Acura Integra 1998 Service Manual Download Page 219

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Summary of Contents for Integra 1998

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Page 35: ...Maintenance Lubrication Points 4 z Maintenance Schedule NormalConditions 4 4 Maintenance Schedule Severe Gonditions 4 6 ...

Page 36: ...atchor trunkhingesandlatch Doorhjnges upperandlower Doorooendetent HondaWhiteLithiumGrease 1 9 Rearb akecalipers Silicone grease 20 Powersteeringsystem Genuine HondaPowerSteering Fluid V or S 21 Ai conditioning compressor Refrigerant oii ND O L8 P N38897 PR7 A01AHor 38899 PR7 A01 ForRefrigerant HFC 134a R 134a APISERVICE LABEL APICERTIFICATION SEAL Recommended engineoil Engin oil viscositylor ambr...

Page 37: ... at at I qfl j__ n til i l _ _ NOTE Lubricateall hinges latches and locksoncea year ln corrosiveareas morefrequentlubricationis necessary We recommend HondaWhiteLithiumGrease 4 3 ...

Page 38: ...9 9 9 g E a i E S o o F g 6 s 9 F e 3 l F i gE SggE c n g 5 6 E 9 j c o 3 6 6 m c o c o 5 r o tr E q s r E 9 9 5 r n r o E r EF i 9 n o E E E i E 5 j 5 6 i t E v 6 i I i i 9 o 6 o E P 9 9 9 0 9 E E P o g E i j q g o i b i E 9 s 3 e 9 9 E E 6 E E E a a o 3 a a a E E a a a E E a a a a a a o a a a a a a a a a a a a a a a a a a a a a a a a O a a a a a a a a a I E 5 E E 9 u i i t 4 l E a E 3 6 E E a p ...

Page 39: ...E e r g G b z E i E l I s a z p 9 9 E 3 I E i H i g E z 9 i g E T 3 P j F o z 9 g o 9 c H i H i P i o 6 J o o e g s c E Y 6 o E E i 3 i 9 d E t t x d i l p i 9 3 E E E o E i E 9 9 3 R o o E g t S h o 5 e E6 6 t a o a a a o a a E E tr E 6 o E E E E q 3 i 6 6 3 a t a 4 5 a ...

Page 40: ... g E E E 1 i c 5 i T F b i e c i o 583 gHi r E z l 9 IEZZ E EE ii aF E 3 3 X o l 1 E 5 6 5 i i A 9 P 9 d i l f f F I S q F o t j l e e e i t EEFEE E F I F E T I I E I P P E I i o o c o e 5 t 6 t 6 s E d l e a E q i I H i R E 1 l i 5 i t E 3 o ct ti 0 3 i b i x i I 6 E g o E o E 3 r t i i P J z P o 9 i b E E 9 p f 9 E E 6 E a o a E a a E i s E 6 a o a a a a a o o a a a a o a a a a a a a a o a a a o...

Page 41: ...D o c 1 E F o o E 9 9 s B 99 9 R 6 i i q 3 EeiEiiE O P P E P s d i E t f c o q q u J F o u 9 t Y t h z 9 o l t gET ci r r B P P J F z E E E g 9 a I 9 E 9 6 q o 6 a o E q 5 i t o E E 6 s 9 3 E i 3 3 3 i F I P E c E 3 6 x d 5 9 9 9 o o o I E t e g E t H g a P 3a ei E i E i 6 3 9 i E o E z 5 a 9 8 Y 9 G g s T E n E 9 t E i E 3 E 9 a a c i e a E a o o a o o o a o a a a a o o a a o a a a a o I 6 p 6 i ...

Page 42: ...r a Engine Engine Removal lnstallation 5 1 Cylinder Head Valve Train 6 1 E n g i n e B l o c k 7 1 Engine Lubrication 8 1 IntakeManifold Exhaust System 9 1 Cooling 10 1 ...

Page 43: ... a EngineRemoval lnstallation Speciaf Tools 5 2 Engine RemovaUlnstallation 5 3 Mount Bracket Torque 5 17 ...

Page 44: ...Special Tools Rel No I ToolNumber Description Oty I PageReterence o 07MAC SL00200 BallJointRemover 28mm l 5 1 0 L ...

Page 45: ...be sure that they do not contact other wiring or hoses or intedere with other parts NOTE Anti theft radioshavea codedtheftprotection cir cuit Besureto getthecustomer s codenumberbetore Disconnecting the battery Removing the No 32 7 5A fusefrom the under hoodfuse relay box Removing the radio After service reconnectpowerto the radioand turn it on Whenthe word CODE is displayed enterthe cus tomer s5 ...

Page 46: ...1 0kgt m 7 2lbf ft Remove the evaporative emission EVAP canister hose B18B1 B 18C1 eng nes control 5 4 7 Removethe brakeboostervacuumhose evapora tive emission EVAP controlcanisterhoseand tuel returnhose 818C5 engine Remove the enginewire harness connectors on the rightsideof enginecompartment 6 x 1 0 mm 9 8 N m l1 Okgl m ...

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Page 48: ... 4kgt m 17 tbt ft 5 6 A C COMPRESSOR EELT l 15 t o Remove theenginegroundcableat the bodyend Remove theadjusting boltandmountingbolts then removethe power steering P S pump belt and pump Do notdisconnect the P Shoses MOUNTINGBOLTS I x 1 25 mm 24 N m 12 4kgt m 17 lbl ft Loosen the idler pulley bolt and adjusting bolt then remove the air conditioning Ay C compressor belt IDLERPULLEYBOLT 10 x 1 25mm ...

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Page 50: ...s LOWCRRADIATOR HOSE HEATER HOSE HEATER HOSE LOWERRADIATOR HOSE UPPER RADIAToR HOSE UPPER RADIATOR 1 i r f c 5 8 t 27 lAutomatictransmission Removethe ATF cooler hoses Remove the radiatorassembly seepage10 5 Remove theA C compressor Do notdisconnect Ay C hoses 8 x 1 25 mm 24 N rn 12 4 kgl m 17 lbf ft 24 29 HOSES ...

Page 51: ...gt n tlo lbt ft Replace 81881 818C5engines PRIMARY HO25 CONNECTOF GASKET Replace GASKET Replace S LF LOCKING NUT 8 x 1 25mm 16 N m 1 6kgf m 12 tbt fr Replace f UT 10 x 1 25 mm 54 N m 5 5 kgf m 40 lbf ftl Replace 8 x 1 25mm 24 N m 2 4 kgt m 17 lbf frl Replace 31 Remove the shift rod and extension rod Mff 8 x 1 25 mm 22 N m 12 2 kgl m 16lbt ttl 32 Removethe shift cable A T I x 1 25 mm 22 N l 12 2 kg...

Page 52: ...dure NOTE Adjustthe tool so the jaws are parallel to eachother 12x 1 25mm 5 jl0 35 Remove the driveshafts CAUTION Do not pull on the driveshaft the CV joint may comeaoart Usecarewhen prying out the assembly Pull it straight to avoid damagingthe differential oil sealor intermediateshaft dust seal NOTE Coatall precision Iinishedsurfaces with clean enoine oil DRIVESHAFT ...

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Page 56: ...nt then tightenthe bolvnutson thetfansmlssion side Leave the mount boltloose AIT 12x 1 25mm g N m 6 5 kgl m cont dl 5 14 47 thl ftl o l lf MOUNT EOLT 1 2 x 1 2 5m m 64 N m 6 5 kgf m 47 lbf fr I I 2 I n s t a l l t h e e n g i n es i d e bolvnutson the engtne toose M T mount then tightenthe side Leavethe mount bolt 1 0 x 1 2 5m m 52 N m 15 3kgf m 38 tbf ft Replace 3 Tightenthe mountbolton thetransm...

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Page 58: ...e heater valveopen seepage10 6 Adjustthethrottlecable seesection11 Check theclutchpedalfreeplay seesection12 Checkthat the transmissionshifts into gear smoothlY Adjustthe tensionof the following drive belts Alternator belt seesection23 P Spumpbelt seesection171 A CcomDressor belt seesection 22 Inspect for tuelleakage seesection1ll After assembling fuel line parts turn on the ignitionswitch do not ...

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Page 62: ...2 4kgl m 17 rbf ftt q 44N mtr 5kst m v ahp w q7 10 x 1 25 mm 54 N m 15 5kgf m 40 rbt frl P S PUMPBRACKET 10x 1 25 mm t ltri rH ir I r rN m 4 5kgf m 33lbtftl FRONTSTIFFENER A C COMPRESSOR BRACKET I x 1 25 mm 24 N m 2 4kgf m 17rbf ft 12x 1 25mm 57N m15 8kgt m 42 lbf ftt 6 HEAr d 1N rNsuLAroR I H Gh o r l sxrlomm v 12N m11 2 kgf m 8 7tbf ftt ...

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Page 65: ... 130lbf ft 1 Remove cylinderheadcover ADJUSTINGSCREW LOCATIONS EXHAUST UP MARKS TDCGBOOVES 2 Setthe No 1 pistonat top deadcenter TDC see page6 12 UP markon the pulleyshouldbe at the top and the TDCgrooveson the pulleyshould align with the TDCgroove on timing belt back cover TDCmark paintedwhite on the crankshaft pulleyshouldalignwith pointeron the timing belt lower cover Number1 pistonat TDC POINT...

Page 66: ...ylinder Number4 piston at TDC LOCKNUT9x0 75mm 25N m 2 5kgl m 18lbtft Tightenthe locknutand recheck clearance again Repeat adjustment if necessary R o t a t et h e c r a n k s h a f t1 8 0 c o u n t e r c l o c k w i s e camshaft pulleyturns 90 The UP markshould be on the exhaust side Adjustvalveson No 3 cylin der 8 Rotatethe crankshaft180 counterclockwise to bring No 2 pistonto TDC The UP mark sho...

Page 67: ...Usingthe 6 mm boltssupplied with the tool mount the two uprightsto the cylinderheadat the end camshaft holders The uprights fit asshown 7 Insertthe crossshaftthroughthe bottomholeof thetwo uprights 8 9 1 0 Selectthe 7 8 in diameterlongcompressor attach mentandfastenthe attachment to the No 4 holeof the leverarmwith thespeedpinsupplied Position the pistonat TDCand insenan air adaptor intothe sparkp...

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Page 69: ...ustment page6 9 Replacement page6 10 Beplacewhen damaged or deteriorated 8 x 1 25mm 37 N m 3 8kgf m 27 lbf ft BACKCOVER Installwith concave surfacefacing out Remove any oil and clean ADJUSTINGBOLT 10x 1 25mm 54 N m 5 5kgt m 40lbf ltl MIDDLECOV R 6 x 1 0 m m 9 8N m 1 0kgf m 7 2lbl ftl 6 x 1 0 m m 9 8N m11 0kgl m 7 2lbf ftl TIMINGBELT DRIVEPULLEY Remove anyoil anoctean LOWER COVER CRANKSHAFT PULLEY ...

Page 70: ...ew pulley bolt O tightenthe pulleyboltto 196N m 20 0kgim 145 lbf ft loosenthe bolt o retighten it to 177N m 18 0kgf m 130lbift When installing the bolt lubricate the threadsand flangewith engineoil but don t lubricate the washer andDUllev Don tlubricate washer PULLEY HOLDEB ATTACHMENI HEX50 mm OFFSET OTMAB PY3O1OA SOCKET 19mm 07JAA 1020A COMMERCIALLY AVAILABLE ...

Page 71: ...ermakingthe follow ingadjustment Alwavs rotate the crankshaftcounterclockwisewhen viewed from the pulley side Rotatingit clockwise may result in improperadjustmentof the belt ten ston Removethe cylinderheadcover Referto page 6 33wheninstalling Setthe No I pistonatTDC seepage6 12 Rotatethe crankshaft five to six revolutionsto set the belt Setthe No 1 pistonatTDC 1 2 ADJUSTING BOLT 54N m 5 5kgf m 0 ...

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Page 78: ... SPRING s r _ VALVEKEEP NS DOWELPIN SPRING AEIAINER INTAKEVALVESPRING INTAKEVALVESTEMSEAL VALVESPRING SEAT ENOPIVOTBOLT 63 N m 6 4kgf m 46 tbt ftl SIEM SEAL VALVESPRING SEAT rg EXHAUSTVALVE GUIDE INTAKEVALVEGUIDE Inspection page6 26 Replacement page6 27 Reaming page6 28 CYLINDER HEAD Warpage page6 30 L DOWEL PIN CYLINDER HEADGASKET 3LAYERS OFMETALI Replace EXHAUSTVALVE 85N m 8 7kgtm 63lbf ft I App...

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Page 80: ...trol cablewhen installing s esection11and 14 THROTTLE CONTROL CABLE ADJUSTING NUT Removethe enginewire harnessconnectorsand wire harness clampsf om the cylinderheadandthe intakemanifold Fourfuelinjectorconnectors Intake airtemperature lATlsensorconnector Enginecoolanttemperature ECT sensorcon nector TDC CKP CYP sensorconnector lgnitioncoilconnector ECTgaugesendingunitconnector Throttleposition TP ...

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Page 82: ...ecylinderheadcover SIDEENGINE MOUNT 12x 1 25mm 74N m 17 5 kgt m sil lbtft CYLINOER HEAD COVER t L I L 2 1 22 Remove the timingbelt seepage6 10 Remove the camshaft pulleysand backcover CAMSHAFT PULLEYS 23 Remove the exhaustmanifold GASKET Replace SELF LOCKING NUT 8 x 1 25mm 3 l N m13 2kgl m 23 lbf ftl Replace ...

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Page 85: ...etto loosen valvekeepersbeforeinstalling the springcompres sor Install the spring compressor Compress spring and remove valve keeper VALVESPRING COMPRESSOR KDNo 383 with 35JAWor Snap on CF711 Measure cam Iobeheight CamLobeHeightStandard Newl fNTAKE 33 716 mm 11 3271inl EXHAUST 33 528 mm 1 3200 inl VALVESPRING COMPRESSOR ATTACHMENT 07757 PJ1010A Inspect this area for wear o r l _vn r i I 6 23 ...

Page 86: ... Standard New C SorviceLimit D Standard Now D ServiceLimil B Standard New C Standard N6w C ServiceLimit D Standsrd lNow D Servic Limit 11 217 1 221inl 103 80 104 10 mm 14 087 4 098in 6 580 6 590mm 0 2591 0 2594in 6 55mm 0 258 inl 1 35 1 65mm 0 053 0 065in 1 15 mm 0 0 15 inl ExhaustVslve Dimonsions A StandardlNew 27 90 28 10mm 11 098 1 106 in 1O4 OO 10 1 30 mm l 09 t 4 106in 5 550 6 560mm 10 2579 0...

Page 87: ...ith closely woundcoils towardthecylinder head EXHAUST VALVESEAL IBLACKSPRING Replace A uoruEKEEPER 9 PRTNGREYATNER VALVESPRING INTAKEVALVESEAL IWHITESPRINGI Replace I PLASTIC MALLET VALVEGUIDE SEALINSTALLER 07GAD PH70100 t Sz I SPRING V SEAT NOTE lnstall thevalvespringseats beforeinstalling thevalveseals 6 25 ...

Page 88: ... 0 004 0 006inl Service Limit 0 22mm 0 009 in Valve extended 10 mm out from seat lf measurement exceedsthe service limit recheck usrnga new valve l f m e a s u r e m e n t i s n o w w i t h i n t h e s e r v i c e l i m i t reassembleusing a new valve lf measurement still exceeds limit recheck using alternate method below then replace valve and guide if necessary NOTErAn alternatemethodof checking...

Page 89: ...0 C exces3ive heat may loo3enthe valvo seats To avoid burns uss heaw gloveswhen handling the heat dcylinder head 12 21inl 6 27 Workingtrom the camshaft side usethe driverand 8n air hammerto drivethe guide about2 mm 0 1 in towardsthe combustionchamber This will knockoff some of the carbon and make removal easter CAUTION Always wear safety goggles or a face shield when driving valveguides Hold the a...

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Page 91: ...the seat several times PRUSSIAN BLUECOMPOUNO 6 29 o The actualvalveseatingsurface as shown by the bluecompound shouldbe centered on the seat lf it is too high closerto the valve stem you must make a secondcut with the 60 cutterto move it down then one more cut with the 45 cutterto restoreseatwidth lf it is too low closerto the valve edge you must make a secondcut with the 30 cutterto moveatup then...

Page 92: ...cemust be clean UP markon the camshaftpulleysshouldbe at the top Do not usethe middlecoverandlowercoverfor stor ing removeditems Cleanthe middlecoverand lowercoverbeforeinstal lation Replace the washerwhendamagedor deteriorated L Cylinderheaddowelpinsand the oil controlorifice mustbe aligned Whenhand inga metalgasket careshouldbe takennotto fold it or damagethecontactsurface of thegasket Cleanthe ...

Page 93: ...24 1 7 r 1 21N ml2 1kglm 23N m 2 3ksf m 17lbf ftl 17tbf ftr 6 31 CAUTION Make sure that the keywayson the camshaftsare tacing up and No 1 piston is at top dead cenier tTDCt Replacetherockerarms in their original positions 6 Placethe rockerarms on the pivot boltsand the valvestems 7 8 Installthe camshafts then installthe camshaft seals with the openside spring facingin Apply liquidgasketto the head...

Page 94: ...ftl 11 Alignthe markson the cylinderheadplug to the cylinderhead uppersurface then installthe cylin der headplugin the cylinderheadto theend CYLINDEB HEAD PLUG Replace 13 lnstallthe backcover Installkeysintocamshaft grooves NOTE To setthe camshafts at TDCpositionfor No 1 piston alignthe holesin the camshafts with the holesin No 1 camshsftholderssnd insert5 0mm pin punches in the holes 8 x 1 25mm t...

Page 95: ...akesurethe seal is seated securelyin the cornersof the recesses with no gap RUEBER SEAL 18 Apply liquid gasketto the rubbersealat the eight cornersof the recesses NOTE Useliquidgasket PartNo 08718 OO01 or 08718 0003 Check thatthe matingsurfaces arecleananddry beforeapplyingliquidgasket Do not installthepartsif 5 minutesor morenave elapsedsinceapplyingliquidgasket Instead reapplyliquidgasketafterre...

Page 96: ...lidethe coverslightlybackandiorth to seat the rubberseal NOTE Beforeinstallingthe cylinderheadcover clean the cylinder head contactingsurfacesusing a shoptowel Do not touch the partswhere liquidgasketwas applied 6 x 1 0 m m 9 8N m 1 0kgf m 7 2 tblltl 6 34 2 1 Tightenthe nuts in 2 or 3 steps In the final step tightenali nuts in sequence to 9 8 N m 1 0kgim 7 2 tbf ft Afterinstalling checkthat all tu...

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Page 146: ...S800101 07749 00r0000 07973 PE00310 07973 PE00320 07973 6570500 07973 6570600 PistonPinBaseInsert PistonBaseHead SealDriver Pilot Collar RingGearHolder DriverAttachment Driver PistonPinDriverShaft PistonPinDriverHead PistonBase PistonBaseSpring 7 22 23 7 22 23 7 29 1 22 23 7 29 7 2 9 1 22 23 7 22 23 7 22 23 1 22 H H Y E g c a O o 7 2 ...

Page 147: ...f m 54lbf tr Torquesequence page7 7 AUTOMATIC TRANSMISSION WASHER covERs GASKET Replace 11x 1 5mm 76 N m 17 8 kgt m 56lbtft Applyengineoilto the bolt threads andthewashers NOTE Aftertorquing eachcap turncrankshaft to checkfor binding ORIVE PLATE Check for cracks Applyliquidgasket to blockmatingsurface CRANKSHAFT Endplay page7 12 Runout Taper and Out of Round page7 13 Installation page7 26 MAIN AEA...

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Page 149: ...ess is ixedandmustnotbechanged by grinding orshimming OILSEAL Installation page 7 29 Replace MAIN BEARING Radialclearance page 7 8 Selection page 7 I NOTE New main bearings must be selectedby matching crank and block identification m a r k r n g s 6 x 1 0 m m 11N m l 1 kgf m I rbr ft OILJETBOLT 16N m 1 6kgf m 12lbtft Be careful notto damage OILPUMP Overhaul page8 10 Appl liquidgasket to block mati...

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Page 152: ...0 0012 0 0019 inl Service Limit 0 060 mm 0 0024 inl PLASTIGAGE STRIP lf the plastigage measures too wide or too narrow removetheengineif it sstillin the car removethe crankshaft and removethe upperhalfof the bear ing lnstalla new completebearingwith the same colorcode select the coloras shownin the right column andrecheck theclearance CAUTION Do not file shim or scrapethe bearings or the capsto ad...

Page 153: ...d recheck the clearance CAUTION Do not file shim or scrapethe bearing or the capsto adiust clearance It the plastigage showstheclearance is stillincorrect try the nextlargeror smaller bearing thecolorlisted above or belowthatone andcheck clearance again NOTErIt the properclearance cannotbe obtained by usingthe appropriate largeror smallerbearings replace thecrankshaft andstanover Selection CAUTION...

Page 154: ...e the correctbearings ilb Color code is on the edge of the bearing Largerbig end bore Smallerbearing thicker S m a l l e r beal ng thicked 1r I ll li tl il I I z to Smaller rod journal ConnectingRodJournalCodeLocations Lettersor Barsl Beeringldentitication NOTE End playfor the connecting rodsand crankshaft shouldbe inspected beforeremovingthecrankshaft 1 Remove theoil pan oilscreen andtheoilpump G...

Page 155: ... rod caps bearings Keep all caps bear ings in order Lift the crankshaft out o the engine being care ul not to damagejournals CRANKSHAFT 9 Remove the upper bearing halves from connecting rods and set them aside with their respectivecaps 10 Reinstallmain caps and bearingson the engine in proper order 11 lf you can feel a ridge oI metal or hard carbon around the top of each cylinder remove it with a ...

Page 156: ...n the connecting rod doesnot indicateits positionin the engine it indi catesthe rod boresize EndPlay NOTE End play should be inspected beforeremoving crankshaft Pushthe crankfirmly awayfrom the dial indicator and zerothe dial againstthe end of the crank Thenpull the crankfirmly backtoward the indicator dial reading shouldnotexceed service limit CrankshaftEndPlay Standard New 0 10 0 35mm 0 00 l 0 0...

Page 157: ...mplete Supponwith lathe typetoolor V blocks Out of Round and Taper Measureout of round at the middleof eachrod and mainjournal intwo places The difference betweenmeasurements on eachjour nalmustnot be morethanthe service limit JournalOut oI Round Standard Newl 0 005 mm 0 0002 inl max Service Limit 0 010mm 0 0004 inl placesat middle Measure taper nearedges r Measure taperat the edgesof eachrod JOUr...

Page 158: ...02 inl lf measurements in any cylinderare beyond Oversize BoreService Limit replace the block lf the block is to be rebored reler to Piston Clearance Inspection seepage7 16 afterrebor Ing NOTE Scoredor scratched cylinderboresmust be noneo Reboring Limit 0 25mm 0 01inl ll i I I Check thetop oI the blockfor warpage Measurealongthe edgesand acrossthe centeras shown SURFACES TO 8E MEASURED EngineBlock...

Page 159: ...the cylinderblockof all melalparticles Washthe cylin der boreswith hot soapywater then dry and oil immediately to preventrusting NOTE Neveruse solvent it wili only redistribute thegritonthecylinder walls lf scoringor scratches are still presentin cylinder boresafter honingto the servicelimit reborethe engine block NOTE Somelightvertical scoringandscratching is acceptable if it is not deepenoughto ...

Page 160: ...er Standard Newl 80 98 80 99mm 3 188 3 189in Service Limit 80 97mm 3 188 in 15mm 0 6in 3 Calculate the differencebetweencylinderbore diameteron seepage7 14 and pistondiameter Piston to Cylinder Clearance Standard Newl 0 010 0 040mm 0 0004 00016in Service Limit 0 05mm 0 002 inl lf the clearance is nearor exceeds the servicelimit inspectthe pistonand cylinderblockfor excessive wear Ove6ize PistonDia...

Page 161: ...tfacetheintake manjfold 81881engine CONNECTING ROO OILHOLE 81881enginel Positionthe pistonin the cylinder and tap it in usingthe woodenhandleof a hammer NOTE Maintaindownwardforceon the ring com pressorto preventringsfrom expandingbefore entering the cylinderbore 6 Stopafterthe ringcompfessor popsfree andcheck the connectingrod to crank journal alignment betorepushingpistonin to place 7 Checkthe c...

Page 162: ...all pistonsat top deadcenter 7 18 818C5engine ll the crankshaftis alreadyinstalled 1 Setthe crankshaft to BDCfor eachcylinder 2 Remove the connecting rod caps andslipshortsec tionsof rubberhoseoverthe threadedendsof the connecting rod bolts 3 Install the ringcompressor andcheckthatthe bear ing is securely in place 4 Position the arrowfacingthe timing beltsideof the engine The mark mustface thetimi...

Page 163: ... 005 0 006 in CONNECNNG HOO GAUGE 1 t ll the crankshaftis not installed 1 Remove the connecting rod caps then installthe ring compressor and checkthat the bearingis securely in place 2 Positionthe arrow and the mark facingthe timing beltsideot the engine The mark mustface thetimingbeltside of theengine Tb6 arrow musttac6 th timingbeltside of theengine Positionthe pistonin the cylinder and tap it i...

Page 164: ... a piston push a new ring into the cvlinder bore 15 20 mm 10 6 0 8 in f rom the bottom 2 N 4 e a s u r e t h e p i s t o nr i n g e n d g a p w i t h a f e e l e r gauge lf the gap is too small check to see if you have the properringsfor your engine lf the gap is too large recheck the cylinderbore diameter against thewearlimitson page7 13 lf the bore is overthe servicelimit the cylinder blockmustb...

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Page 166: ...baseand pressthe pinout with a hydraulic press Installation 81881engine 1 Usea hvdraulic Dress lor installation Whenpressing the pin in or out be sureto posi tion the recessed tlat on the pistonagainstthe luqson the baseattachment Thearrowmustfacethe timingbeltsideof the engineandtheconnecting rodoii holemustfacethe rearsideof theengine CONNECTING ROD OILHOLE 2 Adjustthe lengthB of the pistonpindr...

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Page 168: ...npin diameter andconnecting rod smallenddiameter PistonPin to Connecting RodInterlerence Standard New i B18Blengine B18Cl 818C5engines 0 013 0 032mm 10 0005 0 0013 inl 0 017 0 036mm 0 0007 0 0014 inl PistonPins Connecting Rods EndPlay t NOTE End play shouldbe inspectedbeforeremoving thecrankshaft ConnectingRodEndPlay Standard New 0 15 0 30mm 10 006 0 012in Service Limit 0 40mm 0 016 in a a It out ...

Page 169: ...umberisstamped on bearing cap th6otherhalfon connectrng rod Inspect bolts andnutsfor stresscracks B18C5 enginc Eachrod falls into one of four toleranceranges from 0 006 to 0 024mm 0 0002 to 0 0009in in 0 003 mm 0 0001 inl increments depending on the sizeof its big end bore lt s then stampedwith a number 21 22 23 24 25or 261indicating the range You maytind anycombination of 21 22 23 24 25ot 26 in a...

Page 170: ...rankshaftclockwise put journalsinto connecting rodsNo 1 andNo 4 andinstall the rod capsandnutstinger tight NOTEIlnstall caps so the bearing recessis on the samesideasthe recess in the rod Checkrod bearingclearance with plastigage see page7 9 thentightenthecapnutsin 2 steps lst step 20 N m 2 0kgf m 14lbf ftl 2nd step 81881engine 31 N m 3 2kgf m 23 lbf ftl 818C1 818C5 enqines 44 N m 4 5kgf m 33lbt f...

Page 171: ...pproximalely 15minutes Applynon hardening liquidgasket to the blockmat ing surfaceof the rightsidecover and installit on thecylinder block NOTEI Useliquidgasket PartNo 08718 0001or 08718 0003 Check thatthe matingsurfaces arecleananddry beforeapplyingliquidgasket Apply liquidgasketas an evenbead centered between the edgesof the matingsurface To preventleakage of oil applyliquidgasketto theinnerthre...

Page 172: ... 25r m 24N m 2 4kgt m 17tbf ft OILPUMP A p p l y l i q u i d g a s k e t o n o i l p u m p a n d r i g h t s i d e cover matinq areas as shown below CYLINDER BI_OCK Applyliquidgasket RIGHTSIDE COVER Apply liquid gasket to lhese potnts to thesepoints Installthe oil pan gasket and oil pan NOTEr Use a new oil pan gasket Tightenboltsand nutsfingertight at six shownbelow pointsas Tightenall boltsand nu...

Page 173: ...al 1 Usingthe special tool drivein the timing pulley end seal untilthe driverbottomsagainstthe oil pump Whenthe sealis in place cleanany excessgrease off the crankshalt andcheckthatthe oil seallip is not distoned SEALDRIVER 07LAD PR4O1OA lnstall sealwith the pannumber facingout Using thespecial tool driveintheflywheel endseal untilthedriverbottoms aqainst block NOTE Align the hole in the driver at...

Page 174: ... o l s 8 2 lllustrated lndex 8 3 EngineOil Inspection 8 6 Replacement 8 6 Oil Filter Replacement 8 7 Oil Pressure Testing 8 9 OilJet Inspection 818C1 818C5 engines only 3 9 OilPump Overhaul 8 10 RemovaUlnspection lnstallation 8 11 tr rl r i ...

Page 175: ...SpecialTools L Ret No Tool Numbel Description Oty PageReference o OTLAD PR40lOA o 7 9 12 6 1 1 0 0 0 1 SealDriver Oil FilterWrench 1 1 8 12 8 8 rrl 8 2 ...

Page 176: ... Cleanthe oil pan gasketmating surfacesbefore installing it 6 x 1 O m m 12 N m 1 2kgf m 8 7 lbf fr I t r g 6 x 1 0m m 11 N m 1 1 kgf m 8 lbl ft GASKET Replace BAFFLEPLATE 8 x 1 2 5m m 24 N m 12 4 kgl n 17 tbf tt ENGINE OILPRESSURE swtTcH 18 N m 1 8 kgf m 13 lbf ft 1 8 in BSPT BritishStandard PipeTaper 28 Threads inch Use properliquidsealant 6 x 1 Om m 1l N m 1 1 kgt m I lbf ft OILPUMP Overhaul pag...

Page 177: ... 1 2kgf m 8 7 lb It 6 x 1 om m 11 N m 1 1 kgl m 8 tbf fi OILJET BOLT 16 N m 1 6 kgt m 13 lbf ft L I I I ij i OILJET Be carefulnot to damage lnspection page8 9 ENGINE OILFILTER Replacement Page8 7 6 x 1 Om m 11 N m 1 1kgf m 8lbf Ir OILSCREEN DOWEL GASKET Replace 6 x 1 O m m 1 1 N m 1 1 a tbf ft k9f m 8 x 1 2 5m m 24 N m 2 4 kqt m 17 lbf ftl ENGINE OILPRESSUBE swrTcH 18 N m 1 8kgf m 13 lbf ftl 1 8 i...

Page 178: ...ulnotto damage Inspect on page8 9 AAFFLEPLATE 6 x 1 0 m m 9 8N ft 11 0kgl m 7 2lbt ftl O RING Replace OILSCREEN ENGINE OILCOOLER CENTER BOLT 73N m 5 kgf m 5a lbt ftl ENGINE OILFILTER Replacement pageI7 Replace OILCONTROL 6 x 1 0 m m 9 8N mlr 0 kgtft 7 2lbtftl GASKET Replace 8 x 1 25mm 2 1N m 2 1kgt m 17lbf ftl DOWEL PINS 6 x 1 0 m m 9 8N m11 0 kgtm 7 2lbf ftl ORIFICE Clean ENGINE OILPRESSURE swrTc...

Page 179: ...the drain plugwitha newwasher andrefill with the recommended oil CAUTION Do not overtightenthe drainplug NOTE Under normal conditions the oil filter should be replaced at every other oil change Under severe condi tions the oil filtershouldbe replaced at eachoil change F f _ o E Requirement APIService Grader Use Energy Consetuing SJ or Energy Conserving ll SHgrade oilSAE 5W 30 preterred Youcanalsou...

Page 180: ...l on the new fil ter Wipe oif seat on engine oil cooler then apply a lightcoatol oil to the filterrubberseal NOTE Use only filterswith a built in bypasssystem Inspect threads and rubbersealsurface tell for Ambi nt Temperature A n o i l w i t h a v i s c o s i t y o f 5 W 3 0 i s p r e f e r r e d f o r improved fuel economy and year round protection in the vehicle You may use a 10 W 30 oil if the ...

Page 181: ...tom of thefilterwhenthe rubbersealis seated 2 Tightenthe filter by turning it clockwiseseven numbers Iromthe markedpoint Forexample if a markis madeunderthenumber 2 whenthe rub ber sealis seated the filter shouldbe tightened untilthe number1 comesupto the markedpoint 818C5engine B1881 818C1engines Numberwhenrubber sealis seated Number after tightening MARK MARK Numberwhen rubber seal is seated I 2...

Page 182: ...heck a l f o i l p r e s s u r e i s N O Tw i t h i n s p e c i f i c a t i o n s rnspect theoil pump seepageg 11 l 2 Oil Jet lnspection 818C1 818C5 engines only 1 Remove the oil jet seepages8 4 or 8 5 andinspect it asfollows a Makesurerhata 1 1 mm O 04 in diameter drill willgothrough thenozzle holefl 2 mm O O5 in diameter a Insertthe other end of the same 1 1 mm 0 O4 in drill into the oit intake ...

Page 183: ...ithout binding 6 x 1 0m m 7 N m 10 7kg m 5 lbf fr OUTER ROTOR Inspection pages 8 11 12 SEALINGBOLT 39 N m 4 0 kgf m 29 rbf ftl t n I F ii lir ffi O RING Replace 6 x 1 0 mm 11 N m 1 1 kgt m 8 tbf fr 8 x 1 25 mm 24 N m 12 4kgl m 17 lbt fr DOWELPIN PUMPHOUSING Inspection pages 8 11 12 Apply liquidgasket to matingsufaceof the cylinderblock when installing 8 x 1 25 mm 24 N m 2 4 kgf m 17 tbt ftl ...

Page 184: ...e timing belt 7 Removethe drive pulley 8 Removethe oil pan and oil screen 9 Removethe oil pump OIL PUMP OIL PAN 8 1 10 Removethe screwsfrom the pump housing then separatethe housingand cover 11 Checkthe inner to outerrotorradial clearance on the pumDrotor Inner Rotor to Outei Rotor RadialClearance Standard Newl O 04 O 16 mm lO OO2 O O06 int ServiceLimir 0 20 mm 0 O08in 12 Checkthe housing to rotor...

Page 185: ...he oil pump Applyliquidgasketto the cylinder blockmatingsur face ol the oil pump NOTE Useliquidgasket PartNo 08718 0001or 08718 0003 a Check thatthe matingsurlaces arecleananddry betoreapplyingliquidgasket a Applyliquidgasket evenly in a narrowbeadcen teredon the matingsurface a To preventleakage of oil apply liquidgasketto the innerthreadsof the boltholes a Do not installthe parts il 5 minutes or...

Page 186: ...IntakeManifold Exhaust System IntakeManifold R e p l a c e m e n t g 2 ExhaustManifold Replacement g 5 ExhaustPipeand Muffler Replacement g 7 tr lrl Fi ...

Page 187: ... damaged d ll ii il nl iii I I ii il lli fr EVAPORATIVE EMISSION EVAP 11 N m l 1 1kg m 8 0 rbf fr INTAKEAIR TEMPERATURE IAT SENSOB 5 x O 8 m m 6 N m 10 6kgf m 4 tbI tt 8 x 1 25mm 23 N m 2 3 kgt m 17 tbf fl INTAKE MANIFOLO Replace if cracked or if mating surfaces are o a m a g e o lrAclvALvE Becareful not to damage 8 x 1 2 5m m 24 N m 12 4kqf m 17 lbI Ir THROTTLE BODY 8 x 1 25mm 22 N rn 12 2kgl m 1...

Page 188: ...or it matingsurfacesare rAcv4f vE 8e caie ul not to IAT SENSOR 8 x 1 2 5m m 24 N m 12 4kgt m 17 tbf fr 22 N m 12 2k l m 16 lbf ftl O BING Replace 5 x 0 8 m m 6 N m 0 6 kgI m 4 tbf trl INTAKEAIR BYPASSVAL BODY INTAKEMANIFOLO CHAMBER 8 x 1 25 mm 23 N m 12 3kgt m 17 tbf ft 8 x 1 2 5m m 22 N m 12 2kgt m 16 tbt tr I x 1 25 mm 24 N m 2 4 kgl m 17 tbf ft 8 x 1 25 mm 24 N m 2 4 kgt m 17 tbf frl HEATERBYPA...

Page 189: ...ith a new gasketif damaged 818C5 engine 5 x 0 8 m m 6 N m10 6kgl m INTAKEMANIFOLD Roplace il cracked or il matingsurfacesare damaged I x 1 25 mm 212 N n 12 2 tsl m 16tbf ftl IDI f AIRCONTROL IACIVALVE Becarefulnot to dsmage 8 x 1 25mm Z N m 12 3kgt m 17tbl ft THROTTLE BODY 8 x 1 25mm 22N m 12 2 kgtm 16tbfft 8 x 1 25 mm 24 N m l2 il kgf m 17rbt ft 9 4 ...

Page 190: ...l lockingnuts when reassembling 81881 818C1engine EXHAUSTMANIFOI D 8 x 1 25 mm 24 N m 2 4 kgf m 17 tbt trl t 8 x 1 25 mm 24 N m 12 4kgt m 17 lbt ftl SELF LOCKING NUT 8 x 1 25 mm 31 N m 13 2kgf m 23 tbl fr Replace 10 x 1 25 mm rt4 N m 4 5 kgl m 33 lbf ttl N ...

Page 191: ...ont d NOTE Usenewgaskets andselt locking nutswhen reassembling 818C5ongine 8 x 1 25mm 2aN m 12 r kgf m 17lbf ftl GASKET Replace 8 x 1 25mm 3l N m 13 2 kgf m 23 lbtftl Replace 10x 1 25mm a l N m 4 5kg m 33lbf ftl EXHAUSTMANIFOLD A 9 6 ...

Page 192: ...e Tightenthe flangenuts in steps alternating side to side Replace 6 x l O mm 9 8 N m l 1 0kgt m 7 2 tbf ftl cont d GASKETS Replace i l i t SELF LOCKING NUTS 1 0 x 1 2 5m m 54 N m 5 5 kgf m 40 tbt ft Replace TWC Insp ction Makea visualcheckfor plugging meltang or crackingof the catalyst EXHAUST r a c g HEATED OXYGENSENSOR PRIMARY XO25I 4N m 14 5kgf m FLASHLIGHT 1 P I i 2ffi t i t rl a 41 I _ _ PIPE...

Page 193: ... m 3 9 kgl m 28 tbt fr 8 x 1 2 5m m 22 N m 12 2kgt m 16lbI ft Replace Tighrenthe boltsin steps alternating side to side SECONDARY HO2S 44 N m 4 5 kgI m 33 rbf fr COVER THREE WAY CATALYTIC CONVERTER TWCI Inspectionpage 9 7 EXHAUSTPIPEA SELF LOCKING NUTS 1 0 x 1 2 5m m 54 N m 15 5kgf m 40 tbfdr Replace 8 x 1 25mm 22 N rn 12 2kgf m 16 lbf ft Replace Tightenthe flangenuts in steps ahernating side to s...

Page 194: ...5kgt m 33 tbf ftt SECONDARY HEATEO SENSOR J SECONDARY H02S 4 0N m 4 5kgf m 33tbf ft 10x 1 25 mm 3 t mt3 9kgt n 28lbf ftl ElacKEr _____ GASKET Replace GASKETS Replace Replace THREE WAY CATALYTIC CONVERTER tTwc Inspection page9 7 SELF LOCKING 10x 1 25mm 5a N m 5 5kgt m 40 tbf ftl Replace 6 x 1 0 m m 9 8N m 1 0kgf m 2lbt ftl 10x 1 25mm 38 N m13 9kgt m 28 lbt ftl Replace 8 x 1 25mm 22N m12 2 kgtm 16lb...

Page 195: ...ndex Radiator Replacement EngineCoolantRefillingand Bleeding CapTesting PressureTesting Thermostat Replacement Testing Water Pump lllustrated Index Inspection Replacement 10 2 10 5 10 6 10 8 10 8 10 9 10 9 10 10 10 11 10 11 ...

Page 196: ...oration and replaceil necessary a Checkall hoseclampsand retightenif necessary a Usenew O ringswhen reassembling RADIATOR Engine coolant refilling andbleeding page10 6 Leak test page108 Inspeclsoldered jointsand seamsfor leaks RAOIATOR CAP Pressure test page10 8 UPPER RADIA rl CONDENSER FAN SHROUD s osection 22 6 x 1 0m m 7 N m 0 7 kgl m 5 lbf ftl 5 x 0 8 m m 4 4 N m 0 45 kgl m 3 3 tbt ft Blow out...

Page 197: ...ENGINE COMPARTMENT HOSECONNECTIONS B18B1engine IDLEAIR CONTROL IAC VALVE O RING Replace BREATHER PIPE ___ rs W l TERHOSES Bl8Cl engine HEATER BYPASS PIPE THERPIPE AT cont d HEATER HOSES 10 3 ...

Page 198: ...lllustratedIndex ENGINECOMPART MENTHOSECONNECTIONS lconi dl 818C5engine IDLEAIRCONTROL IIAC VALVE THERMOSTAT HOUSING O RING Replace O RING Feplace OILCOOLER BYPASSHOSES HEATER vAt_vE COOLER ...

Page 199: ...mm 9 8 N m 1 0 kgf m 7 2 tbt trl LOWER CUSHION CONDENSER FAN SHROUO FAN MOTOR ATF COOLER HOSES COOLING FAN SHROUD O RING Replace 6 x 1 Omm 9 8 N m 11 0kgf m 7 2 tbl ftl LOWERRADIATOR HOSE FAN MOTOR CONNECTOR 5 Remove the tan shroudassemblies andotherparts from radiator Installthe radiatorin the reverseorderof removal NOTE a Set the upperand lower cushionssecurely a Fillthe radiatorand bleedthe air...

Page 200: ...ch 2 Removethe radiatorcap 3 Loosenthe drainplug and drainthe coolant 4 Removethe drainbolt from the cvlinderblock j i I i l ll ENGINE DRAINEOLT 78 N m 8 0 kgt m 54 lbt ft Apply liquidgasketto bolt threadwhen installing WASHER Replace 10 6 5 Apply liquidgasketto the drainbolt threads then reinstall the bolt with a new washerandtightenit securely 6 Tightenthe radiatordrainplug securely 7 Remove dra...

Page 201: ...ands of anti lrcezel coolants a Do not use additionalrust inhibitots or anti tust products they may not be compatible with the coolant EngineCoolant Refill Capacity including reservoir 0 6 0 6 US qt 0 5 lmp qr ll 81881engine Ml7 1 1t t 6USqt 3 9lmp qtl 818B1 818C1 engin s AlTt 1 7 15 0USqt 4 1lmp qt 818C1 B18C5 engines MlTt 1 7t 15 0US 4 1lmp qtl FILLER NECK 9 Pourcoolantintothe radiatorup to the ...

Page 202: ...thencarefullyremove the radiatorcap and fill the radiatorwith engine coolantto the top ot the fillerneck 2 Attachthe pressure testerto the radiatorandapply a pressure of 93 123 kPa O 9 5 1 2 5k g f c m r 1 3 5 1 7 8 p s i 3 Inspect lor engine coolant leaks and a drop in pressure 4 Removethe testerand reinstallthe radiatorcap NOTE a Checkfor engineoil inthe enginecoolantand or coolantin the engineo...

Page 203: ...st a closed thermostat Suspendthe thermostatin a containerof water as shown Heatthe water and checkthe temperature with a thermometer Checkthe temperature at which the thermostatlirst opensand at full litt CAUTION Do not let the ihermometertouch the bottom of the hot container Measure the lilt heightof the thermostatwhen it s fullyopen STANDARDTHERMOSTAT Lift height above8 0 mm O 31inr Stalts open...

Page 204: ...SENDING UNIT 818B1engine OUTLET ECTSWITCH 27 N m 2 8 kgf m 20 lbf fr ECTSENSOR ENGINECOOLANT TEMPERATT IRE IECTISENSOR 18 N m 1 8kgt m 13lbl ft 6 x 1 Omm 11 N m 1 1 kgI m 8 0 lbf ft OUTLET COVER WATERPUMP Inspecl on page10 11 KNOCKSENSOR ADotvtrouidoasket 31 N m 13 2kgt m to t nq uif 23 lbl ftl 818C1 818C5 engines O RING Replace O R I N G Replace 6 x 1 0 m m 12N m 11 2kgt m 8 7 lbI fr THERMOSTAT H...

Page 205: ... seepage6 10 818C1 Bl8C5engines seepage6 48 Removethe camshaftpulleysand the backcover B 1 8 8 1 e n g i n e s e e p a g e 6 2 0 8 1 8 C 1 8 1 8 C 5 engines seepage6 60 Removethe water pump by removingflve bolts NOTE Inspect repairand cleanthe O ringgroove and matingsurfacewith the cylinderblock Replacement 6 x 1 0mm 12N m11 2 kgt m 8 7 tbf tt 4 Install the water pump in the reverseorder of remova...

Page 206: ...foldAbsolute Pressure Sensor 11 54 IntakeAir TemDerature Sensor 11 58 EngineCoolantTemperature Sensor 11 60 ThrottlePositionSensor 11 63 PrimaryHeatedOxygenSensor Sensor l 11 67 SecondaryHeatedOxygenSensor lsensor 2 11 71 Heated OxygenSensorHeater t1 74 FuelSupplySystem 11 76 RandomMistire 11 78 MisfireDetected in OneCylinder 11 79 KnockSensor f A2 CrankshaftPosition TopDeadCenter Cylinder Positio...

Page 207: ...3x 041 xxxxx a 07JAZ 0010008 i0 I oTPAZ oo1o1oo oTsAz ooloooA O 07406 oo4oool Vacuum Pump Gauge 0 30in Hg Vacuum Pressure Gauge 0 4 in Hg SCSService Connector Backprobe Set FuelPressure Gauge 1 t1 135 146 141 149 151 1 11 151 1 11 32 51 70 AO 86 139 2 11 34 r I ir 1jg 121 11 2 ...

Page 208: ...163 IELO IDLEAIRCONTROL IIAC VALVE Troubleshooting page11 1OO CRANKSHAFT SPEED FLUCTUATION CKF SENSOR TroubJeshoonng page 1t 90 FASTIDLETHERMO VALVE A T modet Inspection page1 l 110 INTAKEAIRTEMPERATURE IA1 SENSOR Troubleshooting page1 l 58 POWER STEERING PRESSURE IPSP swtTcH Troubleshooting page11 108 IGNITION CONTROL Builtintothe distributorl Testing section23 ENGTNE cooLANT TEnapenerune ectisen...

Page 209: ...ROL SOLENOID VALVE Troubleshooting pagerr rqo IDLEAIRCONTROL IAC VALVE Troubleshooting page1l 100 ELECTRICAL LOAD Troubleshooting p a g e1 1 8 8 POWER STEERING PRESSURE IPSP swtTcH Troubleshooting page l1 108 IGNITION CONTROL SENSOR SECONDARY HO2S Troubleshooting Page11_71 Built into the distributod Testing section 23 ENGINE COOLANT IECDSENSOR Troubleshooting page1160 SECONDARY HEATED SPEED FLUCTU...

Page 210: ...RCONTROL IIAC VALVE Troubleshooting page11 100 INTAKEAIR TEMPERATURE IIAT SENSOR ELECTRICAL LOAD DETECTOR ELD Troubleshooti page1188 Troubleshooting page11 58 POWER STEERING PRESSURE PSP swrTcH Troubleshooting page11108 SPEEO FLUCTUATION CKF SENSOR Troubleshooting page1190 SENSOR KS Troubleshooting page11 82 ENGINE COOLANT TEMPENATUR IECTISENSOR Troubleshootang page11 60 PRIMARY HEATED OXYGEN SENS...

Page 211: ... BYPASS IAB CONTROL DIAPHRAGM 818C1 engineonlyl Troubleshooting page11 135 i i i r l l i INT AIR POSITIVE CRANKCASE VENTILATION PCV VALVE Inspection page11 140 BYPASS IIAB CONTROL SOLENOID VALVE 818C1ongineonly Troubleshootrng page11 135 PGM FI MAIN RELAY RelayTesting Page11124 Troubleshooting Page11 1 25 L ENGINE CONTROL MODULE IECM Tro bleshooting Page1150 SERVICE CHECK CONNECTOR 2P Troubleshoot...

Page 212: ...page11146 EVAPORATIVE FUEL FILL CAP FUEL TANKPRESSURE SENSOR Troubleshooting page11142 APOBATIVE EMISSION EVAPORATIVE EMISSION EVAPIBYPASS SOLENOID VALVE Troubleshooting page1 1 146 EVAP CONTROL CANISTER Troubleshooting page11 146 EVAP TWOWAYVALVE Testing page11 151 FUELINJECTORS Beplacement page 11 119 FUEL FITTINGS Precautions page11 1 15 Disconnection page11 1t 5 Connection page11 1 16 RETURN P...

Page 213: ...Bl8BI engine MANIFOLD ABSOLUTE PEESSURE IMAP SENSOR EVAPORATIVE EMISSION EVAP THREE WAY VALVE EVAPORATIVE EMtssloN EVAP TWOWAY VALVE EVAPORATIVE EMISSION EVAP CONTROL CANISTER EVAPORATIVE EMISSION EVAP PURGE CONTROL SOLENOID VALVE 1 1 8 L ...

Page 214: ...RE MAP SENSOB FRONT OF VEHICLE INTAKE AIR EYPASS IIAB VACUUM TANK To EVAPORATIVE EMISSION EVAP THREE WAYVALVE O Vacuum hoseNo EVAPORATIVE EMISSION IEVAPICONTROL CANISTER EVAPORATIVE EMtSSION EVAP TWOWAY VALVE INTAKE BYPASS IABI CONTROL SOLENOID VALVE INTAKEAIR BYPASS IABI CHECK VALVE cont d 11 9 ...

Page 215: ...FUEL PRESSURE REGULATOR MANIFOLD ABSOLUTE PRESSURE MAPISENSOR EVAPORATIVE EMISSION IEVAPI PURGE CONTROL SOLENOID VALVE To EVAPORATIVE EMISSION IEVAPI THREE WAYVALVE L EVAPORATIVE EM SSTON EVAP TWO WAY VALVE EVAPORATIVE EMISSION EVAP CONTROL CANISTER 1 1 1 0 ...

Page 216: ...ER O FUELPRESSURE REGULAToR FUEL PUMP FPl FUEL TANK FUELTANKEVAPORATIVE EMISSION IEVAP VALVE FUELPUI SATION DAMPER AIRCLEANER RESONATOR THREE WAYCATALYTIC CONVERTER TWC POSITIVE CRANKCASE VENTILATION IPCV VALVE EVAPOMTIVEEMISSON IEVAPIOONTROL CANTSTER EVAPORATIVE EMISSION IEVAP PURGE CONTROL SOLENOID VALVE EVAPORATIVE EMISSION EVAP TWOWAYVALVE EVAPOBATIVE EMISSION IEVAP BYPASS SOLENOID VALVE EVAPO...

Page 217: ... FP FUEL TANK I 13 FUELTANKEVAPORATIVE EMISSION EVAP VALVE 19FUELPULSATION DAMPER 9 AIRCLEANER O RESONATOR I t a z I VacuumhoseNo iio INTAKEAIRBYPASSIIAE CONTROL DIAPHRAGM VALVE 9 INTAKEAIRBYPASS IABICONTROL SOLENOID VALVE 6I INTAKEAIRBYPASS IAB VACUUMTANK CI INTAKEAIRBYPASS IABICHECK VALVE 9 THREE WAY CATALYTIC CONVEFTER TWC 2jI POSITIVE CRANKCASE VENTILATION PCV VALVE EVAPORATIVE EMISSION EVAPIC...

Page 218: ...D FUELFILTER O FUELPRESSURE REGULAToR FUELPUMP FP FU LTANK FUELTANKEVAPORATIVE EMISSION EVAPIVALVE FUELPULSATION DAMPER AIRCLEANER RESONATOR THREE WAYCATALYTIC CONVERTER TWCI POSITIVE CRANKCASE VENNLATION PCV VALVE EVAPOMTIVEEMISSION EVAP CONTNOL CANISTER EVAPONATIVE EMISSION EVAP PURGE CONTROL SOLENOID VALVE EVAPORATIVE EMISSION IEVAP TWOWAYVALVE EVAPORATIVE EMISSION IEVAP BYPASS SOLENOID VALVE E...

Page 219: ...o FAOIAIOB FAN FELAY CONOEI SEh FANFELAY FUSES r 1 BATTERY 100A INTERIOF LIGHT 7 5A HORNSTOP120A o rcl A o BACK UPIRADIO 17 5 A Fr Mt15Al I NO I3FUEL PUMP ISRS UNIN 15A a JNo 25METER 17 5 Al O No 15ALTERNATOR SPSENSOR 7 5A 0 No 17HEATER A CR LAY 7 5 A i No 31STAnTEB SIGNAL 7 5 A in the under hood fuse relaYbox ...

Page 220: ...SENSOF sEitsoi FUEI TANK PFESSI RE gEl soR CO IIFOL SOLENOIDVAIVE soLtltoto vlLvEt2 ytEc PREgsuiEEwrc8 s col oaFY 1 USA 2 818C1 engine 3 A T 4 B18Cl 818C5 engines BFAK SWITCII IATSENSOR cont d 1 1 1 5 ...

Page 221: ...l oFN Btx 1 J ECt SE SOR neonerJf l cnvELx L IAT SENSOR vsveLu JJr 5l neozgr x _l F cnN Blx 1 J fP SENSOR 11 u l I WECSOLENOID I VALVE VTEC PIIESSUFE swtTcH BLU BLK o o l I aq l i crdl fri t l Fli __ i CXFSEN90B _ _ _ J PAI ARY HO2S SENSOR 1 cfl4 ft 1 YEVBED l f g t I FEo cBN ___l F f I cnr wxr _ lFj I IIAPSENSOB cill 4 818C1 818C5 engines 5 81881engine 1 1 1 6 ...

Page 222: ...KFlll No 1FUELINJECTOF c122 No 2 FUEL lNJEctoa cl2t No 3FUELhUECTOB c t2a t _ _ _ c l24 v r ar x Jf ll BED ____L _____ e I veuer x Jffil 8LU 1 vevarx Jf 3 l vtt t No FUEL IiUECTOB ELu aeor wttr ngot Icrlo cKFsElison l hrr l 11 17 ril 4 818C1 818C5 engines ...

Page 223: ...tsE coNTRoL SECONOAFY H02S sEtisoR2 f tl T l PgP SWTICH u n J r B L K L G301 r I_ G40 l eu ter ffr l BLU VHT tsfi l I BrK ____ l vevar x Jffil BLK BLU 1 I DATA UNK COI NECTOF anvwrrJ senvrce crecx Blx coNNEcroF 8nN BtxlJ GFN wHr WHI REO BLK 2r818C1engine 5 81881 engine 1 1 8 L ...

Page 224: ... LT GRN BLK entZonl fl enx onn f_ l IYEVBLU t l t t l v t l Jtc GAUGE ASSEIIBLY To RADIATOA FANRELAY COT IDENSER FAIIRELAY ToA CCOIPRESSOB CLTITCH NELAY To A Cs i tlcH 1 USA 3 Ay T A TGEARPOslNOiI ND CATOS s 1 1 1 9 ...

Page 225: ... BtJ BIJ AEL CRN RED Btx _L c21r Btx UNDEFHOOD FUSE RELAY 8OX w T UNOEEDASH FUSE RELAY BOX u o Jfffi A r GEARPOSITION I ELK YHI 1 srvrrc1 n I l lf ic41 a T c4t3 PTTP SRS lID O5A c xlt wrrzneo I I Euc YEL l BLVRED I ca 9 ar uzwrrJ wHr ED l I YEVGRN t c55l YEVBLU f c4a0 ELX YEL 1 USA 11 20 ...

Page 226: ...t r YEVGR YEL 8rx I eLx YrKI GRI ELU l YEVGR eu 1 FUELTANK PRE9SUNE SENSOR c793 EVAPBYPASS SOLENOIOVALVE tn jf rn YEVBLU l F YEV9LU r rcnrf lI r rcnlrt GRN BLX I f cRri Erx BLK YELI l Br t wrr eru l alrf Brx r rrr lf Erx wrr 11 21 ...

Page 227: ...SystemDescription SystemGonnectors IEngine Compartment c1G c113 c132 cr31 L UNDER t ooD FUSE RELAY BOX MAIN WIRE HARNESS WIREHARNESS 11 22 ...

Page 228: ...tor of femaleterminalst Viewfromwire side c l 1 4 l 1 2 l 3 l f t veunEo l ftTGAN wHr FfRFo cBN rF1 1 1 2 l l f 1 1 3 1 l fr r r l ttICtBrK ll IBrKMHr lll 1 1 2 3 l 7 FIGF ErK l ftlA o BLK I ftl rltsat l l c21a r r l r l 3 l tilBL dn l 1 IBLK Illl ttTcAN FEp l c220 lal8C1 818C5 ngin l rF r 1 1 l 3 l tiTRE l 42 BLU FED I ll lt 6Ec l ffi l l Y E f I t1 l f l distinguish them for example cont d 11 23...

Page 229: ...SystemDescription SystemConneetors IEngineCompartment cont dl t ENGINE WIRE HARNESS c1 ENGINE COMPARTMENT WIRE HARNESS ...

Page 230: ...I r ft filiHr REo l Ttftrx rEl I 3 lwHtsLU I ffiFffi c134 l818C1 ngincl c125 fiTFED Bru lFTn rrc lBr Eo BLu l l T l l t TBLi _ l NOTE Difterent wireswith the samecolor have beengivena numbersuffixto distinguish them ior example YEUBLKTand YEUBLK arenotthe same O Related to FuelandEmissions System Connector of maleterminals Viewfromterminalside Connector of femaleterminals Viewfrom wire side YET BL...

Page 231: ...I ll SystemDescription SystemGonnectors Dashand Floor ENGINE COMPARTMENT WIRE HARNESS PGM FIMAIN RELAY OASHBOARD WIRE HARNESS L 1 J ...

Page 232: ...ated to FuelandEmissions Svstem t 1 L i r t l ItFr r ll F5r d l rri I l HiN I r r r l Connector of maieterminals Viewfrom terminalside Connector of femaleterminals Viewfrom wire side t H l F I T iiTAN it TBrrH l r I rrlcLM l F t r I Lit TilwHr om ftl wii l 1 1 1 l t f l l 3 l l fi fal vw l t 8ttru I I lsru ia cont d 1 1 2 7 2 5 r5 o 5 1 1 3 1 1 1 s r_ l rI iw r Lj L tl lt a qrr l ...

Page 233: ...SystemDescription SystemConnectors Dashand Floor cont d C551 UNDER DASH FUSE RELAY BOX ...

Page 234: ...I t c R N a 91Nrq r YFT GFN b E L qll 1 2 3 5 6 8 I l 0 l 1 t2 t 3 1 1 l 5 1 6 I t 18 1 9 20 L I a Ii L 1E D4 I tl qlr NOTE Different wireswith the samecolor havebeengiven YEUBLKTand YEL BLK arenotthe samel O Related to FuelandEmissions System o Connector of maleterminals Viewfrom terminalside Connector o femaleterminals Viewfrom wire side a number suffix to distinguish them for example cont d 11 ...

Page 235: ...SystemDescription SystemConnectors Dashand Floor cont d c405 SERVICE CHECK c410 ECM DI Cilo9 ECM C tL REARWIRE HARNESS n l 11 30 L ...

Page 236: ...r of maleterminals Viewfromterminalside Connector of femaleterminals Viewfrom wire side c4r3 a Tl otolt EcM ct cir5l r TJJ 7 f TGnBru l tt cnN Brx Il tIl acR l FI H ffi 2 a 5 8 9 1 0 l t t2 t5 t6 l7 8 r9 20 z2 z3 21 25 23 21 28 a I 2 3 o a I r0 1 t 12 t3 1a t5 l l t7 1a 1sl 21 t 3 6 7 E 9 to t1 12 1 3 1 4 2 5 6 7 E N O T E suffixto distinguish them for example ...

Page 237: ...ructions Thescantool or testercanreadthe Diagnostic TroubleCodes OTC freeze framedata currentdata andother EngineControlModule ECM data Freeze framedataindicates the engineconditions when the first malfunction misfireor luel trim malfunction wasdetected lt canbe usefulinformation whentroubleshooting B Whenthe MILhasnotcomeon butthereis a driveability problem referto the SymptomCharton page11 36 C ...

Page 238: ...sefrom the underhoodfuse relay boxfor 10 seconds BACKUP RAOIO 7 5AI FUSE UNDER HOOD FUSE RELAY BOX lll FinalProcedure thisprocedure mustbedoneafteranytroubleshooting 1 Remove the SCSService Connector if it isconnected NOTE lf the SCSserviceconnectors is connected andthereare no DTCS storedin the ECM the MILwill stavon whenthe ignitionswitchis turnedON ll 2 Dothe ECMReset Procedure 3 Turnthe igniti...

Page 239: ...below checkthe systemaccording to the procedure described orthe appropriate code s listedon thefollowingpages How to Usethe BackPlobeSets Connect thebackprobe adapters to thestacking patchcords andconnect thecordsto a multimeter Usingthewireinsulation asa guidefor the contoured tip of the backprobe adapter gentlyslidethe tip intothe connector lrom thewire sideuntilit comesin contact withterminalen...

Page 240: ...electricalconnections Bringtho tester probe into contact with the terminalffom the tcrminal side of wire harnessconnectorsin the engine compartment Forfemaleconnestors iust touch lightly with the tsster probe and do not insertthe probe TESTER PROB cont d TERMINAL 1 1 3 5 ...

Page 241: ...er Position sensorcircuit 11 58 Intake Air Temperature lAT sensorcircuit 7 1 t 100 ldle Air Control lAC Valve 8 1 11 1 0 Fastidle thermo valve I 1 1l l l ldlespeedadjustment 10 11 132 Throttlebody 1 1 11 1 3 0 Throttlecable 12 11 54 lvlanifold AbsolutePressure MAP sensor I J 1 1 6 3 ThrottlePosition TP sensor 1 4 1 1 8 6 Barometric pressure BARO sensor 1 1106 A Tgearpositionsignal seesection 23 1 ...

Page 242: ...lythe sameas tachometer indication at idlespeed 81881 818C1 engines 750t 50rpm 818C5 engine 8001 50 rpm YES Vehicle Speed TheECMconverts pulsesignalstrom theVehicle SpeedSensor VSS intospeeddata Nearly the sameas speedometer indication YES Manitold Absolute Pressure MAP Theabsolute pressure created in the intakemanifold by engineloadandspeed With enginestopped Nearlythesameasatmo sphericpressure A...

Page 243: ...loopstatus 30o 41 YES Term Trim Long Fuel Longtermfueltrim in computedtrom shorttermfuel trim andindicates changes occurring in thefuelsup ply systemovera longperiod lf longtermfueltrimis higher than1 00 theamou nt of injected fuelmustbe increased ll it is lowerthan 1 00 the amountof iniected fuelmustbe reduced 14 2Oo YES lntakeAir Temperature rAT TheIATsensorconverts intakeairtemperature into vol...

Page 244: ...lant above 154 F 68 C dutycontrolled GRN BLU FLR FUEL PUMPRELAY Drives fuelpumprelay 0 V fortwo seconds afterturningignition switchON ll thenbattery voltage 1 7 BLVBED ACC fuCCLUTCH RELAY DrivesA C clulch relay Withcompressor ON 0 V Withcompressor OFFt baftery voltage 1 8 GRN ORN MIL I 4ALFUNCTION INDICATOR LAMPi DrivesMlL With MILturnedON 0V Wjth MILturnedOFF battery vottage 19 WHT GRN ALTC ALTER...

Page 245: ...e for theDTC Batteryvoltage at all times t 1 WHT RED CKFM CKF SENSOR I 4SIDE GroundforCKFsensor 12 BLUI EL CKPM CKP SENSOR M SIDE Groundfor CKPsensor WHT BLU TDCM TDC SENSOR M SIDE Ground tor TDCsensor 14 CYPM CYP SENSOR M SIDE Groundfor CYPsensor 15 BLU BLK VTPSW VTEC PRESSUFE SWITCH DetectsVTECpressureswitch sr9nal Withengineat low rpm 0 V Withengineat highrpml batteryvoltaqe 1 6 1 GRN PSPSW P S...

Page 246: ...tectsprimaryoxygensensor signal Withthrottlefullyopened fullywarmedup engine above0 6V Withthrottlequickly closed below0 4V 8 RED VEL IAT INTAKE AIR TEMPERATURE SENSOR Detects IATsensor signal WithignitionswitchON ll about 0 1 4 8V depending on intake air temperature 1 0 YEL BLU vcc2 SENSOB VOLTAGE Providessensorvoltage WithignitionswitchON ll about5 V WithignitionswitchOFF 0 V 1 l GRN 8LU SG2 SEN...

Page 247: ...Temperature Circuit Range Performance Problem ECTsensor Coolingsystem 11 60 P0117 6 Engine Coolant Temperature Circuit Low Input Short in ECT sensor circuit ECT sensor ECM 1 t 61 P 0 1 1 8 6 Engine Coolant Temperature Circuit HighInput Openin ECTsensorcircuit ECTsensor ECt 4 1 t 62 P 0 1 2 2 l 7 l ThrottlePosition Circuit Low Input Openor shon in TPsensor circuit TPsensor ECM 11 63 P0123 7 Throttl...

Page 248: ...aryHO2S SensorI MAPsensor Contaminated fuel Valveclearance Exhaust leakage 1 1 7 6 P0172t45l SystemToo Rich Fuelsupplysystem PrimaryHO2S Sensor 1 MAPsensor Contaminated fuel Valveclearance 1 1 7 6 iil 174l RandomMisfire lgnitionsystem Fuelsupplysystem MAPsensor IACvalve Contaminated fuel Lackoffuel t1 78 P0301 71 P03Q2 l 121 P0303 73 P0304 74 Cylinder1 Cylinder 2 Cylinder 3 Cylinder 4 Misfire Dete...

Page 249: ...rcuit Range Performance Problem ECM Baro sensor 1 l 86 P1107 3 Barometric Pressure Circuit Lowlnput ECM Barosensor TCM ECMto TCMharness 11 87 P1 108 13 Barometric Pressure Circuit HighInput ECM Barosensor 11 41 P1121 11 ThrottlePosition LowerThanExpected TPsensor P 1 1 2 2 1 1 J ThrottlePosition HigherThanExpected TP sensor P1 t 28 5 ManifoldAbsolutePressure LowerThanExpected MAPsensor 1 1 5 7 P 1...

Page 250: ...2 9 Cylinder Position Sensor No Signal CYPsensor CYPsensor circuit ECM 1 1 8 3 P1456 6 90 Evaporative Emission Control SystemLeakDetected Fuel TankArea Fuelfill cap Vacuumconnection Fueltank Fueltankpressure sensor EVAPbypass solenoid valve EVAP two wayvalve EVAPcontrolcanister ventshutvalve EVAP controlcanister EVAPpurgecontrolsolenoid valve 1 1 1 4 6 P14s7 5 90 Evaporative Emission Control Syste...

Page 251: ... T Fl DataLine TCM ECM 11 93 P1681 30 A TFl SignalA Low Input AFSALine TCM ECM 11 95 P1682 30 Ay T FlSignalA HighInput AFSALine TCM ECM 11 95 P1686 31 A I FlSignslB Low Input AFSBLine TCM ECM 11 95 P1687 3rl A TFl SiSnalB HighInput AFSBLine TCM ECM 11 95 P0700 P1705 P1706 P1753 P1758 70 P1786 P1790 P1791 P t192 P1194 Automatic Transaxle Sectionl4 ...

Page 252: ...ode DTC lf the problemis intermittent andyou can tduplicate thecode do notcontinue through theflowchart To do sowill onlyresultin confusion and possibly a needlessly replaced ECM Open and Short arecommonelectrical terms An openis a breakin a wire or at a connection A shortis an acci dentalconnection of a wire to groundor to anotherwire In simpleelectronics this usuallymeanssomethingwon t work at a...

Page 253: ...Control Functions L Starting Control Whenthe engineis started the ECMprovides a richmi ure by increasing fuelinjector duration 2 FuelPumDControl Whenthe ignitionswitchis initiallyturnedon the ECMsuppliesgroundto the PGM FI main relaythat supplies currentto the fuel pump for two secondsto pressurize the fuel system Whenthe engineis running the ECMsuppliesgroundto the PGM FI main relaythat suppliesc...

Page 254: ...m the solenoid valveis deactivated bythe ECM andintakeairflowsthroughthe shortintakepathin orderto reduce the resistance in airflow Sell diagnosis Function lMalfunction Indicator Lamp MlL l Whenan abnormality occursin a signalfrom a sensor the ECMsuppliesgroundfor the MILand storesthe codein erasable memory Whenthe ignitionis initiallyturnedon the ECMsuppliesgroundfor the N4lL tor two seconds to c...

Page 255: ...pen in ih6 wires IPGlines 1 Turntheignition switch ON ll 2 Measurevoltage between bodygroundandECMconnec torterminals A10andA23indi vidually Chockfor an open in the wire or bulb 1 Turntheignitionsw tchOFF 2 Connectthe ECMconnector ter minal418to bodyground with 3 Turnthe ignitionswitchON ll Repair open in the wire sl between ECMand G101 located at thermostat housingl that had morethan1 0V lstherel...

Page 256: ...age11 52 cont d Th M lfunction Indic tor Llmp lMlll t yr on or comlr on ltt two aaconda Ch ck th Dirgnoitic tioubl Cod IDTC 1 Connocta 6cantool or Honda PGMTester 2 Turntho ignitionswitchON ll 3 Readtho DTCwith the scan tool or HondaPGMT6st6r Go to trouHorhooting proQduaaa koo p g6 I 1 3 ll Ch ct th DTCby MIL indication 1 Turnth ignitionswitchOFF 2 Connectthe SCSseNic con n ctor to the sorvico che...

Page 257: ...ct Fl E M 15A fusein the under hoodIuse relaybox Ropsir short in tha wirc botw on Fl E M 15Al tu3c rnd PGM FIm in t lry Rool c Fl E M l15A tu Inspect No 13FUELPUMP SRS UNIT l5A fuse in the undeF dashfuse relaybox Reo ir sholt in th wiro botw n No 13 FUELPUMP SRs UNIT 15 Al fur nd FGM FIm in rclay Repl co No 13 FUELPUMP SRSUNIT 15Alturr Ch6ckfor shon in a son3or 1 Turnthe ignitionswitchON ll 2 Disc...

Page 258: ...inals A 11 andA24indi vadually R6pe ropen in the wire sl between ECM1A11 A24l and PGM FImain elay Checkfor poor connections or loose wi es at the PGM FI main relay Test tho PGM FImain ral v seepage11 124 Checkfor an open in the wires LG1 LG2line3l 1 Reconnect all sensorconnec tors 2 Reconnect the ECMconnector D 16P 3 Turntheignition switch ON ll 4 Measure voltage between body groundand ECMcon nect...

Page 259: ...ation L Turnthe ignitionswitchON ll 2 Check th MAPwith the scan tool Intermittenttailulo systami OK at thk lime Chocktor pooacon noctions or loosa wir 3 al C114 MAPs n3orldnd ECM lsapprox 0 kPa 0mmHg 0in Hg or 2 8V indicated Chccklor an opan or 3hoJtin tho MAP3on or 1 TurntheignitionswitchOFF 2 Disconn6ctth6 MAP sensor 3Pconn6ctor 3 Turnlhe ignitionswitchON lll 4 Ch ckthe MAP with the scan tool ls...

Page 260: ...16P 3 Checkfor continuity between the MAP sensor3P connector t e r m i n a l N o 3 a n d b o d y grouno Repeirshort in th wirg b woen ECMlD3l and MAPs6n3or Substitutea known goodECM and rochack lf no mal MAPb indi catod r placethe original ECM MAPSENSOR 3PCONNECTOR C114 MAP RED GRN Wire sideof fomalelerminals 11 55 ...

Page 261: ...ls No 3andNo 2 4 TurntheignitionswitchON ll 5 Ch ckthe MAP with the scan tool ls 101kPa 760 mmHg 30 0 in Hg 1 0V or higherindicated Checktor an open in wire SG1 linel 1 Remove thejumperwire 2 Measure voltagebetween the MAPsensor3Pconnector teF minals No I andNo 2 Repairopen in the wire between ECMl012l and MAPs nsor lsthereapprox 5V Checkfor an open in the wire MAPline 1 TurntheignitionswitchOFF 2...

Page 262: ... 1 Turntheignition switch ON ll 2 Checkthe MAPwith the scan tool ls 54 1kPa 406mmHg 16 0 in Hg or higherindicated Intermittentlaihre system i3 OK at this time TheMILhasbeenreoonedon DTCP1129is stored Problemverification 1 Start the engine Hold the engineat 3 000rpm with no load in Parkor neutral until the radiatorfancomeson then letit idle 2 Check the MAPwith the scan tool ls43 3kPa 325mmHg 12 8 i...

Page 263: ...k the IAT wirh the scan t o o l ls 302 F 150 C or higher or H Limitin Hondamodeo the PGMTester or 0 V indicated ls thecorrect ambient temPer atureindicated Roolace the IATsensor Into mittent feilur6 aystemh OK at this timc Checkto Dootcon nections or loose wires at Cl20 lATsensor snd ECM Checktor a 3hort in the IAT sen 1 Disconnect theIATsensor con 2 Checkthe IAT with the scan tool ls 302 F 150 C ...

Page 264: ...M ls 4 F 20 C orless orL Limitin Hondmodeof PGM Tester or 5V indicated Ch ck tor an open in ihe IATs6n 30r 1 Disconnect the IAT sensor connectot 2 Installa jumperwire between the two terminalson the IAT sensor connector 3 Check the intakeair tempera turewiththescantool ls 4 F 20 C or less orL Limitin Hondmodeof PGM Tester or 5 V indicated Chockto an opon in thc wiros lAT SG2lin6l 1 Turntheignition...

Page 265: ... DTCS first then trou NOTE lf DTCP0117andlo Po l 18 are storedat the sametime as DTC bleshoot DTCP0 l16 PossibleCause ECTsensordeterioration Malfunction in thethermostat andthecoolingsystem lroubleshooting Flowchart I 11 60 THERMISTOR Th MILhasbeenreoortedon DTCP0116is stored Problemveritication 1 S t a r tl h e e n g i n e H o l dt h e engineat 3 000rpm with no load in Parkor neutralluntil therad...

Page 266: ... the wires ECT line r rurnInergnrtron swttchuFf 2 Disconnect the ECMconnec tor D 16P 3 Checklor continuitybetween ECTsensorconnectortermi nalNo 1andbodyground Checktor short in the TCM IECT linell 1 Disconnect the 22Pconnector fromtheTCM 2 Checkfor continuitybetween ECTsensorconnectortermi nalNo 2 andbodyground lstherecontinuity Repair shon in the wire botween ECM lD2 TCM and ECT sensor iT 011tl T...

Page 267: ... 4 F 20 C or less orL Limit in Hondamodeof PGMTester or 5 V indicated Chock toranoponintheECT s6n sor t utsconnect tne ELI sensor 2 Installa jumperwire between the two terminalson the har nessside of the ECTsensor 3 Checkthe ECTwith the scan tool ls 4 F 20 C or less orL Limit in Hondamodeof PGMTestedor 5 V indicated Ch6ckIor an open in the wires IECT SG2lines 1 TurntheignitionswitchOFF 2 Installa ...

Page 268: ...10 when thethrottleisfully closed andapprox 90o o whenthe throttle isfullyopened lntermittenl tailure systemis OK at this time Checktor poor con nections or loose wires at Cl15 TPs nsor end ECM Checklor an open in ihe wire VCC2line 1 Turnthe ignitionswitchOFF 2 Disconnect theTPsensor con nector 3 Turnthe ignitionswitchON ll 4 Measure voltage between TP sensorconnectorterminals No l andNo 3 lsthere...

Page 269: ...N lli 3 Measure voltagebeween ECM connector terminalsD1 and D 1 1 lsthereapprox 0 5V whenthe throttle isfullyclosed and approx 4 5V whenthethrottle isfullyopened Substitutea known goodECM and echeck It olescribedvolt age is now available oplacethe o iginal ECM Checktor shon in the TCM 1 TurntheignitionswitchOFF 2 Disconnect the 22Pconnector fromtheTCM 3 Turntheignition switch ONlll 4 Measure volta...

Page 270: ...isfullyclosed andapprox 90 whenthe throttle isfullyopened Intermittoni ailure systemis OK al this time Checktor poor con nectionsor loosewires at C115 TPsensor and ECM Checkfor an open in the TP sen sot 1 Turnthe ignitionswitchOFF 2 Disconnect theTPsensor con nectot 3 Turntheignition switch ON ll 4 Measure voltagebetweenTP sensorconnector terminals No 3andNo 1 lsthereapprox 5 V Checkfor an open in...

Page 271: ...P1121 ThrottlePosition TP lowerthanexpected 12 9 M Ti 12 2tA T I P1122 Thescantool indicates Diagnostic TroubleCode DTC P 122 ThroftlePosition TP higherthanexpected 17 2 1818C1 818C5 engines 17 6 81881 engineM T 16 5 81881 engine A T TheMILhasbeenreoortedon OTCP1122is stored Problemverification 1 Turntheignition switchON ll 2 Checkthe throttleposition w ththescantool lsTP or lessindicated when the...

Page 272: ...ICH AIR LEAN FUEL RANO Thescantoolindicates Diagnostic TroubleCodeIDTCIPO13l A lowvoltageproblemin the primary Heated OxygenSensor HO2S Sensor 1 circuit Th6MILh r baan ago t d on DTCm131 it 3to d Problcm vcrificrtion 1 Dothe ECMResetProcedure 2 Start the engino Hold the engane at 3 000rpm with no loadlin Parkor neutral until th radiatorIan cofies on 3 Test drive with the A Tin E position M Tin4thg...

Page 273: ...ch OFF 2 D i s c o n n e c t t h e E C M c o n n e c t o r D 1 6 P 3 Check for continuity between HO2Sconnectorterminal No 1 and body ground 11 68 Check ror a short in the HO2S 1 Turn the ignition swilch OFF 2 Disconnectthe Primary HO2S Sensor 1 connector 3 Stan the engine and let it dle 4 Checkthe Primary HO2S Sen sor 1 output vohage with the Frompage 11 67i Subslitute a known good ECM and rechec...

Page 274: ...eignition switch ON t Check thePrjmary HO2S Sen sor l outputvoltagewith the scantool Intermittentfailur svstem is OK at this time Checkfor poor con nectaons or loosewires at C113 PrimaryHO2Slsensor lll and ECM 5 PRIMAnY HO2S Sensor 1 CONNECTOR tC1t3l PHO2S WHT Wire side of female terminals ECMCONNECTOR D 16PI JUMPER WIRE PHO2S WHT F r 1 2 3 l sG2 5 10 12 1 3 GBN BLU Wire side of female terminals c...

Page 275: ...ed NOTE ll DTCP013 t P0132 and orP0 135 are storedat the sametime as DTCP0133 troubleshoot thoseDTCS first then troubleshoot DTCP0133 PossibleCause PrimaryHO2S sensor 1 Deterioration o PrimaryHO2SHeater sensor 1 Deterioration Exhaust systemleakage Troubl shootingFlowchart lit ll r ThoMILhasboonraDortcdon DTCP0133is storcd Problemverificttion 1 DotheECMReset Procedure 2 Startthe engine Hold tho eng...

Page 276: ...sor2 l and ECM Does thevoltage stayat 0 3V or less Checkfor a short in th HO2S 1 TurntheignitionswitchOFF 2 Discon nect the Secondary HO2S Sensor 2 connector 3 Starttheengine 4 Checkthe Secondary H02S Sensor 2 output whhthescan tool Doesthevoltage stayat 0 3V or less Checktor a short in the wire SHO2S line r I urnrnergnt on swttchuFF 2 Disconnect the ECMconnec torD 116P 3 Checkfor continuitybetwee...

Page 277: ...e 1 Turnthe ignitionswitchOFF 2 ConnectECMconnectorter m i n a l sD 1 3a n d D l 4 w i t h a jumperwire 3 Turntheignition switchON ll 4 Checkthe Secondary HO25 Sensor 2 outputvoltage with thescantool Repair opsn in the wire b tweon ECM D14or O13 and Secondary HO2S Sensor2 lsthere0 6V or more Substitutea known goodECM end r6check It symptom indica tion goesaway rcplacethe origi nalECM tI t ffi tl j...

Page 278: ...emve tication 1 DotheECMReset Procedure 2 Start the engine Hotd the engineat 3 000rpm with no load in Parkor neutral until theradiator fancomeson 3 Checkthe Secondary HO2S Sensor2 outputar 3 000rpm th thescantool Intarmittert lailurg systsm i OK at thi time Chsckfor Doorcon nections o loose wi es at C451 SecondaryHO2Slsonsor 2 nd ECM Doesthe voltagestaywithin 0 3 0 6V tortwo minutos ...

Page 279: ...red Probl mverilication 1 DotheECMReset Procedure 2 Starttheengine lnt rmitlent failure 3vslemis OK at this time Checkfor Poo con noction3o loose wire ai Cl13 PrimaryHO2S S nsor 1ll gl51 lSocondaryH02S lSensor2 and ECM Checkfor an open or short in tho HO2S 1 TurntheignitionswitchOFF 2 Disconnect the PrimaryHO2S Sensor 1 Secondary HO2S Sensor 2 connector 3 At the HO2Sside measure resistance between...

Page 280: ...nd HO2S lsthere0 1V or less Substitutea known goodECM and r chcck tf 3ymptom indica tion goesawey repl cethe odgi nelECM PRIMARY HO2S Sensor1 CONNECTOR C113 SECONDARY HO2S Sensor2ICONNECTOR C45tr Wiresideof femaleterminals ECMCONNECTOR A I32P IGP lG1 so2HTC GRN RET c 4 tr A 4 PO2HTC ltoRN BLKt T PGl BLK 2 a 1f lefil tt 12 t5 t5 1 t 8 t9 20 22 23 25 26 l 2 8 23 Wiresideof temaleterminals Frompage 1...

Page 281: ...0172 troubleshoot thoseDTCS first thentroubleshoot DTCP0171 andlotP0172 PO107 P0108 P1128 P1129 MAPSensor P0135 PrimaryHO2SHeater Sensor 1 P0137 P0138 Secondarv HO2S Sensor 2 P0141 Secondary HO2S Heater Sensor 2 P1259 VTEC Svstem PossibleCause DTCP0171 too lean Drc P0172 Svstem too rich FuelPumpinsufficient flowpressure FuelFeedLineclogged leaking FuelPressure Regulator stuckopen FuelFilterclogged...

Page 282: ...heradiator lan comeson 2 C h e c kt h e P r i m a r yH O 2 S Sensor1 output with the scantool Chock the tuel pump fuel feod pipe fuol fiher and tuol prcssure regulator Doesit stayat lessthan0 3V or morethan0 6V Rapl ce the Primary HO2S Sen 3orll Checklor a sticking or l aking EVAPpurge control solenoid Witha vacuumpump applyvacu um to the EVAPpurgecontrol solenoid valve Doesit holdvacuum Chock the...

Page 283: ...DTC P0171 P0172 Fuelmetering P0505 ldle ControlSYstem P1361 P1362 TDCsensor P1381 P1382 CYPsensor P1508 IACvalve PossibleCause Fuelpumpinsufficient fuelpressure amountof flow Fuellineclogging blockage leakage Fuel ilterclogging a Fuelpressure regulator stuckopen Distributormallunction o lgnitioncoilwireopen leakage lgnitioncontrolmodulemalfunction Valves carbondeposit a Compression low IACvalvemal...

Page 284: ...thetime of itsoccurrence and DTC P0301 P0302 P0303 or P0304 will be stored Then afterthe m sfirehasceased the MILwittcomeon lf misfiringthat increases emissionsis detectedduringtwo consecutive drivingcycles the MIL will come on and DTC P0301 P0302 P0303 or P0304 will bestored NOTE lf someof the DTCS listedbelowarestoredat the sametime as a misfireDTC troubleshoot thoseDTCS first then troubleshoot ...

Page 285: ...a clicking sound at the fuel injector in the problem cylinder Check for an openor shon in the harness betweenECMand the fUelinjector Repairopenor short in the wiro Replace tho luel inisctor Sub3titute a known good ECMandrach ck It symptom indicrtion 90e3away replace the originalECM Problemve ification 1 Afterchecking thefreeze data dotheECMReset Procedure 2 Exchange the sparkplugfrom the problemcy...

Page 286: ...n d e r with one from anothercylin der 2 Lettheengine idlelortwo min uteS 3 Test drive thecarsevoraltimes in the rangeofthe treezedata Int rmitt nt mislire due to bad contact in tho tuel iniector con nectorlfiring is OKat thb time Doesthemisfireoccurinthe othercylinder whosetuelinjector wasexchanged Replace the laultv tuel iniector Checkthe following items Cylinde lerk down Compaession CrankshaflP...

Page 287: ...mav b naccrsrryl Chcckfor poor connactionso loos wir botw n Cl33 knock s nlor KSlrnd EcM Ch6ck or a 3hort in tho wirc IKS lin6l 1 TurntheignitionswitchOFF 2 Disconnect the knocksensor connector 3 Checkfor continuitybetween ECMconnector terminalsD6 andbodyground R o i short in thG wire batwaan ECMlD6l rnd knock n3or Checkfor an opcn in lho wiro IKSlin l Checkfor continuitybetweenECM connector termi...

Page 288: ...determines ignitiontiming at stan up cranking andwhen crankangleis abnormal TheCyp Sensordetectsthe positionof No 1cylinder for sequential fuelinjection to eachcylinder NOTE ll DTCP1359 is storedat the sametime asDTCP0335 P0336 Pl361 P1362 P1381 and orP1382 troubleshoot DTC P1359 first thentroubleshoot thoseDTCS Problcmva itic lion 1 DotheECMReset Procedure 2 Stantheengine Th MIL ha3bacn r oort d ...

Page 289: ... Check tor a shott in the CKP TDC CYP s6nsor C h e c k f o r c o n t i n u i t y t o b o d y ground on both terminals oI the indicatedsensor individuallY ReDlace lhe distributor housing sen3or seesection23 Reoairopen in lhe indicatedsen sor wires seelable lsthere0 5 1 0kg Checklor a short in the wire3 CKP TDC CYP linesl Checkfor continuitybetween bodygroundand ECMconnector terminals C2 C3and or C4...

Page 290: ...tatethe left front 6 M e a s u r e v o l t a g e b e t w e e n ECM connector terminals C18 and A9 Substitutea known goodECM and recheck H symptom indica tion goesaway replacetho origi nalECM Does the voltage pulse 0 V and 5 V or batteryvoltage Checklor a shori in th ECM 1 TurntheignitionswitchOFF 2 Disconnect the ECMconnec torC 31P 3 Turntheignition switch ON lli 4 Blockthe right front wheel andsl...

Page 291: ...re 2 Start the engine Hold the ongineat 3 000rpm with no load in Parkor neutral until the mdiatorlan comeson then leth idle 3 Connectthe SCSservicecon nector 4 Test drivewith the A Tin E position M Tin 4th goar 5 Accoleratefor five seconds usingwide openthrottle Int imitt nt f llur y t m ir OK rt thi tim ls DTCP1106 indicated Substltuto r known good EGM and rech ck tf rymptom indic lion gooarway r...

Page 292: ...orC 131P 3 DisconnBct the 22Pconnector lrom theTCM 4 Chechtorcontinuitybetween body groundand ECMcon nsctorterminalC2l Repairshon in tha wira bctwesn ECMlC21 nd TCM ls OTCPl107indicated Substitutc s known good ECM tnd rochcck lf symptom indica tion 9063aw y replscotho origi n l ECM 1P1108 The scantool indicates Diagnostic TroubleCode DTC P1108 A highvoltageproblemin the Barosensor circuit A Tonly ...

Page 293: ...P con nector 3 Turntheignition switch ON ll 4 Measure voltagebetlveenbody ground andtheELD3Pconnec torte minal No 1 Repairop6n in the wire baiwe n No 15ALTERNATOR SPSENSOR 17 5Al fus in the under dash luse relaybox and ELD Chocklor short in the wire EL line Measurevoltagebetweenbody groundandtheELD3Pconnector terminal No 3 lsthereapprox 5 Vl Checkfor a short in the wire EL linel 1 Turntheignitions...

Page 294: ...onnect the ELD3P con nector 3 Checkfor continuitybetween body groundand the ELD3P connector terminalNo 2 Bepairopon in the wire bstween ELOconnectorand G402 Checktor an opon in the wire IEL linell 1 Disconnect the ECMconnec tor D l6Pi 2 Checkfor continuitybetween theELD3Pconnector terminal No 3 and ECMconnector ter minalD16 Repairopen in the wir between ECMl016landrheELD lstherecontinuity Checkfor...

Page 295: ...determined limit CKFSENSOR CONNECTOR IC 110 T l r T IJI I crr e f fcxr na BLU RED D lwHr REDI Terminal sideof maletermanals TheMILhasbeon ooortedon DTCP1336and or P1337aro stoaed Problemvo itication 1 Dothe ECMReset Proced re 2 Starttheengine lntermittent feilure swtem is OK at ihis timo Chcckfor ooor oon noctionsor loosewir ei C110 CKF sonsor andECM Checkfor anopenin tho CKFsen sor 1 Turntheignit...

