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Honda 2002 EP3, Service Manual

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Summary of Contents for 2002 EP3

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Page 2: ...02 03 EP3 service manual...

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Page 4: ...nic mechanical photocopying recording or otherwise withoutthe priorwrittenpermission o the publisher Thisincludes text figures andtables As vou readthis manual vou will tind information thatis precede...

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Page 6: ...aintCodes 2002 Model 1 2 Chassis andPaintCodes 2003 Model 1 3 ldentification NumberLocations 1 4 Warning Caution LabelLocations 1 5 Under hood Emission ControlLabel 1 7 LiftandSupport Points 1 8 Towin...

Page 7: ...S 6 SiRwith sideairbagsystem Canada e CheckDigit l ModelYear 2i 2002 g Factory Code U Hondaof U K Manufacturing in Swindon England h SerialNumber U S 300001 1 V hicle ldentification Numbo and Federal...

Page 8: ...em Canada CheckDigir Model Year 3 2003 Factory Code U Hondaof U K Manufacturing in Swindon England SerialNumber U S 400001 f 700001 Vehicleldentification Number and FederalMotor Vehicle Saletv Standar...

Page 9: ...General Information ldentificationNumberLocations Vehicle ldentification Number vlN Vehicle ldentificalion Numbe lvlN 1 4 I 0 EngineNumber t...

Page 10: ...theU S mooet Passenger s Compartment SRSINFORMATION U S model SRSWARNING INFORMATION FRONTPASSENGER MODULEDANGER MONITOR NOTICE SIDEAIRBAGCAUTION Locatedon driver s ano passen9er s doorjamb notshown S...

Page 11: ...n Warning Caution LabelLocations cont dl SRS WARNING LABEL SERVICE INFORMATIONLABEL Undor hoodEmission Control Informationlab l and ENGINE COOLANTINFORMATION RADIATOR CAPCAUTION BATTERY CAUTION 1 6 t...

Page 12: ...LATIONS APPLICABLE TO2O03 MODEL YEAR NEWPASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO2OO3 MODEL YEAR NEWLEVIILEVPASSENGER CARS rH Engine andEvaporative Families EngineFamily ModelYear 2 2002...

Page 13: ...d 3 Raisethe hoistto full height and inspectthelift pointsfor solidcontactwith the lift blocks Safety Stands To supportthe vehicleon safetystands usethe same suppon points Band C asfor a frame hoist A...

Page 14: ...an acceptable way of towingthe vehicle Sling typeEquipment Thetow truckusesmetal cables with hookson theends Thesehooksgo around partsof the frameor suspensionandthe cablesliftthat endof thevehicle o...

Page 15: ...iginal partshaveself adhesive labels Replacement body partshavegenericself adhesive labels The originalengrneor transmissionVIN plateistransferredlo a replacement engineor transmissionand attachedwith...

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Page 18: ...L r a Specifications...

Page 19: ...55 in Brushlength 10 5 mm 0 41 in l 1 5mm 0 06 in Brushspring tension 2 9 3 5N 0 30 0 36kgf 0 7 0 8tbs Starter Output Commutator micadepth 0 50 0 80mm 0 020 0 031 in 0 20mm 1O OO8 in Commutator tunout...

Page 20: ...21560 2159 in 5 445 mm 0 214 in Exhaust 5 450 5 460 mm 0 21460 2150 in 5 42 mm 0 213 in Stem to gLride clearance lntake 0 030 0 055 mm 0 00120 0022in 0 08mm 0 003 in Exhaust 0 055 0 080 mm 0 00220 003...

Page 21: ...25 0 65mm 0 010 0 026 in 0 20 0 70mm i0 008 0 028 in 0 75mm 0 030 in OiI FEDERAL I 4OG UL 0 80mm 10 031 in Piston pin 21 953mm l0 8643in Pin to piston clearance 0 005 0 002 mm 0 00020 0 00008 in 0 005...

Page 22: ...0 070 0 135 mm 0 00280 0053 in 0 15mm 0 006 in Rear 0 070 0 135 mm 0 00280 0053 in 0 15mm 0 006 in Balancer shatts shaft to bear ng clearance No 1iournal front shaft 0 050 0 082 mm 0 00200 0032 in 0 1...

Page 23: ...Mea3urem nl Oualification Slandardor New ServiceLimit Clutch pedal Height fromthefloor 193mm 7 60 in Stroke 130 140 mm15 1 5 5in 10 16mm 0 39 0 63in Disengagementheightfrom the floor 1 15 mm 4 53 in m...

Page 24: ...Diameterof needlebearingcontact area clutch housing side 35 000 35 015 mm 1 3780 1 3785 in 34 95 mm 1 376 in Diameter of distance collarcontact alea 39 937 39950mm 1 5723 1 512ain 39 88 mm 1 570 in D...

Page 25: ...rkto synchro sleeve clearance 0 35 0 65mm 0 014 0 026 in i 1 0mm 0 039 in Reverse shift fork Finger thinkness 13 4 13 7 mm 0 527 0 539 in Fork to reverse idlergear clearance 0 20 0 59mm 0 007 0 024 in...

Page 26: ...dor New ServiceLimit Wheelalignment Camber Front 0 00 45 Rear 0 45 45 Caster Front 1 33 11 TotalToe lrytt Rear 0 3 mm 0 0 12 in lN2 mm 0 08 in Frontwheel turningangle lnsidewheel 37 40 2 Outside wheel...

Page 27: ...r 0 015 mm 0 0006 in Brake pads Thickness Front 10 0 mm 0 39 in 1 6 mm 0 06 in llear 9 0mm 0 35 in 1 6 mm 0 06 in StandardsandServiceLimits Brakes a e AirGonditionin Item Moasurement Oualilication Sta...

Page 28: ...cm 122 cuin Compression ratio 9 8 Valve train Chain drive DOHC VTEC 4valves percylinder Lubrication system Forced wetsump withtrochoid pumP Oilpumpdisplacement At 6 000 engine rpm 54 30 57 4 USqo minu...

Page 29: ...of parkingbrake Mechanical actuating rearwheels Padfrictionsurfacearea Front 45cm 7 0 sqin x2 Rear 28cm 4 3 sqin x 2 TIRES Sizeoffrontandreartires Pl95 60 81588V Sizeo sparetire T125r0D1595M AIR CONDI...

Page 30: ...A Lightbulbs Headlight high beam 12 v 60w Headlight low beam 1 2 V 5 5 W Frontturn signal liqhts 12V 21W Front parlinq lights 1 2 V 5 W Bear turnsignal lights 12V 21W FronVrear side marker lights 1 2...

Page 31: ...BodySpecifications Unit mm in 1 555 61 6 1 i140 56 71 2 14...

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Page 34: ...nce Schedule for Normal Conditions Listedby Distance Time Maintenance Schedule for Severe Gonditions Listedby Distance Time Maintenance Schedule Listed by Maintenance ltemfor Normal Conditions 3 8 Lis...

Page 35: ...selectcableends manual transmission Throttlecableend dashboard lower panelhole Silicone grease 9 1 0 1 1 1 1 4 1 6 1 7 Brakeboosterclevis CIutchboosterclevis Shift leverpivot Pedallinkage Batteryterm...

Page 36: ...t o o o o o o a9 Y 3 3...

Page 37: ...1 0 25mm 0 008 0 010 in Exhaust 0 28 0 32mm 0 011 0 013 in Replace spark plugs UseIZFR6K 11 NGK orSKJ20DR M11 DENSO 1 0 1 1mm Do itemsin A B alqq 120 000 mi 192 000 km 6 years I Replace transmission f...

Page 38: ...ncluding ABS Checkthe mastercylinder proponioning control valve andABSmodulator or damage andleakage Check allfluidlevels andcondition ottluids check forleaks lf necessary addMTFlseepage13 3 engioe co...

Page 39: ...conditions Extensive idl ng or longperiods of stopandgodriving suchasa taxior a commercial delivery vehicle Trailer towing driving witha car top carrier ordrivinginmountainous conditions Driving onmud...

Page 40: ...addMTF see page133 engine coolant brake fluid and windshield washer fluid Inspect exhaust system Check catalytic converter heatshield exhaust pipeandmuffler fordamage leaks andtightness see page9 8 In...

Page 41: ...ervals a Replaceair cleanerelement Every 30 000 miles 48 000 km Replace sparkplugs Every 110 000 miles 176 000 Lm Inspect valveclearance Inspect every 110 000 miles 176 000 km otherwise adiusl only if...

Page 42: ...uspension components Driveshaft boots Checlparking braleadjuslment a a O a o a Visually inspect thefollowing items Brake hoses andlines including ABSi Allfluidlevels andcondition oflluids Exhaust syst...

