cleaning do not saturate the seat with liquid and do not spray steam on the seat Do not repair torn or frayed seat back covers Replace the seat back cover After a collision in which the side airbag was deployed replace the seat back cover and the side airbag with ne...

Page 1403: ...n switch OFF and disconnect the nega tive cable from the battery and wait at least 3 minutes before beginning the following procedures Before disconnecting the SRS main harness 18P con nector A from the SRS unit disconnect both airbag 2P connectors C D and both seat belt tensioner 2P connectors F H Before disconnecting the cable reel 2P connector B disconnect the driver s airbag 2P connector C Bef...

Page 1404: ...negative cable from the battery and wait at least 3 minutes before begin ning the following procedures Before disconnecting the SRS main harness 18P connector A from the SRS unit disconnect driver s airbag 2P connec tor C and front passenger s airbag 4P connector D Before disconnecting the SRS floor harness 18P connector E from the SRS unit disconnect both seat belt tensioner 2P connectors G I bot...

Page 1405: ...8 models or 4P 99 01 models connector between the front passenger s airbag and SRS main harness NOTE When disconnected the airbag connector is automatically shorted DRIVER S SIDE LEFT SIDE WIRE HARNESS 2P CONNECTOR FRONT PASSENGER S SIDE RIGHT SIDE WIRE HARNESS 2P CONNECTOR Side Airbag Disconnect side airbag 2P connector from the SRS floor harness NOTE When disconnected the side airbag connector i...

Page 1406: ...K position or remove the key from the ignition so that the steering wheel will not turn NOTE When the airbag and cable reel are disconnected and the battery is reconnected and the ignition switch is turned ON II the SRS unit will store this as an open in the driver s airbag inflator and the SRS indicator light will come on In such a case confirm the DTC then clear the SRS unit memory For disconnec...

Page 1407: ...TC proceed with the troubleshooting for this code Precautions Use only a digital multimeter to check the system If it s not a Honda multimeter make sure its output is 10 mA 0 01 A or less when switched to the smallest value in the ohmmeter range A tester with a higher output could dam age the airbag circuit or cause accidental airbag deployment and possible injury Whenever the ignition switch is O...

Page 1408: ...r this code Precautions Use only a digital multimeter to check the system If it s not a Honda multimeter make sure its output is 10 mA 0 01 A or less when switched to the smallest value in the ohmmeter range A tester with a higher output could damage the airbag circuit or cause accidental airbag deployment and possible injury Whenever the ignition switch is ON II or has been turned OFF for less th...

Page 1409: ...f these methods A Connect the Honda PGM Tester to the 16P Data Link Connector DLC and follow the tester s prompts If the tester indicates no DTC DTC 9 1 or DTC 9 2 double check by jumping the service check connector and watching the SRS indicator light see page 24 36 DATALINKCONNECTOR 16P HONDA PGM TESTER ...

Page 1410: ... a main code and a sub code Including the most recent problem up to three different malfunctions can be indicated In case of a continuous failure the DTC will be indicated repeatedly see example 1 below In case of an intermittent failure the SRS indicator light will indicate the DTC one time then it will stay on see exam ple 2 below If both a continuous and an intermittent failure occur both DTCs ...

Page 1411: ...s Reading With the PGM Tester Connect the Honda PGM Tester to the 16P Data Link Connector DLC and follow the tester s prompts If the tester indi cates no DTC DTC 9 1 or DTC 9 2 double check by jumping the service check connector and watching the SRS indicator light see next page DATA LINK CONNECTOR 16P HONDA PGM TESTER ...

Page 1412: ...gnition switch ON II The SRS indicator light comes on for about 6 seconds and then goes off Then it will indicate the DTC 3 Read the DTC 4 Turn the ignition switch OFF and wait for 10 sec onds Then disconnect the SCS short connector from the service check connector 2P SCS SHORT CONNECTOR 07PAZ 0010100 In case of main code is 3 sub code is 4 record a DTC 3 4 Reading the sub code Count the number of...

Page 1413: ...tay on see example 2 below If both a continuous and an intermittent failure occur both DTCs will be indicated as continuous failures When the system is normal no DTC the SRS indicator light will stay on see example 3 If the SRS indicator light comes on continuously without any DTCs there may be a problem in the light circuit Examples ofthe DTC Indications 1 Continuous failure SRS Indicator Light i...

Page 1414: ...ctor take a test drive quick acceleration quick braking cornering and turn the steering wheel fully left and right and hold it there for 5 to 10 seconds to find the cause of the intermittent failure If the problem recurs the SRS indicator light will stay on 6 If you can t duplicate the intermittent failure the sys tem is OK at this time 3 Turn the ignition switch ON II 4 The SRS indicator light co...