Page 296: ...there1 6 3 2kO Checkfo a aho t in tho wi o CKFlines Checkfor continuitybetween bodygroundandECMconnector terminalC1andC11individually Rapair ihort in the wire between ECM C1 C11 lnd th CKFsensor lstherecontinuity Sub3titutea known goodECM snd recheck lt 3ymptom indicr tion gogr away replacothe origi nal ECM ECMCONNECTOB C 12PI CKFP CKF M wHT REDI Wireside offemale terminals BLU RED o Y I 3 5 I 1 t...

Page 297: ...YPsensorland ECM ls DTCP1359 indicated Checkfor poor connections or loosewires betweenthe CKP TDC CYP sensorandthe ECM Substitutea known goodECM and recheck It symptom indica tion goesaway replaceih6 origi nalECM PGM FI System CrankshaftSpeedFluctuatio CKFI Sensor cont d ECMlnternal Circuit L I P1607 Tfrescantool indicates Diagnostic TroubleCode DTC Pl607 An ECMInternal CircuitFailure A The MIL ha...

Page 298: ...Startthe engane Allow the engineat idlefor oneminute lntermittent failure swtem is OK at lhis time Checklor poor con n ctions or loose wires at C420 ITCMIand ECM ls DTC P1660indicated Checkfor an open in the wire ATCHK line 1 TurntheignitionswitchOFF 2 Checkfor continuitybetween ECMconnecto terminal C19 andTCM26Pconnector termi nalNo 20 Repairopen in the wire between ECM Cl9 andTCM lstherecontinui...

Page 299: ...and No 15 ALTERNATOR SP SENSOR 17 5Al tu3e in th under dash fu3e r laybox Repair opon in tho wire b twoen TCMandG101 ls there banery voltage Checkto an open o 3hort in tha TCM Substitutea known goodTCM andrecheck ls DTCP1660 indicated Substitute a known good ECM and rschsck lf symptom indica lion 9o w y roplacetho origi nal ECM TCMCONNECTOR 26P Cir2ol LG BRN BLK 1 2 3 5 6 7 E 9 1 0 1 1 14 15 16 17...

Page 300: ...TCP1681 P1682 P1686end or P 1687 arestored Problemverificetion 1 DotheECMReset Procedure 2 orivethecarfor several miles s o t h a t t h e t r a n s m i s s i o n upshiftsand downshiftssev erarlrmes Intormittentlailure systemis OK at thi3 tim Checktor ooo con nections or loo3o wir6s al C419 TCM nd ECM lsDTCP1681 P1682 Pl686 and orP1687 indicated Checktor a short in th6 wires AFSA AFSBlinel 1 Turnth...

Page 301: ...lAC V8lve The valvechanges the amountof air bypassing intothe intakemanifoldin response to electric currentcontrolledby the ECM Whenthe IACValveis activated thevalveopensto maintain the properidlespeed 81881engine B18Cl B18C5 engines aresimilarl YELI F om PGM FI BLK MAIN RELAY VARIOUSSENSORS L 11 96 ...

Page 302: ...P0505 or P 1508 checkthefollowingitems Adiust theidlespeed seepage 11 111 ALTFRsignal seepage11 101 Airconditioning signal seepage 11 102 Brake switch signal seepagell 104 Starter switch signal see page11 1051 A 4gearpositionsignal seepage1l 106 A T PSPswitchsignal seepage11 108 USA Fast idlethermovalve seepage11 110 Hosesandconnections IACvalveandits mountingO rings ll the aboveitemsarenormal sub...

Page 303: ...on 1 S t a r tt h e e n g i n e H o l dt h e engineat 3 000rpm wathno load1inParkor neutral until the radiatorfan comeson thenletit idle 2 With the scantool checkthe followingitems Throttle position shouldbe approx 10 withthethrot tlefullyclosed Enginecoolanttempera tureshouldbe 116 212F 80 100 c lf theyare not withinthe spec repair thefaultysen sorcrrcuft 3 C h e c k t h e e n g i n es p e e da t...

Page 304: ...Slartthe engineand let it idle 4 Put your finger on the lower port in the thronle bodv Chackanginacoobnt Lv l and fo ai in th cooling ry l m It OK r place tha fatt ldla lftarmo valva Doestheenginespeed drop Putyour linger on the upporport in thethrottle body Chacl tor vrcuum leek3 m lc ilJa th6 throttlo valvo ir com plotaly cloaad rnd ropair aa nac a3aatY ooesihe engin6speeddrop Adiutt th idl p d ...

Page 305: ...acv BLK BI UI The MIL has been reoorted on OTC Pl508 is stored lntermittent failure svstemis OK at this time Checkfor ooor con nectionsor loosewires at C116 lACvalveland ECM ls DTCP1508 indicated Checktor an open in lhe wire llGPlline 1 TurntheignitionswitchOFF 2 Disconnect the IACvalvecon 3 Turntheignition switch ON ll 4 Measure voltagebetlveenbody ground andtheIACV connector terminalNo 2 Repairo...

Page 306: ...ECMcon nector terminal C17 lsthereapprox 5V Checkthe operationofthe ALT 1 Turnthe Onition switch OFF 2 Reconnect the ALT GRN4P 3P connector to theALT 3 S t a r tt h e e n g i n e H o l dt h e engineat 3 000rpm wkh no load in Parkor neutral until the radiatorfan comeson thenletit idle 4 Measure voltagebet veen ECM connector termina lsC17andA9 Ropair short in the wir6 between th6 ECM C17 and the ALT...

Page 307: ...itchOFF 2 Disconnect the ECMconnec tor C 31P 3 Ch6ck or continuity betwe n body ground tnd ECM con nectorterminalC5 lsthere approx 5 V Rapair rhortInthowirabatwaon th EcM c5l andthc A c pre sur rwitchot A Cdiod Subtlilut I known ood Ecttl lnd raahack lf prtactibad voft rgo ir now avaihbla tcplaca lh originll ECM Saatha air condhiond in plc tion 1 r ction 221 Checklor an opan in th wi a ACClin l 1 ...

Page 308: ... Starttheeogine 2 TurntheblowerswitchON 3 Turnthe y CswitchON Checklor sn open in th6 wire IACSline Measurevoltage betweenECM connector terminals C5andA9 Air conditioningsignali3 OK Repafu open in the wire between the ECM C5 and th A C D es sureswitchor A C diode lsvoltage lessthan1 0V Substitute e known good ECM nd echeck lf 3ymptom indi cation goes away rcplaco th original ECM 56 the air conditi...

Page 309: ...oRNSTOP 20Al fuse Replacetha HORNSTOP 20Al Ius Repairopen in the wire be tween the brtke switch and tho HORNSTOP 20Al tuse Inspectthe brake switch see section23 Checktor an open in the wire BKSW line 1 Depress thebrakepedal 2 Measure voltagebetweenECM connector terminals D5andAg withthebrake pedaldepressed Repairopen io th6 wiaebatweon the EcM lDs rnd the brake switch Brakeswitch signalis OK ldleC...

Page 310: ...nnectorterminalsC6 and Ag with the ignitionswitchin tho startposition lll Inspect the No 31 STARTER SIG NAL 7 5 Alluse intheunder dash fuse relay box ls therebatteryvoltage Repair3hort in the wire be tween tho ECM lc6l rnd the No 31 STARTER SIGNAL 7 s Al tus or the PGM FImain r lay Roplacethe No 31 STARTER SIGNAL17 5 Al fuso Starterswitch signalb OK Ropairopen in tho wire botwaon ih6 ECM CGland th...

Page 311: ...heignition switch ON ll 2 observethe A T shitt position indicator andselect eachPosi tionseparately 560the A T go r position indice tor inroectionlseosection141 Checktor r 3hort in tho wiro ATP PNlino 1 Iurn the ignitionswitchOFF 2 Disconnect the ECMconnec torC 31P 3 Checkfor continuitybetween body groundand ECMcon nector terminalC29 lsthereapprox 5V Rcpairshort in the wir6 batwoen tho ECM lc29l a...

Page 312: ...6 wiro bo twoen tho ECM C291 and tho gru96 a3sgmbly Repairopen in GRN wir bo twaan thc gauga srembly nd tho A T g ar po3ition gwitch lstherelessthan1 0V Chod for an opon in tho wir6 ATP PNlinel Measurevoltage betweenECM connector terminalsC29and A9 with the transmission in E posi tron R psir op n in GRN WHTwiro b twcanth gaugcrsr mbly and thc A T ge r po ition 3whch lstherelessthan1 0V A T g6erpos...

Page 313: ...al Checklor anop nin the wire PSP SWlinel 1 TurntheignitionswitchOFF 2 Disconnect the PSPswirch2P 3 Turntheignition switch ON ll 4 At the wire side connectthe PSPswitch2P connector ter minals No 1 andNo 2witha iumperwire 5 MeasurevoltageteNveenECM connector terminals C16and A9 lstherelessthan1 0V Repairopen in the wire be tween the ECMlcl6l nd the PSP3witch Repai open in BLK wire be tween the PSP ...

Page 314: ...t in the wire PSP SWlihell 1 Turnthe ignitionswitchOFF 2 Disconnect the ECMconnec torC 31P 3 Checktor continuitybetween bodygroundandECMconnec torterminalCl6 lstherebattery voltage ReDair short in the wire between the ECM lC16 and lhe PSP switch Substitutoa known goodECM and recheck lf prescribedvolt a96 is now available replacethe originalECM A 32P ECMCONNECTORS Wiresideof temaleterminals c 13lPl...

Page 315: ...t idlethermovalveis factoryadiusted it shouldnot be disassembled 1 Remove the intakeairductfrom thethrottlebody 2 Startthe engine 3 Putyour fingeroverthe lowerport in throttlebody andmakesurethatthereis air flow with the engine cold engine coolanttemperature below86 F 30 c LOWER PORT lf there is no air flow replacethe last idle thermo valveand retest Startthe engine Holdthe engineat 3 000rpm with ...

Page 316: ...eidlespeed checkthe followingitems TheMILhasnot beenreported on lgnition timing Sparkplugs Aircleaner PCVsystem Canada Pullthe parkingbrakeleverup Startthe engine thencheckthatthe headlights areoff 1 Start the engine Hold the engine at 3 000 rpm with no load in Park or neutral until the radiatorfan comeson thenletit idle Connect a tachometer Disconnect the 2P connectors from the ldle Air Control l...

Page 317: ...e 7501 50 nm 818C5engine 8001 50 rpm Turnthe headlights off ldlethe enginefor one min ute with heaterfan switchat Hl and air conditioner on thencheckthe idlespeed ldl spoodshouldbe Bl8Bl ongin M T 820i 50 rpm lvT 840t 50rpm inParkor neutral 818C1 ngino 850i 50 rpm 818C5engino 1 050t 50 rpm NOTE lf the idle speedis not within specification seeSymptomCharton page1 36 L i l I h lffi il tfl ffi 11 112...

Page 318: ...FuelSupplySystem FuelLines Check fuelsystem lines hoses tuelfilter andothercomponents for damage leaks anddeterioration andreplace if necessary 11 1 1 3 ...

Page 319: ...l FuelSupplySystem FuelLines cont d Checkall hoseclampsandretighten if necessary GAUGE ING UNIT Cl mp in fto middl Clrmp in th middl 11 114 ...

Page 320: ... damaged A disconnected quick connect fittingcanbe reconnected buttheretainer on thematlngpipecannotbereused once it hasbeenremovedfrom the pipe Replace the retainer when Replacing thefuelpump Replacing thefuelfeedpipe It hasbeenremovedtrom the oiDe lt is damaged RETAINER I Disconnection t Do not smokcwhiteworkingon the fuel system Keepopenflamesaway from your wotk area L Relievefuel pressure see ...

Page 321: ...replacing thefuelpump replacing thefuelfeedpipe it hasbeenremovedfrom the pipe it isdamaged i l i l f 1 1 1 1 6 IA __ Conneciion Do nor smoke wntle workhg on rhe fuel system Keep open tlames away trom your work arsa L Checkthe pipe contact area for dirt and damage and clean if necessary Inserta newretainer intotheconnector if the retainer is damaged or after replacing thefuelpump replacing thefuel...

Page 322: ...onnectfittingsonto the pipe until both retainerpawlslockwith a click Ingsouno NOTE lf it is hardto connect puta smallamountof newengine oilonthepipeend Connectionwith new retainer 5 Makesurethe connectionis secureand the pawls are lirmly lockedinto place checkvisuallyand by pullingtheconnector RETAINER Reconnect the batterynegative cable and turn the ignition switchON ll thefuelpumpwjll runfor abo...

Page 323: ...t the batterynegative cablefrom the bat tery negative terminal Remove thefuelfillcap Usea box end wrenchon the 12 mm banjobolt at thefuelfilterwhileholding thefuelfilterwith another wrench Placea rag or shop towel over the 12mm banjo bolt Slowly loosenthe 12 mm banjobolt one complete turn 11 1 1 8 I NOTE Replace thewasherswhenever the 12mm banjo boltis loosened or removed lnsDection 1 Relieve fuel...

Page 324: ...pagel l _121 lf the fuel pressureis lower than specified inspect for Clogged fuelfitter Faulty fuelpressure regulator seepage ll 121 Fuellineleakage FuelInjectors Rsplac msnt E oo not smokeduringthe work Keepopen flamesawayfrom your work area 1 Relieve fuelpressure seepage1l g 2 Disconnect theconnectors from thefuelinjectors 3 Disconnect the vacuumhoseand fuel returnhose trom thetuelpressure regul...

Page 325: ...iniectors Coatnew O ringswith cleanengineoil and put them onthefuelinjectors Insert the injectors intothefuelrailfirst Coatnewsealringswith cleanengineoil andpress themintorheintakemanifold To preventdamageto the O rings installthe luel injectors in the fuel railfirst theninstallthem in the intakemanifold Alignthe centerlineon the connector with the mark on the fuelrail FUELRAIL MARKINGS 13 14 1 5...

Page 326: ...tor Check thatthe fuel pressure riseswhenthe vacuum hosefrom the fuelpressure regulator is disconnect edagain lf the fuel pressuredid not rise replacethe fuel pressure regulator VACUUM FUELPRESSURE R place AA i I I Replacem6nl Do not smoke while working on tucl sys tem Keepopenflamc away from your work area 1 Placea shop towel underthe fuel pressure regula tor thenrelieve fuelpressure seepage11 1 ...

Page 327: ...atorvacuum hose disconnected and pinchedlaiter makingsurethat the tuel pump and the fuelpressure regulator areOK Place a shoptowelunderandaroundthefuelfilter Relieve fuelpressure seepage11 1 18 Supportthe fuel filterwith a wrench as shown then removethe 12mm banjoboltandthe tuelfeed pipelrom thefuelfilter Remove thefuelfilterclampandfuelfilter lnstallthe new fuel filter in the reverseorderof remov...

Page 328: ... 3 4 5 FUEL PUMP YEL GRNI IGN 1 IYEL GRN JUMPERWIRE Wiresideof femaleterminals Checkthat battery voltage is available between the fuel unit sub harnessconnector terminal No 2 and body ground when the ignition switch is turned ON Wiresideof femaleterminals lf battery voltage is available check the fuel pump ground lf the ground is OK replacethe fuel pump lf there is no voltage checkthe wire harness...

Page 329: ...alof the PGN4 Fl mainrelay lf thereiscontinuity go on to step3 lf thereis no continuity replace the PGM Fl main relayand retest To lGN 1 To GROUND To ST SWITCH To ECMCONNECTOR TERMINAL A16 FLRI To BAT To ECMCONNECTOR ftNMNALS All andA24 lGP V To FUELPUMP 3 Attachthe batterypositiveterminalto the No 5 ter minalandthe batterynegative terminalto the No 3 terminalof the PGM Fl main relay Thencheckthat...

Page 330: ...lay lstherebattery vohage Check foi an open or shori in the wire lG1 line 1 Turn the ignitionswitchON ll 2 Measure the voltage between the PGM Fl main relay 7P con nectorterminalNo 5 and body ground R pairopen or short in the wire betwo n the PIGM FI main relav and the No 13 FUEL PUMPISRSUNIT 15Altuse ReDlacethe No 13 FUEL PUMPISRSUNID 15 Al fuse in the under dash tuse relay oox Checkfor an open o...

Page 331: ...eignition switch ON ll 4 Measurevoltage between ECMconnector terminals A10 a n d A 1 1 a n d b e t w e e n A 1 0 and 424 Repaaropen in lhe wir bet ween the ECM1A11 A24l and the PGM FI main relay Repldcethe PGM FImain relay lstherebattery voltage Substitutea known goodECM and recheck It prescribedvohage is now available roplacelhe o ig inalECM lsthere1 0V or less Checkthe PGM Flmain relay lseepage1...

Page 332: ...e clamps thentwist hosesasyou pull to avoiddamaging them 7 Place a tack or othersupport underthetank 8 Remove the strapnuts and letthestrapsfallfree 9 Remove the fueltank lf it stickson the undercoat appliedto its mount carefully pry it offthe mount 10 lnstallthedrainboltwith a newwasher thencoatthe drainboltwith Noxrust1248 Allow the Noxrustto dry tor 20 minutes 11 Installthe remaining parts inth...

Page 333: ...rottle Body TB ldleAir Control lAC Valve fastidlethermovalve A T modelonly andintakemanifold A resonator inthe intakeair pipeprovides additional silencing asair is drawnintothe system B18Cl enginelB18Bl B18C5enginosdoes not havs the IABsysteml IAB CONTROL sollNolD VALVE VARIOUS SENSORS IAB CONTROL DIAPHRAGM IiITAKE AIRPIPE INTAKEMANIFOLD INTA E AIR DUCT RESONATOR ...

Page 334: ...aircleaner element every30 000milos 48 000 km or 24 months whichevercomesfirst Severecond tions Usenormalschodule exceptin dustyconditions Clean aircleaner element ev6ry15 000mil s 24 000km or 12monthsand replaceevery 30 000miles 48 000 km or 24 months whichevercomestirst INTAKEAIR DUCT 11 129 ...

Page 335: ... idle 2 Check thatthethrottlecableoperates smoothlywilh no bindingor sticking Repair asnecessary 3 Checkcablefree play at the throttlelinkage Cable deflection shouldbe 10 12mm 3 8 l12 in l ADJUSTING NUT t il qr ll 11 1 3 0 TINGNUT lnstallation 1 Openthethrottlevalvefully then installthethrottle cablein the throttlelinkage and installthe cable housingin the cablebracket 2 Startthe engine Holdthe en...

Page 336: ...r you release the accelerator pedal CABLEBBACKET lnstallation Openthe throttlevalvefully then installthethrottle cablein the throttlelinkageand installthe cable housingin the cablebracket Stanthe engine Holdthe engineat 3 000rpm with no load in neutraluntilthe radiatorfan comeson then letit idle l 3 5 CABLE BRACKET THROTTLE LINK ADJUSTINGNUT With partA of the cablebracket supportthe cable sheathso...

Page 337: ...Hold the engine at 3 000 rpm with no load in Park or neutral until the radiator fan comes on then let it idle 2 Stop the engine and checkthat the throttle cable operatessmoothly without binding or sticking lf the throttle body pon is clogged clean it with carburetor cleaner lf there are any abnormalities in the above steps checkfor Excessivewear or play in the throttle valve shaft Sticky or bindin...

Page 338: ...ble Afterreassembly adjustthethrottlecable page11 130 131 andA Tthrottlecontrol cable section l4 Ior carswith A T TheTPsensoris not removable IOLEADJUSTING SCREW FASTIDLE THERMO VALVE A T model onlyl Inspectaon page11 l10 l 12 2 kgf m 16lbf ft 11 1 3 3 ...

Page 339: ...llowthe selection of the intakepathmostfavofable for a given enginespeed Satjsfactory powerperformance is achieved by closingandopeningthe intakeair bypass lAB controlvalves Hightorque at low RpMis acheived whenthe valvesareclosed whereashighpowerat highRPMis achieved by whenthe valvesare opened IAB CONTROL VALVES ECM i l l f 1 l i 11 134 r _ CHECI VALVE ...

Page 340: ...manifold Checkfor an open in the wire llABSOLline 1 TurntheignitionswitchOFF 2 Disconnect the IAB control solenoid valve2Pconnector 3 Turnthe ignitionswitchON ll 4 Measure vohagebetween the IABcontrolsolenoid valve2P connector terminals No 1 and N o 2 lsthere batteryvoltage Chackfor rn op n or 3hort in the wire lABSOLline Measurovoltagebetweenbody g r o u n d a n d t h e I A B c o n t r o l soleno...

Page 341: ...acethe originalECM IABcontrolsvstomis OK Checklor a shon in the wire lAB SOLline 1 Turnthe ignitionswitchOFF 2 Disconnect the ECMconnector A 32P 3 Checkfor continuitybetween bodygroundandthe IABcon trol solenoid valve2Pconnec torterminalNo 1 lstherebattery voltage Repairopen in the wire betwaon ECM lA26 and the IAB control solenoidvalve2Pconnectoa Checktor an open in the wiro GNDline r 1 Turnthe i...

Page 342: ... in closecontactwith the stopwhen vacuumhoseis disconnected With the engineat idle checkthat of the IABcontrolvalveis in closecontactwith the full close screwwhen the vacuumhoseis connected lf anytaultis found cleanthe linkage 8ndshaftswith carburetor cleaner lf the problemstillexistsaftercleaning dis assemble the intakemanifoldandcheck the IABvalvebodyassembly 11 137 ...

Page 343: ...ometer Checkand adjustthe idle speed if necessary see page 11 11 Warmup andcalibrate theCOmeteraccording to the metermanufacturer s instructions Checkidle CO with rhe headlights heaterblower rearwindowdefogger coolingfan andaircondition er off NOTE Canada Pullthe parkingbrakeleverup Startthe engine then checkthatthe headlights are olf COmetershouldindicste0 17o maximum DescriDtion The Three Way Ca...

Page 344: ...arv HO2S P0141 Secondary HO2SHeater PossibleCause TWCDeterioration Exhaust systemleakage Troubleshooting Flowchart Problemverification 1 DotheECMReset Procedure 2 S t a r tt h e e n g i n e H o l dt h e engineat 3 000rpm with no load in Parkor neutral until theradiator fancomeson 3 Connect the SCSservice con 4 Testdrive40 55 mph 64 88km h for approx two min utes Thendecelerate Ior at least3 second...

Page 345: ...intake manifold vacuumand theblow by gasisdrawndirectly intotheintake manifold PCVVALVE MANIFOLD BLOW BY VAPOR FRESHAIR 11 140 Inspection 1 Check the PCVhosesandconnections for leaksand croggrng BREATHER HOSE l r I 2 At idie makesurethereis a clickingsoundfrom the PCVvalvewhen the hose betweenPCVvalveand intakemaniloldin lightlypinchedwith your fingers or plters lf thereis no clicking sound checkt...

Page 346: ...rthroughthe EVAPcontrolcanister and intoa pon on the intakemanifold Thepurgingvacuumiscontrolled by the EVAPpurgecontrolsolenoid valve C FuelTankVapor ControlSystem Whenfuelvaporpressure in thefueltankis higherthanthe setvalueof the EVAP two way valve the varveopensano regulates the flow of fuelvaporto the EVAP controlcanister Frcm No 15 FUEL TANK PRESSURE SENSOR EVAP THREE WAY VALVE EVAPCONTROL C...

Page 347: ...ing ArethevacuumlinesOK Problgmverilication 1 DotheECMReset Procedure 2 Remove thefuelfillcap 3 Turnthe ignitionswitchONlll 4 Monitorthe FTPsensorvolt a g e w i t h t h e H o n d a P G M Tester or measurevoltage botweenbody ground and ECMconnector terminalD15 Int6rmittenttailure 3ystemi3 OK at thb tirn6 Chocklor poor con n clions or loo3e wire3 ot C421 locltod rbovo under d h fuso r lay boxl C510l...

Page 348: ...hOFF 2 Disconnect the ECMconnec tor D 16P 3 Checklor continuitybetween the ueltank pr sslrre sensor 3P connectorterfiinal No 3 andbodyground Ropri 3hon in tho wira betwaGn the fuel t nk prosaurasan3orand ECMtD15t Substitutas known goodECM nd recheck It normel fuel tenk pressure son30r is indicatod raplacgtho o iginal ECM FUEL TANK PRESSURC SENSOR 3PCONNECTOR lc792l PTANK ILTGRN sG2 IGRN BLKI Wires...

Page 349: ...lt a g e w i t h t h e H o n d a P G M Tester or measurevoltage betweenbody ground and ECMconnector terminalD15 Intormittontfailu e syst6mis OK at ihi3 time Chackfor poor con nections or loo3e wires at C421 locatodabovo undel dashfu3e rolaybox C510 loc ted undor acc6s3Dan6ll C792Ituol trnk Dro su 6sen3orl andECM lsthereapprox 2 5V Checktor an open in the wire SG2lino 1 Turnthe ignitionswitchOFF 2 ...

Page 350: ...ector terminals D15andD11 Ropairopon in the wire betwe n ihe lual tank ore ure sen3orand the ECM D151 lsthereapprox 5V Substitutee known goodECM and racheck lf normal fuel tank pressuresensoris indicated replacethe originalECM ECMOONNECTOR D I16P PTANK LTGRNI SG2IGRN BLKI Wiresideof femaleterminals 11 145 ...

Page 351: ...ONTROL CANISTER VENT SHUT VALVE O RING Replace ECMCONNECTOR A I32P T op a g e1 1 1 4 7 Tho MIL ha3 bcan t6po tod on DTCP1 t56 or P1457i 3toLd Chcckthe EVAPcontiol canittc vont shut valva 1 Disconnect the vacuumhose Irom the EVAPthree way valveand conned a vacuum pumpto thehose 2 Removethe EVAPcontrol canister vent shutvalve rom the canister 3 Turnthe ignitionswitchONlll 4 Applyvacuumto thehose Cha...

Page 352: ...pen in the wir6 betweon the EVAP control canistor v6nt shutvalveendthe No 15ALTER NATORSPSENSOR 17 5 Al tu e Ch cktor rn op n in iho wire IVSV line 1 TurnthoignitionswitchOFF 2 Reconnect the 2P connector to the EVAPcontrolcanister ventshutvalve 3 Turntheignition switch ON ll 4 Measurevoltage between ECN l connector terminals A29 andA10 Repairopen in the wire beiwa n the EVAP cont ol cenister vent ...

Page 353: ...r an openin the wire llcl line 1 Turntheignition switch OFF 2 Disconnect the 2P connector from the EVAPpurgecontrol solenoid valve 3 Turntheignition switch ON ll 4 At the harness side measure voltage betweenthe EVAP purge controlsolenoid valve 2P connector terminal No 1 B1 8 C 5e n g i n e N o 2 a n d bodyground EVAPPURGE CONTROISOLENOID VALVE 2PCONNECTOR IC114 B18C1 Cl8Bl engines 818C5 engine PCS...

Page 354: ...h a 3 Start the engine and check for vacuum at the vacuum hose ls there vacuum EVAPTWO WAY Check the EVAP two way valvel See EVAP two way valve test see p a g e1 1 1 5 1 Replace the EVAP two way valve Checkthe EVAPbypasssolenoid 1 Disconnect the vacuumhose from the EVAP two way valve and connecta vacuumpump to the hose 2 Turntheignition switch ON lli 3 Applyvacuumto the hose Checklor a short in th...

Page 355: ...nal No 1 andbodyground Doesvalveholdvacuum Roprir opon in tha wiro batwatan EVAPpu g6 control solcnoid valvc and thc No 15 ALTERNATOR SP SENSOR 7 5Al fu3 Ch6cktor an opon in the wile I2WBSlin6l L TlrrntheignitionswitchOFF 2 Reconnect the 2P connector to the EVAPbypasssolenoid 3 Turntheignition switch ON ll 4 MeasurevoltagebetweenECM connector terminalsA28 and A10 Checkthe following parts lor leaka...

Page 356: ...e v a c u u ms t a b i l i z e s v a l v eo p e n s b e l o w 0 8 k P a 6 m m H g 0 2 i n H g o r a b o v e2 1 k P a 16 mmHg 0 6 in Hg installa newvalveandretest 4 Movethe vacuumoumo hosefrom the vacuumfit ting to the pressurefining and move the vacuum gaugehosefrom the vacuumsideto the pressure sideasshown PRESSURE stoE Slowlypressurize the vaporlinewhilewatchingthe gauge The pressure shouldbesta...

Page 357: ...nsaxle Clutch 12 1 Manual Transmission 13 1 Automatic Transmission 14 1 Differential Manual Transmission B1881 engine 15 1 818C1 engine 15 9 B18C5 engine 15 19 Automatic Transmission 15 27 Driveshafts 16 1 ...

Page 358: ...l lnstallation 12 5 SlaveCylinder Removal lnstallation 12 6 PressurePlate Removal lnspection 12 7 ClutchDisc Removal lnspection 12 a Flywheel FlywheelBearing fnspection 12 9 R e p l a c e m e n t 12 9 Clutch Disc PressurePlate lnstallation 12 10 Release Bearing Removal lnspection 12 11 fnstaffation 12 12 ...

Page 359: ... o 6 aa G 07JAF Pl il701 1A OTLAB PVoO l OOor o7924 PD20003 o7NAF PR30100 o7746 0010100 o77490010000 o7936 3710100 ClutchAlignmentDisc RingGearHolder ClutchAlignmentShatt Attachment 32 x 35 mm Driver Handle 1 1 1 1 l 1 1 2 7 1 2 7 a 9 1 0 1 2 1 A 1 0 1 2 1 0 12 tO 1 2 7 8 1 0 ...

Page 360: ...m 1 5 kgt m 11 tbf tr CLUTCHMASTERCYLINDER Removal lnstallation page 12 5 Adjustment page12 4 19 N m 11 9kgl m 14 tbf ft R LEASEBEARING 15 N m 1 5kgf m 11 lbf fr ICLUTCH PIPE CLUTCHPIPE FLYWHEEL Inspection page 12 9 Replacement page 12 9 JOINT I x 1 25 mm 25 N m 2 6 kgf m 19 tbf frl I TRANSMISSION Removal see CLUTCHDISC Removal lnspection page 12 8 lnstalfation page 12 1O section13 1 2 x 1 0m m 10...

Page 361: ... 5 51 in TOTALCLUTCHPEDAI FREE PLAYI 12 21 mm 0 47 0 83 inl includingtho p6dalplay CLUTCH PEDALHEIGHT 164 mm 16 46inl to the tloor CLUTCH PEDALDISENGAGEMENT HEIGHTI 83 mm 3 27 inl minimumto the floo t 5 Turnthe clutchswitch oradjusring bolt in 3 4 to 1 full turn further TightenlocknutA LoosenlocknutB on the clutch interlockswitch Measure the clearance betweenthefloorboardand clutchpedalwith the cl...

Page 362: ...the clutchpipeandreservoir hosefrom the clutch mastercylinder Removethe clutch mastercylinder NOTE Do not spillbraketluidontheclutch master cylinderdamper CLUTCHPIPE 15 N m 1 5 kgf m 11 lbt Ir 5 cLulcH MASTER CYLINDER Installthe clutchmastercylinderin the reverseor der of removal NOTE Bleed the clutchhydraulic system seepage I z o l cturcH MASTER CYLINDER Pryout the cotterpin and pullthe pedalpino...

Page 363: ...N 08798 Installthe slave cylinderin the reverseorder of removal NOTE Makesurethe bootis installed on the slave wlin lar CLUTCH PIPE 1 5 N m 1 1 5 k g t m 1 1 l b f t t l SLAVECYLINDER 9002t I x 1 25rnm 22 N m 12 2kgl m 16 lbl lt 9 i Brake Assembly Lube Bleedthe clutch hydraulicsystem a Attacha hoseto the bleeder screw andsuspend the hosein a containerot brakefluid a lvlake surethereis an adequate ...

Page 364: ... ADJUSTER BOLT BOLT WASHER To preventwarping unscrewthe pressureplate moi rnting bolts in a crisscrosspattern in several steps then removethe pressure plate FEELER GAUGE CLUTCHALIGNMENT DISC OTJAF_PM7011A 5 6 Inspectthe pressure platesurfacefor wear cracks and burning Inspect the fingersof the diaphragm springfor wear at the releasebearingcontactarea DIAPHRAGM SPRING PRESSURE PLATE Inspectfor warp...

Page 365: ...0003 CLUTCHALIGNMENT SHAFT 07NAF PR30100 HANDLE 07936 3710100 Inspectthe liningof the clutchdiscfor signsof slip pingor oil lf it is burnedblackor oilsoaked replace it Measure the clutchdiscthickness lf thethickness is lessthanthe servicelimit replace the clutchdisc StandardlNew 8 3 9 0mm 10 33 0 35in SorvicaLimit 6 0mm 10 2i inl CLUTCH DISC 3 lf the rivet depth is lessthan the servicelimit reolac...

Page 366: ...inga dialindicator through at leasttwo full turns Push agsinstthe Jlywheeleachtime youturn it to takeup the crank shatt thrust washerclearance NOTE Therunoutcanbameasured with enginein stalled SiEndrrd Ncw 0 05mm 0 002inl max SerYiccLlmh 0 15mm 0 006inl DIALINOICATOR lf the runoutis morethanthe servicelimit reolace the flywheel Turnthe innerraceof the flywheel bearingwith your tinger Thebearing sh...

Page 367: ...LE 07936 3710100 RINGGEARHOI DER 07LAB PV001O0or 07924 PD20003 4 Drivethe new flywheel bearinginto the flywheel us ing the specialtools as shown DRIVER 07749 0010000 FLYWHEEL Alignthe hole in the llywheel with the crankshalt dowelpinandinstallthe flywheel Installthe mount ing bolts fingertight Install the special tool as shown thentorquethe flvwheelmounting boltsin a crisscross patternin severalst...

Page 368: ...he specialtools Recheck thediaphragm springfingers for height see page12 7 CLUTCHHOUSING BELEASE AEAFING RELEASE FORK Remove the release forkfromthe clutchhousingby squeezing the release fork setspringwith pliers Re move the releasebearing Checkthe release bearingfor playby spinningit by hand lf thereis excessive play replace the release bearing with a newone CAUTION The releasebearing is packed w...

Page 369: ...FORKBOLT 29 N m 3 0 kgl m 22 tbt ttl Alignthe detentof the release fork with the release fork bolt then pressthe releasefork overthe release fork bolt NOTE UseonlySuperHighTempUreaGrease P N o8798 9002 Movethe release fork rightandl6ft to makesutethat theforkfits properly against the release bearing 8nd that the releasebearingslidessmoothly 4 lnstallthe releasefork boot 6 P N08794 6 tPlN08798 RELE...

Page 370: ...ork Removal 13 17 Shift Rod Removal 13 18 Shift Fork Assembly Index 13 19 Clearance lnspection 13 20 Mainshaft Assembly fndex 13 21 Clearance fnspection 13 22 Disassembly 13 25 Inspection 13 26 Reassembly 13 21 CountershaftAssembly Index 13 28 Clearance Inspection 13 29 Disassembly 13 30 Inspestion 13 31 Reassembly 13 32 Synchro Sleeve Synchro Hub Inspection 13 34 Installation 13 34 SynchroRing Ge...

Page 371: ...9 0010000 Mainshatt Holder Mainshaft Base Adjustable Bearing Puller 25 40mm Attachment 42 x 47mm Attachment 52x 55mm Driver 40mm l D Attachment 30 mm l D Attachment 35 mm LD Pilot 28mm Driver 1 l 1 1 1 1 I 1 1 1 1 3 4 0 1 3 4 0 13 36 37 13 36 37 13 27 33 1 3 2 7 3 3 13 36 37 O Mustbeusedwithcommercially available 3 8 16SlideHammer a o aJ 3 i0 j r I tll h ll 1 t i l ffi1 Ir IlI xr IJ F ii l l ...

Page 372: ...ldbe replaced at everyoil change Oil Capacity 2 2 i 2 3 US qr 1 9lmp qtl at oil ch nge 2 3t l2 1US qt 2 Olmp qtl at ovorhaul AlwaysusegenuineHondamanualtransmission fluid MTF Usingmotor oil can causa tiffershift ing becauseit does not containthe proper addi Back upLight Switch Replacement NOTE To checkthe back up lightswitch seesection 23 1 Disconnect the connector then removethe back up lightswit...

Page 373: ...take8ir ductandthe aircleanerhous ing assembly AIRCLEANER HOUSING ASSEMBL Disconnect the back uplight switchconnectorand thetransmission groundwire BACK UP LIGHT SWITCH CONNECTOR TRANSMISSION TRANSMISSIO GROUND WIRE HANGEB B 4 Removetne lowei radiator hose clampfrom the transmission hsngerB INTAKEAIR DUCT 13 4 5 Remove thewire hsrness clamps VSSCONNECTOR Disconnectthe starter motor cablesand the v...

Page 374: ...d 10 1 1 6tr SELF LOC1 ING NUT Replace Disconnect the heatedoxygensensor HO2S con nectors then removethe exhaustpipeA and the three way catalyticconverter B 18C1 and B18C5 engines Feplace THREE WAY CATALYNC CONVERTEN lg18C1 lnd 818C5 onginrsl Removethe cotter pins and loosenthe castlenuts then separatethe ball joints from the lower arm seesectiotr l8 LOWER ARM DAMPER CASTLE NUT FORK 13 Removethe r...

Page 375: ...FT DRIVESHAFT Replace trweinnro ora ot 15 Remove the heatshield Bl8c1engine 16 Remove the bolt thendisconnect the extension rod 17 Remove theclipandthe springpin thendisconnect the shiftrod 8 x 2 2 m m SPRING PIN CLIP Replace fl noo fl i l I mm PIN PUNCH 818c1 ngin l 13 6 18 Removethe front Bl8C1 engine and the rear enginestiffeners REARENGINE STIFFENER R e m o v et h e c l u t c h c o v e r 8 1 8...

Page 376: ...ission hangerB 3 Removethe set screws the springs and the steel balls BACK UP LIGHT swrTcH TRANSMISSION HANGER B STEELBALL D 5 16in SETSCREW WASHER Replace Remove the reverse idlergearshaftbolt 1 3 1 0 5 Loosen the transmission housing attaching bolts in a crisscross pattern in several steps then remove them TRANSMISSION Remove the 32mm sealing bolt Expandthe snapring on the countershaft ball bear...

Page 377: ...atefrom thetransmission housing 72 fifi THRUSTSHIM 10 Removethe l6 mm sealingbolt and the oil gutter plate OILGUTT6RPLATE lf the clearance are not within the standard mea surethe width of the groovesin the reverse change holder Standard RevsrseSide 7 05 7 25mm 0 278 0 285in 5th Side 7 4 7 7 mm 0 29 0 30in REVERSE SIDE lf the width of the grooves are not within the standard replace the rsversechang...

Page 378: ...holder Standard 0 5 1 1mm 0 02 0 04in Sorvice Limit 1 8mm 0 07inl 4 lf the clearance is morethanthe servicelimit mea surethe widthof the reverse changeholder Standa d 13 0 13 3mm 0 512 0 524inl lf the width is not within the standard reDlace the reverse changeholderwith a newone lf the width is within the standard reDlace the reverse idlergearwith a newone REVERSE IDLER GEAR REVERSE CHANGEHOLDER R...

Page 379: ...iftpiecewith a newone lf the width of the grooveis within the standard replace the shiftarm holderwith a newone SHIFTPIECE t _ O SHIFTARM HOLDER SHIFTPIECE Measurethe clearance betweenthe selectarm the interlock Standard 0 05 0 25mm 0 002 0 010in Service Limit 0 5mm 0 02 inl and INTERLOCK lf the clearance is morethanthe servicelimit mea surethewidthof the interlock Standard 9 9 10 0mm 10 390 0 394...

Page 380: ... 2 4 4 3 6 6 8 9 0 0 0 1 0mm 0 039 in 2 4 4 3 7 6 8 9 0 0 0 1 2mm 0 047in D 2 4 4 3 8 6 8 9 0 0 0 1 4 mm 0 055 in 24439 689 000 1 6mm 0 063in 73 14 7 Measure the clearance betlveen the shiftarm holder andthechange piece Standard 0 05 0 35mm 0 002 0 014in Service Limit 0 8mm 0 03in lf the clearance is morethanthe servicelimit mea surethe grooveof thechangepiece Stsndard 12 05 12 15 mm 10 1744 0 t78...

Page 381: ...eceandthe interlock 2 Remove thechangeholderassembly and 1 0 lf the clearanceis more than the service limit mea surethe width of the changepiece Standard 12 05 12 15mm 0 4744 0 4783inl CHANGE PIECE lf the width is not within the standard replace the changepiecewith a new one lf the width is within the standard replacethe selectarm with a new one SELECT ARM SHIFTPIECE SHAFT INTERLOCK ...

Page 382: ...attleHolderAssembly Disassembly Reassembly Lrrl al Err rrry nscs srrrrrry rt El Prior to reassembling qeanalltheparts insolvent drythemandapplylubricant to anycontact surfaces f SELECT RETUBN SPRING 13 16 ...

Page 383: ...ft andthecountershaft assemblies springwasherandthe washer differential assembly from the clutch OIFFERENTIAL ASSEMBLY 4 Remove the chamber plate SPRING WASHER 1 Remove the m biieswith the sl NOTE Tapeth the mainshaft a Remove the spr MAINSHAFT COUNTERSHAFT Remove the housr ng CLUTCH HOUSING CLUTCH HOUSING CHAMBER PLATE etsY 2r 5 cyl _ iv 13 17 ...

Page 384: ... bolt and the springwasher 3 Removethe set screw then removethe springand the steelball 4 5 Removethe shift rod then removethe change prece Remove the oil seal CHANGE I PIECE SPRING L 25 6 r 1 01 in STEEL B D 5 16 OILSEAL Replace q SHIFT ROD BOOTS SPRING WASHER SETscrew ATTACHING BOLT ...

Page 385: ...orto reassembling cleanallthe partsin solvent drythem andapplylubricanttoanycontactparts 5 mm PINPUNCH sTH REVERSE SHIFT FORK 3RD rTH SHIFTFORK 1ST 2NDSHIFTFORK SHIFTPIEC ShiftForkAssembly lndex l I t 1 3 1 9 ...

Page 386: ...sis not within the standard replace the shiftfork with a lf the thickness of the shiftfork fingersis within the standard replacethe synchrosleevewith a newone 3 Measure the clearance betweenthe shift pieceand the shiftforkshafts Standard 0 2 0 5mm 0 008 0 02inl Service Limit 0 8mm 0 03 inl SHIFTPIECE It the clearance is morethanthe servicelimit surethe widthof theshiftpiece Standard 11 9 12 0mm 0 ...

Page 387: ...RO RING Inspection page13 35 ANGULAR BALLBEARING Inspecttor weat anooporaron Notethedirection of installation 818C1 nd 818CS ongin In3tallationdot ils p go 13 27 I L SYNCHRO SPRING 3RDGEAR Inspection page13 22 STOP RING TAPEN RING NEEDLE BEARING Inspect for wear anooperaton SPACER SYNCHRO RING Inspecton page 13 35 SYNCHRO SPRING 5TH REVERSE SYNCHRO HUB sTH REVEBSE SYNCHRO SLEEVE SYNCHRO SPRING SYN...

Page 388: ...nl 13 22 Engine Type 8 1 8 C 1 8 1 8 C 5 8 1 8 B 1 Standard 34 92 34 97mm l 375 1 377 in 34 42 34 47mm 1 355 1 357 in Service Limit 34 8mm 1 370 in 34 3mm 1 350 in 2 It the clearance is morethanthe servicelimit mea surethethickness of 3rd gear li the thickness of 3rd gear is lessthan the ser vicelimit replace 3rd gearwith a newone lf the thickness of 3rd gear is within the service limit replace th...

Page 389: ...e 818C1 B l8C5 81881 Standard 31 42 31 47mm 1 237 1 239inl 30 92 30 97mm 11 211 1 2 tg inl Service Limit 31 3mm 11 232 inl 30 8mm 1 2 1 3 i n 5 lf distance is notwithin the standard replace the spacer collarwith a new one lf distance is within the standard measure thethickness of 4thgear lf the thickness of 4th gear is lessthan the ser vicelimit replace 4thgearwith a newone lf the thickness of 4th...

Page 390: ...is within the standard measurethe thickness of sth gear Standard 31 42 31 17mm 1 237 1 239 inl ServiceLimit 31 3mm 1 232 inl 7 lf the clearance is morethanthe servicelimit mea suredistance on thespacer collar Stsndard 26 03 26 08mm 1 025 1 027 in lf the thickness of sth gear is lessthan the ser vicelimit replace 5thgearwith a newone lf the thickness of sth gear is within the service limit replace ...

Page 391: ...N Removeth synchro hubs using a press and the stsel blocks as shown Use ot a jaw type puller cancausedamageto the gearteeth Supportsth gear on steelblocks and pressthe mainshaft out of the sthsynchrohub asshown sTHSYNCHRO HUB sTHGEAR 3 Support3rd gear on steelblocks and pressthe mainshaft out of the3rd 4thsynchrohub asshown ...

Page 392: ...7 99O mm 1 1015 1 1020 inl Se viceLimit A 27 940 mm 11 1000 inl B 37 930 mm 11 4933 inl C 27 930 mm 1 0996 inl 2 Inspect for runout Standard 0 02mm 10 0008 inl max ServiceLimit 0 05mm 0 002inl NOTE Supportthe mainshaftat both ends shown lnspect oil passages forclogging lf the runout is more than the servicelimit reolace the mainshaft with a newone lf any parts of the mainshaftare lessthan the serv...

Page 393: ...ngthe special toolsand a press asshown NOTE Afterinstalling checkthe operation of the 3rd 4thsynchrosleeveand hub 81881engine DR VER 40 mm l D 07746 0030100 AITACHMENT 35mm LD 07746 0030400 3RD 4TH SYNCHRO HUB f 2ND GEAR 818C1and B18C5engines Assemblethe 3rd 4thsyn chro hub and sleevetogetherbeforeinstalling them on the mainshaft 3RD 4TH PRESS SYNCHRO HUB ORIVER 40 mm LO 07746 0030100 Closedend fa...

Page 394: ...ST 2NO SYNCHRO HUB SYNCHRO SPRING DAMPER lST GEAR LOCKNUT Replace r08 0 108N m il1 0 0 11 0kgJ m 180 0 80rbt fi SPRING WASHEB BALLBEARING anooperalron NEEDLE BEARING Inspect for wear anooperaron sTHGEAR 4THGEAR 3RDGEAB 2NOGEAR NEEDLE SEARING Inspectfor wea anoopera on SPACER FRICTION DAMPER NEEDLE BEARING anooperalton COUNTERSHAFT Inspection page13 31 DOUBLE CONE SYNCHRO Bl8Cl snd 818C5ongines Ins...

Page 395: ... THRUSTSHIM Standard 1 945 1 955mm 0 0766 0 0770inl SPACER COLLAR Stand rd 29 07 29 09mm 11 1 4 1 1 15 inl lf the thicknesses of 1stgearandthe thrustshim are lessthan the standard replace them with newones lf the thicknesses of 1stgearandthe thrustshim are within the standard replace the 1sv2ndsyn chrohubwith a newone lf thethicknesses of 2ndgearandthe spacercol lar arelessthanthe standard reDlace...

Page 396: ... spring washer WOODBLOCKS Removethe ball bearingusing a bearing puller as shown BALLBEARING 13 30 4 Remove the bearing outer race then remove the needlebearingusinga bearingpulleras shown NEEDLE BEARING CAUTION Remove the gears using a press and the steel blocks as shown Use oI a iaw type puller can cause damage to the geal teeth Support 4th gear on steel blocks and press the countershaftout of st...

Page 397: ... mm 0 9815 inl B 36 930 mm 1 4539 in C 32 950mm 1 2972 inl Inspectoil passagefor clogg ng lf any partsof the countershaft are lessthanthe servicelimit replace countershaft with a new one ano oamage I 2 Inspect for runout Standardr 0 02mm 0 0008 in max Service Limit 0 05mm 0 002 in NOTE Supportthe countershaft at both ends shown Rotatetwo complete l f t h e r u n o u ti s m o r et h a n t h e s e r...

Page 398: ...springon lst gear Installthe lst 2ndsynchrohub by aligningthe fin gerson the frictiondamperand the groovesin the lst 2ndsynchrohub asshown lST 2ND 13 32 1STGEAR 5 lnstallthe reverse gear Installthe synchrospring and the doublecone synchro 818C1and 818C5engines or synchro ring 81881engine asshown OOUELE CONE SYNCHRO SYNCHRO SPRING REVERSE GEAR 6 Assemblethe frictiondamper the needlebearing and 2nd ...

Page 399: ... 07746 0030100 ATTACHMENT 30 mm I D 077 6 0030300 10 I PRESS 11 Installthe needlebearing then installthe balt bear ing usingthe specialtoolsand a pressas shown DBIVER 40mm LD 07746 0030100 ATTACHMENT 30 mm LD 07746 0030300 t 12 S e c u r e l y c l a m pt h e c o u n t e r s h a f t a s s e m b l y i n a benchvisewith wood blocks Install the springwasher tightenthe locknut then stakethelocknuttab i...

Page 400: ...lf replacement is required alwaysreplace the synchrosleeveandsynchrohubasa set lnstallation Whenassembling the synchrosleeveand synchrohub be sureto matchthe threesetsof longerteeth 120 degrees apart on the synchrosleevewith the threesets of deepergroovesin the synchrohub CAUTION Do not install the synchrosleevewith its longerteeth in the synchrohub slots becauseit will damagethe springring SYNCHR...

Page 401: ...ing on the matchinggear Rotatethe ring makingsurethat it doesnotslip Measurethe clearancebetweenthe synchroring andgearalltheway around NOTE Holdthesynchroringagainst the geareven ly while measuring theclearance SynchroRing to Goar Clearance Standard 0 85 1 10mm 0 033 0 0 Binl Service Limh 0 4mm 0 02in DoubleConeSvnchro to Gea Clgarance Standard r OuterSynchroRingto SynchroConel 0 5 1 0mm 0 02 0 0...

Page 402: ...40mm 07736 A010o0A 2 Remove the oil sealfrom the clutch housing CLUTCH HOUSING 13 36 BALLBEARING 3 Drivethe new oil sealintothe clutchhousingusing thespecialtools asshown ATTACHMENT 2 x o7mm 077ir6 x 10300 OILSEAL Replace Drivethe ball bearingintothe clutchhousingusing the specialtools asshown DRIVER 07749 1U 0 PILOT 28 mm 07746 0041100 ATTACHMENT 52x 55 mm 07 46 0010400 ...

Page 403: ...BLEBEARING PULLER 25 40 mm 07736 3 Position the oil guideplateand new needlebearing in the bore of the clutchhousing then drive in the needlebearingusingthe special toolsasshown NOTE Position the needlebearingwith the oil hole facingup NEEDLE OILHOLE OILGUIDEPLATE CLUTCH HOUSING lnstallthe bearingretainer plateandnewlockwash er thenbendthe tab against the bolthead 8 x 1 0 m m 15N m11 5 kgf m 11lbt...

Page 404: ...3RD 4TH SYNCHRO HUB SPACER COLLAR sTHSYNCHRO HUB MAINSHAFT WASHER BALLBEARING Trythe 1 68mm 0 0661 inI shim 5 Measure distance between the end of the clutch housingand bearinginnerrace NOTE Use a straight edge and depth gauge a Measure at three locationsand averagethe read ings Selectthe prcpe 72 mm thrustshimfrom the chart by usingtheformulabelow NOTE Useonlyone72 mm thrustshim Shim SelectionForm...

Page 405: ...000 1 47 mm 0 0579 in AE 23961 P21 000 L50mm 10 0591 rn 23962 P21 000 1 53mm 0 0602 in AG 23963 P21 000 1 56 mm 0 0614 in AH 23964 P21 000 1 59mm 0 0626 jn 23965 P21 000 1 62mm 0 0638 in 23966 P21 000 1 65mm 0 0650 in AK 2 3 9 6 7 P 2 t 0 0 0 1 68 mm 0 0661 In 23968 P21 000 1 71mm 0 0673 in 23969 P21 000 1 74mm 0 0685 in AN 23970 P21 000 1 77mm 0 0697 in AO 23971 P21 000 l 80mm 0 0709in 1 72mm THR...

Page 406: ...d with a plastic hammer Threadthe mainshaft holderbolt in untilit justcon tactsthewidesurface of the mainshaft base MAINSHAFT f M E ffi f xex I J l l Borrs L LE MAINSHAfi HOLDER 07GAJ PG20110 13 40 Zerca dialgaugeon the endof the mainshaft Turnthe mainshaft holderboltclockwise stopturn ing when the dial gaugehasreachedits maximum movement The readingon the dial gaugeis the amountof mainshaft end p...

Page 407: ...m 3 1kgf m 22tbfitl SHIFTROD 7 Installtheoil chamberplate 7 L 25 6 mfi BOI zt tt o ti t I Y b CI 6 x 1 0 m m 12N m 1 2kgl m 9lbf ft 8 Install thedifferential assembly DIFFERENTIAL ASSEMBLY Position the springwasherandthe washerontothe mainshaft bearing Installthe mainshaft the countershaft andthe shift forkassemblies NOTE Align the fingerof the interlock with rhe groovein theshiftforkshaft MAINSHA...

Page 408: ...hift pieceand the theshiftpieceshaft interlock then install t2 6 x 1 0 m m 12N m 11 2 kg m I lbf ftl 13 42 13 Measure the distance aftermountingthe shift pieceshaft lf it sincorrect checkthe installation Distance 11 9 12 3mm 0 47 0 48inl Installthe reverseidler gear and the reverse gearshaft idler 14 REVERSE IDLER GEAR ...

Page 409: ...t P N 08718 0001 to the threads 16mmSEALING BOLT 29N m13 0 kgt m 22lbf ftl Apply ljquidgasketto the surfaceof the transmis sionhousing asshown NOTE Useliquidgasket P N08718 0001 Remove the dirt andoil from thesealingsurface Sealthe entirecircumterence of the boltholesto preventoil leakage lf 20 minuteshave passedafterapplyingliquid gasket reapplyit and assemble the housings and allow it to cure at...

Page 410: ...f the countershaft bearing TRANSMISSION HOUSING 13 44 23 Checkthat the snap ring is securelyseatedin the grooveof thecountershaft bearing Dimension asinstalled 4 6 8 3mm 0 181 0 327inl 24 Installthe transmission hangerA and back uplight switchclarnp then tightenthe transmission hous i n g a t t a c h i n g b o l t si n t h e n u m b e r e d s e q u e n c e shown below ATTACHING BOLTS I x 1 25mm 27...

Page 411: ...SE GEAR SHAFTBOLT 10x 1 25mm 32 mm SEALING BOLT 44N m 14 5kgtm 33 lbf ftl 13 45 STEELBALI 27 Installthe steel balls the springs and the set scfews lnstallthe back up lightswitchandthetransmission hanger B 8x 1 25 mm BACK UP LlGl T SWITCH 24N mt2 akgt rn 25N m 2 5kgf m 18lbf ftl 17tbf ft 12x 1 0mm 22 N ln 12 2kgl tn 16rbf ftl ...

Page 412: ...draiseit to the enginelevel Install the transmission mountingboltsandthe rear mountbracket bolts SELF LOCKING BOLT 12x 1 25mm 64N m 6 5kgf m 7 lbtftl Replace 1 4 x 1 5m m RELEASE FORK BOOT i l r i i 13 46 6 Raise thetransmission theninstallthetransmission mounr NOTE Torquethe mountingbolt and nutsin the sequence shown CAUTION Checkthat the bushingsare not twisted or offset tz x t zsmm 64N m 6 5 kg...

Page 413: ...1 engin 10 Install the front stifteners 818C1 engine and fear engine REARENGINE STIFFENERS 12x 1 25mm 57 N m 15 8 kg m 42 tbr ltl H f I B o 1 25mm N m 2 4kgf m rbf ftl 12x 1 25 mm 57N m 5 8 2 tbtft 8x 1 25 mm 8 24N m 2 4kgtm 17tbtftl FRONT ENGINE STIFFENERS B18Clengine 12 x 1 25 mn1 57 N m 5 8kgt m 42 tbl ftl 21 1 1 11 Install thestiffener 818C5 engine 8 x 1 25mm 24 N m 2 4kg m 1 tbf ftl 8 x 1 25m...

Page 414: ...m 12 2 kgfm 16lbt ft I e erru 1l PUNCH EXTENSION ROD 6 x 1 0 m m 9 8N m11 0 kgfm rbf ft SHIFTRODBOOT SPRING PIN 1 ffi A W Nfu rry CLlp HOLE 13 48 DRIVESHAFTS 15 lnstallthe intermediateshaft 8nd the driveshafts seesection16 NOTE Beplacethe set ringswith new ones 16 Installthe ball joints onto the lower arm soessc tion 18 17 Install the rightdamperfork seessction18 10r 1 25 mm 43N mlir akgtm 32lbtft...

Page 415: ... 5 5kgt m 40 tbt frl THREE WAY CATALYTIC CONVENTER Bl8Cl and 8 18C5 engincsl 19 Install the enginesplashshield 20 lnstallthe slavecylinder then instsllthe clutchpipe bracket NOTE Useonly SuperHighTemp Urea Grease P N08798 9002 6 x 1 0 m m 9 8N m11 0 kgtm 7 lbI ft SLAVE CYLINDER 8 r 1 25mm 22N m12 2 kotm_ 9 x 21 16tbt ftt Connectthe vehiclespeedsensor VSS connestor andthestanermotorcables Install t...

Page 416: ...TRANSMISSION GROUND WIRE 25 lnstallthe air cleaner intakeduct AIRCIfANER HOUSING ASSEMBLY HANGER B hoqsing assembly and the air 6 x 1 0 m m 9 8N m 11 0 kgf n 7 lbt ft AI8 INTAKEDUCT Y 1 Reiillthetransmission with il seepage13 3 Connect the positive cablefirst thenconnect the negative cableto the battery Check theclutchoperation Shiftthetransmission andche6 or smoothopera tion 30 Checkthe front whe...

Page 417: ... 9 8N m 1 0kgl m 7 lbt ft liAru vll o FTNGS Reptace f REAR JOINT EUSHING I x 1 25mm 22 N m 2 2kgt m 16lbf ft EXTENSION MOUNTING cusHtoN 6 7 EXTENSION END WASHER B MOUNTING COLLAR EXTENSION MOUNTING BRACKET x 1 25mm SHIFTLEVER BALLSEAT g sHrFr LEVER V ousrssflg 3li T lib l 8 x 2 2 m m SPBING PIN Repl6ce I t SHIFTROD 0 ttt REAR JOINT COLLAR SHIFIRODBOOT rM tllL e THRUSTWASHER sHtFrLEVER KNoB 7 8N m ...

Page 418: ...alve Assembly ATF Pump Inspeclton Main Valve Body Disassembly lnspection Reassembly Regulator ValveBody Disassembly lnspection Reassembly Lock upValve Body Disassembly lnspection Reassembly SecondaryValve Body Disassembly lnspection Reassembly ServoBody 1 4 1 2 4 14 126 1 4 1 2 7 1 4 1 2 4 Disassembly lnspection Reassembly 1st holdAccumulator Right SideCover Disassembly lnspection Reassembly Mains...

Page 419: ...sembly Housing Puller ClutchSpringCompressor ClutchSpringCompressor VTPressure Hose 2210mm A TPressure Hose Adapter SCSServiceConnector BackprobeSet A TPressureGaugeSetdpanel Ay T Low PressureGaugew panel Adjustable Bearing Puller 25 40mm Attachment 32x 35 mm Attachment 62x 68 mm Attachment 72x 75 mm Drive 40mm l D Driver DriverAttachment 1 1 I I 1 1 1 l l 11 115 164 14 148 151 14 117 14 148 151 1...

Page 420: ...cControl Thevalvebodiesincludethe mainvalvebody the secondary valvebody the regulator valvebody the serbvobody and the lock up valvebody throughthe respective separator plates Theyareboltedto thetorqueconverter housing The main valve body containsthe manualvalve the 1 2 shift valve the 2 3 shitt valve the Clutch Pressure Control lCPC valve the 4th exhaustvalve the relielvalve and the ATF pump gear...

Page 421: ...eased Reverse reverseselectorengagedwith countershattreversegearand 4th clutch locked All clulchesreleased Generaldriving sta ts o f in 1st shitts automatically to 2nd 3rd then 4th dependingon vehicle speedand throttlepositlon Downshiftsthrough3rd 2nd and 1st on deceleration to stop The lock upmechanismcomesinto operationin in Zna 3rd and 4th gear For rapidacceleration at highwayspeedsand generald...

Page 422: ...I TOROUE ASSEMBLY VEHICLE SPEED SENSOR IVSS VALVE BODIES 1STHOLDCLUTCH 3RD CLUTCH COUNTERSHAFT SPEED SENSOR M A I N S H A F T SPEEDSENSOR 1STCLUTCH I I COUNTERSHAFT 14 5 ...

Page 423: ...ulic pressure throughthe mainshaft by a circuitconnected to the internalhydrauliccircuit 3rd Clutch The3rd clutchengages disengages 3rd gear andis locatedat the endof the counte shaft oppositethe rightsidecover The 3rd clutch is suppliedhydraulicpressureby its ATF feed pipewithin the countershaft 4th Clutch The 4th clutch engages disengages 4th gear as well as reversegear and is locatedat the midd...

Page 424: ...FT COUNTERSHAFT ONE WAYCLUTCH PARKING GEAR COUNTERSHAFT 1STGEAR COUNTERSHAFT REVERSE GEAR REVERSE SELECTOR SELECTOR HUB TOROUE 4TH CLUTCH LOCK UP CLUTCH DRIVEPLATE ATF PUMP COUNTERSHAFT 4TH GEAR DIFFERENTIAL COUNTERSHAFT 2ND GEAR COUNIERSHAFT 3RDGEAR FINALDRIVEN GEAR 3RD CLUTCH 14 7 MAINSHAFT3RDGEAR ...

Page 425: ... X x X x t 1 S T o X o X X X X X X 2ND o X o o x X X X X 3RD o X o X o x X X X 4TH o X o X X o o X x E 1 S T o X O X X x X X X 2 N D o X o o X X X X X 3RD o X o X o X X X X f l o X o o X x X X X tr o o o X X X X X X O Operates Xr Doesn toperate 1r Althoughthe lst clutch engages drivingpower is not transmittedas the one wayclutchslips 2 The one wayclutch engageswhen accelerating and slipswhen decel...

Page 426: ...shaft Position Hydrsulicpressureis not applied10the clutches Poweris not transmittedto the countershaft The countershaftis lockedby the parkingbrakepawl interlocking the parkinggear TOROUE CONVERTEB PARKINGGEAR REVERSE SELECTOR REVERSE GEAR REVERSE SEI ECTOR HUB SERVO VALVE SHIFTFORK SHAFT cont d 14 9 ...

Page 427: ...dto the 1st holdclutchon the sub shaft Powertransmittedto the mainshaft1st gearis conveyedviathe countershaft1stgearto the one wayclutch andviathe sub shaft1stgearto the 1st hold clutch The one wayclutch is usedto drivethe countershaft and the lst holdclutchdrivesthe countershatt via the 4th gears 3 Poweris transmittedto the final drivegear which drivesthe final drivengear SUB SHAFT4TH GEAR 1ST HO...

Page 428: ...ethe application of torqueis reversed 3 The counterforce conveyedto the countershaft4th gearturnsthe sub shaft4th gearvia the mainshaft4th gear At this time sincehydraulic pressure is alsoappliedto the 1st clutch counterforce is alsotransmittedto the main shatt As a esult enginebraking can be obtained with 1stgear CLUTCH SUB SHAFT 4TH GEAR SUB SHAFT 1ST GEAR t TOROUE CONVERTER FINALORIVE SUB SHAFT...

Page 429: ...miftedto the mainshaft2nd gearis convey dviathe countetshaft2nd gear which drivesthe countershaft 3 Poweris transmittedto the tinal drive gear which drivesthe final drivengear NOTE Hydraulicpressure is alsoappliedto the 1st clutch but sincethe rotationspeedof the 2nd gearexceedsthat of lst gear power from 1st gearis cut off at the one wayclutch TOROUECONVERTER 2NDCLUTCH MAINSHAFT FINAL DRIVEGEAR 1...

Page 430: ...clutch which rotatestogetherwith the mainshaft and the mainshaft1st gear rotates 2 Poweris transmittedto the countershaft1st gear which drivesthe countershaftvia the one wayclutch 3 Poweris transmittedto the finaldrive gear which drivesthe final drivengear NOTE In lDr lor lDil position hydraulicpressureis not appliedto the tst hold clutch TOROUE CONVERTER 1ST CLUTCH MAINSHAFT FINALORIVE GEAR COUNT...

Page 431: ...ershaft2nd gear which drivesthe countershaft 3 Poweris transmittedto the final drive gear which drivesthe final drivengear NOTE In or f_fl position 2nd speed hydraulicpressure is alsoappliedto the 1st clutch but sincethe rotationspeed ot 2nd gearexceedsthat of 1st gear power from lst gearis cut off at the one wayclutch TOROUE CONVERTER MAINSHAFT COUNTERSHAFT FINALDRIVEGEAR L 2ND CLUTCH 14 14 FINAL...

Page 432: ...ear 2 Poweris transmittedto the final drive gear which d ivesthe linal drivengear NOTE In or position 3rd speed hydraulicpressure is alsoapplied10the 1st clutch but sincethe rotarronspeed of 3rd gearexceedsthat ot 1st gear power from lst gearis cut ott at the one wayclutch TOROUE CONVERTER MAINSHAFT COUNTERSHAFT cont d 14 15 MAINSHAFT 3RD GEAR 3RDCLUTCH ...

Page 433: ...the countershaft4th gear which drivesthe countershaft 3 Poweris transmittedto the finaldrive gear which drivesthe tinal dtivengear NOTE ln position 4th speed hydraulicpressure is alsoappliedto the lst clutch but sincethe rotationspeedof 4th gearexceedsthat of 1stgear power from 1st gear is cut ofl at the one wayclutch TOROUECONVERTER MAINSHAFT4TH GEAR 4TH CLUTCH MAINSTIAFT COUNTENSHAFT 14 16 L ...

Page 434: ...ar 2 Hydraulicpressure is alsoappliedto the 4th clutch Poweris transmittedfrom the mainshaftreversegearvtarne reverseidlergearto the countershaltreversegear 3 Rotationdirectionof the countershaftreversegear is changedvia the reverseidlergear 4 Poweris transmittedto the final drive gear which drivesthe linal drivengear TOROUE CONVERTER 4TH CLUTCH MAINSHAFT COUNTERSHAFT REVERSE SELECTOR HUB FINAL OR...

Page 435: ...e TcM sensors and four solenoidvalves shifting and lock upare electronically controlledtor comfortabledrivingunderall conditions The TCM is locatedbelow the dashboard behindthe left side kick panelon the driver sside Shilt Control Lock up Control Solenoid ValveA Lock up Control Lock upControl SolenoidValve I I ...

Page 436: ...gnalssentfrom sensors andactuates the shiftcontrolsolenoid valvesA andBcontrolshifting Also a GradeLogicControlSystemhasbeenadoptedto control shiftingin positionwhile the vehicleis ascendingor descending a slope or reducingspeed w u Lock upcondition B Lock upOFF OFF OFF Lock up slight ON OFF Lock up half O N O N Lockup full O N O N LOCK Up during deceleration O N Duty operation OFF ON Shift contro...

Page 437: ...throttlepositionsensor enginecoolanttemperaturesensor barometricpressuresensor bral e switchsignaland shift lever positionsignal to controlshiftingwhile a vehicleis ascendingor descending a slope or reducing speed SIGNALSDETECTED l Driving Resistance Judgement of Controlling Aroa Ascendingmode Fuzzylogicl Gl dual Ascendingmode SteopAscondingmode oescondingmode Gradu l D conding modo Slecp D condin...

Page 438: ...ivingto widenthe 3rdgeardrivingarea This in combinationwith enginebrakingfrom the deceleration lock up achievessmooth drivingwhen the vehicleis descending Therearetwo descending modeswith different3rd geardrivingareasaccording to the magnitude of a gradientstoredin the TCM Whenthe vehiclejs in 4thgear andyou aredecelerating on a gradualhill or whenyou areapplyingthe brakes on a steep hill thetrans...

Page 439: ...SWITCH LOC UPCONTFOL LOCK UPCOIITBOL SOLENOIO VALVE B SHIFICONTROL SOLENOID VALVE A sHrFtc0NtRot SOLENOIDVALVES cT SAFOS S ATCHK ACCt scs LG1 LG1 NMSG NC NCSG vcc2 TPS sG2 ECT BAios s ATCNI ACCt LG1 LG2 2 5 7 I 1 0 1 1 2 3 5 6 7 8 9 l o 1 5 1 6 20 22 23 24 2 5 26 12 l 4 1 7 l g 20 14 22 r ...

Page 440: ...ch is attachedto the engine Fluid lows through the regulatorvalveto maintainspecifiedpressure throughthe mainvalvebodyto the manualvalve directingpressure to eachof the clutches SHIFTCONTROLSOLENOID VALVE ASSEMBLY RIGHTSIDECOVER LOCK UPVALVE BODY SERVO BODY SECONDARY VALVE BODY VALVE BODY REGULATOR V BODY LOCK UP OIL PUMPGEARS SOLENOID VALVE ASSEMBLY TOROUE HOUSING cont d C I r Y 14_23 ...

Page 441: ... body consistsof the regulatorvalve the torqueconvertercheckvalve the coolercheckvalve and the lock upcontrolvalve LOCK UP CONTROL VALVE Lock up Valve Body The lock upvalvebody with the lock upshift valveand lock uptiming B valveis locatedon the regulatorvalvebody LOCK UPSHIFYVALVE TIMI GB VALVE REGUI ATOR VALVE COOLERCHECKVALVE ...

Page 442: ...he illustration below ENGINE NOT RUNNINGI ENGINE RUNNINGI STATORSHAFT Stator Reactior Hydrrulic PrcsrureControl Hydraulicpressureincresse accordingto torque is performed by the regulatorvalve using stator torque reaction The stator shaft is splinedto the stator and its arm end contactsthe regulatorspring cap When the vehicle is acceleratingor climbing TorqueConverterRange statortorque reactionacts...

Page 443: ...pressure goingto the hydrauliccontrolsystem 4TH EXHAUST VALVE 2 3 SHIFTVALVE CPCVALVE RELIEF VAI VE MANUALVALVE MAIN VALVEEODY SecondaryValve Body Thesecondary valvebodyis locatedon the mainvalvebody Thesecondary valvebodyhousesthe 3 2 kick downvalve the 4 3 kick downvalve the 2 3 orificecontrolvalve the orificecontrolvalve the 3 4 shitt valve the modulator valve and the servocontrolvalve ORIFICE ...

Page 444: ...umulator pis tons THROTTLE AccumulatorPistons The accumulator pistonsareassembled in the servobodyand rightsidecover The 1st hold clutchaccumulator pistonis in the rightsidecover andthe 1st 2nd 3rd and4thaccumulator pistonsarein theservobodv lST HOLDACCUMULATOR PISTON lST ACCUMUI ATOR 2ND ACCUMULA 3ROACCUMULATOR PISTON THBOTTLE LONGVALVE RIGHTSIDECOVER 14 27 ...

Page 445: ...rottleValve Throttle B Pressure NO DESCRIPTION OFPRESSURE NO DESCRIPTION OFPR SSURENO DESCRIPTION OFPRESSURE 1 LINE 6C MODULATOR LOCK UP CONTROL SOLENOID VALVE A 55 THROTTLE B LINE 6D MODULATOR LOCK UP CONTROL SOLENOID VALVE B 56 THROTTLE B LINE a LINE THROTTLE B LINE 10 1STCLUTCH 5d THROTTLE B LINE 1 5 1ST HOLD CLUTCH 90 TOROUE CONVERTER 4 LINE lST HOLD CLUTCH 9 1 TOROUE CONVERTER LINE 1 8 LINE 9...

Page 446: ...e regulatorvalveand becomeslinepressure 1 The torque converterinlet pressure 92 enters 94 ol torqueconverterthroughthe oriliceand discharges into 9O The torqueconvertercheckvalvepreventsthe torque converterpressurefrom rising Underthis condition the hydraulicpressureis not appliedto the clutches NOTE When used l ft or right indicatesdirectionon the hydrauliccircuit cont dl 14 29 ...

Page 447: ...utch and 1st holdaccumulator Fluidflows bv wav of LinePressure 4 1 2ShiftValve 2 3 ShittValve 3rd ClutchPressure 31 3 4 ShiftValve 4th Clutch Pressure 41 ManualValve lst hold ClutchPressure 15 lsfhold Clutch The modulatorpressure 6 is suppliedto the 1 2 and 2 3 shift valves The laneDressure 1 alsoflows to the throttlevalve B NOTE When used left or right indicatesdirectionon the hydraulicci cuit 14...

Page 448: ... 1 2and 2 3 shift valves Also line pressure 1 goesto the modulatorvalvethroughthe filler and becomes the modulatorpressure 6 Modulatorpressure 6 is notsupplied to the 1 2 2 3and3 4shiftvalvesbecause the shiftcontrolsolenoid valvesA andB areturnedON bvtheTCM NOTE Whenuse left or right indicates direction on the hydraulic circuit cont d 14 31 ...

Page 449: ...ewill moveasthe enginepoweris transmitted The line pressure 1 becomesthe modulatorpressure 6 by the modulatorvalveand travelsto 1 2and 3 4 shift valves The l 2 shiftvalveis movedto the rightsidebecause the shiftcontrolsolenoid valveA is turnedOFFand B is turnedONby theTCM Thisvalvestops2ndclutchpressure andpoweris nottransmitted to the2ndclutch Linepressure 4 alsoflowsto the servovalveandlinepress...

Page 450: ...result the 1 2shift valve is movedto the left and uncoversthe port leadingto the 2nd clutch the 2nd clutchis engaged Fluidflows by way of Linepressure 4 r 1 2ShiftValvei 2 3ShiftValve zndClutchPressure 21 i 2ndCluch Thehydraulic pressure alsoflowsto the lst clutch However no pow ris transmitted because ofthe one wayclutch NOTE When used Ieft or right indicatesditection on the hydrauliccircuit 14 3...

Page 451: ...covering the port leadingto the 3rd clutch Sincethe 3 4shiftvalveis moved to the rightto voverthe portto the 4thclutch the 3rdclutchis turnedon Fluidflowsby way of Linepressure 4 rj 1 2ShiftValve 2 3ShiftValve 3rdClutchPressure 31 r 3 4ShiftValve notcontrolledl 3rdClutchPressure 30 3rd Clutch The hydraulic pressure alsoflowsto the lst clutch However no poweris transmitted because of the one wayclu...

Page 452: ...4thclutch Sincethel 2 and2 3 shiftvalvesarekepton the leftside the fluidflowsthroughthe 4thclutch the poweris transmitted throughthe 4th clutch Fluidflows byway of Linepressure 4 1 2ShiftValve 2 3ShiftValve 3rdClutchPressure 3 1 t 3 4ShiftValve 4thClutchpressure 41 ManualValve 4thClutchPressure 40 4thClutch The hvdraulicpressure alsoflowsto the 1stclutch However no poweris transmitted because of t...

Page 453: ... 1 2shiftvalveto the servovalveviathe servocon trol valve causing the shiftforkshaftto be movedin the reverse direction Underthis condition the shiftcontrolsolenoidvalveA is turnedON whereasthe valveB is turnedOFFas in 3rd gearin E ot O position As a result the 1 2shiftvalveis alsomovedto the left Thefluid 3 will flow throughtne servovarve andmanualvalveto the 4thclutch poweristransmitted throught...

Page 454: ...oughthe manualvalve Thenlinepressure 3 flows throughthe 1 2shift valveto the servo valvevia the servocontrolvalve causingthe shift fork shaft to be movedto the reversepositionas in position However the hydraulicpressureis not suppliedto the clutches Poweris not transmitted NOTE When used left or right indicatesdirectionon the hydrauliccircuit 14 37 ...

Page 455: ...isto bypass theconverter therebyplacing thevehiclein directdrive t owerlrotl The power flows by way of Engine I Driveplate I Torqueconverter I Lock uppiston I Damperspring I Turbine I Mainshatt 2 Operation clutchotl With the lock upclutchoft the tluidflows in the reverse of clutch on As a result the lock uppistonis movedaway from the convertercover that is the torqueconverterlock upis released tro...

Page 456: ...liedduringdeceleration in 3rd and 4th gear The lock upsystemcontrolsthe rangeof lock upaccording to lock upcontrolsolenoid valvesA and B andthe throttle valveB Whenlock upcontrolsolenoid valvesA and B activate modulatorpressure changes Lock upcontrolsolenoid valvesA and B are mountedon the torqueconverterhousing and are controlledby the TCM LOCK UPCONTROL LOCT UPSHIfT VALVE AlF COOIER tocK uP coNT...

Page 457: ...orkingon both endsof the lock upshift valveareequal the shift valveis movedto the rightsideby the tensionof the valvespringalone Thetluidfrom the ATF pumpwill llow throughthe left sideof the lock upclutchto the torque converter that is the lock upclutch is in OFFcondition NOTE When used left or right indicatesdirectionon the hydrauliccircuit LOCX UPCONTROI LOCK UPCOITTFOT VATVE MOOUTATOR PRESSURE ...

Page 458: ...tionof the lock uptiming B valveis deter minedby the throttleB pressure tensionof the valvespring and pressure regulated by the modulator Alsothe position of the lock up controlvalveis determined by the backprossure of the lock up controlvalveandtorqueconverter pressure regulated by the checkvalve With lock up controlsolenoid valveB keptOFF modulatorpressure is maintained in the left end of the lo...

Page 459: ... pressure is stilllow so lock uptiming B valveis kepton the rightsideby springforce With lock upcontrolsolenoidvalveB turnedON the lock upcontrolvalveis movedsomewhatto the leftside causing backpressure F2 to lower Thisallowsa greateramountof fluid F1 to work on the lock upclutchto engagethe clutch Backpressure F2 whichstillexists prevents the clutchfrom engaging fully NOTE Whenused eft or right i...

Page 460: ...valve Underthis condition throttleB pressure workingon the rightendof the lock up controlvalvebecomes greaterthanthat on the leftend modulator pressure in the leftend hasalreadybeenreleased by the solenoid valveB the lock upcontrol valveis movedto the left As this happens torqueconverter backpressure is fully released causingthe lock upclutchto betullyengaged NOTE When used lelt or right indicates...

Page 461: ...B DutyOperation ONe OFF The TCM switchessolenoidvalveB ON and OFFrapidlyundercertainconditions The slight lock upand half lock up regionsaremaintained so asto lockthetorqueconverter properly NOTE Whenused eft or right indicates direction on the hydraulic circuit tocK uPcol TFoL SOTENOID VALV B IOCK UPCOITTROL VALVE locK uP trMrr GB vAlv I 14 44 I u ...

Page 462: ...ions 4 JJ N 7 v A0t t t AUTOMATICTRANSAXLE IAiTI GEARPOSITIONSWITCH VEHICLE SPEED SENSOR VSSt COUNTERSHAFT SPEED SENSOR MAINSHAFT SPEED SENSOR THROTTLEPOSITIOT TPI e SHIFTCONTROL SOLENOID VALVEA B ASSEMBLY I i l 1445 ...

Page 463: ...RN BLK I GRNI VHT GRN RED GRN GBN BI K GRN 8LU GRN YET LTGRN M HT NoTE I To5v T 1o12v 14 46 GAUGE ASSEMBTY AiTGEAR POSITION INOICATOR Tolzv lGl rRANsMrssroN coNTRoL M DULE rrcMr fu g I f J rrpprlo rlo lru lrrpn tflt ti t lrrezlerer 5V FEGULATOR F GRN BLU l GRN YEL l t TGRN aWHT v ...

Page 464: ...PCONTBOL 135Eil 1o uo u 4i85El o P uo u TCMT6nninal locations TCM B l22P Conn ctor VREF IATCHK IBASOSS IAFSAIAFSB IFAS ISCS T t T I l J l vt l i 1M l L lr t lt t r rr 1 r rartsurssrot coNTFoL M DULE tTcMr l t E l t n r r r t t t t NMSG INC INCSG ISH A ISH B ILC A ILC B 5 7 6 I 1 0 1 1 1 2 5 7 8 I 1 0 1 5 1 6 1 7 1 20 2 5 1 2 1 4 1 1 7 1 9 2 0 1 J TCM A 26P1 Connector 14 47 ...

Page 465: ...Battery voltage A9 ATPD4 A Tgear position switch E positioninput I n E p o s i t i o n 0 V In other than El position Batteryvoltage 4 1 0 ATPPN A Tgear position switch E andE positions input InEorEpositions OV InotherthanE or N position Battery vottage 4 1 1 ATP R A T gear position switch E positioninput lnEposition oV lnother thanE position 8attery voltage 412 t G l Powersupplysystem With ignitio...

Page 466: ...downshift 5 V for an instant B7 AFSA Upshifvdownshiftcomparative srgnal output Withengineidling 0 V At upshiftor downshift 5 V for an instant B8 NCSG Countershaft speedsensorsignal ground Always 0 V B9 NC Countershaft speedsensorsignal Input Depending on vehiclespeed Pulsingsignal Whenvehicleis stopped 0V B 1 0 NM Mainshaft speedsensorsignal input Depending on vehiclespeed Pulsing signal When vehi...

Page 467: ...shtray Turnthe ignitionswitchON ll andobserve the DTCon the screen ofthe OBD ll ScanTool or HondaPGMTester After determiningthe DTC referto the electrical systemSymptom to Component Charton pages14 54 and 14 55 NOTE SeetheOBDllScanToolorHondaPGMTesteruser smanualfor specific instructions OBD IlSCANTOOL or HONDA PGM TESTER SomePGM Fl problemswill alsomakethe lol indicatorlightcomeon After repairing...

Page 468: ...chandobserve the E indicator light Codes1 through9 areindicated by individual shortblinks Codes1Oandaboveare indicated by a seriesof longandshort blinks Onelong blinkequals10shortblinks Add the long and shortblinkstogetherto determine the code Afterdeter miningthecode referto the electrical systemSymptom to Component Charton pages14 S4 and55 F ii r J Se OTCI Soo DTC2 Long blink Short blinb lfive t...

Page 469: ...gitalmultime ler asshown How to uss the Blckprobr Sat Connectthe backprobeadaptersto the st8ckingpatch cords and connectthe cord to a multimeter Using the wire insulation as a guidefor the contoured tip of the backprobe adapter g ntlyslidethe tip intothe connector from the wire untilit comesin contact with theterminalendoJthewire BACKPROBE SET 07sAz 001000A tworequired DIGITAL MULTIMETER lcomm rci...

Page 470: ...eremovingthe fuseso you can resetthem o TheTCMmemorycannotbe clearedby usingthe OBDll ScanToolor HondapGMTester besureto removethe BACK UPfuseto resetthe TCM BACKUP 7 5A FUSE J UNDER HOOD FUSE RELAY BOX FinalProcodurs NOTE Thisprocedure mustbe doneafteranytroubleshooting 1 Turnthe ignitionswitchOFF 2 Resetthe TCM 3 Disconnect the OBDll ScanToolor HondaPGMTesterfrom the DataLinkConnector or removet...

Page 471: ...ected A Tgearpositionswitch connector Openin A f gearpositionswitchwire Faulty A f gearpositionswitch 14 64 P0753 71 Blinks Failsto shift between1st 4th or 2nd 3rdgearonly Failsto shift stuckin 4thgear Disconnected shiftcontrolsolenoid valveA connector Shortor openin shiftcontrolsolenoid valveA wire Faultyshiftcontrolsolenoid valveA 14 66 P0758 8 Blinks Failsto shift stuckin 1stor 4th gears Discon...

Page 472: ...S for the automatic transmission controlsys tem the scantool or testeralso indicates code P0700 simultaneously CodeP0700meansdetectionof some automatic transmission problemon the PGM Fl controlsystem lf theself diagnostic E indicator lightdoesnot blink performan inspection according to thetablebelow NOTE lf a custombrdescribes the symptomfor codeP1706 6 P0725 11 or P0715 15 it will be necessary to...

Page 473: ...th TCM 2 Turntho ignitionswitchON ll 3 Nleasure tho voltage betwson the820andA13or A26tormi nals Raplir opan or 3hort in tha wi a b twa n th B20 t lmin l nd th EcM lsthereapprox 5 V Checktor a Shortto Powa i Measuretho voltag botwoenthe A16andA13or A26terminals Rap fu ahorl to Pow t in tha wlra b tw n th A16t rmln l rnd tho lock up c filtol lolaooid valvo A Moaaurc Lock uP Contlol Sole noid Vrlvo ...

Page 474: ...rol noid YalvaA Mqltura Lock up Control Sol noid Vrlv A R 3i t nc t tha Solonoid Connactor Msasurgth6 resistancebetween terminalNo 2 otthe lock up con trol solonoidconnectorand body grouno Chack for opln In tha wira b tw n th A16 tormin l nd th lock up control ol noid valvaA lsthe resistance12 250 Raplacathc locl up control rola noidYrlv 3lambly TCMCONNECTOR A I26PI WIRESIDEOFFEMALE TENMNALS LOCK ...

Page 475: ...her sistance 12 25A 14 58 u NO OBD ll Scrn Tool indicrt 3 Cod P1758 Self Oiagnosis E indicato light blink3twics MoasuroVREFVohago 1 Disconnect the A 26P and B 22P connectorsfrom the TCM 2 Turnthe ignitionswitchON ll 3 Measuretho voltage between the 820andA13or 426termi nats Rapairopan or lhort in iho wiro batwaan tho 820 terminal and th ECM ls thereapprox 5 V Checkfor a Shon to Powar Measurethe vo...

Page 476: ...noid valvaB Maasuro Lock up Control Sola noid V lvo B Rosist nc6 at the SolonoidConnactor Measure the resistance between terminal No l of the lock uocon trol solenoid connector andbody grouno Chack tor open in tho wir6 botwe n th A15 to minal and tha lock up conlrol aolenoid v lv B lsthe resistance 12 25O Roplace lhe lock upcodrol role noid vrlvo a embly TCMCONNECTOR A I26PI WIRESIDEOFfEMALETERMIN...

Page 477: ...he Malfunction lndi cator Lamp MlL blinks seo soctionl1 Ooesthe OBDll scantool indi catethe anothorcodeor isthe MILblinking Morrur VBEFVohag 1 TurntheignitionswitchOFF 2 Disconnect the A 26P and B 22P connectors trom the TCM 3 Turnthe ignitionswitchON ll 4 Measurethe voltage b6twson the 820andA13or 426termi nats RcpaiJopon or thort in tha wlJa b tt r n lho 840 t rlnlnal md lh ECM ls there approx 5...

Page 478: ...Ch d tho Sp dom t r Op r don Checkthatthe spoedometgr opeF at scorrsctlv R t r io ctlon 23 lor v hlcl p d tlnto IVSSIt rt Ch ck thr VSS Voh g 1 Baise th6car 2 Shift the transmissionto E position 3 Disconn cttho A 26P and B 22P1 conn ctorsfrom the TCM 4 Turnthe ignitionswitchON ll 5 Rotatethe front wheel snd checkfor th6 voltagebotws n the 95 and A 13or 426 termi nals Blockth oth6rwheel so it doesn...

Page 479: ...eATPRVoltage 1 Turntheignition switch ON lli 2 shitt to all positionsother thanE 3 Measure the voltagebetween theA11and413 or 426termi nals Check for short in ihe wire betwe nthe 411 termin l andthe A T gear position switch or A T g6ar position indicator lf wire is OK checktor lo6e TCM connec tors lf necessary substitute a known goodTCMandrech ck ls there battery voltageT MeasureATPPNVolt go 1 S h...

Page 480: ...ha At torminal and tho A T goar position switch or tho A T ge r po ldon indlcltor lf wiro is OK ch ck for looso TCM con noctors lf nocoalary lubctiiuto a known good TCMrnd rech ck M6a urc ATPI Voltagc 1 Shiftto all positionsotherthan tr 2 Measurethe voltag betweon the 46 and Al3 or 426 termi nals Chock for 3holt in the wiro b6two6n tho AOtorminal and tho A T gear po3ition witch or tho A T ger po i...

Page 481: ...O OBDll ScsnTool indicate Code P1706 Self diagnosis E indicator light blinkssix times MeasuroATPRVoltago 1 Turntheignition switch ON ll 2 Shiftto E position 3 Nleasure the voltage between the411and413 or 426termi nals Repairopen in the wire bctwean the A11 te minal and the A T gearposition switch MoasureATPPNVolt ge 1 Shiftto E orE position 2 Measure the voltagebetween the410 andA13or 426termi nal...

Page 482: ...eth voltage b tween the A7 and A13 or A26termi nals Raprir opon in tha wir lratwaan lh A t rminal nd tho A T gear position 3witch Mea3u ATP1 Vohage 1 Shiftto E position 2 Measurethe voltage between the A6 andA13 or A26termi nats Raplir opon in tho wiro bdtw on the A6 tarminal lnd thc A T goal position swhch Ch cklor loora TCM connactoa3 It ncccsa ry sub3titutc 6 known good TCMand roch6ck TCMCONNEC...

Page 483: ...MINALS 14 66 TCMCONNECTOR A 26PI OBDll ScanTool Indicat Code m7 Self Diagnosis E indicator ligln blinb sovontimes Repairopen or 3hort in the wiro betwoon tho 820 terminal 3nd the ECM lsthereapprox 5 V Chocklol a Shortto Power Measurethe voltagebetweenthe 43 andAl3 or 426terminals Repailshort to powgr in the wire belwoon the A3 termin l and th6 shift controlsolonoidvalvoA Measure Shift Contlol Sole...