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Page 44: ...ging Circuit Troubleshooting 4 22 Drive BeltInspection 4 26 Drive BeftReplacement 4 26 Drive BeftAuto tensioner Inspection 4 27 Drive Beft Auto tensioner Replacement 4 28 Alternator Reolacement 4 29 A...

Page 45: ...EngineElectrical SpecialTools I Number Tool Number Description otv o 07746 0010400 07749 0010000 Attachment 52x 55 mm Driver 1 1 C 4 2 a...

Page 46: ...H INTERLOCK SWITCH Test page4 6 STARTER StanerCircuitTroubleshoot ng page4 5 SolenoidTest page4 7 Performance Test page4 8 Replacement page4 9 Overhaul page4 10 l a r l l i I _ r t _ 1 _ _ I t t i l t...

Page 47: ...StartingSystem CircuitDiagram ilo 20lOA USA motkl No 2 l50A C nid model UiIOEN H D fUSE REI IY BOX UNDEiOASTI FUST ifLAY 80x Y STHOT inSTA8T illl cLuTot Tr8LocK swtlcH 4 4 a...

Page 48: ...the batterycondition Checkelectrical connections at the battery the negativebaftery cableto body the enginegroundcablesandthe starterfor looseness andcorrosion Thentry startingthe engineagain Did the...

Page 49: ...ktheseitemsuntilyou find thecause Starterarmaturedragging Shortedarmature winding Excessive dragin engine 8 Check theengine speedwhilecranking theengine ls the engine speed above 100tpm YES Goto step9...

Page 50: ...terminalandthe armaturehousing ground There shouldbe continuity lf thereis continuity goto step3 lf there is no continuity replacethe solenoid 3 Checkthe pull incoilfor continuitybetwee n the S termin...

Page 51: ...rpinionmovesout it is working propefly Disconnect the batteryfrom the M terminal lf the piniondoesnot retract the hold incoil of the solenoidis working properly 4 8 L 5 Disconnect the batteryfrom the...

Page 52: ...from the B terminal on the solenoid then disconnect the BLK WHT wire B fromtheSterminal 10x 1 25 mm 44N m a 5 kgf m 33lblft 8 x 1 25mm 9 N m 10 9 kgf m 7 lbl ft 7 9 10 1 1 2 S 12x12smm 6 i l N m 6 5k...

Page 53: ...StarterOverhaul Disassembly Reassembly f _2 1 rw h a A q z hsc6 b OVERRUNNING CLUTCHASSEMBLY G SOLENOID LEVER o lu V rN A c Jli X S o 7 o a 4t fr ffiA v 9 ffitr D lW ENDCOVER t 4 STARTERSOLENOID 4 10...

Page 54: ...the specifications in step5 or recondition with 500or 600sandpaper B 6 5 Checkthe commutatordiameter lf the diameteris belowthe servicelimit replacethe armature Commutator Diameter Standard Newl 28 0m...

Page 55: ...Limit 0 20mm 0 008in Checkfor continuitybetweenthe segmentsof the commutator lf an opencircuitexistsbetweenany segments replacethe armature M 4 12 9 Placethe armature A on an armaturetester B Holda ha...

Page 56: ...turehousing B li thereis continuity replacethe armaturehousing 13 Starter Brush Holder Test 14 Checkthatthereis no continuitybetweenthe brushholder A and brushholder B lfthere is continuity replacethe...

Page 57: ...ely Checkthe conditionof the flywheelring gear Replaceit if the starterdrivegearteethare oamageo 19 4 14 i Starter Reassembly 20 Prybackeachbrushspringwith a screwdriver then positionthe brushabouthal...

Page 58: ...lgnitionSystem ComponentLocationIndex SPARK PLUG Inspection page 4 19 IGNITION COIL lgnition Timing Inspection page 4 17 Removal lnstallation page 4 18 4 15...

Page 59: ...lgnitionSystem Gircuit Diagram No 20lOA USAmo l No A l50A Cmrda model UNDEB HOOD FUST 8TIAY M lG1tioT in0N ll rd SIARIilll 4 16...

Page 60: ...er spromptsin the SCS menu seethe testeroperator smanual Connectthe timing lightto the serviceloop o 6 Pointthe lighttowardthe pointer A on the cam chaincase Check the ignition timingunderno load cond...

Page 61: ...onSystem lgnitionCoilRemoval lnstallation 1 Removethe ignitioncoilcover A then removethe ignition coils B 6 x 1 0 m m 2 Installtheignitioncoilsin the reverseorderof removal 9 8N m 1 0kgf m 7 2lbfftl 4...

Page 62: ...eformed electrodes Do not adjustthe gap of iridiumtip plugs A replacethe sparkplug if the gap is out of specification ElectrodeGap Standard New 1 0 1 1mm 0 039 0 0 in ServiceLimit 1 3mm 0 051in l f lm...

Page 63: ...entLocationIndex CHARGING SYSTEM INDICATOR lnthe gaugeassembly q o DRIVE BELT Inspection page4 26 Replacement page4 26 BATTERY Test page22 50 ALTEBNATOR Troubleshooting page4 22 Replacement page4 29 O...

Page 64: ...L CircuitDiagram flo l0Al uSAhod l ilo 20l50Al C n d mod l UNDTR XOOD FUSI RILAY MX Ifmlil t t T ilt l 4 21...

Page 65: ...plexcontrolsystemas indicatedby the diagnostic troublecode DTC see step8 on page22 172 1 5 Disconnect the enginewire harness6Pconnector from the startersub harness6Pconnector 4 22 4 6 Measurethe volta...

Page 66: ...etween the ECMandthe enginewire harness6Pconnector t NO Go to alternatorand regulatortest AlternatorandRegulatorCircuitTest 1 Besurethe batteryis sufficientlychargedand in goodcondition seepage22 50 a...

Page 67: ...lacethe alternatorcomponents seepage4 30 1 4 24 AlternatorControlSystemTest NOTE Aftertroubleshooting performthe engine controlmodule ECM idlelearnprocedure seepage 1 1 1 3 9 1 Checkfor properoperatio...

Page 68: ...heck seepage11 6 lf prescribed voltageis now available replacethe original ECM I Turnthe headlights and ignitionswitchOFF Disconnect ECMconnectorB 24P 10 Checkfor continuitybetweenECMconnector termina...

Page 69: ...r A iswithinthe standard range B asshown lf it isoutofthestandard range replace thedrivebelt see page4 26 4 26 DriveBeltReplacement 1 Movethe auto tensioner A to relievetensionfrom the drive belt B an...

Page 70: ...essmoothlyand without anyabnormalnoise lf the tensionerdoes not move smoothlyor thereis abnormalnoise replacethe auto tensioner 7 8 Removethe auto tensioner seepage4 28 Install thetensioner pulley Cla...

Page 71: ...26 2 Remove the idlerpulley 6 x l 0 m m 9 8N m 1 0kgl m 7 2 tbf ft d I 6 x 1 0 m m 12N m 1 2 kgt m 8 7lbt ft 3 Removethe tensionerpulley x 1 25mm 22N m 2 2kgt m 16lbf ft 4 28 4 Removethe auto tension...

Page 72: ...t 6 Removethe drive belt seepage4 26 7 Removethe threeboltssecuringthe alternator 8 x 1 25mm 22 N n 12 2kgl m Disconnect the alternatorconnector A and BLK wire B from the alternator 8 N m 10 8 kgf m 6...

Page 73: ...w BEARING PULLEY LOCKNUT a TERMINAL INSULATOR REARHOUSING ASSEMBLY INSULATOR BUSHING PULLEY W UF oy REARBEARING FRoNr B b J y RE LN I vVFko qtr njlv V r V BRUSH 11 BRUSH HOLOER HOLDER TNSULATOR l VOLT...

Page 74: ...ethe alternator seepage4 29 3 lf the front bearingneedsreplacing removethe pulleylocknutwith a 10mm wrench A anda 22 mm wrench B lf necessary usean impact wrencn Removethe harnessbracket A insulator B...

Page 75: ...9 lfyouarenotreplacing thefrontbearing and or rearbearing goto step 16 Remove therotorfrom thestator driveendhousing Inspectthe rotorshaftfor scoring and inspectthe bearingjournalsurfacein the statorh...

Page 76: ...hebearingusingthe innerrace 13 Removethe front bearingretainerplate s q H E 6 e u s f r 1 s 14 Supportthestatorhousingin a vise and driveout the front bearingwith a brassdrift and hammer 15 Witha hamm...