Page 1415: ...rn the ignition switch ON II 4 The SRS indicator light comes on for about 6 seconds and goes off Remove the SCS service connector from the MES connector 2P within 4 seconds after the SRS indicator light went off 5 The SRS indicator light comes on again Reconnect the SCS service connector to the MES connector 2P within the 4 seconds after the SRS indicator light comes on 6 The SRS indicator light g...

Page 1416: ...onnector to the MES connector 2P Do not use a jumper wire SCS SERVICE CONNECTOR 07PAZ 0010100 4 Turn the ignition switch ON II 5 The SRS indicator light comes on for about 6 seconds and goes off Remove the SCS service connector from the MES connector within 4 seconds after the SRS indicator light went off 6 The SRS indicator light comes on again Reconnect the SCS service connector to the MES conne...

Page 1417: ...Troubleshooting 96 98 Models Diagnostic Trouble Code DTC Chart 24 41 24 44 24 44 24 46 24 48 24 50 24 52 24 52 24 54 24 56 24 58 24 60 24 60 24 62 24 64 24 66 24 68 24 68 24 70 24 72 24 74 ...

Page 1418: ...24 98 Diagnostic Trouble Code DTC Chart 24 100 24 104 24 104 24 105 24 106 24 107 24 108 24 108 24 109 24 110 24 111 24 112 24 112 24 113 24 114 24 115 24 116 24 116 24 117 24 118 24 119 ...

Page 1419: ...t failure DTC 9 1 it means there was an internal failure of the SRS unit or faulty SRS indicator light circuit Do the troubleshooting for intermittent failures see page 24 87 2 In case of an intermittent failure DTC 9 2 it means there was an internal failure of the power supply VB line Do the troubleshooting for intermittent failures see page 24 87 ...

Page 1420: ...24 135 24 135 24 136 24 137 24 138 24 139 24 139 24 140 24 141 24 142 24 183 24 143 24 144 24 145 24 183 24 146 24 147 24 148 24 149 24 155 24 159 ...

Page 1421: ...ine cranking this may be self diagnosed as a failure in the SRS system and the SRS indicator light may indicate DTC 7 2 In this case first check the No 7 10 A fuse in the under dash fuse relay box Next erase the DTC memory see page 24 37 and check the DTC If DTC 7 2 doesn t reappear the SRS unit is normal ...

Page 1422: ...inals MAIN WIRE HARNESS To GAUGE ASSEMBLY DASHBOARD WIRE HARNESS DASHBOARD WIRE HARNESS To GAUGE ASSEMBLY C325 LEFT ENGINE COMPARTMENT WIRE HARNESS 20P CONNECTOR C339 LEFT ENGINE COMPARTMENT WIRE HARNESS 5P CONNECTOR C418 MAIN WIRE HARNESS 20P CONNECTOR C475 MAIN WIRE HARNESS 3P CONNECTOR C477 MAIN WIRE HARNESS 8P CONNECTOR C502 DASHBOARD WIRE HARNESS 20P CONNECTOR C508 DASHBOARD WIRE HARNESS 22P ...

Page 1423: ...s 3P connector Front passenger s seat belt buckle switch 3P connector right side wire harness 3P connector OPDS unit wire harness 8P connector OPDS unit wire harness 4P con nector and right side wire harness 4P connector Under dash fuse relay box SRS main harness 2P con nector main wire harness 12P connector left side wire harness 18P connector and left engine compartment wire harness 16P connecto...

Page 1424: ...tor main wire harness 20P connector and left engine compartment wire harness 20Pconnector Dashboard wire harness 30P connector and dashboard wire harness 22P connector Dashboard wire harness 8P connector main wire har ness 8P connector and SRS main harness 8P connector Left side wire harness 2P connector and SRS floor har ness 2P connector ...

Page 1425: ...ol to the cable reel 2P connector Connecting the Special tool to the SRS main harness 2P connector Fuse Box and Connector Locations cont d Driver s airbag 2P connector and cable reel 2P connector Cable reel 2P connector and SRS main harness 2P connector Troubleshooting 99 01 Models ...

Page 1426: ...t side or Front passenger s seat belt tensioner 2P connector and right side wire harness 2P connector right side NOTE Left side is shown Connecting the special tool to the SRS main harness 4P connector Connecting the special tool to the left side wire harness 2P or right side wire harness 2P connector 07TAZ SZ5011A 07SAZ TB4011A 07SAZ TB4011A 07XAZ SZ30100 ...