Page 484: ...ontrol 3olanoid Mearur Shitt Control Sol noid Valv A Re3istsnceat th Sol noid Connactor Measur the rosistancebetween terminal No 1 of the shift control solenoidconnectorand body oround Chcck tor ooen in th6 wir6 betwocnthe A3 tclminll nd tho hift control 3ol6noidvrlvo A lstherosistsnce 12 250 Repl c6 th hltt control 016 noidvalvoaarcmbly TCMCONNECTOR A I26PI WIRESIDEOFFEMALE TERMINALS SHIFTCONTROL...

Page 485: ...ON A 26PI OBDll Scan Tool Indicrt 3 Code m758 sell Diagnosi3 Q indicator light blink3 igl ttlm Moasur VREFVoh go 1 Disconnect the A 26P and B 22P connectorsfrom tho TCM 2 Turnthe ignitionswitchON lll 3 Measurethe voltage between the 820andAl3 or A26termi nals R pair opan or 3hort in thc wira b twrqn th 820 tormin l and th ECM ls thereapprox 5 V Checkfor Short to Powor Measurethe voltagebstweenthe ...

Page 486: ...an lhc A2 tarminal and th6 ihlft control 30lcnoid valvaB M ur Shift Control Sol noid Valv B R rid c rt tha Sol noidConnactor Measurethe resistanc6between terminalNo 3 of th shitt control solenoidconnectorand body ground Ch ck for open in lh wi batwaonth6 42 torminrl rnd tho ahitt controllolanoid valvaB lsthe resistancel2 250 TCMCONNECTON A I26PI WIRESIDEOFFEMALE TERMINALS SHIFTCONTROL SOLENOID CON...

Page 487: ...OBD ll Scrn Tool Indlcat Cod m720 Self diagnosis E indicatol lighl blinksninetim6 lsthe countershaftspeedsen sor installedproperly Moas ra Cour 6Ghaft Sp od Sen 60r R6Btanca gt iha SaGol Con n c tor 1 Disconnect the 2P connector trom the countershafl spgod sensorconnectof 2 Measurethe resistanceol the countershaftspeedsensor ls the rosistance 400 600O CheckCountorrhcft Spe d Son 3ol for r Shon Cir...

Page 488: ...nce betweenthe 88 and gg termi nals Ropairlooto torminsl or opgn in the wires b twoon th6 88 nd 89 torminalsand tho countor3haft spoads nsor ls the resistance 400 6000 Chockfor loo3o TCM connodor lf neceatary substitute a known good TCM and rochock Frompage14 70 TCM CONNECTORB I22P WIRESIDEOFFEMALE TERMINALS 14 71 ...

Page 489: ...oTCM connac or3 t nacaasary substituto a known good TCMrnd r chock OBDll ScsnTool Indicat6 Code P1792 Sett diagno3i3 E indicatol light indicatesCode 10 Chock tor Anothor Codo or MIL Blinking 1 Turnthe ignitionswitchON ll 2 Checkwh ther rhe OBD ll scantool indicates another codeor the Malfunction Indi cator Lamp MlL blinks see section11 DoestheOBDll scantool indi cateanother codeor isthe MILblinkin...

Page 490: ...ndAl3 or 426 termi nals Rapairopan or lhort in tho wira bctwo6ntho AStarminal and tho lgnhion coil lsthere baneryvoltage Chacktor loose TCM connector lf necasllry 3ub3titule a known good TCMsnd recheck Troubleshooting Flowchart lgnitionCoil J U PoaaibleCau3 Di conn c od ignition coil con nactot Short or opcn ignition coil wira Frulty ignition coil WIRESIDEOFFEMAI T TEBMINALS t t t t BRN BLK 14 73 ...

Page 491: ...connector PGsiblecau3 Short ot oDenin LT GRN wite betwoen the 82 lcrminal and ihe ECM Faulty baromotric Prelsure IBAROIignsol NOTE Tho BAFO sensor is builtintotheECM V q J WIRESIDEOFFEMALE TERMINALS MeasureVREFVolttge 1 Turnthe ignitionswitchOFF 2 Disconnect the A 26P and B 22P connectorsfrom the TCM 3 Turntheignition switch ON ll 4 Measurethe voltage between the 820and413 or 426termi nals Repairs...

Page 492: ...for continuitybetweenthe 82terminal ofthe TCMortheC21 terminalot the ECMand body ground Ch ck or loose TCM and ECM connoctots lf n cessary sub3ti tut6 a known good TCM and rochock WIRESIDEOFFEMALE TERMINALS TCMCONNECTOR B 22PI WIRESIDEOFFEMALE TERMINALS 14 75 ...

Page 493: ... B 22P connec tor lrom theTCM 3 Turnthe ignitionswitchON ll 4 Measurethe voltageAg and C9terminals of tho ECMcon nectors lsthereapprox 5 V Chockfor loore TCMconnectoE lf noceilary subrtitula a known goodICM rnd rcchock Repair opon in the FAS wirc b we nthe TCMsndths ECM ElectricalTroubleshooting TroubleshootingFlowchart FASSignal v U PG iblo Cru Short o opon FASwira Feoltv ECM To page14 75 TCMCONN...

Page 494: ... b tweon th c9 torminal of th6 EcM c 3 lP conn6ctoror the 819 torminal of th fcM B l22Pl connoctorand body ground B pllr rhort in th FAS wiro b tw n th TCM nd th ECM Chacktor looaa TCM connactora lf nacaaary aubatltuta I known good TCM nd rach k TCMCONNECTOR B 22P WIRESIDEOFFEMALE TERMINALS ECMCONNECTOR C 31PI WIRESIDEOFFEMALE TERMINALS 14 77 ...

Page 495: ...S 4 OBDll Sc n Tool indicrt6 Codo P0715 self diagnosisEl indicalor light indicatosCode15 Check themainshatt andcounler shaftsoeedsensor installation Arethe mainshaft andcountershalt speedsensorinstalled properly M6asure Mainshtft Spood Son sor Rgsi5tanco at ths SonsolCon nec tor t Disconnect the 3P connector Irom th6 mainshattspeed sensor connedor 2 Measurethe rcsistanceof the mainshaftspeedsensor...

Page 496: ...haftsp6edsen sorconnector 2 Checkfor continujty between theB10terminalandthe No 3 terminal of the mainshatt speedsensorconnector R paiaopon in tha wir bctwoan th 810 t rmin l lnd th m in 3hrft apaadsanaor CheckNMSGWl e Continuity Checkfor continuity b twoenthe B 17 terminalandthe No 1t6rmi nal oI the mainshaftspeeds6n sorconnector Rapairopan in thc wiia batwacn th6 Bl7 t rmin l nd th m ln 3hdt rDa...

Page 497: ...asurethe line pressure see pag614 98 R prir tho hydraulic syltcm n cGsary socpago1 98 lsthelineprsssure withinthe servic limit Repl c6 th6 Lock upControl Solenoid Velva As3ambly nd Rschock 1 Replace the lock upcontrol solenoidvalvey y B assembly seepage 4 87 2 Turn the ignitionswitchOFF and resetthe TCM memory by removingthe BACKUP fuse in the und r hood fuse rolaybox tor more than 10 seconos 3 Us...

Page 498: ...he 1st 2nd 3rd and 4th clutch pressure seepage 14 lseachclutchpressure within theservice limit R p ir lhG hydraulic ry3t m ra nac 3 ry l3 e pago 1 991 Roplace the Shilt Contiol SolonoidValve A B Assombly thon Recheck 1 Turn the ignitionswitchOFF and resetthe TCM memory by removingthe BACKUP fuse in the under hood fuse relaybox for more than 10 seconds 2 Orivethe vehicleat over 12 m p h 2 0k m h i ...

Page 499: ... from tho sgrvicechock connlc tor and rachock lsthe specialtool SCSService Connedor connected to the servicecheckconnector Ch ck tho O IndicatorLight Shiftto E position Chocktor loos TCM conn ctoi3 lf nece3s ry subttitute a known good TCMand r ch ck Doesthe E indicator light comeon Ch ck the GroundCircuit 1 Turnthe ignitionswitchOFF 2 Disconnect the A 126P con nectorfrom the TCM 3 Checklor continu...

Page 500: ...en or short in tho wire betweon the A17 torminal tnd the gaugeas3emblv ll the wire is OK chock tor a faulty Eli indicatorlight bulb or a f ulty gauge assgmbly printgd circuit board Ch ckD INDfor an OpenCircuitr 1 Turnthe ignitionswitchOFF 2 Disconnect the A 26P con nector fromtheTCM 3 Checktor continuitybetween the A17 terminaland the teF minalof the gaugeassembly connector seesection23 Rap ir ope...

Page 501: ... 4 Measurethg voltag bstwegn the A17 t6rminaland body ground Rapalr ahort to powar In tha wiru b tw n th A17 l rmin l lnd tha gaug cr mbly M a3ur ATPD voh g 1 Turnthe ignitionswitchOFF 2 Conn ctth A 26P conn c tor to the TCM 3 Turnth ignitionswitchON ll 4 Shift to any positionother than E position 5 Moasurethe vohag b tween the A9 tormin l and body ground Ch ck tor r rhort to groundin tha wir b tw...

Page 502: ...etwoon thoA24andA13or 426termi nalswith the Ay C compressor OFF Ropairopen in tho wira batwaen th A24 termin l and rhc A C comprclsor clulch ralay ls therc batteryvoltage A C aignalis OK Chgckfor loo3eTCM connoc 1013 lf neces3ary 3ub3tituto d known goodTCMrnd rcchock Inspect tho A C sy tem lso lection 221 J Symp om Lock uDclutch dog3 not have duty opor tion ION OFF Lock upclutch doe3 not ongago TC...

Page 503: ...koswitch circuit soo3 qtion231 ArethebrakelightsON Mea ur6 STOPsw voh ge 1 TurntheignitionswitchOFF 2 Disconnect the A 26P and B 22P connectorslrom the TCM 3 Moasurethe voltage botween the 812andA13or 426termi nals with the brake podal depressed R plir opon in the wire Itstwoon th 8 l2 torminal andbi ke svtidt 8rak6switch signalb OK check lor loose TcM connoc to s lf nsce ary sub3tituts a known go...

Page 504: ...onnectthe No 1 terminalof the lock uD controlsolenoidvalve connectorto the batterypositiveterminal A clicking soundshouldbehea d Connect theNo 2 terminal to the batterypositive terminal A clicking soundshould be heard Replace the lock up controlsolenoid valve assembly if no clicking soundisheard 1 Removethe mountingbolts and lock upcontrol solenoid valveA Bassemblv Checkthe lock upcontrolsolenoidv...

Page 505: ...rd Connect the No 3 terminal to the battery positive terminal A clicking soundshould be heard Replace the shift controlsolenoidvalve assembly if noclicking soundis heard J 1 0mm N m 1 2kgf m 8 7lbf ft UYM 6 x t2 a SOLENOID v SHIFTCONTROL SOLENOID VALV A B ASSEMBLY Replacement Removethe mountingboltsand shift controlsole noidvalvely Bassemblv NOTE Be sureto removeor replacethe shiftcon trol solenoi...

Page 506: ...ssion housing Remove the mainshaft and countershaft speedsen sors Installthe mainshaft andcountershaft speedsensors inthe reverse orderof the removal 6 x 1 0 m m 12N rn11 2 kgtm 8 7tbttrt Transmission Control Module TCM Replacement 1 Removethe two clipssocuringthe kickpanel then removethe oanel 2 Disconnect the connectors andremovetheTCM 6 x 1 0 rnm 12 N m 1 2 kgt m 8 7 tbt ft CONNECTORS ...

Page 507: ... 22 24 31 63 64 C D E H L V Harshupshift 3 4 16 tl 23 28 32 63 64 C D E I L V Harshdownshift 2 1 16 17 21 27 34 63 64 o Harshdownshift 3 2 16 11 22 2A 39 57 63 64 Harshdownshift 4 3 16 17 23 40 56 63 64 C D E I Flares on 2 3upshift 16 17 22 24 25 29 31 E L V Flares on 3 4upshift 16 11 23 25 24 30 32 E L V N Excessive shockon 2 3uDshift 16 11 22 24 29 38 46 64 E L N Excessive shockon 3 4upshift 16 ...

Page 508: ...noid valveA defective t5 Torqueconverter one wavclutchdefective 54 Lock up controlsolenoid valveB defective 1 6 ThrottlevalveB stuck 55 Servocontrolvalvestuck 1 1 Throttlecontrolcableout of adiustment 56 4 3kick downvalvestuck 1 8 1 2shiftvalvestuck 3 2kick down valvestuck 19 2 3 shiftvalvestuck lst holdclutchdefective 20 3 4shiftvalvestuck 59 st accumulator defective 2ndaccumulator defective 60 l...

Page 509: ...nsoalpopsout R8 Variousshiftingproblems R9 R1O Harshupshifts R l l Symptom to GomponentGhart Hydraulic System cont d 14 92 J v 4 J PROBABLE CAUSEDUETO IMPROPER REPAIR R1 lmproperclutch clearance R2 lmpropergearclearance R3 Parkingbrakeleverinstalledupsidedown R4 One way sprag clutch installedupsidedown R5 Reverse selectorhub installeduosidedown R6 ATF pump binding R 7 Torqueconverternot fully seat...

Page 510: ... lf the 1st leed pipe is damagedor out of round replaceit A worn or damagedspragclutchis mostlya resultof shiftingthe transmission in El or LDll position whilethe wheelsrotatein reverse suchasrocking the vehiclein snow P Inspect the trame for collision damage Inspectlor damageand wear 1 Reverse selectorgearteeth chamfers 2 Engagement teeth chamfersof countershaft4th and reversegear 3 Shift fork fo...

Page 511: ...Testdrive the vehicleon a flat road in the position Checkthat the shift pointsoccurat approximatespeedsshown Alsocheck for abnormalnoiseandclutchslippage NOTE Throttlepositionsensorvoltagerepresents thethrottleopening 1 Remove theTCM seepage14 52 2 Setthe digitalmultimeter to checkvoltagebetween84 terminaland A13or A26 terminalfor the throttleposi tion sensor 84 Terminal DIGITAL MULTIMETER Commerc...

Page 512: ...hrottlepositionsensor voltage 1 0V mpn 8 0 10 0 20 0 23 0 km h I J C t O I 32 2 37 O Throttlepositionsensor voltage 2 5V mph 21 0 25 O 38 0 43 0 km h 33 8 40 2 61 2 69 2 Fully opened throttle mph 31 0 36 0 63 0 71 0 km h 49 9 57 9 1 0 1 4 1 1 4 3 Throttle Opening Unit ol spced itth 3 d 3rdr znd 2nd r lst Throttlepositionsensor voltage 0 5V mpn 17 5 20 5 6 0 9 0 3rdr1st km h 24 2 33 0 9 7 14 5 3rd ...

Page 513: ...oiseorclutchslippage 2 Upshifts anddownshifts shouldnotoccurwith the shiftleverin this position E Reverse Position Accelerate from a stopat tullthrottle andcheckfor abnormalnoiseandclutchslippage 6 Testin E Parking Position Parkvehicleon slope app ox 16 applythe parkingbrake and shiftintoE position Release the brake the vehicle shouldnot move Throttle Opening Unit of spoed Lock upcontrol solenoid ...

Page 514: ...e enginespeed 6 Allow two minutesfor cooling then repeatthe test in Dll and oositions NOTE a Stallspeedtests shouldbe usedtor diagnosticpurposesonly Stallspeedshouldbe the same in E tr tr and Fositions Stall SpeedFPM rpm Specification Bl88l ngine2 5q rpm Bl8Cl engine2 i 10 pm SorviceLimit 81881engins2 350 2 650rpm Bl8Ct ongine2 250 2 550rpm TROUBLE PROBABLE CAUSE StallrpmhishinE E I and position L...

Page 515: ...TICK Changing DRAIN 1 8 x 1 5m m 49 N m 15 0kgt m 36 lbf ftl Bringthe transmission up to operating temperature by drivingthe vehicle Parkthe vehicleon level ground turn the engineoff then removedrainplug anddrainthe automatic transmission fluid ATF Reinstall the drainplugwith a new sealingwasher then refillthe transmission with the recommended fluid to the uppermarkon the dipstick Automatic Transm...

Page 516: ...uge 07406 OOTOOOO andthe A T pressure gaugehosesandadap ters shown above 4 Startthe engine andmeasure the respective pres suresas follows a LinePressure a ClutchPressure a ClutchLow HighPressure a ThrottleB Pressure 5 Installa new sealing washerandthe sealingbolt in the inspectionhole and tighten to the specified torque TOROUE 18N m 1 8 kgf m 13lbf ft NOTE Do not reuseold sealingwashers always rep...

Page 517: ... 9 0kgflcm 120 130psi 780kPa 8 0kgflcm 110psi Clutch znocruiltr 1 No or low lsr hold C utch lr 2nd C ltch 2nd Clutch 420 440kPa 14 3 4 9kg cm 61 70psi throttle controldrum tully closed 8 0 880kPa 18 5 9 0kgflcm 120 130psi throttle controldrum more than1 4ooened 400 kPa 4 1kg cm 58psi throttle control drum 780 kPa 8 0kgflcm 110psi throttlecontroldrum morethan 1 4opened 3rd Clulch No or ow I q le 4t...

Page 518: ... to position 5 Slowlymovethethrottlelinkage to increase engine rpm untilpressure is indicated on the A T pressure gauge Thenrelease the throttlelinkage allowingthe en gineto returnto an idle andmeasure the pressure reading 6 Withthe engineidling liftthethrottlecontroldrum up approximately l12 of its possible travelandin creasethe enginerpm until pressure is indicated on the gauge then measure the ...

Page 519: ...ServiceLimit 2ndClutch ior No or low 2ndpressure 2ndClutch 420 880kPa 4 3 9 0kgf cm 61 130psi varieswiththrottle openrng 400kPa 4 1kgflcm 58psi with throttle control drum released 780kPa 8 0kgflcm 110psi withthrottlecontrol drum morethan 1 4 openeo 3rdClutch No or low 3rd pressure 3rdClutch 440 880kPa 4 5 9 0 kgf cm 64 130psi varieswith throttle opening 4thclutch Noor low 4th pressure 4th Clutch 1...

Page 520: ...lly closed throttleB pressure 6 Movethe throttlecontroldrum to fully opened throttleDosition 7 Measure fully opened throttleB pressure THROTTLE B PRESSURE INSPECTION HOLE PRESSURE SHIFTLEVER POStnON SYMPTOM PROBABLE CAUSE FLUIDPRESSURE Standard Service Limit ThrottleB 6ll orJDi Pressure too high Throttle Valve B 0 1 5 k P a O O 1 5 kgl cm 0 2 1 p s i throttlecontroldrum fully closed No or low Thro...

Page 521: ...EANER HOUSING ASSEMBLY Removethe startermotor cablesand cableholder from the startermotor MOTORCABLE CABLEHOLDER STARTER MOTOR STARTERMOTORCABI E 14 104 5 Removethe transmission ground cable from the transmission hanger Disconnect the lock upcontrolsolenoid valvecon nectorandthe shift controlsolenoid valveconnec tor then removethe harnessclampon the lock up controlsolenoidharnessfrom the harnesss1...

Page 522: ...x 1 5m m 49 N m 5 Okgt m 36 lbf fr V 9 Removethe splashshield SPLASHSHIELD 6 x 10 mmBOLT CLIP 5 pcs 10 Remove the cotter pins and castle nuts then separate the balljointsfromthe lowerarm seesec tion 18 11 Remove the rightdamper forkboltanddamperpinch bolt then separaterightdampertork and damper PINCHBOLT SELF LOCKING NUT Replace a COTTERPIN Replace DAMPEBFORK 14 105 ...

Page 523: ... NOTE Coat all precisionfinished surlaces with cleanengine oil Disconnectthe primary heated oxygen sensor HO2S connector Removethe exhaustpipe A 5 t o PRIMARY HEATEO OXYGEN SENSOR HO25l CONNECTOR SELF LOCKING NUT Replace 14 106 J J l 1 8 17 Removethe intermediate shaft Remove the shittcablecover thenremovethe shilt cableby removingthe controllever CAUTION Take care not to bend the shifr cable whil...

Page 524: ...tener and torque converter cover 22 Removethe eight drive plateboltsone at a time while rotating the crankshaft pulley EOLTS ATFCOOLER Replace HOSES ENGINE STIFFENER COVER TRA 14 107 23 Placea jackunderthe transmission raisethetrans missionjust enough to take weight off of the mounts then removethe transmtssion mount TRANSMISSION MOUNT 24 Removethe transmission housingmountingbolts and rearenginem...

Page 525: ...lllustratedlndex Transmission Right SideCover 6A 12J 3 lt 14 108 J ...

Page 526: ... THRUST NEEDLE EEARING NEEDLE EEARING MAINSHAFT 1sTGEAB MAINSHAFT IsTGEAR coLLAR ROLLER coLLAR o R NG Reptace FEED PIPE FLANGE o RtNG Reptace SNAP RING 1sT HoLD cLUTcHFE D ptpE SUB SHAFT LOCKNUT TFLANGE NUT Reptace suB SHAFT CONTCAL SpRtNG WASHER Reptace SUB SHAFT 1sTGEAR LocK WASHER Reptace THRoTTLE coNTRoLDRUM 6 THRoTTLE coNTRoLDRUM SPRING OILSEAL Replace THRoTTLE coNTRoLcAELEBRAGKET sHtFT coNTR...

Page 527: ...lllustratedIndex Transmission Housing u i 14 110 ...

Page 528: ...m NEEDLE B ARING sETRING lsT HoLDcLUTCH ASSEMBLY o RtNGs Reptace THRUST WASHER THRUST NEEDLE BEARING NEEDLE BEARING SUB SHAFT 4TH GEAR OTHRUST NEEDLE BEARING sUB SHAFT 4THGEAR coLLAR SUB SHAFT SUB SHAFT NEEDLE EEARING NEEDLE BEARTNG sToP ATFGUTDE cAp Reptace REVERSE IDLER GEAR sHAFT HoLDER NEEDLE BEARING i sHrFTcoNTRoLsoLENotDvALvE A B sHrFT coNTRoLsoLENotD vALVEFTLTER GASKET Replace TRANSMISSIoN ...

Page 529: ...lllustratedIndex Torque ConverterHousing ValveBody 14 112 I 6A x t ...

Page 530: ...OOLER CHECK VALVESPRING cooLERcHEcKVALVE TOROUESPECIFICATIONS REGULAToR vALvE BoDY sToP SHAFT o RING Reptace 6 STATOR SHAFT ATFFEED PIPE MA NVALVE BOOY cHEcKBALL DowELPrN ATFPUMP DRIVE GEAR ATFPUMP DRIVEN GEAR SHAFT OO ATFPUMP DRIVEN GEAR MA NSEPARAToR PLATE 6 DowELPIN CONTROL SHAFT DETENT ARMSPRING OETENT ARMSHAFT DETENT ARM coUNTERSHAFT ToRoUE coNVERTER HoUSING NEEOLE BEARING ATFGUIDE PLATE ToRo...

Page 531: ...alingwashers RIGHTSIDECOVER GASKET Beplace J mm BOLTS 6 x 1 0 c B MAINSHAFT Replace LOCKNUT RIGHTSIDECOVER CONICAL SPRING WASHER COUNTERSHAFT LOCKNUT SUB SHAFT LOCKNUT Replace CONICAL SPRING WASHER Replace Replace 1ST CLUTCHASSEMBLY PARKINGBRAKELEVER CONICAL WASHER Replace SPRING J _7 SUB SHAFT 1 PARKING GEAR ONE WAYCLUTCH 1STGEAR NEEOLE BEARING 1STGEARCOLLAR SEALING WASHERS Replace JOINTBOLT otPs...

Page 532: ... shatt NOTE a lvlainshaft and countershaftlocknutshave left handthreads a Cleanthe old countershaft locknut it is usedto pressthe parkinggearon the countershaft a Always wear salety glasses CAUTION Keepall of the chiseled paiticlesout of the transmission ll fcH sEL Jl o r o 6 Removethe lock pinthat was installed to holdthe sub shaft 7 Removethe specialtool from the mainshattafter removingthe lockn...

Page 533: ... HOUSING MOUNTINGBOLTS TRANSMISSIONHOUSING TRANSMISSIONHOUSING GASKET Replace REVERSE GEARCOLLAB NEEDLE BEARING REVERSE GEAR MAINSHAFT SU8 ASSEMBLY 14 116 LOCXWASITEF Replace 4 REVERSE SELECTOR COUNTERSHAFT SUB ASSEMELY DIFFERENTIAL ASSEMBLY J ...

Page 534: ...nger Align the springpin of the controlshatr wirh the transmission housinggrooveby turningthe control shatt Installthe specialtoolon the transmission housing then removethe housingas shown TRANSMISSTON HOUSING HOUSING PULLER 5 6 Remove the countershaft reverse gearwith the col lar and needlebearing Removethe lock bolt securingthe shilt fork then removethe fork with the reverseselectorfrom the coun...

Page 535: ...ULATOR COVER ATF FEEO PIPE Bolrs 3 ATF Bott FEED PIPES DOW I PIN LOCK UPSEPARATOR PLATE REGULATOR VALVE EODY SERVODETENT SASE ATF STRAINER LOCK WASHER ATF FEED DOWELPIN ATF PUMPDRIVEN GEARSHAFT ATF PUMP ORIVENGEAR SEPARATOR a ATF FEEDPIPE o ll coNrRoL E Sl AF r ATOR PLATE _ro rr _ ...

Page 536: ...e the eightboltssecuring the lubricator plate and lock upvalvebody then remov th lubricator plate Iock up valvebody andseparator plate 7 Removethe one bolt securingthe regulatorvalve body then removethe regulatorvalvebody 8 Removethe statorshaft and stop shaft 9 Remove the detentspringfromthedetentarm then removethe controlshaftfrom the torqueconverter housrng 1O Removethe detentarm and detentarm ...

Page 537: ...The tip is a springguide Tow6 d outsid ot valvo bodY Tow6rd in3id6ol valvo bodv 14 120 CaDswith hollowendsare installed with the hollow end away from the insideof the valvebody Capswith notchedendsareinstalled with the notch toward the insideot the valvebody Capswith tlat endsanda holethroughthe centerare installed with the smaller holetowardthe inside of the valvebody Toward ouGida ol valvo body ...

Page 538: ...e It shoulddroDto the bottom of the bore underits own weight lf not repeatstep4 then retest lf the valvestill sticks replacethe valvebody InsDect the valvefor anvscuffmarks Usethe ATF soaked 600 paperto polishofl anyburrsthat are onthe valve thenwashthe valvein solventanddrV it with compressed air Rollup halta sheetot ATF soaked paper andinsert it in the valve boreof the stickingvalve Twist the pa...

Page 539: ...capinthevalvebody and securewith the roller VALVE BODY VALVE 14 122 I a Setthespringinthevalveandinstallthem inthevalve oooy Pushthe springin with a screwdriver theninstallthe spnngseat SPRINGSEAT VALVE EODY Install the valve spring and cap in the valve body Push the cap then install the clip ...

Page 540: ...ial Clearance Standald Newl Drive geal O 21O 0 265 mm O O083 O O104in Dfiven geal 0 07O 0 125 mm O O028 O 0049 in ATF PUMP DRIVEN GEAR Groovedand chamfered side facingup ATF PUMP DRIVEGEAR ATF PUMP DRIVEN GEAR Inspectteeth for wear and damage lnspect teethfor wearanddamage 3 Remove the ATF pumpdrivengearshatt andmea surethe thrust clearance oI the ATF pump driven gear to main valvebody ATFpumpDriv...

Page 541: ...Replace valvebody as an assemblyif any psrts 8re worn or damaged a Checkall valvestor free movement It anv fail to slidefreely seeValve Body Repairon page 14 121 CAUTION Do not use a magnet to lemove tho check balls it may magnoliz the balls 2 3 SHIFTVALVE CHECK BALLS 3 14 124 ARM SHAFT DETENT ARM RELIEF VALVE MAIN VALVE BODY Inspectfor wear scratches and sconng Y I ...

Page 542: ... Fro Lsngth No ot Coils o 9 Reliefvalvespring 4th exhaustvalvespring 2 3 shift valvespring CPCvalvespring 1 2 shift valvespring 1 1 O O43 1 0 o o39 o 9 o o35 1 3 0 O51 o 9 o 035 8 6 O 339 7 1 O 280 7 6 O 299 9 4 0 370 8 6 O 339 37 1 1 461 60 3 2 374 57 Ot2 244 35 3 1 390 40 4 1 591 18 5 z o 6 1 4 5 14 125 ...

Page 543: ...ATF a Alignthe holein the regulator springcapwith the holein the valvebody pressthe springcapintothe bodyand tightenthe lock bolt LOCKBOLT 6 x 1 Om m 1 2 N m1 1 2 COOLER CHECK DOWELPINS 2 REGULATOR SPRINGCAP ROLLER REGULATOR VALVE BODY Inspectfor wear scratches and sconng o i i ll W_ VALVE SLEEVE LOCK UP CONTROL VALVE SPRINGSPECIFICATIONS Unitof length mm in No Spring Standard Newl Wiro Dia o D Fr...

Page 544: ...ged o Checkall valvesfor free movement lf any fail to slidefreely seeValve Body Repairon page 14 121 a Coat all partswith ATF beforereassembly LOCK UP SHIFTVALVE LOCK UP TIMINGB VALVE SPRING SPECIFICATIONS Unit of length mm in LOCK UPVALVE No Spring Standard New Wire Dia o D FreeLength No of Coils o r Lock upshift valvespring Lock uptiming B valvespring o 9 o o35 o 8 o o31 7 6 O 299 6 6 O 260 73 7...

Page 545: ...a Checkall valvesfor tree movement lf any fail to slidefreely seeValve Body Repairon page 14 121 a Coat all partswith ATF belorereassembly CAUTION Do not use a magnet to remove the check balls it may magnetizethe balls ORIFICECONTROL VALVE 2 3 ORIFICECONTROL VALVE DOWELPIN 2 a fl a tio 16 FILTER Replace o SECONDARY VALVE BODY Inspectfor wear scratches and sconng 4 SHIFTVALVE i fl J tq fr b VALVE C...

Page 546: ...4 3kick downvalvespring Orifice controlvalvespring 2 3orificecontrol valvespring 3 4shiftvalvespring Servocontrolvalvespring Modulator valvespring 1 3 0 051 1 0 0 039 0 8 0 031 0 9 0 035 0 9 0 03s1 0 9 0 035 1 3 0 051 8 6 0 339 6 6 0 260 6 6 0 260 6 6 0 260 7 6 0 299 6 4 0 252 9 4 0 370 4s 6 1 795 24 511 t221 48 2 1 898 33 0 1 299 52 0 2 0471 34 1 1 343 39 3 1 547 11 0 14 7 14 9 26 8 12 4 14 129 ...

Page 547: ...ll passages a Replace valvebody as an assemblyif any partsare worn or damaged a Coat all partswith ATF beforereassembly a Replace the O rings 9 l l l 1STACCUMULATOR COLLAR O RING Replace 1STACCUMUI ATOR PISTON 4TH ACCUMULATOR PISTON O RING Replace Replace SERVOBODY Inspectfor wear scratches and sconng THROTTLE ADJUSTING BOLT CAUTION Do not loosenor VALVEB a l l l li il 14 130 Replace a ...

Page 548: ...umulator spring 3rd accumulator spring 2nd accumulator spring 0 7 10 028 1 4 0 0 5 5 1 4 O 0 5 5 1 4 0 055 2 6 0 r02 2 5 O 098 2 8 O 1 1 0 3 6 O 1 4 2 6 2 8 5 8 5 8 5 I o _ J I o J 1 7 5 22 O o 244 1o 33 5 10 33 5 1o 33 5 lo 642 lo 6421 10 68 9 lo 866 3 4 0 1 3 3 9 4 1 5 1 6 3 4 4 1 5 1 6 3 4 4 1 6 1 6 3 8 103 3 4 067 105 4 4 150 105 2 l 4 142 1 0 8 9 4 2 8 7 1 0 5 1 1 2 12 4 2 1 2 1 6 8 6 1 9 1 J...

Page 549: ...out all passages a Coat all partswith ATF beforereassembly rl SNAPRING lST HOLD ACCUMULATOR COVER O RING Rephce N1ST HOLD ACCUMULATOR SPRING lST HOLOACCUMULATOR PISTON RIGHTSIDECOVER ra SPRING SPECIFICATIONS O l Unit of length mm in No Spring Standard New Wire Dia o D Free Length No of coils o lst hold accumulator spring 4 O O 1 57 2 1 5 O 8 4 6 71 7t2 a23l L 14 132 ...

Page 550: ...lbl ltl Replace Left hand threads THRUST WASI R 4TH GEAR CONICAL SPRING WASHER Replace 1ST CLUTCH ASSEMBLY O RINGS Replace THRUSTWASHER THRUSTNEEDLE EEARING NEEDLE EEARING 1STGEAB MAINSHAFT Checksplinesfor excessive wear ano oamage Checkbearingsurfacefor scoring scratches and excessive wear NEEDLE BEARINGS THRUSTNEEDI E BEARING 4TH GEARCOLLAR 2ND 4TH CLUTCH BEARING THRUSTNEEDLE BEARING lST GEAR CO...

Page 551: ...ASHER TH GEARCOLLAR 2ND 4TH CLUTCI ASSEMALY THRUSTWASHER 36 5 x 55 mm Selectivepart THRUSTNEEDLE BEARING zND GEAR BEARING THRUSTN EDLE BEARING MAINSHAFT 14 134 3 Torquethe mainshattlocknutto 29 N m 3 O kgf m 22 lbt tt NOTE Mainshaftlocknuthas left handthreads 29 N m 3 0ksl m 22 lbf ftl Hold 2nd gearagainstthe 2nd clutch then meas ure the clearance between2nd gearand 3rd gear with a feelergauge NOT...

Page 552: ...hin tolerance J No Part Number Thickness 1 90441 PG4 010 4 0Omm 0 157 in 2 90442 PG4 OlO 4 05 mm 0 159 in 3 9 0 4 4 3 P G 4 O 1 0 4 1 Om m O 1 6 1 i n 4 90444 PG4 010 4 15 m m O 1 6 3i n 5 90445 PG4 010 4 2 0 m m O 1 6 5 i n 6 90446 PG4 010 4 2 5 m m O 1 6 7 i n 7 9 0 4 4 7 P G 4 0 1 0 4 30 mm O 1 69 in I 90448 PG4 0 10 4 3 5 m m 0 1 7 1 i n 9 90449 PG4 010 4 40 mm 0 173 in 1 0 90450 PG4 000 4 4 5...

Page 553: ...1STGEAR TFANSMISSION HOUSINGBEARING REVERSE GEARCOLLAR LOCKNUT FLANGE NUTI 23 x 1 25mm 1 0 3 0 1 O 3 N m 1 0 5 0 l O 5 k g f m 75 9 0 75 9rbf lrl Replace Left hand threads BEARING REVERSE SELECTOR REVERSE SELECTOR HU8 COUNTERSHAFT Checksplinesfor excessive wear and damage 4TH GEAR NEEDLE EEARING Check bearing surface for scoring scratches and excessive wear DISTANCE COLLAR 28 mm Selective part 2ND...

Page 554: ... not allow th count rshaftto fall rnd hit the ground T T 2 Assemblethe partson the countershaftas shown below NOTE a Lubricateall partswith ATF duringassembly a Before installingthe O rings wrap the shaft splines with tape to prevent damaging the O rings EEDLEEEARIIIG DISTANCECOLLAR 28 mm Selectivopart THRUSTNEEDLEBEARING BEARING GEARCOLLAR TI BUST NEEDLEBEARING WASHER CLUTCHASSEMBLY cont d 14 137...

Page 555: ...h ATF duringassembly 1 Remove the countershaft bearing fromthetransmis sionhousing seepage14 156 2 lnstallthepartsbelowon thecountershaft usingthe specialtool and a pressas described on this page NOTE Do not assemblethe O rings during an spection REVERSE SELECTOR HUB 4TH GEAR BEARING DISTANCE COLLAR 28 mm Selective part 2ND GEAR THRUSTNEEDLE BEARING 3ROGEAR THRUSTNEEDLE BEARING SPLINED WASHER BEAR...

Page 556: ...EABiONE WAY CLUTCH 1ST GEAR ASSEMELY NEEEDLE EEARING lST GEARCOLLAR TRANSMISSION HOUSING BEARING REVERSE GEAR COLLAR COUNTERSHAFT SUB ASSEMBLY Measurethe clearance betweenthe 2nd gearand the 28 mm distancecollarwith a feeleroauoe NOTE Takemeasurements inat leastthreeplaces and usethe averageas the actualclearance STANDARD O 10 O 18 mm O 0O4 O OO7 inl 2ND GEAR FEELER GAUGE DISTANCE COLLAR DISTANCE ...

Page 557: ...ter replacing the distancecollar make surethe clearance is within tolerance No PartNumber width 1 90503 PC9 OOO 39 00 mm 1 535in t 90504 PC9 000 39 10 mm 1 539in 90505 PC9 000 39 20 mm 1 543in 90507 PC9 O00 39 3Omm 1 547in 5 90508 PC9 OOO 39 05 mm 1 537 in 90509 PC9 000 39 15 mm 1 541 in 7 90510 PC9 000 39 25mm 1 545 in I 90511 PCg 000 38 90 mm 1 531in I 90512 PC9 OO0 3 8 9 5m m 1 5 3 3i n 14 140 ...

Page 558: ...CLUTCH COUNTERSHAFT lST GEAR COUNTERSHAFT lST GEAR SCREWDRIYER 14 141 Inspect the parts as follows PARKING GEAR Inspectthe parkinggear for wear and scoring ONE WAY Inspect the one way clutch for damages and faully movement 1STGEAR Inspect countershaft 1stgear Ior wearandscoring 3 Afterthe partsareassembled holdcountershaft l st gearandturntheparking gearinthedirection shown to be sureit turnsfreel...

Page 559: ...ft splineswith tape to preventdamagingthe o rings TRANSMISSION HOUSING TRANSMISSION HOUSING BEARING 1ST HOLO C UTCH ASSEMBLY O RINGS Replace THRUSTWASHER THRUSTNEEDLE BEARING NEEDLE BEARING 4TH GEAR THRUSTNEEDLE AEARING 4TH GEARCOLLAR NEEDLEBEARING 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 lbf tt SUB SHAFT Checksplinesfor excessive wear and oamage Checkbearingsurfacefor scoring scratches and ATF Replace NEE...

Page 560: ...vethe sub shaft Installnew O ringson the sub shaft NOTE Wrapthe shaftsplineswith tapeto prevent damagingthe Orings Place the sub shaft inthe transmission housingand installthe 1st holdclutchassembly Installnew ATFguidecapusingthe specialtools as shown NOTE Installthe ATF guide cap in the direction shown ORIVER TTACHMENT 3 2 x 3 5 m m 07746 O010100 CLUTCH ASSEMBLY 14 143 ...

Page 561: ... the new needle bearing in the transmission housingusingthe specialtoolsand a pressas shown PRESS ATTACHMENT 32 x 35 mm 07746 0010roo Expand the snapringwith snapringpliers then in sertthe ballbearingpart wayinto the housingus ingthe special toolsanda pressasdescribed instep 1 Installthebearing with the groovefacingoutside the housing Release the pliers thenpushthe bearing down into the housing un...

Page 562: ...CH CLUTCHPISTON DISCSPRING CLUTCH DRUM O RINGS Replace RETURN SPRING SPRING RETAINER SNAPRING cLUTcH PLATES Standardthickness 1 6 mm 10 063 inl cont d CLUTCHDISCS Standardthickness 1 94 mm O 076in SNAPRING CLUTCHEND SNAPRING SPRING CHECKVALVE 14 145 ...

Page 563: ...CSPRING CLUTCHOrSCS 1 94 rr m 0 076 inl CLUTCTIPISTON DISC SPBING cont d ENDPLATE I i l CLUTCH PISTON 2NOCLUTCH DRUM O RINGS Replace CHECKVALVE cLuTcH Drscs Slandard thickness 1 9 4 m m 0 0 7 6 i n 4TH CLUTCHDRUM CLUTCHPLATES Si ndard thickness 2 00 mm 0 079 in CLUTCHENDPLATE 14 146 SNAPRING ...

Page 564: ...l ST HOLDCLUTCH SNAPRING CLUTCHENDPLATE cLuTcH Drscs Standardthickness 1 94 mm 0 076 inl SPRINGRETAINER RETURN SPRING DISC SPRING CLUTCHPISTON O RINGS Replace t Standardthicknoss 1 6 mm 10 063in l 14 147 ...

Page 565: ...4 148 3 Installthe specialtools as shown CLU CHSPRING COMPRESSOR BOLTASSEMBLY 07GAE PG O200 ol O GAE PG4I 2OA CI UTCH SPRING COMPRESSOR BOLTASSEMBLY 07GAE PG40200 ot OTGAE PG4O2OA CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE PX40100 CLUTC ISPRING COMPRESSOR ATTACHMENT 07LAE PX0100 ot 07HAE P150100 CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE PX Iq ol 07HAE...

Page 566: ...ontact with the springietainel RETAINER 4 Compressthe returnspring Do not set here RETURNSPRING 14 149 5 Removethe snap ring Then removethe special tools springretainerand returnspring Wrapa shoptowelaroundthe clutchdrum andap ply air pressure to the fluid passage to removethe piston Placea fingertip on the otherendwhileap plyingair pressure COMPRESSED AIR HOSENOZZLE OSHA approved 30 psi CLUTCH SN...

Page 567: ...valve if it s loose replacethe prston NOTE Except 1sr hold clutch CHECKVALVE PISTON 14 150 3 InstalltheDistoninthe clutchdrum Applypressure and rotateto ensureproperseating NOTE Lubricate the pistonO ringwith ATFbefore installing CAUTION Do not pinchtho O ringby installingthe piston with too much force CLUTCHDRUM Installthereturnspringandspringretainer andpo sitionthe snap ring on the retaine CLUT...

Page 568: ... 07LAE PX40100 o1 07HAE PL50100 CLUTCHSPRING COMPRESSOR ATTACHMENT OTLAE PX4OlOO SPRING COMPRESSOR ATTACHMENT 07LAE PX40100 ol 07HAE PL50100 l CAUTION lf either end of th6 compreaso attachment is set over an areaof the springlstainer which is unsuo portedby the retumspring the retainermay b damaged Besu ethe specialtool is adiustedto have full contacr with the springretainer SPECIAL TOOL RETAINER ...

Page 569: ...CLUTCH 14 152 10 Soakthe clutchdiscsthoroughlyin ATF for a mini mum of 30 minutes 11 Startingwith a clutch plate alternatelY installthe clutchDlatesanddiscs Installthe clutchendplate with flat sidetoward the disc NOTE Beforeinstallinq the platesanddiscs make surethe insideof the clutchdrum is ttee of dirt or other loreignmatter CLUTCHENDPLATE Installin this direction 12 Installthe snap ring SCREWD...

Page 570: ...t hold O 65 O 85 mm 0 026 O 033inl O 65 0 85 mm 0 026 0 033 in O 40 0 60 mm O 016 O O24 in O 40 0 60 mm O O16 O O24 in O 5O O 8O mm O O2O O O31 in CLUTCXENOPLATE 14 153 1ST 2ND 3RD and 4TH CLUTCHENDPLATE lST HOLD CLUTCHENDPLATE PlateNo PanNumb r Thickn6ss I 2 3 4 5 6 7 8 I 1 0 22551 P56 N00 22552 P56 N00 22553 P56 N00 22554 P56 N00 22555 P56 N00 22556 P56 N00 22557 P56 N00 22558 P56 N00 22559 P56 ...

Page 571: ...l sealusing the sDecialtools as shown 14 154 2 Drive in the new mainshaft bearing until it bottoms in the housing using the special tools as shown 3 Installthe new oil sealflushwith the housingusing the soecialtools as shown ATTACHMENT 6 2 x 6 8 m m 07746 0010500 ATTACHMENT 7 2 x 7 5 m m 07746 0010600 I ...

Page 572: ...ial lools as shown 3 8 16 SLIDEHAMMER Commercially available ADJUSTAELE BEARING PULLER 25 40 mm 07736 AO1000A 2 3 lnstall the ATF guide plate Drivethe new bearinginto the housingusingthe spe cial tools as shown ATTACHMENT 6 2 x 6 8 m m 07746 0010500 0 0 03 mm l0 0 001 inl a 14 155 ...

Page 573: ...0010500 TFAr SMTSSION T oUSING zs qnH 1b22 PRESS MAINSHAFT BEARING 2 Expandeachsnapringwith snapringpliers insert the new bearing part wayintothe housing usingthe soecialtools anda oressasshown Installthe bear ing with the groovefacingoutsidethe housing NOTE Coat all partswith ATF Release the pliers thenpushthe bearing down into the housinguntilthe ringsnapsin placearoundit DRIVER 07749 0010000 Ma...

Page 574: ... snapringpliers insertthe new bearing pan wayintothe housing usingthespe cialtools anda pressas shown Installthe bearing with the groovefacingoutsidethe housing NOTE Coat all pans with ATF Release the plie s thenpushthe bearing down into the housinguntilthe ringsnapsin placearoundit usingthe specialtools as shown DRIVER 07749 OOlOO00 ATTACHMENT 6 2 x 6 8 m m 07746 0010500 4 GROOVE After installing...

Page 575: ...ol tolerance selectand installthe appropriate parl ing brakestop from the tablebelow 3 PARKING ERAKE PARKING BRAKESTOP Atter replacing the parkingbrakestop makesure the distanceis within tolerance z lvleasuring Mark PartNumber l 24537 PA9 003 1 1 0 0 m m 0 433in 1 1 0 0 m m 0 433in 2 24538 PAg 003 10 80 mm 0 425 in 10 65 mm 0 419 in 3 24539 PA9 003 10 60 mm 0 417 in 10 30 mm 0 406 in 1 Installthe ...

Page 576: ...ATF FEEDPIPES O RING STATOR SHAFT SHAFT t I t U ATF FEED PIPES STOP SHAFT 6 x 1 0 mm Bolts 6 TOR COVER ATF FEEDPIPE VALVESPRINGS TOROUE CONVERTER CHECK VALVE COOLER CHECKVALVE LOCK UP SEPARAT PLATE REGULATOR VALVE BODY 6 x 1 0 mm 8olls 3 LOCKWASHER SERVODETENT BASE ATF STRAINER SUCTIONPIPE COLLAR 6 x 1 0m m Bohs 4 DOWELPINS 2 MAIN VALVE BODY SERVOEODY SEPARATOR VALVE P I N S 2 SEPARATOR 6 x 1 0m m...

Page 577: ...TF feed oipes 14 161 7 Install the servobodyandseparator plate sixbolts 8 Installthe accumulator cover threebolts 9 Installthe servodetentbaseand ATF strainerand new lock washers threebolts 1O Tighten the four boltsto 12 N m 1 2 kgt m 8 7 Ibf ft on the main valvebody Makesurethe ATF pumpdrivegearandATF pump drivengearshaft move smoothly 11 lf the ATF pump drivegear and ATF pump driven gearshaftdo ...

Page 578: ... 49 N m 5 O 36 tbf fr CONNECTOR BRACKET NEEDLEBEARII G REVERSE GEAR MAINSHAFT SHIFTFORK REVERSE SELECTOR SUB ASSEMBLY 14 162 r 42 TOROUECONVERTER HOUSING TRANSMISSION HOUSING MOUNTING BOLTS 18 10 x l 25 mm 44 N m 14 5kgf m 33 lbf ftl TRANSMISSIONHOUSING GASKET BEVERSE GEARCOLLAR LOCKWASHER Replace I ...

Page 579: ...nd the lock tab againstthe bolt head SHIFTFORK 23 Installthe reversegear with the collarand needte bearingon the countershaft 24 Align the springpin of the controlshaft with the transmission housinggrooveby turningthe control shaft 25 Placethe transmission housingon the torquecon verter housingwith a new gasket and the three dowelpins CONTROL TRANSMISSION HOUSING lnstall thetransmission housing mo...

Page 580: ... I i I BRAKE LEVER CONTROL SHAFT 1STCLUTCH COUNTERSHAFT 14 164 32 Installthe old conicalspringwasherand locknuton the countershaft Tightenthe old locknutto seatthe parkinggearto the speciJied torque then remove them NOTE Do not usean impactwrench alwaysusea torque wrenchto tightenthe locknut Countershaft locknuthasleft hand threads TOROUE to3 N m 10 5kgf m 75 9lbl ft PARKING GEAR Install the sub s...

Page 581: ...ainshaftand countershaftlocknutshave left handthreads TOROUE MAINSHAFT 78 N m 8 0kgf m 58 lbf ft COUNTERSHAFT 103N m 10 5kgf m 75 9lbtft SUB SHAFT 93 N m 9 5ksf m 69 lbf ftl MAINSHAFT LOCKNUT Lefthandthreads PIN 8 mm pin commercially 40 Stakeeachlocknutusinga 3 5mm punchasshown LOCKNUT O 7 1 2 mm 0 03 O 05 inl Setthe parkingbrakeleverin the E position then verifythatthe parkingbrakepawlengages the...

Page 582: ... throttlecontrol drum with the drum springon thethrottlecontrolshaft TOROUE 7 8N m 10 8kgf m 5 8lbf ftl Install thetransmission mountbracket TOROUE 49 N m 5 0kgf m 36lbf ft Installthe ATFcoolerlineswith the joint boltsand newsealing washers TOROUE 28 N m 2 9kgf m 21 lbf ft Install theATFdipstick 14 166 ...

Page 583: ... TorqueConverter Drive Plate J J 6 x 1 0m m 12 N m l 2 kgt m 8 7 lbt fil 1 2 x 1 0m m 74 N rn 7 5 kgf m 54 lbf fil Torquein a crisscross pattern 0 00 ORIVEPLATE 14 167 ...

Page 584: ...ssion on a transmission jack and raiseit to the enginelevel 4 Attach the transmission to the engine then install the transmission housingmountingbolts and two rearenginemountingbolts with new washers TRANSMISSION HOUSING MOUNNNGBOLTS 12x 1 25mm 64 N m 6 5 kgf m 47 lbf ftl REARENGINE MOUNT BOLTS 1 4 x 1 5m m 118 N m 112 0kgl m 86 8 rb tr WASHEFS 14 168 5 Installth transmission mount 6 Instsllthe tr...

Page 585: ...m 1 2 kgf m 8 7 tbt fr l0 x 1 25 mm 43 N m 4 4 kgf m 32 lbl ftl 1 0 Tighten the crankshaft torque see section 6 pulley bolt to specified 11 Connectthe ATF cooler hosesto the ATF cooler lines seepage14 174 12 Connectthe throttlecontrolcableto the throtrlecon trol drum andinstalltherightfront mount brackel THROTTLE CONTROL DRUM THROTTLE CONTROL CABLE END ATFCOOLERUNES ATF COOLERHOSES lO x 1 25 mm RI...

Page 586: ... 5 17 Installthe right and lelt drivershafts seesection 16 NOTE Turn the right and le t steering knuckle fully outward and slide the right driveshaft into the differential until you leel its spring clip engage the side gear Slidethe left driveshaft into the intermedi ate shaft until you feel the spring clip of the inter mediate shaft engage the driveshaft 18 Install right damper fork then insrall ...

Page 587: ...he ringterminal is facingout seesection23 6 x 1 0 mm 12 N m 1 2 kgf m 8 7 lbl ft 9 N m 0 9 kgf m 7 lbt ttl STARTERCABLE TERMINAL STARTERCABLE 24 Installthe air cleanerhousingassemblyand intake arroucl AIR CLEANER HOUSING INTAKEAIR ASSEMBLY 2 7 Refillthetransmission with ATF seepage14 98 Connectthe batterypositive and negative cablesto the battery Startthe engine Setthe parking brake andshiftthe tr...

Page 588: ...MOORE J3A O5_A DISCHARGEHOSE 14 172 BUCKET 7 With the water andairvalvesofl atach the water and air suppliesto the flusher Hot water if available 8 Turnon the flusherwater valveso water will flow throughthe ATFcoolerfor 10 seconds lf water does not flow throughthe ATF cooler it is completely plugged cannotbe flushed andmust be replaced 9 Depress the triggerto mixthe flushingfluidintothe water flow...

Page 589: ...rinseafter each use Fillthe can with water and pressurize the can Flushthe discharge lineto ensurethat the unit is clean 2 lf discharge liquiddoesnot foam the orificemaybe blocked 3 To clean disconnect the plumbingfrom the tankat the largecouplingnut 4 Remove the in line filtertromthedischarge sideand cleanif necessary 5 The fluid oriticeis locatedbehindthe filter Cleanit with the pickstoredinthe ...

Page 590: ... Connection Connect theATFcoolerhosesto thejoint linesandATFcooler andsecure themwiththe clipsasshown ClamDthe ATF coolerhoseat the yellow mark as shown JOINTPIPES TRANSMISSION 1 2 ATF COOLER HOSES 3 5 m m i211 14 174 ...

Page 591: ...praceqpropenyrs o ssction 1 1 Removethe centerconsole seesection20 2 Shiftto N position then removethe lockpinfrom the cableadjuster _ l l r_8J ll l i l ll 11 l rr LOCKNUT 7 N m 10 7kgt m 5 lbf fr 3 Removethe shift cablebracket 6 x 1 0mm 12N m 1 2kgt m 8 7 lbf ftl 4 Removethe shitt cableholder 5 Removethe shift cablecover 6 Removethe controlleverfrom the controlshaft then removethe shift cable Tak...

Page 592: ...ignedwiththe holein the shiftcable Cable Too Short NOTE Therearetwo holesintheadjuster Theyare positioned 9Ooapartto allowcableadiustment in 1 4 turn Incremenrs 4 lJtheholeisnotper ectly aligned loosen thelocknut on the adjuster andadiustas required 5 Tighten the locknut to 7 N m 0 7kgf m 5lbf ftl 6 Installthe lockpinontheadiuster lI youfeelthelock pinbindingasVoureinstall it the cableis stillout ...

Page 593: ...or iniuries a Foradditionalprecautions leferto theSRSsub section in section23 9 8 N m 1 0kgl m 7 2 lbl ltl SHIFTLOCK SOLENOID SHIFTLEVER KNOB 5 N m 10 5kgf m 4lbl Irl AUTOMATICTRANSAXLE GEAEPOSITION SWITCH Testing seeSection23 Apply non hardening threadlock sealant f sxrrrrruorcaron PANEL PUSHKNOB 9 8 N m 11 0kgt m 7 2 lbl ftl o r 6 stLrcoNE GREASE _Gl SILICONE GREASE LOCKPINROD 3 N m O 3kgt m 2 t...

Page 594: ... SRSunit the ailbags could accidentally deployand causedamageor iniulies a Foradditionalprecautions leferto theSRSsub section in section23 14 178 1 3 Checkthat the indexmark on the indicatoraligns with the markon the shitt indicatorpanelwhen the transmission is in NEUTRAL lI not aligned removethe centerconsolelseesec tion 20 Loosenthe shift indicatorpanelmountingscrews and adiustby movingthe Panel...

Page 595: ...ing tempera ture the coolingfan comeson 1 Verifythat thethrottlecontrolcableis clampedcor rectlyin three positions CONTROLCABLE LOWER HOSE Clampat the end of bluetapeon the cable Verilythatthe throttlecontroldrumis synchronized with thethrottlelinkage whiledepressing andreleas ing the accelerator pedal ll thethrottlecontroldrumis not synchronized with thethrottlelinkage adjustrhethrottlecontrolcab...

Page 596: ...kthat thereis playin thethrottlecontroldrum while depressing the accelerator pedalto the full throttle position Removethe cableend of the throttlecontrolcable from the throttlecontroldrum Check that the throttle coritrol drum moves smoothly 14 180 ...

Page 597: ...ROTTLE ATF COOLER PIPE LOWER HOSE Clampat the end of bluetape on the cable Verilythat the throttlelinkageis in the fully closed posttron Loosenthe locknutof the throttlecontrolcableat the throttlelinkage CONTROL CABLE LOCKNUTS 14 181 Pushin this directron Removethe free play of the throttlecontrolcable with the locknut whilepushingthe throttlecontrol drum to the tull closed potisionas shown 5 Tigh...

Page 598: ... Differential Manual Transmission 81881 engine 15 1 818C1 engine 15 9 818C5 engine 15 19 Automatic Transmission 15 27 ...

Page 599: ...ngine Special Tools 15 2 Differential lllustrated Index 15 3 Backfash Inspection 15 4 FinalDrivenGearReplacement 15 4 Bearing Replacement 15 5 Oil SealRemoval 15 5 SideClearance Adjustment 15 6 Oil SealInstallation 15 8 t ...

Page 600: ... No Tool Numbei Description otv PageReJerence o 5 al r q oTJAD PH80101 o7746 0030100 o7749 0010000 07947 SD90200 SealDriverAttachment Driver 40 mm LD Driver SealDriverAttachment 1 5 8 1 5 5 6 1 5 8 1 5 8 o t o d F F P 15 2 ...

Page 601: ...d damage Replacement page 15 4 DIFFEBENTIAL CARRIER Inspection page 15 4 BALLBEARING Inspectfor wear and operation Replacement page 15 5 BALLBEARING Inspectfor wear and operation Replacement page 15 5 1 0 x 1 0m m 101 N m 110 3kgt m 74 5 lbt tt Lefahandthreads 80 mm SHIM Selection page15 6 Removal page 15 5 Insrallation page 15 8 15 3 ...

Page 602: ...FinalDriven Gear RePlacement 1 Removethe boltsin a crisscross patternln several steps then removethe linal drivengear trom the differential carrier NOTE The final drivengear bolts have left hand tnreaos 1 0x 1 0m m 101N m 110 3 kgf m 74 5lbf fll Left hand threads FINALDRIVEN GEAR OIFFERENTIAL CARRIER Installthe finaldrivengear by tighteningthe bolts in a crissc osspatternin severalsteps OIALINDICA...

Page 603: ...ailable BALL BEARING 2 lnstallnew ball bearingsusingthe specialtool as shown NOTE Drivethe bearingssquarelyuntil they bot tom againstthe carrier DRIVER 40 mm l D 07746 00301OO BALL BEARING t 2 Removethe differential assembly Removethe 80 mm shim from the transmission housrng 80 mm SHIM TRANSMISSION HOUSING 3 Remove the oil sealfrom the transmission housinq 4 Removethe oil sealfrom the clutch housi...

Page 604: ...allthe 80 mm shimthat was removed mm SHIM 15 6 3 Installthe transmission housing seesection 13 NOTE Donot applyliquidgasketto the matingsur face of the clutch housing Tightenthe transmissionhousingattachingbolts seesectionl3 8 x 1 2 5m m 27 N m 2 8 kgf m 20 lbf ft Usethe specialtool to bottom the differentialassem bly in the clutch housing Measureclearancebetweenthe 80 mm shim and bearingouter rac...

Page 605: ... PL3 BOO 1 6 mm 0 0630in H 41448 PL3 BO0 1 7mm 0 0669 in J 41449 PL3 800 1 8 mm O O7O9 inl K 41450 PL3 BOO 1 OSmm O O41 3 in 4 1 4 5 1 P L 3 B O O 1 15 mm O O453 in M 4 1452 PL3 BO0 1 25 mm 0 0492in N 41453 PL3 800 1 35 mm 0 0532in P 41454 PL3 800 1 45 mm O 0571in o 41455 PL3 BOO 1 5 5m m O 0 6 1 O i n R 41456 PL3 BOO 1 65 mm 0 0650in 41457 PL3 BOO 1 75 mm 0 0689in T 4 1 4 4 1 P 2 1 O O O 1 85 mm ...

Page 606: ...tion 1 lnstallthe oil sealintothe transmission housingus ing the specialtools as shown DRIVER 07749 0010000 OILSEAL Replace HOUSING 15 8 Installthe oil sealintothe clutchhousingusingthe specialtools as shown ORIVER 07749 OO10000 OILSEAL Replace ...

Page 607: ...tial lllustrated Index 15 11 Backfash Inspection 15 12 FinafDrivenGearReplacement 15 12 Tapered RollerBearing Replacement 15 13 OilSealRemoval 15 13 BearingOuter RaceReplacement 15 14 TaperedRollerBearingPreload Adjustment 15 15 Oif SeafInstallation 15 17 ...

Page 608: ...t OTHAJPK402O1 oTJAD PH80101 OTNAD PX4Ol OO 07746 0030100 07749 0010000 o7947 SD90200 PreloadInspection Tool SealDriverAttachment DriverAttachment Driver 40 mm l D Driver SealDriverAttachment t 5 t 5 15 14 t 5 1 4 1 5 1 3 1 5 1 4 1 5 1 7 1 7 1 4 1 1 t ai I ri I f li 1 5 1 0 L ...

Page 609: ...for wear and ooeration Replacement page15 13 BEARING OUTERRACE Inspectfor wear and damage Replacemenl page15 14 1 0 x 1 0m m DIFFERNTIAL CARRIER Inspection page15 12 101 N m 10 3kgf m 74 5 lbf It Le thandthreads TAPERED ROLLER BEARING Inspecttor wear and operation Replacement page 15 13 FINALDRIVEN GEAR Inspect tor wear and damage r Repfacement page 15 12 BEARING OUTERRACE 79 5 mm SHIM Selection p...

Page 610: ...rier FinalDrivenGearReplacement Removethe boltsin a crisscross patternin several steps then removethe tinal drivengearfrom the difterential carrier NOTE The final drivengear bolts have left hand threads 10 x l O mm 101 N m l 10 3kgt m 74 5lbf ft Left hand threads FINAL DBIVENGEAR Chamferon insidediameter of finaldrivengearIacescarrier Installthe final drivengear by tighteningthe bolts in a crisscr...

Page 611: ...ngpreload wheneverthe taperedrollerbearingis replaced a Checkthe taperedrollerbearings for wearandrough rotation lI taperedrollerbearings areOK removalis not necessary 1 Remove the taperedrollerbearings usinga bearing pullerand bearingseparatoras shown BEARING PULLER Commercially available BEARING SEPARATOR Commercially available Installnew taperedrollerbearings usingthe special tool as shown NOTE...

Page 612: ... PH80101 DRIVER 40 mm LD 07746 O030100 3 TRANSMISSION HOUSING Remove the bearing outerraceandthrustshimfrom the clutch housing CLUTCH HOUSING ORIVER ATTACHMENT 07NAD PX40100 ATTACHMENT o7f AD PX40lOO DRIVER o7749 0010000 TRANSMISSION HOUSING BEARING OUTER RACE 79 5 mm SHIM BEARING OUTER RACE THRUSTSHIM T 2 5 mm 10 098inl lnstallthe new thrustshimand79 5 mm shim then drivethe bearingouter racesin t...

Page 613: ...ndrive the bearingouter racein the transmission housing seepage15 14 NOTEI a Installthe bearingouter racesquarely a Checkthat there is no clearancebetweenthe bearing outerrace thrustshimandtransmission housing With the mainshattand countershaftremoved in stallthedillerential assembly andtorquetheclutch housingand transmission housing 8 x 1 2 5m m 27 N m 2 8 kgf m 2O lbf ft NOTE lt is not necessary...

Page 614: ...0 0697 in 41482 PsD 000 1 80 mm 0 0709 in AX 4 1 4 8 3 P 5 D 0 0 0 1 83mm 0 0720 in 8 Recheckthe taperedrollerbearingpreload 9 How to selectthe correct79 5 mm shim 1 Compare thetaperedrollerbearing preload you get with the 79 5 mm shimthat was removed with the soecifiedmeanDreload of 2 50 N m 25 5 kgf cm 22 lbf in 2l ll vourmeasured taperedrollerbearing preload is lessthanspecified subtractyour sf...

Page 615: ...ransmission housingus ing the specialtools as shown Installthenew oilsealintothe clutchhousingusing the soecialtools as shown DR vEN o7749 0010000 DRIVER 07749 OOIOOOO OIL SEAL Replace OILSEAL Replace HOUSING SealInstallation 15 17 ...

Page 616: ...ferential 818C5 engine SpecialTools 15 20 LimitedSlipDifferential Description 15 21 OperationalGheck 15 23 Rotating Torque Gheck 15 23 lffustrated Index 15 24 Tapered RollerBearingPreload Adjustment 15 25 ...

Page 617: ...Special Tools j l II 1I I o 15 20 ...

Page 618: ...tial carrierwheneitherwheelslips 2 Construction The unit consistsof the two sidegears four shortpiniongears four long piniongears two thrustwashers a center washer and a carrierthat housesthe gearsandwashers Oneshon and one long piniongearare in meshwith each otherandareallowedto walkaroundthe sideoears w I I I a e Differentiatcarrier a Thrustwasher Leftsidegear O Center washer g Rightsidegear O P...

Page 619: ...ckwise direction Thisallowsthe outerwheelto turn moretimesthanthe innerwheelwhenthevehiclegoesarounda turn PINIONGEAR ILONG Whenlimitingdifferential action Thelimitedslipdifferential actsto limitthe differential actionwheneitherwheelslipson iceor snowor on turn This is doneby usingthefrictioncreated between eachgearanddifferential carrier 1 Thepinionsareforcedagainst thedifferential carrierby thef...

Page 620: ...gbrakeandblockthe rearwheels Raisethe front of the vehicle and supportit with safetystandsin properlocations seesection1 With the engineoff shift the transmission into Neutral Measurethe rotatingtorque with a beam type torquo wrench in the directionshown Rotatethe torquewrenchmorg than two completeturns and takethe maximumreading Shift the transmissioninto 1st gear and measure the rotating torquea...

Page 621: ...T 2 5mm 0 098 in TAPERED ROLLER BEARING lnsoectfor wear and ooeration Replacement page15 13 BEARING OUTERRACE Inspect forwearanddamage Replacement page15 14 10x 1 0mm 101 ln 10 3kof m 7a 5lbf ftl Left hand threads FINALDRIVEN GEAB Inspect forw6aranddamag9 Replacement pagel5 12 TAPERED ROLLER BEARING InsDect forw arandoo ration Replacement page 15 13 TBEARING OUTEBRACE Inspectlor wear and damage Re...

Page 622: ...one 79 5mm shim in the transmission housing then drive in the bear Ingour rrace Nototheseitemsduringrassembly Install the bearingouterracesquarely Checkthat there is no clearancebetweenthe bearingouter race shims and transmission housing With the mainshattand countershaftremoved installthedifferential assemblv Assemble theclutch housingandtransmission housingwithouta sealing a9ent andtorquethecase...

Page 623: ...685 in 41481 PsD 000 1 77mm 0 0697 in 4 1 4 8 2 P 5 D 0 0 0 1 80 mm 0 0709 in AX 41483 P5D 000 1 83 mm 0 0720 in 15 26 8 Howto select thecorrect79 5mm shim 1 Compare thetaperedrollerbearingpreload you get with the 79 5mm shim that was removed with the sDecified preloadof 2 50N m 25 5 kgf cm 22lbf in 2 lf vour measured taperedrollerbearingpreload is lessthan specified subtractyour sfrom the sDecifi...

Page 624: ...on Speciaf Tools 15 2A Differential AutomaticTransmissionl lllustratedIndex 15 29 Backlash Inspection 15 30 Bearing Rep acement I 5 30 Differential CarrierReplacement l5 31 OilSealRemoval 15 32 Oil SealInstallation SideG earance 15 32 ...

Page 625: ...mbel Description Oty I Pag6Retolence o 9 oTJAD PH80200 oTNAD P200100 o7746 0030100 o7749 0010000 o7947 SD90200 Pilot 26 x 30 mm Driver 52 x 55 mm Driver 40 mml D Driver Driver Attachment 1 I 1 1 l r5 34 15 34 15 30 32 33 15 34 15 34 o b_ ...

Page 626: ...Differential AutomaticTransmission lllustratedIndex FINAL DRIVEI GEAR BALLBEARIiIG tot ENTIAL caRRlER R O L L E R 5 x l O m m BALL BEARING 15 29 ...

Page 627: ...in 3 lf the backlashis not within the standard reDlace the differential carrier 15 30 I BearingReplacement NOTE Checkthe bearings for wearandroughrotation lf the bearingsare OK removalis not necessary 1 Removethe ball bearingsusinga bearingpuller Installthe new ballbearingsusingthe specialtool with a pressas shown SIDEGEARS EEABINGPULLER CommerciallY available DRIVER 40 mm l O 07746 0030100 ...

Page 628: ...edometer drivegearwith the 5 x 1Omm ro er SPEEDOMETER DRIVE GEAR Install in this direction Cutout ROLLER 5 x 1 0 m m 5 Alignthe hookedendot the snapringwith the pin ionshaftas shown then installthe snapringin the dilJerential carriergroove Hooked end SNAP RING Installin this direction 6 Installthe final drivengear then tightenthe bolts to the specifiedtorque TOROUE 103 N m 10 5 kgt m 76 lbl ttl NO...

Page 629: ... 50 mm O O98 in thrustshiminthetrans missionhousing NOTE Do not installthe oil sealyet TRANSMISSION HOUStf G Install the differential assembly intothe torquecon verterhousingusingthe specialtool as shown DRIVER 40 mm l D 07746 0030100 DIFFERENTIAL ASSEMBLY 1 TOROUECONVERTER HOUSING Assemblethe transmission lseesection 141 Installthe transmission housing andtightenthebolts seesection 14 TOROUE CONV...

Page 630: ...STSHIM 80 mm NOTE Il the thrustshim to ball bearing outerrace clearance measured instep5 iswithinthe standard it is not necessary to performsteps 7 and 8 Removethe transmission housing Replace the 2 50 mm 0 098 in thrust shim with the oneof the correctthicknessselectedin step6 Installthe transmission housing seesectjon 14 7 L Part Number Thickness 904r4 689 000 90415 689 000 90416 689 000 90417 68...

Page 631: ... Clearance cont d 9 lnstallthe oil sealllushwith the transmission hous ing usingthe specialtools as shown ATTACHMENT o7947 SD90200 1 0 PILOT 2 6 x 3 0 m m oTJAO PHA0200 Installthe oil sealllush with the torqueconverter housingusingthe specialtools as shown 15 34 ...

Page 632: ... ...

Page 633: ...0200 07746 0010300 07746 0010400 07746 0030400 07749 00r0000 07965 SD90100 SupportBaseAttachment Attachment 40 x 50 mm l D BallJointRemover 28 mm Attachment 42x 47mm Attachment 52x 55mm Attachment 35 mm l D Driver SupportBase 1 1 1 1 1 1 I 16 16 16 18 16 4 t o t o 16 17 18 t6 17 16 16 17 18 16 16 o 6i o 6 2 ...

Page 634: ...acked Replaceit if necessary BOOT BANDS 1 Loosen thewheelnutsslightly Raisethe front of ca and support it with safety standsin the prope locations seesection1 Remove thewheelnutsandfrontwheels 5 Drainthe transmission oil or fluid seesection13or 14t NOTE lt is not necessary to drainthe transmission oil or fluidwhenthe leftdriveshaft is removed R a i s et h e l o c k i n gt a b o n t h e s p i n d l...

Page 635: ... apply penetratingtype lubri cantto loosenthe balljoint Prythe driveshaftassemblywith a screwdriver as shown to force the set ring at the driveshaftend pastthe groove Be carefulnot to damagethe oil sealswhenpryingwiththe screwdriver 12 Pullthe inboardjoint and removethe right drive shaftfrom the differential caseasan assemblv CAUTION Do not pull on the driveshaft as lhe inbosrd ioint may come 8p8r...

Page 636: ...a visewith softjaws thenremovethe setringfrom the inboardjoint Remove the boot bandson the inboardioint and outboardjoint CAUTION Takecarenot to damagsth boot lf the boot bandis a weldedtypeor a low profile type boot band carefully cut it off with a pairof diagonal cutters 2 lf the bootbandis a doubleloopbandtype raise the bandbendasshown OOUBI E LOOPBAND Replace cont d 16 5 ...

Page 637: ...ks Marla 4 Markthe rollersand spiderto identifythe locations of rollerson the spider thenremovethe rollers VI YLT BEARING REMOVER Commercially available 5 Remove the circlip 6 Markthe spiderand driveshaft to identifythe posi tion of the soideron the shaft 7 Remove the spiderusinga bearingremover 8 Wrapthe splineson the driveshaft with vinyltapeto preventdamageto the boots APE ouTBoaRDBOOT Insp ct ...

Page 638: ...1 1 Inspect the outboardioint for faultymovementand wear lf any roughness or excessplayisfelt replace the outboardjoint 16 7 ...

Page 639: ...et Greasequantity lnboardJoint Alf models 120 130g l1 2 1 6ozl OutboardJoint USAmodel 90 100S 13 2 3 5oz Canada model 105 115g 3 7 4 1ozl The Canadamodelusesa TPE Thermoplastic Polyester Elastomer outboardjoint boot Usethe ear clamptype boot bandin theoutboardjoint bootset SETRING Replace INBOARD BOOT 1 Packcavitywith grease Packcavitywith grease OUTEOARD BOOT with grease OOUBLE LOOPBANDS Replace ...

Page 640: ...y USAmodel 90 100g 3 2 3 5oz Canada model 105 115g 3 7 41oz I 5 Installthe spideron the driveshaftby aligningthe markson the spiderandendof the driveshaft Fitthe circlipintothedriveshaft groove NOTE Alwaysrotatethe circlipin its grooveto be sureit isfullyseated c nc t SPIDEB 6 Fitthe rollersto the spiderwith theirhighshoulders facingoutward Notetheseitemsduringreassembly Reinstall the rollersin th...

Page 641: ... DRIVESHAFT 1 6 1 0 8 9 Fit the joint boot ends onto the driveshaftand Jornts W h e n i n s t a l l i n gt h e o u t b o a r dj o i n t b o o t o n a Canada model be surethe endof the bootis seated inthe groovesof the driveshaft andoutboardioint Adjustthe lengthof the driveshafts to the specifica tions below then adjust the boots to halfway between full compression andfull extension NOTE The endso...

Page 642: ...le loop band onto the boot with the bandendtowardthefrontof thevehicle L X P BANO DOUBI f Pullup the slackin bandby hand Makea markonthe band10 14mm 0 4 0 6 in from the clip Threadthe free end ot the bandthroughthe nosesectionof the commercially available boot bandtool KD 3191 or equivalent and intothe sloton thewindingmandrel Placea wrenchon the winding mandrelof the boot bandtool and tightenthe ...

Page 643: ...enfold overthe remaining tail ontotheclio 7 Unwindthe boot bandingtool and cut off the excessfree end of the bandto leavea 5 10 mm 0 2 0 4in tail protruding from the elip HAMMER 5 10mm 0 2 0 ainl 16 12 8 Bendthe bandend by tappingit down with a nammer NOTE Makesurethe banddoesnot move Removeany greaseremainingin the surround ingsurfaces ...

Page 644: ...dwith a com mercially available bootbandpincers BOOTAANDPINCERS Commercially available Oetiker 1098 or equivalent POSTION Measurethe clearance betweenthe closedear portionof the band Siandard 0 3mm 0 0 12in lf the band s clearance is not within the standard closethe earportionof the bandfurther NOTE Makesurethe banddoesnot move Removeany greaseremainingin the surround ingsurfaces 1 6 1 3 ...

Page 645: ...me diateshaftgroove KNUCKLE OUTBOARD JOINT 16 14 4 lnsenthe inboardend of the driveshaft intothe dif ferentialor intermediate shaft until the set rino locksin the groove INEOARD JOINT INBOARD JOINT Replace lnstallthe damoerfork overthe driveshaft andonto the lowerarm Installthe damperin the damper fork so the aligningtab is alignedwith the slot in the damoerfork ALIGNINGTAB 6 Looselyinstallthe fla...

Page 646: ...whh tho pin hols Do not align the nut by loosening __coTTEF PtN CASTLE NUT 12x 1 25mm 49 59N m 5 0 5 0kgf m 36 t3 lbl ft Beplace On reassembly bendthecotterpin 8 Install a newspindlenut thentightenthe nut 9 Installthefrontwheelwith thewheelnuts NOTE Beforeinstalling thewheel cleanthe mating surfaces of the brakediscandthewheel FRONT WHEEL WH EL NUT12x 1 5mm 108N m 11 0 kgtm 80lbf ft 10 NUT22x 1 5 ...

Page 647: ...on Remove theexternal circlip Press the intermediate shaftout of the shaftbearing usingthe special toolsanda press 6 Press the intermediate shaftbearingout of the bear ingsupportusingthe specialtools anda press Pross I DnrvER t 07749 0010000 ATIACHMENT il2 x 47 mm 07746 0010300 FLOATING SUBBER DAMPER Check for deterioration anooamage l lol I SEARING SUPPORT Check for damage SUPPORT BASE ATTACHMENT...

Page 648: ...bf ft EXTERNALCIRCLTP INTERMEDIATE SHAFTRING Pack the interior of theouterseal 2 0 3 5s 0 07 0 12oz INTERNAL CIRCLIP INTERMEDIATE SHAFTBEARING Replace BEARING SUPPORT L Pressthe intermediate shaftbearinginto the bear ingsupponusingthe special toolsanda press 2 Seatthe internalcirclipin the grooveof the bearing support Pressthe intermediate shaft into the shaft bearing usingthe special toolsanda pr...

Page 649: ...ols NOTE Installthe sealflush with the bearingsup pon lnstallation 1 Insertthe intermediate shaftassemblyinto the dif ferential CAUTTON Hold the interm diate shaft horizontal to prev ntdamageto the diff6rentialoil soal 2 Installthe threedowelbolts thentightenthem ATTACHMENT 40x q mm l D 07LAD PW50601 DOWEL AOLTS 10 x 1 25mm 39N m 4 0kgf m 29lbtftl new ser nng in the intermediateshaft INTERMEDIATE ...

Page 650: ...e contentspage include or are locatednear SRScomponents Servicing dissssembling or replacing theseitemswill requirespecialpr6cautions andtools andshouldtherefore bedoneby an authorized Acuradealer To avoid rondoringths SRSinoparstivo which could rad to parsonaliniury or doath in the ov nt of sev6 o trontal collision all SRSsarvicework must be perto med by an authorizodAcuradsalor lmpropor 3orvic p...

Page 651: ...SealRingGuide PistonSealRingSizingTool BeltTensionGauge BallJointRemover 28 mm BallJointBootClipGuide Attachment 23x 25 mm ValveSealRingSizingTool P SJointAdapter Pump P SJointAdapter Hose P SPressure Gauge Pressure ControlValve Pressure Gauge Universal Holder Attachment 32x 35 mm Driver Locknut Wrench 40mm FrontHubDis Assembly Tool Cylinder EndSealSlider SleeveSealRingSizing Tool I 1 1 1 1 1 l I ...

Page 652: ...ndadjustif necessary POWER STEERING GEARBOX RackGuid Adjustment page17 21 Removal pago17 4 1 Disassembly page17 44 Reassombly page 17 49 Installation page17 58 STEEBING COLUMN Removal page17 28 Inspection pago 17 30 Installation page 17 3 1 GNMON SWITCH Seesection23 POWER STEERING PUMP PumpBeltInspection page17 20 PumpBeltAdjustment page17 20 PumpPr ssuro Check page17 22 Roplacament page17 35 Dis6...

Page 653: ...alvebuiltintothe pump Thefluid pressure from the pumpis delivered to thevalvebodyunitaroundthe pinionof the steering gearbox Thevalveinsidethevalvebodyunitcontrols the hydraulic pressure andchanges the direc tion of the tlow Thefluidthenflowsto the powercylinder whererackthrustis generated Fluidreturning from the power cylinder flowsbackto the reservoir wherethefluid is filtered andsupplied to the...

Page 654: ...e innercircumference of the cam ring hasan extendedportionwith respect to the centerof the shaft so the rollers movedownwardin the axialdirection asthe carrierrotates As a resultof this rollermovement the internalvolumeof the vanechamberwill change resulting in fluid intakeanddischarge STARTOFFLUIDINTAK FLUIDINTAKE FLUIO MOVEMENT FLUIDDISCHARGE DISCHARGE PORT The vanesare pushedonlo the innercircu...

Page 655: ...nce betweenthe ends of the meteringorificeincreases A pressure differ enceis createdbetween thetop and bottomendsof the flow controlvalve too pushingthe flow control valveto openthe by passpassage This allowsthe excessfluid to returnto the inlet port preventing pressure at the discharge port trom risingexces As the enginespeedcontinues to increase the flow controlvalve is pushedbackfurther When th...

Page 656: ...trolvalveopens to relievethe pressure As the flow controlvalveis pushedbackby the pressure difference this time the flow of fluid in the bypasspassage increases controlling the pressure outsidethe meteringorifice The above operatrons are repeatedto provideconstantdischarae pressure from the pump I Decresses excossive vibration in the valve VALVE cont d 17 7 ...

Page 657: ...haftis double structured with the inputshaftconnected to the piniongear bothof whichareinterconnected with thetorsionbar The pin insertedin the valveandthe pinionshaftgrooveengage this allowsthe pinionshaftto rotatetogetherwith the Because of thisconstruction the difference in anglein the circumferential directionbetweenthe inputshaftandthe valve becomeslargeraccordingro the torsionalstrengthol th...

Page 658: ...the steer ing resistance increases In otherwords the passages becomelargerand powerassistincreases whenthe steeringeffort would normallybe high forexample when parkingor makinglow speedturns andthe passages becomesmallerand power assistdecreases when the steeringeffortwould normallybe low for example when drivingat high speedsor straight ahead FLUIOPASSAGE TO POWER CYLINDER Ce r r V K Pressure Con...

Page 659: ...sroo hish Too low relief press ire Normallineandhos6 I I I i Faultyvalvebody unit Normal Abnormal r l r l l Faultypump assembly Faultytlow controlvalv6 Ch ckthe tegd and returncircuitlinesand hoso betweenthe gearbox and pump for clogging and detormation Checkpump fluid Pressuro ses page 17 221 Mgasure stoady stat fluid Pres_ surewhile idlingwith the both valv6Iullyopon It shouldbe 1 500kPa 15 kgf ...

Page 660: ...he steering column related pan s tau y eennglornt Faultyrackendtio rodondballjoints Intgrferonce in the steeringsystem Normal lmproperlyadjustedrackguide Checklor bent rackshaft Checkpump fluid pressure see page 17 22 Turn the steoringwheelfully to the right and l ft while idling wilh the pressurecontrolvalve Iully open and measure theIluid pressure lt should be 6 400 7 400kPa 65 75 kgflcmr 924 1 ...

Page 661: ...dproperly lf the problem is not correctedby adjustingthe rack guide replsco the gearbox Checkthe belt for slippageand adjustas nec ssary s6epage 17 20 A and B cylinder lines are nor mal chgckwheolalignment se section18 Whe6lalignmentis abnormal adjustas needod It shouldbe 0 7 1 2N m 7 12 kgl cm 6 10 lbf in or below with the steering rack in the straightahoaddriving position wh el alignment is norm...

Page 662: ...fluid lovel lf fluid level is OK chockO rings and seals on both 6nds ot the pump suction hose and the P S pump housingmating surfaces and tho oumo shaft oil sealfor suction lgakr Roplacoparts as n6c6ssary Pump b lt slipping on pulloy pumpstopsmomentarily Adiust b6lt t nsion s6epage 17 20 or r6olac b lt Chockif pump pressureis normal andthe gaugeneedletrav lis 500 kPa 5 kgl cm 71 psi or lesB Ch ckt...

Page 663: ...se though not loud from tho valv6 body unit can be heardwhen turn ing the steering wheelto full lockin eitherdirection Thisis normal Do not hold the steeringwh6el at tull locktor morethat live secondswh n inspecting Loosesteeringshaft connector tie rod or ballioint Checkand tighten or replace pans as necessary Columnshaftwobbling Reolace thecolumnassemblv Checkihe rackguidetor proper adjustment se...

Page 664: ...rushedinlethoseor a loosehoseclampallowingair into the suctionside of the sys tem Tighten or replace as oecessary Check the oumoshaftoil seal Checkthe reservoirfor cracks NOTE Pumpnoiseup to 2 3 minutesalter startingin cold weather is normal Comparepump noiseat operat ing tomperatureto anothersimi larvehicle lf pumpnoiseis abnormally loud removeandinspect the pumpfor wear and damage seepage17 36 T...

Page 665: ...tho cylindgr ond sealon thegearhousing side Replacoth cylindor end sealon ths cylinderend side Leakingfrom cylinderend into righttie rodboot Leakingfrom the thaft upperend sectionor pin ongagement sgc tionofth6 Dinion shaft RoDlace tho valvebodv unit I I Tightenconnector lf it still leak ing replace th lin cylinderor valvehousing Leakinglrom cylind6rline A or B conn6ction Etflare nut Leakingcaused...

Page 666: ...r l6akin suctionsid ot th sys tem rgservoir suction hose frontpumps al Tightonthe fitting lI its still leak ing replacethe O ringor outlet hose Leakingat the threadedfitting Leaking at theswaged oint Loakingbecauseof damage de terioration or improperassem Replace or repairas necessary Pumpoutlotline high pressure Pumpsuctionline low pressure 17 17 ...

Page 667: ...steeringlinkageand gearboxas described on the neldpage PowerAssistCheckwith VehicleParked Checkthe power steeringfluid level seepage 17 21 andpump belttension seepage17 201 Startthe engine allow it to idle andturn the steer ing wheelfrom lock to lock severaltimes to warm upthe fluid Attacha springscaleto the steering wheel Withthe engineidlingandthe car on a clean dry floor pull the scaleas showna...

Page 668: ...ge BOOT Inspect lor damageanddeterioration STEERING JOINTS Check or loosejoint bolts PINIONSHAFTGROMMET Insp6ct for damageanddeterioration STEERING TIE ROD LOCKNUT Check or looselocknut Inspect for loosemountingbolts GEARBOX MOUNTINGCUSHIONS Inspect for deterioration BALLJOINT Inspectfor damageanddeterioration Seepago 17 61 lor replacement 17 19 ...

Page 669: ...sion gauge i i i i I h lt l I i CRANKSHAFTPULEY BELT TENSION GAUGE 07JGG 001010A Inspect the pumpbeltfor cracks or anydamage Replace the beltwith a new oneif necessary Mea3urementwithout BahTonsionGaugo Apply a forceof 98 N 10 kgt 22 lbll and measurethe deflectionbetweenthe power steeringpump and the crankshaft pulleys Drllection Us d B6h 11 5 13 5mm 0 45 0 53in New Bsh 8 0 10 0mm 10 31 0 39inl PO...

Page 670: ... off the engine Discard thefluid 2 RETURN HOSE From theoilcooler 4 Reinstallthe returnhoseon the reservoir 5 Fillthe reservoir to the uDDer levelline 6 Startthe engineand run it at fastidle thenturn the steeringfrom lock to lock severaltimesto bleedair from thesystem 7 Recheck thefluid levelandaddsomeit necessary CAUTION Do not lill the reservoir boyond thc upper levelline J 4 NOTE Performrackguid...

Page 671: ...ure to the adapter Installthe powersteeringpressure gaugeto the P S joint adapter pump Opentheshut offvalvefully Openthe pressure controlvalvefulli 1 Startthe engineandletit idle Turn the steeringwheel from lock to lock several timesto warmthefluidto operating temperature Measuresteady state fluid pressure while idling lf the pump is in good condition the gaugeshould readlessthan 1500kPa 15kgflcm ...

Page 672: ...atingsurface andIlarenutconnections PUMPASSEMBLY Check Ior leaksatthepumD seal inletandoutletfittings Inspecthosesfor damage leaks interference or twisting Inspect fluidlinesfor damage rusting or leakage Inspectfor leaksat hoseand lineiointsor connections Bl8Cl engine Exc pl 818Cl engine 17 23 ...

Page 673: ...r to tho SRSsub soc tion in 36ction23 Disconnectthe battery negativecable then discon nectDositive cable Removethe accesspanelfrom the steeringwheel lower cover CABLEREEL L SRSMAIN HARNESS 17 24 Disconnect the connectorbetweenthe airbagand cablereel NOTE SomeSRSsystemconnectors havea spring loadedlock To releasethe lock pull the spring loaded sleeve toward the stop Then pull the connectorhalves ap...

Page 674: ...iniury NOTE lf an intactairbagassemblyhas been removed from a scrappedcar or has beenfound defective or damagedduringtransit storageor service it shouldbe deDloyed seesection23 TORX BOLT 9 8N m 1 0 kqtm 6 5lbf ft TORX BOLT 9 8N m11 0 kgf m 6 5 lbf ft CRUISE COTROL SET RESUMESWITCHES CAUTION Carefullyinspect the airbsg assemblybetore inst8ll ing Do nol install 8n airbag assemblythat shows signs ot ...

Page 675: ...and reposhioningthe 3teeringwho confirm thst the airbag a33emblyis sscurely attached to th steering wheel otherwi3e severepersonaliniury could result during airbag deploymenl 1 Beforeinstsllingthe steeringwheel centerthe cable reel Do this by first rotatingthe cable reel clockwiseuntil it stoos Then rotate it counterclock wise approximately two turns until The arrow makeon thecablereellabelpointss...

Page 676: ...recompletelyconnected the pawl is released and the springloadedsleeve lockstheconnector SPRING LOADED SLEEVE Attachthe connectorin the holder then installthe access panelon the stee ing wheellowercover Connectthe positivecablefirst then the negative cableto the battery After installing the airbagassembly confirmproper systemoperation Turn the ignitionswitchON ll the instrument panelSRSindicatorlig...

Page 677: ...ve the airbagassembly and steering wheel seepage17 25 2 Remove the lowercover 3 Remove the driver skneebolster R e m o v et h e c o l u m n c o v e r sb y r e m o v i n gt h e screws 1G LOWER COVER 17 28 1 9 Removethe SRSwire harnessconnectorfrom the connector holder Disconnect the cablereelconnectorand SRSmain wire harness connector seepage17 24 CONNECTOR HOI DER SRSWIREHARNESS CONNECTOR Disconne...