Page 77: ...ethe rectifier assembly Diodesare not availableseparately lf allthe diodesareOK go to step 17 t L o l B P P P P P 4 34 1 9 r a Alternator Brush Inspection 17 Measure the lengthof bothbrushes A witha v...

Page 78: ...no continuitybetweeneachleadandthe coil core B lf thereis no continuity goto step22 lfthere is continuity replacethe alternator Assemblethe alternatorin reverseorderof disassembly and notetheseitems B...

Page 79: ...djustment page12 4 t _ _ CRUISE CONTROL ACTUATOR Test page 4 43 Replacement page4 44 CRUISE CONTROL UNIT lnputTest page 4 40 BRAKE PEDAL POSITION SWITCH Test page22 84 Pedal Height Adjustment page 19...

Page 80: ...rcuitDiagram No aloAl USAnod l No 20 itoAl C md modrl UISEF NOOD fUS iILAY IOX to ots BU YIL lcl H0Tii0llilll mdSTARTlllll 1 Honilsffroi CTuICII PEDAL P0sm0 swtrct 2 6 1 1 1 3 cnu6EcoNTnoL uNtT l0 4 3...

Page 81: ...disconnected termrnats YEL BLUA EL a r i a c a a l i c noticeably higheror lowerthanwhat was set 1 Checkvehiclespeedsensor VSS seepage22 65 Checkcruisecontrolactuator seepage4 43 2 Checkcruisecontrol...

Page 82: ...uttonis pushed 1 CheckSET RESU ME CANCEL switch seepage4 42 2 Checkcruisecontrolunit seepage4 40 Open circuit loose or disconnected terminals GRYiRED LTGRN BLK Setspeedwill not resume whenRESUME butto...

Page 83: ...ldbe locked Faultyactuator Poorground G301 An open in the wire Shon to ground arcswhen Doweris connected 2 BLU lgnitionswitchON ll main swltchON and brakepedal pressed then reteaseo Checkfor voltageto...

Page 84: ...5A fusein the under dash fuse relaybox Blowncruiseindicatorbulfl Faulty gaugeassembly An openin the wire 12 BLU VVHT lgnitionswitchON ll and main switch ON raisethe front of the vehicle and rotateonew...

Page 85: ...not as specified replaceillumination bulbs C or the switch 11v1 Position 1 4 OFF 9 ON o o J o 4 42 r Set Resume Cancel SwitchTest Replacement 1 Removethe two screws then removethe switch Checkfor con...

Page 86: ...eis not locked replacethe cruisecontrolactuatorassembly 6 Checkthe operationof the actuatormotor in each outputlinkagepositionaccordingto the table You shouldbe ableto hearthe motor Battery power Dola...

Page 87: ...ethe cablefrom the bracket Disconnect the 4Pconnector and removethe three boltssecuringthe cruisecontrolactuator 2 6 x 1 0 m m 12N m 1 2kgf m 8 7lbf ft 4 44 rla 3 Removethe actuatorcover A then remove...

Page 88: ...nut E andturn the adjustingnut F untilthe free playis asspecified then retightenthe locknut ClutchPedalPositionSwitchTest 1 Disconnect the 2Pconnectorfrom the clutchpedal positionswitch A CLUTCH PEOAL...

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Page 91: ...with otherparts 1 Securethe hoodin the wide openposition support rod in the lowerhole 2 Makesureyou havethe anti theft codefor the radio thenwrite down the frequencies for the radio s presetbuttons 3...

Page 92: ...lelinkandcruisecontrollink by hand then removethe throttlecable A and cruisecontrol cable B fromthelinks Loosen the locknuts C and removethe cablesfrom the bracket 11 Relievefuel pressure seepage11 14...

Page 93: ...A andclutchline bracketmountingbolt B 15 Removethe shiftcable A and selectcable B 5 4 4 16 Disconnect the enginecontrolmodule ECM connectors A and mainwire harnessconnector B Removethe harnessclamps...

Page 94: ...ge13 3 26 Drainthe engineoil seepage8 5 27 Disconnect thestabilizer links seepage18 18 28 Disconnect the suspension lowerarm balljoints seestep3 on page18 19 29 Removethe driveshafts seepage16 3 Coata...

Page 95: ...r thehoist 33 Remove theupperhose A andheater hoses B 34 Bemovethe radiator seepage10 10 35 Attachthe chainhoistto the engineasshown 5 6 36 Remove thetransmission mountbracket support boltandnuts 37 R...

Page 96: ...mount mountingbolts 40 Remove thefrontmountbracket mountinq bolt 41 Attach thesubframe adapterto frontofthe subframe thentighten theknurled knob Raisethejack Lineup the slotsin the armswith the bolt h...

Page 97: ...ressorclutchconnector A then removethe Ay C compressor B without disconnecting theA C hoses Checkthatthe engine transmission is completely free of vacuumhoses fuel andcoolanthoses and electrical wirin...

Page 98: ...rontsubframeadapterEOS02C00001 1 1 lnstalltheaccessory brackets andtightentheir boltsand nutsto the specifiedtorques 10x 1 25mm il4 N m 4 5kgf m 33lbl ft A CCOMPRESSOR BRACKET 10x 1 25mm 44N m 4 5kgf...

Page 99: ...noiseand vibration and reducebushinglife 3 Installthe A C compressor A andconnectthe compressorclutchconnector B 8 x 1 25 mm 22N m12 2 kgf m 16lbf ft 4 Supportthe subframewith the subframeadapter and...

Page 100: ...sethe hoistto full height Tightenthe front enginemount bracketmounting bolt l 1 t2 12x 1 25rnrn 64N m 6 5 kgf m 47tbt ftl 13 Lowerthe hoist 14 Remove thechainhoistfromtheengine 15 Installthe radiator...

Page 101: ...catalyticconverter TWC assembly A usenew gaskets B and new self lockingnuts C D 21 d ry 6 8x 1 25 mm 22N m 2 2kgl m 16tbt ft Connect the air fuel ratio 4 F sensorconnector D andsecondaryheatedoxygense...

Page 102: ...lamps B 30 Connectthe ECI 4 connectors A and mainwire harnessconnector B Installthe throttlecable seepage11 164 then adjustthe cable seepage11 163 Installthecruisecontrolcable seepage4 44 then adjustt...

Page 103: ...ftl Install theclutchslavecylinder A andclutchline bracketmountingbolt B 6 x 1 0 m m 9 8N m 1 0kgf m 7 2 tbt ft 6 8 x 1 25 mm 24 N m 2 4kgl m 5 14 37 Installthebatterycables A on the under hood fuse...

Page 104: ...ll do not operatethe starter sothat the fuel pump runsfor about2 secondsand pressurizes the fuel line Repeat this operationtwo or threetimes then checkfor fuel leakageat any point in the fuel line Re...

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Page 106: ...r Head Removal 6 23 WC Actuator Exhaust Camshaft Sorocket Repf acement 6 24 Cylinder Head Inspection forWarpage 6 25 Rocker ArmAssembly Removal 6 26 Rocker ArmsandShafts Disassembly Reassembly 6 27 Ro...

Page 107: ...0204 o 07NAB 0010404 G 07VAE 001010A OTZAJ PNAAlOO E OTZAJ PNAA2OO O I 07ZAJ PNAA300 tro 07742 0010100 07746 001o4oo D 07749 0010000 Air Pressure Regulator ValveGuideReamer 5 5mm Socket 19mm HolderHan...

Page 108: ...GNITION COIL COVER CYLINDER HEAD COVER Removal page 6 22 lnstallation page 6 41 CAM CHAIN Bemoval page6 12 Installation page6 15 frn tJ p CAMCHAINGUIDEB CAMCHAINGUIDEA VARIABLE VALVE TIMING CONTROL tw...

Page 109: ...OSITION ICMP SENSOR TOPDEADCENTER TDC SENSOR CAMSHAFT HOLDER f fr T F F g Y R LI CAMCHAIN GUIDE B EEI g oowetew EXHAUSTCAMSHAFT SPROCKET Removal page6 24 Installation page6 25 EXHAUSTCAMSHAFT ROCKER A...

Page 110: ...Removal page6 23 Inspection page6 25 Installation page6 39 EXHAUSTVALVE Removal page6 31 Installation page6 37 INTAKEVALVE Removal page6 31 Installation page6 37 CYLINDER HEAD GASKET H v spntruc il G...

Page 111: ...he four sparkplugs 8 Attachthe compressiongaugeto the sparkplug note 6 6 V 9 10 Openthe throttlefully then crankthe enginewith the startermotor and measurethe compression Compression Pressure Above 93...