Page 1427: ...2P connector and SRS floor harness 2P connector left side or Front passenger s side airbag 2P connector and SRS floor harness 2P connector right side NOTE Left side is shown Left side wire harness 2P connector and SRS floor har ness 2P connector left side or Right side wire harness 2P connector and SRS floor har ness 2P connector right side Fuse Box and Connector Locations cont d Troubleshooting 9...

Page 1428: ...e or SRS floor harness 4P connector right side NOTE Right side is shown Right side wire harness 24P connector and main wire harness 24P connector Connecting the special tool to the SRS floor harness 4P connector SRS TEST BOX 4P 07XAZ S1A0100 ...

Page 1429: ...nnected Do not disassemble or tamper with the airbag 1 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s preset buttons 2 Disconnect the battery negative cable then discon nect the positive cable from the battery and wait at least 3 minutes 3 Disconnect the airbag connector s Driver s Airbag Remove the access panel from the steering wheel then dis...

Page 1430: ...8 Models FrontPassenger sSide Remove the two mounting nuts from the bracket Lift the front passenger s airbag out of the dashboard by covering the lid and dashboard with a cloth and prying carefully with a flat tip screwdriver NOTE The lid of the airbag has pawls on its side which attach it to the dashboard 99 01 Models ...

Page 1431: ...interfering with other parts 5 Install new airbag s Driver s Side Place the driver s airbag in the steering wheel and secure it with new Torx bolts 96 98 Models Front Passenger s Side Place the front passenger s airbag in the dashboard Tighten the front passenger s airbag mounting nuts 99 01 Models ...

Page 1432: ... panel on the steering wheel 96 98 Models 7 Reconnect the battery positive cable then connect the negative cable 8 After installing the airbag confirm proper system operation Turn the ignition switch ON II the SRS indica tor light should come on for about 6 seconds and then go off Make sure horn button works Take a test drive and make sure the cruise con trol switches work 9 Enter the anti theft c...

Page 1433: ...4 Remove the seat assembly then remove the seat back cover see section 20 7 Install the new seat back cover see section 20 8 Install the seat assembly see section 20 then con nect the side airbag harness 2P connector to the SRS floor harness 2P connector 9 Reconnect the battery positive cable then connect the negative cable 10 After installing the side airbag confirm proper sys tem operation Turn ...

Page 1434: ...he frequencies for the radio s pre set buttons 2 Disconnect the battery negative cable then discon nect the positive cable from the battery and wait at least 3 minutes 3 Remove the left and or right B pillar trim panels see section 20 4 Disconnect the seat belt tensioner 2P connector s from the left side wire harness driver s side and or the right wire harness front passenger s side NOTE When disc...

Page 1435: ...ct the left side wire harness 2P connector to the driver s seat belt tensioner and or the right side wire harness 2P connector to the front passen ger s seat belt tensioner 10 Reconnect the left side wire harness or the right side harness 2P connector to the tension reducer connector 11 Reinstall the B pillar lower panel door opening trim and door sill molding 8 Reinstall the shoulder harness anch...

Page 1436: ...e 13 After installing the seat belt confirm proper system operation Turn the ignition switch ON II the SRS indicator light should come on for about 6 seconds and then go off 14 Enter the anti theft code for the radio then enter the customer s radio station presets ...

Page 1437: ... be deployed while still in the vehicle The airbags should not be considered as salvageable parts and should never be installed in another vehicle Confirm that each airbag is securely mount ed otherwise severe personal injury could result from deployment 1 Disconnect both the negative cable and positive cable from the battery 2 Confirm that the special tool is functioning properly by following the...

Page 1438: ...e it in a sturdy plastic bag and seal it securely CAUTION Wear a face shield and gloves when handling a deployed airbag Wash your hands and rinse them well with water after handing a deployed airbag Triggering the Seat Belt Tensioners NOTE If an SRS vehicle containing one or both intact seat belt tensioner s is to be entirely scrapped the seat belt tensioner s should be triggered while still in th...

Page 1439: ...ctivation the tensioner can become hot enough to burn you Wart thirty min utes after activation before touching it 8 Dispose of the complete tensioner assembly No part of it can be reused 9 Repeat steps 3 thru 8 on the other side if that ten sioner has not been triggered Airbag and Seat Belt Tensioner 96 98 Models Simultaneously DeployingAirbagsand Triggering Seat BeltTensioners 1 Disconnect both ...

Page 1440: ...d Airbag or Pretensioner SpecialProcedure During airbag deployment and preten sioner activation the airbag and tensioner assem blies can become hot enough to burn you Wait 30 minutes after activation before touching them 10 Dispose of the complete airbag and tensioner assembly No part of them can be reused 1 Confirm that the special tool is functioning properly by following the check procedure on ...