Page 678: ...r Remove the steeringjoint bolts and movethe ioint towardthe column 1 1 JOINTCOVER 12 13 Disconnect the ignitionswitchconnectors from the under dash fuse relay box Removethe steeringcolumn by removing the aftaching nutsandbolts 17 29 ...

Page 679: ...the endof thetilt lever Preload 70 90 N 7 9 kgl 15 20 lbll lf the measurementis out of the specification adjustthe preloadusingthefollowingprocedures a Loosen the tilt lever andsetthe steeringcolumn in the neutralposition b Remove the 6 mm lockboltandremovethe stop c Adjustthe preloadby turningthe tilt lockboltleft or right d Pull up the tilt leverto the uppermostposition and installthe stop Check...

Page 680: ...lnstallation RETAINING COLLAR 13N m 1 3kgf m 9tbf ft FLANGE BOLT 22 N m 2 2kgt m 16lbf ftl STEERING JOINTBOLTS 22 N m 2 2kgI D 16tbf ftl cont d STEERING COLUMNASSEMBLY 17 31 ...

Page 681: ...upper steeringjoint bolt UPPER STEERTNG JorNTBoLT STEERING JOINT Slipthe lowerend of the steering joint ontothe pin ion shaft Line up the bolt holewith the groove aroundthe shaft and looselyinstallthelowerbolt NOTE Be sure that the lower steeringjoint bolt is securelyin the groove in the steeringg arbox prn ron Beforetighteningthe steering joint bolts pull on the steeringioint to makesurethat the ...

Page 682: ... signalcanceling sleeve ontothe combination switch Installthe cablereel andconnectthe cruisecontrol switchconnector Connect the cablereelconnectorand SRSmain wire harness connector seepage 17 27 NOTE Align the slot in the cablereelwith the pro jectionon the canceling sleeve CABLEREEL CONNECTOR HOLDER COMBINATION SWITCH SLEEVE SRSWIRE 17 33 12 Installthecolumncovers UPPER COLUMNCOVER LOWER COLUMN C...

Page 683: ...elow Slidethe hoseoverthe lineuntilit contacts the stop CAUTION Ch ckall clamps for deterioration or defor mation replacethe clampswith new ones it necessary HOSECLAMP b Positionthe hoseclampsat the pointsindicatedby b in the drawingbelow Slidethe hoseoverthe lineuntilitcontactsthestop 2 5 5 5mm 0 01 0 22in RETURN LINEJOINT 28N m 12 9 kg m 2 l lbf ft PUMPOUTLET HOSE High pressure 37N m 3 8kgtm 27 ...

Page 684: ... Wipeoff anyspilledfluidat once Remove the pumpmountingbolts then removethe pump NOTE Do not turn the steeringwheel with the pump removed Coverthe openingof the pump with a pieceof tape to preventforeign materiaifrom entering the oumo Connectthe pump inlet hoseand the pump outlet hose High pressure Tightenthe pump fittings securelv Looselyinstallthe pump in the pump bracketwith the mountingbolts n...

Page 685: ...Do not allowdust dirt or otherforeignmaterials to enterthe powersteering system Replace the pumpasan assembly if the partsindicated with asterisk l arewornordamaged FLANGE BOLTS 20N m 2 0kgf m 14tbf ftl 5 mm ROLLER PUMPCOVER 5 mm ROLLER IPUMPHOUSING 51x 2 4mm O RING Replace 13x 1 9mm O RING Replace INLETJOINT FLANGE BOLT 11N m 1 1kgt m 8 tbf fr PUMPSEAL Replace r aao ro a PUMPDRIVE SHAFT BALLBEARI...

Page 686: ...tersideplate pumpcam ring pump rotor pumpvanes sideplateando rings 8 Bemovethe circlip then removethe pump drive shaft by tapping the shaft end with th plastich8m mer 9 Remove the pumpsealspacer andpumpseal I Flow ControlValv 1 Checkthe flow control valve for wear burrs and other damageto the edgesof the groovesin the valve FLOW CONTROL VALVE Inspectthe bore the flow control valvefor scrstches or ...

Page 687: ...low controlvalvetestsOK reinstallit in the pump lf theflow controlvalvestillleaksair replace the pump as an assembly Theflow controlvalveis not available seDaratelv 17 38 BallBearing 1 Inspectthe ball bearingby rotatingthe outer race slowly lf any play or roughness is felt replacethe ballbearing 2 Replace the ballbearingusinga press Removal ln3tall Pross I installwith the red shieldedside facing d...

Page 688: ...ut 29mmS rcKET Z g u mmclRcLlP BALLBEARING PUMPDRIVESHAFT PUMPSEALSPACER a 7 Assemblepump rotorto the pump coverwith the markson the rotortacingdown Setthe 10vanesin the groovesinthe rotor NOTE Besurethatthe roundendsof the vanesare in contact with the slidingsurface of the cam ring 8 4 fluid and installit into the groovein the pump cover 5 Install the outersideplateoverthetwo rollers PUMPFOTOR PU...

Page 689: ... kgl m 14rbf ftl EI 15 2 2 4 Replace Groov6s i I 1 I I 17 40 14 t c 13 Coat the flow control valve with power steering fluid Installthe flow controlvalveand spring on the pumphousing Coatthe O ringwith powet steeringfluid and installit on theflow controlvalvecap Install the flow controlvalvecapon the pump hous ing andtightenit FLOW CONTROL VALVE n m O RING SPRTNG E 215 2 x2 1 KWM Reptace o ra Y l ...

Page 690: ...BSairbag system removethe steeringwheel seepage 17 24t 5 Remove the steering 6 Remove the steeringjoint lowerbolt and movethe iointtowardthe column STEERING JOINT LOWER SOI T cont d 19 Installthe pulleyas shown below then loosely installthe pulleynut Holdthe steeringpump in a visewith softjaws CAUTION Be carelul not to damlge tho pump hou3inowith ths ilws of th6 vies Holdthe pulleywith the special...

Page 691: ...Avoid damagingth ball ioint boot t ePrace BALL JOINT REMOVER 23 mm 07MAC SL0020o 10 Disconnect the shiftlinkage M Tmodel seesection 13 A T model seesection14 11 Disconnect the secondary heatedoxygensensor H02Slconnector and separate the three way cat alyticconvenerby removingthe self locking nuts NOTE Alwaysreplace the gaskets with newones SECONDARy HEATED OXycENSENSOR SELF LOCKING NUT 17 42 Repla...

Page 692: ... do not hinderin the gearboxremoval Do not loosenthe cylinderlinesA and B between the valvebodyunit8ndcvlinoer ADJUSTABLE HOSECLAMP Removethe steering gearbox mounting bolts 16 RETURN HOSE GEARBOX MOUNTING BOTTS 17 43 t7 1 9 Pullthe steeringgearboxall the way down to clear the pinionshaftfrom the bulkhead and removethe pinionshaftgrommet Move the steeringgearboxto the right so th left rackend clea...

Page 693: ...eair hoseandclips 3 Remove thetie rodendandlocknut Removethe boot bandsand tube clamps Pullthe boots awayfrom the endsof the gearbox TUBECLAMP CLIP BOOT 17 44 SPRING 5 Holdthe leftendof the steeringrackwith a wrench andunscrew the rackendwith a wrench TIE ROD LOCK WASHER BePlace Loosenthe locknutand removethe rack guide screw Remove the springand rackguidefrom the gearbox housing 7 RACK GUIDE scnE...

Page 694: ...disassembly FLANGE BOLT 10 CYLINDERLINEB VAI VEBODY UNIT 1 1 Orilla 3 mm 0 12in diameterholeapproximately 2 5 3 5mm 0 10 0 14in in depthin the staked pointon thecylinder NOTE Oo not allow metal shavingsto enter the cylinderhousing 12 Installa pulleryoketo the steeringgearbox Clamp the pulleryoke in a vise with soft jaws as shown then loosenandremovethecvlinderend CYLINDEREND STAKED POINT i D pth 2...

Page 695: ...5mm 07NAD SR3020A CYLINDER END SEAL 19 Carefully pry the pistonsealring and O ringoff the oistonof the rack CAUTION Be carelul not to damage the inside of sealring groovewhen remoyingthe sealring lnserta 24 long 3 8 driveextensjon andthe spe cialtool intothe cylinder from thegearboxside CAUTION Becarefulnot to damagethe insidesur lace of the housingwith the lools Setthe gearboxin a press then pres...

Page 696: ...lvehousing NOTE Theremay be the slidingmarkstrom the sealring on the wall of the valvehousing Replace thevalvehousingonly if thewall is stepped 2 1 22 23 Checkfor wear burrs and other damageto the edgesof the groovesin the sleeve NOTE The pinionshaftand sleeveare a precision matchedset lf eitherthe pinionshaltor sleeve mustbe replaced replace the bothpartsasa set SLEEVE SEALRINGS Check for peeloff...

Page 697: ...pinion shaft groove whgn removing the valvo sealring and O ring SLEEVE Cutting slot position 17 48 t f Removethe valve oil seal and wave washer ring from the pinionshaft NOTE Inspectthe ball besringby rotatingthe outer raceslowly lf thereis excessive play replace the pinionshaftandsleeve asan assembly The pinionshaftand sleeveare a precise fit do not intermix old and new pinion shaftsand steeves V...

Page 698: ...the powersteering system Usethe appropriate specialtools wherenecessary FLANGE BOLT 20 N m12 0kgf m 14lbl ftl VALVEHOUSING CYLINDER LINEB 26N m 12 7 kgf m 20 VALVEOILSEAL Replace SLEEVE SEALRINGS Replace st cEvE VALVE SEAL Replace WAVEWASHER VALVCSEALRING Replace O RING Replace PINIONSHAFT RACK GUIDE SCREW LOCKNUT cEARBoxHousrNc b SPRING f ACKGUIDE BACKUP RING Replace GEAR HOUSING CYLINDER END Rep...

Page 699: ...E Do notover expandthevalvesealring Sr lino E lip VALVESEALRING Replace Do notover expand 17 50 7 Apply power steeringfluid to the surJaceof the valveseal ring that was installedon the pinion shaft Apply powersteeringfluid to the insideof the spe cialtool Setthe largerdiameterend of the special tool overthevalvesealring Movethe sDecial tool uo and down several timesto makethe valvesealringfit in t...

Page 700: ...einsidesurfaceof the soecial tool SLEEVE SEALNING SIZINGTOOL 0r9 a sat02n0 Insertthe sleeveintothe special tool slowly Move the sleeveeach direction severaltimes to makethe sealringssnuglyfit in the sleeve NOTE Besurethatthe sealringsarenotturnedup 13 14 t o 17 51 Cutout 1 7 Applypowersteering fluidto the surface of the pin ion shaft assemble the sleeveoverthe pinionshaft by aligningthe locatingpi...

Page 701: ...ing fluid I i I VALVEOILSEAL Replace VALVEHOUSING Vinyltape PINION E SITEVESEALRINGS Replace 8e surethatthe sealringsarenot turnedup then install Insert the pinionshaftintothe valvehousing CAUTION Be careful not to damagethe valve seal rings Remove thevinyltapefrom the pinionshaft Seding lip lrce 17 52 24 Press the pi ion shafvsleeve intothe valvehousing usinga hydraulic pressasshown NOTE Checktha...

Page 702: ...O ringasshown Coatthe pistonseal ring and insideof the special toolwith powersteering fluid Carefullvslidethe tool onto the rackand over the pistonsealring 30 Movethe specialtool backand forth severaltimes to makethe pistonsealringfit snuglyin the piston 28 29 PISTON Replace 3 1 Coatthe slidingsurfaceof the specialtool and new cylinderendsealwith powersteering fluid Placethe sealon the specialtool...

Page 703: ... Holdthe flangebolt and tightentheflangenutagainst the rackby hand Installthe cylinderend sealinto the bottomof the cylinderby pressingon the bolt with a pressas shown CAUTION Do not push on th boh with excossive lorce as it may damagethecylinder end seal Press I 12x 170mm FLANGE BOLT 12mm FLANGE NUT Wrapvinyl tapearoundthe rackend edges and coatthe surfaceof the tapewith the powersteering fluid N...

Page 704: ...linderend by screwingit intothe cylin der Aftertighteningthe cylinderend stakethe point of thecylinderhousingshownbelow NOTE Stakein the cylinderin the positionopposite from where the stakewas removedduring disas semory Stakepoint Dopth 1 0mm 0 04inl 4 0mm 0 16 inl CYLINOER END 46 47 49 coatthe new o ring with greaseand installit in the grooveinthe gearboxhousing Apply greaseto the needlebearingin...

Page 705: ...tallthe spring rackguide screwand locknuton the gearboxhousing Adjust the rackguide screw seepage17 2 ll NOTE After adiusting checkthat the rack moves smoothlyby slidingto rackrightandleft 17 56 STEERING RACK WOODENBLOCK 54 Installthe new lock washer in the groove in the steeringrack Screweach rackend into the rack Holdthe leftend of the steeringrackwith I wrench andtighten to th rackendswith anot...

Page 706: ...lthe boots in the rack end with the tube clamps NOTE Installthe bootswith the rackin the straight aheadposition rightand left tie rodsare equal in length RACKEND TUBECLAMP 17 57 o t Adjustthe air tube fitting positionot the boots by turningit asshownbelow Connectthe air tube betweenthe right and left boot then installthe clipson the cylinderline B as snown Installthe righiclip inthisposition cont ...

Page 707: ...n CAUTION Bo caretulnot to bond or damrge the powcr steeringlineswhen in3t8llingthe grlrbox 1 Beforeinstalling the gearbox slidethe rackall the way to right 2 Passthe right side of the stseringgearboxabove andthroughthe rightsideof the rearbeam 3 Holdthe steeringgearboxand slidethe rack8ll the wayto the right 4 Rsisethe left side of the steeringgearboxabove andthroughthe leftsideof the rearbeam 5 ...

Page 708: ...llowingoperation Centerthe cable reel by first rotating it clockwise approximately two turns until the arrow mark on the labelpointsstraightup Slipthe lowerendof the steering ioint ontothe pin ion shaft lineup the bolt hole with the groove aroundthe shaft andtightenthe lowerbolt NOTE Connectthe steeringshaft and pinion with the cablereelandsteeringrackcentered Be surethat the lower steeringjoint b...

Page 709: ...returnlineclamp 12 CLIP 38N m 13 9 kgl m 28 lbf tl 17 60 13 Installthe three way catalyticconverterwith the newgaskets and newself locking nuts andconnect the secondaryheatedoxygensensor HO2S con nector SECONOARY HEATED OXYGEN SENSOR CONNECTOR 22N m 2 2 kgf m 16lbIft Connectthe shift linkage M T model see section 13 A T model seesection14 Threadthe rightand lefttie rodendsonto the rack an equalnum...

Page 710: ...ion sec tion with grca3o 1 Remove the bootfrom thetie rodend andwiDethe old grease off the bsllpin 2 Packthe lowerareaof the ball pinwith freshgrease 3 Packthe interiorof the new boot and liDwith Jresh grease CAUTION r Keepgreaseoff tho boot inst llrtion section 8nd ths tapered3cctionif tho ball pin Do not lllow du3t dirt or other foreign matcrials to entarlh6 boot 1 7 1 8 Lfp A 1 L I ru Install t...

Page 711: ...val 18 11 WheelBearingReplacement 18 14 Knuckle 1nsta11ation 18 16 Lower BallJoint Replacement 18 17 BallJointBootReplacement 18 19 Suspension Arms Removal lnspection 18 20 lnstallation 18 21 FrontDampel Removal 18 22 Disassembly lnspection 18 22 Reassembly 18 24 fnstaffation 1A 25 RearSuspension TorqueSpecifications 18 26 Hub BearingUnit fffustratedlndex 18 27 Removal 18 29 lnstallation 18 30 Sus...

Page 712: ...5 sDgo1oo o 07974 SA50700 Hub Dis AssemblyBase HubDis Assembly Tool BallJointBootClipGuide BallJointRemover Base BallJointRemover 2S mm Attachment 62 x 68 mm Oriver BallJointRemover lnstaller BallJointInstaller Bsse Support Base BallJoint BootClipGuide 2 18 14 1 18 14 15 1 18 1s 1e 1 r8 r8 1 I 1A 12 13 1 18 14 15 1 I 18 14 15 r I r8 r7 1 18 17 r 18 14 rs r I 18 19 re F E E L o I o L tr F rr ml o d...

Page 713: ...emoval lnspection page18 20 Installation page18 21 STABILIZER BAR Removal lnspectaon page18 33 Installation page18 35 STABILIZER BAR Removal lnspection page18 20 Installation page18 21 REARDAMPER Removal page18 3o Disassembly page 18 39 Inspection page18 40 Reassembly pagel8 41 Installation page18 42 UPPER ARM Removal lnspection pagel8 33 Installation page18 35 LOWER ARM Removal lnspection page18 ...

Page 714: ...alignmentequipment to measure wheelalign ment caster camber toe and turning angle Follow the equipment manufacturer s instructions 1 Check thecasterangle Caslerangle 1 10 t 1 2 lf out of specification checkfor bent or damaged suspension compohents Camber Inspection NOTE Use commerciallyavailablecomputerized four wheelalignment equipment to measure wheelalign ment caster camber toe and turning angl...

Page 715: ...ailable computerized four wheelalignment equipment to measure wheelalign ment caster camber toe and turning angle Follow the equiDment manufacturer s instructions 1 Release parkingbrake NOTE Measuredifferencein toe measurements with thewheelspointedstraightahead lf the parkingbrakeis engaged you may get an incorrect reading Reartoe in 2 11 mm l1l16i 1 15in lf adjustment is required go to step2 lf ...

Page 716: ...nd turning angle Follow the equiomentmanufacturer s instructions 1 Turn the wheel right and left while applyingthe b r a k e a n d m e a s u r e t h e t u r n i n ga n g l eo f b o t h wneels Turningangle lnward whsol 36 00 t 2 Outward wheel 30 30 rotorencel lf the turningangleis not within the specifications checkfor bent or damagedsuspension compo nenrs 18 6 ...

Page 717: ...tandard replace thewheelbearing WheelRunout Raise thevehicleoff the ground andsupportit with satetystandsin the proper locations seesection1 Check for bentor deformed wheels Attachthe dialgaugeasshown Measure the wheelrunoutby turningthewheel Frontand RoarWhoolAxial Runout Standard Stcsl Whoel 0 1 0mm 0 0 04inl Aluminum Whcel 0 0 7 mm 0 0 03inl Sorvlc Limit 2 0mm 0 08inl FrontEndRoarWhod Rldisl Ru...

Page 718: ... 83N m 8 5kgf m 61lbf ft CASTLE NUT 12x 1 25 mm 39 47N m 4 0 4 8kgtm 29 35 lbf ft FLANGE BOLTS 14x 1 5mm 89N m 9 1kgl m 56lblft FLANGE NUT 8 x 1 25mm 22N m 2 2kgf m 16lbtftl 8 mm BOLT 22 N m 2 2ksnm 16lb ft Replace FLANGE BOLT 14x 1 5mm 89N m 19 1 kgt m 66 lbl ftl FLANGEEOLT l0 x l 25 mm 4i N m 4 4kgl m 32 lbf ft FLANGE BOLT 12x 1 25mm 64 N m 6 5kgtm iU lbfftl SELF I OCKING NUTS 22N m 2 2kgtm 16lb...

Page 719: ...ngsurfaces ofthe brakediscandthewheel All exceptTyps R Model3 CASTLE NUT 12x 1 25 nn COTTER PIN Replace WHEELBEARING Replace LOWER EALLJOINT Beplacement page1817 Replacement pagel8 14 CIRCLIP SCREW 5 x 0 8 m m FRONT HUB tV ai 1 eetL rotNtgoot Y conen erru I Reptace I CASTLE NUT 12 x 1 25fin BRAKEOISC Replacement page18 1 1 Inspection section 19 6 mm BRAKEDISCRET WHEEL cont d 12x 1 5m n 18 9 ...

Page 720: ...lling thewheel cleanthe matingsurfaces ofthe brakediscandwheel Type R Modsl CASTLE NUT 12x 1 25mm CAUPER MOUNTINGEOLT 12x 1 25fim COTTERPIN Replace WHEELBEARING Replace Replacement Page18 14 SPLASH GUARO LOWERBALLJOINT Replacement page18 17 SCREW 5 x 0 8 m m I rl I I i 1l l tl CASTLENUT 12x 1 25mm SPINDLE NUT 2 x 1 5 mfi 6 mm BRAKEDISCRETAINING SCREW WHEEL NUT 12x 1 5 mm 1 8 1 0 ...

Page 721: ...ng the c8liperflom the undercarriage CALIPER BRACKET MOUNTINGBOLTS 12x 1 25mm 7 Remove the 6 mm brakediscretaining screws BRAKEDISC Check for wearandrust Inspection section j9 8 Screwthe two I x L25 mm bolts into the disc to pushit awavfrom the hub NOTE Turn each bolt two turns at a time to pre ventcocking thediscexcessively Remove the brakediscfrom the knuckle Check thefront hubfor damageor crack...

Page 722: ...hown Insertthe jaws carefully makingsure you do not damagethe ball joint boot Adjustthe jaw spacing byturningthe pressure bolt NOTE lf necessary apply penetratingtype lubri cantto loosenthe balljoint BALLJOINTREMOVER 28 mm 07MAC SL00200 HEXNUT NUT 10x 1 25mm li N m la akgf m 32 tbfft On reassembly bend the cotter pin 18 12 17 Oncethe tool is in place turn the adiustingbolt as necessary to makethe ...

Page 723: ...joint 12x 1 25mm 23 24 Remove the cotterpinfrom the upperballjointcas tle nut andremovethe nut Installthe12mm hexnuton the balljoint Be surethat the hex nut is flush with the balljoint pin end or the threaded sectionof the balljoint pin mightbedamagedbythe balljoint remover Usethe special lool asshownon page18 12 to sep aratethe balljoint andknuckle NOTE lf necessary apply penetratingtype lubri ca...

Page 724: ...talling whon prossedclear KNUCKLE FRONT HUB Removethe circlipand the splashguard from the knuckle SPLASH GUARD Check for bending anddamage 18 14 FRONT HUB 3 Press thewheelbearingout of the knuckle usingthe soecialtools anda Dress asshown DRIVER 07749 0010000 ATTACHMENT 5 2 x 6 8 m m 07746 0010500 Remove the wheelbearinginnerracetrom thefront hubusingthe specialtoolanda commercially avail ablebeari...

Page 725: ... the inside Be careful notto damage thesleeve of the packseal Installthe circlip securelyin the knucklegroove SCREWS 5 x 0 8 m m 4 9N m 0 5kgf m 3 5lbtftl SPLASH GUARO 7 Install the splashguardandtightenthe screws 1 8 1 5 Installthefront hubon the knuckle usingthespecial toolsanda pressasshown CAUTION Takocsronot to distort tho splashguard pre3s DRIVER I 0 a9 0010000 v ATTACHMENT 6 2 x 6 8 m m 077...

Page 726: ...5mm 49 59N m 5 0 6 0kgfm 36 i lbfft 3 Installthe knuckleon the upperarm then tighten the castlenut andinstalla newcotterDin COTTER PIN Replace On reassembly bendthecotterpin CASTLE NUT 12x 1 25 mm 39 47N m 4 0 4 8kgf m 29 3s rbr ft ar COTTER PIN 1 8 1 6 4 Installthe wheelsensorwith the sensormounting bolts torvehicles with ABS lnstallthe sensorwire with the two 5 mm bolts for vehicles with ABS NOT...

Page 727: ...m118 5 kgt m 134lbl ftl Replace NOTE Aftertightening us a drift to stake thespindlenutshoulder against the driveshaft 11 Check the tront wheel alignment and adjust if nec essary see page l8 4 1 2 4 5 Remove the knuckle seepage18 11 Remove the bootby pryingthe setringoff C h e c kt h e b o o t f o r d e t e r i o r a t i o n a n d d a m a g e replace if necessary Installthe specialtoolson the ballj...

Page 728: ... BallJointReplacement confd 8 Installthe balljoint bootandsetring usingthe spe cialtool 9 1 0 Install the knuckle seepage18 161 Checkthe tront wheelalignmentand adjustif nec essary seepage18 4 BALLJOINTBOOTCLIPGUIDE 1 8 1 8 ...

Page 729: ... tho boot 4 Install the bootin the grooveof the bootinstallation section securelv thenbleedair Installthe upperand lowerballjoint boot set rings usingthe specialtools asfollows Lower ball joint Adjust the specialtool with the adjustingbolt until the end of the tool alignswith the grooveon the boot Slidethe set ring overthe tool andintoposition Upperballjoint Holdthe tool overthe balljoint then sli...

Page 730: ...heck for bending anddamage SELF LOCKING NUT x 1 25 mm Reolace 14x 1 5mm SELF LOCKING NUT 14x 1 5mm Replace FLANGE BOLTS 14x l 5 mm FLANGE BOLT 10x 1 25mm Checkfor deterioration ano oamage LOWER ARM Check for damage LOWER ARM RUBBER BUSHING Check for deterioration anooamage Seepage18 22 tor OAMPER FORK Check for damage bushing replacement and damage STABILIZER END RUBBER BUSHING Check for deteriora...

Page 731: ... BOLT STABILIZER EUSHING SELF LOCKING NUT I x 1 25mm 22 N m12 2kgt m 16lbf ft Replace FLANGE BOLT 12x 1 25mm FLANGE NUT I x 1 25mm 22 N m 2 2kgt m 16lbf ft BADIUSARMWASHER B SMALL I D 64N m 6 5kg m 47lbt ft SELF LOCKING NUT 14x 1 5mm 83N m 8 5kgI m 61lbl ftl Replace RAOIUS ARMWASHER A LARGE I O I SILICONE GREASE RUBBER BUSHING FLANGE BOLTS 14x 1 5mm 89N m 9 1kgf m 66lbtft RS LSModebi SELF LOCKING ...

Page 732: ...MPER FORK FLANGE BOLT SELF LOCKING 10x 1 25mm Replace COMPRESSORI lComm rci lly Yrll blcl ARAN CKO T N MST 580A T N 72IX or aouivalant Removethe damper by removingthe two flange nuts 2 Removethe springcompressor then disassemble the damperasshownon the neldpage Inspection 1 Reassemble all parts exceptthespring 2 Pushon the damperasshown 3 Checkfor smooth operationthrough a full stroke bothcompress...

Page 733: ...MPER MOUNNNG BASE DAMPER MOUNNNG RUBBER DAMPER MOUNTINGCOLLAR DAMPER MOUNTING RUBAER Check for deterioration anooamage DAMPER MOUNTNG RUBBER Checkfordeterioration anooamage SPRING MOUNNNGRUABER Check for deterio ation anooamage SPRING MOUNTINGRUBBER Checkfor detorioration anddamage Check for weakened compression anddamage DUSTCOVER PLATE DAMPEBSPRING Checktor weakend compression or damago Checktor...

Page 734: ...asshown Position the dampermountingbaseon the damper unitasshown 61 30 13 I STRUTSPRING COMPRESSOR Commercially available BBANICKO T N MST 580A T N 7200 or equivalent SPRING LOWER SEAT ALIGNINGTAB G fL l r r l I 1a 24 Compress the damperspringwith the sprlngcom pressor Install the dampermountingwasher and loosely installa newself locking nut Holdthe dampershaftwith a hexwrenchandtight enthe self l...

Page 735: ...fts off the safetystand The ltoor jack must be securelyposi tionedor personal iniurymay result Tightentheflangebolt Tightenthe self locking nut Tightenthe flangenutson the top of the damperto 3 FLANGENUTS 10x 1 25 mm 49N m 15 0 kgtm 36 lbtft Tighten to thistorquein step8 4 5 6 7 8 the specified torque 9 lnstallthe brakehose mountswith the brakehose mountingbolts ERAKEHOSEMOUNTINGBOLT 18x 20mml GS ...

Page 736: ... 29N m13 0kgt m 22 lbf ft Beplace FLANGE BOLT 10 x l 25mm 54 N m 5 5kgl m 40 lbtft FLANGE BOLT I x 1 25mm Typ6R 30N m 3 1kgf m 22 lbtft ExceptTyp6 R 22 N m 12 2l gl rn 2 lbiftl FLANGE SOLT 10r L25 mm 5 1N m 5 5kg m 0 lbf ftl CALIPER BRACKET 10x 1 25mm 56 N m 5 6kgf m 41lbl ftl NUT MOUNTING 39N m14 0 kgl m 29 lbtftl BOLT 22x 1 5mm 181N m 18 5 kgf m 134lbf ft Replace NOTE Aftertightening usea drift ...

Page 737: ...installing the brakedisc cleanthe matingsurfaces ofthe rearhubandthe brakedisc Beforeinstalling thewheel cleanthe matingsurfaces ofthe brakediscandthe wheel All oxcoptTypoR Modol3 6 mm FLANGE BOL SPINDLE 22x 1 5mm Replace 6 mm BRAKEDISCRETAINING WHEEL 12x 1 5mm cont d 18 27 ...

Page 738: ...on HubBearingUnit cont d TypeR Model TRAIUNGARM REARWHEEL SPLASH GUARD HUBBEARING UNIT SPINDLE WASHER SPIND1INUT 22x 1 5mm HUBCAP Replace 6 mm FLANGE BOLT 6 mm BRAKEDISCRETAINING SCREW WHEEL NUT 12x 1 5mm I I 18 28 ...

Page 739: ...Take care notto damage thehubunit ondisassembly 4 Pullthe parkingbrakeleverup 5 Remove the hubcap 6 R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t t h e n removethe nut 7 Remove the 6 mm brakediscretaining screws Replace 8 9 Release the parkingbrakelever Remove the 6 mm flangeboltsandcalipershield CALIPER SHIELD Checkfor bending or damage 6 mm FLANGE BOLTS cont d 18 29 ...

Page 740: ...akedisc Remove the hub unitfrom the knuckle BRAKEHOSEMOUNTINGBOLT 10x 1 25 mm 18 30 lnstallation l Install thehubunit spindle washer andbrake disc NOTE Washthe bearingandspindlethoroughlyin high flashpointsolventbeforereassembly Beforeinstalling the brakedisc cleanthe mating surfaces of the rearhubandthe brakedisc HUSUNIT SPINOLE WASHER Installthe brakecaliperwith the caliperbracket mountingbolts ...

Page 741: ... 2tbtftl 6 Install a newspindlenut thentightenthe nut 7 Installa new hubcap 8 Install the rearwheelwith thewheelnuts NOTE Beforeinstalling thewheel cleanthe mating surfaces of the brakediscandthewheel REARWHEEL WHEEL 12x 1 5mm SPINDLE NUT 22x 1 5mm 181N m 18 5 kgt m 134lbl ftl 108N m111 0 kg f m 80 lbf tr Beplace NOTE Aftertightening usea drift to stakethe spindlenut shoulder against thespindle co...

Page 742: ...MBUSHING Check for deterioration anddamage COMPENSATOR ARM Checkfor bending and damage FLANGE BOLT 10 x 1 25mm STABILIZER ENDBUSHING Check for deterioration anddamage COMPENSATOR ARMBUSHING Check for deterioration anddamage FLANGE EOLT l0 x 1 25mm BOL 8 x 1 25mm STABILIZER LINK Check for bending anddamage Check thebushing for deterioration anddamage ARM BUSHING 18 32 Checkfor deteriorationand dama...

Page 743: ...amage TMIUNG ARM Check for bending anddamage COMPENSATOR ARM BUSHING Ch6ckIor deterioration anooamage FLANGE BOLT 10x 1 25mm STABILIZER ENDBUSHING Chocklor deteriorationand damage FLANGE BOLT 10x 1 25mm LOWERARM Check tor cracks anddamage STABIUZER UNK COLLAR Checkfor deteriorationand damage LOWEBARM BUSHING Check for deterioration anddamage BOLT I x 1 25mm STABILIZER UNK Check tor bending anddama...

Page 744: ... 2kgtm 16lbtft STABILIZER BAR Alignthestabilizer mark with endof stabilizer bushing FLANGE BOLT 10x 1 25mm 54N m 5 5kgf m 40lbtft FLANGE BOLT l0 x 1 25mm 39N m 0 kgt m 29 lbtftl UPPER ARM TRAILING ARM FLANGE EOLT 10 x 1 25mm 54 N m 5 5kgf m 40lbf ft COMPENSATOR ARM SILICONE 5tr l GREASE COMPENSATOR ARM BUSHING FLANGE BOI T 10x 1 25mm 54 N m 5 5kgf m Olbf ft FLANGEBOLT 10x 1 25mm 64 N m16 5 kgl m 4...

Page 745: ...ilizer bushing Ar UPPEB ARM rz tot t d Ja n _oY t a stLtcoNE GREASE BUSHING ADJUSTING BOLT IFLANGE BOLT l0 x 1 25mm 6 4N m 6 5kgt m FLANGE BOLT 10x 1 25mm 5 N m 15 5kg m 40 lbt ftl STABILIZER BUSHING FLANGEBOLT 10x 1 25mm FLANGEBOLT 10x 1 25mrn 39N m r 0kgf m 29lbtftl 5 aN m 15 5 kgl m a0 COMPENSATOR AFM UPPER ARM TRAILING ARM FLANGE BOLT 10x 1 25mm 54N m 15 5 kgf m lbf ftl SILICONE 4 i cREAsE COM...

Page 746: ...20 Remove thetwo flangenuts Hatchback DAMPER ACCESS PANEL 10x 1 25 mm Removethe wheel sensorwire brackets for vehicles with ABS NOTE Do not disconnect the wheelsensorconnec tor 18 36 5 Remove theflangebolton the damper Remove the flangeboltthatconnects the lowerarm to thetrailing arm 7 Lowerthe rearsuspension andremovethedamper DAMPER ...

Page 747: ...y v il blol BRANICKo T NMST 580A T N72dt or quiv t nr Removethe springcompressor then disSssemble the damperasshownon the nextpage Inspection 1 Reassemble all parts exceptthe spring 2 Pushon the damperasshown 3 Checkfor smooth operationthrough a full stroke both compressionand sxtension NOTE The dampershouldmove smoothly lf it doesnot no compression or no enension the gas is leaking andthe dampers...

Page 748: ... DAMPTRMoUNnNG __re Check for deteriorationDAMPERMOUNnNG anddamag6 L AR Ag liillffi DAMPTR MoU nNG __ _____ e DUST COVEB Ch6ck for b nding andoamage DUST OOVER BOOT Ch ck for deterioralion and damage MOUNNNGBASE DAMPEB MOUNTING RUBBER Checklor deterioration anooamage SPRING MOUNTING RUBBER Checkfor deterioration anooamage Checkfor weakness compression anddamage DUSTCOVERPLAT DUST COVER Check forbe...

Page 749: ...nglowerseatasshown Position the dampermountingbaseon the damper unitasshown STRUTSPRING COMPRESSOR lComm rci llv availabls BRANICKO T N MST 58OA T N 7200 or oquivalent DAMPER MOUNTTNG a a 18 39 Compress the damperspringwith the springcom pressor lnstallthe dampermountingwasher and loosely installa newself locking nut Holdthe dampershaftwith a hexwrenchandtight enthe self locking nut SELF LOCKING N...

Page 750: ... avoidtwistingwires Raise the rearsuspension with a floor iackuntilthe vehicle just liftsoffthe safetystand The floor jack must be securely posi tionod or personaliniury may result 5 Installthe dampermountingbolt and the flange bolt thentightenthe bolts NOTE The dampermountingboltand the flange bolt shouldbe tightenedwith the damperunder vehicleload FLANGE EOLT 10x 1 25m n 54N m 5 5kgf m 40lbt ftl...

Page 751: ...the damperto the specified to que Install the damperaccess panelby aligningthe tabs on the panel Sedanonly Installthe trunksidepanel seesection FLANGE NUTS 10x 1 25mm 49 N m 5 0kgt m 36lbl ft 10 Installthe rear wheels seepage l8 32 18 41 ...

Page 752: ...Brakes Conventional Brakes lg 1 Anti lockBrakeSystem ABS 19 23 ...

Page 753: ...10 FrontBrakeCaliper Disassembly Reassembly l9 1l MasterCylinder Brake Booster Removal 1nsta lation 19 13 MasterCylinderInspection 19 14 PushrodClearance Adjustment 19 14 BrakeBooster Inspection lg 15 RearBrakePads Inspeetion and Replacement l9 16 RearBrakeDisc DiscRunoutInspection 1g 18 DiscThickness and Parallelism Inspection t9 18 RearBrakeCaliper Disassembly Reassembly l9 19 BrakeHoses Lines I...

Page 754: ...SpecialTools Ref No Tool Number Description oty I PageReference o 07JAG SD40100 Pushrod Adjustment Gauge 1 19 14 o 19 2 ...

Page 755: ...B R moval lnstallation pag 19 t3 Mast rCylinder Inspection page19 14 Pushrod Cl6aranc6 Adjustment page19 14 BRAKEBOOSTER BrakeEoostorInspoction page 19 15 Removal lnstallation pags 19 13 BMKEPEDAL lnspection and Adjustment page19 5 PARKING ERAKE Adjustment page 19 6 PARKING BRAKE CABLE lnspoction andRoplacement page19 22 REARDISCBRAKES RearBrakePads page19 16 RearBrake Disc page19 18 RearBrake Cal...

Page 756: ...k properly or if thereis damage or signsof fluidleakage Checkfor a differencein brakepedalstrokebetlveen quickandslowbrakeapplications Replace the mas ter cylinderif thereis a differencein pedalstroke O BrakeHoses Visuallycheckfor damageor signsof fluid leakage Replace the brakehosewitha newoneif it isdarnaged or leaking CaliperPBton Sealand Pkton Boots Checkbrakeoperation by applying the brakes V...

Page 757: ...nt tighten the locknutfirmly Do not adjustthe pedal height with the pushroddepressed 1 5 kgf m 11 lbt ftl 19 5 Screwin the brakeswitch until its plungeris fully depressed threadedend touchingthe pad on the pedal arm Then back off the switch 1 4turn to make 0 3 mm 0 01in of clearancebetweenthe threadedendandthe pad Tightenthe locknutfirm ly Connect the brakeswitchconnector CAUTION Makesurethat the ...

Page 758: ...o setthe self adjusting brake beforeadiustingthe parkingbrake 1 Raisethe rearwheelsoIt the ground and suppon the car on safety stands ato t the trort whoels bsfore jacking up the roal ot tha car 2 Makesurethe parkingbrakearm on the rearbrake caliDer contactsthe brakecaliperpin 19 6 8 3 Pulltheparkingbrakeleverup onenotch Removethe rearconsole seesection20 Tightenthe adjusting nut untilthe rearwhee...

Page 759: ...edingpro cedure and checkedafter bleedingeach brakecaliper Addfluidasrequired 1 Makesurethe brakefluid levelin the reservoir is at the MAX upper levelline MAX UPPER I IVEL LINE CYIINDER Havesomeoneslowlypumpthe brakepedalsever al times then applysteadypressure Loosen the brakebleedscrewto allowairto escape from the system Thentightenthe bleedscrewse curely Repeat the procedure for eachwheelinthese...

Page 760: ... hosesandpin bootsfor damage or deterioration Removethe pad shim pad retainers and pads OUIER PAD Checktor wear PADRETAINERS 19 8 Usingverniercalipers measure the thickness ot eachbrakepad lining The measurement does not includepadbacking platethickness BrakoPadThickness St8ndard TypeR Modol 10 5 11 5mm 0 41 0 45in All except Type R Model 9 5 10 5mm 0 37 O ial inl ServiceLimit 1 6mm 0 06inl lf the...

Page 761: ...shinthe pistonsothat the caliperwill fit overthe pads Makesurethat the pistonboot is in position to preventdamagingit when pivotingthe caliper down Pivotthe caliperdown into position then installthe caliperbolt and tighten it Be carefulnot damage the pinbootwhenpivotingthecaliperdown CAUPERAOLT Typ R Mod l 4 N m 5 0kgl m 36lbtft All xc pt Typ R Modcl 32N m 13 3 kgf m 24 lbf ftl 1 3 Depress the bra...

Page 762: ...or brakediscreplacement Whenthe vehicleis equippedwith a limitedslip differential raise both front wheels off the ground 3 Loosenthe front wheelnutsslightly then raisethe vehicleandsupportit on safetystands Remove the frontwheels Remove the brakepads seepage19 8 Usinga micrometer measurediscthicknessat eightpoints approximately 45 apart and 10 mm 0 4in in from the outeredgeof the disc Replace the ...

Page 763: ...essed air Beforereassembling checkthatall partsarefreeof dustandotherforeignparticles Replace partswith newoneswheneverspecified to do so Makesureno din or otherforeignmatteris 8llowedto contaminate the br8kefluid AlwaysuseGenuineHondaDOT3BrakeFluid Usingnon Honda brakefluid cancaus6corrosionand d crease the lift of the system ffl Userecommended rubbergreasein the calipersealset 61 Userecommended ...

Page 764: ...h compressed air Beforereassembling checkthatall partsarefreeof dustandotherforeignparticles Replace partswith newoneswhenever specified to do so Makesureno din or otherforeignmatteris allowedto contaminate the brakefluid AlwaysuseGenuine HondaDOT3BrakeFluid Usinga non Honda brakefluidcancausecorrosion anddecrease the liJe of the system ff Userecommended rubbergreasein the calipersealset 6 lruse r...

Page 765: ...m the operatingrod of the brakebooster lf the clevis is loosened adjust the pushrod length before installing the brakebooster 13N m 1 3kgf m 9 lbl ft LOCX PIN 9 Remove the four boostermountingnuts 10 Pullthe brakeboosterforwarduntilthe clevisis clearof the bulkhead 11 Remove the brakeboosterfrom the enqinecom panmenL 12 Installthe brakeboosterand mastercylinderin the reverse orderof removalandnote...

Page 766: ...enginevacuumsupply and maintainan engine speedthatwill deliver66 kPa 500mmHg 20 in Hg vacuum 5 With a feelergauge measure theclearance between the gaugebodyandthe adjusting nut asshown Clsarance 0 0 i mm 0 0 02inl VACUUMGAUGE lCommelciallyavailabl 0 101kPa l0 760mm H9 30in Hgl AINUSTINGNUT BRAKE BOOSTEB MAS ER CYLINDER NUT 15N m ll 5 kgf m 11lbl ftl CAUTION Do not spill blake fluid on the vohicle ...

Page 767: ...pedal lightly Applyjust enoughpressure to hold back automatic transmission creep lf the brakepedal sinksmorethan 25 mm 1 0in in threeminutes the mastercylinderis faulty A slightchangein pedal height when the A C compressorcycleson a n d o f f i s n o r m a l T h eA C c o m p r e s s o rl o a d changes the vacuumavailable to the booster LeakTest 1 Depress the brakepedalwith the engine running then ...

Page 768: ...port the caliperwith a pi c ot wire so that it doss not hanglrom ths brakohose PARKINGBRAKECAALE cALtpEB MOUTTT NG EOLTS PAD SPRING Replace CALIPER NOTE Checkthe hosesand pin bootsfor damage or deterioration PIN EOOT 1 9 1 6 4 Remove the padshims padsandpadretainer PADRETAINERS r l V INNERPADSHIM Checkfor weakness All exc pt Type R mod ll Using vernier calipers measurethe thicknessof eachbrakepad ...

Page 769: ...ykote I77 greaseto bothsidesof the PADS shim ApplyMolykote M77grease to bothsidesof the Rotate the caliperpistonclockwise into placein the cylinder thenalignthe cutoutin the pistonwith the tab on the innerpadbyturningthe pistonback CAUTION Lubricato th boot with rubbor grease to avoid twisting the piston boot lf the piston boot is twist d back it out so it sits properly Install the brakecaliper ln...

Page 770: ...inished if its runout is greater than 0 10mm O O04 in DiscThickness and Parallelism Loosenthe rearwheel lug nutsslightly then raise the vehicleandsupportit on safetystands Remove the rearwheels Remove the brakepads seepage19 16 Using a micrometer measuredisc thicknessat eightpoints approximately 45 apartand 10 mm 0 4in in from the outeredgeof the disc Replace the brakedisc if the smallestmeasureme...

Page 771: ...tall partsarefreeof dustandotherforeignparticles Replace partswith newoneswhenever specified to do so Makesureno dirt or otherforeignmatteris allowedto contaminate the brakefluid AlwaysuseGenuineHondaDOT3BrakeFluid Usinga non Honda brakefluidcancausecorrosionanddecrease the life of the svstem Type RModel 10mm FLANGE BOLT 34N m 13 5 kg m 25tbtftl All 6xc ptTyp6R Modet 8 mm FLANGE BOLT 23 N m 2 3kgf...

Page 772: ...runit ifequipped for damageand leakage CAUTION Replacethe braks hoseclip wheneverthe brakehoseis serviced 15N m11 5 11tbl f0 MASTERCYLINDER Io BBAKE UNE 15N m 1 5kgt m 11lbf ft BnAKE HOSE Io CALIPER IMNJOBOLTI 3aN m13 5 kgf m 25lblft BLEED SCREW I N m 10 9 ks m 6 5lbf ftl ABSMODULATOR UNIT Io BRAKE LINE 15N m 1 5kg m 11lbtftl BRAKELINE Io BRAKEHOSE 15N m lt 5 kgf m 11lbf ftl BnAKEHOSE Io CALIPER I...

Page 773: ...caliper 5 BRAKEHOSE MOUNTINGBOLT RS LS GS 8x 20mm Installthe brakehoseon the knuckleand damper first thenconnectthe brakehoseto thecaliDer with the banjoboltandnew sealing washers BRAKEHOSE ERAKEHOSEMOUNTING EOLT18x 16 mm 22 N m 2 2 kgt m 16 tbf ftl GS Rand Type R 8x 25 mm 22 N m 2 2kgf m 16lbf ftl BANJOEOLT tO r 1 0 mm 34 N m 3 5kgf m 25 lbf ft CAUTION Do not twist the brakehoseexcessively Instal...

Page 774: ...and premature cable lailure CLEVISPIN LOCK PIN PARKINGERAKELCVER Check for smooth EOUALIZER Slidingsurface PARKING BRAKE swtTcH Disconnect the parkingbrakecablefrom the leveron the caliperby removingthe lock pin and clevispin and removethe cablefrom the arm by removingtheclip PARKING BRAKECABLE CLEVIS PIN CLIP Replace lSlidingsurlace 19 22 ...

Page 775: ...torDoesNot GoOff 19 42 DTC11 13 15 17 WheelSensor Open Short to Body Ground Short to Power l9 44 DTC12 14 16 18 WheelSensor Electrical Noise IntermittentInterruption 19 45 DTC21 24 Pulser 19 46 DTC31 38 Solenoid 19 47 DTC41 44 WheelLock 19 50 DTC51 MotorLock 19 51 DTC52 MotorStuckOFF 19 52 DTC53 MotorStuckON 19 55 DTC54 Fail safe Relay t9 57 DTC61 62 lgnitionVoltage 19 59 DTC71 DifferentDiameterTi...

Page 776: ...SpecialTools ReI No Tool Numbe 07PAZ 0010100 19 24 ...

Page 777: ...SOR UNDER H X D ABS MODULATOR UNIT FAIL SAFE RELAY RIGHT FRONT WHEEL SENSOR LEFT FROl T WHEEL SENSOR UNDER HOOD FUSE RELAY BOX ABS INDICATOR UNDER HOOD ABSFUSE RELAY 8OX ABS81 20AI FUSE AASMOTOR 40Al FUS AASPUMPMOTORRELAY GAUGEASSEMBLY D Dtrt HORN STOP I2OA FUSE A8S UNIT 10AI FUSE RRDEFFI YI7 5AI FUSE 19 25 ...

Page 778: ...ateo the wheelsto ensUre maximumgripforcefromthetires andit therebyensures maneuverbiIity andstabiIity of thevehicIe TheABScalculates the slip rateof the wheelsbasedon the vehiclespeedandthe wheelspeed thenit controlsthe brake fluid oressure to attainthetargetsliprate Features Gonstruction Grip Foact ot Ti c tnd Rotd Surfuco COEFFICIEUT OF FNIG TPN SlipRrtr BRAKING START POINT i l A f 3t rp withou...

Page 779: ... sliprateis high The pressure reduction controlhasthree modes pressure reduction pressure retaining andpressure intensifying Self diagnosisFunction TheCPUS in theABScontrolunitcheckthe circuitof the system Theself diagnosis canbeclassifield intotwo categories Initialdiagnosis Performed rightaftertheenginestartsanduntiltheABSindicator goseoff Regular diagnosis Performed rightafterthe initialdiagnos...

Page 780: ...ic circuitisthe independent four channel type onechannel tor eachwheel L __ RF LR Pressureintensifying mode Inlet valve open outlet valve closed Mastercvlinder fluidis pumpedoutto thecaliper Inletvalveclosed outletvalveclosed Caliper fluid is retained bythe inletvalveandoutletvalve lnletvalveclosed outletvalveopen Caliper fluidflowsthroughthe outletvalveto the reservolr Whenstartingthe pressure re...

Page 781: ...perfluid pressure The pump motorstartsatthistime As thewheelspeedis restored the inletvalveopensmomentarily to increase the caliper fluid pressure WheelSensor Thefourwheelsensors arethe magnetic contactless type As thegearpulserteethrotatepastthewheelsensor s magnetic coil ACcurrentis generated TheACfrequency changes in accordance with thewheelspeed TheABScontrolunitdetects the wheelsensorsignalfr...

Page 782: ...l 3 5 6 7 8 I 10 1 l 12 115t 8 1 9 MAI E S1IITCN 06 d 8 p d l s d tGNtroti SWITCH p i GAUGEASSEMBLY CONNECTORS 16PCONNECTOR O number SfMEL f lBU Y EtU 4 coiboz EOWI BFAKESWITCH CONNECTOR fi tr FAIL SAFE RELA CONIiECTOR T r 1 2 1 M A ff t P t 3 ffi Jr t r_E 1 l lXl I tlL jlJr l y L tr J lLlAZ PUMP MOTOR CONNECTOF tr numb r F L IJ Tsrminalsids ol femalo tominals 5P CONNECTOR f rF Tt FUSE N0 ftJSE UB...

Page 783: ...EISENSOf 61 r Ej ABSCONTROL UNIT22PCONNECTOR O numbed WHEEL SENSON CONNECTOR FRONT JEIL rGT r REAR l r 2 l SERVICE CHECK CONNECTOR 2P 1 t 1 l ABSCONTROL UNIT12PCONNECTOR l number n t l l r 2 3 l 4 l s6 l lrl Bl iiltilld 6 1 8 9 10t l t2 14 1 6 1 l l t 9 20 21 22 DATALINKCONN CTOR 16P 12 13 1 5 19 31 Wiresidsot lemaletsrminals ...

Page 784: ... LTGRN BLK FLW FronLleft wheel negative Detectsleft frontwheel sensorsrgnal 0 053 V or above 0sci oscope 0 15 Vp por above 7 GBN ORN FLW Front left wheel positive Turnwheelat E 1turntsecona l GRN FRW Front right wheelnegative Detectsright front wheel sensorslgnal 8 9 1 FR N I GRN BLK Front right I I wheelpositive Stops 0 25 1 15 V 1 0 GRN WHT STOP Detectsbrakeswitchsignal 1O GND Brakepedal Depress...

Page 785: ...w0 3V 1 7 LT BLU RLW Rear left wheel positive Detectsleft rearwheel sen sorsignal 1 7 1 8 q 3 Turnwheelat l turn second AC 0 053V or above oscilloscope 0 15 Vp por aoove 1 8 GRY RLW _ Rear left wheel negative 1 9 GRNIVEL RRW Rearright wheel positive Detectsright rearwheel sensorsrgnal 19 20 20 BLU EL RRW Rear right wheel negative Stops 0 25 1 15 V 2 1 YEUGRN FSR Fail safe relay Drivesfailsaferelay...

Page 786: ...olenoid valve 4 GND YEL WHT RL OUT Rearleft outlet Drivesleft rear outlet solenoid valve 5 GND ON Below 0 3V YEUBLK FR OUT Front right outlet Drivesright front outlet solenoid valve 6 GND 7 BLK GND2 Ground 2 Ground 7 GND Below 0 3V 8 YEL RR IN Rear right inlet Drivesright rear inlet solenoid valve 8 GND 9 OFF Batteryvoltage I RED B LU FL IN Front left inlet Drives left front inlet solenoid valve 9...

Page 787: ...nedOFF 4 ForDTCS 12 14 16 18 2 1 22 23 24 51 52 and 53 the indicatorgoesoff when the vehicleis drivenagainandthe systemis OK afterthe ignitionswitchis turnedfrom OFFto ON ll However if the DTCis erased the CPUis reset andthe indicator goesoff rightafterthe engineis startedif the systemis OK DiagnosticTroubleCode DTC 1 lf the CPUcannotbeactlvated andthe indicator comeson the DTCis not memorized 2 T...

Page 788: ...he causeof the problemis stillpresentandthe ABSindica tor is stillon Following theflowchartwhenthe ABSindicator doesnotcomeon canresultin incorrect diagnosis 2 Ouestion the customeraboutthe conditions when the problemoccurred andtry to reproduce the sameconditions for troubleshooting Findout when the ABS indjcatorcameon suchas during initialdiagnosis duringABS control afterABS control whenvehicles...

Page 789: ...ode 3 Theblinkingfrequency indicates the DTC NOTE lf the DTCis not memorized theABSindicator will go off for 3 6seconds andthencomebackon 4 Turnthe ignitionswitchOFF andremovethe SCSshortconnector NOTE TheMalfunction Indicator Lamp MlL will stayon afterthe engineis startedif the SCSshon connector is con nected Conditionslor DTCindication Vehicle speedis6 mph 10km h or less TheSCSshortconnector is ...

Page 790: ...Sindicator blinkstwiceandthe DTCis erased lf the indicator doesnot blinktwice repeat steps1 through6 lf the indicatorstaysONafterthe indicatorblinkstwice checkthe DTCbecause a problemwas detected duringinitialdiagnosis beforeshiftingto DTCErasure mode 8 Turnthe ignitionswitchOFF and removethe SCSshortconnector Conditionslor DTCerasure Vehicle speedis 6 mph 10km h or less TheSCSshortconnector is co...

Page 791: ...cal noise interminent interuption o FR 19 45 1 4 FL 1 6 RR 1 8 RL O N Pulser o FR 19 46 22 RR 24 RL ON Solenoid shortto body ground shonto wire o o FR IN 19 47 FR OUT 33 FL IN 34 FL OUT RR IN RR OUT 37 RL IN 38 RL OUT 4 1 ON Wheellock o 19 50 42 FL 43 RR 44 RL ON Motorlock o 19 51 52 ON MotorstuckOFF o 19 52 53 ON Motorstuck ON o o 19 55 54 ON Failsaferelay o 19 57 61 ON lgnitionvoltage o 19 59 7 ...

Page 792: ...ock Checktor n opon in the lcl cir cuit 1 Disconnect the gaugeassem bly 5Pconnector 2 Turnthe ignitionswitchON ll 3 Measure the voltagebotween the gaugoassombly5P con nectorterminal No l and bodyground Repairopen in tho wir betwoan the METER17 5A tuso nd gaugoa embly R pl co tho under dashfuro elay box lopen circuit inside the box l checkthe A8s indicatorbulb in thegaugeassembly R6olace tho ABSind...

Page 793: ...lortgrminalNo 3 to body groundwith a jumper 4 Turnthe ignitions witch ON ll R pairopan in tho wiro botw an the gaug r mbly nd body ground Ropsirpoor ground lcil i l DoestheABSindicator comeon Roplac6th6 printod circuit bo rd in tho gaug6assembly GAUGEASSEMBLY 5PCONNECIOR F q l 1 l l 3 l 4 1 5 l J6ii 6r xr JUMPER I wrRE I Wre sid6of lemaleterminals 19 41 ...

Page 794: ...NDcircuit 1 Connect the ABS controlunit 22Pconnector terminalNo 1 to body groundwith a jumper 2 Turnthe ignitionswitchON ll Ropairopon in tha wiro botwocn tho ABS control unit and body ground Ropairpoo ground G701 Checkfor an open in thc lG2 ci cuit Measurethe voltagebotweenthe ABS control unit 22Pconnector terminal No 11andbodyground Roprir opon in thc wira bdtwoen tho REAROEFROSTER RELAY 17 5Al ...

Page 795: ...l No 4 to body groundwith a iump6rwir Rapairopen in tho wire betwaan tho grug 3s mbly nd tho ABS controlunit R pl co tho print d circuit board in tha gluga lrg mbly GAUGEASSEMBLY 5PCONNECTOR n a l l l l 3 l 4 l 5 l I WALP BLU RED JUMPER I wrRE I L Wire sideof femalet6rminals 19 43 ...

Page 796: ...he resistance between the appropriate wheelsensor and 1 circuit terminals seetable Ropairopen in the or cir cuit wire or 3hort to the l cir cuit wire in the l l circuit wire between tho ABS control unit and th6 appropriatewhgel 3en Replaceth6 appropdate wh el sensot ls the resistance OK FronvRear 450 2 050O 20 c 68 F NOTE lf you do not erasethe DTC the ABS indicatorwill not go off until vehiclespe...

Page 797: ...heel sensor i circuitterminals see table R psirshort to wire betweenthe appropriale wheol sensor and the other wheel sensor lstherecontinuity Erasothe DTCand test drivethe vehicle lf ABS indicatorcomes on and same OTCis indiceted reDlace the ABScontrol unil NOTE ll theABSindicator comeson forthe reasons described below the indicator shouldgo offwhenyoutest drive thevehicle at speeds above19mph130 ...

Page 798: ... drive the car at 19 mph 30km h or more Doesthe ABS indicatorcome on andareoTCs21 24indi cated Th ytiam i OK t thi tim Checkthe appropriatepulsergear tor a chippedtooth seetable Rcpl c ih drlv h tt or th hub unil Chippld pubd g r l Chcckfor loo c ABS control unit connectors ll nace ery aubrti tute known good ABS control unit and racheck 9 46 DTC AppropriatePulger 21 Right front 22 Left front Right...

Page 799: ...orm the appropriatotrou bleshootingfor OTC54 Chockfor a short to body ground in tho solenoidcircuit 1 TurntheignitionswitchOFF 2 Disconnectthe modulator unit connector snd the ABS controlunit12Pconnector 3 Chocktor continuity between the appropriateABS control unit 12Pconnectorsolenoid c i r c u i tt e r m i n a la n d b o d y ground seetable Rep ir short to bodv ground in the appropri te sol noid...

Page 800: ...du lltor unit Chackfor an openin tho solonoid 1 Removethe jumper wire lrom themodulatorunitconnector 2 Connectthe modulator unit connector 3 Connect thefail saferelaycon nectorterminal No 3 to body groundwitha jumperwirc 4 Checktho rosistancebetween the appropriateABS control unit 12Pconnector terminal andbodyground seetable ls the resistance OK lN 8 10020 C 68 F OUT 3 5o 20 C168 F Chockloi a 3hor...

Page 801: ...he solenoid 1 Connect the modulatorunit connector 2 Checkfor continuitybetween the appropriateABS control unit 12Pconnector terminal and all other solenoidcircuit terminals seetable lsthorelessthan 3 0 Checkfor looseABS control unit connectors lf nocassary substi iute a known good ABS control unit and recheck Frompage19 48 ABS OONTROLUNIT 12PCONNECTOR Wiresideot femaleterminals 19 49 ...

Page 802: ...he brakos drag C h e c kt h e i n s t a l l a t i o n o f t h e appropriate wheelsensorinstal lation seetable Th6 orobablo cau3o was the vehiclespun duringcornaring lf the problemoccursagcin chockth6 modulator u ing tho HondaPGMTertar DTC AppropriateWheelSensor 41 Right front 42 Left front 4 Right rear 44 Leii rear Troubleshooting DTC41 44 WheelLock 19 50 ...

Page 803: ...ndicrtor comason With tho SCSrorvic conn c tor connectad aa paga 19 37 DTC51 ir indicrt d Problcmva ficltioni 1 Eras th DTC 2 Test drivethe vehicleat 6 mph 10km h or moro ooestheABSindicator com6on andis DTC51indi cated Th63ystcmi O t thir timc 19 51 ...

Page 804: ...en in the MOTOR circuit 1 Disconnect the pump motor 2 Connectthe pump motor relayconnector terminalNo 3 to No 4 with a jumperwire 3 Measure the voltagebetween the pump motor connector t e r m i n a l N o l a n d b o d y ground PUMPMOTORCONNECTON u_l_lj I MOTOR tWHTt n Y L Terminal sideof temaleterrninals YES Checkthe ABS MOTOR 40A f u s e i n t h e u n d e rh o o d A B S fuse relaybox and reinstal...

Page 805: ...it Measurethe voltagebetweenthe pump motor connector terminal No l andNo 2 Repeiropen in th6 wiro bstw en tha pump motor and body gaound Ropairpoo ground lc202l ls there batteryvoltage Frompage19B 52 Terminal sideol female terminals 19 53 ...

Page 806: ...n tho A8S controlunit 12Pcon nectorterminalNo 12 and bodyground R p ir op n In th wir batw n th und r hood ABS tu r l Y box lnd th ABScodrol unil Checklor a rho to pow r in th PMRcircuii 1 Removo thejumperwirefrom pump motor relayconnedor 2 Starttheengine 3 ireasur6 the voltage betwoen th6 ABScontrolunit 12Pcon nectorterminalNo 12 8nd bodyground R p ir hort to pow r In th wil brtwa n lh und hood A...

Page 807: ...and rcchock Chocktor an opcn in thc MCK circuit 1 Turntheignition switch ON lll 2 Measurethe voltage betvveen the under hoodABSluse relay box 4PconnectorterminalNo 2 andbodyground R psir opan in thc wiro botwoon thc undar hood ABS tuso rolay box nd lho ABScontJolunh lsthereapprox 10V Chocktor n opon in tho MOIOR circuit 1 Disconnect the pump motor connector 2 Measurethe voltage botween t e r m i n...

Page 808: ...it12Pconn6ctor 3 Checklor continuity b tween t e r m i n a lN o 1 2 a n d b o d y ground R6pair3hort to body ground b tween th6 under hood ABS fuso rolay box nd the ABS con irol unit lf tho problom occurs again roplacotho ABScontlol unh COIVTROL UN T I2P OONI ECTOR Lr r F T t 1 t 2 t 3 l 4 t 5 1 6 l FT sTrrFoFiFZ _T PMR tYEL RED o Y wire sideof lemaleterminals 9 56 ...

Page 809: ...odABS fuse relay box and reinstallthe luse if it is oK R olacotho fu3 nd rochocl Checkthe fail saferelay seesec tion 23 and leavotho tail safe retayremoved Chocklor an opan in th6 8 cir cuit Measurethe voltagebetweenth fail saferelayconnectorterminal No 1 andbodyground Ropairopon in tha wire botwecn ths undor hood ABS fuso rol y box nd ihe tail 3at r lay ls there batteryvoltage C h o c k t o r n o...

Page 810: ... Turnthe ignitionswitchON ll 3 Measurethe voltage between the terminalNo 21 and body ground Repairshort to powor in tha wirc betwoon the ABS control unit rnd tho tail sla rehy ls there batteryvoltage Chgckfor a 3hortto body ground in th6 FSRcircuit Checkfor continuiw betweenthe ABS controlunit 22Pconnector terminal No 21andbodyground Rapairshort to bodv ground in the wir betwoon the ABS con trol u...

Page 811: ...o SCS3ervico connac tor connected aoe pag 19 371 DTC61 62 r indlc t d Problcm veriticrtion 1 Erase the DTC 2 Test drivethe vehicleat 6 mph 10km h or more Doesthe ABS indicator comeon Th tFl m is OK t thi timo Parform tha approprirta lrou blcahootingtor th code ls DTC61or 62indicated t 19 59 ...

Page 812: ...oting CentralProcessing Unit CPU With the ignition switch ON lll tho ABS indicator does not go off With the SCSserviceconnec lor connectgd sss page 19 3 DTC81is indic ted Problemve ification 1 Erasethe DTC 2 Test drive thevehicle DoestheABSindicator comeonandis DTC81indi cated R place th6 ABScontrol unit lntermittent failure the vehicle is OK rt this time 19 60 ...

Page 813: ...D motorconnectors 2 Disconnect the brakelines then removethe modulatorunit Installation 1 lnstallthe modulatorunit thenconnect the brakelines Tightenthe flarenutsto 15N m 1 5kgf m 11lbf ft 2 Connect the modulatorunitandpumpmotorconnectors 3 Bleedthe brakesystem startingwith thefrontwheels 4 Startthe engine andcheckthatthe ABSindicator goesoff 5 Test drive the vehicle andcheckthattheABSindicator do...

Page 814: ...sure the air gap between tho wheelsensorand pulsersllthe way aroundwhilerotatingthe pulser Standard 0 4 1 0mm 0 02 0 04in NOTE lf the gap exceeds1 0mm 0 04in the probabilityis a distortedsuspension arm which shouldbe reDlaced Front R 1 L TJ t t l E t E_ Installthe ABS controlunit in the reverseorderof removal Startthe engine and checkthat the ABS indicator goesoff Test drive the vehicle and checkt...

Page 815: ... Becareful when installing thesensors to avoidtwistingthewires Front 6 x 1 0 m m 10N m 1 0kglm 7 lbf ft 6 x 1 0mm l0 N m 11 0kgt m 7 lbl ftl Rlal 6 x 1 0 m m 10N m11 0ksf m 7 lbf ft 6 x 1 0 m m 10N m 1 0kgl m 7 lbfft FNONT WHEELSENSOR 9 63 ...

Page 816: ...llation 20 50 Mirror Visor and Mirrot Covet Replacement Haichback 20 51 Sedan 20 51 Rearview MirrorReolacement 20 52 RoofMoldingRep acament 20 164 DoorandSid Moldings Replacement 20 165 Moonroot lnd6x Hatchback 20 77 Sodan 20 8il Openerand Latch Replacement 20 156 OpensrCables Replacamsnt 20 154 Retainersand W atherstrip Replacement 20 160 Seats FrontSeatRomoval 20 103 FrontSeatReplacement 20 104 ...

Page 817: ...0 15 OUTER WEATHERSTRIP Replacement page20 15 INNERWEATHERSTRIP Replacement page20 15 POWERMIRROR Replacement page2o 49 COVERPANEL PLASTICCOVER Replacement Page20 4 HINGE I ffis a d mr tAg lF T ROD DOORPANEL Replacement page20 4 i t lGN sS 20 2 SPEAKER COVER ...

Page 818: ... HANNEL Replacemenr pase20 14 OUTERHANDLE mw p POWER DOOR LOCKSWITCH c9 INNERHANDLE ROD INNERHANDLE TRIM Replacement page20 10 CENTER LOWER GLASSRUNCHANNEL Replacement page20 14 LOCKCYLINDER REGULATOR Replacement page2O 10 POWER WINDOW MOTOR W STFIKER Adjustment page20 48 ROD PROTECTOR 20 3 ...

Page 819: ...ct the power door lock connector l I i 20 4 3 Remove the armrest Pocket v Screwlocation I eF Y I v ARMREST POCKET 4 Release the clipsthat holdthe doorpanel NOTE Removethe door panelwith as littlebend ing as possible to avoidcreasing or breaking it 95 mm 3 74 inl nYLf P to ciintr L r 132 2 REMOVER SNAP ON 4177 or equivalent 11 77in Cliplocations TRIMPAD REMOVER then remove the clip using a trim pad...

Page 820: ...rs Screwlocations 8 DOORLOCKUNIT FRONT CONNECTOR SPEAKER 6 PLASTIC COVER 7 Removethe cover panel then disconnect the power mirror connector see page 20 49 Detachthe grommetsand harnessclips then care fully remove the plasticcover a Grommetlocat ons 2 Q Harness clip locations 3 GROMMET BeJoreinstallingthe plasticcover make sure the door harness and connectors are astened correctly on the door a Con...

Page 821: ...over PLASTIC COVEB 1l Install allremoved oarts andfastenthedoorharness correctly a Grommetlocations 2 Or Harness clip locations 3 GROMMET PLASTIC COVER FRONT SPEAKER DOORLOCKUNIT 20 6 ARACKET 12 lnstall the doorpanel seepage2O 4 NOTE a lMakesurethe door harnessis not pinched a lf necessary replace anydamaged claps a Makesuretheconnectors areconnected properly 13 Inslallthearmrestpocketandinnerhand...

Page 822: ...clips Screwlocation 1 CONNECTOR Detach the connector rom the door 8OD PFOTECTOR 4 Removethe bolts Boltlocations 2 6 x 1 0 mm 9 8 N m 1 0ksf m 1 2 thl tt 5 Pullout the outer handle Prythe outerhandlerodout of itsjoint usingdiagonal cuners NOTE a To easereassembly notelocation of theouter handlerod on the joint beforedisconnecting it a Takecare not to bendthe outer handlerod a Usea shop towel to pro...

Page 823: ... INNERHANDLE ROD 6 8 Disconnect the cylinderrod as shown NOTE Takecarenot to damage the lockcylinder joint OUTER HANDLE CYLINDER ROD 7 V SHOPTOWEL Remove the cylinderswitchlrom the outerhandle Scrswlocation 1 OUTER HANDLE i4 cYLtNDER swtTcH Pull out the retainerclip then cylinderand cylinderprotector LOCKCYLINDER li clrP Replace S o YLTNDER CYLINDER PROTECTOR RETAINER CLIP Installation isthe rever...

Page 824: ...e screw Screw locations 3 6 x 1 0 m m I fiNrrlr rnr 6 Nm 0 6kgfm law iw r i CONNECTOR Detachthe connector 5 Removethe latch throughthe holein the door NOTE Takecarenot to bendlhe outerhandlerod and cylinderrod CYLINDER ROD 6 lnstallalion isthe reverse of the removalprocedure NOTEI a Makesurethe innerhandlerod lockrodandcon nectorare connectedproperly a Make surethe door locksand opensproperly 20 9...

Page 825: ...over then removethe screws NOTE Wheninstalling the channel guidecover ap ply the double faced adhesive tape to it Screwlocations 3 CENTER CHANNEL GUIDE Remove the center channel guide by pulling it upward Ofimnrrrn 20 10 6 Carefully movethe glassuntilyoucanseethe bolts then loosenthem Slidethe guideto the rear then removethe glass from the guide NOTE Takecarenot to dropthe glassinside the door Bol...

Page 826: ...around the guidepinto show the originallocation GUIDEPIN GUIDE PIN MOUNTING BOLT 6 r 1 0m m 3 N mlO 3kgl m 2 tbf trl GUIDEPIN GUIDEPIN SEAL 20 11 Disconnect the connector then removethe regula tor throughthe centerholein the door NOTE Scribea linearoundthe rearrollerguidebolt to show the originaladiustment Boltlocations 6 6 x 1 0 m m I N m 0 8 kgf m 6lbt ftl REGULATOR cont d ...

Page 827: ... Detach the clips then peel and remove the glass run cnanner Clip locations 3 1 0 GLASS STOPPER FRONTCHANNEL CENTEB CHANNEL 20 12 1 1 NOTErlf necessary remove the glassstopper When installing the glass stopper align it with the notch in the outer weatherstrip Grease allthesliding surlaces of the regulator where shown Installthe power window motor on the regulator Checkthat the regulatormovessmooth...

Page 828: ...edin the center channelguide properly GUIDEPIN GLASS CHANNEL GUIDE Rolltheglassup anddownto seeiI it movesfreely withoutbinding Also makesurethat thereis no clearance between theglassandglassrunchannel whentheglass is closed Adjustthe position of the glassas necessary lseepage20 16 GUIDE PIN GLASS CENTER CHANNEL GUIOE 1 7 1 8 CENTEB CHANNEL Attach the door harness to the door correctly see page 20...

Page 829: ...nstallation isthereverse oftheremova Iprocedure NOTE a Fittheglass runchannels intothefrontandcenter channels asshown CENTERLOWER GLASSRUN Installthecenterchannel whilepushing the glass as shown Makesurethe glassrunchannels arenottwisted Peelthe centerlower glassrun channelout of the centerchannel NOTE Wheninstalling applyclearsealant to loca tions on the centerchannel GLASS RUN CHANNEL _ ffiil wd...

Page 830: ...LDING CLIP 4 Installation is the reverse of the removalprocedure NOTE a It necessary replace anydamaged clips a Wheninstalling alignthe rearedgeot the outer moldingwith the rearedgeof the door OUTERMOLDING i __ t _ ri o ta c 1 i NOTE a Beforeinstalling the innerweatherstrip applyclear sealantto locations on the door as shown a It necessary replaceany damagedclips Sealant Cemedine 8500 or equivalen...

Page 831: ...l DOORPANEL 3 Connect the power window switch to the door harness Make sure the guide pin is installedin the center channel guideproperly CENTER CHANNEL GUIDE GUIDEPIN 20 16 5 Raisethe glassas iar up as possible and hold it against the glassrun channel 6 Loosenthe rollerguide bolts and adjustthe glass so it is parallel with the glassrunchannel GUID PIN CENTEB CHANNEL GUIDE ROLLER GUIDE BOLTS 7 Tig...

Page 832: ...nelevenly 12 Checkfor waterleaks NOTE Do not use high pressure water 13 Routethe doorharness andconnectors andfasten them to the door seepage2O 5 Disconnect the powerwindowswitchlrom thedoor harness theninstallthepowerwindowswitchinthe doorpanel seepage20 l6 Attachthe plasticcover then installthe doorpanel seepage 2O 4 1 4 20 17 ...

Page 833: ...ex Passenger s F R o d J ARMREST POCKET 1 g INNER MOLDING r 6ld t DOOR PROTECTOB 9 l TWEETEB 20 18 POWER WINDOW swtTcH Replacement page20 20 DOORPOCKET SPEAKER COVER Q t n N a x l rz r s ti 7t i 1 N J r a 1 ot n 6 w S PY DETENT ...

Page 834: ...GULATOR Replacement page20 26 ROLLER LOCKCYLINDEN Replacement Page20 23 GLASSGUIDE Replacement page20 26 OUIER HANDLE STOPPEB PLATE 6r 6f J d l l CYLINDER PNOTECTOR INNERHANDLE ROD Replacement page20 23 INNERHANDLE TRIM _ cYLINDER SWITCH y Replacement page 20 23 q INNER 6 tp rw STRIKER Adiustment page20 48 LATCH Replacement page 20 24 d LOCKROD PROTECTOR RoDPRoTEcToR 20 19 ...

Page 835: ...ock connector INNER 20 20 3 Removethe armrest pockel V Screw location 1 TRIM PAD REMOVER SNAP ON 4177 ol equivalent 1 2 m m 0 47 inl T I mm 0 04 in I 45 rnm Cliplocations A C l i p 1 11 77inl B C l i p 8 NOTE Loosen the screw then remove the clip using a trim pad or clip remover A I Y v ARMREST POCKET 4 Release the clipsthat holdthe doorpanel NOTE Removethe door panelwith as littlebend ing as poss...

Page 836: ...tor l _ Cliplocations 4 INNERMOLDING DOORPANEL t INNER MOLOING wtNDow CONNECTORS Screwlocations 8 FBONTSPEAKER 6 Remove the bracket door lock unit and front speaker DOORLOCKUNIT 7 Remove thecoverpanel thendisconnect the power mirrorconnector seepage20 49 Detachthe grommetsandharness clips thencare tully removethe plasticcover a Grommetlocalions 2 O Harness clip locations 3 R A 1 POWERMIRROR CONNEC...

Page 837: ...ndpreventwater reaKs a Do not plugthe elongatedhole ADHESIVE COVER PLASTIC COVER Pass the door harness through the hole in the plastrc cover 1 1 Install allremoved parts andtastenthe doorharness correctly O Grommet locations A 2 Or Harness clip locations 3 1 GROMMET HARNESS PLASTIC COVER Install the doorpanel seepage2o 21 NOTE a Make surethe door harnessis not pinched a lf necessary replaceany dam...

Page 838: ... 4 N m 1 0ksf m i ryty J Cliplocations 2 20 23 I N N E R HANDLE CONNECTOR 4 Remove the latch Screwlocations 3 6 x 1 0mm 6 N m 0 6kgl 4 tbf tr 5 Pullout the outer handlewith the latch Prytheouterhandle rodoutol itsjointusingdiagonal culters NOTE a To easereassembly note location of the outer handlerod on the joint beforedisconnecting it a Takecarenot to bendthe outer handlerod a Usea shop towel to ...

Page 839: ...erse of the removalprocedure NOTE Makesurethe innerhandle rod lockrodand connectorare connectedproperly 6 7 v Disconnect the cylinderrod as shown NOTE Takecarenot to damagethe lock cylinder Jornt OUTER HANDLE SHOPTOWEL Remove the cylindefswitchfrom the outerhandle Pull out the retainerclip then remove the lock cylinderand cylinderprotector 8 L g o cYLTNDER lnstallation isthe reverse of the removal...

Page 840: ...a linearoundthe locknutto showtheorigi nal adjustment Bolt locations 2 f 6x 1 0mm r lE s 8N m Z 11 0 kel m 7 2tbr ril __ _ _ a llut location l I lX x r 2s mm W i 1i T ru_ otn l_ IN ADJUSTINGBOLT Removethe front sashthrough the center hole in the ooor as snown FRONT SASH 5 Installation isthe reverse of the removalprocedure NOTE After installing adjustthe positionol the front sashas necessary a Alig...

Page 841: ...removetheni Glass stopper locations 2 fo A r r r i t rQ a1lL iqW A 3 i l o Jl r ruf v rsxen flff arur rrr_ Carefully movethe glassuntilyoucanseethe glass mountingbolts then removethem NOTE Scribea line aroundthe glassmounting bolts to show the original adjustment i goll locaiions 3 1 rr 6 x l o mm L qlqj I Nm 0 8kstm 6rbrfrl a L c tio fil Locati hN lLoosen 5 Carefullypull the glassout of the windo...

Page 842: ...ribea line aroundthe locknutsto show the originaladjustment a Nut locations 4 A Eolts locations 3 _i I LOCKNUT REGULATOB ADJUSTING BOLT Removethe glassguide NOTE a Holdthe adjustingboltwith a hexwrenchwhen removingthe locknut a Scribe a linearound the mounting nutto showthe original adjustment a Nut locations 3 I x 1 25mm 22 N m 2 2 kgf m 16 tbt frl LOCKNUT ffi ADJUSTING BOLT a ir frr cont d 20 27...

Page 843: ...power window switch on the door panel see page 20 41 When reinstalling the plasticcover apply adhesive along the edge where neccessaryto maintain a con tinuous seal and prevent water leaks see page 2 0 2 2 14 Install the doorpanel seepage20 21 Doors Glass RegulatoriGlass Guide I l 20 28 L OuterMoldingReplacement NOTEr Lower the glassJully 1 Remove Door panel lsee page 2O 2O Power mirror see page 2...

Page 844: ... llr ff1 r ff d T I l tj fit tt l i xffi il __ _ ro_r ...

Page 845: ...Doors RearDoorIndex Sedan HINGE 6 il TuJo w k e i l WEATHERSTRIP Replacement page20 39 Replacement page20 32 I Replacement page20 38 20 30 ...

Page 846: ...INSIDE STABILIZER REGULATOR Replacement page20 35 CENTER GLASS GUIDE Beplacement page20 35 INNER HANO h 1 7 v LATCH PROTECTOR Replacement page 2o 35 Sr 20 31 ...

Page 847: ... in ner handle Disconnect the power window switch connector l ti I I 20 32 L Removethe armrestPocket V Scrowlocation 1 qE v l v ARMREST POCKET 4 Release the clipsthat holdthe door panel NOTE Removethe doo panelwith as littlebend ing as possibleto avoidcreasingor breakingit 45 mm 1 77in SNAP ON _ r A177 ol 4 oquivafont 1mm 45 0 04 in I Cliplocations 8 5 Removethe door panel by pullingrt upward ...

Page 848: ...a Applyadhesive alongthe edgewherenecessary to maintaina continuous sealandpreventwater leaks a Do not plugthe elongatedhole a Grommet locations 2 q GROMMET BBACKET Pass the door harness through the hole in the plastc cover 9 lo ELONGA HOLE Installthe door panel seepage20 32 NOTE a Make surethe door harnessis not pinched a lf necessary replace anydamaged clips a Makesuretheconnectors areconnected ...

Page 849: ...1 0 mm A Clip location l 9 8N m 1 0kglm I otn __ TUBE Pullout the outer hbndlewith the latch Prytheouterhandle rodout of itsjointusingdiagonal cuners NOTE a To easereassembly notelocation of theouter handlerod on the joint beloredisconnecting it a Take carenot to bendthe outer handlerod a Usea shoptowel to protectthe openingin the door BUSHING Replace h 5 Installation isthe reverse of the removalp...

Page 850: ...ctorare connectedproperly Scaew locations 2 tr l Glass Regulatol Center Glass GuideReplacement BOLT 8 x 1 25 mm 22 N n 12 2kgl m 16 lbt ft a Door panel seepage 20 32 a Plasticcover seepage 20 32 Connectthe powerwindowswitchto the doorhar ness seepage20 41 Peelthe weatherstrip awayfromthe door seepage Loosenthe insidestabilizers NOTErScribe a linearound the boltsto showthe original adjustment Caref...

Page 851: ...OTE Takecarenot to dropthe glassinside the door x ST 20 36 6 Remove thecenter glass guide NOTE a Hold theadiusting boltswithahexwrench when removing the locknuts o Scribe a line around the locknuts to show the originaladjustment a Nut locations a a 2 B O 1 12 x 1 25 mm v1 j LOCKNUT t S t Y l 22N m 2 2 ksf m Vuloru __ ...

Page 852: ...or mark the locationby scribinga line acrossthe sec tor gear and regulator V Bolt locations 3 POWER wlNDow MOTOR CONNECTOR REGULATOR 9 Grease all the sliding surlaces of the regulator and center glass guide where shown 10 lnstallthe power window motor on the regulator l 1 Check that the regulator moves smoothly by con nectinga I2 V batteryto the power window motor seesection 23 V Adjusting bolt I ...

Page 853: ...gthe edgewhereneccessary to maintain a con tinuous seal and prevent water leaks see page 20 33 16 lnstallthe doorpanel seepage2O 32 OuterMoldingReplacement NOTE Lowerthe glassfully 1 Remove the doorpanel seepage2O 32 2 Peelthe weatherstrip awayfromthedoor see page 2O 39i thenremovethe screw 3 Startingat the rear pry the outer moldingup and detachthe clips then removethe outer molding NOTE Takecare...

Page 854: ... a Cliplocations 3 i I L 5 l f l l a 1 B 2 rf NOTE a Before installingthe weatherstrip apply clear sealantto locations Sealant Cemedine 8500 or equivalent a It necessary replace anydamaged clips l t A I l IW _ locations il Itr rtl 1 8 20 39 ...

Page 855: ...Doors GlassAdjustment Adjustingbolt locknutlocations NOTE Take carenot to damagelocation on the front sash INSIDE STABILIZEB 20 40 r GLASS GLASSGUIDE GLASS a o a t STABILIZER ...

Page 856: ...T 3 Removethe door panel seepages2O 2O 32 NOTE It necessary peeloff the plasticcover Removethe power mirror seepage 20 49 5 Remove the power window switch from the front ooor paner i Screw locations 5 v Cliplocations 3 FRONT DOOR PANEL 6 Connectthe powerwindow switchto the doorhar nessconnectors Front DOOR HARNESS POWER WINDOW swtrcH 7 To preventthe glassfrom contacting the body hold the glass and...

Page 857: ...ce B Clearance SectionO GLASS Section Ql RETAINEB RETAINER 20 42 B Clearance H Clearance socrion GLASS GLASS StandardClearance a Permissible tolerance t 0 1 mm O 04in Front 111and 121 Rear 13 and 141 Unit mm iin Measuring Point o r 9 Clearance t l 0 8 o 03 3 O 1o 12 1 0 3 o 41 B 9 3 0 37 9 9 0 389 5 6 to 22l Measuring Point 6 Clearance n to 0 39 2 5 1 0 1 6 O o 241 B 5 _ l to 2J 1 1 5 o 45 1 2 1 o...

Page 858: ...OPPER r7 PLATE lErt 7 LOCKNUT 4 Loosen the nutsandlocknuts securing theglass guide andregulator Adjustthe glasslore and aft by movingthe glassguideandregulator NOTE Hold rhe adjustingbolts with a hex wrench when loosening the locknuts 5 Repeat steps 3 thru 4 untilclearance H is within the specifiedlimits then tasten the glassguideand regulator Press the stopperplatesagainst the glassstop pers then...

Page 859: ... 20 44 Doors GlassAdjustment cont d out LOCKNUT REGULATOR ADJUSTING BOLT NOTE Turnthe front and rearadjustingboltsthe sameamountto keepthe regulator parallel with the seatingsur aceot the door Aftertighteningthe adjusting bolts makesurethat the endsof the adjusting boltsstillprojectout of the locknuts 4 Alignthe frontsashwith the glassusingthe ad justingbolt at the bottom of the lront sash 5 Move ...

Page 860: ...he center glass guide and adiust the glassJoreand aft by mov ing the center glassgurde NOTE Hold the adiLrstingbolts with a hex wrench or flat tip screwdriverwhen loosening the locknuts STOPPER PLATE 4 Repeat steps 2 and 3 untilclearance H is withinthespecified limits thenfastenthecenter glassguideand rollerguide Press thestopper plates agarnst theglass stop pers thenfastenthe stopper plates NOTE ...

Page 861: ...I li lliun fiJrtr l A l 3 Loosenthe upperlocknuton the centerglass guide andturntheadjusting boltuntilclearance B is withinthe specified value ADJUSTING BOLT LOCKNUT 22 N m 12 2kgt tn 16 lb ttl GLASS NOTE Do not adjustthe loweradjusting bolts on the centerglassguide 4 Move the glassup and down to seat jt then measure clearance B at the designated locations 5 Measure clearance H againto makesureit ...

Page 862: ...20 42 Center Pillarsection WEATHERSTRIP 1 7 Check for water leaks NOTE Do not use high pressurewater 18 Routethe doorharness andconnectors andlasten themto the door seepages20 22 331 19 Disconnect the powerwindowswitchfromthe door harness then installthe power window switch on the doorpanel seepage20 41 20 Attachthe plasticcover then installthe doorpanel seepages2O 2o 321 20 47 ...

Page 863: ...hingeto makethe door edgesPARALLEL with the bodV HINGE HINGEMOUNTING BOLTS 8 x 1 25 mm 29 N m 3 0 kgf m 22 lbt lt Loosenthe hingemounting bolts and movethe door BACKWARD or FORWARD UP or DOWNas necessary to equalrze tne gaps Lower the g lass SHOPTOWEL Checkfor waterleaks i DOOR N 4ake surethe doorlatihes securely without slamming lf it needsadjustment 1 Draw a linearoundthe strikerlor reference 2 ...

Page 864: ... CONNECTOR 3 Installation is the reverseof the removalprocedure HOOKS 5 x o 8 m m I l Sedan 1 Removethe door panel seepage20 201 and dis connectthe connector 2 Pryout the coverpanelwith a flat tip screwdriver then removert CAUTION Whenpryingwith a tlattip screwdriver wrap it with protective tape to prevent damage COVEB PANEL 3 Removethe screwswhile holdingthe mirror Screw locations A Screw 2 qu 5 ...

Page 865: ...flat tip screwdriverwith a shop towel 1 Remove the pivot then removethe snap ring as shown Remove thejoint pin thenremovethe mirrorholder assnown _ t a i i l Install thesnapring SNAPRING Install the pivot NOTE Apply greaseto the locationsindicatedby the arrows JOINTPIN 6lr PIVOT 6t1 JOINT PIN 6tl 3 lnstallthejoint pin ...

Page 866: ... MIRROR VISOR HOOK 4 Turn the actuatorto the originalposition Remove the screws then removethe mirrorcover Screwlocations 3 MIRROR COVER ACTUATOR 5 Installation isthe reverse of the removalprocedure 20 51 Sedan 1 Remove the mirrorholder 2 Turn the mirror base forward then screws remove the Screw locations A S c r e w 4 B Screw 1 MIRROR BASE 3 Detachthe hook then removethe mirrorvisor ...

Page 867: ... reverseoI the removal procedure ACTUATOR MIRROR COVEB Mirrors MirrorVisorand MirrorCover RearviewMirrorReplacement rl rl I 20 52 L 1 Prythe coveroff usingthe endof a flattip screw drive r CAUTION To preventdamageto the mirrorand cover wrap the endol the screwdriver with a shop towel 2 Removethe screws then remove the rearview mirror REARVIEW MIRROR 3 lnstallation is the reverse of the removal oro...

Page 868: ...NG CLIPD 2 Green AINER 2 Yellow WINOSHIELD Removal page20 55 Installation page20 56 REAR GLASSBRACKET 2 r A RET a REAR WINDOWMOLDING UPPER FASTENER 2 Self adhesive type glassside UPPER FASTENER 2 Selfadhesive_type hatchside SIDERUBBER DAM 2 OUARTER GLASS Removal Page20 73 SPACER 2 Installation Page20 73 TAPE B 2 ADHESIVE Ar I BUSHING SEAL 2 Removal page20 61 Installation page20 62 NOTE The numbers...

Page 869: ...WINDOW Removal page 20 68 Installation page 20 69 UPPER RUBBER DAM CLIPE 2 White cLlP F 2 Lefr Whire Right Elue CLIPA 8 Red B fq LOWERRUBBER DAM A RET g REARWINDOWMOLDING GLASSBRACKET 2 AINER 2 Yellow UPPER FASTENER 2 Self adhesivo type glassside Krrr FA TENER 2 Clip type body side LOWERCOVER 20 54 r o sPAcER 4 q LowEB FA TENER 2 Self adhesive typ slasssid LOWERFASTENER 2 Self adhosive type body s...