Page 112: ...ve smoothly lf any rockerarm needsreplacing replacethe primaryand secondaryrockerarms asan assemblv andtest lfthe intakeprimaryrockerarm movesfreely go to step 4 6 Repeatstep3 on the remainingintakepr...

Page 113: ...othly lf any rockerarm needsreplacing replacethe primaryand secondaryrockerarms as an assembly andtest Removethe specialtools Tightenthe camshaftholdermountingboltslo 22N m 12 2 kgf m 16lbf ft Tighten...

Page 114: ...t NOTE Adjustthe valvesonly when the cylinderhead temperatureis lessthan 100 F 38 C 1 Removethe cylinderheadcover seepage6 22 2 Setthe No 1 pistonat top deadcenter TDC The punchmark A on the variablev...

Page 115: ...e feelergauge A betweenthe adjusting screw B andtheendofthe valvestem andslideit backandforth you shouldfeela slightamountof drag 6 10 5 lf youfeeltoomuchortoolittledrag loosenthe locknut A andturn th...

Page 116: ...seepage6 41 1 1 12 Crankshaft PulleyRemovaland Installation Special Tools Required Holderhandle07JAB 001020A Holderattachment 50 mm 07NAB 001040A Socket 19mm 07JAA 001020 4 or a commercially availabl...

Page 117: ...m 25 0kgf m 181tbf ft with a torquewrenchand 19mm socket C Do not usean impactwrench Install thesplash shield seestep20on page5 12 Insta ll front tires wheels ll l l t rL a 5U 1J I t t 5 6 12 CamChai...

Page 118: ...VTC oil controlsolenoidvalveconnector B Removethe VTCoil controlsolenoidvalve see step1 on page11 127 Supportthe enginewith a iackand wood block undertheoil pan Removethe groundcable A and removethe u...

Page 119: ...haft counterclockwise to compress the auto lensioner Alignthe holeson the lock A andthe auto tensioner B theninsena 1 5mm 0 06 in diameterpin C intothe holes Turnthe crankshaft clockwiseto securethe D...

Page 120: ...etthe crankshaft to top deadcenter TDC Align the TDCmark A on the crankshaft sprocketwith the pointer B on thecylinder block Setthe camshaftsto TDC The punchmark A on the variablevalvetiming control V...

Page 121: ...crankshaft sprocket Installthecam chainon the VTCactuatorand exhaustcamshaftsprocketwith the punchmarks A alignedwith the two coloredpieces B B 6 16 5 Installthe camchainguideA A andtensioner arm B 6...

Page 122: ...pply liquidgasket P N08718 0009 evenlyto the cylinderblockmatingsurfaceofthe chaincaseand to theinnerthreads of theholes Apply liquidgasketto the cylinderblockupper surfacecontactareas A on the chainc...

Page 123: ...n installingthe chaincase do not slide the bottomsurfaceon the oil pan mountingsurface 9 6 x 1 0 m m 12N m 1 2kgt m 8 7lbf ft 6 x 1 0 m m 1 2 N m 1 2kgf m 8 7lbf ft 6 18 t 16 lnstallthe sideenginemoun...

Page 124: ...nector A andVTCoil controlsolenoidvalve connector B 21 Installthe crankshaft pulley seepage6 12 22 Installthe cylinder headcover seepage6 41 23 Installthe drivebelt 24 Installthe splash shield D Auto...

Page 125: ...ndthe auto tensioner B theninserta 1 5mm 0 06 in diameterpin C intothe holes Turnthe crankshaft clockwiseto securethe oin 4 Removethe auto tensioner 6 20 cont dl Installation 1 Installthe auto tension...

Page 126: ...gasket Instead reapplyliquidgasketafterremovingold residue 6 Installthe chaincasecover 4 6 x 1 0 m m 12N m 1 2kgt m 8 7tbf ft Apply liquidgasket alongthebroken line ChainCase OilSealInstallation Speci...

Page 127: ...Gylinder Head CylinderHeadCoverRemoval 1 Removethe intakemanifoldcover 2 Removethe four ignitioncoils seepage4 18 3 Removethe dipstick A and breatherhose B 6 22 4 Removethe cylinderheadcover V t t 1 i...

Page 128: ...drive belt seepage4 26 Removethe intakemanifold seepage9 3 Removethe air cleanerhousing seestep7 on page 5 2t 5 Removethe water bypasshose A Removethe exhaustmanifold seepage9 7 Removethe cam chain s...

Page 129: ...ence untilall boltsare loosened CYLINDER HEADBOLTSLOOSENING SEQUENGE 14 Remove thecylinder head 6 24 VTCActuator Exhaust Camshaft SprocketReplacement Removal 1 Remove thecamchain seepage6 12 2 Holdthe...

Page 130: ...72 N m 7 3kgf m 53 lbf ft 4 Install thecamchain seepage6 15 1 CylinderHeadInspection for Warpage Removethe cylinderhead seepage6 23 Inspectthe camshaft seepage6 29 Checkthe cylinderheadfor warpage Mea...

Page 131: ...A A 3 Removethe camshaftholderbolts To Drevent damagingthe camshafts unscrewthe boltstwo turnsat a time in a crisscross pattern CAMSHAFTHOLDERBOLTSLOOSENING SEOUENCE 6 26 4 Removethe cam chainguide B...

Page 132: ...erarm assembly do not removethe camshaftholderbolts The boltswill keep the holders springsand rockerarmson the shaft Priorto reassembling cleanall the partsin solvent dry them and apply lubricantto an...

Page 133: ...rance Standard lNew lntake 0 025 0 052mm 0 0010 0 0020in Exhaust 0 018 0 056mm 0 0007 0 0022in Service Limit 0 08mm 0 003in 5 Repeatfor all rockerarmsand bothshafts lfthe clearance is overthe Ilmit re...

Page 134: ...2 2kgt m 16lbf ft 6 mm bolts 12N m 1 2kgf m 8 7tbf ftl 6 mm bolts 0 I I 3 Seatthe camshaftby pushingit awayfrom the camshaft pulleyendofthe cylinder head 4 Zerothe dial indicatoragainstthe end of the...

Page 135: ...icelimit andthe camshafthasbeenreplaced replacethe cylinderhead lf the camshaft to holder clearance is beyondthe servicelimit andthe camshafthasnot been replaced go to step 10 Camshaft to HolderOil Cl...

Page 136: ...movedso thateachitem can be reinstalledin its originalposition 1 Removethe cylinderhead seepage6 23 2 Usingan appropriate sized socket A and plastic mallet B lightlytap the valveretainerto loosen the...

Page 137: ...t recheckit usinga new valve lf the measurementis nowwithin the service limit reassemble usinga new valve lfthe measurementwith a newvalvestill exceeds the servicelimit go to step3 lntake Valve Stem t...

Page 138: ...der headto 300 F 150 C Monitorthe temperature with a cookingthermometer Do not getthe head hotterthan300 F 150 C excessiveheatmay loosenthe valveseats _ Jfillr 4fi 11 tT 7 Workingfrom the camshaftside...

Page 139: ...head Valve Guide Installed Height Intake 15 2 16 2mm 0 598 0 638in Exhaust 15 5 16 5mm 0 610 0 650in 6 34 10 Coatboth reamerandvalveguidewith cuttingoil Rotatethe reamerclockwisethe full lengthof the...

Page 140: ...w 1 25 1 55mm 0 049 0 061in ServiceLimit 2 00mm 0 079in 6 After resurfacing the seat inspectfor evenvalve seating ApplyPrussian Bluecompound A to the valveface Insert thevalvein itsoriginallocation in...

Page 141: ...A Intake Valve Stem Installed Height Standard New 40 8 41 0mm 1 606 1 614 in ExhaustValve Stem Installed Height Standard New 54 6 54 8 mm 2 150 2 157 in l lf valvestem installedheightis overthe standa...

Page 142: ...austvalveseal C hasa blackspring D andthe intakevalveseal E hasa white spring F Theyare not interchangeable 6 lnstallthe valvespring Place theendofthevalve springwith closelywound coilstowardthe cylin...

Page 143: ...ntothe rockershaftholder then installthe rockerarm assembly B on the cylinder head Apply liquidgasket alongthe brokenline 6 38 l 5 6 Removethe boltsfrom the rockershaftholder Makesurethe DUnch markson...

Page 144: ...block Always usea new cylinderheadgasket Setthe crankshaft to top deadcenter TDC Align the TDCmark A on the crankshaft sprocketwith the pointer B on the cylinderblock 4 Installthe cylinderheadon the b...

Page 145: ...t loosenthe bolt and retightenit from the firststep 9 Aftertorquing tightenall cylinderheadboltsin two steps 90 per step lf you are usinga newcylinder headbolt tightenthe boltan extra90 FIRSTSTEP SECO...