Page 1441: ...caution Follow the procedure Deploying the Airbags In vehicle NOTE If an SRS vehicle is to be entirely scrapped its airbags or side airbag should be deployed while still in the vehicle The airbags or side airbag should not be considered as salvageable parts and should never be installed in another vehicle Confirm that each airbag or side airbag is securely mounted otherwise severe personal injury ...

Page 1442: ...cial tool is functioning properly by following the check procedure on the tool label or the procedure on page 24 175 3 Remove the B pillar trim panel see section 20 4 Cut off the seat belt tensioner connector then strip the wire ends and connect the special tool alligator clips to them as shown Place the special tool about 30 feet away from the vehicle DEPLOYMENT TOOL 07HAZ SG00500 7 Connect a 12 ...

Page 1443: ...mes on the tensioner is ready to trigger 7 Push the tool s deployment switch to trigger the tensioner igniter The tensioner should take up the slack in the belt pop the clip off and lock the belt in its retracted position If the tensioner works and the green light on the tool comes on continue with this procedure If the tensioner doesn t work yet the green light comes on its igniter is defective G...

Page 1444: ...t triggered yet the green light comes on an igniter is defective Go to Damaged Airbag or Pretensioner Special Procedure During airbag deployment and preten sioner activation the airbag and tensioner assem blies can become hot enough to burn you Wait 30 minutes after activation before touching them 10 Dispose of all the airbags and tensioners completely No part of them can be reused 1 Confirm that ...

Page 1445: ... cause serious injury CAUTION Carefully inspect the airbag before installing it Do not install an airbag that shows signs of being dropped or improperly handled such as dents cracksordeformation Do not disassemble or tamper with the airbag 1 Make sure you have the anti theft code for the radio then write down the frequencies for the radio s preset buttons 2 Disconnect the battery negative cable th...

Page 1446: ... 99 01 Models 99 01 Models 8 Remove the steering wheel using a commercially available steering wheel puller 96 98 Models 99 01 Model 9 Remove the steering column covers 96 98 Models ...

Page 1447: ...rness wires so that they are not pinched or interfering with other vehicle parts After reassembly confirm that the wheels are still turned straight ahead and that the steering wheel spoke angle is correct road test If minor spoke angle adjustment is necessary do so only by adjusting the tie rods not by removing and repositioning the steering wheel 12 Set the cancel sleeve so that the projections a...

Page 1448: ...l switch connector 96 98 Models 14 Install the steering column covers 15 If necessary center the cable reel New replace ment cable reels come centered Do this by first rotating the cable reel clockwise until it stops Then rotate it counterclockwise about 21 2 turns until the arrow mark on the cable reel label points straight up 96 98 Models 99 01 Models ...

Page 1449: ...en the nega tive cable 20 After installing the cable reel confirm proper sys tem operation Turn the ignition switch ON II the SRS indica tor light should come on for about 6 seconds and then go off Make sure horn button works Make sure the headlight and wiper switches work Go for a test drive and make sure the cruise con trol switches work 21 Enter the anti theft code for the radio then enter the ...

Page 1450: ... and cable reel see page 24 33 NOTE When the disconnected the airbag connector is automatically shorted Front Passenger s Airbag Remove the glove box see section 20 Disconnect the 2P 96 98 Models or 4P 99 01 Models connector between the front passenger s airbag and SRS main harness see page 24 33 NOTE When disconnected the airbag connector is automatically shorted Side Airbag 99 01 Models Disconne...

Page 1451: ...nstall the access panel on the steering wheel 10 Reconnect the front passenger s airbag 2P 96 98 Models or 4P 99 01 Models connector to the SRS main harness 2P 96 98 Models or 4P 99 01 Models connector then install the glove box 11 99 01 Models Reconnect the side airbag 2P con nectors to the SRS floor harness 2P connectors 12 Reconnect the left side wire harness 2P connector to the driver s seat b...

Page 1452: ... the frequencies for the radio s preset buttons 2 Disconnect the battery negative cable then discon nect the positive cable from the battery and wait at leasts minutes 3 Disconnect the side airbag 2P connector 4 Remove see section 20 Seat assembly Front side trim Center pillar trim Lower anchor bolt 5 Pull back the carpet remove the two Torx bolts using a Torx T30 bit then remove side impact sen s...

Page 1453: ...lead to personal injury or death in the event of a severe frontal collision all SRS service work must be performed by an authorized Honda dealer Improper service procedures including incorrect removal and installation of the SRS could lead to personal injury caused by unintentional activation of the front airbags seat belt tensioners and side airbags 99 01 models Do not bump the SRS unit Otherwise...

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