Page 870: ...ield wiperarmsandairscoop seesection 231 2 Detachthe clipsfrom the retainers then remove bothsidemoldings as shown NOTE lf necessary replace anydamaged clips 3 Remove the rightandleftglassbrackets WINOSHIELD Peeloff the uppermolding NOTE Whenthe uppermoldingremoval is dillicult cut theupperrubberportionO off thencutthe side rubberportion UPPER MOLDING ADHESIVE WINDSHIELD 5 Remove the other retaine...

Page 871: ...h a knifeto a thicknessof about2 mm O 08in on the bonding surfacearoundtheentirewindshield opening flange a Donot scrapedownto the painted surtaceoJthe body damagedpaint will interferewith proper bondang a Removethe rubberdam from the body a Mask off surrounding surfacesbeforepainting Clean thebodybonding sur face witha sponge damp enedin alcohol NOTE After cleaning keepoil grease andwater from ge...

Page 872: ...ERMOLDING 10 mm 0 39in WINDSHIELD LOWERRUBEER OAM 8 20 57 Installthe glassbracketsand retainers as shown NOTE Thenumbers afterthe partnamesshowthe quantitiesof the partsused BRACKET 2 7 Setthe windshield ontheglassbrackets thencenter it intheopening Makealignment marksacross the windshield andbodywith a grease pencilat thefour potnrssnown 6 ERACKETS NOTE Adjustthe glassbrack ets to centerthe winds...

Page 873: ... n kBB i KKKxxl DAM 20 58 1O Witha sponge applya lightcoatoI bodyprimer to the original adhesive remaining aroundthe wind shieldopeningllange Let the body primerdry tor at least10 minutes NOTE a Do not applyglassprimerto the body and be carelulnot to mix up glassand body primer sponges o Never touchthe primed surfaces with yourhands a Mask olf the dashboardbe ore painting the flange epptvbodyp ime...

Page 874: ...e Lightlypush onthe windshield untilitsedgeistullyseatedonthe adhesive allthe way around NOTE Do not closeor openthe doorsuntiladhe sive is dry SUCTION CUPS ALIGNMENT MABK t ADHESIVE 15 Installthe clips on i Cliplocations A ClipA a both side moldings B C l i pB 2 _ _ C ClipC lHatchback 2l lSedan 4l D ClipD Hatchback 2l EV ClipE 2 Y r i P l Y___ F ClipF 2 _ F F Left Whitel Right Blue E Whilel I A l...

Page 875: ...tallation lf the car has to be used with in the first four hours it must be driven slowly a Keep the windshielddry for the first hour after installation a Check that the ends ol the side moldingare set under the air scoop gC L I PE 19 Reinstall all remaining removed parts NOTE Advise the customer not to do the Iollow ingthingsfor two to threedays a Slamthe doorswith allthe windowsrolledup a Twistt...

Page 876: ...S PROTECTIVE TAPE Hatchback CAUTION a Use coversto avoiddamagingthe interior a Wear glovesto removeand installthe glass a Do not damagethe defrosterglid lines a Takecarenot scratchthe rearwindow moldino 1 To removethe rearwindow tirstremove the Rearshelf seepage20 91 Hatchsidetrim andhatchtrim panel seepage 20 14A1 a Highmountbrakelight seesection23 a Rearwindow wiperarm andrearwindow wiper motor ...

Page 877: ... usea put ty kniteto scrape off alltracesof oldadhesive then cleanthe rearwindow surlacewith alcoholwhere new adhesiveis to be applied NOTE Makesurethe bondingsurfaceis keptfree of water oil and grease CAUTION Avoid setling ths rear window on its edges the molding can be permanentlydetormed NOTE Cleanthe shadowed area REAfi WINDOW 20 62 Apply the uppersealto the insideface of glassas shown Gluethe...

Page 878: ... ALIGNMENT MARK REARWINDOW 1O Install the rearwindowtrim With a sponge apply a light coat oI glassprimer aroundthe edgeof the rearwindow then lightly wipe it off with gauzeor cheesecloth N O T E I a Donotapplybodyprimerto the rearwindow and do not get bodyandglassprimerspongesmlxed up a Nevertouchtheprimed surlaces with Yourhands lf you do the adhesive may not bondto the rear window properly causi...

Page 879: ...dener together on a glassor metal plate with a putty knife NOTE a Cleanthe platewith a spongeandalcoholbefore mixing a Follow the instructionsthat came with the adhesive Beforefillinga cartridge cut the end of the nozzle as shown 10 mm 10 39inl 7 mm O 27inl 1 4 20 64 RearWindow Installation cont d 10 mm 10 4inl L 15 Packadhesiveinto the cartridgewithout air pock ets to ensurecontinousdelivery Putt...

Page 880: ... NOTE Advisethe customernot to do the tollow ing thingsfor two to threedays a Slamthe doorswith all the windows rolledup a Twistthe bodyexcessively suchaswhengoing inandout of driveways at anangleor drivingover rough unevenroads RearWindow Molding 2 3 6 Replacement Remove the rearwindow seepage20 61 then move the uoDerseal Place the rearwindowon itssurface asshown v a helperholdingthe rearwindow C...

Page 881: ...ht coat of glassprimer to the surfaces NOTE o Applyglassprimeraround theentiregrooveo the new molding a Do not applyglassprimerto the outersurface 9 Run a bead of adhesivein the groove of the moldtng M O L D I N G 20 66 1O Placethe rear window outside up then alignthe joint of the molding with the T mark at the top of the gtass as snown MOLDING 1 1 wtNDow Pressthe moldinginto positionaroundthe ent...

Page 882: ...ow overthe opening setthe rearwin dow on the hatch then centerit in the opening Glass Surrace I surface to be l A w r p e d c l e a n n v I 7 ar J sK L g _t 1 4 sucTroN cuPs HATCH 15 Mark the molding lip with a grease pencil as shown MOLDING 16 Trim the moldinglip as shown MOLDING LIP UUI OII 17 Close the hatch then check the gap between the molding lip and body 18 lf the molding lip contacts the ...

Page 883: ...utterblade Removethe clips then removethe lower cover NOTE Usea clipremover to remove the clips _ n _ i MOLDING v 4 CLIP REMOVER LOWERCOVER 20 68 L 4 Peeloff the molding NOTEiWhenmolding removal is dif icult cut the molding with a knife REARWINDOW S 5 Pull down 20 100 CAUTION cessively the rear of the headliner see page Take carenot to bendthe headlinerex 6 Apply protectivetape to the edgeof the b...

Page 884: ...painted surfaceot the body damagedpaint will interferewith proper bonding a Remove the upperandlowerfastenersfrom the oooy a lvlaskoff surrounding surfacesbeloreapplying primer Clean thebodybonding surlacewitha sponge damp enedin alcohol NOTE Ajter cleaning keepoil grease andwaler lrom gettingon the surface lf the oldrearwindow isto bereinstalled usea put ty knifeto scrapeoff alltracesoJoldadhesiv...

Page 885: ...pper fasteners and glue the lower tastenersto the body as shown NOTE The numbersafter the parts namesshow quantityol the part used UPPER FASTENERS 2 7 Gluethe sideandlowerspacers andfasteners to the insideface of the rear window and molding as shown NOTE Thenumbers afterthe partnamesshowthe quantitiesof the parts used Spacer Iastener locations s SPAC R 4 rr P K r lr rcrumerur nitanrs lB LOWER SPAC...

Page 886: ...terialsaway trom the primedsurface fu5 t apptygtassp im rhe e All around 10mm 0 4 in ALIGNMENT MARK S 1 11 Witha sponge applya lightcoatoJbodyprimer to the original adhesive remaining aroundthe rearwin dow openingflange Letthe body primerdry tor at least1Ominutes NOTE a Do not applyglassprimerto the body and be carelul not to mix up glass and body primer spon9es a Never touchthe primed surfaces wi...

Page 887: ... close the doors until the adhesiveis dry ALIGNMENT MARK 16 Scrapeor wipethe excessadhesive ofl with a put ty knife or towel NOTE To removeadhesive lrom a paintedsurface or therearwindow usea softshoptoweldampened with alcohol 17 lnstall the lowercover 18 Letthe adhesive dryfor at leastonehour thenspray water over the rear window and check for leaks Markleaking areas lettherearwindowdry thenseal w...

Page 888: ...akesurethe bondingsurfaceis keptfree of water oil andgrease CAUTION Avoid s6tting tho qurrtsr glass on its edges th molding canbe permanentlydstormed NOTE Cleanthe shadowed area 3 CLIP cont d CAUTIONi Wearglovesto removeand installthe quarter glass Useseatcoversto avoid dsmaging any surfaces 1 To removethe quarter glass firstremovethequarter trim seepage20 93 2 Frcm insidethe car usea knifeto cut ...

Page 889: ...ces of urethane tape Setthe quarterglassuprightin the opening makealign ment marksacrossthe quanerglassand bodywith a greasepencilat the three pointsshown then removethe quarterglass NOTE Be carefulnot to touchthe quarterglass whereadhesive willbeapplied 6 With a sponge applya lightcoatof glassprimerto the insidefaceof the quarterglassas shown then lightlywipeit off with gauze or cheesecloth NOTE ...

Page 890: ...r together on a glassor metalplatewith a puttyknife NOTE Cleanthe platewith a spongeandalcoholbefore mrxrng Followthe adhesive manufactur s instructions Before filling as shown Cutnozzle end a cartridge cut the end of the nozzle 10mm 10 39 in 7 mm 10 27 in 20 75 ffi AoHEs vE 8 mm 10 3 inl 2 mm 0 08 in in SIDESPACER 10 Packadhesive intothe cartridge withoutair pockets to ensurecontinuous delivery P...

Page 891: ...eaks lvlarkleakingareas and letthe quarterglass dry thensealwith sealant NOTE Letthe carstandfor at leastfour hoursafter quarterglassinstallation lf the car hasto be used withinthefirstfour hours it mustbe drivenslowly Reinstall allremaining removed pans NOTE Advisethe customernotto do the following thingsfor two to threedays Slamthe doorswith allthewindowsrolledup Twistthe body excessively suchas...

Page 892: ...ge20 80 GLASSBRACKET Replacement page20 81 SUNSHADE RAIL FRONTDRAIN CHANNEL DRAINCHANNEL FRAMESEAL FRONTDRAINTUBE V SLIDESTOPPER LINK FRAME Replacement page 20 80 FRONTRAIL HOLDER REARDRAINTUSE GUIDERAIL Replacement page20 81 II RIGHTREAR llj DRA N vaLVE f r rr I DRAINVALVE I il i r l FRoNT DRATN VALVE 20 77 ...

Page 893: ...y l 2 3 4 Glassdoes not move and motor does not turn glasscan be moved with moonroofwrench 1 Blownfuse 2 Faultyswitch 3 Batteryrun down 4 Delectivemotor 5 Faultyrelay GlassHeight Adiustment The roof panelshouldbe evenwith the glassweather srrip to within1 8 t O 5mm O 07t 0 02 in allthe way around lf not slidethe sunshade back and 1 Tilt upthe glass 2 Loosenthe bolts and adjustthe glass 3 Repeaton ...

Page 894: ...t then install the motor Installthe glass then checkfor water leaks NOTE Do not use high pressure water Installthe headliner 1 2 3 Glassand Sunshade Replacement Open the sunshade Tilt up the glass Remove the bolts then remove the glass from the glass bracket V Bolt localions 6 GLASS t 4 Remove thescrew andliftthesunshade railoneach srcle 5 Slide the sunshadetorward then remove the sunshade v Screw...

Page 895: ...6 1 0kgf 7 2 tbl 1 O kgfm I 1 lIltl Cliplocations 2 4 FRAME Oisconnect the draintubes Remove the bolts then removethe lramefrom the car NOTE Youmay require assistance whenremoving the trame A Bolt locations 8 TUBECLIP FRAMESEAL Pullthe draintubes out the front and rearpillars NOTE Beforepullingout the draintube tie a string to the end of it so it can be reinstalled REARDRAIN TUBES 7 Installation i...

Page 896: ... 6 x 1 0 mm 9 8 N m 1 0 kgf m I 7 2 l V Screwlocations 2 e I Y 6 7 Remove the anchorspringon eachside Remove the nuts andscrews then lift and remove bothguide rails andcable assembly fromtheframe Removethe sunshadeand both sunshaderails FRAME V Nut screw locations A V N u t 2 Bv Screw 4 4 Remove the trontdrainchannel on eachside V Clip locations 2 I NOTE To install Iillrhe groovein eachgrommetwith...

Page 897: ...om the guide rail STOPPER To install insertthe anchor rod by turningthe sropper90o 9 Separate the glassbracket lifter slidestopperlink andslider ANCHORROD 1 1 Installation isthe reverse of the removalprocedure NOTE a Damagedpartsshouldbe replaced a Applygrease to the shding portion INNER CABLE o GLASS ERACKET LIFTER SLIOER NOTErTo install applymultipurpose greaseto the lifterand slidestopperlink C...

Page 898: ...old the switch to closethe glass whjle you measure orce requiredto stop it Attach a springscaleas shown Readthe force as soon as the glassstops moving then immediatelyreleasethe switch and spflngscate CAUTION Whenusinga sp ingscale protectthe leadingedgeof the glasswith a shop towel ClosingFo ce 200 29O N 2O 30 kst 44 66 lbf SPRING scAt_E lf the forceis not withinspecification installa new lockwas...

Page 899: ...ement page MOTOR Replacement page20 87 FRONTDRAIN CHANNEL SUNSHADE RAIL GUIOERAIL Replacemenl page20 88 REARRAIL HOLDER SEAL FRONTDRAINTUBE r r REARDRAINTUBE RIGHTREAR ORAINVALVE A FRONTORAIN q vawe 20 84 z 2 ORAINCHANNEL HoR I v o bYP FRAME Replacement page20 87 u 51 q I ...

Page 900: ... by hand seepage20 87 GLASSBRACKET Symptom Probable Cause Water leaks 1 Clogged draintube 2 Gap betweenglassweatherstrip and roof panel 3 Detectiveor improperlyinstalledglassweatherstrip 4 Gap betweendrainsealand roof panel Windnoise 1 Excessive clearance betweenqlassweatherstriD and roof oanel Motor noise I 2 3 Loosemotor Worn gearor bearing Cableassemblydeformed Glass does not move but motor tur...

Page 901: ...e Checkthat the alignment left andright then install the motor Installthe glass then checkfor water leaks NOTE Do not use high pressure water lnstall the headliner 20 86 Glassand Sunshade RePlacement 1 Openthe sunshade 2 Tilt upthe glass 3 Removethe bolts then removethe glasslrom the glassbracket Usethemoonroof GLASS ERACKET Removethe screwsand lift the sunshaderails Silde the sunshade forward the...

Page 902: ...aderails TUBE CLIP CONNECTOR Make surethe slidersare parallel when installing the motor FRAME FRAMESEAL DRAINTUBE To Install slidethe draintube over the framenozzleat least 10 mm 0 4 in EOLT 6 x 1 0 mm 9 8 N m l1 Okgf m 7 2 tbt ltl Loosen the front bolts Fo ward 6 7 SUNSHADE RAILS Pullthe draintubesout of the front andrearpillars NOTE Beforepullingout thedraintube riea string to the end oI it so i...

Page 903: ...f rrt 7 2 lbl lrl GLASSBRACKET SLIDER LIFTER SUB SEAL rnorur r l i r RAIL o ol i 9 Sliderhe qldss brackel slrder liftel backward then remove it NOTE Install the rear rail holder then glue the sub seal to the lrame FRAME 20 88 3 Remove the screwg then removethe sunshade rail by sliding it backward SUNSHADE RAIL SUNSHADE RAIL 7 Removethe screws attachingthe guiderail then lilt the guiderail 8 Remove...

Page 904: ...CHORROD 1 4 20 89 12 Slidetheguiderailbackward thenremove theguide railfrom the innercable NOTE To install apply caulkingto the guide rail mountingsurtaceon the frame Applycaolking before installing theguiderail 13 Remove the screws then removethe cableassem bly trom the frame NOTE Takecare not to bendthe cabletubes NOTE To install fillthegroove In eachgrommet withsealant Installation is the rever...

Page 905: ...hold the switch to closethe glasswhile you measure Jorcerequiredto stop it Attach a springscaleas shown Readthe lorce as soon as the glassstops moving then immediately release the switchand springscale CAUTION when usinga springscale proteclthe leadingedgeoI the glasswith a shop towel ClosingForce 200 290 N 20 30 ksf 44 66 lbtl lf the forceis not within specitication installa new lockwasher adiust...

Page 906: ...y NOTE Remove thedriver s kickpanel whilepulling the hood releasehandle KICKPANEL Pullthe doortrim back then removethe front pillar trim Cliplocations 4 lnstallation is the reverseof the removal procedure NOTE lf necessary replace any damaged clips FRONTPILLAR 1 2 Hatchback Reartrim panel Sidet impanel Ouarterpillartrim panel removal REAR SHELF Remove the rearseat seepage20 110 Removethe trunk mat...

Page 907: ...cesspanelfrom the sidetrim Danel Cliplocations Atr Clip 2 i _ l HOOKS HOOKS HOOKS SPEAKER LID LEFT ACCESS PANEL PANEL BV Clip 2 P v_ 1 oK tLh 8 Remove thesidetrim Panel Cliplocations A Clip 4 B CliP 4 h l l r l l A H s l g t C C l i p 3 D V c l i p 1 ill 1 zz77z7v I W I W y _ Bolt screwlocations A Bolt 2 B Screw 2 I 4 w w__ NOTE Disconnectthe cargoarealight connector Jromthe lelt sidetrim Panel CA...

Page 908: ...s A Clip 7 B C l i p 3 W ML W NOTE Remove the lront seat belt lrom the belt gurde BELT 13 Installation isthe reverse of the removalprocedure NOTE a lf necessary replaceany damagedclips a Wheninstalling the sidetrim panel makesure thereareno twists or kinksin the front andrear seat belts a Wheninstalling the reartrimpanel install theclips as follows 1 Pullthe innerclipup as shown t Q INNER dm r cLr...

Page 909: ...HOLE CAP UPPER ANCHORBOLT 7 16 20 UNF 32 N m 3 3 ksf m 24lbl ft Apply liq ridthreadlock ANCHORCOVER FRONT SEAT BELT LOWERANCHOB BOLT 7 16 20 UNF 32 N m 3 3 kgf m 24 lbl ttl v 20 94 ANCHORCAP 3 Removethe front and reardoor trim NOTEr Wheninstalling the tront andreardoortrim alignthem with the door openingflangenotch 4 Removethe centerpillartrim Cliplocations 2 CENTERPILLAR TRIM 5 Installation is th...

Page 910: ...wayon eachside Cliplocations 2 REARPILLAR TRIMPANEL SII IMOLDING 3 Removeboth rearpillartrim panels Cliplocations 12 NOTE When installing makesure the rearwindow defoggerwire harnessis routedproperly 1 I 4 Removethe rearshelltrim panel V Cliplocations 2 5 Sliptherearseatbeltthroughtheslitintherearshelf REARSHELF Removethe seatlockcover seepage20 113 and highmountbrakelight seesection 23 20 95 ...

Page 911: ... rt t 8 lf necessary removethe beltholecapandspeaker cover from the rearshelf Screwlocations 3 BELTHOLE CAP PUSH REARSHELF 20 96 9 lnstallation isthe reverse of the removalprocedure NOTE a It necessary replaceany damagedclips a When installing the rearshelf make surethere are no twists or kinks in the rearseatbelt ...

Page 912: ...reartrim panel V Cliplocations A V C l i p 4 l Push the inner clip NOTE Do not pushrt in too far 2 Detachthe clip by pulling it INNERCLIP ffi co r I l 5 BV Clip 2 1 Loosenthe innerclip 2 Detachthe clip by pulling it Installation isthe reverse of the removalprocedure NOTE a It necessary replaceany damagedclips a Wheninstalling the reartrim panel installthe A clipsas follows 1 Pullthe innerclipup as...

Page 913: ...ard Hatchback 1 Remove a Doortrim seepage20 93 Frontpillartrim seepage20 91 a Ouartertrim seepage20 93 a Coat hanger seepage20 93 a Rearviewmirror seepage20 52 2 Remove the sunvisor and holder from eachside Sc ewlocations 6 l r LOCKWASHER o rtsid cl H A2P suNvlsoR ERACKEr HOLOER 20 98 3 Remove the lront and rear ceiling lights then dis connect the connectors Screw nut locations A Screw 2 B N u t 2...

Page 914: ...movethe socketpluglrom rhe frameby turningit 9Oo 6 Removethe upperanchorboltsfrom the front and rearseatbelts seepages20 117 1211 7 Remove the upperportionof the quarterpillartrim panel then detachthe headliner clipon eachside A Cliplocations 2 A I Removethe roof trim Openthe hatch then Removethe headliner ROOF TRIM HEAOLINER moonroofmodel removethe rearroof trim cont d HEADLINER 8 20 99 ...

Page 915: ...lold or bendit Also be carefulnot to scratchthe body a Checkthat bothsideso the headliner aresecure ly attachedto the trim and panels a When installingthe rool trim installthe ioint toward the rear HEAOLINER HEADLINER 20 100 Sedan 1 Rem ove a Centerpillarlower trim seepage 20 94 a Frontand reardoortrim seepage20 94 a Frontpillartrim lseepage20 9 a Centerpillar trim seepage20 94 a Rearpillartrim pa...

Page 916: ... connect the connectofs Screw nut locations A A CONNECTOR FRONT LIGHT CEILING REARCEILING LIGHT HOOK A N LENS CONNECTOR Remove the grab handles Iront and senger s and grab holF caps dl ver sr GRABHANDLE GRAEHOLECAPS Screw locations c i E I 6 t J 20 101 ...

Page 917: ...door openrng Installation isthereverse oftheremoval procedure NOTE a Wheninserting the headliner throughthe door opening be caretul not to fold or bend it Also be careful not to scratch the body o Check that both sidesof the headlinerare secure ly attached to the trim and panels a When installing the roof trim install the joint toward the rear 7 8 HEAOLINER HEAOLINER ...

Page 918: ...5m m I 22 N m 12 2kst m 16rbf rt _ NOTE When installing usey RONT SEAT 2 Slidethe front seat forward then removethe seat track end covers CAUTION When p ying with I llat tip screwdliver wrap it with protective tape to prevent damage liq0id thread lock Lift the lront seat then disconnectthe seat switch connector driver s belt SEATTRACK ENOCOVER SEATBELT SWITCH CONNECTOR 5 Carelullyremovethe front s...

Page 919: ...screws thenremovethe centercover SEATBELT BUCKLE see page 20 119 scREws 4 Removethe hook andfastener then fold the seat back cover back RECLINE COVER SCREW 20 104 5 Fold the seat back Qoverand pad then remove the bolts Boli locations 2 SEAT EACK COVER PAD 6 Removethe pivot nut PLAIN WASHER PIVOTNUT 8 x 1 25mm 22 N n 2 2 kgt m t 6 tbt ttl Removethe seat back NOTE Take carenot to bendthe hingebracke...

Page 920: ...T ACCESSCAELE RECLINE ADJUSTER 9 Separate the seattrack and reclineadjuster Boli nut locations AA Bolt 1 i I 8 x 1 25mm ii rrr rz z ror I _ _ B V N u t 2 8 t 1 25 mm 1QL zz ttt S2 2 2kefm 16 tbl ttl I RECLINE ADJUSTER 1O lnstallation isthe reverse of the removalproceclure NOTE a To preventwrinkleswhen installing a seat back cover makesurethe materialis stretchedeven ly over the pad betoresecuringa...

Page 921: ...ER RECLINE AI USTER 8 x 1 25mm 2 2N m 2 2kgf m 10x 1 25 mm 47Nm 4 Ekgl m 35 tbt ftl CLIP 16tbf ftl RECUNE COVER SEAT TRACK WASHER 8 x 1 25mm 22N m l2 2kgl m 16tbtftl SEATTRACK Reassembly in the reverse orderof disassembly REAR HEIGHT KNOA 8 x 1 25mm 20 N m 12 0 kgt m 14tbtft CLIP 8 x 1 25mm 22 N n 12 2kgl m 16tbf tt NOTE Makesurethe bushingand pivotwasherareinstalled properly a To preventwrinklesw...

Page 922: ...tipscrew 2 Installation isthe reverse of the removalprocedure Z tz il H SeatBeltSwitchHarness Location NOTE When installing the seatcushion makesurethe seatbeltswitchharness andconnector arefastened cor rectlyon the seatcushionframe Harnos cliplocations SEATBELTSWTTCH CONNECTOR To seatbelt buckle SEAT EELT SW TCH HARNESS TORSION BAR _2Ut foo 1 l o a 20 107 ...

Page 923: ... the hooksandfasteners thenfoldthe seat backcoverback FASTENER SEAT 8ACK COVER Remove the headrest and headrest Screw o FASTENER gurde location 1 HEADREST HEADREST GUIDE KNOB SEAT BACK 20 108 o 4 Removethe lumbarsupportknob LUMBAR SUPPORT KNOB J tf 5 Remove the seat back coverby releasing the inside clrps Clipremoval SEAT BACK COVER 6 Pullback the edge of the seat backcover all the way around then...

Page 924: ...ckthe edgeof the seatcushioncoverallthe way around then releasethe cltps 3 SEATCUSHION COVER CLIP lnstallation is the reverseof the removalprocedure NOTE a To preventwrinkleswhen installing a seatcover makesurethe materialis stretchedevenlyover the pad beforesecuringatlthe clrps a Replace the released clips with new ones UPHOLSTERY RINGPLIERS commercially available SEAT COVER WIBE Padside 20 109 ...

Page 925: ...rsand body 1 Foldthe seatbackslorward 2 Removethe clips then lold the trunk mat V Cliplocations 14 I i M l _ Y STRIKER I TRUNKMAT 20 110 3 Removethe clip pin on eachside Slidethe seat backs outward thenremovetheseat backsJromthe pivotbracket SEAT BACK SEAT BACK PTVOTBRACKET CLIPPIN ...

Page 926: ...I LATCH COLLAR LATCH SEAT LATCH LATCH COVER T BACK LATCHCOLLAR SEATBACK COVER NOTE Whenremoving the striker removethe side trim panel seepage2O 91 Boltlocations 2 InStallation isthe reverse ot the removalprocedure NOTEI a Make surethe seatbackslock securely a lf necessary adjustthe strikers o Before attaching theseat backs andseatcushion makesuretherearenotwists or kinksinthe rear seat belts a Whe...

Page 927: ...ips V Cliplocations 8 SEAT BACK TRUNI MAT SEAT BACK 20 112 3 Detachthe hook then removethe trunk mat TRUNK x w Y HOOK 4 Removethe bolts then removethe seat back V Boltlocations 4 REAR SEATLATCH LOCK CYUiIDEB see pog 2G113 REAR SEAT HVOTBNACKET s6e page 20 113 SEAT BACK I Jr 6 x 1 0mm I ET 9 8 N m 1 0kgl m I E 7 2 tbt ht I q7 2 SEAT BACK ...

Page 928: ...VER Rea seat pivot bracketremoval NOTE Wheninstalling thepivotbolt applygrease to it TOOTHED BUSHTNGLOCKWASHER 7 lf necessary remove therearseatlatch lockcylinder andrearseatpivotbracket Reaiseat latch Lockcylinderfemoval Prythe rearshelfup after removingthe rearshelf trim panel seepage 20 95 and seal lock cover NOTE Take care not to bendthe lock rod V Bolt screw locations AV Bolt 2 6 x 1 0 m m I ...

Page 929: ...seat back a Betoreattaching the seat back sidebolsters and seatcushion makesurethereareno twistsor kinks in the rearseat belts and centerbelt a Wheninstalling the seatcushion slipthe seatbelt buckles throughthe slitsin the seatcushion Remove the seat back seepage20 110 Removethe latchcoverand latchcollar seepage 20 111 Remove allthe clipsfromrhe backof the seatback then Ioosenthe seat backcover Pu...

Page 930: ...EAT BACK COVER CLIP SEAT BACK COVER CLIPS Seatcushioncover aemoval Hatchback 1 Remove the seatcushion seepage20 1 I 1 2 Remove the cushion centertrim panel v Screwlocations 2 3 f t v J Removeall the clips rom underthe seatcushion then loosenthe seat cushioncovers SEATCUSHION COVEFS CLIP backthe edgesof the seat cushioncoversall way around then releasethe clips 4 Pull the SEATCUSHION covERs CLIP 20...

Page 931: ...he edgeof the seatcushioncoverallthe way around then releasethe clios SEATCUSHION COVER Installation is the reverseo fthe removalprocedure NOTE a To preventwrinkleswheninstalling a seatcover mark surethe materialis stretchedevenlyover the pad beforesecuringall the clips a Replace the released clips with new ones UPHOLSTERY RINGPLIERS Commercially available t 2 CLIP CLIPS 20 116 NEWCLIP ...

Page 932: ...seatbeltfrom the beltquide BELT GUIDE 5 Remove the anchorcoverandanchorcap UPPER ANCHOR EOLT 7 16 20UNF 32N m 3 3kgtm 24rbf ftl RETRACTOR MOUNTI IIG BOLT 6 r 1 0 m m 9 8N m 11 0 tgf m 1 2 tblJftl PROTECTOR LOWER ANCHOR BOLT 7 16 20 UNF 32N m 3 3kg m 24tbf ftl ANCHORCAP AL RETMCTOR BOLT 7 16 20UtrtF 32N m13 3 lgi m 2 atbtftl 7 Removeall the anchorboltsand the retractorbolt removethe retractormounti...

Page 933: ...ck ANCHOR c I COVER FRONT SEAT BELT LOWER ANCHOR BOLT 7 16 20UNF 32 N m 13 3ksf m 24 tbl trl I I I PILLAR TRIM A Cliplocations 2 144l I Il ru I _ t __ SLIT 20 118 ANCHORCAP 4 Remove the retractor bolt then remove the bolt and retractormounting Iront seat belt FRONTSEAT BELT RETRACTOR MOUNTING EOLT 6 x 1 0m m 9 8 N m 1 Okgl m 7 2 tbl ltl RETRACTOR RETRACTOR BOLT 7 16 20UNF 32 N m 3 3kgf m 24 tbt ft...

Page 934: ...eatbeltswitchconnector driver s removethecenteranchorbolt thenremove the seat belt buckle Screwlocations 2 CENTER ANCHOBBOLT 7 t t6 20 UNF 32 N m 3 3 kgf m 7 2 lbt lt Apply ljquidthreadlock SEATBELTSWITCH CONNECTOR sEAr BEL _ BUCKLE CENTER COVER Upperand lower anchorbolt construction Hatchback PLAIN WASHERS UPPER ANCHOR SPRING WAVE ANCHOR cont d 20 119 ...

Page 935: ...LT Applyliquid thread lock Centeranchorbolt construction TOOTHED LOCKWASHER CENTER ANCHOR Installation is the reverseof the removalprocedure NOTE a Make sureyou assemble the washersand collarson the upperand lower anchorbolts as shown a Beforeattaching the sidetrim panel Hatchback or centerpillarlowertrim Sedan makesuretherearenotwists or kinks in the front seat belt PLAIN BUSHING WAVEWASHER 20 12...

Page 936: ... andthe retractormountingbolt then removethe rea seatbelt and centerbelt Checkthat the retractorlockingmechanismfunctionsasdescribedon page20 124 RETRACTOR MOUNTING BOLT 6 x 1 0 mm 9 8 N m 11 0kgf m 7 2 tbt ltl UPPER ANCHORBOLT 7 16 20UNF 32 N m 3 3kgl m 24 tbl lrl COVER RETRACTOR REARSEAT BELT RETRACTOR BOLT 7 16 20 UNF 32 N m 3 3 kgf m 24 tbt ft PROTECTOR COVER CENTER BELT LOWERANCHORBOLT 7 16 2...

Page 937: ...ts 3 Check thatthe retractor lockingmechanism functions asdescribed on page20 124 a Trunkmat seepage20 97 a Reartrim panel seepage 20 971 a Trunk side panel seepage20 97 UPPER ANCHOR BOLT 7 16 20 UNF 32 N m 13 3kgtm 24 lbtltl RETRACTOR MOUNTING BOLT 6 x 1 0m m 9 8 N m 1 0kgf m 7 2 tbl ltl RETRACTOR BOLT 7 16 20UNF 32 N m 3 3kgl m 24 tbt ttl RETRACTOR CENTER ANCHOREOLTS 7 16 20UNF 32 N m 3 3kgf m 2...

Page 938: ...t W ANCHOR Retractor boh construction CENTER ANCHOR lnstallation is the reverseof the removalorocedure NOTE o Make sureyou assemble the washersand collarson the upperanchorbolt as shown a Betoreattachingthe sidetrim panel Hatchback or rearshelf Sedan make surethere are no twists or kinks in the rearseat belt a Betoreattachingthe seat back sidebolsters Sedan and seatcushion makesurethereare no twis...

Page 939: ... move menton the anchorbolts lf necessary removethe anchorboltsand checkthat the washersand other partsarenotdamaged or improperlyinstalled Check the seatbeltsfor damageor discoloration Cleanwith a shoptowelif necessary CAUTION Useonly soap and water to clean NOTE Dirtbuild upin the metalloopsof the upper anchorscan causethe seatbeltsto retractslowly Wipethe insideof the loopswith a cleanclothdamp...

Page 940: ...removethetoothedwasherfromthe child seatanchorplate Usethe childseatanchorplate with the toothedwasherattachedto it a Wheninstalllng a childseaton the rearseat fol low the intructionsol the manufacturer of the childseat a Additional anchorplatesareavailable Do not use the child seat ancho plate lor any othel purpose it is designedexclusivelyfor in stallationot a childseat Make sure the rear seat b...

Page 941: ...emovel Hatchback a Frontseat seepage 20 103 a Rearseat seepage20 110 a Rearshelf seepage20 91 a Reartrim panel seepage20 921 a Sidetrim panel seepage20 92 a Frontseatbeltloweranchor seepage20 117 a Frontandrearconsoles seepage20 130 Kickpanel seepage20 91 a Dashboard lowercover seepage20 133 a Openercover seepage20 156 Sedan a Frontseat seepage 20 103 Rearseat seepage20 1121 o Rearpillartrim panel...

Page 942: ...ldings a lf necessary separate the doorsillmolding and carpet A Pushnut locations 5 Hatchback A Cliplocalions 4 M Sedan A Cliplocations 3 ffil w Push nut locations 4 PUSHN Replace DOORSILLMOLDING V Cliplocations A V C l i p 2 B C l i p 1 ffi u C Clip 1 D Clip I m a l WffiI _ cont d 20 127 ...

Page 943: ...ck as shown 20 128 6 Cut the carpetunderthe parkingbrakelever PARKINGERAKE LEVER CARPET 7 Removethe dashboard centerbracketand center beam bracket V i Bolt locations AV Bolt 4 exr zsmm I B Bolt 1 6 x 1 0 mm 9 8 N m 11 0kgt m 7 2 thl trl 22 N m I 12 2kgt m I tu u C Boll 2 6 x 1 Omm I 9 8 N m I l 0kglm i 7 2 tbt4tl Cut here ...

Page 944: ...he carpetoverthe rearconsole bracket REARCONSOLE BBACKET P REARDOOR SILLMOLDING 9 CAR a Reattach the cut area in the carpet seepage 20 128 asfollow 1 Cleanthe backof the carpetwith a sponge dampened in alcohol Attachthe fasteners to the edgeol the car pet with doublelaced adhesivetape FASTENERS CARPET 3 Align the carpet with the fastener pressthe carpetdown securely then CARPET a Reattach the cut ...

Page 945: ...dOFFfor lessthanthreeminutes becarefulnot to bumpthe SRSunit the airbagscouldaccidentally deployand causedamageor injuries a Foradditionalpfecautions reterto theSRSsub section in section23 PASSENGER S AIRBAG SRSUNIT 20 130 NOTEr Takecarenot to scratchthe lront andrearcon soles anddashboard 1 Remove the access cap CAUTION Whenpryingwith a tlattip screwdriver wrap it with protective tape to prevent ...

Page 946: ... rearward Removethe ashtrayand front consolepanel Screwlocations 2 Disconnect the connector 5 Remove the Screws NOTE Remove the shiftleverknob M T Screwlocationi 4 6h ro I SHIFTLEVER KNOB FRONT CONSOLE 6 Remove thefrontconsoleasshown NOTE Wrapthe shiftleverandAy T gearpositionindica tor panelwith a shoptowelto preventdamage 20 131 ...

Page 947: ...assemble the front and rear con soles r Scrrw Cliplocations loc tion3 5 A j Clip 2 B r Clip 2 C Clip 2 1F a g E 20 132 Screw locations 9 A A w REARCONSOLE PARKING BRAKE COVER COVER SET PLATE 8 Installation isthe reverse of the removalorocedure ARMREST CONSOLE 80X ...

Page 948: ...eor inturies a Foradditionalprecautions reJer to the SRSsub section in section23 FRONT PASSENGER S AIRBAG SRSUNIT CAUTION Whenpryingwith a flat tip screwdriver wrap it with protectivetape and applyproteclivetape around the relatedparts to preventdamage Instrumentpanel Dashboad lower cover Kneebolster temovat 1 Lowerthe steering column 2 Removethe screwsand detachthe clips then re movethe instrumen...

Page 949: ...Er Theoriginalradiohasa codedtheft protec tioncircuit Besureto getthe customer s codenum ber before disconnecting the battery removingthe No 47 7 5A tusefrom the under hood fuse relaybox removingthe radio Afterservice reconnect powerto the radioandturn it on When the word CODE is displayed enter the customer s 5 digit code to restore radio ope ation KNEEBOLSTER 20 134 CONNECTOR CASSETTE Bolt locat...

Page 950: ...lefrom the heat er unit AIR MIX CONTROL CABLE CONNECTORS 6 Pullthe heater controlpanelout thendisconnect the connectors NOTErTakecarenot to bendthe air mix control caote HEATER CONTROL PANEL 7 Installation isthe reverse of the removalprocedure NOTE Makesurethe connector andair mix con trol cableare connectedproperly cont d 20 135 ...

Page 951: ...w locstion I 6F i r Clip hook locations A C l i p 1 BV Hook 3 Installation isthe reverse of the removalprocedure NOTE Make sure the connector is connected properly 20 136 Flont passenger s Carefullypry the sideair vent at the lower edge then pullit out A Clip hooklocations AA Clip 1 BV Hook 2 SIDEAIR VENT PROTECTIVE TAPE Sidedeloggertrim removal Carefully prythesidedefogger trimat the rearedge the...

Page 952: ...x removal 1 Openthe glovebox 2 Removethe screw then removethe damperfrom the glove box 3 Removethe screw then removethe glovebox Bolt scrow Al Bolt 2 A q l locations B Scr w 1 od il 4 Removethe damperand striker Nut screwlocations A Nul 1 B Screw 2 9 E e_ 5 Installation isthe reverse of the removalprocedure 20 137 ...

Page 953: ...n n e r r h e n i r i u a a h l a NOTErTheoriginal radiohasa codedthettprotec tioncircuit Besureto getthe customer s codenum ber before disconnecting the battery removingthe No 47 7 5A fusefrom the under hoodtuse relay box removingthe radio After service reconnect powerto the radioandturn it on Whenthe word CODE is displayed enter the customer s 5 digit code to restore radio operation DRIVER S AIR...

Page 954: ... NOTE To preventdamageto the steeringcolumn wrap it with a shoptowel l Boh nut locations AA Bolr 2 8 Nut 2 8 x 1 2 5m m 22 N m 12 2kgl n 16 tbf ft o21 13 N m 11 3kgl m J Prbl rll _Urr rr t __ STEERING JOINT COVER STEERING COLUMN 3 Remove thenuts thenremove thefrontpassenger s airbagbracket Nutlocations 4 6 x 1 0 mm L 9 8 N m 1 okgt m 7 2tbt rrU FRONTPASSENGEB S AIRBAG PASSENGER S SRSMAIN AIRBAGBRA...

Page 955: ...nd remove the dashboard CAUTION Useprotectivetapeon the bottom of the front pillartrim NOTE a Take care not to scratchthe dashboard a To prevent damage to the shiftleverandA T gear positionindicatorpanel wrap them with a shop rowet V Eolt localions 6 6 x 1 0m m 9 8 N m 1 0kgf m 7 2 hl ltl 9 Installation is the reverse of the removalprocedure NOTE a Makesurethe dashboard fits ontothe bodycor rec y ...

Page 956: ...helpfulwhen removingthefront bumper Takecarenotto scratch thefront bumperandbody Bohscrewlocetion3 E 4 A 7 B 1 2 C 1 2 D 8 6 x 1 0 m m i 9 8N m 1 0kgfm I 2rbl ftl J 6 x 1 0 m m 9 8N m 1 0kgf m 8 x 1 25mm 22 N n l 2 2kgl m 7 2bftrl _ r _ 6tbt 1t _ _ BUMPER BEAM GUSSET g GUSSET Type RModel I D FRONTBUMP R cont d ...

Page 957: ...r Replacement cont dl Solt scaew location3 A 5 F F FRONT TURN SIGNALLIGHT HOLDER l r SIDECLIPS SIDEPLATE FRONT BUMPER Mffil R wf SIGNALLIGHT FRONT SPOILER Type Rl Installation isthe reverse of the removalprocedure 20 142 ...

Page 958: ...bl ftl t z Cliplocation3 2 REARBUMPER CONNECTOR Disconnect nQn wl lvxvn NOTE lf necessary disassemble the rearbumper Cliplocatiom 9 Scr wlocationr 4 l _ 4h E t s BEARBUMPER UPPER BEAM LICENSE PLATE LIGHT REARBUMPER Removethe absorber bumper rearoumper Deam V Bolllocations 4 beamgussetand 1 2 x 1 2 5m m 64 N m 16 5kgf m 47 rbf rtl ACCESSCAP ABSOREER BUMPER BEAM GUSSET lnstallation isthe reverse of ...

Page 959: ...nnectorand grommetfromthe reartrunkarea Remove the clips and bolts then removethe rearbumper V Cliplocations 5 A Boltlocations 2 A r El El EE A tn r LICENSE PLATELIGHT CONNECTOR 20 144 GROMMET 4 lf necessary removethe license platelight harness bracketand lensfrom the rear bumper seepage 20 1431 5 Remove the absorber bumperbeamgussetandrear oumperoeam V Eoltlocations 4 12x 1 25 mm I 64 N m 16 5kgl...

Page 960: ...llation isthe reverse of the removalprocedure NOTE r Makesurethe licenseplatelight connector is connected andthe grommetis installed properly Makesurethe rearbumperengages the sideclips securely REABBUMPER 20 145 ...

Page 961: ...cations l6 NOTE lf necessary remove the hood hinge V Boltlocations 4 G 6 r t o n Yz s e N 1 okot m E z zrur rtr i 2 Remove the bolts thenremove the hood i Boltlocations 4 3 Installation isthe reverse of the removalprocedure NOTE a lf necessary replace anydamaged clips a Make surethe hood lockssecurely a Make surethe hood opensproperly a Adjustthe hoodalignment 6 x 1 Om m 9 8 N m 1 0kgl m 7 2 tbfft...

Page 962: ...n the hood edgecushions as necessary to makethe hood fitflush with the body at front and sideedges 3 Adjust the hood latchto obtainthe properheightat the forward edge HOODEDGE CUSHION NOTEi Movethe hoodlatchrightor lett untilthe striker is centeredin the hood latch as shown HOODLATCH HOOOLATCH 7 2lblltl 4 After adjustment tighteneach bolt securely ...

Page 963: ... 1 8 V C l i p 3 A r N fN l l y lrl HATCHTRIMPANEL 20 148 5 Removethe rearwiper motor seesection23i NOTE Detachthe clips by slidingthe hatch trim panel forward then remove it Remove thehatch spoiler asdescribed on page20 161 ifsoequipped Disconnect the connectors then removethe wire harnesses fromthe hatch 4 A Specialbolt locations 2 V I Clip locations A V C l i p 3 B A C l i p 6 i I A A w h g b l...

Page 964: ... the corners of the glassmay hit the roof and break HATCH 8 7 SUPPORT STRUT L Removethe nuts then removethe hatch Nutlocations 4 22 N m 12 2kgl m 16 tbt fr HATCH NOTE lf necessary replacethe supportstrut lf necessary removethe hatch hinge V Boll locations 4 I x 1 25mm 22 N m 2 2kgl m HATCH 1 0 HATCH Installation is the reverse of the removalprocedure NOTE a lf necessary replaceany damagedclips a M...

Page 965: ...he bodyatthe rearedge 5 Adiustthe hatchsidestop so thatthereis no clearance betweenit andthe body sidestop thentightenthe mounting bolt TvpeR HATCH EDGECUSHION STOP Typ R Modoll SIDE STOP lTyp R Modell HATCH EDGE CUSHION stoE STRIKER HATCH EDGECUSHION Type R Model SIDE STOP Hatch side SIDESTOP Bodyside 6 x l 0 m f t 9 8N m 11 0kg m 7 2tbf ftl 6 x 1 0 m m 9 8N m 1 0kgt m 2 tbf ftl SIDE STOP Hatch s...

Page 966: ...anpullit backinwhen the trunk lid is reinstalled 2 Removethe bolts then remove the trunk lid Bolt locaiions 4 6 x L O m m 6 9 8N mn o ksf m l r 7 2 tbt ht Clip locations A Clip 3 B Clip 1 4 i w j CA Clip 5 q r TRUNKLID OPENER CAELE TRUNKLID LATCH seepage20 1591 WIREHARNESS 3 lf necessary removethe trunk lid hinge NOTE a Removethe rearshelt seepage20 95 CONNECTOR CONNECTOR a Remove the torsionbarsw...

Page 967: ...it the rearwrndow when removingthe bolts 4 Installation is the reverse o the removalprocedure NOTE a Makesuretheconnectors areconnected properly a Adjustthe torsionbarslore or aft with the tor sion bar assemblytool as shown O Normal Position O Higher tension a Make surethe trunk lid lockssecurely a Make surethe trunk lid opensproperlv a Adiustthetrunklid alignment ...

Page 968: ... makethetrunklidfit flushwith the bodyat the rearandsideedges 3 Adjust the lit betweenthe trunk lid and the trunk lid openingby movingthe striker TNUNKLIDEDGE CUSHION TRUNKLIO HINGE NOTE Move the strikerright or left until it s centered in the trunk lid latch as shown 6 r 1 0m m 9 8N m 1 O kgf m 7 2 tbt ltl 6 x 1 0mm STRIKER STFIKER 4 After adjustment tighteneach bolt securely Adjustment 20 153 ...

Page 969: ...crawlocalions 8 M 6h _ NOTE Loosenthe screw then remove the clrpusinga clipremover FuelLid OpcnerCableslHatchback NOTE Remove the rear seat seepage20 1 l0 rear trim panelandsidetrim panel seepage20 91 then pullthe carpet back as necessary seepage20 126J A Clip cablo cushion location3 A A Clip 1 I A Clip 6 FUELLIOLATCH seepage20 157 d FUELLID HOODOPENER 20 154 ...

Page 970: ...epanel seepage20 97 C a C l i p 1 E A C l i p 1 D Clip 3 w l tQ r Clip cabl6 cushion locations A Clip 1 B V Clip 2 Qs r lww F Cablecushion 1 6t ei TRUNK LID LATCH seepage20 159 see page 20 157 Installation is the reverseof the removalprocedure NOTE a Makesureeachopenercableis routedandconnected properly a Makesurethe hood hatch trunklid andfuellid openproperly OPENER seepage20 157 20 155 ...

Page 971: ...Grease eachlocation ofthe hoodlatchindicated bvthe arrows Prythe lid OPENER COVER Remove thekick panel seepage 20 9r FuelLidOpener Hstchbackl Bolt screwlocdions A Boh 2 6 x 1 0 m m 9 8 N m 11 0kgf m 7 2 lbl lrl B V S c r e w 1 FUELLID RELEASE HANDLE I b t lnstallation is the reverse of the removal procedure NOTE a Make sureeach openercableis connectedproperly a Make surethe hood locks securely a M...

Page 972: ...kgt m 7 2 tbl trl J FUEL LIDOPEiIER CABLE see page 20 154 155 FUELLIDLATCH Remove thefuellid latch by turningit 90 FUELLIO Installation is the reverseof the removalprocedure NOTEI a Makesureeachopener cableis connected properly a Makesurethefuellidfitsflushwiththe body a Makesurethetuellid lockssecurely a Makesurethetrunklid andfuellid openproperly FUELLIDLATCH Hatchbsck Remove therearshellandrear...

Page 973: ...en disconnectactuatorrod Remove the hatchlatchandactuator Screwloc6tion3 A 3 I 3 ACTUATOR 20 158 4 Remove the lockcylinderby turningit 45 Boltlocation 1 6 x 1 o m m I 9 8 N m 11 0 kstm i l ztb ft lt LOCK CYLINDEB Installation isthe reverse of the removalprocedure NOTE a Apply greaseto the hatch latch a a a Make surethe hatch lockssecurely Make surethe hatch opensproperly N4ake surethe connectoris ...

Page 974: ... take them out Boltlocation 1 CONNECIOR LOCK CYLINDER r 2 Disconnect the cylinderrod CYLINDER ROD CYLINOER ROD 5 lnstallation isthe reverse of the removalprocedure NOTE a Apply greaseto the trunk lid latch Removethe bolts then removethe trunk lid Bolilocations 3 TRUNK LID LATCH 3 latch 6 x 1 0 m m I LOCKCYLINDER 9 8 N m 11 0kgf m I t r a a a Makesurethe trunklid lockssecurely N ake surethe trunkli...

Page 975: ... MOLDING REAR l I FRONT GLASS CENTER PILLAR MOLDING NOTE The numbersafterthe par1names show the quantities ot the pans used WEATHER STRIP PILLAR WEATHER STRIP RETAINER Installation is the reverseof the removalprocedure NOTE a Checkthe weatherstripfor damageor deterioration and replaceit it necessary a After installing the weatherstrip check forwater leaks a lJ necessary adjustthe positionof the do...

Page 976: ...tlocltion3 4 Type R Model a f ut locltlona 4 Applyliquid threadlock 6 x 1 0m m 9 8 N m 1 0kgf m 7 2 tbt ltl CONNECTOR 3 Remove the hatchspoilerby turningthe clipnut on the left side counterclockwise Applyliquid thread lock Installation is the reverse of the removal procedure HATCHSPOILER HATCH 6 x 1 0 m m 9 8N m 11 0 kgt m 2tbt ftl 4 Installation isthe reverse of the removalprocedure 20 16 1 ...

Page 977: ...carenotto bendthefenderwelltrim Beforeinstalling the fenderwelltrim cleanthe body bondingsurface with a spongedampened in alcohol Aftercleaning keepoil greaseo waterfrom getting on the surface Adhesivearea ADHESIVE FENDERWELL TRIM 20 162 ...

Page 978: ...lterapplying thesealant install the hatchweatherstrip ALIGNMENT MARK HATCH WEATHERSTRIP T unk Lid Weatherstrip ALIGNMENT MARK TRUNK LID WEATIIERSTRIP Wheninstalling thehatchortrunklidweatherstrip align it with the alignmentmark on the hatch or trunk lid opening NOTE a Makesurethereareno wrinklesin the weatherstrip a Checkfor water leaks ALIGNMENT MARK BODY Forward 20 163 ...

Page 979: ...clive tape on the body SIDEMOLOING Pull and slide the root molding then detach the bracket on the end of the roof molding from the pin ROOF MOLDING PIN Bodyside ROOF MOLDING ROOF MOLDING 20 164 Pullthe roof molding up detach the bracket from the pin then remove the roof molding Installation isthe reverse oI lhe removalprocedure NOTE a Take carenot to damagethe windshield side molding a Makesurethe...

Page 980: ...c h b a c k 3 Dv Cliplsedan 1l CV Clip Harchback l Sedan 2 STEEL OOOR MOLDING CORE STEEL COBE CORE Hatchback Sedan V Plasticnut location Hatchback 1l lsedan 1 FRONTDOOB MOLDING Installation is the reverse of the removal procedure NOTE lf necessary replace any damaged clips NEWAOHESIVE TAPE Thickness 1 2 mm 0 05 in Sedan 6 A DOOR rvrororuc lS r tl t f i r i cLrP REARDOOR MOLDING O t DOORMOLDING NOT...

Page 981: ...e lowerclip usang a clip remover Removethe lowerclips then removethe sidesillpanel by sliding it forward Hatchback NOTE When removrng the srde qil iJffi1 Sedan INNER FENDER SILI PANEL To installthe sidesillpanel removethe sideclipsfrom the body installthem on the sidesillpanel then install the sidesillpanelon the car NOTE a Takecare not to twist the side sill panel a lf necessary replaceany damage...

Page 982: ...ndthe gapbetweenthe taillightandbody asshown thenpress the embleminto place Removethe application tape NOTE a Beforeapplying cleanthe body surlacewith a spongedampenedin alcohol a Atter cleaning keepoil greaseand water trom gettingon the surface a When applying make surethere are no wrinklesin the rearemblem AttachmentPoint Hatchback REARTURN SIGNALLIGHT DOHCVTEC GSR sDecialEditionlUsa Ls s EMBLEM...

Page 983: ...cation tapewith the body lineandthe wheelwellopening as shown then pressthe emblem intoplace Remove the application tape NOTE Beforeapplying cleanthe bodysurface with a spongedampened in alcohol Aftercleaning keepoil grease andwaterfrom gettingon the surface Whenapplying makesurethereareno wrinklesinthe rearemblem Attachment Point i l TYPE R REAR EMBLEM Alignwiththerearturn sagnal light TYPE R SID...

Page 984: ... lea beam mounting bolts be sure to replacethem with new ones 6 x 1 0 mm 9 8 N m 1 0kgf m 7 2 rbf ft REABBEAM BRACE REARBEAM COLLAR 10x 1 25mm 44 N m 4 5 kgl m 33 tbf ft REARBEAM REARBEAM 1 4 x 1 5m m 89 N m 9 1kgf m 66 tbt frl Replace Sub frame 20 169 ...

Page 985: ...i 1 7 7 O 6 9 l 2 0 5 l O 8 l SECTION BB DD d 2 5 l r 0 BASE LiNE d 1 1 5 0 17 O 661 Fea Eeam Pornt Model Dls6 G M T A T UJ 514 3 20 261 5 0 1 5 1 9 7 o 0 1 0 2 5 0 98 1 0 5 3 305 5 1 2 0 3 Model Distt d Hatchback Sedan i 2100 42 71 2 1 5 0 84 6 1 03 6 2682 1 0 5 6 2611 1 0 2 8 2661 1 0 4 8 o 2607 102 6 2657 104 6 558 t22 Ol 674 126 51 20 170 o11 5 0 45 L FronrStopper Front OamperLowef Sush ...

Page 986: ... tQ 1 3 8 i5 41 t I o rln lls POINIx 20 171 ...

Page 987: ......

Page 988: ...Unit Replacement 21 2O Overhaul 21 21 HeaterUnit R e p f a c e m e n t 2 1 2 2 Overhaul 21 24 HeaterControlPanel Repfacement 21 25 Overhaul 21 26 HeaterValve Cable Adjustment 21 27 Air Mix ControlCable Adiustment 21 27 Mode ControlMotor T e s t 2 1 2 4 Repfacement 21 24 Recirculation ControlMotor T e s t 2 1 2 9 Repf acement 21 29 Relay T e s t 2 1 3 O HeaterFan Switch T e s t 2 1 3 0 Mode Control...

Page 989: ...ul page21 24 RECIRCULATION CONTROL MOTOR Iest page 21 29 Seplacement page 21 29 BLOWER RESISTOR Test page21 9 AIR MIX CONTROL CABLE Adjustment page 21 27 Replacement page 21 26 A C SWTTCH with A cl Test page22 20 RECIRCULATION CONTROLSWITCH Test page21 31 HEATERFAN swrTcH Test page 21 30 MODECONTROL MOTOR Test page21 28 Replacement page2 l 28 CONTROL SWITCH Test page21 3 l HEATERCONTROLPANEL Repla...

Page 990: ...HeaterDoor Positions I I Hor fr coor r O tt IHEAT VENTI cont d VENTDOOR 21 3 ...

Page 991: ...HeaterDoor Positions cont d fr seel 21 4 ...

Page 992: ...w DEFI 21 5 ...

Page 993: ...CircuitDiagram R CIRCULATION coNTROt MOTOR UNDER HOOD FUSE RELAY BOX N0 41 1004 N0 42 40A J o r r l BtK 21 6 ...

Page 994: ...ERMOST withA ci II BLU RED RED I t DASH LIGHTS BRIGHTNESS CONTROLLER 8LK _tr G20t G40t I r 1 A r r A A r r A A t t A _ A _ l t t t t r t l t t J I t t l J t t l l t t l J l I r V V I r V V t r v V I t V q 21 7 ...

Page 995: ...blower outlet Cloggedheatetvalve Faultvair mix door Heater valve cable adjustment lsee page 21 27 Air mix controlcableadiustment seepage21 27 Faultythermostat seesection 10 Cloggedevsporator with air conditioning FrozenevaDorator with air conditioning Mode controlmotor does not run or one or more mooesare inoDeratave Followthe flowchart seepage21 14 Recirculation controldoor does not changebetween...

Page 996: ... OFF Doesthe blowermotorrun Turnthe ignitionswitch OFF Measurethe resistancebetween the No 2 andNo 4 terminals of the blowerresistor ls thereapprox 2 3 ohms Remove the heatercontrolpanel seepage21 25 Turnthe ignitionswitch ON ll At the heaterfan switch6P con nector ground each of these wiresindividually inthefollowing order BLUwire BLUMHT wire BLU YEL wire BLU BLK wire To page21 10 cont d 21 9 ...

Page 997: ...or View from wire side Frompage21 9 View trom wire side BLU ilif frilt lt BLU WHT ls therecontinuity BLU BLK BLU lz Turnthe ignitionswitch OFF Remove the heater conlrol panel s e e p a g e 2 1 2 5 Check eachwireforcontinuity be tween the heaterfan switch 6P connectorand body ground ELIJwire BLU WHTwire BLU YEL wire BLU BLK wire Replace the heat6r fan switch Bepair short in the wire sl be tween the...

Page 998: ...Turnthe ignitionswitch ON ll Doesthe blowermotor run Disconnect the blowermotor2P connector and measure the vol tage betweenthe BLU vVHT wire terminal and body ground ls therebatteryvokagel Turnthe ignitionswitch OFF Rernovethe blower motor relay from the under hood fuse relay boxandtest it seepage2l 30 Roplscotho blower motor olsy Measurethe voltagebetweentho N o 3 t e r m i n a l a n d b o d y g...

Page 999: ...wire terminal and body ground Repairopen in the BLU Bl Kwir6 between the blowea motor and the hoster lsn switch ls therebatteryvoltage Turnthe ignitionswirchOFF Checkfor continuityin the BLK wire between the heater fan switch and bodyground Checkfo anoDenin th6 8LK wire botwo n th haat r tan switch and body ground ll th6 whe is OK check tor poor ground at G201and401 Rsplac the heat r fan switch ls...

Page 1000: ...use r lav box and th und r drsh tuse relav box ls there batteryvoltage Turn the ignitionswrtchOFF Checkfor continuitybetweenthe No 2 terminaland bodyground Checkfor anoDenin the BLKwir belween the undor hoodfuso re lay box and body ground It the wire is OK checkforpoor ground at G201 and G4O1 Ropairopenin the BLU WHTwire betweenthe undor hoodfuse re lav box and the blow r motor 2 1 4 ...

Page 1001: ...connectthe mode control mo tor 8P connector Turn the ignrtionswitch ON ll Measurethe voltage between the BLK YELwire terminal and bodyground Repairopen in ths BLK YELwire between the und r dashfusehe lay box and the mods cont ol motoa Turnthe ignitionswirchOFF ls there battery voltage To page21 15 21 14 ...

Page 1002: ...lseepage21 25 Checkthe mode controllinkage anddoorsfor smoothmovement Disconnectthe heater control panel14P connector Ropairthe modocontrcl linkag or doors Do the modecontrollinkage and doorsmove smoothly Checkeachwirefor continuitybe tween the mode control motor and bodyground YEL BLU wire YELwire BLU WHTwire GRN YEL wire YEL RED wire ReDlace the mode conlrol molor Ropaiianyshort in the wiiolslbe...

Page 1003: ... No I GRN YEL Checkeachwirefor continuitybe tween the mode control motor and the hoatercontrolpanel YEL BLU wire YELwire BLUMHT wire GRN YEL wire YEL RED wire R6pairany openin th wirels be tween the modo control motoi and the heater control oan Replacethe hsatarcontrol panol View from wire side yEL 1iu 1 N V i 21 16 ...

Page 1004: ...ulationcon trol motor 4P connector Turn the ignitionswitch ON lll Measurethe voltagebetweenthe BLK YELwire terminal l and bodvground1 Repairopon in the 8LK YELwire botwo n th6 undeFdaahfus6 r6 lay box andths acirculationcon lrol motor ls therebatteryvoltage lurn the ignition switch OFF T o p 6 g e2 1 1 8 cont d 21 17 ...

Page 1005: ... the GRN WHT and orGRN REO wire s between tho recirculation control motor and the heaioi control Dan6l Check the same wires for voltage Repair short to power in tho BLK YELwire between the recir culation control motor and the heater control oanel lThis damages the heater control Dan ls there 6ny voltage Check for continuity in the GRN WHTand GRN RED wires betweenthe recirculation control motor and...

Page 1006: ...N YEL HEAT VENT INPUT 2 YEL HEATiDEF INPUT q RED BLKCOMBINATION LIGHTSWICH INPUT 3 YEL BLU DEF INPUT 1 0 RED BRIGHTNESS CONTROLLEROUTPUT BLK GROUND OUTPUT 1 1 BLU RED A C THERMOSTAT INPUT 5 GRN RED RECIRCULATE INPUT GRN HEATER FAN SWITCH OUTPUT 6 GRN WHT FRESH INPUT 7 YEL RED VENT INPUT 1 4 BLK YEL INPUT 21 19 ...

Page 1007: ... duct 1 2 HEATER DUCT 21 20 With Air Conditioning 3 b Removethe evaporator seepage22 26 CLIPS 9 8N m11 0 kgf m 7 2 rbf ftl 4 Disconnect the connectors from the blowermotor the blower resistorand the recirculation control motor 5 Remove the wireharness clipfromthe recirculation controlmotor andrelease thewireharness fromthe clampon the blowerunit Remove the two mountingbolts the mountingnut and the...

Page 1008: ...kesureits positioning will not allowthe recirculation controldoor to be pulledtoo far Attachthe recirculation controlmotorandall links then connectpower andground and watch the movementof the recirculation controldoor RECIRCULATION CONTROL MOTOR Test page21 29 BLOWER RESISTOR Tost page21 9 g BLOWER MOTOR Test page 21 11 Replacement page 21 29 Overhaul 21 21 ...

Page 1009: ...evdely scald you 2 Ooenthe clamD then disconnectthe heatervalve cablefrom the heatervalvearm HEATERVALVE CABI E I i 21 22 3 Disconnect the heaterhoseslrom the heaterunit CAUTION Enginecoolantwill damagapaint Ouick ly rinse any spilled engine coolant from painted sudaces NOTE Engine coolantwill runout when the hoses are disconnected drainit into a cleandrip pan 4 Removethe mountingnut from the heat...

Page 1010: ...1 0kgf m 7 2 lbf ftl I r 1 25mm 22 N m 12 2kgf m 16 lbf ft Il I I lnstallin the reverse orderof removal Makenoteof theseitems Applysealant to the grommets Do not interchange the inletandoutlethoses Makesurethatthe hoseclampsaresecure Loosen the bleedbolton the engineandrefillthe radiatorand coolant reservoirwith the proper enginecoolantminure seesection10 Tightenthe bleed bolt when all the trapped...

Page 1011: ...perarm Remove the two screwsandthe heatercorecover Removethe screw and the pipeclamp Pullout the heatercore NOTE Be carefulnot to bendthe inlet and outlet pipesduringheatercore removal Assemblein the reve seorderof disassembly 6 HEATER CORECOVER OAMPERARM COVER HEATEFCORE DAMPERARM r rll I Y HeaterUnit Overhaul 21 24 ...

Page 1012: ...emove the heatercon trol paneland the centerair vent NOTE The locking tabs of the hazardwarning switch and heatercontrolpanelconnectorsareon the bottom CENTER AIR VENT REARWINDOW D FOGGER swtrcH HAZARD WARNING swrTcH CONNECTORS 4 Remove the fourself tapping screwsandthe center atrvent Install inthe reverse orderof removal andadjustthe air mix controlcableat the heaterunit seepage 21 271 ltnecessar...

Page 1013: ...Slidethe largesectionof the cablehousingout of the cableholder beingcarefulnot to damagethe cablestops Carefullyremovethe cut piecesof the cablehous ing with a smalltlat tip screwdriver Hookthe tip of the new airmix cableto the temper aturecontrollever thenpushthe cablehousing into the cableholderuntil it locksplace 3 AIR MIX CONTROL CABLE 5 NOTEr Atter assembly checkthat the temperature controlle...

Page 1014: ...valve arm STOP 6 Gently slidetheheater valvecablehousing backfrom the end enoughto take up any slackin the heater valvecable but not enoughto makethe tempera ture controllevermove thensnapthe heatervalve cablehousinginto the clamp NOTE The air mix controlcableshouldalwavsbe adjustedwheneverthe heatervalvecablehasbeen disconnected HEATER VALVECABLE i CLAMP 1 Disconnect the airmix controlcablefromth...

Page 1015: ...r shortingthe other terminals ThemodecontrolmotorisOKif it runswhenjumping the tirst terminalagain lf the modecontrolmotordoesnol runinsteD2 re move it and checkthe modecontrol linkageand doorsfor smooth movement lf the mode control linkage anddoorsmovesmoothly replace the mode controlmotor Replacement MODECONTROL MOTOR Disconnect the modecontrolmotor 8P connector and removeit lrom the heaterunit ...

Page 1016: ...ulation controlmotor for a longtime lf the recirculation controlmotordoesnot runinstep 1 removeit andchecktherecirculation controllink ageanddoorlor smoothmovement If the recircu lation control linkage and door move smoothly reDlace the recirculation controlmotor 3 1 Disconnect the 4Pconnectorfrom the recirculation controlmotor andremovethe wire harnessclipfrom it 2 Removethe two screws the recirc...

Page 1017: ...n powerand groundareconnected to the No 2 and No 4 terminals andthereshouldbe no conti nuitvwhen9oweris disconnected rl I tb I HeaterFan Switch Test Checkfor continuitybetweentheterminals according to the table below Terminal Position F D B E c OFF o o 2 o o 3 o o G _o 21 30 ...

Page 1018: ...Checkfor continuitybetweenthe terminals according to the table below Terminal Position 5 6 Fresh o 1 Recirculate o o Checkfor continuitybetweenthetermsssssafrinals according to the tablebelow Terminal Position 1 2 3 7 I Heat G Heat Def o Def G o G o Heat Vent o ...

Page 1019: ... fndex 22 29 Replacement 22 30 CfutchInspection 22 32 CfutchOverhau1 22 33 Ref ief Vafve Replacement 22 34 A C CompressorBelt Repf acement 22 35 Adiustment 22 36 Condenser Repf acement 22 37 A C System Service Evacuation 22 38 Charging 22 39 LeakTest 22 39 ReadSRS precautionsbefore working in this area ...

Page 1020: ...Special Tools B f No Tool Numbor D scription Oty I PagoRoterencr o 07JGG 001010A 07sAz 0010004 BeltTensionGauge BackprobeSet 1 22 36 lncludedin the BeltTensionGaugeSet T N07TGG 0010004 22 2 ...

Page 1021: ...ge22 27 SERVICE VAI VE ILOW PRESSURE SIDE SERVICE VALVE HIGH PRESSUEE SIDE SIGHTGLASS CONOENSER Replacement page2237 A C PRESSURE SWITCH COMPRESSOR When the refrigerant pressureis below 200 kPa 2 0 kgllcm 28 psi dueto refrigerant leakage or above3 100 kPa 32kgtcm 460 psi due to relrigerant blockage the A C pressuresw tchopensthe circuitto the A Cswitchand stopstheairconditioning to protect thecomp...

Page 1022: ...Y CONOENSER FANRELAY COMPRESSOR CLUTCH RELAY RADIATOR FANREI AY Locatedin the under hoodtuse relaybox A C DIODE CONNECTOR lLocated abovetherightkickpanel MAINWIBEHARNESS A C WINEHARNESS A C WIREHARNESS A C PRESSURE SWITCH CONNECTOR CLUTCH CONNECTOR 22 4 ...

Page 1023: ...q l i tli T f7 r I BIU RED I 1 8LU REO if PRESSUFE Y SWTCH YEL N4 T lvc DIODE BLUiRED I I Y r G8N I Y ES 1i 31 I ts fts 1 I I I BLK I G 1 0 1 BLI BED I I I r r I FANMoToRY I I I I 8LK T G201 G401 V I BLU LK f7 I BLU Y L V I BLUMHT V I BLU BLU RED BLK YEI fti i BLK I G 1 5 1 ...

Page 1024: ...R 134a Theyarenotcompatible Useonly the recommended polyalkyleneglycol PAG refrigerant oil ND OIL 8 P N38897 PR7 A01AH or 38899 PR7 A01 designed for the R 134a compressor Intermixing the recommended PAG refrigerant oil with any otherrefriger antoil will resultin compressor failure All AVC systemparts compressor discharge line suctionline evaporator condenser receiver dryer expansion valve O rings ...

Page 1025: ... I I SYMPTOM REMEDY Radiator fan doesnot run at all Perform the procedures in theflowchart seepage22 8 Condenser fan doesnot run at all Performthe proceduresin the flowchart seepage22 1O1 Bothfans radiatorand condenser do not run for enginecooling but they both run with theIVCon Perform the procedures inthe tlowchart seepage22 12 Bothfansdo not runat all Perform the procedures inthe flowchart seep...

Page 1026: ... b o d y ground lstherebattery voltage Connect the No 1 and No 2 ter minalswith a jumperwire Doestheradiator fanrun Checkfor continuityin the BLK REDwire betweenthe No 1 ter minalandtheradiator fan Repairopen in tho BLK RED wir6 b6twaon the undor hoodfuso r6l6vbox andthe radirtorf6n lstherecontinuity CheckIor continuityin the BLK wire betweenthe radiatorlan andbodyground Chockfor n opon in tho BLK...

Page 1027: ...heignitionswitchON II Measure thevoltagebetween the N o 4 t e r m i n a l i a n d b o d y ground Ropairop n in the GRNwire be tween the undor hoodIuse elaybox andthe A C diode lsthere batteryvoltage Repairopen in the BLK YELwire botwean the under hoodtuse relay box snd the under daah fuso relaybox 22 9 ...

Page 1028: ...LU BLKwire betweenlhe No 1 ter minalandthecondenser fan Ropairopen in the BLU BLKwir between tho undor hoodfu3e relaybox andlh condan3er fan lstherecontinuity Checkfor continuityin the BLK wire betweenthe condenser fan andbodyground Checktor an ooen in the BLK wir6 betwoen the condan3erfan and body ground lf the wire is OK check for poor ground at Gr51 ReDlace the condenser fan motor CONDENSER FAN...

Page 1029: ... b o d y ground R prir op n In th BLK YELwir batwaen tha undar hood fuaa ral y box and tho undar daah furo rclay box R movethe A Cdiode from ths und6r hoodtuso relavbox ls the A C diodeOK R prir op n in tha BLU YELwir batw n th und r hood tu rol y box nd th A C dlod Frompage22 10 CONDENSER FANRELAYIP SOCKET I 22 1 ...

Page 1030: ...wire terminal and body ground Repairopen in the GRNwire b tween the ECTswitch and the under hoodluse rel6vbox ls there battery voltageT Turn the ignition switch OFF and c h e c k f o r c o n t i n u i t y i n t h e B L K wire between the ECT switch and body ground Checkfor en ooen in the BLK wire between the ECTswitch and body ground ll th wire is OK checklor poor ground at G101 ls there continuit...

Page 1031: ...Both Fans Eoth lans do not run et all Removothe A C diodefrom the under hood fuse relay box lstheIVCdiodeOK Repeiropen in the BLU RED wire between the A C diode and the A C Dr ssure swhch 22 13 ...

Page 1032: ...nect the No 1 and No 2 ter minalswith a jumperwire Discon nect the compressor clutch1Pconoector Checklor continuityin the RED wire betlveen the No 1 terminal andthecompressor clutch Reprir open in tha BEDwira botwoon th6 undar hoodfusc rolay box and lhs comp osror clutch In3p6ct th compre3sor clulch clear nc and the comDressor cfutchti fdcoil se ptge22 321 COMPRESSOR CLUICHRELAY P SOCKET JUMPER WI...

Page 1033: ...K YELwiro betwsen tha undor dashtu3a rehy box rnd the undor hood fw6 i6lry box Turntho ignitionswitchOFF and reinstallthe compressorclutch Makesurothe y Cand heaterfan switchesare OFF TurntheignitionswitchON l1 Using a BackprobeSet T N 07SAZ 001000A measure th voltagebetweenthe No 17termi nal oI the ECMconnocrorA 32P and body ground wirh the ECM connectors connected R pair op n in tho BLK R O wiro...

Page 1034: ...he BLU RED wire terminal and bodyground Repeiropon in the BLU REDwiro botwoon the A C D ossuro 3witch andthe A Cdiode Turnthe ignitionswitchOFF Checkfor continuity betweenthe No 1 and No 2 torminalsof the A Cpressureswitch Checkfor Ay C systempressure Recon nect the A C pressure switch2Pconnector Repbce the A C pro ur6 3witch Viewfromwireside YEL WHT BLU RED l l fo page22 17 22 16 ...

Page 1035: ...erm6tlt lstherebattery vohageT Moasure tho voltagebetween the YEL A VHT wire terminal and bodyground Repairop6n in the YEL WHT wire betwGenthe A C pressure switch sndthe A C thermostat lsth6re batteryvoltage TurntheignitionswitchOFF Reconnect the A Cthermostat3P connector and connectthe BLU REDwireterminal to groundwith Do the radiatorand con denserfans run and the compressor clutchengage Turnthei...

Page 1036: ...n switch 6Pconnector Checklor continuityin the GBN wire betweenthe heatercontrol panelandthe he6ter fanswitch Repairopen in the GRNwire be tween the hestercontrol panel andthe heaterfan switch Check for continuity in the BLK wire betweenthe heater fan switchandbodyground Check for an ooen in the BLK wire between the hetter fan switch and body ground ll rhe wire is OK check for poor groundat G401an...

Page 1037: ...houldgo off at 37 F 3 C or less andshould comeon at 39 F 4 C or more lf the light doesn tcome on and go off as specified replace theAy C thermostat 1 2 V 3 W 1 8 W A B C Relays Test Thereshouldbe continuitybetweenthe No 1and No 2 terminalswhen powerand groundareconnected to the No 3and No 4terminals and thereshouldbe no conti nuitvwhenDoweris disconnected Radiator fan relay Condenser fan relay Ay ...

Page 1038: ...Checkfor currentflow in both directions betweenthe A and B and B and C terminals Thereshouldbe current flow in onlyonedirection Diode A C Switch Test Test 22 20 NOTE The Ay C switchcontainsa diode Usean analog ohmmeter or a digitalohmmeterequippedwith a diode tesler Check for currentflow in bothdirections between termi nals11and12 There shouldbecurrent flowin onlyone direction po inul 1 1 O N o OF...

Page 1039: ...nrecovering the system usea R 134a refrigerant Recovery Recycling Charging System don t release refrigerant intothe atmosphere 6 Add refrigerant oil afterreplacing thefollowingparts NOTE To avoidcontamination do not returnthe oil tothe container oncedispensed and nevermix itwith otherrefriger antoils lmmediatelyafterusingtheoil replacethecaponthecontainerandseal itto avoidmoisture absorption Do no...

Page 1040: ...tures of air and R 134ahave been shown to be combustible at levated pros3ures and can result in lire or explosioncausing iniury or plop rty damage Neverusecomprossgdair to pressure iest R 134aserviceequipment or vehicleair conditioner sYstsms A d d i t i o n a lh e a l t ha n d s a f e t yi n f o r m a t i o nm a y b e obtainedfrom the refrigerantand lubricantmanufac tures Connecta R 134arefrigera...

Page 1041: ...alve Cleanor replace Receiver dryeroutlet is cool and inlet iswarm shouldbewarm during operal onJ Clogged receiver dryer Replace Suction pressure abnormally high Low pressure hoseandseryice valvearecooler thanthetemPera turearound evaporator Expansion valveopentoo long Looseexpansioncapillary tube Repair or replace Suctionpressureis loweredwhen condenseris cooled by water Excessiverefrigerant in s...

Page 1042: ...ury or property damage Neverusecompressedair to pressure test R 134aserviceequipment or vehicleair conditioner systems A d d i t i o n a lh e a l t ha n d s a f e t yi n f o r m a t i o nm a y b e obtainedfrom the refrigerant and lubricantmanufactur ers Connecta R 134arefrigerantRecovery Recycling ChargingSystemto the vehicle as shown follow ingthe equipmentmanufacturer s instructions Insena therm...

Page 1043: ... level Fromeachpoint drawa horizontal lineacross the delivery temperature Thedelivery temperature shouldfall between thetlvo lines Complete the low sidepressure testandhighsidepressure testin the sameway Any measurements outsidethe linemay indicate the needfor furtherinspection kpa lkst cm tpsil 2900 t30 I4 01 250 t25 t3601 2000 20 I28ol 80 70 3 0 rp lkgf cm l lpsil DELIVERY PRESSURE OEL vENY PRES...

Page 1044: ...efore installing them NOTE Be sureto usethe rightO ringstor HFC 134a R 134a to avoidleakage applysealant to the grommets makesurethatthereis no air leakage chargethe system seepage22 39 and test its performance seepage22 24l CLIPS SRScomponentsare locatedin this area Reviewthe SRScomponentlocations precautions and procedures in the SRSsection 23 beforeperforming repairsor ser vice 1 Recover the re...

Page 1045: ...nes at eachfit ting and applya thin cost of retrigerant oil ND OIL8 P N38897 PR7 A01AHor 38899 PR7 A01 beforeinstalling them NOTE Be sureto usethe rightO ringsfor HFC 134a R 134a to avoidleakage Installthe expansion valvecapillary tube with the capillary tube in contactwith the suctionline directly andwrap it withtape Reinstall theAy C thermostat sensorto itsoriginal location TAPE Replace Make sur...

Page 1046: ...R 134a A revolving inclineddiscdrivesthe sur rounding10reciprocating pistons As the inclineddiscrevolves it pushesthe pistons protected by a ceramicshoe thus compressing the refrigerant FIELD COIL ar o o ______ __ o _______ r____________l Compressor Description 22 28 ...

Page 1047: ...SET lnspection Page22 32 SNAPRINGA Replace FIELD COIL Inspection page22 32 I COMPRESSOR COMPLETE lDo notdisassemble SUCTION SERVICE VALVE O RING Replace I S V X I I I ory O RING Replace RELICF VALVE R placement page22 34 22 29 ...

Page 1048: ...o mountingboltsandthe condenser fanshroud NOTE Be carefulnot to damagethe radiatorfins when removingthe condenser fanshroud 1 0mm N m 1 0kgt m rbf ftt CONDENSER FANSHROUD COMPRESSOR CLUTCH CONNECTOR 5 Removethe bolts then disconnect the suctionline andthe discharge linefrom thecompressor NOTE Plugor cap the linesimmediately aiterdis connecting to avoid moistureand dust contamina tion 6 x 1 0 m m 9...

Page 1049: ...oulddrain from the new compressor throughthe suction itting r Replace the O ringswith new ones at eachfit t i n g a n d a p p l ya t h i n c o a to f r e f r i g e r a n t o i l beforeinstalling them NOTE Besureto usethe rightO ringsfor HFC t34a R 134a to avoidleakage use refrigerant oil ND OlL 8 P N38897PR7 A0IAH or 38899 PR7 A01 for R 134a DENSO pistontypecompressors onlY To avoidcontamination d...

Page 1050: ...rag Measure the clearance between the Dullev and the pressure plateall the way around lf the clearance is notwithinspecified limits the pressure platemustbe removedand shimsaddedor removedas required followingthe procedure on page22 33 Clearanca 0 50t 0 15mm 0 020 r 0 006in NOTE Theshimsareavailable in threethicknesses 0 1mm 0 3mm and0 5mm 22 32 Checkresistance of thefieldcoil FieldCoil Resistance...

Page 1051: ...BOLT 13 2N m 1 35 kgfm 9 76lbtft I Removethe pressure plateand shim s taking notto losetheshim s sHtM sl 4 3 Remove the snap ring B with a snap ring pliers then remove the pulley NOTE o Be careful not to damage the pulley and com pressorduring removal installation Once the snap ring B is removed replace it with a new one cont d I T vr f f i t l l l r l l I v 22 33 ...

Page 1052: ...the center bolt andtightenit securely makesurethatthe pulleyturnssmoothlyafter it sreassembled ReliefValveReplacement Recoverthe refrigerantwith Recovery Recycling ChargingSystemlseepage22 221 Remove the reliefvalveand the O ring Plugthe openingto keepforeign matterfrom enteringthe systemandthecompressor oil from runningout NOTE Do not letthecompressor oil runout Makesurethereis no foreignmatterin...

Page 1053: ...Manual TransmissionType 1 Loosen the adjust pulley bracket pivot bolt and the adjusting bolt then remove the A C compressor belt from the pulleys 2 Remove the two mounting bolts from the left front engrnemount Remove the engine mount nut washer bolt and the left front engine mount Remove the i C compressor belt ADJUSTPULLEY BRACKET PIVOTBOLT AOJUSTING BOLT 14x 1 25 mm 83N m 8 5kgl m 61rbf ft LEFTF...

Page 1054: ...ut Recheck the deflection of the Ay C compressor belt 22 36 TensionGaugeMethod 1 Attachthe belttensiongaugeto the Ay C compres sor beltas shown below and measure the tension of the belt A C ComprossorBelt UsedBelt 390 5 rcN 4O 55 kgf 88 120lbf New Bslt 7 10 880N 75 90 kgf 170 200lbf PowerSteeringPump Belt UsedBelt 390 540N ito 55 kgl g8 i20 tbtl New Belt 740 880N 75 90 kgt 170 200tbtl NOTE lf ther...

Page 1055: ...x 1 0 m m 9 8N m 1 0kgj m 7 2lbl ft 5 Removethe two mounting bolts then lift out the condenser asshown NOTE Be carefulnot to damagethe radiatorand condenser finswhen removingthecondenser 6 x 1 0 m m 9 8Nm 11 0 kgfm 7 2lbfft lnstallin the reverse orderof removal Makenoteof theseitems lf you reinstsllinga newcondenser addrefriger ant oil ND olL8 P N38897 PR7 A01AH or 38899 PR7 A01 seepage22 211 Repl...

Page 1056: ...on causing injury or property damage Neverusecompressedair to pressure test R 134aserviceequipment or vehicleair conditionet svstems Additional healthandsafetyinformation may beobtained fromtherefrigerant andlubricant manufacturers Whenan A C Svstemhasbeenooenedto the atmo sphere suchas duringinstallation or repair it must be evacuated using a R 134a refrigerantRecovery Recycling Charging System l...

Page 1057: ...arging Open high pressure valveto chargethe systemto the specified capacity then closethe supplyvalve andremovethechargingsystemcouplers R frigeranicapacity 7001og 124 7 llroz Checkthe systemfor leaksusinga R 134a refriger ant leakdetectorwith an accuracy of 14 g 0 5oz peryearor better lf you find leaksthat requirethe systemto be opened to repairor replacehouses fittings etc recoverthe system acco...

Page 1058: ...da 23 164 FrontParkingLights 23 173 FrontSideMarkerLights 23 173 FrontTurnSignalLights 23 173 Hazard WarningLights 23 192 Headlights 23 169 23 253 powerDistribution 23 5 r Air Conditioning Soction21 Alternator 23 99 iCigarette Lighter 23 212 Cruise Control Distributor 23 277 23 88 23 90 lgnitionTiming IndicatorLights Key inReminderSystem MaintenanceReminderSystem Seat BeltR mindor System Side Mark...

Page 1059: ...50200 07TM 001020A Deployment Tool AntennaNutWrench BeltTensionGauge TestHarness FuelSender Wrench SCSService Connector SRSInflator Simulator SRSSimulatorLeadC SCSService Connector 2o Backprobe Adapter l7 mm 1 1 1 1 1 1 l 1 2 23 320 23 203 23 1 t5 23 124 23 90 288 23 301 23 30 l 23 301 23 287 r lncludedin SRSToolSet07MAz SM5000B Usewiththe stakingpatchcordsfrom T N07SM 0010004 Backprobe Set o o 23...

Page 1060: ... groundcablelooselyconnectedor you willse verelydamagethe wiring a The originslradiohasa codedtheft plotection cir cuit Be sure to get the customel s code numbel before disconnectingthe battsry removing the No 47 7 5 A fuse from tho under hoodluse relay box removing the radio Atter service leconnect Dower to the radio and tum it on Whenthe word CODE is displayed enter the customer s 5 digit code t...

Page 1061: ...any movingparts Keepwire harnesses away from exhaustpipesand other hot parts trom sharpedgesol bracketsand holes and from exposedscrewsand bolts GOOD NOTGOOD M A lr lr Testing and Repairs a Do not usewiresor harnesses with brokeninsulation Replace them or repairthem by wrappingthe break with electrical tape a Atter installingparts make sure that no wires are oinchedunderthem a When using electrica...

Page 1062: ...tion identityoneor morepossible causesof the problem 3 lsolata The ProblemBy Testing The Circuit Makecircuitteststo checkthe diagnosis you made in step2 Keepin mindthat a logical simpleproce dureisthe keyto efficienttroubleshooting Testfor the most likelycauseof failurelirst Try to make tests at pointsthat are easilVaccessible 4 Fix The Problem Once the specificproblemis identified make the repair...

Page 1063: ...ntifywire colorsin the circuitschematics W H T W h i t e Y E 1 Y e l l o w 8 1 K B l a c k B 1 U B l u e G R N G r e e n R E D R e d O R N O r a n g e P N K P i n k B R N B r o w n G R Y G r a y P U R P u r p l e LT BLU LightBlue LT GRN LightGreen The wire insulationhas one color or one color with anothercolorstripe Thesecondcolor is the stripe WHT BLK a I t R BELAYlln no Normallyopenrelay rmal po...

Page 1064: ...mpartment ABSPUMPMOTOR RELAY FAN RELAY UNDER HOOD AB i FUSE RELAY BOX IKGmod ll A C COMPRESSOR CLUTCHRELAY RADIATOR FAN BELAY UNDER H X D FUSE RELAY BOX A SMODULA UNIT UNDER HOOD ABII FUSE RELAYBOX KEmodoll a r l r u D tr L ABSPUMPMOTOR 23 7 ...

Page 1065: ... CONTROL UNIT PGM FI MAIN RELAY STARTERCUT RELAYIM TI I Wirecolors BLK WHT BLUi 8LK I I BLK WHT andBLK RED j MOONROOF RELAY Wire colors WHT GBN BLK GRNand 8LK I Wir cotoF WHT GRN BLU RED I lWHT GRN andBLU GRN I POWER WINDOW BELAY 23 8 INTEGRATED CONTROL UNIT ...

Page 1066: ...POWERWINDOW MASTERSWITCH lHas built incontrolunitl ...

Page 1067: ...Relayand Control Unit Locations Dashboard and Floor INTERLOCK CONTROL UNIT A T SS 23 10 ...

Page 1068: ... u i l DASHLIGHTSBRIGHTNESS CONTROLLER Hasbuilt incontrolunit MAINTENANCE REMINDER UNIT MODULEITCMI 23 11 ...

Page 1069: ...Relayand ControlUnit Locations OuarterPanel ABS CONTROL UNIT 23 12 ...

Page 1070: ...156 G 1 5 1 Enginecompartment wire harness C301throughC320 G301 Mainwire harness C201throughC223 G20 landG202 C40lthroughC454 G401 Rearwire harness C501 throughC536 G501 Sedan G502 andG503 Dashboard wire harness C551throughC569 G551 Driver s doorwire harness C601 throughC612 Frontpassenger s doorwire harness C626 throughC634 Leftreardoorwire harness Sedan C65lthroughC654 Rightreardoorwire harness ...

Page 1071: ...ginecompartment Bodyground via engineground EngineGroundCableB Connectorol Terminal Numbelof Cavities Location Connects to Not s r4 Rightsideof enginecompartment Transmission housing Right side of front frame Bodyground via engineground wire B A C Wire Harness Connectoror Terminal Number of Cavities Location Connectsto Notos c151 cl54 c156 8 2 l Righrsideof enginecompartment Leftsideof enginecompa...

Page 1072: ...UNOER HOOD ABS FUSE RELAY BOX CABLE T3 ENGINE GROUND CABLEA ...

Page 1073: ...necompartment Lelt sideot enginecompartment Left sideof enginecompartment Transmission Transmission Transmission Mainwire harness C221 Mainwire harness C222 Mainwire harness 1C223 lvlainwire harness C220 Startersolenoid Enginecoolanttemperature ECT sensor Enginecoolanttemperature ECT gaugesendingunit Back uplight switch Lock up controlsolenoid valveA andB Distributor Crankshattspeedfluctuation CKF...

Page 1074: ...J ENGINE WIREHARNESS 81881 enginel c129 c 1 1 5 c 1 1 4 c121 c t22 c123 c124 23 17 ...