Page 146: ...runsfor about2 secondsand pressurizes the fuel line Repeatthls operationtwo or threetimes then check for fuelleakage at anypointin thefuelline 24 Refilltheradiatorwith enginecoolant and bleed air from...

Page 147: ...s on thecylinder head slidethe coverslightlybackandforth to seat the headcovergasket Inspectthe coverwashers C Replace anywasher that is damagedor deteriorated 6 42 7 Tightenthe boltsin two or threest...

Page 148: ...ncoils seepage4 18 Checkthat alltubes hoses andconnectorsare installedcorrectly lnstalltheintakemanifoldcover 1 1 6 x 1 0 m m 12 N m 1 2 kgfm 8 7tbf ftl 12 Afterassemblv wait at least30 minutesbefore...

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Page 150: ...Replacement 7 8 OilPanRemoval 7 11 Crankshaft andPiston Removal 7 12 Crankshaft Inspection 7 14 Block andPiston Insoection 7 15 Cyfinder Honing 7 17 Piston PinandConnecting RodReplacement 7 18 Piston...

Page 151: ...EngineBlock SpecialTools I Ref No ToolNumber OTZAD PNAAlOO 07746 0010700 07749 0010000 Description Oil SealDriverAttachment96 Attachment 24 x 26 mm Driver Oty 6 1 1 1 o 7 2...

Page 152: ...lection page 7 6 CRANKSHAFT Endplay page7 5 Runout page7 14 Out of Round page7 14 Removal page7 12 lnstallation page7 24 fi fr 8 4 E I BAFFLEPLATE LOWER BLOCK FLYWHEEL CRANKSHAFT OILSEAL TRANSMISSION...

Page 153: ...Measurement page7 15 PISTONPIN Removal page7 18 Inspection page7 19 Installation page7 20 f 6 CONNECTINGROD Endplay page7 5 Smallend measurement page7 19 CONNECTING ROD ENGINE BLOCK Cylinderboreinspec...

Page 154: ...talla new connectingrod and recheck lf it is still out of tolerance replacethe crankshaft see page7 12 5 lnstalla dial indicatoras shown Pushthe crankshaft firmly awayfrom the dial indicator and zerot...

Page 155: ...Oil Clearance No 1 2 4 5 Journals Standard New 0 017 0 041mm Service Limit No 3 Journal 10 0007 0 0016 in l 0 050 mm 0 0020 in Standard Newl 0 025 0 049mm 0 0010 0 0019 in Service Limit 0 055 mm 0 00...

Page 156: ...injournalbores Writedown the crank borecodes lf you can t readthe codesbecauseof accumulated dirt and dust do not scrubthem with a wire brushor scraper Cleanthem only with solventor detergent No 1 JOU...

Page 157: ...i ero n ffi Tr i Creen g jiff i Brown Black lT l o Brown Black 6il Brack l kr ar 7 8 Connecting RodBearing Replacement RodBearing Clearance lnspection 1 Remove the oil pump seepage8 9 2 Bemovethe baff...

Page 158: ...ethe crankshaft and stan over RodBearing Selection 1 Inspecteachconnectingrod for cracksand heat damage Connecting Rod Big End Eore Code Locations 2 Eachrodhasa tolerance rangefrom 0 0 024 mm 0 0009 i...

Page 159: ...urnalcodes to selectappropriatereplacement bearingsfrom the followingtable NOTE Colorcodeis on the edgeof the bearing Whenusingbearinghalvesof differentcolors it doesnot matterwhich color is usedin th...

Page 160: ...tingbolts see step39 on page5 7 4 Removethe front mount mountingbolt see step40 on page5 7 5 Usea markerto makealignmentmarkson the referencelinesthat alignwith the centersof the rearsubframemountingb...

Page 161: ...seepage7 11 4 Removethe oil pump seepage8 9 5 Removethe cylinderhead seepage6 23 6 Removethe baffleplates 7 Removethe 8 mm bolts E 7 12 8 Removethe bearingcap bolts To preventwarpage unscrewthe bolts...

Page 162: ...anufacturer s instructions lf the ridgeis not removed it may damagethe pistonsastheyare pushedout 1 1 t J 14 Usethe wooden handleof a hammer A to drive out the pistons B Reinstall the lowerblockand be...

Page 163: ...Measuretaperat the edgesof eachrod and main journal The differencebetweenmeasurements on eachjournal must not be morethanthe service limit JournalTaper StandardlNewl 0 005mm 0 0002 in max ServiceLimi...

Page 164: ...in B 85 920mm 13 3827 in OversizePiston Diameter 0 25 86 230 85 240mm 3 3949 3 3953in l 4 Measurewear andtaper in directionX and Y at threelevelsin eachcylinder asshown lf measurements in anycylindera...

Page 165: ...dardlNew 0 07mm 0 003in max ServiceLimit 0 10mm 0 004in l PRECISION STRAIGHT EDGE 7 16 7 Calculate the differencebetweenthe cylinderbore diameterandthe plstondiameter lf the clearance is nearor exceed...

Page 166: ...t Do not usestonesthat areworn or broken Whenhoningiscomplete thoroughly cleanthe engineblockof all metalparticles Washthe cylinderboreswith hot soapywater then dry and oil them immediatelyto preventr...

Page 167: ...n them in the ringgroovesuntilthe end gapsare linedup with the cutoutsin the pistonpin bores B NOTE Takecarenotto damagethe ringgrooves Removebothsnaprings A Startat the cutoutin thepistonpinbore Remo...

Page 168: ...n l 2 Zerc the dialindicatorto the pistonpin diameter 3 Checkthe differencebetweenthe DistonDin diameter andpistonpinholediameter in thepiston Piston Pin to PistonClearance Standard Newl 0 005 to 0 00...

Page 169: ...re in the connectingrod andthe pistonpinwith engine oil Heatthe pistonto about 158 F 70 C 3 7 20 4 Installthe pistonpin A Assemblethe piston B andconnectingrod C with the arrow D andthe embossed mark...

Page 170: ...on pusha new ring A intothe cylinder bore15 20 mm 0 6 0 8in fromthe bottom 15 20 mm 0 6 0 8in I Measurethe pistonringend gap B with a feeler gauge lfthegapistoo small checktoseeif you have theproperri...

Page 171: ...1 2 mm 0 05 in i 7 Rotatethe ringsin their groovesto makesurethey do notbind 7 22 8 Positionthe ring end gapsasshown OILRINGGAP About 90 SECOND RINGGAP About 45 OILRINGGAP TOPRINGGAP andSPACER RINGGAP...

Page 172: ...journal alignmentbeforepushingthe pistoninto place Checkthe connectingrod bearingclearance with plastigage seepage7 8 lnspectthe connectingrod bolts seepage7 241 Apply engineoil to the boltthreads th...

Page 173: ...ngrod bolt 1 3 mm 7 24 Crankshaft Installation SpecialTools Bequired Driver07749 0010000 Attachment 24 x 26 mm 07746 0010700 Oil sealdriverattachment 96 o7ZAD PNAAl00 1 Install thecrankshaft endbushin...

Page 174: ...t clockwise andseatthe journals intoconnecting rod No 2 andconnecting rod No 3 Lineup the markon the connectingrod andcap then installthe capsand boltsfinger tight 9 10 11 1 12 Tightenthe connectingro...

Page 175: ...gcap boltsan additional56 Tightenthe I mm boltsin sequence to 22 N m 12 2 kgf m 16lbf ft 17 1 8 1 9 20 7 26 2 1 Usethe specialtoolsto drive a new oil seal squarelyintothe blockto the specifiedinstalle...

Page 176: ...aces bolts and bolt holes Cleananddry the oil pan matingsurfaces Apply liquidgasket P N08718 0009 evenlyto the cylinderblockmatingsurfaceof the oil pan andto the innerthreadsof the bolt holes NOTE Do...

Page 177: ...arm balljoints seestep6 on page18 19 7 Afterassembly wait at least30 minutesbefore fillingtheengine with oil 7 28 v Transmission EndGrankshaft Seal Installation InCar SpecialTools Required Driver07749...

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Page 179: ......

Page 180: ...EngineMechanical t l r_ l...

Page 181: ...EngineLubrication SpecialTools Ref No Tool Number Descriotion Otv o 07HAA PJ70100 Oil FilterWrench I 8 2...

Page 182: ...aon page 7 27 OILPUMP OverhaLrl page 8 8 H L BAFFLEPLATE OILFILTER FEED PIPE Replacement page8 7 OILFILTER Replacement page8 6 OILCONTROL ORIFICE WASHER OILPRESSURE SWITCH SwitchTest page8 4 Oil Press...

Page 183: ...son with the engine running check theengine oil level lf theoil levelis correct Connecta tachometer Removethe engineoil pressureswitch and install an oil pressure gauge A 1 4 Startthe engine Shutit of...

Page 184: ...kgf m 33lbf ft Donotovertighten Reinstall the drainboltwith a new washer B Refillwith the recommended oil seepage3 2 Capacity 4 00 4 2US qt at oilchange 4 2014 4US qt at oilchangeincludingfilter 5 301...

Page 185: ...6 5 lf 4 numbersor marks 1to 4 or V to VVVV are printedaroundthe outsideof thefilter usethe followingprocedure to tightenthe filter Spinthe filter on until its seallightlyseatsagainst the block andnot...

Page 186: ...l filterfeed pipe 3 l n s t a l l t h e t w o 2 0 x 1 5 m m n u t s A o n t o t h e n e w oil filterfeedpipe Holdthe nutwith a wrench then tightenthe othernut 4 Tightenthe oilfilterfeed pipetothe bloc...

Page 187: ...5mm 27N m 6 x 1 0 m m 12N m 11 2 kgf m 8 7lbt ft 2 8kst m 20lbtft Apply engine oilto theboltthreads UPPER BALANCER SHAFTHOLDER BALANCER SHAFT BEARINGS Ptr PUII E U DOWEL PIN REAR BALANCER SHAFT n fs t...

Page 188: ...11 3 Remove anddiscard theoil pumpchaintensioner 4 To holdthe rearbalancershaft inserta 6 mm pin driver A intothe maintenance holein the lower balancershaftholderandthroughthe rearbalancer shaft 5 Lo...

Page 189: ...r axiaI clearance between the rotor A andpumphousing B lf thehousing to rotoraxialclearance exceeds the servicelimit replace theoil pump Housing to RotorAxial Clearance Standard New 0 02 0 07mm 0 001...

Page 190: ...and readthe end olav BalancerShaft End Play Fronl BalancerShaft Standard Newl 0 070 0 135mm 0 0028 0 0053in ServiceLimit 0 15mm 0 006in RearBalancerShaft Standard New 0 070 0 135mm 0 0028 0 0053in l...

Page 191: ...2 in Service Limit 20 03 mm 0 789 in Rear Standard New 24 000 24 020 mm 10 9 t49 0 9457 in ServiceLimit 24 03mm 0 946 in Front Rear 8 12 5 Measurethe diametersof the No 1journalson the front balancers...

Page 192: ...o 2 journaloil clearance is out of tolerance installthe new bearings and recheck lf it is stillout of tolerance replacethe balancershafts No 2 JournalOil Clearance StandardlNewl 0 060 0 120mm ServiceL...

Page 193: ...stallation 1 Makesurethe No 1 pistonis at TDC seestep1 on page6 12 2 Alignthe dowel pin A on the rearbalancershaft with the mark B on the oil pump To holdthe rearbalancershaft inserta 6 mm pin driver...

Page 194: ...ump sprocket C 8 x 1 25 mm 22N m l2 2kot m r6tbt fti pump B theninstallthe oil 7 Removethe pin driver D Tightenlhe oil pump mountingbolts I 8 15 8 Squeeze the new oil pump chaintensioner A then instal...

Page 195: ...theoil pumpchain tensioner 11 Install theoil pan seepageT 27 8 16 I OifPressure Switch Replacement 1 Discon nectthe oil pressureswitchconnector then removethe oil pressureswitch 2 Apply liquidgasketto...

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Page 197: ......

Page 198: ...EngineMechanical IntakeManifoldandExhaustSystem lntake Manifold Removal andInstallation 9 2 Exhaust Manifold Removal andInstallation 9 7 Exhaust Pipe andMuffler Replacement 9 8 r r i 1...

Page 199: ...E Replace if cracked or if matingsurfaceis damaged 6 x 1 0 m m 12N m 1 2kgf m 8 7lbf ft I GASKET Replace 8 x 1 25 2 2 N m 12 2 ksf 8 x 22 k e t9 w k 1 6 25mm m kgf m 1 8 x 1 25 mm 22N m 2 2kgfm 16lbt...

Page 200: ...connecttheintakeairtemperature lAT sensor connector A and removethe breatherhose B then removethe aircleanerhousingcover intake airductassembly C 4 Fullyopenthe throttlelinkandcruisecontrollink by han...

Page 201: ...holdermountingbolt B and harness clampmounting bolt C 9 4 9 Removethe enginewire harnessconnectors and wireharness clamps fromthe intake manifold Fourinjectorconnectors ldleair control lAC valveconnec...

Page 202: ...he innerbolt Tightenthe boltsecuringthe intakemanifoldand bracket 8 x 1 25mm 22 N m 2 2ksf m 16lbf ft 2 w 4 7 5 6 Installthe PCVhose A harnessholdermounting bolt B andharness clampmountingbolt C e li...

Page 203: ...1 0 m m 12N m l 1 2k91 m 8 7 tbf ftl Cleanup anyspilled engine coolant After installation checkthat all tubes hoses and connectors are installedcorrectly Inspectfor fuel leaks Turnthe ignitionswitchON...

Page 204: ...ftl GASKET Replace SELF LOCKING NUT 10x 1 25 mm 44N m 4 5ksf m 33lbt ftl Beplace 10x 1 25 mm 44N m 4 5kgt m 33lbl ftl Replace WASHEB 8 x 1 25 mm 22N m 2 2kgIm 16lbf ft Replace Tighten theboltsinsteps...

Page 205: ...s alternating sideto side NOTE Usenew gasketsandself locking nutswhen reassembling 8 x 1 25 mm 22 N m 2 2kst m 16lbf ftl Replace Tightenthe boltsin steps alternating side toside EXHAUST PIPE B HEATSHI...

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Page 207: ......

Page 208: ...mostat Replacement 10 8 WaterPassage Installation 10 9 Water Outlet Installation 10 9 Radiator andFanReplacement 10 10 FanControls Component Location Index 10 11 Symptom Troubleshooting Index 10 12 Ci...

Page 209: ...age10 17 Replacement page10 17 WATER OUTLET Installation page 10 g f CONNECTING PIPE WATER PASSAGE Installation page10 9 THERMOSTAT Test page 104 Replacement page108 RADIATOR Replacement page10 l0 RAD...

Page 210: ...lf the pressuredrops replacethe cap 3 4 RadiatorTest Wait untilthe engineis cool thencarefullyremove the radiatorcapandfill the radiatorwith engine coolantto the top of the filler neck Attachthe pres...

Page 211: ...mostatif it is openat room remperalure To testa closedthermostatl 1 Suspendthethermostat A in a containerof water Do not letthe thermometer B touchthe bottomof the hotcontainer 2 3 Heatthe water andch...

Page 212: ...age10 6 3 Remove thecrankshaft pulley seepage6 11 4 Removethe six boltssecuringthe water pump then removethe water pump A 6 x 1 0 m m 12N m 1 2kgt m 8 7 rbf ft Inspectandcleanthe O ringgrooveand matin...

Page 213: ...ng it up to the l 4AX mark and inspectthe coolingsystemfor leaks 10 6 CoolantReplacement 1 Startthe engine Setthe heatertemperaturecontrol dialto maximum heat thenturn off the ignition switch Makesure...

Page 214: ...causing the coolingsystemto malfunctionor fail HondaAll SeasonAntifreeze Coolant Type2 is a mixtureof 50 antifreeze and 507o water Pre mixingis notrequired EngineCoolantRefillCapacity includingthe re...

Page 215: ...wer hose then removethe thermostat 6 x 1 0 m m 9 8N m 1 0 kgf m 7 2lbf ft a u i LOWER HOSE 4 Installthethermostatwith a new O ring then installthelower hose 5 Installthe splash shield seestep22on page...

Page 216: ...holes NOTE Do not installthepartsif 5 minutesor more haveelapsed sinceapplying liquidgasket Instead reapplyliquidgasketafterremovingold residue 3 Installthe waterpassage A witha newO ring B 10x 1 25 m...

Page 217: ...R HOSE RESERVETANK A C CONDENSER FANASSEMBLY 9 8N m 1 0 kgfm 7 2lbfft CONNECTORS RADIATOB FANSWITCH CONNECTOB 5 Disconnect the fan motor connectors and radiatorfan switchconnector then pullthe radiato...

Page 218: ...ComponentLocationIndex RADIATORFAN RELAY RADIATOBFAN SWITCH Test page10 17 Replacement page 10 17 UNDER HOOD FUSE RELAY BOX RADIATORFAN ASSEMBLY MotorTest page10 4 CONDENSER FANASSEMBLY MotorTest pag...