Page 1075: ...t sideof enginecompanment Left sideof enginecompartment Lelt sideof enginecompartment Rightsideof engine Rightsideof engine Middleof engine Middleof engine lvlainwire harness C221 Main wire harness C222 Main wire harness C223 Main wire harness C220 Startersolenoid Enginecoolanttemperature ECT sensor Enginecoolanttemperature ECT gaugesendingunit Back uplight switch Distributor Crankshaltspeedfluctu...

Page 1076: ...ENGINE WIREHARNESS 818C1 818C5 engine c 1 0 1 c102 c117 1 3 c 1 1 4 c 11 5 c134 c 1 t 8 c t10 c133 23 19 ...

Page 1077: ...sideof enginecompartment Behindleft headlight Behindleft headlight Behindleft headlight Behindleft cornerof front DUmper Behindleft cornerol front bumper Behindlett cornerof front bumper Behindleft co nerof lront bumper Main wire harness C423 Main wire harness C424 N4ain wire harness C424 Frontfog light system Engine wire harness C126 Enginewire harness C 127 Test tachometerconnector Daytimerunnin...

Page 1078: ...c306 c307 ENGINE COMPARTMENT WIRE HARNESS G301 ...

Page 1079: ...ginecompartment Rightsideof engine compartment Rightsideof engine compartment RightsideoI engine companment Rightsideot engine compartment Right sideot engine compartment Right sideof engine compartment norn Rightfrontsidemarkerlight Rightfrontturn signaUparking light Rightheadlight Lowbeam Rightheadlight Highbeam Radiator lan motor A C wire harness C151 ABSfrontfail saferelay ABSpumpmotor ABSmodu...

Page 1080: ...J UNDER HOOD FUSEiRELAY BOX MAIN WIREHARNESS lcont d c221 c223 Continueson page23 25 23 23 ...

Page 1081: ...assenger s door Underright sideof dash Underright sideot dash Underright side of dash Underright sideof dash Behindright kick panel Behindright kick panel Behindright kick panel Eehindright kick panel Frontpassenger s door wire harness C626 A C diode Heatersub harness A C672 Heatersub harness A C671 Servicecheckconnector ABS sub harness C7Ol Enginecontrolmodule ECfM EnginecontrolmodulelECM Enginec...

Page 1082: ...Continuoson page 23 27 23 25 ...

Page 1083: ...ehinddashboard lowercover Behinddashboard lowercover Center floor Under middle of dash Underleftsideof dash DataIinkconnector DLC A T gearpositionconsolelight Shiftlocksolenoid Ay T gear positionswitch Interlock controlunit Daytimerunninglightscontrol Oaytime runninglightscontrol Cruise controlunit Junctionconnector Transmission controlmodule rcM Transmission controlmodule TCM Rearwire harness C50...

Page 1084: ...II MAIN WIREHARNESS Continuedlrom page 23 25 J c418 c424 c423 c425 C4 r8 c421 c422 c4 13 c417 c112 c45 l UNDER DASH FUSE RELAY BOX I 9 O O O O T o r a _ t n n l J 23 27 ...

Page 1085: ...arcornerof cargoarea Center of cargoareabulkhead Rightsideof cargoarea Rightsideof cargoarea Rightsideof cargoarea Center of cargoareabulkhead Center of cargoareabulkhead Center of cargoareabulkhead Leftsidecornerof cargoarea Mainwire harness C421 Mainwire harness C422 Underdashfuse relay box C912 Underdashfuse relay box C915 Dashboard wire harness C554 Driver s doo wire harness C601 Driver s seat...

Page 1086: ...J c505 c503 1 9 c520 REARWIRE c521 c 5 1 0 G503 23 29 ...

Page 1087: ...sideof rearwindow Above right sideof trunk Rightquarterpanel Rightsideof rearwindow Left sideof trunk lid Centerof trunk lid Rightsideof trunk lid lvlainwire harness C421 lvlainwire harness C422 Underdash fuse relay box C912 Underdashfuse relay box C915 Dashboard wire harness C554 Driver s doorwire harness C6Ol Driver sseat belt switch Parkingbrakeswitch Driver sdoor switch Fuelpump Fuelgaugesendi...

Page 1088: ...l i 1 3 c512 C528 c532 c519 REARWIREHAqNESS 23 31 ...

Page 1089: ...ges Behindgauges Behindmiddleof dash Leftside of dash Behindmiddleof dash Behindmiddleof dash Rightsideof dash Undermiddleof dash Behinddashboard lowercover Undermiddleof dash Under dash fuse relay box C921 Mainwire harness C430 Mainwire harness C452 Mainwire harness C452 Rearwire harness C505 Cruisemainswitch Junctionconnector Gaugeassembly Gaugeassembly Gaugeassembly Gaugeassembly Clock Dashligh...

Page 1090: ...rl j 1 l f a jl T l n n _ _ n n r n _ n n _ L l uuo ult C562 C563 DASHBOABD WIREHARNESS UNDER DASH FUSE RELAY BOX 23_33 ...

Page 1091: ... Behindmirrorpanel Driver sdoor Driver sdoor Driver sdoor Driver sdoor Driver sdoor Driver sdoor Driver sdoor Driver sdoor Driver sdoor Driver sdoor wire harness C506i Driver sdoor speaker Driver spower window motor Powerdoor lock controlunit Left power mirror Left power mirror Left tweeter Driver sdoor lock switch Powermirrorswitch Powerwindow masterswitch Powerwindow masterswitch Driver sdoor lo...

Page 1092: ...J DOORWIREHARNESS 23 35 ...

Page 1093: ...ssenger s door Behindcover panel Frontpassenger s door Frontpassenger s door Frontpassenger s door Frontpassenger s door Frontpassenger s door Frontpassenger s door Main wire harness C401 Frontpassenger s door speaker Frontpassenger s power window motor Rightpower mirror Rightpower mirror Righttweeter Frontpassenger s door lock switch Frontpassenger s power window swrrcn Frontpassenger s door lock...

Page 1094: ...J Harchback PASSENGER S DOORWIREHARNESS FRONTPASSENGER S DOORWIREHARNESS 23 37 ...

Page 1095: ...ft reardoor Rearwire harness C527 Left rearpower window motor Left rearpower window switch Left rearpower door lock actuator RightRearDool Wire HarnesslSedan Connectoror Telminal Numberof Cavities Location Connects to Notes c656 c657 c658 c659 6 2 5 2 Rightreardoor Rightreardoor Rightreardoor Rightreardoor Rearwire harness C528 Rightrearpower window motor Rightrearpower window switch Rightrearpowe...

Page 1096: ...1t t i i LEFTREARDOOR WIREHARNESS WIREHARNESS 23 39 ...

Page 1097: ...2 c663 c664 c665 L O O O c667 J 4 a I Behindleft kick panel Behindleft kick panel Behindleft kick panel Left side of dashboard Roof Roof Roof Under dash fuse relay box C919 Moonroofrelay lvlainwire harness C425 Moonroofswitch Moonroof motor Spotlight Ceilinglight With moonroof With moontoof With moonroof with moonroof With moonroof 23 40 ...

Page 1098: ...ll r 1l it l Hatchback t l r l I i a i UNDER DASH FUSEi RELAYBOX UNDER DASH FUSE RELAY BOX rt r rtl H_l Jftra fifi fi L l r o niin F _ f I o rL l o ffi n ___ __ al 23 41 ...

Page 1099: ...2 2 2 2 Behindrightkickpanel Rightquarterpanel Rightquarterpanel Rightsideof cargoarea Rightsideof trunk Leftside of cargoarea Leftsideof trunk Mainwire harness C407 ABScontrolunit ABScontrolunit ABSrightrearwheelsensor ABSrightrearwheelsensor ABSleftrearwheelsensor ABSleftrearwheelsensor Hatchback Sedan Hatchback Sedan G702 Rightquarterpanel Bodyground viaABSsub harness ...

Page 1100: ...It i l i I i c704 c703 G702 c704 ABS SUE HARNESS Sedan t v 23 43 ...

Page 1101: ...tor Highmountbrakelight Rearwire harness C527 Tailgate openswitch Rightsideof hatch Bodyground via hatchwire narness 1 Hatchback with rearsDoiler SpoilerSub harness Hatchbackwith RearSpoilell Connector or Telminal Numberot Cavities Location Connectsto Notes c761 c762 c763 2 1 1 Rightsideof hatch Middleof hatch Middleof hatch Hatchwire harness C754 Highmount brakelight Highmount brakelight RearWind...

Page 1102: ...l lli l HATCH WIREHARNESS SPOILER SUB HARNESS REARWINDOW DEFOGGER GROUNOWIRE ...

Page 1103: ...ove box Blower resistor C675 4 Behind glove box I Recirculation control motor C676 3 Behindglove box i A C thermostat C677 14 Behind middleol dash Heater sub harness B C681 Connectorol Terminal Number of Cavities Location Connects to Notes c681 c682 c683 c684 1 4 I 6 1 4 Behind middle ot dash Middle of floor Behind middle ot dash Behind middle of dash Heatersub harness A iC677 Mode controlmotor He...

Page 1104: ...hboard lower cover Under left side of dash Under left side of dash Middle of tloor Behind glove box under le t side of dash Underdashfuse reiay box C920 Main wire harness C427 Cablereel SRSunit Frontpassenger s airbagassembly Memoryerasesignal MES connector G 8 0 1 Middleot floor Body ground via SRS main harness I l SRSMAIN HARNESS D 23 47 ...

Page 1105: ...1 2s 26 27 28 29 30 3t 32 33 IJ IJ IJ LI LI IJ LI LJ IJ LI LJ I J r t n n r l r tr t r lr 1n r tr 1 a 12 13 14 15 t6 17 t8 19 20 21 22 I J LI IJ IJ tJ LI LI IJ IJ IJ LI IJ r t l n r 1n t r tr t r 1n r t a 1 2 3 i t 5 6 7 8 9 1 0 1 1 LI IJ IJ IJ LI IJ LI LI I J LI LJ LI 1 2 0 4 WHT GRN Powerdoor lockcontrol unit Not used 1 0 A GRN 4 VHT Rearwindowwashermotor GRN BLK Rearwindowwioermotor 4 1 0A RED ...

Page 1106: ...ts 20 1 0A WHT YEL Daytimerunninglightscontrolunit Canada 2 1 1 0A RED WHT Rightheadlight lowbeam 22 1 0A RE D YE L Lettheadlight lowbeam 23 1 0A GRNor PNK SRSunit VB 24 7 5A GRN ORN Moonroofrelays Powerwindowrelay 7 5A YEUBLU Clock gaugeandindicator lights Integrated controlunit 26 2 0 A GRN BLK Windshield wipermotor windshield washermotor 1 0 A YEUGRN Cigarette lighter 28 1 0 A YEURED Audiounitc...

Page 1107: ...ksideof the under dashfuse relavbox C9l7 lTo mainwir hrrn63 C Oll C 14 To intogrrtod cont ol unhl Cll8lTo m in wiro h rnegr C l ll C315lToro r wire hlrn 3t C504 l C9l2 Tor arwir hrrnsr lc503ll C9l3 fTo mlin wir harnc r lG l 8 l C918lTom in wi o h rn 3 O 9ll 23 50 ...

Page 1108: ...o mainwire harno 31C213 l Compon ntls or Circuit slProtoqted J T5 To under hoodABStuse rel y box c blel o l l o f l f l f erll f os 61 4 0 A WHT ABSpumpmotor No 65 10A fuse 2 0 4 WHT GRN ABSmodulatorunit ViaABSfail safe relay ABSpumpmotorrelay ViaABSfailsaferelav Not used 64 Not used 65 1 0A BRN EL ABScontrolunit MCK 23 51 ...

Page 1109: ...Not u6ed clutchl hyl NOTE Viewfrom the backside of the under hood fuse relav box ClOg To main wiro ha ne3s C215ll C 107 To blow r motor r l yl C908 To m in wiro h rn C2l7ll rr 17 LI Fl 51 LI rl 56 lJ rr 51 IJ C905 To A C compr ssor C9O6 To radirto fan 23 52 Cltl1 lTo main wire harnesslc218ll USA C 10 To mrin wir hlrnoit lC216ll ...

Page 1110: ...5A WHT BLU Clock 8udio unitconnector ECM TCM Maint nance reminderunit 48 4 0 A WHT Combination lightswitch Headlight 49 3 0 A WHT BLU Moonroofrelay 50 4 0 A WHT GRN Rearwindowdefogger Viarearwindowdefoggerrelay 5 1 1 5 4 WHT Combination lightswitch Dashlights 20A WHT GRN Horn hornrelay brakelights AgScontrolunit ECM TCM 1 0 A WHT GRN Turnsignal hazard relay hazard warninglight 54 4 0 A WHT flED No...

Page 1111: ...ng light Turn signal hazard elay Viaswilch Horn BRN YEL YEUFED 8LK Shnermolor BLK RED T G1 Gml G401 ALTERNATOR wHriGRN WHT GRN No rs 7 5A1V LL r _f GRNMHT F ABSconlrollnrt t EcM TcM _ eke ughts GRN RED ECM HT BLK ig ryJ itil F r F UNDEF OASH vlHi nED I4 FUSE FELAY BOX Lz To page 2359 YEITWHT PGM Flmain retav T UNDER DASH I HTa_U l l uSERELAV 8OX fropage 2357 Clock ECM TCM Mainlenance reminder unl ...

Page 1112: ...Hr Tll 11 uo N0 17 7 5A FUSE Fiom page 2356 V L r rr orn N u NoEF DASF FlrsE RE AY Box t I aaaqe zJ L BLUA VHI Bower motor f_ oro G40l BLU YEL ncthermoslal viadiode 8LU BLK Condenser lanmolor JCcompressor clulch BLKRED_ CM BLKRED Radiatorian molor G F N E c M l P36 r1ot 1 nt n n cont d 23 55 _ _ _ l t ...

Page 1113: ...LKWHT I V Topage 23 59 Fuse telay box sockel cRN orREot i BLK YEL Recirdlalion conlrol nolof C lhefmoslal Mods conlrol motor Healer conlrolpanel oaylime running lights relay Canada near washor molor Via rear wiper vasher swilch lgnilion coil Tuln signal harad relay viaswrtcl PGM FI main relay SRS unil VA Cruise conlrol unit BLK TYEL Alernalor r_ TcM BLK YEL t vss E D Jril JSAj Charging syslem l hl...

Page 1114: ...shisld wiper molor Harchback J GRNioRN Moonrool relays f _ G401 WHT YEI Power wrndow masler swnch powe wndow contol unil Via power wndow master swildr R r R k l I Passenqeis power wroow moro I fva powe window nasleswird ard oassenoers oo re r noow swlc BLU gLK_ J GRN BLK I Lslllearpower window molot l_ Viapower ndowmasler switdr drd yEt g K I Rigftrear power window molo l_ Va power mrdowmaslerswrc...

Page 1115: ...plional conneclor B N0 50 40A FUSE From page 23 55 H_ GRN rower door tock controt un t F Halct op ler acluator l Halch lalcn sw rm BLKGFN BLKRED Rear window delogger N0 16 7 sA FUSE Viaswlch f7 I BLUfrEL IGNITION SWITCH lFrom page 2356 ft I WHT BLK f _ Fus irglay boxsoclel G201 G401 Cigaretle lighler Oplional conneclor ACC Audro unilconneclor WHT GRN 23 58 ...

Page 1116: ...6 F Inlegraled control unil ECM PGM FImain relay Keyinlerlock solenoid A T lnteiock conlrol un1 fuT COMSINAT ON LIGHT SWITCH Topage 2360 N0 43 Fom Darainhconneclof olc C ilinq liqhl Cargo area lighl Power antenna molof conneclor cont d 23 59 BLIffiED UNDER DASH FUSE FEtAY 8OX Fuse lay box soc el 7 54 FUSE page 23 54 f 7 I N0 31 75A l N0 33 7 54 stuMHT I_ N0 20 Nolused L I_ ...

Page 1117: ...leglaled conlrol unh Flsorelay boxso el Flssrelay botsock l Fuse relay box sodet COMBINATION LIGHT SWTCH l o PAsslNG t o BEo BLK Healor conlrol panel hghl Mgear posrton consote tighl Cigarcfl 6lighter ashtray lights Gauge lighls Audiounitconnsclor R arwindow delogg r swnch tbht Clock Hazard wanlngswilcilighl Gloveboxlight Oashlightsbnghhess conlroller Leit I I I lronlparkifC lighl FighlJ h J n l f...

Page 1118: ...in retay f ec Dala linkclnneclor DLC I lransmissDn cor ro modlle J TCM ECM LG1 ECM LGz GOl 1 l 8LU GRN ORN BLU vYflt tlEU ORN J v J neo J l i rr n rition t o oarb J ficM r u 4 S h i e l d i n g _ Engife conparlmenl wireharness Main wi harness cont d 23 61 Crankshall speed fluclualion CKF sensor Mainshall speed s6n5o a I Counl shafi speed sensor rVT S condtY f1c2s E Batlsry ground cable El Enginegr...

Page 1119: ... High beam Righl headlighl Low beam Badiator lanmolor LK li li filHi l iffil 1 ELD unit USA UNDER HOOD FUSE RELAY BOX Fuse relayboxsockel Blower molor relay Fuseirelayborsochel iearwnoow oerogger reray G201 l V G401 Topage 23 63 AgSpump motor ABS lailsale relay ac nir n n U Malnwire harness 23 62 ...

Page 1120: ...onneclor DLC BL Fronlpassenge s doorkeycylinder switdr Fronl passonger s door lockswilch Seavice cieckconneclor Clulch swilch MIT wilhcrLr seconlrol Inleock contfolunitl Parking prn swlch J tu t Windshi ld wipefl Iasher sw1ch G40l tr tr N Eng necompanmentwife harness Fronl passenge s door wirehamess Healer sub harness A Healer sutsharness B tr 4 cont d G3o1 From page 23 62 L A T gear posrron swcn ...

Page 1121: ...N DASI FUSEi RELAY BOX Turn sbnal he2ad relay hlegraled conlrol unil BLh Moonlmlleray MooNool switch BLK BLK 8LK ABS SRS indicalor lighvci dril oashlighlsbrighhess clitroller Clock Gauges andindicalor lighls Maiol nan6Gmind a mil R6arwindow d6logger switch A Cqal nergrnet l Gloveboxlighl r Ouiseconlrolnan sw ldr Steleomdio cassello playel G551 23 64 ...

Page 1122: ... swilch I Power window masler swilch Dive sseal beit swilch Foelgaee sending unit Fuelpump FP i Gso2 _ _ _ _______ Halchback r F T6ilertiqhxng conneclor I lil i rror nqfi J License plale lighls Halci opener aotualor Halci opener swilch Rear window wiper molor High mounl hake ighl otw n1 t l _ 1 r 1 7_1 G503 Trunk lalch swildl Tfailer light ngconneclor License plate lighls R i o h l I L J Inner lar...

Page 1123: ...GroundDistribution Circuitldentification cont d B L K l r A8S controlunrt 8LK ryHT J i n out E ABssub hamess B Rear wlndow delogger ground wire I sRsmain hamess 23 66 ...

Page 1124: ...dedtheft protectioncircuit lf serviceto the car requires anyof the tollowing be sure to get the customer scode numberbefore disconnecting the battery removingNo 47 7 5A fusefrom the under hood fuse relay box removingthe radio After service reconnectpowerto the radioandturn it on Whenthe word CODE is displayed entertne customer s 5 digitcode to restoreradiooperation Useeithera JCI or BearARBSTteste...

Page 1125: ...eit Write down how longthe batterywas charged Test LoadCapacity 2 Apply 3O0amp loadfor 15 secondsto removesurtacecharge Allow 15 secondsrecovervoeriod Apply test load seeTest LoadChart Recordvoltageat the end ol 15 seconds Voltagestays above9 6 volts The batteryis OK I Voltagedropsbelow 9 6 volts The battery rs no good Forexample BATT 55B24L MF T I ERY CODE TESTLOADCHART Usethe test loadot 112the ...

Page 1126: ...erminals when poweris disconnected 2 F Z A l El E ey Normally opontype 1 Check continuitybetweenrelayterminals Thereshouldbe continuitybetweenthe A and C terminalswhen power and groundare connect edto the B andD terminals o Thereshouldbe no continuitv when oower is disconnacted o Powerwindowrelay Radiator fan relay Condenser fan relay AVC compressor clutchrelay Typel c I Blowermotorrelay Rearwindo...

Page 1127: ... Hornrelay a Hatchrelease relay Starter out relay PowerRelays ABSpumpmotorrelay ABSfail safe relay ...

Page 1128: ... terminals in each switch position according to the table View from wire side ST IBLK WHT BAT WI TI 7PCONNECTOR 5PCONNECTOR IG2 YELI DASHBOARD LOWER COVER Disconnect the 5P connectorfrom the under dash fuse relay box and the 7Pconnector from the main wrreharness IWHT BI K 4 ll continuity checks do not agree with the table replace the electrical part of the switch see page 23 7 2 View from wire sid...

Page 1129: ...od tuse relavbox removingthe radio After service reconnectoowerto the radioand turn it on Whenthe word CODE isdisplayed enterthe cus tomer s s digitcode to restoreradiooperation 1 Disconnect the negativecablefrom the battery 4 Removethe steeringcolumncovers Romovsths dashboardlowercover8nd knesbolster se6p8g623 71 Disconnsct th6 5P connectorfrom th6 under dash fuse rel8ybox 6nd th 7P conn ctorfrom...

Page 1130: ...and kneebolster s6op8ge23 72 3 Disconnect the 5P connectorfrom the under dash fuse relaybox and the 7P connsctorfrom th main wire harness seepage23 72l 4 Removethe steeringcolumn covars seepage 23 721 5 Remove the columnholdermountingboltsandnuts NUT 13 N m 1 3kgl m 9 4 lbt ftl BOLT 22 N m 2 2kgf m 16 lbf ftl 6 7 Lowerthe stee ingcolumnassembly Center ounch eachof the two shearboltsanddrill theirh...

Page 1131: ...age23 70 A T GEARPOSITION SWITCH Test page23 144 CLUTCH INTERLOCK SWITCHIM T Test page23 79 Switch Adiustment section12 Replacement BATTERY Test page2376 STARTER lest page23 77 SolenoidTest page23 79 Replacement page23 80 Overha 1 page23 81 Reassembly page23 86 23 74 ...

Page 1132: ...401 rAa rtF z5 r3 rr CLUTCH INTERLOCK SW TCH IGNITION X SWITCH _ G l T BTKWHT BLKWHT l l r t r BLKFED 8LU BLK BLK BE I __ lrror oo I I Yffii Tf o u T l i t il r T I twt t l Tl r I A I I B L K tY ltI ffim r l UNDEB HOOD FUSE BELAY BOX No41 100A N0 42 404 ...

Page 1133: ... SWITCH BAT i o jz I I BLKWHT I I I rl oro lI POStlOr l swrTcH Y Nedtal Posilion swilch I I I ELIVRED WHT BLK WHT J FUSBFELAYBox I SLIffiED I IGBY BLU J ECM STASTER Field windiig ly UNDEF HOOO FIJSE RELAY BOX BLI YEL N0 41 100A No 42 40A 23 76 ...

Page 1134: ...lenoid terminal trom the staner Then connecta jumper wire from the battervpositive terminalto the solenoidterminal The starter should crank the engine a It the stsrter still does not crank the engine replaceit and diagnoseits internalproblems a lf the startercranksthe engine go to step 5 cont d 4 NOTE The air temperaturemust be between59 and 100oF 15 and 38 C betore testing RecommendedProcedure a ...

Page 1135: ...rs with automatic transmission check the A T gear position switch neutral position switch and connector On cars with manualtransmission check the starter cut relay clutch interlock switch and connectors NOTE Checkthe No 42 40 A fuse in the under hood fuse relaybox for the startercut relay Check Jor Wear and Damage The starter should crank the enginesmoothly and stead ily lf the starter engages but...

Page 1136: ...als accord ingto the table 2 3 ll necessary replace theswitchor adiusttheswitch position seesection12 Terminal cr t hP i _ B RELEASED PUSHED o o ClutchlnterlockSwitch Test StarterSolenoidTest 1 Checkfor continuitybetweentheterminals accord ing to the table HOLD_ IN COIL 23 79 I I Coil Teminal t 4 s Housing HOLDIN O o PULL IN o o PULL_ IN COIL ...

Page 1137: ...omer s 5 digitcodeto restoreradiooperation Disconnect the negativecabletrom the battery Removethe intakeair duct AIRCLEANER HOUSING R move the enginewire harness andstartercables from their brackets 1 3 INTAKEAIR DUCT ENGINE WIREHARNESS CABLES 23 80 5 Disconnect the startercablefromthe B terminalon rhe solenoid then disconnectthe BLK WHTwire fromthe S terminal Removethe two boltsholdingthe starter...

Page 1138: ...radioandturn it on Whenthe word CODE isdisplayed enterthe cus tomer s 5 digitcodeto restoreradiooperation BRUSHHOLDER Test page23 82 BRUSH Inspectaon page 23 82 SOLENOID HOUSING STEELBALL installsteelball from clutchside k rt l MOLYBDENUM DISULFIDE OVERRUNNING CLUTCH ASSEMBLY Inspection page23 85 PINTON GEAB IDLER GEAR HARNE SBRA KET l 1 FIELD WINDING A f i y5J s SOLENOID PLUNGER STARTEB SOLENOID ...

Page 1139: ...hlyro tate the armature The contactsurfaceof the brushes will besandedto the samecontourasthe commutator 1 Checkthatthereisnocontinuity between the O and O brushholders lf thereis continuitv replacethe brushholderassembly O BRUSH I OLDER O BRUSH HOLDER Insertthe brushintothe brushholder andbringthe brushintocontactwith the commutator then attach a springscaleto the spring Measure thespringten saon...

Page 1140: ...paper g t Inspsctfor damage lf commutator diameter is belowthe service limit replace thearmature Commutator Diameter Measure thecommutator runout lf the commutator runoutis withinthe service limit checkthe commutatorlor carbondust or brasschipsbetween thesegments lf the commutatorrunout is not within the ser vicelimit replace thearmature CommutatorRunout cont d 23 83 Standard NEW Service Limil 29 ...

Page 1141: ...re or vibrateswhile the core is turned the armatureis shorted Beplace the arma ture M cA D PTH Commutator Mica Deoth 5 Checkfor continuitybetweenthe segmentsof the commutator lf an open circuitexistsbetweenanv segments replace the armature 7 With an ohmmeter checkfor continuity between t h e c o m m u t a t o ra n d a r m a t u r ec o i l c o r e a n d betweenthe commutatorand armatureshaft lf the...

Page 1142: ...nning clutchalongthe shaft Doesit move freely It not replaceit Rotatethe overrunning clutch both ways Doesit lockin onedirection androtatesmoothlyin reverse It it does not lock in eitherdirectionor it locksin both directions repl8c it lf the starterdrivegearis worn or damaged replace the overrunningclutch assembly the gear is not available separately Checkthe conditionot the flywheelor torquecon v...

Page 1143: ...FACE NOTE Usethe illustration on page23 81asa reference for reassembly 1 Prybackeachbrushspringwith a screwdriver then positionthe brushabouthalfwayout of its holder and releasethe spnngto hold it there 2 Installthe armaturein the housing Next pry back eachbrushspringagainand pushthe brushdown untilit seatsagainstthe commutator then release the springagainstthe end ol the brush SPRTNG fi49 d EIV I...

Page 1144: ...in iondoesnot retract the hold in coilis workingproperly CAUTION Do not leavethe batteryconnectedfor more than 10 seconds J RetractingTest Disconnectthe battery negativecable lf the pinion retractsimmediately it is workingproperly CAUTION Do not leavethe batteryconnectedfol more than 1Oseconds Starter No oad Test 1 Clampthe starterfirmly in a vise 2 Connectthe starterto the batteryas shown and con...

Page 1145: ...UTOR TopEndlnspeclion page23 92 Removal lnstallation pages23 92 93 Overhaul page2394 Reassembly page23 95 lgnitionCoilTesvReplacement page2396 lgnitionControl Module lCM lnputTest page23 97 PLUGS Inspection pago23 98 IGN TION WIRES Inspection page23 95 SERVICE CHECK CONNECTOR I2PI IWi 6 coloEi BRN WHTI land BLK j ...

Page 1146: ...ECM V I BLU I BI U 8LU l l I r I li3fou v coNNEcroR TACHOMETER UNOER DASH ruSARELAY BOX l t l t Tl l I IGNTTION WlRES ll I SPANK I PLUGS t uragram UNDER HOOO FUSgRELAY 8OX i i T 23 89 ...

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Page 1148: ......

Page 1149: ......

Page 1150: ......

Page 1151: ...terial DISTRIBUTOR IGNITION DII CAP Checkfor cracks wear damage and fouling Cleanor replace O RING Replace CI TDC CKP CYP SENSOR Troubleshooting section Do not disassemble 1 1 q a y DISTRIBUTOR IGNITION IDI HOUSING Checkfor cracksand damage IGNITION CONTROL MODULE ICMI Troubleshooting section11 Inputtest page23 97 LEAKCOVER l I I l ...

Page 1152: ...ection and Test J J 23 95 CAUTION Carelullyremovethe ignitionwiresby pull ingon the rubberboots Donot bendthe wires you might breakthem inside 1 Checkthecondition ot the wireterminals lJanyter minalis corroded cleanit andif it is brokenor dis torted reolacethe wire Checkfor broken corroded and bent terminals IGNITION WIRE Connectohmmeterprobesandmeasure resistance lgnitionWire Resistance 25 kOmax ...

Page 1153: ...itionswitch OFF removethe distribu tor ignition Dl cap Remove thetwo screwsto disconnect the BLK YEL andWHT BLU wi esfromterminals A andB respectively SECONDARY WINDING TERMINAL 3 Usingan ohmmeter measureresistance between theterminals ReDlace the coilif theresistance is not within soecifications NOTE Resistance will vary with the coil temper ature specifications are at 68oF 20oC Plimary Winding R...

Page 1154: ...ge go to step 4 I BLU WIRE YEL GRNI IRE 4 Turnthe ignitionswitch ON ll Checkfor voltage betweenthe WHT BLUwire and body ground Thereshouldbe batteryvoltage a lf there is no batteryvoltage check ignitioncoil WHT BLUwire betweenthe ignitioncoil and tcM a lf thereis batteryvoltage go to step 5 5 Disconnect the 32Pconnectorfrom the ECM and checkfor continuityon the YEUGRNwire between the ICMandECM The...

Page 1155: ... Adjustthe gap wjth a suitable gappingtool and replace the plugif thecenterelectrode is rounded asshownbelow Electrode Gap Standard l 1 r mm 0 043 ooa in E 23 98 3 818C1 engine a Do not adjustthe gap ol a platinumtip plug replacethe sparkplugit the centerelectrodeis roundedor if the gap is not within the specifi cattons ElectrodeGap Standard I t s 3 mm 0 051 3 oo4in 5 PLATINUMTIP NOTE Useonlv the ...

Page 1156: ...ons page23 122 UNDER HOOD FUSE RELAY BOX USA HASbUiIt iN ELECTRICAL LOADDETECTOR ELD UNIT Troubleshooting of ELD secrion11 BATTERY Test ALTERNATORBELT Insp ction andAdiustment page23_115 ALTERNATOR Troubleshooting page23 102 Alternator Fegulator Tosl pages23 105 106 Replacement page107 Overhaul page23 108 23 99 ...

Page 1157: ...a ChargingSystem CircuitDiagram INTEGRATEO CONTROL UNIT V I I ECM V I I UNDER HOOD FUSE RELAY BOX No41 1tl0A N0 42 40A FIETDWINOING WHT 8LU L GFN REO I I I I t ALTERNATOR BLK YEL 23 100 I ...

Page 1158: ...lrcH vI BtKAEt I rt r m rs IUNDER DASH I t 7 5A FUSE RELAYBOX I BLK YEL i TNTEGBATEo I CoNTROL UN T rh 3i i3 v Ynu i UNDEH HOOD FUSE RELAY BOX No 4l 100A 4 No42 40A B FTELDWTNoTNG ECM WHT 8LU L ALTERNATOF CircuitDiagram 23 101 ...

Page 1159: ... lCanadal ChargingSystem Light Check Makesurethe chargingsystem lightcomeson Ch cktor a blown No 15 7 5A tuse and blown charging sys tem light bulb ll the fuse and bulb are OK eptir tho open in lhe WHT BLUor BLK YEL wire Doesthecharging system lightcomeon Ch rging System Light Check cont d Starttheengine Pertormthe Ahernator Regulstol Test s prge 23 101 Doesthecharging system light go off VoltagoC...

Page 1160: ...system light go offi Repairthe shon to ground in tho WHT BLUwiro t Checkfor an opon in lhe L cir cuit 1 Turnthe ignitionswitchOFF 2 Disconnect the 4P connector fromthealternator 3 Groundthe No 3 terminalof the4P 3Plconnector 4 Turnthe ignitionswitchON ll ALTERNATOB irPCONNECTOR ALTERNATOR 3P CONNECTOR Canadal 1 1 2 3 l l iin vr rr Wire sideof temalet rminals Canada L IWHT BLUI L IWHT BLU Wire side...

Page 1161: ...In th wllr IALTClln 1 turn the headlightand igni tion switchOFF 2 Disconnect th6 A 32P con noctorfrom the ECM 3 Ch6ckfor continuity b6tw6en tho ECM connoctor A 32P t rminal No 19and alternator 4Pconnoctortorminal No 2 Rrp h op n In th wh brlw n th rltarn oi nd ECM Ch ct for rhort in th wire ALTC lin l 1 Turn the headlightand igni tion switchOFF 2 Disconn ct the A 32P con n6ctorfrom tho ECM 3 Check...

Page 1162: ... a r tt h e e n g i n e H o l dt h e engineat 3 000rpm with no load until the radiatortan comeson thonletit idle 3 Raisethe enginesp edto 2 000rpm and hold it there lsthevoltage over15 1 V Altsrnator RogulatorTest z 1 Release the accelerator pedal andlettheengineidle 2 Makesureall accessories are turnod off Turn the selector switchto position2 charging 3 Remove theinductive pick up andzerothe amme...

Page 1163: ...rise quickly when the ahernatoris ful fieldcd Do not llow th6 voltag to xc6ed18V it may damagetho ol6drical system NOTE Attacha probeto the VAT 40full field test lead and insertthe probe into the lull field accessholeat the backof the alternator Switchthe field selectorto the A Ground position momentarily andcheck theamperage reading REGULATOB Locatedinside FULLFIELO ACCESS HOLE ENDCOVEB ENDCOVER ...

Page 1164: ...heWHTwirefromthe B terminal Loosenthe adjustingnut then removethe mount Ingnut MOUNTING BOLT MOUNTING NUT 44 N m 4 5kgf m 33lbt ftl 5 Remove thealternator beltfromthealternator pulley 6 Remove the lowermountingbolt thenlilt the alter narorupwaro 3 7 Remove theloweranduppermountingbracketbolts and the mountingbrackets BRACKET BOLTS il4 N m 4 5kgl m 33 lbt ft 8 Remove the adiusting nut anduppermount...

Page 1165: ... and 22 mm wrenches lf necessary use an impactwrench DENSO PULLEY LOCKNUT 1 11N ft 11 3kgf m 82 lbt ft FRONTBEARING STATOR DRIVE END HOUSING OENSO Test page23 1 10 MITSUBISHII Test page23 112 PULLEY CAUTION Do not get grease or oil on the slip rings BRUSHHOLDER INSULATOR offi ENDCOVER k o BRACKET 23 108 L_ ROTOR PULLEY 10 mm 8OX WRENCH BEARING ...

Page 1166: ...eenthe B andP terminals andbetweenthe E ground and Pterminals of eachdiodepair Alldiodes shouldhave continuityin only one direction lf any of the eightdiodesfails replacethe recti ier assembly iDiodesare not available separately 2 Alternator BrushInspection l Removethe end cover then take out the brush holderby removingits two screws Measurethe lengthof the brusheswith a vernier caliper Altelnator...

Page 1167: ...itybetweenthe slip ringsand the rotor or rotor shaft lf the rotorfailseithercontinuitycheck replace the alternator Stator Test 1 Checkthat thereis continuitybetweeneachpairot leads Checkthatthereis no continuitybetweeneachlead andthe coilcore lf the coillails eithercontinuitycheck replacethe alternator 2 3 2 3 23 110 cotl coRE b ...

Page 1168: ... pryingthem a part Becarefulnot to dam agethestatorwith thetip of the screwdriver Separatethe rear housingand drive end withthestatoranached to the rearhousinq nousrng 2 Heatthe rearbearingseatwith a 1 000 W hairdrier for aboutfive minutes 120 140 F 50 60 C HAINDRIER NEARAEARING SEAT STATOR cont d FEARHOUSING DRIVE END HOUSIT G DRIVE END HOUSING REARHOUSING 23 111 t ...

Page 1169: ...ghto ensurea good connectionso the heatwill not damage the diodes Useonly a rgsincoretype solderor solderjoints will cor ode Rectifier Test NOTE Thediodesaredesigned to allowcurrentto pass in one directionwhile blockingit in the oppositedirec tion Sincethe alternatorrectifieris made up of nine diodes eachdiodemust betestedfor continuityin both directionswith an ohmmeterthat has diode checkino capa...

Page 1170: ...arelessthanthe service limit replace them 23 113 J lF MITSUBISHI 1 Checktheresistance between thesliprings Thereshouldbe 1 8 3 0ohms lf resistance meetsthespecification go to step2 lf resistance does not meetthe specification replacethe alternator SLIPRII GS Checkthat there is no continuitybetweenthe slip ringsandthe rotoror rotorshaft lf the rotorfailseithercontinuitycheck replace the alternator ...

Page 1171: ...REARBEARING 1 Pushthe brushesin then inserta pin or drill bit about1 8mm diameter toholdthemthere ARUSHES Heatthe rear bearingseat in the rear housingas describedon page 23 12 After heating continue immediately with assembling beforethe rearbear ingseatcoolscompletely Putthe rearhousing stator assembly and drive end housing rotorassemblytogether tighten the four through boltsandpulloutthepin THROU...

Page 1172: ...tionof the belt NOTE lI necessary adjustthe P Spumpbelt see section 17 and A C compressor belt seesection 2 2 1 BeltTensionGaugeMethod Following the gaugemanulacturer s instructions attach the belt tension gauge to the belt and measurethe tension Tension 340 490 N 35 50 kgf 77 11O lbf NOTE On a brand new belt onethat hasbeenrun f o r l e s st h a n f i v e m i n u t e s t e n s i o ns h o u l db e...

Page 1173: ...orthe A C system seesection22 UNDER HOOD FUSE RELAY BOX CONDENSER FANRELAY Test page23 69 RADIATORFAN RELAY Test page23 69 FAN MOTOR Test page23 119 TORFANMOTOR Test page23 119 l t t t t t t t l c Ll L t t lf l l f1 a l f r a r I i I r r l la t fr a t L I r t 1 l l tr z N L ...

Page 1174: ...uitDiagram WithoutA Cl UNOEF OASH FUSE NELAY BOX ffi I YELf rl t BTK EL l RAOIATOR FAN S YITCH foN above 199 F 93 C J BLIVREO BLK I G201 G401 IGNITION SWITCH N0 41 lmAl No 42 104 RADIATOR FAN RELAY 23 117 l ...

Page 1175: ...anControls IGNTION SWITCH BAI WHT ELK WHTT rcotr UNDER DASH I FUSE 8ELAY 8ox I l I BL rYEL t rYEL l BLUiYEL I I I h Ith T o o o 8LU RED A CSYSTEM l u UNDER HOOD FUSEi NELAY BOX No41 100A No42 40A 23 114 ...

Page 1176: ...edairfrom the coolingsystemafterinstalling the radiator fan switch seesection10 1 Remove the radiator fan switchfrom the thermostat housing 2 Suspendthe radiatorfan switch in a containerol coolanlasshown Heatthecoolantandcheckengine coolanttempera ture with a thermometer Checkthe continuitybetweentheA andBterminals accordingto the table 23 119 TermInal Operatlon Tcmoerature O N 1 9 6 2 0 3 F 9 1 9...

Page 1177: ...rLocationIndex page23 121 TerminalLocationIndex page23 121 EulbLocation pag623 122 Disassembly page23 127 Removal paqe23 126 FUELGAUGESENDING UNIT Test page23 132 Replacement page23 132 PARKING BRAKE SWNCH Test page23 135 ARAKEFLUIDLEVELSWITCH Test page23 135 ENGINE OILPRESSURE SWITCH Test p6ge23 130 ENGINE COOLANT TEMPERATUFE IECTIGAUGE SENOING UNIT Test page23 134 23 120 ...

Page 1178: ...YSTEM S epage23 140 c1 cl0 I Jilliltl ates page23 131 t Test page23 132 a1 u u 7 n u w oe r 7 t tt 1 r I l I z a y l t tr 9 I I l 11 I t Jl r to ei I rl F e l rle ENGINE COOLANT TEMPERATURE Gauge T st page23 134 Sending UnitTest page23 134 IECTI GAUGE A1 A5 D 1 D 1 3 ililtl illl SPEEOOMETER lndicates 60 mph at 1025 rpm or 60 km h at 637 rpm of the vehiclespeedsensor VSS coNNECTOR A C557 coNNECTOR ...

Page 1179: ... 1 4WI HATCH OPEN INDICATOR LIGHT 1 4 W Harchback TRUNK OPEN INDICATOR LIcHT 1 4 W Sedan OntheABS SRS printedcircuitboard LEFTTURNSIGNALINDICATOR LIGHT 1 4 WI CHARGING SYSTEMLIGHT 1 4 WI A T GEARPOSITION INDICATOR LIGHT 1 t2 W x 7 HIGHBEAMINDICATOR LIGHTI1 4 A LOW ENGINE OIL PRESSURE INDICATOR LIGHT 1 4 W MALFUNCTION INDICATOR LAMP MtLl 1 4Wl LIGHTS 13 4 W x 3 REMINDER LIGHTI1 4 WI cRursELTGHT 1 4...

Page 1180: ...o unrno I To pase 2312s BtU No rs 10A FUSE V I GAUGE ASSEMBLY YEUBLU t J 1l il I I SPEED I I SENSoBIVSS t MAINTENANCE REMINDER UNIT TCM ECM CRUISE CONTROT UNlT f7 I oRN BLKMHT I G501 I YEUGRN YE l n t l P ffirxl l o u RED BLU J CRUISE CONTROL UNIT BLK I G 1 0 l 23 123 UNDEFHOOD FUSE RELAY BOX ...

Page 1181: ...O I coNrRor uNrT T l ffi l lI ni lI i il i i t i i l i I L__ i L _ i Hatchback Sedan 012 GRNORN v ECM l o u BLK G20l G401 RIGNT TURN SIGNAL INDICATOR L GHT 1 4w TAILGATE OPEN INDICATOR LIGHT 1 4 9 RED BLU GBN RED ABS CoN FOL U lT I NTEGFATED I INTEGBATED v v roL I or frro ts Fo j BED BLU GRN RED GHNi RED r r l A A A Yu Y r Y l3 i 13ffi3 ll l i Iib T I T _ GXXX G3O1 23 124 ...

Page 1182: ...123 UNIT V V I I t l t l WHT GFN BLU REO lon WHT IU I I I ALTERNATOR lo PNK J HAZARO WARNING swtTcH MENTENANCE REMINDER LIGHT 0 4v i lo PNK I I I J MAINTENANCE REMINDER UNIT 011 YEUREO I T P BLK I G201 G401 LOW ENGINE OIL PFESSURE INDICATOR LIGHT 0 4w 23 125 J ...

Page 1183: ...l carefully withoutdamaging the clips 23 126 3 5 Tiltthe steering wheeldown with thetilt adjustment lever Removethe threemountingscrews and spreada protectivecloth on the steeringcolumn PROTECTIVE CLOTH Prythe gaugeassembly out anddisconnect allcon nectorsfrom it 6 GAUGEASSEMBLY Take out the gauge assembly as shown GAUGEASSEMBLY ...

Page 1184: ...W x 3 t ENGINE COOLANT TEMPERATURE IECTI GAUGEUNIT Test page23 134 TACHOMETEF UNIT Specification page23 121 SRSPRINTED CIRCUITBOARD d dP METER HOUSTNG FUELGUAGEUNIT Test page23 131 r ror 6rH SPEEDO ODO TRIP METERUNTT SPEEDOMETER Specification page23 121 Troubleshooting Page23_128 ODOMETER Troubleshooting page23 128 TRIPMETER Troubleshooting Page23 128 TACHOMETER MOUNTING SCREW x 3 PRINTED CIRCUIT ...

Page 1185: ...01 To3t thc BLK YELwiro 1 Conn6ctth WHTtest harness clip to the positiveprob of a voltmeter andconnect theRED t stharness clipto the nogative probe 2 TurntheignitionswitchON lll R p lr op n Intho BLK YEL wire brtw n th VSSandth under dr h tu r l y box Tort th BLU WHTwiro Connectthe GRN test harness clip to the positiveprob ot a voltmeter and connectthe RED test harnessclip to the nggatjve probe Ro...

Page 1186: ...d Doesvoltagepulsefrom0 to approx 5V or more SpocdomatcrTe3t 1 Disconnoct the 16Pconngctor B from the gaugeassem 2 Touch8 probeto the ORN wire and connectit to body groundthrougha voltmetor 3 Slowly rotate one wheel with theotherwheelblocked Repairopen in the ORNand BLU WHT wire botw en tho VSS nd the soa do mster Doesthe meterindicate puls ing voltage WHTTEST CLIP TESTHABNESS OTLAJ PT3O2OA FEDTES...

Page 1187: ...etromthe engineoilpres sureswlrcn ENGINE OIL PBESSURE SWITCH Checkfor continuitybetweenthe positiveterminal andtheengine ground withtheignition switchOFF a lf there is continuity go to step 3 a lf there is no continuity replacethe switch Checklor continuity again thistimewith theengine running a lf there is continuity go to step 4 a lf there is no continuity the switch is OK Makesureengineoil leve...

Page 1188: ... a lI the voltageis not as specified checkfor an open in the YEL WHT BLU WHT or BLK WHTwire poorground G501 G502 3PCONNECTOR View from wire side 6 Turnthe ignitionswitchOFF Attacha jumperwire between the BLKMHT and YEL WHTterminals then turn the ignitionswitch ON 1 Checkthat the pointerof thefuelgaugestarlsmov ing toward the F mark CAUTION Turnthe ignitionswitchOFFbeforethe pointerreaches F on the...

Page 1189: ...thefuelgaugesendingunit 4 Removethe fuel gaugesendingunit o 23 132 FloatPosition E 1 t 2 F Resistance Ol 1 0 5 11 0 2 5 5 3 9 5 2 5 5 lreasurethe resistance betweenthe A andBtermi nalsat E empty l 2 halffull andF full bymov ing the tloat 6 Checkthe changein resistance by movingthe float uo anddown 1 lf unable to obtaintheabovereadings or if resistance doesnotchange replace thefuelgaugesending unit...

Page 1190: ...onnector from the fuel gaugesendingunit Connect the A BLV WHT terminalto the C BLU WHT terminalwith a jumperwire lf the Iightcomeson the problemiseitherthe sendingunit or its ground lf the light doesnot come on the problemis anopeninthe BLU WHT wireto thegaugeas sembly no power to the gauge or a blown bulb a lf the light comeson add approx 4 1 1 U S Gal O 9lmp Gal of fuel thelightshould go off wit...

Page 1191: ...ure to do so may damagethe gauge a lf the pointerof the gaugedoesnot move at all checklor an openin the YELor YEL GRN wire lf the wires are OK replacethe ECTgauge a lf the ECTgaugeworks test the ECTsending unrt ECTSendingUnit Test Disconnect the YEL GRN wire from the ECTsend ingunit With the enginecold usean ohmmeterto measure resistance betweenthe positive terminal andthe en gine ground Checkthe ...

Page 1192: ...age23 164 Terminal l rr ril lt POSITIVE BODY UP o o DOWN il r 1 T T L J BrakeFluidLevelSwitch Test Removethe reservoir cap Checkthat the float movesup and down freely if it does not replacethe reservoircap assembly Checkfor continuitybetweenthe terminalsin each lloat positionaccordingto the table POStnVE TERMINAL RESERVOIR CAP DOWNPOSITION 4l NEGATIVE TERMINAL MAGNET POSITTVE TERMINAL raoo Switch ...

Page 1193: ... Assembly page23 120 VEHICLE SPEED SENSOR IVSS Onth6transmission housing Test page23 128 129 Replacement page23 130 MAIMTENANCE REMINDER UNIT Behindth dashboardlowercover InputT6st page23 139 Maintenance Reminder System ComponentLocationIndex t 23 136 I ...

Page 1194: ... until rhe car reaches 12 O7O 160 km 7 500 t 100 miles Beyondthe 12 o1O 160 km 7 5OOt IOOmile interval the light will continueto glow after the bulbcheckuntil you turn the ignitionswitch otf or resetthe unit To resetthe unit the car must be parkedand the ignitionswitch must be ON ll Pressthe resetbuttonon the unit for morethan three seconds and the reminderlight will go off NOTE Turnthe ignitionsw...

Page 1195: ...MaintenanceReminderSystem CircuitDiagram UNOER HOOO FUSEIRELAY BOX N0 41 lmA No42 40A MAINTENANCE REMINDER UNIT 8LK c201 G401 23 138 ...

Page 1196: ...lesult is not obtained ORN I BLK Underall conditions Checkfor continuityto ground Thereshouldbe continuity Poorground G201 G4011 An open in the wire 2 WHT BLU Underallconditions Checkfor voltageto ground Thereshouldbe batteryvoltage BlownNo 47 7 5A fusein the under hood fuse relaybox An openin thewire 3 YEL lgnitionO N flr Checklor voltageto ground Thereshouldbe batteryvoltage BlownNo 25 7 5A fuse...

Page 1197: ...Index GAUGEASSEMALY Removal page23 126 Disassembly page23 127 BulbLocations page23 122 INTERLOCK SYSTEM Description page23 147 A T GEARPOS TION INDICATOR InputTest page23 142 A T GEARPOSTTION SWITCH Test page23 144 R6olacement section14 S 23 140 ...

Page 1198: ...gauqe assembly D4 TRANSMISSION CONTROL MODULE rrcM f7 I I GRN BLK c6 c7 c 8 l c 9 NTERLOCK CONTROL UNIT f7 I GRNMHT BLK TRANSMISSION CONTROL MODULE TICM GRN CRN BLU LTGRNMHT GRN YEL Nol9 104 FUSE f7 I RED BLK A TGEAR POSITION SWTCH R E D I I I Y DASH LIGHTS BFIGHTNESS CONTROLLER BLK oro G40l G20l G401 A TGEAHPOSITION NDICATOR DIMMING C RCUIT A TGEAR POS TION CONSOLE LIGHT 1 4w t 2 23 141 ...

Page 1199: ...inalsto be sure theyareall makinggoodcontact a lI theterminals arebent looseor corroded repair them as necessary and recheckthe system a lI theterminals lookOK makethefollowing inputtests at the connector l anytestindicates a problem findandcorrectthe cause then recheckthe system lf all the inputtests proveOK the gaugeassem bly must be faulty replaceit CONNECTOR B 23 142 ...

Page 1200: ...lon full bright Checkfor voltagebetween RED BLK and REDterminalsl Thereshouldbe batteryvoltage Faultydash lightsbrightness control system An open in the wire 1 GRN WHT Shiflleverin position NOTE Don tpushthe brakepedal Check or continuityto ground There should be continuity NOTE There should be no continuity in any other position FaultyA T gearpositionswitch Poorground G201 G401 An openin the wire...

Page 1201: ...ee play adjustthe installing positionof the switch as described on the next page terminal sroe A T Geal PositionSwitch lwithout cluise control Back uD Noutral Light Switch PositionSwitch A T G arPositionSwitch lwith cluise controll Back up Neutlal Light Switch PositionSwitch Terminal P m _ B F G N iT L c D J K tr o o a o o E o o E o o N o _o o tr o o o o E o _o o o rermrnal t t _ B E F G N M L c D...

Page 1202: ...he l4P connector clampthe harness and installtheconsole 5 A T GearPositionSwitch A T GearPositionSwitch Adjustment 1 Shitt to the position and loosenthe nuts 2 Slidethe switch in the directionof position lwithin2 0 mm O 079 in lsothatthereiscontinuity betweenthe A and L terminals in the rangeoI free play oI the shift lever 3 Recheckfor continuitybetweeneach of the ter manals NOTE a ll adjustmentis...

Page 1203: ...E a The shift levercannotbe shiftedwhen the brakepedaland the accelerator are depressed at the sametime a Incaseof systemmalfunction the shiftlevercanbereleased by pushinga keyintothe release slotnearthe shiftlever SRScomponents arelocatedin thisarea Reviewthe SRScomponentlocations precautions andprocedures in the SRS section 23 beloreperformingrepairsor service KEYINTERLOCK SOLENOID and KEYINTERL...

Page 1204: ...ly lockedin parking pinswitchis ON a solenoid is activated makingit impossible to removethe ignitionkey from the ignitionswitch To be ableto removethe key the shift levermust be in E and must be securelylockedin this position parkingpin switch must be turnedoft by the lock pin The shift lever is in any othel position than El and the psrking pin switch is ON CYLINDER The shitt lever is in l and the...

Page 1205: ...le cRNA VHT I andcRNMHT arenotthesame WHT BLK WHI cnrruvgr BRAKE LIGNTS CSUISE CONTROLUNIT ABS COIITROL UNIT ECM INTEBLOCK CONTROL UNIT A IGEAR POStTION INOICATOR v t UNDER HOOO FUSEi RELAY BOX N0 41 100A N0 42 404 YEUBLU cnrivrr WHT BLU KEY INTERLOCK swtTcH THBOTTLE PosrT 0N TP SENSOR f7 I RED BLK Cjl inposiron E t 23 14A ...

Page 1206: ...ule TCM FaultyECM Faultybrakeswitch Faultythrottleposition TP sensor An open in the wire lgnitionswitch ON ll Brakepedaland accelerator pushedat the same me Checkfor voltageto ground Thereshouldbe lessthan batteryvoltage t GRN WHT Shift leverin position E Checktor continuityto ground Thereshouldbe continuity FaultyA T gear positionswitch Poorground G20 1 G401 An openin the wire 3 YEL BLK lgnitions...

Page 1207: ...replacethe steering lockassembly keyinterlock solenoid is not avail ableseparately _____ ___ ___l Position J 7 lqnition s wirch ACC Keyplshedin G o Keyreleased o o 15 20ohms l ParkingPin Switch Test 1 2 Replacement 3 Removethe lront console seesection20 Oisconnect the parkingpin switch3P connector from the mainwire harness CheckIor continuitybetweenthe terminalsin each switch positionaccordingto t...

Page 1208: ...instep5 3 Removethe shift lock collarand the solenoidpin 4 Remove theselfiockingnutsandshiftlocksolenoid theninstallthenew solenoid in the reverse orderof removal SHIFTLOCK SOLENOID SHIFTLOCKCOLLAR SELF L NUTS Replace 9 8N m 1 0kgf m 7 2 lbI Ir 5 Checkand if necessary adiustthe solenoid spo sition a Whenthe shiftlocksolenoid is ON checkthat thereis a clearance of 2 5 O 5mm 0 098 t O 020in betweent...

Page 1209: ...tthesame REAR WINDOW DEFOGGER RELAY REAFWINDOW DEFOGGEN INDCATOR LGHT f 7 I I BLU YEL WHT BLK WHT REO WHT WNDSHIELDWIPERi WASHER SWITCH INT OFF INT f7 f7 t l t l YEUBLU 8LU GRN BLUMHT J wtN0sHr 10 WIPER MOTOR UNDER DASH FUSARETAY BOX F rmecnlleo counoL ultr YEUBLU r YEUBLU YEUREO YEUREO t l I YEURED LOW ENGINEOII PRESSURE INOICATOB LIGHT WINDSHIELD WIPERMASHER I swlTcH t f 7 I V t l YEL J FEAR wtN...

Page 1210: ...CUT RELAY BruiBLK i rrrl r SEATBELT REM NDEB LIGHT 1 4w INTEGRATEO CONTROL UNIT FRONT PASSENGER S DOOR SWITCH 23 153 ...

Page 1211: ... as necessary and recheckthe system a lf theterminals lookOK makethelollowinginputtests at the connectorand under dash luse relaybox ll anytestindicates a problem findandcorrectthe cause then recheckthe system lf allthe inputtestsproveOK thecontrolunitmust be faulty replaceit 15P CONNECTOR NOTE a Ditferentwireswith the samecolorhavebeengiven a numbersuffix to distinguishthem lor example GRN BLU1 a...

Page 1212: ...shed Faultydefoggerswitch Poorground G201 G401 An openin the wire 2 BLU YEL lgnitionswitch ON ll Connectto groundrThe rear window defoggershouldwork and the defoggerswitch indica tor lightshouldcomeon BlownNo 16 7 5A fusein the under dash fuse relay box Faultydeloggerrelay Blownbulb An open in the wire YEL BLU lgnitionswitch ON ll and windshield wiper switch INT Checklor voltageto ground Thereshou...

Page 1213: ...ionswitch is turnedON Blown bulb An openin the wire Start the engine Checktor voltageto ground Thereshouldbe batteryvoltage lnsufticientoil lmproperlubrication Faultyengineoil pressure switch 1 GRN BLU Driver sdoor open Checkfor continuityto ground Thereshouldbe continuity Faultydriver sdoor switch An openin the wire 2 LT GRN RED Frontpassenger s door swrlcn open NOTE Before testing removeNo 43 7 ...

Page 1214: ...tartercut relay M T Faultyneutralpositionswitch A T An open in the wire 2 D lgnitionswitch ON ll brakefluid reservoir full and parkingbrake teveroown Connectto ground Brake systemlight shouldcome on Blown brakesystem light An open in the wire Bulb Check System brakesystem light No Terminal Test condition Tost Desiled result Possiblocause if lesult is not obtained 23 157 ...

Page 1215: ...f the key in remindercircuit andto page23 148 for the inputtest of the beepercircuit Whentheignition keyis notremoved thekey inreminder inthe integrated controlunitsenses groundthroughthe closedignitionkey switch Whenyou openthe driver s door the beeper circuitsenses groundthroughtheclosed doorswitch With groundat the LT BLU and GRN BLU terminals the beepersounds 1 Remove thed shboardlowercoverand...

Page 1216: ... the enginerunning voltageis applied to the Ilash er circuitof the integrated controlunit With normaloil pressure the oilpressure switchisopenandthe low en gineoil pressure indicatorlightdoesnot operate lf the oil pressure switch closesmomentarily morethan O 5 seconds butthenopensagain terminal YEL RED will sensegroundthroughthe switch The integrated con trol unitwillthenprovideandremovegroundtor ...

Page 1217: ...HEADLIGHTS ComponentLocationsIndex HIGHBEAMINDICATOR LIGHT lnthegalge assembly BulbLocations page23 122 COMAINATION LIGHTSwlTCH Replscement page23 168 Test page23 162 Adjustment page23 170 Replacement page23 170 CONTBOL UNIT Can d Input Testpage23 164 23 160 ...

Page 1218: ...cement page23 177 TAILLIGHT Replacement page23 174 Bulbr placement page23 174 LICENSE PALTELIGHTS Replacement page23 177 INNERTAILI IGHT Replacement page23 175 Bulbreplacement page23 176 Replacement page23 175 8ulb replacement page23 176 23 161 ...

Page 1219: ... LIGHTS BFIGI ITNESS CONTROLLER DASH TIGHTS RED CRN I Ailsurax Yller l I BL I I I l G201 G401 PANK NGLGNTS TALLGHTS LICENSE PLATE LIGHTS UNDER HOOD FUSE RELAY BOX RED BtU N0 21 104 No 5 10A I I I No22 I No4 lroA 1oA I T I No30 7 5A I N0 32 00A 8LK I G20l G40l 23 162 ...

Page 1220: ...L l t Yro IiivP I swrrcH BLK I I l G301 RED GFN t GRN RED A Y r ro I 3Ai 5 I I I DAYTIME BUNNING L GHIS RESISTOR UNDER DASH FUSE FELAY BOX No 21 i uoo N0 20 JOA N0 18 7 5A I I lrrt llrffi ltlrr I No 3o Q 7 sA I N0 32 104 RED GqN RED YE RED BL RED TVHT FED BLK REO 8LK WHT YEL YEUBLK l l I i n i i ffi liilTl I I ri J i F BEDE U 1 4 l l oo qff 0 36 45 1 il 23 163 ...

Page 1221: ...good contact a lf the terminals arebent looseor corroded repair them as necessary and recheckthe system a ll the terminalslook OK makethe lollowingin put tests at the connector lf any test indicatesa problem find and cor rect the cause then recheckthe system lf allthe inputtestsproveOK the controlunit must be faulty replaceit 4PCONNECTOR 8PCONNECTOR GNN RED WHTiRED WHT YEL REO WHT RED GRN YEL BLK ...

Page 1222: ...e batteryvoltage BlownNo 48 40A fusein the he under hood fuse relay box Faultycombinationlight switch An open in the wire WHT RED Combination light switch is OFF connect a jumperwire between the YEL BLK and WHT RED terminals then turn the ignition switchON ll Left and right headlight high beamlshouldbe on but dim and high beamindicatorlight should comeon Poorground G20 1 G4O1 G301 Blown bulbs Faul...

Page 1223: ...nnect the 4P and 7P connectorsfrom the switch Checktheconnector andsocketterminals to besure theyareallmakinggoodcontact lf theterminals are bent loose or corroded repairthemas necessary and recheckthe system Checklor continuitybetweenthe termanals in each switch positionaccordingto the table B D E H 4PCONNECTOR 7PCONNECTOR 23 166 ...

Page 1224: ...t Switch OFF d I Lr G Not us d Tuln SignalSwitch Terminal Position F J Headlight switch OFF m o o D LOW o o o o HIGH o o o o Passing switch OFF ON o o LEFT RIGHT I Position Terminal B RIGHT o o NEUTRAL LEFT o o 23 167 ...

Page 1225: ...runninglightsresistorbecomes vely hot when the daytimerunninglights arc on do not touch it or the attachinghardwareimmediatelyaltel the lights have been tulned otf 1 Disconnect the 3Pconnector from the resistor DAYTIMERUNNING LIGHTSRESISTOR 2 Measure the resistance betweenthe resistor termi nals A and B and the power terminalC Resistance 1 4 O 1 O O7o Replace the resistorwith a new one il any of t...

Page 1226: ...tandyieldsa spotlight effect whichimproves visibility duringnightor foulweatherdriving For easieraiming the headlights are equippedwith verticaland horizontal gauges NOTE As the outer lensesare madeof a resinmaterial don t coverthe headlights when they a e turnedon OUTERLENS CONVEXLENS SU8 REFLECTOR SECONDFOCUS INTERRUPTER PLATE REFLECTOR FIRSTFOCUS BULB 23 169 ...

Page 1227: ...ckthat both the horizontal and verticalgauge rcad O a lf the gaugestead O checkheadlightaiming with the aimingchartson page23 171 lf aiming isn t correct refer to the frame repairchart in section 20 a lf oneor bothgaugesdon t read O go to step 23 170 3 Turnthe low beamson lf necessary alignthe verti cal indicator with its O markby turningthe verti cal adjusterwith a Phillipsscrewdriver and check a...

Page 1228: ...n 3000 mm B 23 in 585 mml C 46 1 in 1170 mm D 33 5 in 85Omm E 1 2 in 31 mml HeadlightAiming Low beam Highbeam HEADLIGHT LOW BEAM CENTER FLOOR FLOOR CAUTION The outer lensesget very hot when the hoadlightsar6 on do not cover th m 23 171 ...

Page 1229: ...ngconventional methods Usethe aimingchartson page23 171 BulbReplacement CAUTION a Halogenheadlightscan becomo very hot in use do not touch them or the attachinghaldwareimm6diately after they have been tuh6d ott a Do not try to replaceor cl6anthe headlightswith tho lightson 1 Disconnect the 2Pconnector s from the headlight Turnthe bulb s counterclockwise and removethe bulb s 2PCONNECTORS HEADLIGHT ...

Page 1230: ...the 3P and 2P connectorstrom the lights Turnthe bulb socket45o counterclockwise to re move it from the housing e Ar fl FrontSideMarker Lights 1 Removethe screw and pullthe tront sidemarker light assemblyout of the tront bumper Disconnect the 3P and 2P connectorsfrom the lights Turn the bulb socket45o countefclockwise to re move it from the housing FRONTSIDEMARKERLIGHT Replacement 23 173 ...

Page 1231: ...tedor stayscompressed a After installation run water over the lights to makesurethey don t leak 6PCONNECTOR Replacement Rearturn signal Rear parkinglighis 1 Openthe rearhatch thenremovetheaccesspanel 2 Removethe bulbfrom the bulb socket O REAR TURNSIGNAL LIGHTBULB 32 CP REARPARKING LIGHTBULB 3 CP Brake Taillighr Back up lights 1 Openthe rearhatch 2 Removethe rearpanellining seesection20 i BACK UP ...

Page 1232: ...Removethe four mountingnuts then pull out the taillight Inner Taillight 1 Open the trunk lid 2 3 Disconnectthe 4P connector from the taillight Remove the lour mounting nuts then pull out the innertaillight NOTE a lnspectthe gasket Replace it if it isdistortedor stays compresseo a Alter installation run water overthe lightsto make surethey don t leak INNERTAILLIGHT 4PCONNECTOR TAILLIGHT ...

Page 1233: ...eesection20 2 Removethe bulb from the bulb socket O BRAKE TAILLIGHT BULB132 3 CPI TURN SIGNAL LIGHT BULB 32CP REAR PARKING LIGHT EULB 3 CP 23 176 Inn r Taillight 1 Openthe trunk lid then removethe bulb housing 2 Removethe bulbfrom the bulb housing BACK UP LIGHT BULB 32CP BRAKE TAILLIGHT BULB 32l3CP O n EULBHOUSING ...

Page 1234: ...hts Turnthe bulb socket45o counterclockwise to re move it trom the housing l 2 Removethe glove box and disconnect the 2P con nector Checktor continuitybetweenthe A andBterminals in eachconditionaccordingto the table BULB 3 4Wl Terminal c il l B PUSHED lidclosed RELEASED lidopen o a o v ciot G401 t 23 177 ...

Page 1235: ...EOX t X f i l L r c r T s w r c ffiwHT lf FEDGaN TGEANPOSITION INOICATOR OIMMING CIFCUIT ATTGEAB POSITION CONSOLE LIGHT CRUISE COI TROL DIMMING CIRCUIT CRUISE CONTHOT MAIN SWITCH LIGHT GAUGE LIGHTS HAZAFDWABN NGSWITCH LIGHT HEATER CONTROL PANEL LIGHTS REAR WINDOW DEFOGGER SWITCH LIGHT 23 178 ...

Page 1236: ...lem find and cor rect the cause then recheckthe system It allthe inputtestsproveOK the dashlights brightness controller mustbefaulty replace it 3PCONNECTOR View lrom wire side Possiblecause if result is not obtained No Wire Test condition CONTROLLEB Test Desired resull BLK REO BLK Underall conditions Checkfor continuityto ground Thereshouldbe continuity Poorground G201 G4O1l An openin the wire 2 R...

Page 1237: ...ck CEILING LIGHT Test R6placem6nt page23 183 SPOTLIGHTS TesVReplac ment page23 182 FRONT PASSENGER S DOOR swlTcH Test page23 158 2 HATCHLATCH SwlTCH TesVReplacement page23 186 DOORSWTTCH Test page23 158 1 TRUNKLATCH swrTcH TesVReplacement TesVReplacement page23 186 page23 185 23 180 l ...

Page 1238: ...GircuitDiagram UNDEF HOOD FUS gRELAYBOX Wilh moonrool l Er WHT FED LT NTEGRATED T CoNTROL I UNIT I lSedan l TRUNK L GHT sw I lff lh i T Lir lb F 23 141 ...

Page 1239: ...ens Remove the two screws thenpullout the housing Hatchback 1 2 3 CONNECTOR BULB 5 Disconnect the connectorfrom the housing Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table Terminal ttr l B o r B C o r C LEFT ON o o OFF RIGHT ON o o OFF l p l l LEFIII RIGH II l b l l 8 O B ...

Page 1240: ... out the housing 5 Checkfor continuitybetweenthe terminals in each switch positionaccordingto the table FromNo 43l 5A FUSE lnthe undeFhood fuserelaybox 4 Disconnect the 3Pconnector from the housing Teminal t t l B o r B c D OFF o o DOOR o o ON o o 3PCONNECTOR LENS CeilingLightTest Replacement 23 183 ...

Page 1241: ...vethe screw then pull out the housing HOUSING 4 Disconnect the3Pconnector from the housino CONNECTOR 23 1a4 5 Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table rermrnal Position B o r B c D OFF o 1 o DOOR o A o ON o a o J FromNo i 7 5A FUSE lntheunder hood fuse relay box A 0 N z D l l owt OFF f o B To DOOR I ...

Page 1242: ...ity between the A and B terminalwith the cargo arealightswitchON 2PCONNECTOR EULB 3 4W A l Trunk LightTest Replacement Sedan 1 Openthet unklightcover 2 Pryoutthe lightassembly 3 Disconnect the 2Pconnector from the housing 4 Makesurethatthe bulb is OK Checkfor continuity between the No 1and No 2 terminals 2PCONNECTOR ti t t r B t FromNo a3 7 5Al FUSE lnthe under hood fuse r laybox 23 185 t r T t l ...

Page 1243: ...onnect the lockrodfromthetrunklatchswitch Disconnect the trunk openercablefrom the truok latch switch O O TRUNKLATCHSWITCH 23 146 Hatchback 1 Open the hatch and disconnectthe 6P connector fromthe hatchlatchswitch 2 Thereshouldbecontinuitybetween theA andBter minals lf necessary removethe three mounting bolts to pull out the hatchopeneractuatorfrom the latch then disconnect the lock rod from the ha...

Page 1244: ...H UNOER HOOD FUSEi RELAY BOX EACK UP LIGHT swtTcH onlhe r I ransnBgon I GRN BLK I I J TRAILER L GHT NG CONNECTOR GRN BLK I zA arcx up I P LIGHTS f r zce 21 I BLK I I I G503 YEL I SnoriARr r r r i 3 f iil re V oNh posirion E l I GRN BLK 23 147 I ...

Page 1245: ...uity butthe back up lightsdo not go on checkfor Poorground G503 An openin the wire A 6 AutomaticT ansmission NOTE Checkthe No 19 7 5A fuse in the under dash fuse relay box beforetesting 2 1 Test the back uplight swirch by shiftingthe shift leverto and turningthe ignitionswitch ON ll lf the back uplightsdo not go on checkthe back up light bulbsin the taillightassembly lf the fuseand bulbsare OK dis...

Page 1246: ... BrakeLights CircuitDiagram UNDER HOOO FUSE RELAY BOX ry BRAKE SWITCH O lIpushed WHT GF I HONN INTEFLOCK LEFI BRAKE LIGHT 32CP il l i l_t INNEN TAIILIGHT WHTiGRN GRNA HT J GRNMHT 23 189 l I ...

Page 1247: ...ise control syst m Wilh cruise control sYstem Checkfor continuity betweenthe B andC terminals There should be continuitywith the brake pedal pusneo a lf thereisno continuity replace the switchor ad just pedalheight seesection 19 o It thereis continuity but the brakelightsdo not go on inspectfor Poorground G5O3 An openin the wire A B FS A l t L t l t Z C D B ran l l t l tLatl c LEDtypel 1 Remove th...

Page 1248: ... two nuts thenremovethe highmount brakelight from the rearshelt 2 3 2 2PCONNECTOR Turnthesocket45o counterclockwise to remove the bulb Installthe high mountbrakelightin the reverseor derof removal andcleanthe rearwindow glassbe tore installing CAUTION When installingthe high mount brake light makesurethe rubbersealfits againstthe reai window evenly 3 Installthe highmountbrakelightin the reverseor ...

Page 1249: ...FLIGHYS lnthegaugoassembly EulbLocations page23 122 COMBNANON LIGHT SWTTCH Replacement page23 168 Test page23 166 FUS RELAY BOX HAZARDWARNINGSWITCH Replacement pago23 195 Test pag 23 195 i l r 1uuij tjt ffi r _ n t l l r n L J J u UBNSIGNAL HAZARD RELAY InputTest page23 194 I 23 192 ...

Page 1250: ... RED GRN V rclrrtor swror WHT BLK WNT BLK YEL WHT GRN I GFNBLUGRIVBLU J J I V V GRNIELUTRATLER I L GHTING I CONNECTOR TRUNSIGNAL swrTcH F Not used GBN ORN G R N i o R N GRNALU GRN BLU RED t l t l r l I t OASH LIGHTS BFIGHTNESS CONTROLLEH f f r n RN YE t T BLK GRN YEL t t t o l I RE lo 8LK 8LK I G201 G401 GFN BLU 23 193 ...

Page 1251: ... Telminal Test condition Test Deairedresult Possiblecause it result is not obtained lgnitionswitch ON ll and turn signal switch in right or left connect the B terminal to the L rermtnat Checkfor continuityto ground Thereshouldbe continuity Poorground G201 G401 An open in the wire lgnitionswitch ON ll and hazard warning switch OFF Checkfor voltageto ground Thereshouldbe batteryvoltage BlownNo 20 10...

Page 1252: ...he centervent 2 Disconnect the 10Pconnector lrom the switch HazardWarning Switch Test 1 Removethe hazardwarningswitch 2 Checktor continuitybetweenthe terminals in each switch positionaccordingto the table HAZARD WARNING Position Terminal B c D F H OFF o o o e o ON o o o o o o P t O 1OP CONNECTOR A B C D I I o N t LEFI 0 r 23 195 ...

Page 1253: ... under hoodfuse relay box removingthe radio After service reconnectpower to the radioandturn it on Whenthe word CODE isdisplayed enterthe cus tomer s 5 digit code to restoreradiooperation STEREO RADIO CASSETTE PLAYER Removal page23 199 Terminals page23200 RIGHTTWEETER Replacement page23 200 BIGHT REAR SPEAKER Replacement page 23 201 LEFTREAR SPEAKER Replacement page23 201 POWER ANTENNAMOTOR Test p...

Page 1254: ...e23 200 FRONT PASSENGER S ooon SPEAKER Beplacement page23 200 RIGHT TWEEIER Replacement page23 200 POWER ANTENNAMOTOR Test page23 202 Replacement page23 203 USA LEFT SPEAKER Replacement page23 201 Hatchback S6dan ANTENNAMAST Replacement page23 203 Installation page23 204 ANTENNATUBE Replacement page23 205 23 197 ...

Page 1255: ...ED BLK UNDER DASH FUSE RELAY BOX FRONT PASSENGER S oooR SPEAKER ANTENNA MAST LEFT REAB SPEAKER RIGHT REAR SPEAKEB rn a l l t t l o 4 l l t l x ANTENNA LEAD BLU YEL GRY rrVHT REO YEL ERNMHT POWER ANTENNA MOTOR wilh lheantenna reraded lully BLK I G551 8LK I G503 No4l 100A No42 40A r c RED GRNV STEBEO RADIOi CASSETTE PLAYER 23 198 ...

Page 1256: ...erto theradioandturnit on When the word CODE is displayed enter the cus tomer s 5 digitcodeto restoreradiooperation 1 Removethe centerconsole seesection20 2 Remove the cigarette lighterassembly seepage 23 2131 FRONTCONSOLE Remove the fourmountingscrews thenremovethe front console Loosenthe two mountingscrews then disconnect the 16Pconnector and the antenna lead and Dull out the stereoradio cassett...

Page 1257: ...A 1 7 I SPEAKER COVER 2PCONNECTOR Terminals T rminal Wire Connectato FoTANTENNA LEAD oItt FRMINAL a9 A 16 A I RED GRN Frontpassenge s doorspeaker A2 BLU GRN Driver s doorspeaker O A3 RED BLK Lights on signal A4 WHT BtU Constant power Tuning memory A5 YEL RED ACC Mainstereopowersupply A6 YEL GRN Radio switched power1To antenna A7 BLU YEL Leftrearspeaker A8 RED YEL Right rearspeaker A9 BRNi BLK Fron...

Page 1258: ...eaker Sedan 1 Remove the threescrewstrom the trunkside then femovethe speakercover 2 Removethe four screws then disconnectthe 2P c o n n e c t o rf r o m t h e s p e a k e r a n d r e m o v et h e speaker LEFTREAR SPEAKER OUARTER I I z TRIMPANEL I EFTREAR SPEAKER 2PCONNECTOB 2PCONNECTOR SPEAKER COVER REARTRAY SPEAKER COVES I 23 201 ...

Page 1259: ...disconnectpower from the B terminal lf the motor lails to run or doesnot run smoothly replaceit WHT RED BLK Ttffili u YEL GRN ANTENNAMAST StickingAntenna The antennasticks in eitherthe up or down position Usingthe antenna wrench removethe antennanut spacer seepage23 203 Cleanthe antennamast housingthreads and rein stallthe spacer 2 1 PLASTICSLEEVE ANTENNA MAST Tighten the antenna nut with the ante...

Page 1260: ...Removethe motor and antenna as an assembly NOTE Tightenthe antennanut then tightenthe motor bracketnut AntennaMast Replacement Removal NOTE Theantenna mastalonecanbe replaced without havingto removethe power antennamotor 1 Removethe antennanut and spacer 2 Carefully withdrawthe antennamastwhileextend ing it by turningthe radioswitch ON ANTENNANUT SPACER ANTENNA MAST DRIVE CABLE ANTENNANUT WRENCH 0...

Page 1261: ...type andthosewithout an O ring oldtype whichrequire different space s To preventa leak makesurethat thereis no antenna collarsealinthe antenna col larwhenusinga nut with anO ring lf necessary removethe seal thereis anantenna collarsealinthe antenna col larwhen usinga nut withoutan O ring It neces sary installa seal the spacermatchesthe type of antennanut With an O ring ANTENNA NUT__ a 1 i lr O RIN...

Page 1262: ...h the screwthat is usedto clampthe tube to the motor Without an alignmont markr Insen onlv the tube and installthe tube motor assemblvin the car Adjust the tube so that the collar lits properly againstthe body andmarkthe tube andmotor Removethe tube motorassemblyagain Alignthe markon the tubewith the markon the motor and tightenthe clampingscrew With an alignmant m ALIGNMENT MARK CLAMPING SCREW Wi...

Page 1263: ...ckout from the dashboard then discon nectthe 4Pconnector 4PCONNECTOR CLOCK BATTERY UNDER HOOD FUSE RELAY BOX WI T BLK I A BAT I 1GN TION Y t No3o 7 sA v F nrrn l I WHT BLU l wHT 8LU al STEREO BADIOi CASSETTE PLAYEF BLK G201 G401 BLK Ground B YEL r G 1 pry Mainclock power sup c RED BLK Lights on signal D WHT BLU Constant power Timememory Terminals 23 206 ...

Page 1264: ...utions and procedures in the SRSsection 23 beforeperformingrepairs or ser vtce HORN Test page23 211 HORNSWITCHES Test page23 209 CABLEREEL Replacement page23322 UNDER DASH FUSE BELAY BOX s i i l rrj _LJLi lJJJ I r t t L I t HORNRELAY I Wirecolo6 WHT GRN WHT GRNI LBLU GRN andBLU REO I Test page23 70 23 207 ...

Page 1265: ...UNOEF HOOD FUSARELAY BOX CRUISE CONTROI SET RESUME SWTCH ih c uteconrol 23 208 ...

Page 1266: ...n discon nectthe positivecable and wait at leastthreemin uIes Disconnect eachairbagconnector Driver sSide a Removethe accesspanelfrom the steeringwheel then disconnectthe 2P connectorbetweenthe driver s airbagandcablereel FrontPassenger s Side Remove theglovebox a Disconnect the 2P connectorbetweenthe front passenger s airbagandSRSmainharness 1 Remove the dashboard lowercoverandkneebolster seepage...

Page 1267: ...10 9 10 1 1 12 lf all tests prove OK reinstallthe driver s airbag assembly re erto the SRSsub sectionin section23 Reconnect the driver sairbagconnectors and rein stallthe access panelon thesteering wheel Reconnect the front passenger s airbagconnector andreinstall theglovebox Connect the batterypositivecable thenconnect the negative cable Atterinstalling the airbagassembly confirmthat the SRSindic...

Page 1268: ...onnect the 1Pconnector from the horn lP CONNECTOR MOUNNNG BOLT IBODY GROUND Testthe horn by connectingbatterypowerto one terminaland groundingthe body ground The horn should sound lf the hornfailsto sound checktor taultyhornassembly faultymountingbolt J ...

Page 1269: ...Gigarette Lighter CircuitDiagram UNDER HOOD FUSURELAY 8OX 3o 75A J Y Lit is I r OASH LIGHTS ERIGHTNESS CONTFOLLER BLK G201 G401 23 212 ...

Page 1270: ...HT t 1 4W l EULBCASE FRONTCONSOLE PANEL THERMOFUSE CASE RINGNUT THERMALPROTECTOR scREws ILLUMINATION RING CrcANETTE LIGHTER socxET Wheninstalling the cigarettelighter aligneachlug on the face panel illumination ring and cigarette lightersocketwith the grooveof the hole then po sitionthe bulbhousingon the thermalprotectorbe tween the stops in the consolepanel Makesurethat the groundwire bulbsocket ...

Page 1271: ...rument panelsendsa signalto the defoggertimer in the integrated controlunit andthe defoggerstayson for 25 minutesor untilthe ignitionswitch is turnedoff The indicatorlight in the switch comeson when the defoggerworks UNDER OASH FUSE RELAY BOX r luijij u l NEARWINDOW DEFOGGER SWITCH Removal page23 217 Test page23 217 REAR DEFOGGER REI AY Test page23 69 23 214 ...

Page 1272: ... J DASH LIGHTS BRCHTNESS CONTROLLER CNTION swrTcH 8AT T 7 l I I I I WNT BLK WHT REAR WiNDOW DEFOGGER BtK GRN l ELKGRN BLI RED 1 A T L l l t l t l t l l UNDEFHOOD FUSE RELAY BOX No41 100A N0 42 40A G201 G401 G201 G40l Hatchback G771 Sedan iG503 I 23 215 ...

Page 1273: ... t r t a f u o OJ o o c c Defoggerworks but indicator light does not go on BLK YEL or BLU YEL Defoggerdoes not work and indicatorlight does not go on 3 G201 G401 YEL BLU YEL or BLK YEL Defoggerdoes not work but indicatorlight goeson 1 2 3 G 77 1 G503 BLU YEL or BLK YEL BLK GRN or BLK WHT Operation time is too long or too short normaloperationtime is 25 minutes 23 216 ...

Page 1274: ...ocket 45o counterclockwise andremove theillumination bulb REARWINDOW DEFOGGER SWITCH INDICATOR BULB o 84 W l Switch Test NOTE Be careful not to damage the heater con trol centerair vent 1 Carefullypry the switch out of the heater con trol centerair vent 2 Checktor continuitybetweenthe terminals accord ingto the table Terminal pLN _ B c D E F PUSHED o o o o o o RELEASED o _o o o I 6PCONNECTOR REARW...

Page 1275: ...ndthe negativelead to the negativeterminal Thereshouldbeapproximately 6 V with the ignition switch and defoggerswitch ON a lf the voltageis as specified the defoggerwire is OK a lf the voltageis not asspecified repair the defog ger wire lf it is morethan 6 V lookfor the damageon the negativehalf on the grid lf it is lessthan 6 V lookfor the damageon the positivehalf of rhe grid 3 NOTE To makean el...

Page 1276: ...Moonroof ComponentLocati Inde J I on x Jwire colors GRN BLK IWHT GRNand BLK I Test page23 68 23 219 ...

Page 1277: ...Moonroof CircuitDiagram UNDER HOOD FUSEi RELAY 8OX No41 100A N0 42 40A IGNIT ONSW TCH M MOONROOF M0TOR Harchback BLK G201 G401 MOONROOF M0TOR Sedan 23 220 ...

Page 1278: ...d 9 i 9 3 o 6 b H 6 s 6 3 x i t c 3 o c B F 1 9 o E E 3 g c 9 o 6 Moonroof does not move but motor turns 1 Moonroot does not move ano motor does not turn moonroof can be moved with moonroot wrenchl ln all switch positions E G401 WHT GRN BLK GRN BLK With OPEN swttcn GRN RED With CLOSE swttcn GRN YEL ElectricalTroubleshooting 23 221 I ...

Page 1279: ...hood fuse relay box or No 24 17 5 Al fuse in the under dash fuse relay box an openin the wires GRN BLK cRN WHT or looseterminals faultymoonroofrelay lf thereis battery voltage go to step5 Connectthe No 4 terminalto the No 3 terminal andthe No 1terminalto theNo 2 terminal withjum perwires The moonroolshouldopenwhen the ig nitionswitchis turnedON ll 4 5 KNEEBOLSTER LOWER COVEB 2 Carefully pry the sw...

Page 1280: ...terminalsin each switch positionaccordingto the table MOONROOF SWITCH 1 2 Motor Test Removethe headliner seesection20 Disconnect the 2P connector from the moonroof moror Checkthe motor by connectingpowerand ground accordingto the table NOTE Motor clutchtest is in section20 Hatchbackl Sedanl View from terminalside lf the motor tails to run or does run smoothly reptace rt Terminal Conditbn ll B OPEN...

Page 1281: ...Power Mirrors ComponentLocationIndex I POWERMIRRORS T st page23 228 Replacom6nt s6ction20 Mirror ActuatorRepl6cemenl page23 229 FOWER MIRROR SWTCH Function Test page23 227 Test page 23 226 23 224 ...

Page 1282: ...I CircuitDiagram UNDER DASN FUSE RELAY BOX YEL t I Zu x I I POWER MIRROR SWITCH UNDER HOOD FUSE FELAY BOX LEFT l_L______ ___l l t l t YEURED Hatchback 23 225 ...

Page 1283: ...heckfor continuitybetweenthe terminalsin each switch positionaccordingto the table MirrorSwitch a a a a a a a a A J Terminal Position E D G c F R OFF o o UP o o o o G DOWN o o G o LEFT o o o o RIGHT o o o o L OFF o o UP o o o o DOWN o o o o LEFT o o o o RIGHT o o o o 23 226 ...

Page 1284: ...orshouldtilt down orswingleft whenyou turn the ignitionswitchON ll a lf themirror doesnottiltdown ordoesnotswinglett check for an open in the YEL WHT or YEL BLKr wirebetween the leftmirrorandtheswitch lf thewire is OK checkthe lett mirroractuaror a lf the mirrorneithertilts down norswingsleft repair the YEL REDr wire betweenthe letr mirrorand the swtlcn a lf the mirror operatesproperly check the m...

Page 1285: ...0 LEFTREARWINDOWMOTORisedan Test page23 240 POWER WINDOWRELAY Test page23 69 LEFTREAR WINDOWSWITCH Sedan Test page23238 Replacement page23239 FRONT PASSENGER S WINDOWSWITCH Test page23 238 Replacement page23239 FRONTPASSENGER S WINDOWMOTOF Test page23 240 RIGHTREARWINDOWSWITCH Sedanl Test page23 238 Replacement page23 239 RIGHTREARWINOOW MOTORlsedanl Test page23 240 a r r r r r n n r n T l t r L l...

Page 1286: ...ircuitDiagram Sedan RIGHT REAR WINOOW MOTOR BLK LEFTREAR WINOOW MOTOF BLUIRED I swrrcH UNDEF HOOD FUSE RELAY BOX UNDEF DASH FUSE NELAY BOX IGNITION SWITCH FRONT PASSENGECS WINDOWMOTOR 5S rricot c F 23 231 ...

Page 1287: ...ir PowerWindows Circuit Diagram Hatchback I FED BLU DRIVER S WINDOW MOTOR 23 232 ...

Page 1288: ...3 E 3 o E g i oi o o g 3 c q 3 E B g B B I o c 6 z 3 6 N z 6 z 6 N F z B All windows do not work 1 2 G201 G401 G501 G502 BLK YEL WHT RED Driver swindow does not work 2 5 WHT YEL Driver swindow does not work in AUTO 2 3 BLU BLK WHT Passenger s windows do not work Rightfront 1 2 5 BLU BLK Left rear 1 4 5 GRN BLK Right rear l t 4 5 YEL BLK Sedan 23 233 t ...

Page 1289: ...he connectorand socketterminalsto be surethey are all makinggood contact a ll theterminals arebent looseor corroded repair them as necessary and recheckthe system a lf the terminalslookOK makethe followingin out tests at the conneclor lf a test indicates a problem find andcorrect the cause then recheckthe system lf allthe inputtestsproveOK the powerwin dow masterswitchmustbefaultV replaceit GRN BL...

Page 1290: ...N ll check the front passenger s wtnoow molor It should run the window moves down Faultyfront passenger s window motor An open in the wire 5 GRN YEL ano G R N Connectthe GRN BLK and GRNterminals and the GRN YEL and BLK terminalswith jumper wires then turn the igni tionswitchON ll Checkthe left rearwindow motor It shouldrun the window movesdown Faultyleft rearwindow motor Faultyleft rearwindow swit...

Page 1291: ...inuity Poorground G502 An openinthe wire lgnition switch ON ll Checkfor voltageto ground Thereshouldbe batteryvoltage BlownNo 24 7 5A fuseinthe under dash fuse relay box BlownNo 10 or No 11 20A fuse in the under dash fuse relay box Faultypowerwindowrelay An openinthewire Connectthe WHT YEL and RED YELI terminals and the RED BLU1 and BLK3terminalswith jum per wires then turn the ignition switchON l...