Page 219: ...EDURE Radiator fan doesnot run at all RadiatorFanCircuilTroubleshooting seepage1O 14 Radiator fan doesnot run for enginecooling but it runs with A CON RadiatorFanSwitchCircuitTroubleshooting Open seep...

Page 220: ...o CircuitDiagram UIIDEF HOOD FJSE NILAY BOX No 20loA USA modd No 20l50A Cm de mod l UNDEN DASX FUSE RELAY BOX lG2H0TiiAClill 0N lllrndSTABI llll 10 13...

Page 221: ...ET Terminalsideof femaleterminals ls therebatteryvoltage YES Goto step4 NO Replace theunder hood fuse relay box I 10 14 4 C o n n e c t t h eN o l a n d N o 2 t e r m i n a l s o f t h e radiatorfan r...

Page 222: ...terminalNo 1 and body ground lf the wire is OK checkfor a poor groundat G301 1 AN MOTOR2PCONNECTOR rftr T Y 9 10 Reinstall the radiatorfan relay Disconnect the radiatorfan switch2Pconnector Connectthe...

Page 223: ...wire is OK checkfor a poor groundat G301 1 10 16 RadiatorFanSwitchCircuit Troubleshooting Short NOTE Aftertroubleshooting performthe engine controlmodule ECM idle learnprocedure seepage 11 1 3 9 1 Re...

Page 224: ...th a thermometer Do not letthethermometer B touch the bottomof the hot conlainer 4 Measurethe continuitybetweenterminalNo 1 and terminalNo 2 accordingto the table Termina Operation lTemperature 1 swtT...

Page 225: ......

Page 226: ...1 6 11 117 11 1 1 8 11 127 11 128 11 128 11 129 1 I 1 3 0 I t t 5 5 1 1 1 3 4 11 1 3 5 11 1 3 7 11 1 3 8 11 1 3 9 11 1 4 0 11 141 11 144 Fuel PressureTest 11 145 Fuel Lines Inspection 11 146 FuelLine...

Page 227: ...0 07406 004000A 07zAJ S5A0100 VacuumPump Gauge 0 30in Hg Vacuum Pressure Gauge 0 4 in Hg Backprobe Set FuelPressure GaugeAdapter Pressure GaugeAdapter FuelSenderWrench Hose Oil Pressure A TPressure Ho...

Page 228: ...MTester A or an OBDll scantool to the DataLink Connector DLC B locatedunderthe driver sside of thedashboard 3 5 Turntheignition switchON ll Checkthe Diagnostic TroubleCode DTC and note it Also checkth...

Page 229: ...tthe ECMasdescribedabove 2 DotheECMidlelearnprocedure seepage11 139 3 Turnthe ignitionswitchOFF 4 Disconnectthe OBDll scantool or HondaPGM Testerfrom the DLC NOTE The ECMis partof the immobilizersyste...

Page 230: ...00A 2 Usingthewire insulation asa guidefor the contouredtip ofthe backprobeadapter gentlyslide the tip intothe connectorfrom the wire sideuntil it touchesthe end of the wire terminal 3 lf you cannotge...

Page 231: ...hicle selectrical devices light horn radio etc How to Update the ECM 1 Turnthe ignitionswitchON ll Do not startthe engIne 2 Connect the HondalnterfaceModule HlM to the DataLinkConnector DLC A locatedu...

Page 232: ...ECT SensorCircuit HiqhVoltaqe seepage11 59 P0122 t7 ThrottlePosition TP SensorCircuitLow Voltaqe seeDaqe11 60 P0123 7 ThrottlePosltion TP SensorCircuitHiqhVoltaoe seepaqe11 62 P0128 87 P0128 CoolinqSV...

Page 233: ...Position TP Sensor SignalHigher Than Mani old Absolute Pressure l 4AP Sensor Signal Loqer Than Expected ManifoldAbsolutePreisure MAP SeiiioiSgnul Hiqher ThanEx seepage11 84 Engine Control Module ECN4...

Page 234: ...nsorB TopDeadCenter TDC Sensor No Siqnal seepage11 95 P r456 90 P1456 Evaporative Emissions EVAP ControlSystem Leakaqe FuelTankSvstem seepage11 175 P14s7 90 P1457 Evaporative Emissions EVAP ControlSys...

Page 235: ...Checkthe idlespeed seepage11 138 Inspect adjust the throttlecable seepage1 1 163 Inspectandtestthe throttlebody seepage11 160 2 3 ldlespeedfluctuates MlLworksOK no DTCS set 1 DotheECMidlelearnprocedur...

Page 236: ...rol signaltube 3 betweenthe fuel pipeandthe fueltankvapor controlvalve 4 Inspectthe fueltankvaporventtube betweenthe EVAPcanisterandthe fueltankvaporcontrolvalve Checkthe EVAPcanister Malfunctioning g...

Page 237: ...ndent of the systemto permitminimaldriving Self diagnosis Whenan abnormalityoccursin the signalfrom a sensor the ECMsuppliesgroundfor the malfunctionindicatorlamp MlL and storesthe diagnostic troublec...

Page 238: ...meas almospnencpressure At idlespeed about 20 4 1kPa 150 310mmHg 6 1 2i n H q 0 71 3V The ECTsensorconvertscoolanttemperatureintovoltage and signalsthe ECM The sensoris a thermistorwhose internalresis...

Page 239: ...amountof injectedfuel Thiscvclekeepsthe airlfuelratiocloseto the stoichiometric ratiowhen in closedloopstatus o 7 1 5 YES LongTerm Fuel Trim Longterm fueltrim is computedfrom shortterm fueltrim and in...

Page 240: ...TTERY 8oA ONo 6 ECU ECM 15A1 3 No 20lG 40A1 Canada 50A ONo l4 OPTION 40A1 No 9 BACK uP 7 5A1 lo No 7 HORN STOP 15A UNDER DASH FUSE RELAY BOX ONo 17FUEL PUMP 15A No tACG 10A ONo 1IGNCOIL 1sA q No 10MET...

Page 241: ...stems a SystemDescriptions cont dl ECMElectrical Connections No INJECTOR No 2INJECTOR No 3 INJEC OB No tINJECTOF MAPSENSON TPSENSOR IATSENSOR ECTSENSOB CMPSENSOR B TDCSENSOSJ CKPSENSOR 1 1 1 6 F VERSE...

Page 242: ...PCANISTER VENTSHUTVATVE sotENotovAtvE A FSENSOR A FSENSOR sENSOn1 CMPSENSOFA VIC OILCONTROL SO ENOIDVALVE wEcorl PRESSUSE SWTICH VTECSOLENOID cont d 11 17 No 1 IGNITIONCOIL No 2lGNlllONCOIL No 3 IGNIT...

Page 243: ...Fueland Emissions Systems SystemDescriptions cont d ECMElectrical Connections ARAKEPEDAL POStTtON SWTTCH IMMOBILPENUN T EPSCONTROT UNIT GAUGEASSEMBLY 1 1 1 8 TERMINALLOCATIONS...

Page 244: ...BLK PG2 POWER GROUND Ground fortheECMcircuit Less than1 0V atalltimes 5 BLK PG1 POWER GROUND Ground fortheECMcircuit Less than1 0V atalltimes 6 RED AFS AIR FUEL RATIO A F SENSOR SENSOR 1 stDE Detects...

Page 245: ...nsor voltage Withignition switch ON ll about5 V Withionition switch OFF about0V 22 AFSHTC AIR FUEL RATIO A iFiSENSOR HEATER CONTROL SIDE Detects a Fsensorheater voltage With ign tionswitch ON lll bane...

Page 246: ...IRF SWITCH Detects VTEc oilpressure switch sional Withengine atlowengine speed about0 Wirhenoine athiohenoine soeed batterv voltaqe 10 WHT BLU ALTL ALTEBNATOR L SIGNAI I Detects alternator Lsignal Wit...

Page 247: ...tch OFF about0 V 6 BLKATr HT SO25HTC SECONDARY HEATED OXYGEN SENSOR SECONDARY H02S HEATER CONTROL Drives secondary HO2S heater With ignitionswitchON ll bafteryvoltage Wilhfullvwarmedupengine running d...

Page 248: ...CH Detects brake pedal oositionswitch sional Withbrake pedalreleased about0 V With hrake nedal nresse l batterv voltaoe 23 LTBLU K LIN E Sends andreceives scan Withignition switch ON li r pulses or ba...