Page 1292: ... vou cannotisolatethe switchto test it Instead run the masterswitchinput test procedures No 1 2 3 and 7 on page 23 234 lf the tests are normal the driver s switchmustbefaulty Front Passenger sSwltch Terminal J o I uain Position I Switch OFF ON G_ o o OFF G o UP ON o o o OFF o o DOWN ON o o G _O OFF G o A B C D E F G H I J K L M N O L ft RearSwitch Terminal E F G o I Main Position I Switch OFF ON o...

Page 1293: ...nput test p oceduresNo 1 2 3 and 5 on page23 236 lf the testsare normal the driver s switchmustbeiaultv r ir i l r JJ iill ryfi Front 1 Remove the passenger s doorpanel seesectaon 20 2 Disconnect the 5Pconnector from the switch 3 Checkfor continuitybetweenthe terminals in each switch positionaccordingto the table Real Sedan 1 Removethe innerhandle seesection20 2 Disconnect the 5Pconnector from the...

Page 1294: ... two mountingscrewsandthe switch POWER MIRROR swtrcH scBEws MasterSwitch Replacement Passenger s Window Switch I J I Replacement Front 1 Remove the passenger s doorpanellseesection 20 2 Disconnect the 5Pconnector from the switch 3 Remove the two mountingscrewsandthe switch Rear Sedan 1 Removethe innerhandle seesection2O 2 Disconnect the 5Pconnector from the switch 3 Remove the two mountingscrewsan...

Page 1295: ... connecting powerandgroundto tho A anO8 errninals Thgohmrneter neede shouldmove backand forth alternately 1 2 Passenger s Window Motor Test Remove the passenger s doorpanel seesection 20 Disconnect the2Pconnector from the motor NOTE a Frontpassenger s dooris symmetricalto driver s door a Theillustration showsthe rightreardoor leftrear door is symmetrical 2PCONNECTOR Viewfromterminal side 3 Testthe...

Page 1296: ...T PASSENGER S DOORLOCKSWITCH Test page23 249 DRIVER S DOOR KEYCYLINDER SW TCH Test page23 248 OOORLOCKACTUATOR Test page23 246 Replacement section20 DRIVEB S DOOR LOCKSWITCH Test page23 249 oooRLocK CONTNOL UNIT InputTest page23 244 J I Forthis model a new doorlocksvstemhasbeenadootedto imDrove convenience andsalety lf the key is insertedinto the driver sdoor kev cvlinder turnedto the unlockpositi...

Page 1297: ...AY BOX N0 41 1004 No s4 40A DFIVERS DOOR KEY CYLJNOER SWITCH WHT GRN FRONT PASSENGERS DOOR LOCK ACTUATOR T l 4 il LEFT REAR DOOR LOCK ACTUATOR RIGHT NEAR DOOR LOCK ACTUATOH 4 ill HATCH LOCK ACTUATOR T l fl LTGRN LTBLU A t l t J KEY i A t l T t l l KEY BLK I G503 LK BLK l l t l A A l G501 G2r G502 ercl BLK l G5o1 G502 LOCK o POWER DOOR LOCK CONTROL UNIT 8LK A l G501 G502 23 242 ...

Page 1298: ...oor lock switch All doors 2 G501 G502 GRN RED or GRN WHT Oneor more doors I 2 3 WHT REDor YEL RED Doorsdon t lock or unlockwith the passenger s door lock switch All doors 1 G201 G401 BLK RED or BLK WHT One or moreooors 1 2 3 WHT RED or YEL RED Doorsdon t lock or unlockwith the driver sdoor lock knob All doors 1 2 3 G501 G502 BLU RED or BLU WHT Oneor moredoors 1 2 3 WHT RED or YEL RED Doordon t loc...

Page 1299: ...hey are all makinggood contact a lf the terminals arebent looseor corroded repair them as necessary and recheckthe system a lf the terminalslookOK makethe followingin put tests at the connector lf anytest indicates a probiem find and cor rect the cause then recheckthe system lf allthe inputtestsproveOK the controlunit must be faulty replaceit 14PCONNECTOR View from wire side 23 244 ...

Page 1300: ...HT Driver sdoor lock switch in LOCK Checklor voltageto ground Thereshouldbe 1 V or less Faultydriver sdoor lock switch Poorground G501 G502 An openin the wire GRN RED Driver sdoor lock switch in UNLOCK 5 BLK WHT Rightfront door lock switch in LOCK Checkfor voltageto ground Thereshouldbe 1 V or less Faultyfront passenger s door lock switch Poorground G201 G401 An open in the wire BLKi RED Rightfron...

Page 1301: ...n by connecting powerand groundaccordingto the table CAUTION To preventdamageto the acluator ap ply battely voltage only momentarily if the actuatorfailsto work properly replaceit Terminal D E Position LOCK o UNLOCK o 5 Checkfor continuitybetweenthe terminalsin each switch positionaccordiogto the table DOORLOCKKNOB Terminal il t F c B LOCK o o UNLOCK o o 23 246 ...

Page 1302: ...ATOR J 23 247 RearPassenger s Door NOTE Left rearactuatoris shown right rearactuator is similar Viewfromlerminal side Checkactuatoroperation by connecting powerand groundaccordingto the table CAUTION To preventdamage to the actuator ap ply battery voltage only momenta ily 4 lf theactuator tailsto workproperly replace it Term inal Position B LOCK o UNLOCK o o ...

Page 1303: ...ositionaccordingto the table FrontPassenger s DoorKeyCylinder Switch Test 1 Removethe door panel seesection20 2 Disconnect the3Pconnector from theswitch FRONT PASSENGER S DOORKEY CYLINDER SwlTCH CONNECTOR 3 Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table Terminal il __ tt UNLOCK o o OFF Terminal P __ c LOCK o o UNLOCK o o UNTOCK I UNLOCK r O I LOCK 23 248 l__ JK...

Page 1304: ...emove the inner handle trim 2 Disconnect the 3Pconnector from the switch 3 Checktor continuitybetweenthe terminals in each switch positionaccording to the table oooR LOCK swtTcH Terminal t r B c LOCK o o OFF UNLOCK o o 4 23 249 ...

Page 1305: ... from theswitch 3 Checkfor continuitvbetweenthe terminalsin each switchpositionaccording to thetable 6PCONNECTOR 3 Checkactuatoroperationby connecting power and groundaccording to thetable CAUTION To prev nt damage to the actuator apply battery voltage only momeniarily 1 lfthe actuator failsto workproperly replace it 23 250 Terminal ilil t B c LOCK o o UNLOCK o Terminal ilil E LOCK o UNLOCK o o UN...

Page 1306: ...itionaccording to thetable HATCH OPENEH RELAY HATCH OPENER ACTUATOB UNDER HOOD FUSE RELAY BOX UNDER DASH FUSE RELAY BOX l a l l f q l l ELUMHT YEURED t l S l 0 f tl I o P E N E Fl t l I I l n _i t l 8LK BLK t l t l t t G503 G503 BATTEFY Y I r t I Ilm 1 u I N o v I I f 4oA r T I WHT RED I r u r I I L 2oA I I WHTiGRN fi l t_ ___J KEY Terminal c rosrUon 1 UNLOCK LOCK F 23 251 t1 I K E Y _ J ...

Page 1307: ...o mountingboltsto pull outthe hatchopenerswitchfrom the hatch 1 2 1 2 HatchOpenerActuatorTest Remove the reartrim panel seesection20 Disconnect the 2Pconnector from the actuator 3 Checkactuatoroperationby connecting powerand groundaccording to thetable CAUTION To prevent damage to the actuator apply battery voltageonly momentarily Terminal Position B O N o OFF Terminal Position B OPEN o 23 252 4 l...

Page 1308: ...bLocations page23 122 MAIN SWITCH Test page23 261 Replacement page23 261 SET RESUME SWITCH Test page23 259 Feplacement page23 259 BRAKESwlTCH Test page23 262 CLUICHSWITCH IM T Test page23 262 cRutsE A TGEAR POSITION swtTcH Test page 23 144 263 InputTest page23257 cont d 23 253 ...

Page 1309: ...CruiseControl ComponentLocationIndex cont d ACTUATOR ASSEMBLY Test page23 264 Cable adjustment page23 264 23 254 ...

Page 1310: ... B l A i Y l D GBY c IT GRN RED LTGRN BLK BLK I 201 3401 I I I I VEHICLE SPEED SENSOR VSS M T CLLTCH SWITCH A T A T G E A R PostT oNswrc oN E trtr 8LK 8LK l l t l 0 _ L G301 G2Al G401 UNDER HOOD FUSEiFELAY BOX UNDEF DASH FUSEi RELAY BOX lNDICATOR L GHT 0 91W BLU RED 23 255 ACC ACCELERATION OECiDECELERATION ...

Page 1311: ... BRN BLK BRNi REDor PNK Cruisecontrolcan be set but indicatorlight does not go on 1 G201 G401 YELor RED BLU Cruisespeedis noticeablyhigher or lower than what was set 1 Excessive overshooting or undershooting when trying to set speed I Steadvsoeedis not heldeven on a flat road with cruisecontrolset 1 J Cardoes not decelerate or accelerate accordingly when SET or RESUME button is pushed 1 LT GRN BLK...

Page 1312: ...ood contact a lf theterminals arebent looseor corroded repair them as necessary and recheckthe system a lf the terminalslookOK makethe followingin put tests at the connector It any test indicates a problem find and cor rect the cause then recheckthe system lf allthe inputtestsproveOK the controlunit must be faulty replaceit 3 CRUISE CONTROL UNIT View from w re s ce cont d LT GRN RED 14PCONNECTOR 2...

Page 1313: ...tton pushed Checktor voltageto ground Thereshouldbe batteryvoltage FaultySET RESUME switch Faultycablereel An open in the wire 8 LT GRN RED SETbutton pushed I PNK MT Clutchpedal released A Tr Shift leverin 2l Dl o o l Checkfor continuityto ground Thereshouldbe continuity NOTE Thereshouldbe no con tinuity when the clutch pedalis depressed or when the shift leveris in other positions Faultyor misadj...

Page 1314: ... wait at leastthreemin utes 2 Disconnect eachairbagconnector Drivor sSide a Removethe accesspanelfrom the steeringwheel then disconnectthe 2P connectorbetweenthe driver s airbagandcablereel FrontPassenge s Side a Remove the glovebox Disconnect the 2P connectorbetweenthe front passenger s airbagandSRSmainharness Removethe dashboardlower coverand kneebolster seepage23 71 Disconnect the cablereel3Pco...

Page 1315: ...e switch Not used 7 Terminal t n l 2 3 SET ON G o RESUME ON o o lf alltestsproveOK reinstallthe sevresume switch Reconnect the driver sairbagconnectors and rein stallthe access panelon the steering wheel Reconnect the front passenger s airbagconnector andreinstallthe glovebox Connect the batterypositivecable thenconnect the negative cable After installingthe airbag assembly confirm that the SRSind...

Page 1316: ...mentpanelfrom the dashboard seepage23 126 2 Removethe switchfrom the dashboard then dis connect the 5Pconnector 3 Checkfor continuitybetweenthe terminals in each switch positionaccordingto the table a lf thereis no continuityin any position replace the switch Teminal Jt tt c D OFF o a o o 7 ON o o o o A B C D E J 23 261 ...

Page 1317: ...essary replacethe switch or adjust pedal height seesection19 A B f t l t r I f I PEDAL Terminal r __ B c D RELEA SED CF o PUSH ED o o 1 Disconnect the2Pconnector trom theswitch 2PCONNECTOR CLUTCHSWITCH CLUTCH PEDAL Checkfor continuitybetweentheterminals accord ing to the table 3 lf necessary replacethe switch or adjust pedal height seesection12 Terminal t i 1 I RETEASED o o PUSHED 23 262 ...

Page 1318: ...backand forth at each position withouttouchingthe button andcheckfor con tinuity within the rangeof free playof the shitt lever a lf thereis no continuitywithin the rangeof free play adjustthe installationpositjonof the switch View lrom terrninal side A B C D E F G 3 lf necessary replacethe switch seesection 14 H I J K L M A T GoarPositionSwitch Forcruisecontrol Terminal _ n a o o o o E o o E tr t...

Page 1319: ...moothly without bindingor sticking Startthe engine andwarm it up to normaloperat ing temperature radiator fans come on twice Measure how farthe outputlinkage movesfromthe fullyclosedposition Freeplayshouldbe 11 t 1 5 mm 0 43 t 0 06 in FREEPLAY 1M 5 mm 0 43 1 0 06 in FULLY CLOSED POSITTON 4 lf the freeplayis not within specs loosenthe lock nut and turn the adjustingnut as required NOTE It necessary...

Page 1320: ...PER ARMS BLADES Replac6ment page23 272 WINDSHIELD WIPER MOTOR Test page23271 Replacement page23 272 WINDSHIELD WASHER MOTOR fest page23 27 4 REAR WINDOW WASHER MOTOR Test page 23 2 14UNDER DASH FUSE RELAY BOX INTERMTNEMTWIPER FELAYCIRCUN lntheintegrated controlunit InpurTest page23 154 I ul REARWINDOWWIPER MOTOR Test page23 273 23 265 ...

Page 1321: ...SOX NTE NMI TEI II WPES RELAY CIFCUIT Inlheinr6grar6d nlrolun I IGNITION SWTCH UNDER HOOD FUSE RELAY BOX GRI BLK GFIVBLK WINDSHIELO WPENJWASHER SWITCH BLK G201 G401 Wilhcombined washer wiDer ooeralion BLI GRN I A w os M WASHER Y MoroF 8LK I G301 23 266 I ...

Page 1322: ...N BLK ln INT I 3 YEL BLU BLU GRN ln LOor Hl 1 2 BLU BLU YEL In MIST 1 2 BLU YEL Rearwindow wiper does not work 2 Gs03 GRN BLK GRN LT GRNi BLK Bladesdo not returnto parkpositionwhen the switch is turnedOFF 2 BLU WHT LT GRN BLK Intermittentcycle is erraticor wipers do not work intermittently a YEL BLU BLU GBN Littleor no washerfluid rs pumped 4 3 I 2 G301 BLK GRN BLU BLK Wiperand washerdo not work a...

Page 1323: ...iewthe SRScomponentlocations precautions and procedures in the SBSsection 23 beforeperformingrepairsor ser vtce 1 Removethe steeringcolumncovers UPPER COVER Disconnect the 8P and 6P connectorsfrom the switch 3 Removethe two screwsand the switch 4 Installin the reverseorderof removal 23 26A ...

Page 1324: ...ringcolumncovers Disconnect the 8P and 6P connectorsfrom the switch ll necessary remove thetwo screwsandtheswitch Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table 3 WIPERS wASHERS swtTcH cont d I J K A B C O 23 269 ...

Page 1325: ...Wiper WssherSwitch I L J K o di wm I i 4l rt J o MIST MIST OFF INT Terminal t _ c n E H o o INT o o o o LO o o HI G o Mistswitch 0N o o Washef switch 0N o o qI t t x 1 r h l X r a l J q Teminal t r __ J K N Washer switch 0N o o o o OFF o o ON o o Washer switch 01 1 tlwiper 0N o o G o f 23 270 I ...

Page 1326: ...connectingbattery power and groundaccordingto the table lf the motor doesnot run or lails to run smoothly reptacerr Terminal Position D GRN BLK BLU BLU YEL LOW SPEED It o HIGHSPEED o D GRN BI K A IBLUTYEL B Br Ul 7 Reconnect the 5P connector to the wiper motor assemory Connect an analog voltmeter between the E BLU WHT andthe C BLK terminals Runthe mo tor by turningthe wiper switch ON LOor Hl po si...

Page 1327: ......

Page 1328: ... assemDty 5 Connectan analogvoltmeterbetweenthe D LT GRN BLK andB BLKIterminals Runthe motorby turningthe wiper switch ON The voltmelershouldalternately indicateO V and morethan4 V NOTE Usean analogtester 1P CONNECTOR A GRN BLKI C IGRN Viewfromterminal side 2 Testthe motorby connectingbatterypowerto the A GRN BLK andgroundto the C GRN terminals The motor shouldrun smoothly C IGRN 23 273 ...

Page 1329: ...ewipermotor Remove thethreemountingboltsandthe wipermo tor assembly 5 6 Installin the reverseorderot removal I I t Wipers Washers RearWindow Wiper Motor WasherMotorTest l 2 Removethe front bumper seesection20 Disconnectthe 2P connectorfrom the washer motor RESERVOIR 1 WINDSHIELD REAR wtNDow 3 Testthe motorby connecting batterypowerto the A terminal andgroundto the B lterminal a lf the motordoesnot...

Page 1330: ...e reservoir Remove the windshield wiperarmsand air scoop seepage23 272 Thenremovethe washernozzles anq noses Installin the reverseorderof removal NOTE a Takecare not to pinchthe hosesduringinstal ralron a Installthe cljpsfirmly a After installing adjust the aim of the washer nozzles REAF WINDOW WASHER NOZZLE WINDSHIELD WASHER NOZZLE MOUNTING BOLTS 9 8 N m 1 0 kgl m 7 2 lbf ftl n V Q V n WasherRepl...

Page 1331: ... Seff diagnostic Procedures 23 287 Reading theDTC 23 287 Erasing theDTCMemory 23 289 Troubleshooting Intermittent Failures 23 289 Diagnostic TroubleCode DTC Chart 23 290 SRSIndicatorLightWire Connestions 23 252 Ff owcharts 23 293 Ailbag Repf acement 23 317 Disposaf 23 320 CableReel Replacement 23 322 SRSUnit Replacement 23 326 1 Connectors 23 28 t r Spring foaded LockConnector 23 284 Spring loaded...

Page 1332: ...320 to SRSINDICATOR LIGHTin GAUGEASSEMBLY 5PCONNECTOR SRSMAINHARNESS To MAIN WIREHARNESS 3PCONNECTOR SRSMAIN HARNESS to UNDER DASH FUSE RELAY BOX 2PCONNECTOR HARNESS to FRONT PASSENGERS AIRBAG 2PCONNECTOR SRSMAIN SERVICE CHECX CONNECTOR 2PI IBRNAAIHT BLK to CABLEREEL 2PCONNECTOR MAINWIREHARNESS to DASHBOARD WIRE HARNESS 16PCONNECTOR ERASE SIGNAL MES SRSUNIT GBOUNO SRSMAIN HARNESS SRSUNIT lncluding...

Page 1333: ...Goi 2 Themicroprocessor mustcomputethe signalsandsendsignals to the airbaginflators 3 Theinflatorsmustigniteanddeploythe airbags sE Lr r UNDERDASH FUSE RELAY BOX Dnftr s Atac ranroq I I M P A C T I F80t T PASSEI GEffS AIRSAG INFLAIOR Drc MESSCS rDC Self diagnosis System A self diagnosis circuitis builtintothe sRs unit whenthe ignitionswitchis turnedoN ll the sRS indicator lightcomes on andgoesoff ...

Page 1334: ... 7 ECM SERVICE CHECK coirNEcTon WHT BLK WHT t DATA LINK CONNECTOF DLC r6P UNDEF DASH FUSURELAY 80x ELKRED J PGM FI main r lay MEIiIORY ERASE r2pt SIGNAL MESI coNNECToR 2P SRS UNIT TERMJNALS BLX G201 G401 NOER NOOD FUSE RELAY BOX SRSINDICATOR LIGHT 0 4W 10 14 1 13 6 7 VA 3 VB SRS UNIT 1 6 1 7 1 5 9 1 8 8 DRIVER S AJFBAG INFLATOR 1 3 6 7 I 1 0 1 1 3 1 4 1 5 1 7 1 8 lerminalsdeo maletefinnals 23 280 ...

Page 1335: ...thanthreeminutes becaretulnot to bumpthe SRSunit the airbagscouldaccidentally deployandcausedamageor iniuries Wheneverthe airbaghasbeenactivated replacethe SRSunit The original radio hasa codedtheft protectioncircuit Besureto getthecustomer s codenumberbeJore dis connectingthe batterycables 23 281 AirbagHandlingand Storage Do not try to disassemble the airbag lt hasno service a b l e p a r t s O n...

Page 1336: ... lessthan 80 humidity no mois ture place Do not spillwateror oil on the SRSunit andkeeDit awavtrom dust During installation or r6placement be careful not to bump impactwrench hammer etc the areaaround the SRSunit The airbagscould accidentally deploy andcausedamsgeor injuries v InspectionAfter Deployment After a collisionin which the airbagsw6re deployed replace the SRSunit andinspect thefollowing ...

Page 1337: ...termittent problems thataredifficultto diagnose BackprobingSpring loadedLock Connectors When checkingvoltage or resistanceon this type of connectorthe first time it is necessary to removethe retainer to inserttesterprobesfrom thewireside NOTE lt is not necessary to reinstallthe removed retainer the terminalswill stavlockedin the connec tor housing To remove the retainer insen a flat tip scrGirdr b...

Page 1338: ...o release the lock pullthe spring loaded sleeve toward the stopwhileholdingthe opposite halfot theconnector Thenpuiltheconnector halves apart NOTE Be sureto pull connector half on the sleeve and not on the SPRII G LOADED sL EEvE Donotpullonthis haltof the connector Conneqting 1 Hold the pawl sideconnectorhalf and presson the backof the sleeve side connectorhalf in the direction shown As the two co...

Page 1339: ...oredisconnecting thecablereel2Pconnector B disconnect the driver sairbag2Pconnector C 1 Disconnect the negativebafterycable and wait at leastthreeminutes 2 Disconnect the airbagconnector s Driver sSide Removethe accesspanelfrom the steeringwheel then disconnectthe driver s airbag 2P connectorand cablereel2Pconnector CABLE REEL 2 CONNECTOR Front Ps sngar 3 Sid Removethe glove box then disconnectthe...

Page 1340: ...on k6y to o LOCKposition or removetho keylrom thc ignition ro that the steering wheel will not turn NOTE Whenthe airbagandcablereelaredisconnected and the batteryis reconnected and the ignitionswitchis turnedON ll the SRSunitwill storethis as an open in the driver sairbaginflator and the SRSindicator lightwill comeon In sucha case makesureto con firmtheDTC thencleartheSRSunitmemory Fordisconnectin...

Page 1341: ...10mA 0 01A or lesswhen switchedto the smallestvaluein the ohmmeterrange A testerwith a higheroutputcoulddamsgethe airbagcircuitor causesccidental airbagdeployment andpossible injury Whenever the ignitionswitchis ON ll or hasbeenturnedOFFfor lessthanthree SRSunit the airbags couldaccidentally deployandcausedamageor injuries Beforeyou removethe SRSmain harness disconnect the driver sairbagconnector ...

Page 1342: ...will indicate the DTC The DTCconsists of a maincodeanda sub code Including the mostrecentproblem up to threedifferent malfunctions canbe indicated ln caseof a continuous failure the DTCwill be indicated repeatedly seeexample1 below In caseof an intermiftent failure the SRSindicator lightwill indicate the DTConetime thenit will stayon seeexarn ple2 beiow lf botha continuous andan intermittent failu...

Page 1343: ...emoryis erasedby blinkingtwo times Turn the ignitionswitchOFF and wait for ten sec onos Troubleshootin g Intermittent Failures lf the ewas a malfunction but it doesn trecur it will be storedin the memoryas an intermittent failure andthe SRSindicator lightcomeson Atter chockingths DTC troubleshoot asfollows 1 Readthe DTC see Reading the DTC 2 Erasethe DTC memory see Erasingthe DTC Memory 3 With the...

Page 1344: ...23 301 Increased resistance in the driver sairbag inflator 23 301 1 3 Shortto anotherwire in the driver sairbao inflato or decreased esistance 23 303 1 4 Shonto powerin the driver sairbaginflator 23 305 t 5 Shortto groundin the driver sairbaginflator 23 301 2 1 Openin the passenger s airbaginflator Troubleshooting 23 309 Increased resistance inthe passenger s airbag inflator 23 309 Shortto another...

Page 1345: ... ment 23 326 9 2 2 x 10 1 lnternal failureof the SRSunit SRSunit replace ment 23 326 SRSairbagsdeployed SRSunitmustbe replaced SRSunitreplace menl 1 ln caseof an intermittent failureDTC9 1 it meanstherewas an internal failureof the SRSunitor a faultySRSindica tor lightcircuit Dothetroubleshooting for intermittent failures seepage23 289 2 ln caseof an intermittent failureDTC9 2 it meanstherewas an ...

Page 1346: ...o GAUGEASSEMBLY CiP7 C449 TERMINAL SIDEOFMALETERMINALS C553 CEo1 C802 C804 WIBESIDEOFFEMALE TEFMINALS DASHBOAND WIRE HARNESS To UNOEF DASH FUSE RELAY BOX 2PCONNECTOR C427 MAINWIREHARNESS 3PCONNECTOR C r49 MAINWIBEHARNESS 16PCONNECTOR C551 DASHSOARD WIREHARNESS 2OpCONNECTOR C553 DASHBOARD WIFEHARNESS t6P CONNECTOR CssT OASHBOARD WlnEHABNESS SPCONNECTOB To GAUGEASSEMBLY C801 SRSMAIN HARNESS 2PCONNEC...

Page 1347: ... fuse and checkthat the SRSindicator lightcomeson Doostho SRSindic lor light como on YES END Ch ck th6 wir ham ls b twoen fu3esnd gauge 3sembly Checkfor an open in the wire harnessbelweentuse No 25 7 5A andthegaugesssembly andrepair Check thatthesRSindicator lightcomeson Doo3the SRSindicatorlight comeon YES NO NO END Ch6cktho SRSindicatorlight bulb 1 TurntheignitionswitchOFF 2 Remove thegaugeassem...

Page 1348: ...inted circuit board in the gaug assembly Checkthe wiro ham ss of tho SRSindicltor light circuh ll l 1 Turnthe ignitionswitchOFF 2 Disconnect the main wire harn ss16Pconnector lrom thedashboard wireharness 3 Connecta voltmeter betlveenthe No 15torminal of the mainwireharness 16Pconnector andground 4 Turnthe ignitionON ll andmeasure voltage 13there 8 5 V or lc r tor 3lx s condr lftor th ignition swi...

Page 1349: ...Ch cklh wir h rn r of thc SRSindic tor circuit l3l 1 Tlrn the ignitionswitchOFF 2 Oisconnoct the b8ttery negativ cable then the positivo cable andwait throe ftinutes 3 Disconnect the driver sairbagand front passenger s airbagconnectors seepage23 285t 4 Disconnect the SRSmain harness18Pconnectortrom tho SRSunit 5 Fsconnectthe batteryDositivocable th n reconnectth negativecable 6 Connecta voltmeter ...

Page 1350: ...relaybox ls the luse OK YES NO Roplscethe f se and erescthe memory 1 Replace theNo 23 10Alfuse 2 Erasethe DTCmemory seepage23 289 3 TurntheignitionswitchON ll Doesth6 SRSindicatorlight go off afterrix socond6 I YEs No I ENO Contilmthe DTC and continuotroubleshooting Checktor an openin ths SRSmain hlrna3r VBtinc 1 Disconnect the batterynegative cable thon disconnect the positivecable andwait tor th...

Page 1351: ...uit 1 Turnthe ignitionswitchOFF 2 Disconnect the dashboardwire harness5P connector fromthegaugeassembly 3 Checkresistance betweenthe No 5 terminalof the dash board wire harness5P connectorand ground There shouldbe 1 MOor more ls the resistance as apocifiad YES NO c To page23 299 Short to ground in tho gauga aatambly raplacetho gauge asscmblY Frompage23 296 A SRSMAIN HARNESS 18PCONNECTOR JUMPERWIRE...

Page 1352: ... d ciJcuit bolrd in th g ug 9 emblY ch ck loi n op n in th SRSindicltor ligl t circuh 1 Turnthe ignitionswitchOFF 2 Disconn ct the dashboardwire harnoss5P connector from th6 gaugeassembly 3 Checkresistancobetweenths No 6 t rminal ot the SRS main harneas18Pconngctor and No 5 terminalof th6 dashboard wire harness5Pconnector thereshouldbs 0 1 0 0 lr tha raaidanca aalpacifiad YES NO D Topage23 300 E T...

Page 1353: ...here thould b 1 M0 or more L tha rcrbianca ra apacifiad YES NO Short to groond in th6 d8hboard wirc hrJn 3 ropair th d hborrd wir h ma Chacl lor a rhort to ground in tha SRSmain h no3s 1 Disconnectth6 SRSmain harness3p connectorlrom the mainwir harness 2 Chockresistancebetwoenthe No I terminal of the SRS main harngss3Pconnoctorand ground Thereshould be 1 M0 or more l tho raainanca ar apacifiad YES...

Page 1354: ...Pconncctor chatcl the conn6c toa lf the connocto is OK substitute a known good SRS unit and rechock It the problom is still prescnt r phca the SRSmain har noas MAI WIREHARNESSlGP CONNECTOR Terminalsid ol maleterminals Chocktor an ooenin the dashboardwire haino 1 Disconnect the dashboard wire harness16Pconnector fromthe mainwireharness 2 Checkresistance between the No 6 terminalofthe SRS main harne...

Page 1355: ...F 2 Disconnect the batterynegativecable then disconnect the positivecable andwail for thrceminutes 3 Disconnect the driver sairbag2Pconnectorlromth cable reel2Pconnector CAUTION Do not disconnoct tho palF nger r ilb g con nector 4 Connect thesDecial tool12o to thecablereel2Pconnec tor 5 Reconnect the bsftery positivecable then reconn cttho negativecable 6 Erase the DTCmemory se page23 289 7 Beadth...

Page 1356: ...nect the oositivecable and wait tor three minutes 2 Disconnectthe front passenger sairbag connectorfrom theSRSmainharness 3 Disconnect the SRSmain harness18Pconnector from the SRSunit Oo not disconnect the specialtool 2 O fromtheSRSmainharness 2Pconnector 4 Checkresistance between terminalsNo 1and No 13of the SRSmain harness18Pconnector Thereshouldbeaoorox 2 0 3 0o b tho rodstancaas specifiedT YES...

Page 1357: ...TOR t2 0 JACKI 07SAZ T8 11A Erase the DTCmemory seepage23 2891 Roadthe DTC seepage23 287 o1 rr u GoNNECTOR 120 07TAZ S250200 cont d SRSSIMULATOR I EADC orTAZ SZ5011A nd SRSINFLATOR SIMULATOR 120 JACKI 07SAZ TBrl011A TrVto reproducethe SRSindicatorlight 1 Erasethe DTCmemory seepage23 289 2 TurntheignitionswitchON ll andcheckthattheSRSindi catorlightcomeson for about six secondsand then goes off Dos...

Page 1358: ...hen disconnect the positivecabl and wait forthres minutes 2 Disconnscttho front passenger sairbagconnoctorfrom theSRSmainharn ss 3 Disconnect the SRSmain harness18Pconnoctor from the SRSunit Oo not disconnect the specialtool 2 0 taomthe SRSmain harmaa2Pconnector 4 Checkresistancebetwoontermin9ls No 1 and No 13of the SRSmain harness18Pconnector TheroghouldbeaDorox 2 0 3 0o b tho roaidanca r aDacifi...

Page 1359: ...sct th6 oositivecable andwait for three minutes 3 Disconn ct the driver sairbtg 2P connectorfrom the cablereel2Pconn6ctor CAUTION Do not disconnost tha p r3ong t s rirbag connoclor 4 Connectthe SRSserviceconnector 2 O to the cablereel 2Pconnector 5 Reconnect the batterypositivecable then reconnectthe negativecabl 6 Erasethe DTCmemorylseepage23 289 7 Readthe DTC seegage23 2aiL 3DTC1 4indicrtod YES ...

Page 1360: ...move thespecialtool 20 from theSRSmainharness 2Pconnoctor 4 Disconnect the SRSmain harness18Pconnector lrom tne stts untr 5 Reconnectthe battery positivecable lhen reconnoctthe negativecable 6 Connecta voltmeter betweenthe No 1 terminal of the SRSmain harnessl8P connectorandbody ground 7 Turn the ignitionswitchON ll and measure voltage Thereshouldb6 0 5v or l ss 8 Tr rrn the ignitionswitchOFF 9 Co...

Page 1361: ...t forth oe minutes 3 Disconnect the driver sairbag2P connoctorfrom the cablereel2Pconnector CAUTION Do not disconnscttha pt 3onga t rirbrg connoctor 4 Connectthe specialtool 20 to tho cablereel2Pconnec_ tor 5 Reconnect tho batterypositivecablo then reconnoctthe negativ cable 6 Erasethe DTCmemory seepage23 289 7 Readthe DTC seepag623 2871 k DTC1 5indicated YES NO Sho t to gtound in tha drive s ri6a...

Page 1362: ... 1 Disconn ctth baftery negativecable thon disconnect the positivecable andwait tor three minutos 2 oisconnectthe front passengor s airbag2P connector trom the SRSmain harness 3 Remove thespecial tool 2O tromtheSFSmainharness 2Pconnector 4 Checkresistancebetweenthe No 1 terminal of the SRS main harness18Pconnector and ground and between the No l3 terminalof the SRSmainharness 18Pconnec tor andgrou...

Page 1363: ...inutes 3 Disconnectthe front passonger sairbsg conn ctortrom the SRSmain harness s6 paoe23 285 4 Connectth6 sDecialtool 2 o lo th6 SRSmain hatnoss 2Pconnoctor CAUYIO Oo not ditconn ct th drivo t ritb g conn c tor 5 R6connedthe banery positivecablo then r6connecttho negativecabl6 Erasetho DTCmemory s6opage23 289 Readthe DTC seepage23 287 Try to raproduc th SRSindicltot light 1 Er6s6th6 DTCmemory se...

Page 1364: ...8Pconnector from th6 SRSunit Do not disconnect the specialtool 2 O fromthg SRSmainharness2Pconnector 4 Check resistance betweon the No 10terminalandNo 14 terminalof the SRSmain harness18Pconnector There shouldbe 2 0 3 00 Wiresideot female termtnals SRSUNIT Poor contact at tho SRS main harna3r 18Pconnoctor ch ck tho connoctor It th conn ctor ii OK 3ub3titut6 a known good ShS unh lnd r check It tho ...

Page 1365: ...ct thepositive cable andwaitforthreemanutes 3 Disconnect the front passenger s 6irbag2P connector romtheSRSmainharness seepage23285 4 Connect the special tool 2 0 to the SRSmain harness 2Pconnector CAUTION Do not disconnectthe drive s i bag conn c_ tor 5 Reconnect the batterY positive cable then reconnect the neoative cable s i M t HIArfss 2P r t cTd FNO ITPASSENGER S AIRBAG 2t tat ccTon lntermitt...

Page 1366: ...rbsg 2P connectortrom tho cablereel2Pconn ctor 3 Disconnect ths SBS main harn6ss18Pconnectorfrom the SRSunit Do not disconn cttho spscialtool 20 trom the SRSmsin harness2Pconngctor 4 Checkresistanco betweenth6 No 10terminaland No 14 terminalof tho SRSmain harn ss 18Pconnector Thgre shouldbs spprox 2 0 3 00 b tha a nanca aarpaclfiad YES NO FrultySRS unit r plrc rh SRS unit1 p s 23 326 Shon to anoth...

Page 1367: ... thb timo SoeTtoubl shootinglmormittent Failuraaon P ge 23 289 Ch6cktor a 3hon to powol in tha pa3tonga t lirbag infla_ to 1 Turnthe ignitionswitchOFF 2 Disconnectthe battory negativecable then disconnect the oositivecable andwait tor three manutes 3 Disconnect the front passenger s airbag2P conn ctor IromtheSRSmainharnoss seepage23 285 4 Connect the soecial tool 2 0 to the SRSmain harness 2Pconne...

Page 1368: ...emoveth specialtool 2O from the SRSmain harness 2Pconnector 5 Reconnect the batt6rypositivecable then reconnectthe negativecable 6 Connecta voltfieter betweenthe No 10 terminal of SFSmainharness 18Pconn6ctor andground 7 Turn th6 ignitionswitchON ll and measurevottage Thereshouldbe0 5V or less 8 Connecta voltmeter betwoenthe No 14 terminal ol the SRSmain harness18Pconnector and ground and measure t...

Page 1369: ...di catorlight comeson for aboutsix secondsand then goes off Doo6tho SRSindic tor light stay on Chgcktor a short to ground in the Pa t ngd 3 tirbag inflttor 1 Tlrn theignitionswitchOFF 2 Disconnect the batterynegativecable then disconnect the oositivecable andwait for thr 6 minutes 3 Dis onnectthe front passenger s airbag2P connector fromtheSRSmainharness seepage23 285 4 Connoct the special tool 2 ...

Page 1370: ...lereel2Pconn6ctor 3 Disconnect the SRSmain harness18Pconnector trom thesRs unir 4 Bemove thespecial tool 20 fromtheSRSmainharness 2Pconnector 5 Check resistsnce between the No l0terminaloftheSRS main harness18Pconnector and ground and between the No l4 terminalof theSRSmainharness 18Pconnec Thereshouldbe 1M0 or mor SRSMAIN HARNESS 18PCONNECTOR SRSunit r pbco th SRSunh lsoo Short to glound in th6 S...

Page 1371: ...eftcodefor the radro then write down the frequenciesfor the radio s pre set buttons 2 Disconnect the batterynegative cable then discon nectthe positivecablefrom the battery and wait at leastthreeminutes 3 Disconnecting the airbagconnector s Driver sSide a Removethe accesspanelfrom the steeringwheel then disconnectthe 2P connector betweenthe driv er sairbagandcablereel NOTE When disconnected the ai...

Page 1372: ...o that it is not pincbedor interferingwith other parts 5 Install the newairbag s Driver s Side Placethe driver s airbag into the steering wheel andsecureit with newTorxbolts TORXBOLT 9 8N m 11 0 kgf m 7 2tbf ft TORXBOLT 9 8N m lt o kgt m 7 2lbf ftl Reptace U36a Torx T30 bit Front Paseenge s Side Placethe front passenger s airbaginto the dash bosrd Loosely installallfour mountingnuts Tighten the up...

Page 1373: ...llthe accesspanel on the steering wheel 23 319 7 Connectthe bafterypositivecable then connectthe negative cable After installingthe airbag confirm propersystem operal on Turn the ignitionswitchON ll the SRSindica tor light shouldcome on for about six seconds andthengo off Makesurebothhornbuttonswork Takea testdrive and makesurethe cruisecon trol switches work Entertheanti theft codefor the radio t...

Page 1374: ...t from deployment 1 Disconnect the batterynegativecable then discon nectthe positive cable 2 Confirmthatthe special tool is functioningproperly by followingthe checkprocedureon the label on the tool or on page23 321 Driver sAirbag 3 Removethe accesspanel then disconnectthe 2p connector between the driver sairbagandthe cable reel DRIVEE S AIRBAG CABLEREEL 2PCONNECTOR AirbagDisposal Oit ER SAIREAG 2...

Page 1375: ...ghas beenremovedfrom a scraDDed vehicle or has beenfound defective or dam agedduringtransit storageor service it shouldbe deoloved asfollows Positionth airbaglaca up outdoorson tlat ground at l astthirty leet 10m ftom any obstacles or people 1 Confirm thatthespecial toolisfunctioning properly by tollowingthe checkprocedure on thls pageor on thetool lab 2 Followsteps5 6 7 and 8 ol the in vehicle de...

Page 1376: ...ou havethe anti theftcodefor the radio then write downthe frequencies for the radio spr setbutton 2 Disconnect the batterynegative cable then discon nect the positivecablefrom the battery and wait at leastthreeminutes 3 Removethe accesspanelfrom the steeringwheel thendisconnect the 2Pconnector betweenthe driv er sairbagandcablereel NOTE Whendisconnected the airbagconnector is automaticallv shoned ...

Page 1377: ...e steering wheelfromthe column Remove the steering columncovers UPPER COLUMN COVER 8 HORNCONNECTOR 1 0 Disconnect the 3Pconnector between the cablereel and mainwire harness and removethe 2Pconnec tor between thecablereelandSRSmainharness CABLEBEEL CABE R EL 2PCONNECTOR 11 Removethe cable reel fromthecolumn cont d 23 323 ...

Page 1378: ... the cablereel projections GROOVES Carefully install thecablereelon thesteering column shaft Thenconnectthe 2P connector to the SRS main harness and connectthe 3P connector to the mainwire harness CANCELS SLEEVE CABLEREEL 13 CABLEREEL 23 324 Install the steering columncovers lf necessary centerthe cable reei New replace ment cable reelscome centered Do this by first rotatingthe cablereelclockwise ...

Page 1379: ...ibag 2P connectorto the cable reel 2P connector and reinstSllthe access panelon the steering wheel 20 Reconnect the batterypositivecable then the nega tivs cable 21 After installingthe cablereel confirm propersys tgm operation Turn the ignitionswitchON ll the SRSindica tor light shouldcome on for about six seconds andthsn go off Makesurs both horn buttonswork Makesure the headlightand wiper switch...

Page 1380: ...tery andwait at leastthreeminutes Disconnect the airbagconnectors Whendiscon nected the airbagconnectors are automatically shorted Driver sSide Removethe accesspanel from the steering w h e e l t h e n d i s c o n n e c tt h e 2 P c o n n e c t o r betweenthe driver sairbagand cablereel see page23 285 Front Passenger s Side Disconnect the 2P connectorbetweenthe front passenger s airbagand SRSmain ...

Page 1381: ... surethecoverssnaptogetherin the middle 8 l 10 Reconnect the driver sairbag2P connectorto the cable reel 2P connector then reinstallthe access panelon the steering wheel Reconnect the front passenger s airbagconnector to the SRSmainharness Reconnect the batterypositivecable thenthe nega tivecable Afterinstalling the SRSunit confirmpropersystem operation Turnthe ignitionswitchON ll the SRS indicato...

Page 1382: ...AEUl A II ITEGFIF trical Troubleshooting98 OO ...

Page 1383: ...s Hatchback l l0 2 Sedan 110 4 Headlights 1 10 8 Headlight switch 100 Heater Airdelivery 61 Blowercontrols 60 Fans withA C 63 withoutA C 63 2 Horns 40 lgnilion keyreminder 73 lgnition system 20 204 lmmobilizer system 00model 132 lndicators 80 Integrated controlunit 70 Interlock system 98199models 138 00models 138 1 License platelights Hatchback 110 12 Sedan 110 13 Lights on reminder 73 Lowfuelindi...

Page 1384: ...electrical problems Circuit schemalics break theentire electrical system intoindividual syslems liketheLowFuelIndicator Lightonthenextpage Onlyelectrical components thatworktogether areshown together soyouwon tbedistracted byunrelated wires Explanations oftheabbreviations andsymbols usedintheschematics begin onpageE You ll needto knowwhattheymeanbefore youcanuse a schematic effectively ...

Page 1385: ...d intothe connector housing Wiresareidentif iedbytheabbreviated names oftheircolors thesecond coloris thecolorofthestripe Wiresarealso identif iedbytheirlocation ina connector Thenumber 2 nexttothemaleand female wireterminals atC416 for example means thoseterminals joinin cavity 2 ofconnector C41 6 A complete description ofschematic symbols begins onpage O Arowhead means wire connects to another c...

Page 1386: ...of Power Distribution however shows thewiring upstream between thebattery andthefuses f ro unE l i il i v g o FUSE 15 Page 10 7 1 hTt r r T r L J I ruse re I ruse zi ru rE ro a v E t ELECTRTCAL rc PowER sEAr iOA6 I I REcuNrNG I gs r qqrg l I ELD Ul r L J lll3l f t l r f 1 ALTERNAToR tL_Jii1 Distribuiion pago 1G7 SLK BATTERY STARTER BLK 4 t t l STARTER SOLENOID I I G1 BODY r I I I FUSE 1O 754 SgePo...

Page 1387: ...wthefuseisgoodandpower isavailable to theinooerative circuil o l I I FUSE 15 204 UNDER OASH FUSE RELAY BOX FUSE23 10A I O I I l 1 c 7 r I YEL l sHrFT r I LOCK I I SOLENOID L J Page 138 PHOfO2T I lFEt o L J SWITCH Automatic Transmission Page110 13 l PHaro 62 I YEL I zI czra r lclocK l i1 o L J c408 r l HAZARD I t3 S t i L J Page110 8 I c564 1 AUTOMATIC I SEAT BELT I CONTROL J UNIT Page 146 YEI r I ...

Page 1388: ...TS LIGHT Page110 7 Page110 8 Page110 5 Page110 8 Page110 5 Page110 7 Page110 7 r r r t t t l t t t r r r t r t r r r I LICENSE LIGHTS I Page 110 6 l uo O O l L J 1 FUEL PUMP Page 23 1 l l t l LEFT REAR stoE MARKER LIGHT Page 110 7 POWER ANTENNA MOTOR Page 151 t l l l E_ a al J L c549 t HIGH MOUNT BRAKE LIGHT Page 110 9 t t l l REAR wtNDow WIPER MOTOR Page 92 t l l l iIn a I ra T G601 FUELTANK UNIT...

Page 1389: ...LYI r t l L J L r l l l l l O ot i l l I CRUISE I CoNTROL i u t lfthereisnophotonumber below orbeside a connector ground orterminal number lookup thatconnector ground orterminal number intheappropriate Connector ldentification Chart Thechartwilltellyouthecolorofa connector howmanycavities it has whereit slocated andwhatcomponent or harness itconnects to Onthepageopposite thatchartyou ll findan ill...

Page 1390: ...or fortheproblem Example Thehorn A C andtherightheadlight don twork Listallin line andfusebox connectors inthehorncircuit andthencheck thechart sample below YoufindthatC211is common totheA C circuit andtheheadlight circuit soyouinspect c211andfindtheproblem bentterminals Connector 6or more cavities Numbel of Cavities Color 1O GRY I 12 GRY I Wire Harnesses I Main ComPer ror c ntrols I Dashboard I C...

Page 1391: ...ts listed i l i UNDER DASH FUSE RELAY BOX Wires A wavylineattheendof a wrremeans thewireis broken bythebinding of thebookorbya choice bracket butcontinues on thenextpage Wireinsulation canbe onecolor oronecolor withanother colorstripe Thesecond coloris thestripe Thiscircuit continues on another page Thearrow showsdirection ofcurrent flow Tofollow theRED BLKwireinthisexample youwouldturnto page23 5...

Page 1392: ...ismeans theconnector connects to a lead pigtail wireddirectly tothe component Thissymbol represents one busbarinsidethecapof a junction connector A Lrh t nn torcap I contains several busbars A butonlytheoneaflecting thatcircuit willbeshown f Thedots represent tabs on al thebusthat thewire 2 il i I Remaining wiresto see Gauses thesamebusbars arerepresented by a broken line Splices SDlices areshown ...

Page 1393: ...rame Thissymbol represents thebusbarinside a ground connector Thedots a i r nn l L I I I lermtnals connectto t Theground symbol large dot Gsoo istheconnection between the busbarandmetal grounded partof thecar Terminals T m ffi Solid state Fuses Thismeans powerissupplied whentheignition switch isinON ll Diodes A rectifier diodeworkslikea one wayvalve lt allows current to flowonlyinthedlrection ofth...

Page 1394: ...s andsafeprocedures 5 MakeSureTheCircuitWorks Turnonallcomponents intherepaired circuit inallmodes to makesureyou ve fixedtheentifeproblem lftheproblem was a blown fuse besuretotestallofthe circuits onthat use Makesurenonew problems turnupandtheoriginal problem doesnotrecur TestEquipment CAUTION Mostcircuits include solid state devices Test thevoltages inthese circuits onlywith a 1o megaohm orhigh...

Page 1395: ...tequipment shown above contact yourlocaltoolsupplier Fora listof suppliers andtoolnumbers referto Acura Required Special Tools andEquipment Service Bulletin Troubleshooting Precautions BeforeTroubleshooting 1 Check themainfuseandthefusebox 2 Check thebattery fordamage stateof charge andcleanandtightconnections CAUTION Donotquick charge abattery unless the battery groundcablehasbeen disconnected or...

Page 1396: ...e A lossof morethanonevoltindicates a oroblem NOTE Always usea DVOM onhigh impedance circuits A testlightmaynot glow even withbattery voltage present connecthe e fl5Bi lL L t i El L t r f Qli soLENo D I Connect here I l lll I 3f 3JiEx ljlu r o I Testingfor Continuity Whentesting forcontinuity ata connector without wireseals youdonothaveto separate thetwohalvesoflhe connector lnstead orobe theconne...

Page 1397: ...lem Check the circuit forloose dirty or bentterminals sl o o o EEO p t t Testingtor a Short to Groundwith a Test Lightor DVOM 1 Remove theblown fuseanddisconnect theload 2 Connect a testlightordigital volvohmmeter DVOM switched totheappropriate DC voltsrange across thefuseterminals to makesurevoltage ispresent Youmight havetoturntheignition switch to ON check theschematic to see _ SHOFTTO GFOUND t...

Page 1398: ...iggle the harness Continue thisatconvenient points aboutsixinches apart while watching thetestlightor DVOM lftheself powered testlightgoesonor theDVOM displays a lowreading orno reading zero thereisa short to ground inthewiring nearthatPoint SELF POWERED TEST LIGHT or DVOM A 5 Testinglor a Shortwith a ShortCircuit Locator ShortFinder 1 Remove theblown fuse Leave the batteryconnected 2 Connect thes...

Page 1399: ...ing atthefusebox slowly move theshortfinder alongthecircuit wiring Themeter willshowcurrent oulses through sheetmetalandbodytrim As longasthemeterisbetween thefuseand theshort theneedle willmovewitheach current pulse Onceyoumovethemeter pastthepointoftheshort theneedle will stopmoving Check thewiring and connectors inthisareato locate thecause oftheshort tr Li ...

Page 1400: ... Torearwireharness c503 Spare fuse r Not Used O Option B O Option Dashlights O Option ACC O Option lG2 c439 Tomainwireharness 6 n Fl r r r r rl r l r r ri r 1Tl rl r 1 23 24 25 26 27 2a 29 30 31 32 33 t_ 1 u u tJ LJ Ll t Ll tJ l tJ r l n T l T l r t T 1T tr l T tr l r 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 A 2 1 2 2 LI tJ LJ LI tJ I J t J tJ IJ IJ IJ I J r r Tl l t T l T l T 1rn r l T tr l T1 Tl r 1 ...

Page 1401: ...Driver s window motor 120 2 i120 H B iot 120 2 l Sedan i120 H B l0 120 I J 1 3 TURNLIGHTS FUELPUMP SRS UNIT Sedan lo 2 Hazard warning switch 1O 2 PGM FI mainrelay SRSunit I 1 4 I cRUlsE coNTRoL 7 5 10 3 Cruise control ALTERNATOR SPSENSOR 7 5 10 3 Alternator ECMor PCM 00Model ELDunit Gauge assembly PGM Fl TCM 98 99 Modelwith A f Vehicle speed sensor i REAR DEFBOSTER i i RELAY i 10 6 i ABScontrol un...

Page 1402: ... Clock Gauge assembly Integrated control unit Interlock system Maintenance reminder unit Frontwiper washer 26 i FR W PER I FRWASHEB 27 crcnnerre i LTGHTER 28 i RApro i 1 0 i Cigarette lighter 10 s i Stereoradio cassette player 30 I INSTRUMENT I LIGHTS 2e RR FocLtcHT z s 7 5 t l 3 1 i STARTER STGNAL 21 21 1 1 32 i LTCENSE LtcHrS I i TAIL LIGHTS i i 1 0 0 1 i rNrER LocK uNrr l I I 114 Dash console l...

Page 1403: ...iew T102 Ooengine wireharness NotUsed Rear View c2l5 Tomainwireharness T1 ro battery c905 ro F C compressor clutchrelay c2t8 fo mainwire harness Oomain cont d D3 tr tr J r 1 IJ r t IJ r 1 51 LI r 1 56 IJ r l 57 LI Llo wireharness 6 3 ...

Page 1404: ...ntenance reminder unit Stereo radiocassette player TCM 98 99 Models withA T 7 5 10 8 I HEADLIGHT 40 10 8 Headlights Interlock system A T 49 i DRLOCK i suNRooF 10 9 i Moonroof I I RRDEFROSTER B SMALL I Rear window detogger relay I Dash andconsole lights License plate lights I Rear parking lights Taillights I HORN STOP i HAZARD 10 9 Brake switch Hornrelay i Gauge assembly 00Model Hazard warning swit...

Page 1405: ...mainwireharness Fuse Number c903 OoABSpumprnotor relay FuseName ABSMOTOR FUSE ABS82 ABSUNIT Component or CircuitProtected ABSpumpmotorrelay ABSfail saferelay 10 10 Notused I Notused i ABScontrol unit Il f l f l f l CI IC T5 Tobattery rJO 6 5 ...

Page 1406: ...tte lighter Clutchswitch M T Ctock Ctutch interlock switch MfD Combination wiperswitch 2wires Cruise control mainswitch Cruise control unit Dash lights brightness controller Data linkconnector Daytime running lights control unit Canada Front passenger s doorkeycylinder switch Front passenger s doorlockswitch Gauge assembly 2wires Glove boxlight Heater controlpanel Heater tanswitch lgnitionkeyswitc...

Page 1407: ...unded Stereoradio cassette player ABScontrol unit GND1 andGND2 areBLK GND3 andGND4 areBLKWHT Highmount brake light Rear window wipermotor pluseverything grounded through G503 i Rear window delogger G801 l u s l SRSunit 2GRNwires UO rio 6 7 ...

Page 1408: ... DALOCK su BooF 304 FUSE 50 OEFFOSTER ruse srI BsuaLlI I I WH BLK SeePower Distribution pages1Ggand10 9 c432 I BLK WHT I Mff BLK wHr c432 __ x c922 FUSEI8 aurxf G IIGHT RE AY 7 54 FUSE 27 C GAAETTE LG T ER 104 FUSE 28 RADIO f r l SeePower Distribution page10 6 SeePower Distribution page 0 5 E I I L STARTER CUTRELAY Page 21 1 ToFuse31 tordetails seeStarting System pages 21and21 1 SeePower Distribut...

Page 1409: ...SOR IFAN CLUTCN I I RELAY I I RELAY L J Page63 L J Page 62 l UNOER i i I ruser rusez rusEo I if99Ff i s lil l r I ii At L J lLg J 9Yl 1 j se Power l l 3 I f tot Diskibution ubEu uJcv B page10 2 c922 UNDER DASH FUSE RELAY BOX PHOfa 58 rarra t i t FUSE st FusE 3 I dcr rFRwtPE tG nn WIPEF fis fllo o I FUSE 12 TUfN LIGTITS r0A FUSE I5 ALlERNATOf sP sENSoa 7 tA FUSE 19 BACK UP UGHTS t 5a FUSE24 REIAY r...

Page 1410: ...l oe presentIn allcars a wHr GBN I 11 1 uA u a l l PHO ll BLu r vHT I 138 1 I cs31 lI t I r _t r t t t l I t t I L J t J HATCH HATCH OPENER LATCH RELAY Page134 Page134 pHora138 106 c526 GFN c506 c755 cs63 5 r I I c446 7 C804 t J L J PGM FI SRS MAIN UNIT RELAY Page47 Page23 PHoro 6z 98 99 or 24 00 1 I I I I J l l l l REAB coMBr wtNDow NATION WIPER WIPER MOTOR swtTcH Page92 10 2 o 4 lo 2 Page92 ...

Page 1411: ...i c7s3 l rro i 4 0 1 s112 izs rz lf f r A czgs zlczzq i zAcrgq 2Ac1 t2 25X A c420 1Ac2r8 l i l ii l ii l ii l ii i l r t I I t l r l l l l l a l L i L r I L j r L r i i r l EVAPORATIVE EVAPORATIVE IHTAXC VEHICLE TRANSMISSION EIEqTRICAL EMISSION EMISSION AtR SPEED CONTROL o49 BypASS SENSOR MODULE fiCM 9 ie vfD F Afl iiiirss 9F lIioR l oDtllEficM l LTl9 r f I bvpads aoNThoL i rAat vss Pase 3s1 i ELD...

Page 1412: ... tif H q PHOTO6A I I I I I 1 6 c55l 17 C801 Not PffOtO 60Used c439 11 c438 L J 1 0 YEL GFN Not 2 Used I I c66t Allexcept USARS SECURITY SYSTEM CONNECTOR oPTroN ifij l l l l BACK UP LIGHT SWITCH Pages 1 1 0 1 1 01 and 118 L 36 r I I A T GEAR POSITION SWITCH Pages 1 1 0 1 1 0 1 a n d1 1 8 10 4 sRs UNIT Page 47 MOONROOF RELAY Page122 ...

Page 1413: ...FT LOCK SoLENOIO Paqe 13B 98 99 or1381 00 I PHQ O 124 o n Czt38 t 33r o j I i sn 1 Pase 1ss I I T I u 1t Iu c55t 1 Cs57 4 I I L J L J CLOCK GAUGE Page154 ASSEMBLY Pages80 80 2 81 83 and89 PHOIO47 Not 5 Used GBN BLK I I c559 l I I 1 r 1 r 1 I I l 1 WIND SHIELD WIPER MOTOR Page 91 1 t J L J MAINTENANCECOMBI REMINDER NATION UNIT WIPER Page83 SWITCH pHoros2 Page91 STEREO RADIO CASSETTE PLAYER Page 150...

Page 1414: ...UNNTNG oEFoccER uNrr DEFoccER swtrcH It LtcHTs SWITCH Page 44 RELAY paoe 141 I CONTROL Page 64 pHoro 1oo Page 64 or i41 t Uttf PHoro111 sedan pHoro5a j Page 110 9 l c a n a d a i t rarffi JI f t u 1 t 1 r BLK YEL BLK YEL ml r A 1 t 1 t l BLOWEN MOTOR BELAY Page 60 Pttofo 22 rF l t l t l Atc UNDER DASH FUSE RELAY BOX c677 L J J L J A C MODE HEATER THERMOSTAT CONTBOLCONTROI Pages 62 1 MOTOR PANEL an...

Page 1415: ...i HTFEDI i I t l i 1 i n ol N 1 I ii ffirT l i i l l l f r i i 1 i n I li i i I i I rTt ff ih r iwnrneo l wHrREol wHrFEDl I I I i t l ll l r l I I I n a a a a i t i a 3 l 3 1 I I I I a PHoro o I J J L J L J L J SpOTLtcHTS CEIL1NG TRUNK pOWER UNDER DASH eaoelti z I LtcHT CARGO ANTENNA FUSE RELAY Box eige tt z AREA MoToR PHoro 58 faQe 114 2 AIIEA M J rrl tl cii Floil sr Page114 3 pHoro 1as ToFuses7 ...

Page 1416: ...r o I rrr 1 l t l STEERING LOCK Page 138 98 99 or 138 1 f00 N r c452 wHr BLU 00 Model 16r WHT BLU I RS 7 WHT ALU I Y L 2 lt c415 i i t t I l I i olwrme RUNNING LIGHTS I CONTROL uNrT Page1 10 9 Canada 98 99 N 4odels BLU 4 A C566 l t l l STEREO Page 4 A C56 l t l l STEREO RADIO CASSETTE PLAYER Paqe 150 z t l r 7 l N t l i t t aru f wnlalu I wrrier u I o uu ou o oo r 1 r r 1 t r t t t l t t t t t l L...

Page 1417: ...GRN t c418 i 00 4odel ru i _t i 1 cont d L c661 c662 WHl GFN WHT GFN c563 12 cseoi z c448 Cruise 2 o I caeo l c431 1 ia t l L J t 1 t l BRAKE swtTcH Pages23 6 98 39 24 6 00 34 1 39 98 99 39 4 00 44 t 106 110 7 138 98 99 and 138 1 00 PHOTQ129 iF 1 MOONROOF RELAY Page 122 REAR wtNoow DEFOGGER RELAY Page64 HORNRELAY Page 40 L J GAUGE ASSEMBLY page80 coMBr NATION LIGHT SWITCH Page100 HAZARD WARNING sw...

Page 1418: ...ponents cont d FromA on page10 WHT srr i UNDER HOOD ABS FUSE RELAY BOX FUSE 63 ABS82 154 FUSE 62 ABS81 204 t FUSE 61 ABSMOTOR f Y l c9o3 r 1 ABSPUMP I uonracrs I MOTOR i RELAY L___ j Pase 443 c2t3 NotUsed c20a ABS FAIL SAFE RELAY Page44 2 10 10 ...

Page 1419: ... odel inrra r er r ni I I G S R TYPE R VEHICLE SPEED SENSOR RADIATOB FAN SWITCH and 63 2 t l t l L J cl08 vss Page PHATO6IIITJ I I 33 I I c3o1 1 0 Ground Distribution NOTE Wires shown without colorcodes areblack VALVE COVER I I G1 G2 G3 andG101 I I T3 BATTERY Page 10 r r t l l l n I I I I I rl I I I I F to o _ l 1io o o 1 4 ...

Page 1420: ...TED OXYGEN SENSOR TDC HO2S CKP SHIELD CYP Paqe23 4 SENSOR 96 99 or SHIELD 244 00 Page20 BRN BLK CRANK ne_F SHAFT ii pilp i SPEED FLUCTUA CKP CYP SENSOR SHIELO Page20 l 1 l l k T O N K N O C K cKF SENSOR SENSoR KS SHTELD SHIELD paoe 23 2 Page 23 6 96 99 or 98 99 or 242 OOt 24 6 00 r f l i l iiL l r t t t l o BRATDED I WIFE I l l t l k a ill BFAIDEO WIBE BFAIDED WIRE AF CRANKSHAFT SPEED FLUCTUATION ...

Page 1421: ...RIGHT FRONT PARKING TURNSIGNAL LIGHT Pages110 3 1105 and 1 1 0 1 1 ABS FAIL ABS SAFE PUMP RELAY MOTOR Page44 2 Page 44 3 PHO A 7 PHOIA 5 1 r 1 I t t I I t t I UNDER HOOD FUSE RELAY B O X U S A PHAfa 21 BLowER aoAb MOTOR DETECTOR RELAY ELD UNIT Page60 Peq e 22 PIIOTO 22 PHOTO2S r 1 1 t I g ri i l J Yc 7 2t c218 a Y i l J G201 I A A i LY___ jj c206 1 Y C204 l J L J L J 4 I C208 2Y C210 14 2 Pll ...

Page 1422: ...ITCH Page23 6 I Pages44 1 98 99 or 71 and71 1 24 6 00 PHOTO35 PHATA33 r 1 r 1 I l l t t l t WIND SHIELD WASHER MOTOR Page91 t l 2 Y C317 LEFT HEADLIGHT Page110 8 LIGHT MARKER Pages110 3 MOTOR LIGHT 110 5 and Paqe91 P a g e 1 1 01 1 1 1 0 1 1 1 1 0 5 Page91 1 I I I I CRUISE CONTROL ACTUATOR Page34 2 l l Hatch back I nean wtNoow WASHEB MOTOR Page92 I l t t I i ly I 2 Y c a i 8 a c308 3A G301 14 3 ...

Page 1423: ...i PHOTO 76 L__J I l I I l l l o o FRONT PASSENGER S A T DOOR KEY FRONT PARKPtN CYLINDERPASSENGER S SWITCH SWITCH OOOR LOCK Paqe 138 Paqe 130 SWITCH I ge ggtor i or130 2 Paget30 138 1 C00 PHafa o6 or 130 2 pHaro 12a r 1 r 1 I l I t tT t i LrJ I z l t or tY u Yk91i t I zi a I I I I l E r l 1i NOTE Wires shown without colorcodes areblack c403 STEERING LOCK Page73 i Y PAIA LT i i p nron i ffi ro Switc...

Page 1424: ... S GLOVE BOX LIGHT I Page 114 l l l t MOONROOF swtTcH Page122 t l l l 2 Y C664 I F Oerminals 5 10 c661 PHOfA 58 TURN SIGiIAU POWER HAZARD WINDOW RELAY RELAY INTEGRATED paoes11G2 Pages 120 CONTROL ani tt0 and120 2 UN T HOTO O PHOTO PNO O 62 r 1 r 1 1 c 4 5 o l l J c439 COMBINATION WIPERSWITCH Pages9l l r 1 t l l l L J 5 Y C437 l UNDER OASII FUSE BELAY BOX t l t l t l l l c926 1Y C92s 14 I coHuecron...

Page 1425: ...H i I F g u Pages 120 2 120 3 i I anoer 1204 and120 5 I photass t t l t I t l l t I L J l L J fl ll 31 0 r PowER j oRven s OOOR LOCK DRIVER S DOOR KEY CONTROL DOORLOCK CYLINOER UNIT ACTUATOR SWITCH Page 130 1 Page 130 1 Page 130 1 or1303 or130 3 or130 2 Pnofo u PFofo PtaQfoS5 r 1 r 1 l t t t t t I I I t FIFFTo lTl lili a a a o a o a I l _ i l _ _ _ NOTE Wires shown without colorcodes areblack BLlv...

Page 1426: ...Page 110 110 12 1 1 r r 1 1 f t t _r _r r LLIJ L L I REAR wtNDow WIPER MOTOR Page 92 t l PHOTO108 PHOTO148 HATCH LATCH Page114 3 t I l l t l cnv I 1 g c52a HATCH OPENER SWITCH Page134 HATCH OPENER ACTUATOR Page 134 HIGH MOUNT BRAKE LIGHT Page110 6 t l t l 1 g c756 2 I GSand I GS R l r l t G S YF o I a 1 l z I I L ALU 1 atu 1 REO c527 PHOfO 106 HATCH KEY CYLINDER swtrcH Page130 c530 PHA O 137 BLU 1...

Page 1427: ...RIGHT INNER BRAKE LIGHT TAILLIGHT Pages110 7 and110 13 RrcHr l c r rqlt iTfi iff iilt i b 1 0 ii3 3 i3 lts rllr TRUNK LATCH swtTcH Page114 3 t l t l 2 Y C535 RIGHT BACK UP LIGHT Page1101 LEFT REAR TURN SIGNAL LIGHT Page110 5 LEFT REAR PARKING LIGHT Page 1 1 0 1 3 LEFT OUTER BRAKE LIGHT TAILLIGHT Pages1 10 7 a n d1 1 0 1 3 98 99 Model Not useo cs22 HIGH MOUNT BRAKE LIGHT Page110 7 t l REAR wrNDow D...

Page 1428: ...SER FAN MOTOR Page63 t l cl5s STEREO RADIO CASSETTE PLAYEB Page 150 1 t l l l 1 4 ABSCONTROL UNIT Page 44 1 PHO O 100 PHO O 111 Sedan t l t l ctst cssr L J z v v czoe 1 i lt c704 G702 14 9 REAR WINDOW SRSUNIT OEFOGGER Page47 Page64 PHoro 67 r 1 Y c771 G7 1 G80l PHOfO 116 PHOTO67 ...

Page 1429: ...pCMor ECM I g oc et cj P n lciPP lproro t gesgi L _ 4_____ _ __ j pdora t4o toa 98 99l 4ooels _j I u n t jl Jt r 4 Lf 1 I g u L i I rr s 3 f l_ f f L f E i l I A 2 r _ _ _ OFNi 8LU II LT8LUor I BLU GRN o A c F o i F to l PlugWires lg 11 ct og SparkPlugs Y rV Vt WHT BLU ll BLU YEL I wHT 1 L rrl __ Ll oo cr3 c12 a POWERTRATN DcMr rckp M icrb6 or ENGINE uensor Sensor Sensor i coNTRoL ground ground gr...

Page 1430: ...98 s920 Y C40898 s9 13 ll c457 YEUGFN o 98 99 Models BL J 7 ALU c103 cl 09 DISTRIBUTOR ASSEMBLY c418 Terminals 18 20 c452 cl27 BU 9 BLU 7 BLU d c301 JI fil TEST r i I GAUGE lraiii ol3 sseqarv l m e r e r TACHOMETER CONNECTOR IGNITION colL Power lgnition input slgnal Primary outout Enqine soeed coritrol cround ouiaut RPM 20 l ...

Page 1431: ...Lr Y Htll PHoro 70 04 ts z 1l t t t t t t N A T GEAR POSITION swtTcH ALKFEO t1 EIIVRED BLKFED t 2 I BLK RED 4 BLI FED 1 7 8LK BEO I BLKII HT FUSE 41 BATTEiY r00A T o c413 SeePowet Distribution page10 i J T1 BATTERY c444 NotUsed All excepl USAFS c301 c126 PHOTO36 c440 4 PHO O 62 STARTER rrF 1 i rur r snnrea sour 1 Ir Lg i l l t t l l l r l l L J I r I INTEGRATEoI I CONTROL I I l u N r r I tIbEt _J ...

Page 1432: ...VHT o t 0 i I l I a I I I I BLKA HT II 2 A cqqz 4 u 0 tr t I coee Hifr J r SeeGround I Rl i b 1 PHOIO 56 STARTER CUT RELAY SeePower Distribution page10 T1 PHO Q22 BLK REO BLK BEO a z lt lt a c444 Used c444 Allexcept USA RS SeePolYer Distribution page10 BLK REO 1 ALK WHI c301 c126 PHOTA36 c440 BATTERY STARTER rrF 1 H i r I l i e a I l Lg i r i l l l l l l L J I I INTEGRATED coNrRoL I Ll l l t i UND...

Page 1433: ...Charging System 1 Sl Jlit BATTERY l G l SesPower 98 99 f rodels ALTERNATOR lgnition input Load Ground oulpur 22 ...

Page 1434: ...r a I r I Distribution i sr l l r 1q l GAUGE LAi sg tl _ if so EyBL lvi l8iff lEi I LJ n n t f uut I 3 PHafa 53 UNDER DASH r 1 INTEGRATED c438 Not Used UNDER OASH FUSE RELAY BOX FUSE RELAY BOX PHOTO58 c30 r c 127 22 1 ...

Page 1435: ... 6J C446 YEUELK I YEUBLK 1 3 YEL BLK 1 2 YEL BLK c301 c127 YELlBLK SeeGround Distribution page 14 V I J G 1 0 1 1 0 za 11 c10 M4 A11 aL4 A3 A2 41 vBU lcp2 GFr rNJ1 0NJ2 rNJ3 rNJ4 Battery Power Power e oic rjp ira input Fuelinjector controt L o 23 ...

Page 1436: ...___ i 11 Y C439 l tr F 13 UNDER DASH FUSE RELAY BOX PGM FI MAIN RELAY o BLU wHr i 2 A C446 F I T t PORATIVE I fi ilfl tT t il1 ll fltrt I Hlui 1l cl16 l iL l l i i ll 1Y c7s1 i ff H 1 t Fw l L5 1 2 4 r A A L 4 u o A v u r r i o3 rAJBr 1f r I rAc EVAP Fuel start ng I vatue Purgs conttol PumP InPu I vatue Putgsconttol PumP rrrpur I control solenoid control I valvecontrol I l ENGINE CONTROL MODULE EC...

Page 1437: ...SenSOr inpul input input input cround I t c P I n cKF P ttg i a _ OFN BIU T I i I OBN 4 fi_ ffi f tl BFA bE w RF l i lr f i1f l i t t3 r SesGround BFN BLK TDC ASSEMBLY Ff1 cnaHrsxlrr DISTRIBUTORBLU I TDC I ASSEMBLY I 195 lPHofol6 I Jt t f tir 1 F r o r fi81q1 o iil 23 2 ...

Page 1438: ...round Ground Ground signal voltage input ground valvecontrol I j PGIr rcM vBc1 iMAPD PB B u tuo lJ_ _ _ 1 f f s1oT l r f l I u n l l l J i i qill I L _ t i f i LH L i l I 1 lr ll i I 1 l t l i l tr ir ir R K h J 5 i fB 2 l f i _ rr i 11 I t i t I r t i im WS lj tlLds iil t J Jo il l 1 i 3P q L it FF trr 1 l i PHora2a cont d 23 3 ...

Page 1439: ...sr tr f N N 1 N 1 t THROTTLE I A I ENGINE 7 I INTAKE I FTI PRIMARY POSITIONI I I COOLANT I I IAIR I I I HEATED J l o ff ylEUEE l4l Fl3f35H ii elir l l t l f Iam t I Ho2s il Ul 4 i Ll 4iil 1 H il f I J i V l j iil L1 1 tr l r Jlll lUi son I yliiuH I ylLiWE 13 F lsei b i 3i31i l l 1s 1 I l lglp lf I lll 93 l T Fsrs Gs SENSOB I I ISENS PHOTO17 a PHOTO g 10 I lJJtrtr lJ l i iY r Ljf 11 2 y Ct06 j y C1...

Page 1440: ...istribution page10 3 gLKAVHT I I l fir lt I J r I SeeGround BrK BLK I o o T il o R 12 a a G101 PHOfO2S 1 t GNN ORN BLU c454 PHOfO 93 SECONDARY HEATED OXYGEN SENSOR HO2S EVAPORATIVE EMISSION EVAP CONTROL CANISTER VENTSHUTVALVE EVAPORATIVE EMISStON EVAP BYPASS SoLENOtO VALVE GBN NEO c793 c510 c421 c408 EVAP control canistervent shutvalve conrol r l EVAPbypass I ENGINE CONTROL MODULE EcM 429 so2srrlc...

Page 1441: ...OIO129 i 66g ilti5Xx 15l I PHoroT6 ll 3j l i X io i ry Em dui6 Xf A f i Lt F J I i i li l l scs pP8nu I I I illL Service check Brake I i control connector input switch inpul i wEcpressure fiff ii psp lj rslnpur s cninput ii iiror i switch inpur I fi 6 f FJ t i L t L J tx TJ oo l u 1 i uE i T enroLxl i 1 i rf _ en err I i fi i i T t ilrff iJ rl f SeeABS I 6lt uo F i ffi i 1 I i ll i fr 1f il0 3 i i...

Page 1442: ...lsgicI rPlSr ffi l 3 I i oit ortiut 15f 1 ELD unit inpLrt Fan A ccomrossof I cutrol clutchr6lay i t l Upshift Downshift Barometrb l comparalive pressure Altsmator I Altemator l Aff Ft signal input Shfi sensor svolt P Uneukal VSS Iy C on FR output l I datalin acknowledge outpul ref rence input input input signal signal I i 7 i gn ffi er AFsAr As BAo2oun El ot p i 3 fut tTf tL i 4 r r _ _ r 1I T TL ...

Page 1443: ...LAY BOX I doi __ J PHOfQ21 7 in oro za il SeePower Distribution page 10 2 S ePowel za4 Distribution page 0 8 YEUWHT s cccs YEUBLK I See a rmm h rzer System YEUELK 1 3 YEL ALK 1 2 YEUBLK c301 c 127 T o A o n page 24 4 WHT BLU c101 3 Y iniclr6 zo PHOfO 28 9 l I back up input anpul Fuelinjector controt l r L ______r J 24 ...

Page 1444: ...eetntesrateo i Sf 19 1 iL_ 3____ I tr tfl13 UNDER DASH FUSE RELAY BOX PGM FI MAIN RELAY a BLU vHr ll 2 l C446 ln J t l r HrrF lx w l ril E TL j La zsL c sz 6l r I i Jl c408 1 ffJ r 4t iJi ff3 I I itAcrvl Pcs FIB srs iac EVAP Fuel Srading valve purgecontrol PumP anput control solenoid control valvecontrol r poile Rr Rdi e nc rN E c on rli6fi68 uriiEil edr ri cont d 24 1 ...

Page 1445: ...P icl PD CYPP cKFP c20 c8 c29 c22 n T ff J q i t l _l r l Tl Tl o iBlB t t TF T I T I I 1 I r I l l I j _f I ltl l i l J 14 tt tt jrs r r fu i J lEfrlo l lil ffi___j I f uE T tT tr FY a ig cloe Y 9 2 r l PHoIat6 rr o I D I W H T I B l K l tr f fi9 1 o 3 ft3 3 I lPro o I 1 1 i J ___________ I rtr ili o r fioC M ChP M lcYP M ICKF M S nsor Sensor Sengor CKF ground ground qround fl fi L _ _ _ _ _ _ _ ...

Page 1446: ... vccl MAP eB sG1 I B2o Blo 82 413 c19 c17 c7 I I MANIFOLD ABSOLUTE PRESSURE MAP SENSOR POWERTRAIN or ENGINE CONTROL MODULE PCMo ECM c102 c301 c127 i YEUGRN SeeGround Distribution paos14 1 0 SeeGround Distribution pages 4 and1 1 i L p I lg Ll I I ii5ilr I lGNtTtot coxTnol MODULf 0cM L J DISTRIBUTOR ASSEMBLY cont d 24 3 ...

Page 1447: ... nlli i r U E9l fJ PHo2sr i L 29 Y C408 28 Y Y Y Y Y C409 1 1 1 I ii l tr T T T 1l lFffL t lt I i i I I Tfs r a l tr ft f ft tf s i L J ll n i F r t ffi Li l t Lff ffijL ffi l l l Hs T flffiffipg 1 YC115 ll I I vrzu cnr I gllr o i o n l o Y tt 3 c103 1 Y C120 it 9 GBN BLK 7 GRN BIU c421 I t I 1I cqos P02SHTC Primary HO2S hoater comrol I I I I L 24 4 ...

Page 1448: ...i i tl fu I ii ffilE SeeGround c oroat I Pra a62 r I ifitr 9 C421 I 1 l Trl il ii t 1i lffill i I oisinourion 5rr l tenr n lJ i l i fl liilt ttl i fTiUV i y illlilffi il l i l fH iiln i gr 1 r fu I i l iHtreF Y i J fl JL Aunr ABsoL ntr 3 r I s ii ij ri I rnalonr ot i evnp ionrror evlFoypass I Hbzstredret I ioGno o canister vent solenoid kHiH l1 Fi I control valve controt shutvalve valve control i ...

Page 1449: ... ______ f_t _il ______rJ oo Bi i i I i 1 I MrL I connor scs Service check connector input l 2 Brake switch inpul I I f i ii Ecpressure Hi ii psp i l Ksinput switch input coritiot I swilchinput I fl T J S ii oll t i L J i 3 Y c40e 10 lf c40s 12 l c457 26y c408 z l s a r u a r x I o n I i i I _ _ _ _ _ _ l l 1 A rJ l r i o t i f kt l orr i Tl r I o u il n I 1 1 1wec l i rf rsyr sriF rB i i i t n 1 l...

Page 1450: ...ff o I i input input inpd signal sEnal I i ril g iE i i l i i I i l ifit r a l s n b e e r c c w u E i I X3 1 3 lllJij see ciarsins I 55 system n ryss i T l l i r g 9 lI i r r cnr BLK T 4 Y 943 LrGFN I PHoro 63 i i l uu i I GAUGE leairi llJ_s l4BLY i it l i r L J l A l T E n g i n e s p e e d l i rs ipi i i l q 9 B L l lr r oo 8 rc4s7 J l r 1 L r il H l TFsr 1 f 1 NotUsed iadiror reren F8ilil5 o t...

Page 1451: ... I l li acoNrRoL i J MODULE i is i 9 li S j L J p H a r a l o o l l Vehicle speed input c30t CRUISE CONTROL UNIT t l y g I I i ifi L J ir MAINTENANCE REMINDER UNIT 98 9918 y C409 c452 1 2 I BLK YEL BLK I YEL BLK YEL o o m o d e l G S R SeePower a4 Distribution I ease 1o 3 x l c127 c1 t2 VEHICLE SPEEO SENSOF vss PHOfO26 lgnition input Vehicle spoed output Ground 33 ...

Page 1452: ... bytheBLKwiretoG101 Thespeedometer andother control units inthe circuit supply about 5 voltstotheORNwire The vehicle speed sensor VSS intermittently grounds theORNwirewhich generates a pulsed signal init Thenumber ofpulses perminute increases decreases withthespeed ofthecar Refer totheService Manual Section 23 Electrical forspecific tests ortroubleshooting procedures 33 1 ...

Page 1453: ...input t L _ _ _ _ _ _ J UNDER DASH FUSE RELAY BOX I c 1 2 c551 CRUISE CONTROL MAIN swrTcH 1 c555 neoI I SeeDashand Console Lights 2 LT GFN 2 ITGRN c452 l l _J B 3 7 s itch I Poti ef inout l 19 t rgnluon I input oiaie peoar f 1 depressed f Open with BLK YEL 34 ...

Page 1454: ... c4s1 BLU GFNII l i ll uo n 9EcuRIJY SYSTEMAttexcept 1f cooL tNEcroR usARs 1 9 it __ il__ t STEERTNG a g I W H E E L diiiinlor SET RESUME I swrrcH i I cont d c431 BRAKE swtTcH I l P e l L_ffi___ l 3 Y c431 9 f 9 t or 1 L 0 i iF 5 f Y Terminals 1s 17 L f L J t I e o o 5 1 f 4 c 2 o n Tl irt ouu seeABs PGM FI f o ilb i5o I Brake Lghls Automatic rronrneoI r r onrer xI L __i Tl1T l rI slr i input inpu...

Page 1455: ...rol acluator control BRN FEO I ABN BLKT aRNAA HT rr g 1f rf csoz 1oy s y iio o BFN FEDI BFN BLKf BRN n HT oA_____r_A s__l csrs wxr I sru I PrJic CRUISE CONTROL ACTUATOR 8LK 1 BLK 8LK S eGrolnd a page 14 3 Or Distibution n e l I J PHOTO56 SeeGround Distribution c301 D i m m i n s c r r c u r t l I S i P t o I r I r e r _ 31f seeIndicators J llclultl L Y sLt 95 i f I 3 3 9i To o o 0 2 I g c or D4OIO...

Page 1456: ...lf fj 8Blt Y I r I B L U I l s a c1o9 I or f r orc o 9 f t ot ls Btu I aLU 2 I I c3o6 ii l 4n 1 1 l 00 Model il l cRUlsE I RPtvl input I CONTROL I UNIT Models lPHora 55 I oisengage input Vehicle speedinput r L _ _ _ _ _ _ _ _ _ _ ffcr r i M r PNKI Air I Hf tf c417 f n f I ffs ff oa l i uo u uo 1ff i lu r ii iit diF l 1 i f t 1 ffs ff i f ili I oaoe I ftf ll r i p pT l i J l i i l L itliY b t t non...

Page 1457: ...trolunitresponds byallowing thethrottle to close Theclutch switch ortheA Tgearposition switch sends a disengage signal tothecontrol unit thatalsoallowsthethrottle toclose Thecruisecontrol system willsetandautomatically maintain anyspeed above 25mph 40km h Toset it makesurethemainswitch isonandtheswitch indicator ison Then afterreaching thedesired speed press thesetswitch Thissends a set signal tot...

Page 1458: ...3t I GFNvHT I l 6 f _ f irlliin r rs r zy I GFN wHrI r oro o cnrwnr I t i 8 i i i i tZ I Cqtg Cruise C ontrol fii1f Y See lgnition System l 83 ivBU Batteryback up 812 I nE Engine speedinput FPM Shitttock Shiftcontrolsotenoid Look_up coo trol solenoid VehiCle Cifcuit A C on valve control valve control speed input control ilp ui H r j5 X r lru rsHAr lgl l u I L _iq ____E _ ___g _ ___5i ___E _____ t ...

Page 1459: ...1 c co s y oe zr y noe l J i J o l l tcars zo c zo ts A tu I l c ts 25A c42o PHora 51 iF et 6 di iry_ ql E 1 1 oF3 a o ofl n f jfit Bj l 4 p iroir nct t uo r rvooin n icinorvteoge rJGrence sCnior inpui tgnition inpui comparative signahainsnaft speeo sensor countershalt Ground I Sensor qroundsensor inpu ground speedsensor input I gir gig lNcsc rNc i 3J t 91 T a 1 7 r 1 iI a 1 5 tl Jti T h FFlHT rI ...

Page 1460: ... 1 Ti t 1 1 sRS 1 t r ENGTNE r I TRANSM SS ON I r I r ib rsis I coNTRoLl r sb srI coNTRoL I i fl i yjHlr f n ffiii i G401 PHOTO56 r J 1 i J itTffe ir s I IHffilEr iTr s I I voliage l ECM input Iw i o o L t jrfl Si jhfiY t i1 i l_ f o o ror c410 4tr E c4ts 17tr c420 LJ__HSIJ iit Hb f l lz i i Try 1 u u o ft_ ______ ___ __ lfi g to o n J f t ...

Page 1461: ...lft I alo ArI A9 pA Ar 46 i MODULE rCM LTGRN WHT lt I A See A TGear Position lndrcator ra I I I F 4_mlffi xrir L La L g i c558 c430 PHOfO 63 1r F cnN rHr i I GRNATVHT I GRN BED a a f GRN 1f SeeA rT Gear Position lndicator 7 c413 I A T GEAR I POSTTTON i swlTcH I PHA A 0 I I I J BLK 1 BLX c413 arrr Distribution I pase144 b J SeeGround 39 3 ...

Page 1462: ...y back up Btakeswitch input i Shiftlock Shiltconkolsolenoid Lock up control solenoid Linear solenoid Vehicte JirCuif ly Con valve control valvecontrol valve eontrol I soeedinDut control inDut speedinput control input lvss rLUl tacoLl SHB rSHA LCA LCB L s J LS I c23 A2A At7 02 D7 Dl D3 817 8a c23 A28 A17 02 D7 D1 D3 817 88 T lF ffiT il m 1j d H t il Tfl ill ffi lTl i fi ff iy ixFEf llrTril ilfinpl ...

Page 1463: ... MODULE PCM c457 Ground rG1 820 n i 20 BRN BLK BBAIOEDWIFIE Mainshaft speed Sensor Countershaft sensor input qL T 9 speed sensor input 011 016 D10 T I____ T il f l li I ul oo rI I Ij fi l_ l ff s I rl cl02 SeeGround Distribution page14 1 cont d BFN ALK BFN BLK MAINSHAFT SPEED SENSOR COUNTERSHAFT SPEED SENSOR 39 5 ...

Page 1464: ...l jHili ii Ti iF H i ll zrI_ 16 rc4os 14tr c408 LJ_j J tt I ou l I I r rii r r r 9 3 X r g l f t tl il T1 i T ____ 1dnw t il l o n l i I L I I NLi a l_______l l r I_ITI ENGINECOOLANT iddirioil I Jr l g tilu SENSOR lJJal PHora17 c106 GFN BLK SERVICE CHECKCONNECTOR PHOIO 76 T _ 1 liil lFffi I c405 BLI BLK I I SeeGround Distribution pages14 4 and14 5 V I G401 39 6 ...

Page 1465: ...ee nn I ll see nn ll I 91 tniertoct I I il I t c I I Arcear sysrem I ll F i on I ll ioJtion I I Positron i iidlj6 I ll inoii 1o i ll Indicator 12A ___ r1j r i o lL c413 onrwn I cFN I cFN nEo I cFN BLK I cFN BLU I GFNYEI I LrGFN t I A TGEAR ALK 1 ALK orr I POSTTTON i swrTcH I P 1jTO 70 I I I c413 Lr SeeGrourd Oistribution page14 4 Y I J 39 7 ...

Page 1466: ...FUSE 52 HOA STOP 204 c215 c418 ferminals5 7 SeePower Dislribution pag 10 9 l ffiLs SECURITY SYSTEM CONNECTOR oPTroN CABLE REEL Allexcept USARS lt I BLU cFN 5 s _1 7 i i rr 1 J i A f i See Cruise Contol J I STEERING fTlh f Eflsw rcH 40 ...

Page 1467: ...bution Lf je l JPPJ pags 1G6 __li ffi_ GAUGE ASSEMBLY 4 ffi I if T fl r i n i i _ i l 6 j q 1 N l illT ffi o n n l 1 L L L ir J f il i i tl t f fii1ina 15 17 I 1 rtil Ilm i pirjli io 6 i 1 seerndicators r Llll _ ffifi fj LEFT FRONT WHEEL SENSOR RIGHT FBONT WHEEL SENSOR LEFT REAR WHEEL SENSOR PHOTA 46 RIGHT REAR WHEEL SENSOR 44 ...

Page 1468: ...V Ground Ground Ground Ground input inout outp GNo1 GND2 GND3 cNo4 FAfiK scs DLc cNo1 GNDzl GND3 cNo4 FAfiK scs DLc L J 2 y ja c7o3 t l r f 4 f 14y zil czot T T ui I if Jt N ttn i l l f ffff a ffi n lr lt o o I l I l I I ii r i I i l t u o i I 1 I rrlBAl JS n d i I i l7t lc o 0 nn t rat di 44 1 ...

Page 1469: ... 1 0 il cztt aotrn I _____ r ___ il r 11 7 ra _ _ r tt i l l l or F 3 t 1 L6ft Front ABS Solenoid out Right Front ABS Solenoid ouU Left Front ABS Solenoid ln Lefi Sear ABS Solenoid out FL OUI FL N Fn OUI FntN BL OUT lBL tN it 8 r q d Left tront ABS Riohl lront ABS t 6ft rerr ABs t LefttrontABS RightfrontABS LeftrearABS solenoidcontrol solenoidcontrol solenoidconlrol I 44 2 ...

Page 1470: ...BS PUMP MOTOR RELAY PHOTO 13 FUSE65 aasuMr 0A SeeGround Diskibution page14 2 ABS CONTROL UNIT l r F oun y BB r R t I o r ooc motor check I Riohrear ABS ioT rioiJ ntror reraV I conkol t 4 aight near ABS Soleroid ln Righl near ABS Solenold out il PUMP MOTOB G202 44 3 ...

Page 1471: ...it theairbags could accidentally deployandcausedamage or iniuries lgnition rnpul VA tgnition Inpul VB Passenger s arrbag control SFIS indicaior lightcontrol Service MES check nnector connector input Ground Inpu Driver s arrbag conlr0l DLC npuv output ro Y la Y 16 ffi f ffq lJnor rrpassencen l t i rHas bu ll nshorl contac0 I j T fn o t n n non on u Jl oou oou cRN 3 l Y e_er oArALINK sERvrcE 9qe l q...

Page 1472: ... H c556 f f rerminals 1 4 PHoro s4 i i se Power I rt a 4 il J i i 1 cssT GAUGE ASSEMBLY c427 SFSINDICATOf ltGltT m SeeASS I I c452 1 5 RS 14 J 47 1 ...

Page 1473: ...NOER HOOD FUSE RELAY BOX L y J 9 Y C439 KryEL P roro 62 BLK EL ll PHOIO 62 BLOVYER MOTOR FELAY PHOTO22 9s_____i u f i ii o 1 l c6z3 Hfib i ut i a c217 BLU 1 vi r J PHoro u C677 PHOTO69 rI c683 HEATER FAN swtTcH 6 cnr SeeA C Compressor Controls 1 BLK c683 SeeGround Distribution page14 4 I J SeeGround Oistribution page14 2 G201 60 ...

Page 1474: ...BOX SeePower Oistribution page10S O Distribution t I fi F 9 page10 BLKT VEL RECIRCUL ATION CONTROL MOTOR a See Dashand ConsoleLjghts 4 GRN NEO GFN NED I 5 11 cezs n n T I r ___ r5l j I tr fl13 aLKTyE i a o m ELK VEL ll BuevEL See powel FnES l r l i q t 1 r o i_ 61 ...

Page 1475: ...ALK VEL 4 YEVBLK c682 MODE CONTROL MOTOR LT GFNAVHT YEVAEO c682 69 YEL D6lro3t Ssltch l e t _ t I I I I I a at Vo i Swhch F a HiDEF Swltch lf ttto o BLK I 3 u 110 o o on l 1 W rl 61 1 ...

Page 1476: ...ed tothemodecontrol motorthough that modeswitch Themotorthenrunsuntiltheair control doorreaches theproper position Fresh Recirculation Selection Whenyoupress therecirculation button a ground signal issentfromtheheater control panel tothe recirculation control motor Themotor lhenruns until therecirculation doorreaches theopposite Dosition Whentherecirculation button isinthe RECposition battery volt...

Page 1477: ...stribution pagetO 0 BLX YEL I IFi u SeePower Dislribution page1G l NC COMPR SSOR CLUTCH REI AY Ptloron Y c905 f l 1 l ft lll 133 1F f I onbracket 98199 models withA T r l TRANSMTSSTON CONTROL rr P I MoDULE rcM L Z J iuoro sr 24 Y C420 BLK RED POWERTRAIN or ENGINE CONTROL MODULE PCM or ECM PHOfO 77 94 99 ly CONinDut ACS L S s i 98 99s Y C4o8 98 99 27 tl C409 r ao I I aLuneo ar reeFans il aurneo I v...

Page 1478: ...rTcH Low Openbelow200kPa 28psi High Open above 3100 kPa 460 Psi Dislributlon page10 a trall ifrF fl A C THERMOSTAT Otfbelow 3 C 37 F THERMISTOR SeeAir Delivery BLKTYEL Se PoweT 4 il Stt j i c oN It DICATOR A C swrcH I CoNTROL iPANEL r O tI a il au vel N t __ r c684 1 Y C 1 s 4 rr 1r r I i abi6 o ro J cco r t 2 Y C676 BLU REOII 1 t fr 9 9 r r l 62 1 ...

Page 1479: ...rnontheA C comDressor clutch TheA C ONindicator lightcomesonwhentheA C system isrequested A C Thermostat TheA C thermostat is located ontheevaoorator housing TheAJC thermostat turnsofftheA C compressor clutch ifthetemperature atthe evaporator goesbelow 3 C 37 F Thisprevents condensation fromfreezing ontheevaporator fins andblocking theairdelivery intothepassenger compartment Theblower motor willke...

Page 1480: ...er Dbtribution pagelG1 c2 16 1 BLKBEO POWERTRAIN or ENGINE CONTROL A MODULE PCM or ECM PHOIA77 9A 99 PHofa 14a q u s A COI DENSER FAN RELAY PHOTO 23 RADIATOR FAN RELAY Hlofa 22 c215 J 98199 4odels c l t l 8LU BLK c9 t6 c206 c206 ffi t f oo 6 i v ToSplice on facing page c151 c155 BLU BIK BLU ALK CONDENSER FAN MOTOR RADIATOR FAN MOTOR RADIATOR FAN SWITCH Closedabove 93 C 200 F r I see c orno arr Dis...

Page 1481: ...n c408 SeePower Distribution page10 6 a i c151 c154 98 99Models I lC PRESSURE SWITCH Low Openbelow200kPa 28Psi High Open above 3100 kPa 460 Psi 4 SeePo er Distribution page106 SeePowor Dbtribution page1G6 A C THERMOSTAT Oflbelow 3 c 37 F THERMISTOR S eAir Delivery a a i rfrs lt a BTK VEI i 9 1L t 1 I Dimmlng t I HEATER J I cONrR CONTROL Circult r coN INDICATOR 1r ur I 8 8ffiTo o u n r F 9 l 93 r H...

Page 1482: ...I i Er t 11 c402 i l I Btu RED I er uraeo I i 3__J i l t r o I i I oo s x c4oe l rNTl oll ffIE Used I CoNTROL I MODULE PcMor EcM I PHA O 77 98 99 _ P H O T O 1 4 0t a A l 8 99Models NotUsed i rN I oo PF IA c Lf l r i r B I t l I t l x _ 24 t_ l c301 PHOTO36 t 9 GBN SeeGround Distribution page14 2 I I _l r27 A C408 i r I iiiiro I FAN I control t L I irl RAOIATOR I t I FANswtrcH l cl 9J3 39 e e3 c 2...

Page 1483: ...astheonlywire providing ground tothecondenser andradiator fanrelays A C switch on heater fansswitch on radiator fanswitch open andECMor PCMfan controi outputnotgrounded therelaywill deenergize removing voltage fromthecondenser andradiator fanmotors causing themto stop running A C PressureSwitch TheAJCoressure switchislocated inthecondenser outlet linewhere refrigerant isina high temperature high p...

Page 1484: ...E RELAY BOX S eGround Distribution page14 5 ffilfi Eij c914 Hatchback t1 l o nf L f fl onn o I notbepresenl inallcars BL GRN I I I u o l lFl REAR I 5 WTNDOW lll oEFoGGER f tt u i il Fl l T lJ PHoTo102 c753 1 REAR I WINDOW I DEFOGGER I J BLIIGRN c771 1 BLK GFN r I I G 7 1 L of or i BU lt GFNA c516 1 ll ll GRN ll pre6e 2 J C525 BL ll P lorc neof czss msi lllo Y c771 BLK BLK cs16 ln line connectorl m...

Page 1485: ...rtherear window defogger relay andthedefogger ON indicator through theintegrated control unit The defogger ONindicator light comes onandtherear window detogger relaycontacts close Voltage is applied tothedetogger gridonthesurface ofthe rearwindow andthegridheatstherearwindow to remove anyfoglromtheglass A timerintheintegrated control unitwillautomatically tumoffthedefogger atter20to30minutes Refer...

Page 1486: ...eeGround Dishibution page14 5 Y v G401 Window SeeWioef Washer f l l UNDER HOOD Defogser I rUS e IFUSE RELAY I I I llg i 1 11f il ll wlhcombined utr i I I I 8 il o n o I i t i T T 1 7 i l l l i r y a i i i i l i i tr I i Ljiri dt l t h i tf r il L SeeRear Defogger FUSE 26 FFAWASiIEB Seepower page10 5 6 Rear Window Defogger Timer Circult Intermftent WiperRelay Circult EnglnsOil Prgssure Indicatol Fl...

Page 1487: ...em pages 21and21 1 SeeBrake System lndicator I i ht c504 PHO O 62 SBeHeadlight FUSE 31 STAATEA S GTAL 7 54 uee Switch page100 1 I FUSE30 usrnu EtlT UGT Tl 5A S eBrako System lndicator Uqht INTEGBATED CONTROL UNIT PHOfO 62 UNDER OASH FUSE RELAY BOX See Ceiling Light c422 DRIVER S DOOR swtTcH Closedwith dooropen PHoto 88 sedan 70 1 ...

Page 1488: ... fo to IF flt 3 Not used t f if r u tef csoo g rSS r T r UNDER I t FUSE or I ruse zs 9 4 s t i 3ffi8 1ry eeeJo ilEiiv i l3 3 Tii lH ti i r il li lr if g I r o v cl6r NrEGRArED i lltrt 1 3ni iFfi t i Flif r 3i fi i lln I r zr l L g 3 I C439 15 l lal el t 14X 91 3 q NotUsed 816 IUJA LaI Agtt J L g _ _ i _ J I ll ll AsslFrr rBLY GRN NED I PHO O4T c505 GFN BEO 1 8 GFN BEO GRN NEO GFN FED 1 8 GFN FED I...

Page 1489: ...J l i L J g j S3g1 Hr IF 1s f c flls It t i_ I o n o n o L___ s l r i t l I I A r r e x c e p t R s t I ii d i__jflffi i I l ll I Vg l gl o 1 o u i f 1Ri iil I ff i LEb r ji_jb f I l i rsr fX 1s TrP ls eP 1 Lljti seeGround See Grouno oij J i i Anmg l 3 i l ffi Pilr r l t iiYffi i I i J L I i L J rs i r sr i i it 8li6l i iq iit l fl i i i l 1 I r f l B A t J S l J L l y IShtrl l itooo iPPtreo PHoTa...

Page 1490: ...__L___ i u I 3 lf cile ol csss I UNDER DASH FUSE RELAY BOX SesPovrer Distribution p age 1G5 wHr BLU T 1 T c t27 f seeIndicators PHO O 36 I A lower rcrxe I 6l xL PfiESSURE s t i Y l x8i i o t t r r i 1 lr r l L g Z J C tZz H SBeIndicators GAUGE ASSEMBLY r o_ _ i eh fiFs 1 1 c438 c452 r RS4 YEURED 6 1 rr ao I l rlFl ENGTNE OtL I 1 I PRESSURE l Il 8yjl h EnglneOil Pr6guro IndlcatorFlasher Clrcull 72 ...

Page 1491: ...witch closes momentarily more than0 5seconds butthenopens again theYEURED wireatthe integrated control unitwillsense ground through the switch Theintegrated control unitwillthenprovide andremove ground forthelowoilpressure indicator light through theYEURED wire Thelight willflash onandoffuntil youturntheignition switch off The flashing feature willnotworkuntil30seconds after initial voltage isappl...

Page 1492: ...ss t ElY TNTFI E TFn I f tR ii i T t I I i tr aa i t lI t L j i o o u I iff F1 0 l T T i r r iTs t t f l J r o Y I t I SeeGround Distribution page14 5 I I I i I 1 1ilg 8 J39 i ru UNDER DA H I rNrEBroRI BOX I 1 l I _j i li li BOX PHOfA 58 i _I 31_i sl F 1 1 r i l F o c422 tnilll l H ffir i i PT x x fui i ioiffit i ltif i i ilr zt LeJ Liohts ON input Beeper output Door Key Seat belt switch switch sw...

Page 1493: ...eePower Distribution page10 5 SeeGauges I ASSEMBLY Indicators LOWFUEL INDICATOR LIGHT lrnl FUSE 25 ffETEF 7 5A SeePower Distribution page10 5 I c505 UNOER DASH FUSE RELAY BOX D4 L 3 1 0 3 c51l Thermlstor See Gauges L FUEL TANK UNIT 1 ...

Page 1494: ...s heataway fromthethermislor lastenough tokeepitcoolso thethermistor s resistance stays highandthelow fuelindicator lighldoesnotcomeon Whenthefuel level drops below about 2 2gallons thethermistor isnolonger immersed infuel Without thefuelto coolit thethermistor s resistance decreases allowing current toflowthrough thelowfuel indicator lightandthethermistor toground andlhe lowfuelindicator light co...

Page 1495: ...page l0 9 c559 I I I I i jltffi se causss i ffi fi ri l i i 8 l i 9 nH 9 mis gilH4 fi gffi FF 1t1 l r i r r r r n l r z l t l s f t I I L r ilLSl 16llLel l I l l l y l l i lc d I l L J aL 3 J 1I J csse 11 z lf e lf ro ircs60 i I o n o 0 u I o n o i t t t I I See Low Fuel See Door SeeSeatBelt See Brake See Hatch ilizet lndicator Open Reminder Svstem or TrunkLid 1 i Lrght Indrcator tndrcator OpenInd...

Page 1496: ...otI r owENGTNE I OILPRESSURE I INDICATOR LIGH I Yrl L J SeeGauges I lT Gear Position Indicator ff I See Crl Control SeeGround Distribution page14 5 Y I t G401 PHO O 56 T l i 1 SeePGM FI SeeEngine oil Pressure lndicalor Light 98 99 Modets See Maintenance Reminder Light I d I il i fl B I i 1_ i l f l ...

Page 1497: ... 1 811 r SeePower Distrabution page 10 9 SeeTurnSignaland HazardWarningLights See Headlights V tl neoi I GRNtI _ I r__ I I 812 Nor Usod ___l d RIGHT TURN SIGNAL INDICATOR LIGHT H AAS INOICATOR UGHT usA Canada f t ro o il i it l see ABs r I trt a 1 uu ott fl tf sRs INDICATOR LIGHT m XIGH BEAM NDICATOR LIGHT E FUSE 15 ALTEANATOR sP sEl son 54 t Diskibution rr t t i C 5 s 1 ...

Page 1498: ...ution pagol0 5 ENGIIIECOOI ANT TEIiPERATUNE GAUGE I I t I I J c559 c452 PHOTO61 c127 PHOTO36 c107 c505 c511 YEUGBN RS s YEL GBN 1 0 YEUGRN FuelGauge SendlngUnlt Full 2 5ohms Empty 10 110 ohms SeeLow Fuellndicator Ught FUEL TANK UNIT c301 1 1 YEUCRN l n ENGINE I 1 l COOLANT I I TEMPERATURE I I I GAUGE SENDING UNIT PHOfA 17 PfiOrO r8 GS B 81 ...

Page 1499: ...sr l _1 11 1 L ttt r i l ferminals 18 20 Y BLU I I Oerminalsl8 20 98 99 Models r fr fl 00l 4odel GAUGE ASSEMBLY I I t 9 Sse Indicators ry TGear Position lndicatof ODOIIETER TNIPi TEN STEPPER MOTOR 07 f9 99 D6 I t I 98 996 7 v u Jl J f csse t f tt t see vehicte i 33i I 3 tFffi I I n l l l f n l ii i Lri ibr li tfi 81 1 ...

Page 1500: ...es oerminute tromthePCMorECMthe tachometer displays 100RPM EngineCoolantTemperature Gaugeand Fuel Gauge Theengine coolant temperature gauge hastwo intersecting coils wound around a permanent magnet rotor Voltage applied tothecoils through fuse25 generates a magnetic field Themagnetic field controlled bytheengine coolant temperature gauge sending unit causes therotor to rotate and thegauge needle t...

Page 1501: ...ePows Distribulion psgel0 SsgPowsr Disribr rtlon pageiGS MAINTENANCE REMINDER UNIT F ilr a onr I F l F x arr T I T I i r l vEHlcLE I venrcle I SPEED I speed SENSOR I outpur rySS L__J PHaro 26 SeeVehicle SpeedSensor vss lgnition lnp rt Maintenance r mnoar lightconlrol Gfound Vehicle spe d input 83 ...

Page 1502: ... ll asa bulbcheck Between 60001 100miles 9650 t 160km and 7500t 100miles 12070 I 160km thereminder lightwillcomeonfortwoseconds whenyouturn theignition switch toON ll andthenflash foreight seconds more Beyond 7500t 100miles 12070 t l60 km the reminder lightwillstayonwhentheignition switch is intheON ll position until theunitisreset Toresettheunit thecarmustbeparkedandthe ignition switch intheON ll...

Page 1503: ...Dash andConsole Lights 00l4odel t0 ql 98 99 4odels c430 c558 410 S eGaug s lndicators SeeDash andConsola Lights GAUGE ASSEMBLY A r I Gsa I PoEltlon lrdlcator I I I I I I I I t r Indicdo6 I I L a c9 c559 98 99 Models SgsGround Distributon pages l4 and1 5 4 GRNAVHT 5 See lnterlock System Y i GBN i ll I wHr 12 GFNA HT c413 BLK 1 BLK V T I I a_ G40 t PHOTO56 a SeePower DiBaibution 89 ...

Page 1504: ...witch inPARK or HEAD voltage isapplied totheRED BLK wireterminal this changes theindicator panel illumination fromlixed tocontrolled bythedashlights dimmer inpul through theREDwire When thelransmission 98 99 models or powertrain 00model control module TCM or PCM detects anabnormality intheautomatic transmission control system orwhenyourequest diagnostic trouble codes through theservice check conne...

Page 1505: ...F 2 A i l i r I S ePowa Distribution pags 10 5 1 7 RS10 c442 5 GFN BLK c302 Withcombined washer wrper operatron c437 I I I I Or Distribution page14 3 i x i o r u n t 1 r Hil q 1 seecround z_________1 orr tBl u tt I Y I I L____l c G301 PHATA 11 91 ...

Page 1506: ...ar ul u Ti L__j i iiirr 9 oflPl t I Z h p S Rl i a wis h rt lILo N t d d j l if iy f F15 lil i i J _ _ _ _ J rs I csoz i l 1 tnser ilb s il M i i o 1 ffii513 u f ii L l f V q F r Ground i 3 r From C437on rnrspage j k seeIntegrated Control Unit Intermittent wlpcr Rclty Circu l I I i a r a 1 t SeecroundDistribution 1 1 c914 o3 J r I F r i SeeGround Distribution page14 5 V I rd BLK 91 1 ...

Page 1507: ...control unit lntermittent wiper ONinput The integrated control unit lntermittenvPark Wiper Control grounds thelowspeed windings ofthe wiper motor andthewipers makea single sweep every fewseconds SeeLowSpeed above When thewiperreturns tothePARK position thepark switchappliesbattery voltage through the BLUMHTwiretotheintegrated control unit PARK input andthewipers stopinthePARK position 91 2 Mist Wh...

Page 1508: ... REAR wtNDow WIPER MOTOR GFN GFN GRN c526 c516 2 8LK ln line connector may not be presentin all cars c422 PHafo 56 c435 PHOTO48 Or I SeeGround Oistribution page1 7 LTGRN BIK 4 G751 I COMBINATTON Rear I WIPER wtndow swtTcH wiper Washer I Swltch I BLU BLU BLK 8 RS12 BLU 6LK 2 LT GRN BLK c302 c3r8 REAR wrNDow WASHER MOTOR 3 BLK c435 SeeGround Distribution page l4 5 SeeGround Diskibution page1 3 BLK f...

Page 1509: ...E5 L_ HEAOLIGHT NIGH BEAiI 10A FUSE 2I R IIEADUGHT IOW BEAI 104 FUSS 4 R NEADUGH H G8AEAB loA UNDER DASTI FUSE RELAY BOX Jg3i Not Used REO BLU 6 BED BLU r I I c438 l FED BLU FED BLU I I I J o5 LEFT HEAD LIGHT Page 110 8 Canada c30t c307 I DRL I REsrsroR I Page 110 9 otl o1 r o t HEADPAFX I pmx I raax Head I TroN lloht aLIGHT s ch swrrcH I PHaro144 I 100 2 C205 ...

Page 1510: ...e114 i nttexcept l USARS 1 0 t l REAR wtNDow DEFOGGER swtrcH Page114 CIGARETTE LIGHTER Page 114 1 GAUGE ASSEMBLY Page 114 cont d FromA on lacingpage J v i neorcnn I l B E o q R N 3 a J SECURITY SYSTEM cG coNNEcroR oPrloN I N Phoro ttt ___ l O iify to o n ll c44i 7 A p1ora 59 r 1 INTEGRATED I Liohts I CONTROL oN UN T I inDut I rYioTO 62 ToEon nelcpage 1 _ I f 9 I i fow ao i t l t l HEAIER CONTROL P...

Page 1511: ...Bon pr viouspage FUSE RELAY BOX t8 2 C319 c302 LEFT FRONT SIDE MARKER LIGHT Page 110 11 3 l C320 LEFTFRONT PARKING TURN SIGNAL LIGHT Page 110 11 RIGHT FRONT SIDE MARKER LIGHT Page 110 l1 RIGHT FRONT PARKING TURN SIGNAL LIGHT Page 110 11 100 2 ...

Page 1512: ...jr or tr ato ufl j l l t q I il I i Fl Fl r s r t t i LEFT LEFT RIGHT RIGHT LEFT INNER RIGHT INNER NENN ARNXE LICXT NEIN BRAKE LIGHT BRAKELIGHT BRAKELIGHT i rCiirlc irir t iGii PARKTNG ralLLlcHT TAILLIGHT TAlLLlGtlr i f iCii Hatchback LIGHT Hatchback Page110 13 Page110 13 Paoes LEFIOUTER Pages RIGHT OUTER rrd rz BRAKE LTGHT 110 12 BRAKE LIGHT and110 13 TAILLIGHT and110 13 TAILLIGHT sedan sedan Pag...

Page 1513: ...ansmission l A TGEAR POSITION swtTcH L r 1 1 frl_ j I o BLK Y eLr I I I I I Tt erx I eaororoa arrrr i U ro 1 i J r aacr up I 1 LrcHT swrrcH I t _ l 1 tra lsm ss on o n F notot J fi o 8 J fiF JIft 9 t t fi f f l l onn o _ I ilil lli 0 o n ffi l lF l fffi canre l i itdq o n f l g c o g H rt I A F I SeeGround Distribution page14 7 G503 Tt u au I Puoto oe Frrrrra 1 1 0 BLK ...

Page 1514: ...oto u tf l o o o n il l lli o o nur o n o t ul uro lln cn r ar x ff Hl irT GRN 8tx t i r t coNNtcroR Qphft f af see crou c a Distribution _ _ I ri 3rr sr ri l Y9 s ecround 3lflit8 G503 PHO O 102 i rr i 1t o frFH Ffi elcr up r rcxr swncx It_rl fi ffi 1 transm ssion o n F oto oo Jf F 0 3 Jlt t Jf 110 1 ...

Page 1515: ... RELAY BOX HAZARD WARNING SWITCH 1 1 RS10 SeeGround Distribution page14 5 WHT GRN WHT GRN WHT GNN See Dashand ConsoleLights T RED BrK I U cssg SeeGround Distribution page14 5 l f Orrr l r r 91q1 GBN OBN 1 GAUGE ASSEMBLY il r F t pase t 11I csoo i FH i ffi Ell cnn I V l G g l_______ 1F LEFTTUFN rA I l3i o f t LIGHr see Y fH G a u g e s I I r l Inorcarors RIGHTTURN SIGNAL I IDICATOR UGHT T o A o n r...

Page 1516: ...10 PhoTa 62 GFN YEL o nrtaa I GBN BLU T I c516 ln line connector maynotbepresent inallcars a RED BLK See r l _ LEFTFBONT T lo q T PARKING TURN 9 srcNAL LrcHr BLK SeeGround Distribution page1 3 Y T A lerr nean I b I TURN SIGNAL v LIGHT Y t I see cround Or Dist ibution rA 1 il qEll tr LrGHr r m BtcHT FRONT rlo 2 I PARKING TURN S srcNAL LlcHr c203 BLK See Ground Distribtdion page 14 2 I L__J G201 BLK...

Page 1517: ...NG swtTcH 1 1 BS10 SeeGroundDistribution page1 5 YEUBLK SeePower Distribution page1G9 r and Lights c551 Ser BED 8 i5 t IQ 5A See Dasha ConsoleLiC I oret x ll lt 1 c BED 8LK 7 GFX OBN SeeGround Dishibltion page1 5 l 1m arrr L_ tr sf cs63 F page i 11I cr o RIGHTTURN ffiH I H i tr Elt o n l v j G rsl_______ 1F LEFT TURN il H 3 n i Indicators _ _ ___ u T o D o n rnrspage GAUGE ASSEMBLY 98 99l 4odels H...

Page 1518: ...T f l l tr Fro nEon ll I FromFon 6 A PHarassI AP9oross I A PHora 5e I UNDER DASH I I I lllserneuv ttr f 1 1 t Y t2 f T rr rn iii onn to H I o n u o n ll l3l3io Iriftr ffi l_ l r f t coNN croR f t RED BLK See Lr 6pitriiffilI i il ff t Effi if f ffi cro gFJ PaQlAtl Pttofo 02 110 5 ...

Page 1519: ...iler c523 GRN SeeTaillights d SeeTaillights 4 o a il z I xigrr uount 2 l HrghMounl ll Brake Lighi ll Connector GRN HT ll atn i c72 GANAVHT GFNA HT GFNAVHT c754 c762 l H GH I MOUi II BRAK I LIGHI J c753 c754 GRNAVHl GFNAI HT 1 t t I BLK BLK 1 BLK I r 9i 1 I I 5 1 a 8 l l SeeGround Distribdion Page1 1 7 8LK T Y J L cnr rnr ff iioio zo o rfi 9 1 llFl xrcn l 1 l MoUNT lwli Htl t i l i fr s 0 i LEFT BR...

Page 1520: ...sent inallcars cszri S croR c536 GBNAVHT 1 SeeTaillights Y il 1 I GFN vHr __ l LEFT INNER BRAKE LIGHT TAIL LIGHT GRNAVIIT c523 2 SeeTaillights Y tl 1 I GFN wHr __ t RIGHT OUTER BRAKE LIGHT TAIL c521 GFNAVHT SeeTaillights Y lt lt I oRN vHr __ t with Trunk Spoiletr c534 t 1 HighMouni BrakeLight Connector c72 GRN c7n wHT HIGH MOUNT BRAKE 2 LIGHT HighMouni Brake Lighi Conneclol LEFT OUTER BRAKE LIGHT ...

Page 1521: ...7 USAandCanada 98 99 N4odels COMBINATION LIGHT swtTcH I U r Haad lighl Srvllch J SeeHeadlight FEO ALU 1 r Not Used FUSE 2r F HEAOLIGHT LOW BEAM FUSE 4 F _ HEAD UGIIT H qH BEAM UNDER DASH FUSE RELAY BOX Lft OFF HEAD I OFF neao fi l i rcao 1 HlGit H qH 110 8 ...

Page 1522: ...GHTS CONTROL UNIT c302 1 WHT NEO WHT FEO DAYTIME RUNNING LIGHTS RESISTOR c307 c440 I UNDER DASH I FUSE RELAY I 8OX I Pqofa 53 c504 1 8 r I I 1 A C508 l l l PARKING I I BRAKE swrrcH t I Closedwith 4 parkingbrake applreo PHAfO 71 c301 SeeGround Distribution page14 4 Y I I a Lights on Battery inpul Headlight control lgnition Brake system indicator lightcontrol Ground Parking brakeinput r 910 1 110 9 ...

Page 1523: ...dthehighbeams flash Thehighbeamindicator alsoflashes during theflashoDeration Theflashfunction hasnoeffect itthehighbeams arealready on Daytime RunningLightsDayOperation Whenyouturntheignition toON ll withthe parking brake released thedaytime running lights controlunitsupplies battery voltage atthe WHT RED wire Thisvoltage isapplied tothehigh beamheadlights through thedaytime running lights resist...

Page 1524: ... I tl i BED i l l r I oy_____ii t o o a r n l t t l t u ls snarlishts irr I inl i3 iH ll I l tAcszo il r LEFrFRONr i s 3m rlti z csrg 2Y ca2o i fft t 13 I Pase 14 3 l I L__l __ SeeTurn SignalLights env lt YEL I _ Jl c203 110 12 or 110 RIGHTFRONT PARKING TURN SIGNALLIGHT il l Llr_i 193 rI uI o u i r r l il lswitch I l l o r o t I i_ i I rl__r_ _i I L ti J ToG on page 1 1 0 1 1 ...

Page 1525: ... p a g e1 1 0 1 1 REO BLK l a c515 lnline connector maynotbepresent inallcars c523 RED BLK l BEO B K c522 _ 3 C s 2 0 TRAILER LIGHTING CONNECTOR rL 4 Or r SoeGround Distribulion psge14 7 uY 9i 1 il BLK BLK c522 Se Ground Distribution page14 7 rrr BLK 110 12 o r l Gs03 ...

Page 1526: ...rake 3 tnatLen LIGHTING nqrn CONNECTOR cs22 c522 FLui RIGHT REAR PARKING LIGHT BLK li fr t FI Sge Ground Distribution 1 BED BLK c536 c521 ritr INNER BRAKE LIGHT TAILLIGHT RIGHT INNER BRAKE LIGHT TAILLIGHT LICENSE PLATE LIGHTS r a ALK BIK See Ground r Distribution S s Ground Distributign page 14 8 V I l o fI f IJ page 14 8 Y rt A r I BLK c536 L 1 1 0 1 3 ...

Page 1527: ... oir r Swltch I J l t t coMBtNATtoN 1H 8dT I LIGHT lggltl iP 9 l JI See Headlight Switch page 00 ON oN INDICATOR FOG LIGHT IN LINE FUSE PHOfO 123 FOG LIGHT REI AY PHATO 122 SeeHeadlioht Switch page100 cl6 RIGHT FOGLIGHT Tl c42 elurneo ll u of t to u A csro BLU REO ll PHO Otr Ut ry fi ua r o 110 14 c4o a l c3o1 PHoro 122 pHaToll ...

Page 1528: ...LIGHT xe1 orr I swncri ii I _ r I I L Id J I L Y J See HeadlightSwitch page100 1 FUSE30 ttstnoMEt t uGt Ts 7 54 1 19 x 0 u l j tr T fi i f u aE t I I c a 3Jf c566 ll ll ll ll i lii r lr r u i l I OPTION CONNECTOR OashLighis ll BRTGHTNESS 3 a C562CONTROLLER Atl ffi gifli irffit1jr rs l pi l l ol T ilF Jffi i j l LJ Y L i rfr l i ffi l I I RED l2 J cqor 114 ...

Page 1529: ...oI uuu eo t lF r HAZABD r lF r CRUTSE rE I I IWARNTNG lCONrRoLl I i6i i6i i6ii 16l igi i6 Hf ri iLi iJ i Ll sryi 8 f cs63 s f csss L j 1 ri f o l FI oI ir u r out I L Js FED BLK FEO BLK SLK FEO BLK CIGABETTE LIGHTER c404 c67 c684 HEATER CONTROL PANEL C411 FEO BLK 1 2 FED BLK I BBril l I r I I I I I I I u_ c684 C677 c404 1 0 FEO RED 9 BED I J J 114 1 ...

Page 1530: ...REO 12 a C422 if pForo 6 _9I _c s __ PfSE t f T IU E9F FDIhEiii iiD ififr o l8Rllr o ti 91 l1 ii i tr i i usfl lai6iose lL J r f J i E o f u I I I DRIVER S I IF FBONT I IFI LEFTREAR I IFI RIGHT REAB l IDooRswrrcH l IPASSENGEBS I I loo orB l ISSP B ll lF r rlglp i i il r il sf l 11 I lr i 13 c I I t r rn iil onn to o n u oa n 3r J 1 uor f cu i J cszs 1 c g PHOIO 88 Sedan pHOrO 8t PHOrO 92 PHO O 92 ...

Page 1531: ... I I IE 9E RELAY I li z o a c504 Hatchback Se6Power Distribution psge10 7 Sedan I I GAUGE ASSEMBLY SECURITY SYSTEM CONNECTOR oPT ON l t f u X ut 1 1 Sedan o nI 1 Allexcept USARS I a I Hatchback r_t_____ l HATCH LATCH swtTcH Closedwith hatch open LATCH 5 6Ground Distribution page14 7 TRUNK LATCH swtTcH Closedwith trunkopen SeeGround i 3 uii3 l r J BLK ln lineconnector may not be presentin all cars ...

Page 1532: ...ljl c ro TRAILER LIGHTING CONNECTOR 2 Y Cs20 BLXI SeeGround Drstnbutron Orrr Oaqe r4 7or 14 6 T I Y I I I rrr r 910 3 PHOIO102lsedanl 5 A C435 ver IrcsE rv q if T r J l l ti t I oromaticrransmission I Manuarrransmission ll iis i nl ri i ffi il 1 Isw ch Piu J r L r l iUt L _ _L _ _ ___ o 0 l o u I o o to s _ l_____ 1 i isr H j t t lil lfililr ff Lfl6ti i g J F T I BRAKE SWITCH TI Ilj iiifl l tr 3 l...

Page 1533: ...rlrrrol cRNioFN I LTGHT Jl o o P i HAZARD WARNING swtTcH See Dash and Console YL Tum Signal Switch c55t PHaro 5a 6 c434 c442 t UNDER i DASH 1 J t T o 4 r I T illso _r 1 N_ f FUSE FELAY BOX TURN SIG IAU HAZABD RELAY PHO O I t Y F o 9 f 9 1 4 Y 9 4 2 o 1 5 cnr onr I enttonr I cFNBLU itrr q1fi V Vo I naoe l s roi on To Bon I I this Pase tn t o n o n yi HAZANO WANTING swtTcH LrcHT ori c926 ll t 118 1 ...

Page 1534: ...r sDoor Hatchback I Jffi f l n oo n I I ro f4 Distribution L_il _j___ UNDER DASH FUSE RELAY BOX _t t POWER wtNDow BELAY SeeGround Dislribution page1 5 c925 FUSE 11 POWEnwlt DOWrF I c439 PHO O 62 c503 PHOTO 62 cs06 c609 POWER wtNDow MASTER swtTcH 1 Drive 8Swllch 2 BLr 4 7 BLU 3 c603 DRIVER S wtNDow MOTOR SeeGround Distribution page14 5 Y I l lrr I lllt 120 ...

Page 1535: ...t7 BLU YEL 9 From A on facingpage I I I UNDER OASH FUSE RELAY BOX PHOfO 58 PASSENGER S wtNoow swtTcH POWER wtNDow MASTER swrTcH lf ttot see cround arr Distribdion Page14 6 r lgJ i 1 Tt 0 u iilJ 0 u lJ ini zzI ccor u f t oto t s I cssz UF Dow l UP 00wil 120 1 ...

Page 1536: ...o I ro n l t Distribution L_i1 1 l___ _f l POWER wlt IDOW RELAY c925 FUSE 11 POWER WINDOW FF L 204 J c503 c506 t o L j o n tacingpage t o u o n page 12G4 T o D o n page120 5 r l I _t_ 1 c609 l fiu isiii r 8LU _ _ FEO VEL RED YEI ioI t G502 PHATO91 L 1 I r a 1 1 rt r a 1 ALK I I I BLK Ind n 3 1 Y BLK l BLK IIl 1 I SeeGround Distribution Daoe14 6 SeeGIl Distrib page 1 I l l I c603 SeeGround Distribu...

Page 1537: ...u r o 9 t I 1ffil r N J T J ont FRONT PASSENGER S wtNDow swtTcH POWER wtNDow MASTER SWITCH BLU WHT BLU WHT 1 c x rg l cazr r X 1 7 BLU YEL 1 0 u o f tbb _ _sl coos Fronl Passenger s Switch SeeLeftand RightRear Switches Main Swtlch r f ut see cround ar r Distribution ar x I Page 14 6 l p ___f u T uo iII o u u u l ib tu li r l DOWN DOWN 120 3 ...

Page 1538: ...wtNDow swtTcH REO ALU l 2 BLU RED c652 c527 LEFT REAR wtNDow MOTOR GAN YEL c506 c609 POWER wtNoow MASTER swrTcH Ldt Aear Swltch SeeFront Passonoer s andBialt R ar Switches x _ _ _ _ J Y c612 BLK I See Ground Or r Distribution arx I Page 14 6 v c 0 Y t l J _l u5uz OFF OFF oowN DOWfI UP 120 4 ...

Page 1539: ...ow swtTcH c658 r il 6 lrs nI l 4otor hasa sell resetting ll atg g i j r c528 c506 c609 1 9 YEL 1 6 POWER wtNDow MASTEB swtTcH Right Rear Switch Se Front Pagsenoer s andLefi Rear Switches f tt SeeGround arrd Distribution Page 1 6 Y X 3 I l1lt t I c u_z l DOWN I UP T o o t l u P OFF OFF 120 5 ...

Page 1540: ...ch totheAUTODOWN position voltage isapplied through thedrivels switch tothedriver s window motor Thecontrol unit receives pulses atthepulser input while themotor isrunning Whenthewindow isfullydown the motor stops andpulses arenolonger generated by thepulser Thisissensed bythecontrol unitatthe pulsBr input andvoltage isnolonger applied tothe driver s window motor Passenger Windows Withtheignition ...

Page 1541: ...ELAY BOX c661 f _ r I E l q l L J MOONROOF RELAY MOONROOF swtTcH c662 l c665 103 MOONROOF MOTOR l 4otor hasa self resetting ctrcutt Dreaker PAflREI AY ua n F FELA9 see Powet 24 Distribution OFF ctosE OPEN ilj tlr 3 Y C661 ll 122 ...

Page 1542: ...h totheOPEN position voltage isapplied tothemoonroof motor Themoonroot motor isgrounded through the CLOSE contacts ofthemoonroof switch andthe motorrunstoopenthemoonroof CloseOperation Whenyoupushmoonroof switchtotheCLOSE position voltage isapplied tothemoonroof motor Themoontoof motor isgrounded through theOPEN contacts ofthemoonroof switch andthemotorruns toclosethemoonroof RefertotheService Man...

Page 1543: ... lj l J c607 DRIVER S DOOR LOCK swtTcH UNDER DASH FUSE RELAY BOX FUSE1 lR o 204 7 1 6 WHT GRN 1 4 c504 c506 c604 Battery input Unlock Lock rnput input Unlock Lock input input Unlock Lock irput input r a LTGRN I LTBLU 7 7 i LI GRN I LT 8LU _ _J_ jl c529 3 A r A COg BLK REDll BLK wHr 1A cos REO BIK PaAIA t18 l J PHofo 86 HATCHKEY I T _TI FRONT I7 Ft FRONT CYLTNDER llpassENGER sl I PASSENGER S Sil lt...

Page 1544: ...TOR f BrK l l I KEY c511 WHT FED WHT RED c610 PHOTO 85 YEUFED 6 YEL BED 1 YEURED WHT FEO WHT RED 1 1 WHT REO WHT FEO a rro l L f ru_1 i onn o 9 o I lSY Jnt l r F t3 n J fi t 3 FRONT PASSENGER S DOOR LOCK ACTUATOR ffi l i JJ r Ui3 2 BLKFED DRIVER S DOOR KEY CYLINDER swtTcH BLK l BLK L L c633 inoroed sYi f 6 c4o1 WHIFED 13s PHoraTe C516 c421 wnrneo f f eoffl n cto p4oto56 pre sent n allcarst a I I a...

Page 1545: ... I SYSTEM i CONNECTOR I oPloil x 1 9 T GRN BLU AED 1 4 LTBT U I c611 PHOTO85 c634 PHOTO86 2 BLK BEO FRONT PASSEN GER S oooR KEY CYLINDER SWITCH L t J DRIVER S DOOR KEY CYLINOER SWITCH PHOfO A5 FRONT PASSEN GER S DOOR LOCK SwlTCH DRIVER S DOOR LOCK swtTcH 8LK 1 ALX I a 2 at ALK 2 c634 noto tt PHO O 86 c611 PHOfO 85 BLK 130 2 ...

Page 1546: ...UATOR YEUFED 4 yEqFEo c506 WHI FEO YEUBED YEUFED I YEURED WHT REO 2 WHT RED fi WHT FED cs28 c421 ll Prrolo 50 YELRED o 9 0 1 i t 2 veu neo I YEL nED c633 r Aces Ptloro 36 rar ao t onoto aa ao Y i u of tn r o r FRoNT rfi lerr Rell h p i HfSf WHTFEO II WHTFEO c633 t gu q1 2 RIGHT REAR DOOR LOCK ACTUATOR 13 u f iaoros wHT REO I WHT REO lt c4ot 3 cs27 3 PHoro 7s l PHoro 8e wHrFED I wHrFED 5 wHrlF D U ...

Page 1547: ... g _ ry_ J _E gil u il I i eo io r I B i fffil 4 1ry pase lo e RELAY WHI GRN 61 c446 t i 6 uno o u u onl I GAuGE i i 1 i PHoro2s 9 ilSi ito I yffi i Yffii o r l t ia I ffi f ouu I i I I I l fl llF ffi ILF l I 7 F Tr u tilt f I tn l isx fi no ul ii o codeinput enabre I iilfli lT itf Egf LGr J 2 J PCMor 20 tr c4s7 enrerx s crouna t g Bn l l guW U i BFN l i i f g Yffi r T fr I f i I rr l N lr tr I i ...

Page 1548: ...FI mainrelay ThePCMor ECMthen sends power totheignition keytransponder through theimmobilizer receiver unit Thetransponder then sends a coded signal backtothePCMor ECM through thereceiver unit lfthesignal iscorrect the PCMor ECMwillenergize thecar sfuelsupply system bygrounding thePGM FI mainrelay The immobilizer indicator light flashes a codetoindicate thatthecorrect keyhasbeeninserted lfthe igni...

Page 1549: ...r l C f 3 0u 1 f 3 J 11 ff F F kfl t ffBr T EilHr E mli X S T ll ll ffi FL_____r F_ l y c4s1 wnrI t o o o tn r u n i Horncontrol Security Battery lgnition Antenna I a Horncontrol Security Battery lgnilion Antenna I I Drsarm varet rq indicator nPut Groundswitch input r JllXi lJ L control I Ground switchinput s ivitcn inprlt I L J toy T f 1 BrKll rrGRNll LrBLU ll 7 Yi lt t c426 l l lb i ri n a fl r ...

Page 1550: ... 1 1A 19 t l ar x n oll ELKwHr ll GRN YE I t l sA__ _ 9J t 1 ll ll ll iL_____ lL_ ill n 1 sEcuRrrr i I unrock output Loc output fiirn Eg f o i siren contror gil ildib I q Hoodswirch input t r c44i A 7 PHOrO 5e 9 t 1t lf 1ft c 39 ij g ffi U ll o o n I pase ro l ZJ T nT TIf ithT l gs s__ _______ i i iF ifl i I T1 lnro i Ljry i 3 o 0 u if F l oo L sEcuRrrY rtl nooo to f fl tts Jt l 1 I cdHead isht u ...

Page 1551: ...te ru i 1r i ll tl i if L i l r J I l l 1 g c s 2 8 Ij1 l ll l nnn o I ll lH T i a o n oI P olos6 r NDER DAsFI I oo I FUSE BELAY L V J I l r 1 g c s 2 8 I j1 l il l _ o 0 _ o ouno cnNe u I l o rr oisiriourtn or oLtrioutron L J_ i 14 lr c44e 1 1 _ u ll o o 1 1 I ll l pase u u pase 14 8 l fit t gn r t f J l ll V cnrneof 99 to t u iio_ _o 0 cFN BLu ll s u cnr neo I G c open t Indicator ll LrcFNRED ln...

Page 1552: ...EERING LOCK l f ra 1r I 1 0 BLKryI HT c413 A TGEAR POSITION swtTcH r 1 STABTER cuT RELAY a r I c413 J BLK REO 1 1 l r lt totr ba s ri 1 C42A SECURITY ffi P tLt r r I f lsrnnren l l i in Hll n 1lt15 f T td i Ur run ljl T r sriqrF I rgA i I cros ai i li 1 I i T li p d El ii ls8iEl J i l j L l i t il i i t 1 c ot L I PHero 56 cont d a 133 3 ...

Page 1553: ... 79 wnicnr I r f coor B38 tTo II CONTNOL UNIT wHr GRNll PHA O82 ll n io u 11i l ll il L__J ll o n ll A_______t_A DRIVER S UNLOCK ONLY RELAY PHO O 82 GFNAAIHT GBNAVHT GFNrI VHT GRNAiVHT GRNAVHT 4 a 85 79 56 124 ll n o l1 PASSENGER S DOOR and HATCH LOCK ACTUATORS SeoPower DoorLocks pagel3G1 Hatchback or 1sGg Sodan c610 VEL BED 6 YEVREO r ii r sEcuRrw r _ r powER DooR ilril ir fi ynol I unrucn l nl v...

Page 1554: ...d lor60seconds Theparking lights willflash Thesecurity indicator LEDwillflashtwiceper second Thestarter willbedisabled Attheendofthealarm cycle thesystem will automatically rearm Disarming theSecurity System Therearetwowaystodisarm thesecurity system Withthetransmitter o Withthedisarm valet switch When thesystem isdisarmed regardless ofthe method used theparking lights willflash twotimesif thealar...

Page 1555: ...R Dooa Locx c504 wHT cFN SeePower r Distribution page10 2 c516 ln line connector maynotbepresent inallcars UNDER DASH FUSE RELAY BOX SeeGround Distribution page14 7 cs27 c758 c758 BLUAA HT cs30 c524 HATCH OPENER swtTcH HATCH OPENER ACTUATOR il Orr L BLUAA HT 134 ...

Page 1556: ... i r gEr t rmrsutsstot t ll L e 1uiifiin rri I _ _ _ _ _ _ _ _ _ _ __ J J WHT TEL INTERLOCK CONTROL UNIT t l f seeA rGear r A c sg ar Posnon wHrBL ero o i28 cn1 rvxrll Indicalor r o rz g r q l Bi yJL tx o nf y 1a r EAR I G 11 sh ft rever push i a o I P oSlTloN swlTcH il tii oJ tu o 0 ll iJcni L i g J T F A l Y r i 1 r a solenord flom enelgrTing l R Rt i i F 33 Ji i f 3J3u 00 Ji a 3l JlilglL___ _ _...

Page 1557: ...c 4 m 2 Y c 4 I N t l I i BLX U rl o POWERTRAIN CONTROL MODULE PCM YEVBLX INTERLOCK CONTROL UNIT l f tr r I casr a4 J _ ll ij sa l4J l t ii F T t 3il1 fi ifJ t o i f 1 S eA T Gsar Position lndicator liiffo a BLKI 506 Grourd I i o 1 I l s l Prevents shiftlock solenoid tromenergizing unless brakepedalis depressed andaccelerator pedalisnotdepressed NOTE Incaseofsystem malfunction theshiltlever canber...

Page 1558: ...tion inON ll or START lll battery voltage issupplied through luse 25totheshiftlocksolenoid Whenyoupush the brake pedal battery voltage isapplied through the GRN VVHT wiretothetransmission 98 99 models orpowertrain 00model control module TCM or PCM lf atthesametime youdonotpush the accelerator pedal a lowvoltage signal issent through theRED BLK wiretotheTCMor PCM The TCMor PCMthenapplies voltage th...

Page 1559: ...themirrror direction selected I I ruse rz I I xearenrceeuv I 7 5 4 I I Uee FOI ver I l Distribution I I pase 10 6 I L g J UNDER DASH FUSE RELAY BOX 7 ll Cs03 otou oftffi erxner I I x c608 InternalSwitchPositlons Switch l Swltch2 Switch3 Miror direction selected UP A B oowN A LEFT A A E RIGHT B A B Swiich 3 Mirror Ssl3clor Switch LEFT I 1 RIGIfI POWER MIRROR swtTcH BLU WHT BLU IVHI 1 0 BLU HT YEL R...

Page 1560: ...tions according tothemirrror direction selected c506 c421 c401 BLU GRN ALU BLK 3 YEL VI HT 1 B U VHI c629 I POWER MIRROR swrTcH YEU BLU BLK 1 1 BLU BLK BLUA VHI BLUA HT 1 0 YEURED 2 c605 3 YEL FEO YEUBLK 1 BLUA HT YELI VHT PNK YEUFEO BIU GFN RIGHT POWER MIRROR f Inlehal Switch Positions Switch 1 Switch 2 Switch 3 Mirior direction selected UP A B DOWN B A A LEFT A A RIGHT B A 7 Y c503 otou o erxrer...

Page 1561: ...ltage totheleftor right power mirror up down motor asdetermined bythe mirror selector switch Theselected mirror motor is grounded through switchI intheB position toG501 Sedan orG502 Hatchback Whenswitch 2 is moved to position A italsoapplies battery voltage totheselected mirrorlefyright motor Withswitch3 intheA position battery voltage issupplied to both sidesoftheleruright motorso it doesnotmove ...

Page 1562: ..._L____l_J FUSE 47 FUSE RELAY BOX aacxug aao o c217 c551 oPT ON PHOTA 58 CONNECTOR 19 t C551 SeePgwer Distribution 10 8 1 0 RS e c505 Sodan It I t c Not Used 6 l c I Harcnoact j T_ i t See Antenna CRY ALK I csos c506 8RN BLK I c452 c401 FRONT PASSEN GER S DOOR SPEAKER Battery memory Power antenna conrol 150 ...

Page 1563: ...EI r__1 cD r 1 co I IPLAYER CHANGER l l l l r r STEREO RAOTO CASSETTE PLAYER withOptional CDChanger WithOptional CDPlayer c516 ln line connector maynotbepresent inallcars 1 r G r o u n d 150 1 ...

Page 1564: ...DER DASH FUSEiRELAY BOX PHOTA58 STEREO RADIO CASSETTE PLAYER UNDER HOOD FUSE RELAY BOX T Distribution I__i1 __ fr I I I I YEUGBN 2 YEUGFN l WHT BEO 1 c5tI POWER ANTENNA MOTOR ANTENNA LEAO er I FJ c518 SeeGround Distribution page14 7 iT r L tr i 6 Y C217 s A c566 i I t I r i LI t 3E 3 J 1 5 1 arrxa ...

Page 1565: ... I Y SeePowar Distribution page10 5 r I 1 UNDER DASH I f FUSE2S I FUSE RELAY a Jy5t a L SeePower l r f i q t I L 9 J 10 Y C551 8 WHT BLU WHT BLU SeePower Distribution page10 8 WHT BLU SeePower Distribution page10 8 SeeDashand Console Lights T I ao a f J CLOCK Battery memoryJ lgnition Dimming input Ground 1 Y C561 54 ...

Page 1566: ...te Lighter iltt _ j r F UNDER DASH FUSE RELAY BOX See Dashand ConsoleLights BED BLK FEO BLK c569 PHOIQ 68 c569 PHOTO68 CIGARETTE LIGHTER RED 4 BED See Dashand ConsoleLights I I J CIGARETTE E ASHTRAY 155 J o ot ...

Page 1567: ...1 BehindRightSideof FrontBumper 4 Right Front Cornerof EngineCompartment 2 RightSideof EngineCompartment M T 5 RightFrontCornerof Engine Compartment 3 BehindLeftSideof FrontBumper 6 RightFrontof Engine Compartment A T 201 ...

Page 1568: ...tFrontot Engine Compartment 10 Left Front of EngineCompartment 8 CenterFrontof Engine Compartment 11 LeftFrontCornerof EngineCompartment 9 LeftFrontof Engine Compartment 12 Right Side of EngineCompartment 201 1 ...

Page 1569: ...RightFrontCornerof Engine Compartment 16 RightSide of Engine GS RShown OthersSimilar 14 TopFrontof Manual Transmission 17 RightSideof Engine AllExceptGS R 15 TopFrontot Automatic Transmission 18 RightSideof Engine GS R l 201 2 ...

Page 1570: ... Engine Compartment 20 RightSideof Eng Comp A I Shown lvVT Similar c104 6 GRY RS LS AND GS WITHA IT 3 GRY GS R TYPE F 23 RightRearCornerof EngineCompartment 21 RightRearCornerof EngineCompartment 24 Underside ot Under hood Fuse Relay Box l 201 3 ...

Page 1571: ...of Automatic Transmission 98 99Mod Component Location 28 RightSideof Engine 26 TooRearot Transmission 29 CenterRearof Engine Type R 27 LowerRightSideof Engine Compartment 30 CenterRearof Engine AllExceptGS R 201 4 ...

Page 1572: ...GS R 34 LeftRearot EngineCompartment 32 CenterRearot Engine GS BShown Type H Similar 35 LeftRearof EngineCompartment 33 CenterRearof Engine Compartment POWER STEERING PRESSUBE PSP SWITCH 36 LeftBearCornerof EngineCompartment 201 5 ...

Page 1573: ...mponent Location 42 Underside of Car BightBearot Transmission 40 Underside of Car Frontof Manual Transmission 38 BehindLeftSideof Air Scooo 41 Underside of Car Frontof Transmission 98 99 39 Underside of Car LeftFrontCornerof Engine 201 6 ...

Page 1574: ... Car CenterRearol Engine 46 Behind Left Rearwheel Right RearSimilar 44 Underside of Car BehindCenter of Engine 47 Rearof GaugeAssembly 45 BehindLeftFrontWheel RightFrontSimilar 48 Bight Side of SteeringColumn t 201 7 ...

Page 1575: ...ponent Location t f 49 Center of Steering Wheel 52 Rear of Dashboard Lower Cover 50 Topof Steering Column 53 BehindDashboard LowerCover 51 Behind Left Kick Panel 98 99Models 54 Above Left Kick Panel 201 8 ...

Page 1576: ...I 55 Above Left Kick Panel 58 Behind DashboardLower Cover 56 Above Left Kick Panel 59 BehindDashboard LowerCover 57 Above Left Kick Panel 60 Behind DashboardLower Cover 201 9 ...

Page 1577: ...oard LowerCover 65 BehindDashboard LowerCover rt 64 Behind Dashboard Lower Cover SRSMEMORY ERASESIGNAL MEs CONNECTOR c808 2 YEL 62 Rearof Under dash Fuse Relav Box 63 BehindDashboard LowerCover 201 10 66 BehindDashboard LowerCover l l ...

Page 1578: ...67 Below Centerof Dash Left of HeaterUnit 70 Below Right Side of Front Console 68 BehindFrontConsolePanel 71 BelowBearConsole 69 BehindCenter ot Dash 72 BelowGloveBox 201 11 ...

Page 1579: ...onent Location l 73 Behind Glove Box 76 Above Right Kick Panel 74 Behind Right Side Glove Box 77 BehindRightKickPanel 98 99 Modets 75 Below Right Side of Dash 201 12 78 BehindRightKickPanet ECMor pCMRemoved ...

Page 1580: ...ontof Driver sDoor 80 Frontof Driver sDoor Pass Similar Hatchback 8 BLK VHT LEFT c629 8 BLK wHT RTGHT 83 Center of Driver s Door Pass Simila0 Hatchback 81 Frontof Driver sDoor FrontPass Similar Sedan 84 Center of Driver sDoor Pass Similar Sedan 201 13 ...

Page 1581: ...n 85 Rearof Driver sDoor 86 Rearof FrontPassenger s Door I 88 Left B pillar RightSimilar Sedan 89 LeftRearDoorJamb RightSimilar 87 Frontof LettQuarter Panel RightSim Hatchback 90 Frontot LeftRearDoor RightSimilar 201 14 ...

Page 1582: ...rof Left RearDoor RightSimilar 94 Below Driver sDoor SideTnm 92 Frontof LeftQuarter Panel RightSimila0 95 BelowDriver sSeat 93 BehindRightSideof FrontConsole 98 99Models 96 Behind Left QuarterPanelTrim 201 15 ...

Page 1583: ...e of RearSeat RightSimilar Component Location t 100 Behind Bight QuarterPanelTrim Hatchback 98 BelowCenter ot RearSeat 101 BelowLeftSideof Dash withSecurity 99 Behind Right Side ot RearSeat 201 16 102 Center of RearShelf ...

Page 1584: ...of Roof Hatchback 106 Right Side of Cargo Area 104 LeftRearof CargoArea Hatchback 107 CenterRearof CargoArea Hatchback l l J 105 Left Side of CargoArea Hatchback 108 LeftRearof CargoArea RightSimilar Hatchback 201 17 ...

Page 1585: ...runk 98 99Models Sedan Component Location b 112 RightRear ofTrunk 110 BightSideotTrunk Sedan 113 LeftRearof Trunk RightSimilar Sedan 111 RightSideof Trunk ABSControlUnitRemoved 201 1 8 114 Centerof HatchSpoiler Hatchback ...

Page 1586: ...enterof Hatch All exceptGS and GS R 118 Left Side of Trunk Lid Bight Similar Sedan 116 Left Side of Hatch 119 Centerof TrunkLid Sedan 117 RightSide of Hatch 120 BehindCenterot FrontBumper withSecurity 201 19 ...

Page 1587: ...cation iD 121 Below Left Side of Dash 124 Below Left Side of Dash 122 AboveLeftKickPanel Optional 125 Center ot HatchSpoiler Optional 123 BehindDashboard LowerCover Optional 126 Right Side of Hatch Optional 201 20 ...

Page 1588: ... of Roof Sedan 130 Behind Left Side of Dash on Clutch PedalSupport 128 BelowLeftSideof FrontConsole 131 RightSideof FrontConsole 129 BehindLeftSideot Dash on BrakePedalSupport 132 BelowCenterof IntakeManifold l 201 21 ...

Page 1589: ...ne 136 Undersideot Vehicle Forwardof FuelTank EVAPORATIVE EMISSION EVAP BYPASS SOLENOIDVALVE 134 Underside ot Vehicle Topof Catalytic Converter 137 CenterRearof CargoArea Hatchback 135 LowerCenterot Engine 138 CenterRearof CargoArea Hatchback 201 22 ...

Page 1590: ...E EMISSION EVAP CONTROL CANISTER VENTSHUT VALVE 142 Top Centerof Engine FUEL INJECTOR NO 2 c122 2 BLKI 140 BehindRightKickPanel 00Model 143 Undersideof Car Frontof Trans 00Model 141 TopCenter of Engine RS LS GS 144 LeftSideof SteeringColumn 201 23 J ...

Page 1591: ...Gomponent Location 145 Behind Glove Box 201 24 ...

Page 1592: ... Connector View Connector c 5 2 1 4 c 5 2 3 4 C 5 2 7 S e d a n 2 C528 Hatchback 4 C 5 2 8 S e d a n 2 c 5 5 1 3 9 c 5 5 6 4 0 c5s8 A T 1 5 c 5 5 9 2 1 c 5 6 0 3 1 c s 6 3 1 4 c 5 6 4 4 c 5 6 6 2 8 c 6 0 4 2 6 c 6 0 5 1 1 c 6 0 8 1 5 C609 Hatchback 14 C609 Sedan 29 c 6 1 0 4 c 6 2 9 1 1 c 6 7 7 2 5 c 6 8 2 8 c 6 8 3 3 C 6 8 4 2 3 c 7 0 3 1 8 c 7 0 4 4 2 c 8 0 4 3 4 View 202 ...

Page 1593: ...Connector Views J 1 2 3 4 5 6 7 I 1 3 4 6 I 7 1 8 9 1 2 3 4 5 6 7 1 3 2 4 5 6 7 1 2 3 4 c 6 7 1 3 2 4 5 6 7 8 202 1 ...

Page 1594: ...Connector Cavity Numbers Connector Views 202 2 1 3 4 7 6 o 1 0 t2 t3 1 4 t5 16 1 3 4 6 7 E 9 1 0 1 1 1 4 t5 1 6 ...

Page 1595: ...6 1 7 1 8 1 9 20 21 22 23 24 25 1 q l s 6 l z 6 9 1 0 1 1 t2 1 5 1 6 1 7 1 8 l a 20 1 T 4 5 5 7 8 9 1 0 1 1 1 3 1 4 t5 1 6 1 7 1 8 1 9 20 2 l 22 23 24 26 27 2A 29 30 1 3 6 8 9 1 0 1 1 1 2 t3 1 4 1 5 1 6 1 7 t8 1 9 20 21 22 24 27 2A 29 30 32 f t 202 3 ...

Page 1596: ...vecover Topleftsideol bulkhead Bodyground viaengine ground EngineGroundCableB T4 Rightsideofenginecompartment Transmission housing Right frontsideoftrame Bodyground viaengine ground wrre b A C WireHarness Under hood ABSFuse Relay Box Cable 203 c151 c 154 u t S c u t c o 8 GRY 2 GRY 2 GRY 1 GRY Right sideol engine compartment Leftsideofengine compartment Leftsrde ofengine compartment Leftsideofengi...

Page 1597: ... UNDER HOOD ABS FUSE RELAY BOXCABLE BATTERY GROUND CABLE ENGINEGROUND CABLEB A CWIREHARNESS T3 ENGINEGROUND CABLE A t 203 1 ...

Page 1598: ...t rearcornerof enginecompt Left rearcornerof enginecompt Transmission Transmission Transmission Transmission Transmission Transmission Transmission Mainwireharness Main wireharness Mainwireharness Mainwireharness Starter solenoid Engine coolant temperature ECT sensor Engine coolant temperature gauge sending unit Back up lightswitch Lock up control solenoid valveA andB Distributor Crankshaft speedf...

Page 1599: ... ENGINEWIREHARNESS RS LS GS c1o2 c10l c129 c1 12 c 1 t 4 c l 1 7 c t26 c125 t c t27 c 1 1 8 c121 c122 c123 cl24 cl t6 c 1 t 9 203 3 ...

Page 1600: ...e ofengine Middle ofengine Middle ofengine Middle ofengine Middleofengine Leftrearcornerofenginecompt Leftrearcorner ofengine compt Leftrearcorner ofengine compt Right sideofengine Right sideofengine Leftendofengine Leftendofengine Main wireharness Main wireharness Mainwireharness Mainwireharness Starter solenoid Engine coolant temperature ECT sensor Engine coolant temperature gauge sending unit B...

Page 1601: ... ENGINEWIREHARNESS GS R TYPER c101 c102 c 1 t 6 c126 c l 1 7 c l 1 9 c113 C114 c 1 1 5 C10i c104 c105 203 5 ...

Page 1602: ...dle ofengine compartment Leftsideofengine compartment Lettsideofengine compartment Behind leftheadlight Behind leftheadlight Behind leftheadlight Behind leftcorner offrontbumper Behind leftcorner offrontbumper Behind leftcorner offronlbumper Behind leftcornerof rontbumper Engine wireharness Engine wireharness Mainwireharness Main wireharness Main wireharness Front loglightsystem Testtachometer con...

Page 1603: ... ENGINECOMPARTMENT WIREHARNESS 1 c318 c317 c301 c303 c306 c307 203 7 ...

Page 1604: ... compartment Right sideofengine compartment Bight sideofengine compartment Right sideofengine compartment Right sideofengine compartment Right sideofengine compartment Right sideofengine companment Right sideofengine compartment Right sideofengine compartment Right sideofengine compartment Right sideofengine compartment Engine wireharness Engine wireharness Engine wireharness Engine wireharness En...

Page 1605: ... UNDER HOOD FUSE RELAY BOX c224 MAINWIRE HARNESS c102 1 Continues lrom page203 11 203 9 ...

Page 1606: ...els door Under right sideofdash Under right sideofdash Under rightsideofdash Under right sideofdash Behind rightkickpanel Behind rightkickpanel Behind right kickpanel Behind right kickpanel Behind rightkickpanel Fronlpassenger s doorwire narness A C diode Heater sub harness A Heater sub harness A Service check connector ABSsub harness Engine control module ECM PCM Engine control module ECM PCM Eng...

Page 1607: ... r Continues trom page203 13 Contlnues from page203 9 I MAINWIREHARNESS I 203 11 ...

Page 1608: ...ashboard lowercover Behinddashboard lowercover Behinddashboard lowercover Behinddashboard lowercover Behinddashboard lowercover Underleftside of dash Underleftside of dash Underleftsideof dash Underleftsideof dash Underleftsideof dash Behindunder dashfuse relaybox Underlettsideof dash Engine compartment wireharness Engine compartment wireharness Engine comparlmenl wireharness Datalinkconnector DLC...

Page 1609: ...5 c456 4 NAT 14 GRY 16 GRY 3 GRY 4 GRY 3 GRY 5 GRN Behinddashboardlowercover Behinddashboard lowercover Behinddashboard lowercover Centerconsole Undermiddleof dash Underleitsideof dash Rightsideof steerang column Hornrelay Dashboard wireharness Dashboard wireharness Parkpinswitch SecondaryH02S Cablereel lmmobilizer receiver unit RS Allexcept RS 00model G401 Behindlettkickpanel Body ground viamain ...

Page 1610: ...goarea Leftsidecornerofcargoarea Leftsidecornerofcargoarea Leftsidecornerofcargoarea Center ofcargo areabulkhead Rightrearcornerofcargoarea Rightsideofcargoarea Rightsideofcargoarea Rightsideofcargoarea Centerofcargoareabulkhead Centerofcargoareabulkhead Center ofcargoareabulkhead Leftsidecornerofcargoarea Mainwireharness Mainwireharness Under dash fuse relay box Under dash fuse relay box Dashboar...

Page 1611: ... Cs05 CsO4 cs t l c526 cs18 c531 c519 c520 REARWIREHARNESS 203 15 ...

Page 1612: ...ftrearcorneroftrunk Rightrearcorneroftrunk Right rearcorner oftrunk Lettreardoor Right reardoor Leftquarter panel Leftedgeol rearwindow Aboverightsideoftrunk Right quarter panel Rightedgeof rearwindow Leftsideoftrunklid Center ottrunklid Right sideoftrunklid Mainwireharness Mainwireharness Under dash fuse relay box Under dash fuse relay box Dashboard wireharness Driver s doorwireharness Driver s s...

Page 1613: ... r t REARWIREHARNESS J 203 17 ...

Page 1614: ... cover Under leftsideofdash Under leftsideofdash Behind gauges Behind gauges Behind gauges Behind gauges Behind middle otdash Leftsideol dash Behind middle ofdash Behind middle ofdash Right sideofdash Under middle ofdash Behind dashboard lower cover Under middle ofdash Mainwireharness Main wireharness Maihwireharness Main wireharness Mainwireharness Rear wireharness Under dash fuse relay box Cruis...

Page 1615: ... fl r r1a ta ll L j L r t ll i cs62 Cs63 c561 cs64 DASHBOARD WIRE HARNESS UNDER DASH FUSE RELAY BOX 203 19 ...

Page 1616: ...river s door Driver s door Behind mirror control panel Driver s door Driver s door Driver s door Driver s door Driver s door Driver s door Driver s door Driver s door Driver s door Rear doorwireharness Driver s doorspeaker Driver s power window motor Power doorlockcontrol unit Leftpowermirror Leftpowermirror Lefthveeter Driver s doorlockswitch Power mirror switch Powerwindowmaster switch Power win...

Page 1617: ... r Hatchback c9Q8 cooe l r 203 21 ...

Page 1618: ...oor Front passenger s door F ont passengefs door Behind cover panel Front passenger s door Front passenger s door Frontpassenger s door Front passenger s door Frontpassenger s door Front passenger s door Mainwireharness Front passenger s doorspeaker Frontpassengefs powerwindow motor Right power mirror Right power mirror Righttweeter Frontpassenger s doorlock switch Front passenger s power window s...

Page 1619: ... I Hatchback Sedan I PASSENGER S OOOR WIRE HARNESS FRONTPASSENGER S DOORWIREHARNESS 203 23 ...

Page 1620: ...AT 2 GRY Leftreardoor Leftreardoor Leftreardoor Leftreardoor Rear wireharness Leftrearpowerwindowmotor Leftrearpowerwindowswitch Leftreardoorlockactuator RightRearDoorWireHarness Sedan ucz IJOJ c658 uocv 6 NAT 2 GRY 5 NAT 2 GRY Rightreardoor Right reardoor Right reardoor Rightreardoor Rearwireharness Rightrearpowerwindowmotor Rightrearpowerwindowswitch Rightreardoorlockactuator J 203 24 ...

Page 1621: ... _ J L i LEFTREARDOOR WIRE HARNESS RIGHTREARDOOR WIRE HARNESS 203 25 ...

Page 1622: ...uoo4 vooc uooo uoo 2 GRY 3 BRN 4 BRN 4 BLU 2 BRN VVHT 1 WHT 3 NAT Behindleftkickpanel Behindleftkickpanel Behindlettkickpanel Left sideof dashboard Roof Roof Roof Main wireharness Under dash fuse relay box Moonroof relay Moonroof switch Moonroof motor Spotlight Ceiling light with moonroot with moonroof with moonroof with moonroof wirh moonroof l _ a 203 26 t ...

Page 1623: ...o n l L_ r Halchback Sedan UNDER DASH FUSE RELAY BOX ROOF WIRE HARNESS UNDER DASH FUSE RELAYBOX ffin nt 203 27 ...

Page 1624: ...22 ORN 2 ORN 2 ORN 2 ORN 2 ORN Behind right kickpanel Right quarter panel Right quarter panel Bight sideofcargo area Right sideoftrunk Leftsideofcargoarea Leftsideoftrunk Mainwireharness ABScontrol unit ABScontrol unit ABSright wheel sensor ABSrightwheelsensor ABSleftwheel sensor ABSleftwheel sensor Hatchback Sedan Hatchback Sedan G702 Right quarter panel Bodyground viaABSsub harness 203 28 ...

Page 1625: ... i Hatchback Sedan c704 c703 d j r t 203 29 ...

Page 1626: ...dle ofhatch Rear wireharness Rearwireharness Rearwireharness Rearwindowdefogger Spoiler sub harness Rear window wipermotor Highmount brake light Hatchopenerswitch GS GS R RS LS GS t r J I Rightside of hatch Bodyground viahatchwire narness SpoilerSub harness Hatchback GSandGS R c754 c762 c763 1 BLK 1 BLK Rightside of hatch Middleof hatch Middleof hatch Hatchwireharness Highmount brake light Highmou...

Page 1627: ... _ 1 c756 cz5s HATCH WIREHARNESS REAR DEFOGGER GROUND WIRE SPOILER SUB HARNESS 203 31 ...

Page 1628: ...sideofdash Behind glovebox Behind glovebox Behind glove box Behind middle ofdash Main wireharness Mainwireharness Blower motor Blower resistor Recirculation controlmotor A C thermostat Heater sub harness B HeaterSub harness B c677 c682 tJOat t c684 14 GRY 8 GRY 6 NAT 14 GRN Behind middle ofdash Middle offloor Behind middle ofdash Behind middle ofdash Heater sub harness B Modecontrolmotor Heater fa...

Page 1629: ...YEL 2 YEL 2 YEL Underleftsideof dash Behinddashboard lowercover Underleftsideof dash Middleof floor Behindglovebox Underleftsideof dash Main wireharness Under dash fuse relay box Cable reel SRSunit Passenger s airbag assemblY Memory erase signal MES conneclor G801 Middleof floor Bodyground viaSRSmain narness SRSMAINHARNESS Y1 D I i 203 33 ...

Page 1630: ...lor Location Connects to Notes FuelSub harness c510 c791 c792 c793 2 BLK 8 GRY 2 BRN 3 GRY Topoffueltank Belowcenterofrearseat Underside ofvehicle forward offueltank Underside ofvehicle forward offueltank Rear wireharness Fuelpump connector Fuel tankpressure sensor EVAPbypass solenoid valve 203 34 ...

Page 1631: ... REARWIRE HARNESS 203 35 ...

Page 1632: ...d control unit License plate lights Maintenance reminder light Parking lights Power antenna Power doorlocks Power windows Programmed fueliniection system PGM Fl Rear window defogger Stereo sound system Taillights Trunk lioht 11 GRY 18 BBN 4il exceptBS 12 BBN RS Under hood fuse relay box Main Engine CompartmenV Main Engine CompartmenU Main lr Ccompressor controls Automatic transmission controls Blo...

Page 1633: ... window defogger Rear wiDer washer io t l c430 An 8 GRY e8 ee or 1O GRY 00 18 GRN Dashboard Main Under dash fuse relay box Main A Tgearposition indicator Automatic transmission controls lmmobilizer system 00model Programmed fuelinjection system PGM Fl Anti lock brake system ABS Automatic transmission controls Charging system Daytime running lights DBL Front parking lights Hazard warning lights Hea...

Page 1634: ...ghts Anti lock brake system ABS Clock Cruise control Console lights Dashlights Gauges Hazard warning lights lgnition system Maintenance reminder light Engine oilpressure indicator light Programmed fuelinjection system PGM Fl Rearwindow defogger Stereo sound system Supplemental restraint system SRS Vehicle speed sensor VSS Power mirrors Power windows Brake system indicator light Cargo arealight Day...

Page 1635: ... Hazard warning lights Indicators Maintenance reminder light Power antenna Bearwindow delogger Stereo sound system Turnsignal lights ucco 2O WHT Dashboard Dashboard Cigarette lighter Clock Consolelights Dashlights Gauges Indicators Maintenance reminder light Rearwindowdefogger r t l c677 14 GRY Heater sub harness A Heater sub harness B fuCcompressor controls Airdelivery Blower controls Dashlights ...

Page 1636: ...v v v ACU RA II ITEGFIFI Seruice Manual Supplement 2fl l ...

Page 1637: ...General Information Chassis and PaintCodes 1 2 Under hoodEmissions ControlLabel 1 4 Revised Component Terms 1 5 ...

Page 1638: ... GS R with leather seats S Suzuka Factory in Japan Chassis andPaintCodes I U S Model VehicleldentificationNumber and FederalMotor VehicleSafetyStandardCertification 4 door PaintGode COLOR G 95P 19 dt 3 3 door 4 4 door 81881 818B1 1 8f DOHC Sequential Multiport Fuel injected engine 818C1 818C5 1 8f DOHC WECSequential MultiportFuel injected engine PaintCode Nighthawk BlackPearl VoltageBlueMetallic C...

Page 1639: ...d5 speed Manual S Suzuka Factory in Japan CanadaModel VehicleldentificationNumberand CanadianMotor VehicleSafetyStandardGertification PaintGode COLOR NH O 8 1 8 8 1 818B1 1 8f DOHC Sequential Multiport Fuel injected engine 818C1 818C5 1 8 DOHC WEC Sequential MultiportFuel injected engine Nighthawk BlackPearl Championship White SatinSilverMetallic MilanoRed TitaniumMetallic rfilill 1 3 ...

Page 1640: ... BEPLACED AT I20 MONTHS OR200 000 km 120 000 LtS rnirilrren B pLAcE rT EvEFY 60 roNTHs oR 100 000 km 60000 ilLEs C H E C O RA D DT H EC O O L A N I A T T H ER E S E R V E T A N K N O TT H ER A D I A T O F F O RF I J R T H E R I N F O R M A T I O N O N H E C O O L N G S Y S T E M R E A D T H EO W N E N S M A N U A L I C H E C K W I T H Y O U R H O N O A D E A L E R ll 5lil 5 i iX THISVTHCtE CONFOF ...

Page 1641: ...uelTankVaoorRecirculastion Tube FirstldleThermoValve ldleAir ControlThermalValve IACThermalValve FuelInjector Injector FuelIniection Air ControlValve FIAControlValve IntakeAir BypassControlValve FuelInjection Air ControlSolenoidValve FIAControlSolenoidValve IntakeAir BypassControlThermalValve lntakeAir BvDass CheckValve IABCheckValve IntakeManifoldRunnerControlVacuum CheckValve IMRC Vacuum Check V...

Page 1642: ...SolenoidValveB ShiftSolenoidValveB SSValveB ThrottleValveControlModule Throftle Actuator Lock uoClutchControlSolenoidValve Set ToroueConvertor ClutchSolenoid AutomaticTransaxle ClutchPressure ControlSolenoidValveSet TCCSolenoid Av T Clutch Pressure ControlSolenoid ValveSet Lock uoClutchControlSolenoidValve TorqueConvertor ClutchSolenoidValve TCCSolenoidValve AutomaticTransaxlePositionSwitch A TGea...

Page 1643: ... Specifications Standards andServiceLimits g 2 DesignSpecifications 3 15 BodySpecifications 3 18 ...

Page 1644: ...327 4l 33 528 1 3200 0 5 0 02 0 15 0 006 0 04 0 002 Valve Valve clearance Cold lN EX Valve stem O D lN E X Stem to guideclearance lN EX 0 08 0 12 0 003 0 005 0 16 0 20 0 006 0 0081 6 580 6 590 0 2591 0 2594 6 550 6 560 0 2579 0 2583 0 02 0 05 0 001 0 002 0 05 0 08 0 002 0 003 ouu to rutt 6 52 rc 2571 0 08 0 003 0 1 1 0 004 Valve seat width lN EX stem installed height lN EX 1 25 1 55 0 049 0 061 1 ...

Page 1645: ...0 008 0 014 0 20 0 30 0 008 0 012 0 40 0 55 0 016 0 022 0 20 0 50 0 008 0 020 0 20 0 45 0 008 0 018 0 60 0 024 0 60 0 024 0 70 0 028 0 70 0 028 0 70 0 028 Piston Pin o D Pin to pistonclearance 20 994 21 000 0 8265 0 8268 0 010 0 022 0 0004 0 0009 Connectingrod Pin to rodinterference Small end bore diameter Large end bore diameter Nominal End play installedon crankshaft 0 013 0 032 0 0005 0 0013 20...

Page 1646: ...0 2 t 0 007 0 008 5 475 5 485 0 2156 0 2159 5 450 5 460 0 2146 0 2150 0 025 0 055 0 0010 0 0022 0 050 0 080 0 0020 0 0031 in to r ool 5 420 0 2134 0 08 0 003 0 1 1 0 004 Valve seal Width lN 818C1engine B18C5engine EX B18C1engine 818C5engine Stem installedheight lN EX 1 25 1 55 0 049 0 061 0 85 1 15 0 033 0 045 1 25 1 55 0 049 0 061 0 85 1 15 0 033 0 045 37 465 37 935 1 4750 1 4935 37 165 37 635 1 ...

Page 1647: ... 964 20 997 0 8254 0 8267 48 0 1 89 0 15 0 30 0 006 0 012 0 40 0 016 Crankshaft Mainjournaldiameter No 1 2 4 and5 journals No 3 journal Rodjournaldiameter Taper Out ofround Endplay Runout 54 976 55 000 2 1644 2 1654 54 97 4 54 998 2 1643 2 1653 44 976 45 000 1 7707 1 7717l 0 005 0 0002 max 0 005 0 0002 max 0 10 0 35 0 004 0 014 0 03 0 001 max orroto ooool 0 010 0 0004 0 45 0 018 0 05 0 002 Bearing...

Page 1648: ... the reservoirand that remaining in the engine Fueland E MEASUREMENT STANDARD NEW SERVICELIMIT Pressure regulator Pressure with regulator vacuumhosedisconnected kPa kgf cm psi 81881engine 818C1 engine 818C5 engine 270 320 2 8 3 3 40 47 329 378 3 35 3 85 48 55 320 370 3 3 3 8 47 541 Fueltank Capacity US gal lmp gal 5 0 1 3 2 1 1 0 Engine ldle speed with headlight and cooling fan off rpm 81881 818C1...

Page 1649: ...hickness 43 009 43 025 1 6933 1 6939 0 06 0 21 0 0024 0 0083 31 42 31 4711 237 1 2391 43 08 1 696 0 3 0 012 31 311 2321 Countershaft Diameterof needle bearing contact area Diameterof ball bearing contact area Diameterof 1st gear contact area Runout 33 000 33 015 1 299 1 300 24 980 24 993 0 9835 0 9840 36 984 37 000 1 4561 1 45671 0 02 0 0008 max 32 95 1 2971 24 94 0 982 36 93 1 454 0 05 0 002 Coun...

Page 1650: ...r clearance L groove width at Sth gear side at reversegear stde Fork to 5th reverseshift piece pin clearance at 5th gear side at reverse gear side 13 0 13 3 0 512 0 524 0 5 1 1 0 0 2 0 0 0 4 3 7 40 7 70 0 291 0 303 7 05 7 25 0 278 0 285 0 4 0 9 0 016 0 035 0 05 0 45 0 0020 0 018 1 8 0 07 Shiftarm Groove width of change piececontact area Change piece to shift arm clearance 11 8 12 0 0 46 0 47 0 0s ...

Page 1651: ...rk8 Mark9 Mark10 2 05 2 t0 0 081 0 083 2 15 2 20 0 085 0 087 2 25 2 30 0 089 0 091 2 35 2 40 0 093 0 094 2 45 2 50 0 096 0 098 2 55 2 60 0 100 0 102 2 65 2 70 0 104 0 106 2 75 2 80 0 108 0 110 2 45 2 90 0 1 12 0 1 14 2 95 3 00 0 1 16 0 1 18 Discoloration Discoloration Clutchend plate thickness Mark 6 2nd 4th Mark 7 Mark8 Mark9 Mark 10 M a r k1 1 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16 Mark 17 2 55...

Page 1652: ...1 0236 22 9935 23 0065 0 9053 0 9058 13 990 14 000 0 5s08 0 5512 35 000 35 016 1 3780 1 3786 4 1 0 0 0 4 1 0 1 6 1 6 1 4 2 1 6 1 4 8 38 000 38 016 1 4961 1 4967 38 000 38 016 1 4961 1 4967 41 000 41 016 1 6142 1 6148 33 000 33 016 1 2992 1 2998 38 000 38 016 1 4961 1 4967 32 000 32 016 1 2598 1 2605 18 007 18 020 0 7089 0 7094 14 416 14 434 0 5676 0 5683 0 05 0 16 0 002 0 006 0 05 0 13 0 002 0 005...

Page 1653: ...698 2 6254 2 6259 8 97 8 98 0 353 0 3541 5 97 5 98 0 2350 0 2354 7 97 7 98 0 3138 0 3142 7 97 7 98 0 3138 0 3142 1 87 1 97 0 074 0 078 6 018 6 030 0 2369 0 237 4l 9 000 9 015 0 3543 0 3549 8 000 8 022 0 3150 0 3158 8 000 8 022 0 3150 0 3158 2 025 2 075 0 0797 0 081 1 Wearor damage Wearor damage 8 95 0 352 5 95 0 234 7 95 0 313 7 95 0 313 1 82 0 0721 6 045 0 2380 9 03 0 356 8 03 0 316 8 03 0 316 2 ...

Page 1654: ... 2 13 4 22 0 1 A 26 8 26 8 t6 2 13 8 14 2 z J 15 9 o l 2 6 6 3 13 9 32 O 47 8 14 1 1 A 20 8 ttJ J I v 5 Standardsand ServiceLimits AutomaticTransmission cont d Section14 Differential ManualTransmission Section15 Differential AutomaticTransmission Section15 t ilt5stlrrr 4 MEASUREMENT STANDARD NEW SERVICE LIMIT Differential carner Pinion shaft contact area l D 81881 engine B18C1 818C5engines Carrier...

Page 1655: ...ANDARD NEWI Wheel alignment Camber Front TypeR All exceptTypeR Rear Caster Front Totaltoe Front Rear Front wheel turning angle Inwardwheel Outward wheel 0 30 r 1 0 10 r1 0 45 1 i3i 1 1 0 11 0 2 1 0 1 1 1 6 lN 2 lf t7t61 17161 36 00 1 2 30 30 Wheelbearing Endplay Front Rear 0 0 05 0 0 002 0 0 05 0 0 002 Wheel Rimrunout Aluminum wheel Axial Radial Rimrunout Steel wheel Axial Radial STANDARD NEW SERV...

Page 1656: ...k0 1 2 0 6 0 8 12 8 19 2 lgnitionwire Resistance at 68 F 20 C k0 Firinqorder 25max 1 3 4 2 Sparkplug Iype Gap B18B1 818C5 engines 818C1 engine STANDABD NEWI SERVICE LIMIT SeeSection23 1 0 1 1 0 039 0 0431 1 2 1 3 0 047 0 051 i roru t 1 5 0 0591 1 lgnition timing At idling BTDC Red rpm M T AIT Except 818C5 engine16 2 750 Neutral 818C5 engine 16t 2 800 Neutral 16 2 750 t1r or p position Alternator b...

Page 1657: ...18CS engines B1881engine 818C1 818C5engines B1881engine 8 1 8 C 1 8 1 8 C 5 e n g i n e s Water cooled 4 stroke DOHC gasoline engine Water cooled 4 stroke DOHC VTEC gasoline engine Inline4 cylinder transverse 81 0 x 89 0 mm 3 19 x 3 50in 81 0 x 87 2 mm 3 19 x 3 43in 1 834 cm3 m 112cu in 1 797 cm3 m 110cu in 9 2 10 0 10 6 Beltdriven DOHC 4 valvespercylinder Beltdriven DOHC VTEC 4 valvespercylinder ...

Page 1658: ...nt Capacity Lubricant Type Swash plate DENSO 1 0 150m rev 9 15cu in rev 7 600rpm 140m 4 213 fl oz I c z3 rp o ND OILS Condenser Type Corrugated fin Evaporator Type Corrugated fin Blower Type MotorInput SpeedControl Max Capacity Sirocco fan 200w1 t2v 4 speed 450m3 h 15 900 cu fVh Temperature Control Air mixtype Compressor Clutch Type PowerConsumption Dry singleplate poly V belt drive 40W max l12 V ...

Page 1659: ... RelayBox In Under hood Fuse RelayBox In Under hoodABS Fuse RelayBox Headlights Front Side Marker Lights Front Turn Signal ParkingLights RearTurn Signal Lights Brake Taillights High Mount Brake Light 5 RearSide Marker Lights Back upLights LicensePlateLights Ceiling Lights Cargo Area Lights 3 door Trunk Lights 4 door Spotlights Glove Box Light Gauge Lights IndicatorLights lllumination and PilotLigh...

Page 1660: ...BodySpecifications 3 door All except Type R Unit mm in ol F rt o F t t b rl r ...

Page 1661: ...3 door TypeRl Unit mm in o r E F r o r l o cont d ...

Page 1662: ...BodySpecifications cont dl Unit mm in t c o o o N d ln IJ F t ...

Page 1663: ...J Maintenance Lubrication Points 4 2 Maintenance Schedule NormalConditions 4 4 Maintenance Schedule Severe Conditionsl 4 6 J Iuiunnq ...

Page 1664: ...hartbelow 2 Tra nsmission Ma n u a l HondaGenuineMTF 2 Automatic HondaATF 21 ATFY2 3 Brake line lncludes Anti lock brakeline GenuineHonda DOT3BrakeFluid 3 4 Clutchline GenuineHonda DOT3BrakeFluid 3 5 Power steering gearbox Steering greaseP N08733 8070E 6 Release fork Manualtransmission SuperHighTempUreaGrease P N 08798 9002 J Throttle wireend Dashboard lowerpanelhole Cruisecontrolactuator wire end...

Page 1665: ...e E i l t I NOTE Lubricateall hinges latches and locksonce a year In corrosiveareas more frequent lubricationis necessary We recommend Honda White Lithium Grease 4 3 ...

Page 1666: ... 6 9 9 9 6 9 F i g o I v o I I iEs o o i E J 6 3 3 E c A 9 r 9 3 l F i y E o E3e e e g n 9 6 5 5 r r 6 o i q 9 9 9 E E o a i 6 o o o l o o o o tr E g g ots Y 6 6 o o o o E l u 5 9 E E N v j a t 6 U j N F e 6 i F c Y O 6 J 9 r 7 c o o o o i o o i Y g N F r E i o o i 3 h a o t s i 3 a Y A o d 6 u i c 9 i o 6 i E x b F r i P i o 6 o I P T E 5 E i 3 O O O O P P P P o o o t r a F U o o g 9 o y o a E 3 ...

Page 1667: ...i i i o X e J 5 J o q o O o J o u o ol ol 9 d F E 6 b X O n n C L G n b E i t o t L X g x j o o o o o 6 c c 3 o o o o a 0 J o a o c c q v o q O a E t n o J o E L 3 3 o o c C a O y l e 3 i o t s x v X Y o o E o o c a Q c _ s o Y 6 r G J 9 q F U E T o E 9 c E t o o 0 o V c o 0 o s x 9 o o a o 0 q o o c o o c o o o a G c X o o o o c v Y O F J q o o c 9 d o 9 b 6 o 8 O 8 E X o t s R s 9 9 x N N o a E ...

Page 1668: ... Q P 6 c c t EEb 9 J 6 r n F O F j j 6 z E 9 6 3 i e E E s b s i i a I o C 5 E E E I i o J O F F C o E n o o 4 a o O 9 a z P e 6 6 e J C L o o F 6 6 O c o o 6 m m c c a o 6 o q i g e F a E v v 9 c t r t r e q r t 6 0 U U t g r D q r r l r f r q g q t F s n s i v v v q Y 6 E a u U q c S Pc e c b I o I c D o o i o o i o o o g F F o i E E E E H 6 o d d d 5 r o a E o r o P P i a a t L b r r s 9 o E s ...

Page 1669: ... c 3 c o a o E o g P 6 9 6 B o f o O s o L a 6 q a o c o 3 t o r a q 3 a L i w t e P o H i R Et o i 9 O U O q a o o o o U Q o o l9 o 6 o o F v u r 6 L 3 o t s x o o o o c O O O t c I o q o g 0 c o a c o c G a o o f S E t r Y a O r e e P c e 6 c 6 F o Y c E r o y 6 r 7 E c 9 c 3 9 rr u 3 5 O E 6 c F o o 0 v x V c o q a o o 0 o o E E o a o o o o c o 0 o a a c X o 0 i i D O r c o Y O o t t o L o o F ...

Page 1670: ...ing Radiator EngineCoolantRefilling and Bfeeding 10 2 NOTE Referto the 98 INTEGRA ServiceManual PiN61ST705 for the itemsnotshownin thissection f t Outlineof ModelChange Enginecoolanthas beenchanged rfltmlfr ...

Page 1671: ...uch 2 Remove the radiator caD 3 Loosen the drainplug anddrainthecoolant 4 Remove the drainboltfrom the cylinderblock ENGINE DRAINBOLT 78N m 8 0kgf m 58lbf ftl Applyliquidgasket to boltthreadwheninstalling WASHER Reolace DRAINPIUG I _ l I 6 7 5 Apply liquidgasketto the drainboltthreads then reinstallthe bolt with a new washerand tightenit securely Tightenthe radiator drainplugsecurely Remove draina...

Page 1672: ...equired EngineCoolant Refill Gapacity including reservoir 0 6f 0 6USqt 0 5lmp qtlll 81881engine M T 4 4 4 6USqt 3 9lmp qtl B18B1 Bl8Cl engines AIT 4 7 5 0USqt 4 1 lmp qtl 818C1 B18C5 engines MIT 4 7 5 0USqt 4 1 lmp qtl FILLER NECK Fillup to here 9 10 1 1 12 Install the radiator caploosely Install the battery Startthe engineand let it run untilit warms up the radiator fancomeson at leasttwice Turn ...

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Acura Integra 1998, Service Manual

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Summary of Contents for Integra 1998

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