Page 249: ...Fueland Emissions Systems SystemDescriptions cont dl VacuumHoseRouting INTAKEAIR BYPASSCONTROL THERMALVALVE FRONTOF VEHICLE EVAPORATIVE EMISSION EVAP CANISTERPURGEVALVE 11 24...

Page 250: ...O THRONLE BODY OINJECTOR FUEL PULSATION OAMPER I FUEL FILTER FUEL PRESSURE REGULATOR FUEL PUMP FUEL TANK RESONATOR 9 AIRCLEANER POSITIVE CRANKCASE VENTILATION PCVIVALVE THREE WAYCATALYTIC CONVERTER EV...

Page 251: ...LS HEATER TERMINALS Barometric Pressure BAROISensor The BAROsensoris insidethe ECM lt convens atmosphericpressureinto a voltagesignalthatthe ECM usesto modifythe basicdurationof the fuel injection dis...

Page 252: ...alfunctionIndicatorLamp lMlLl Indication ln relation to ReadinessCodes The vehiclehascertain readinesscodes that are part of the on boarddiagnostics for the emissionssystems lf the vehicle sbafteryhas...

Page 253: ...ERMINALS HEATER TERMINALS Starting Control Whenthe engineis started the ECMprovidesa rich mixtureby increasinginjectorduration Throttle Position ITP Sensor TheTPsensoris a potentiometer connected to t...

Page 254: ...sthe intakevalvetiming continuously HIGH i LOW ENGINE SPEED DrivinoCondition VTCControl DescriDtion QrLight load BasePosition Camangleis retardedto reducethe entryof exhaust gasintothe intakeport andt...

Page 255: ...ryof the airlfuelmixtureintothe intakeport and improvethe chargingeffect Camangleis reducedat idleto stabilize combustionand reducesenginespeed lfamalfunctionoccurs theVTCsystemcontrol is disabled and...

Page 256: ...CMPSENSOR A BRN YEL BLU WHT BLU WHT BLK WHT GRN YEL BLU BLK From No il ACC 10A fuse VARIOUS SENSORS CAMSHAFT BLK I t Camshaft Position CMP Sensor TheCMPsensordetectscamshaftanglepositionfor the VTCsys...

Page 257: ...leration with thethrottlevalveclosed currentto the injectorsis cutoff to improvefuel economyat enginespeedsover 1 030rpm Fuelcut off actionalsooccurswhen enginespeedexceeds 6 900rpm regardless of the...

Page 258: ...ermal Valve Whentheengineis running theintake airbypass controlthermalvalvesendsair to the iniectors INJECTOR Throttle Body Thethrottlebody is a single barrel sidedrafttype lt housesthe TPsenserandthe...

Page 259: ...C carbon monoxide CO andoxides ofnitrogen NOx inthe exhaust gasto carbon dioxide C02 dinitrogen N2 andwatervaDor THREE WAY CATALYST FRONTOF VEHICLE 11 34 PositiveCrankcase Ventilation PCVISystem The P...

Page 260: ...sure FTP Sensor The FTPsensorconvertsfueltank absolutepressure intoan electricalinputto the ECMduringthe EVAPleak cnecK SENSOR UNIT EVAPTwo Way Valve and EVAPEyp8s Solenoid Valve The EVAPtwo way valve...

Page 261: ...necoolanttemperatureis low the IACvalveis openedto obtainthe properfastidlespeed The amountof bypassedair is controlledin relationto enginecoolanttemperature INTAKEMANIFOLD IACVALVE AKEAIRDUCT CLEANER...

Page 262: ...otant temperatureis above149 F 65 C W h e n v a p o r p r e s s u r e i n t h e f u e l t a n k i s h i g h e r t h a n t h e s e t v a l u e o f t h e E V A P t w o w a y v a l v e t h e v a l v e o...

Page 263: ...FuelandEmissions Systems I a a SystemDescriptions cont d ECMCircuit Diagram CONNECTOi mrrrrn CMPSENSOR B TDCSENSOn I BRN YEr 11 38...

Page 264: ...wEc solENorD wcoLcoNTnoL SoLENO OVAIVE _YEL aLU __f F 1 RED aLK l Hi I GFN YEL _l t_r I I I SCNSOn L l I ff l_l _ ll t l I croz KnocK l I SENSOn I Y l Ll cont d 11 39...

Page 265: ...issions Systems SystemDescriptions cont dl ECMCircuitDiagram cont d ffi 1t IATSENSOR El l ECTSENSOS T_ I BFN YEL ft l J t I REVERSE I LocK I soleloto vaLvE t j CMPSENSOAA L I J U N C T I O N I CONNECT...

Page 266: ...r BLU J L9l H l lurcrroru F coNNEcroR _1ffi1 1 Fahdl I l r l T 8r K L l EVAPCANISTEB ALK YEL WHT ALU WHT NED WHI GRN JUNCTION CONNECTOR rrrn tcM No 2IGNITION COlt No 3IGNITION COIL PLUG PLUG cont d 1...

Page 267: ...FuelandEmissions Systems a a a SystemDescriptions cont d ECMCircuitDiagramlcont dl IGP2 YEI BLK VET BLK rF rl lF forl JliD l t l MAIN BETAV2 t_ f o tr t l r l r u I SENSOS 11 42 IMMOAIL zER UNIT...

Page 268: ...SECONDAFY H02S s NsoR2l m tlil TPS NSOR l r I CANISTER VEAIT SHUTVALVE t _ lti l EVAPEYPASS solENorD To PS CONTROLUNIT CPU GAUGEASSEMBTY cont d 11 43...

Page 269: ...FuelandEmissions Systems a SystemDescriptions cont dl ECM Circuit Diagram cont d L UNDER HOOD FUSE RELAY9OX lalLREllY _ _l CONN CTOF CONNECTOi WHI NED BLK YET 11 44...

Page 270: ...I TEST TACHOMETER CONNECTO8 UNDER HOOD UNDER DASH FUSE RELAY BOX UNDER DASH FUSE FELAYBOX Brakepedal pressed closed Brakepedal releasedropen POStTtON SWTTCH or 9J3 51 re _ F _ rl 4 ACG 1oAt 1 tGNCO L...

Page 271: ...Code NOTE Do notturn the ignitionswitchoff duringthe procedure All readiness codesareclearedwhen the batteryis disconnected or when the ECMis clearedwith the OBDll scantool or HondaPGlvlTester Low amb...

Page 272: ...gthe orocedure All readiness codesareclearedwhen the bafteryis disconnected or when the ECMis clearedwith the OBDll scantool or HondaPGMTester Enable Criteria ECTat 140 F 60 C or higher Procedure 1 Co...

Page 273: ...utsidethe rangeof any relatedenablecriteria FuelSystemMonitorandReadiness Code This readiness code is alwayssetto available because the fuel systemis continuouslymonitored duringclosedloopoperation Mo...

Page 274: ...15 f r l KNOCK SENSOR Troubleshooting page11 77 Beplacement page 11115 ENGINE COOLANT TEMPERATURE ECTI SENSOR Troubleshooting page11 57 Replacement page 11114 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR Tro...

Page 275: ...PGM Fl System ComponentLocationIndex cont d 11 50 v...

Page 276: ...INKCONNECTOR IDLCI General Troubleshooting Information page1l 3 PGM FI MAINRELAY 1 Troubleshooting page11 97 ENGINECONTROLMODULE General Troubleshootin g Information page113 Troubleshooting pageI 1 96...

Page 277: ...BED sGr GRN WHT 11 52 Wire side of female terminals 8 ls thereabout5 V YES Repair open in the wire betweenthe Eclvl A21 and the MAPsensor l NO Updatethe ECMif it doesnot havethe latest software or su...

Page 278: ...2 9 V or higherindicated YES Go to step8 NO Replace the MAPsensor I 8 Remove thejumperwire 1 2 3 9 Measure voltage between MAPsensor 3P connector terminals No 1andNo 3 MAPSENSOR 3PCONNECTOF vccl Y E L...

Page 279: ...ES Intermittent failure systemis OK at this time I NO Replace the MAPsensor l 11 54 DTCPl129 MAPSensor Signal Higher Than Expected 1 Startthe engine Holdthe engineat 3 000rpm with no load in neutral u...

Page 280: ...P CONNECTOR l r 2 l t l Tr IAT _t RED YELI II Wiresideof female terminais ls there continuity YES Repairshon in the wire betweenthe ECM B 17 andthe IATsensor l NO Updatethe ECMif it doesnot havethe la...

Page 281: ...ideoffemale terminals 6 Turnthe ignition switchON ll 11 56 7 Checkthe IATwith the scantool ls 4 F 20 C or less or L Limitin Honda modeot PGM Tester or 5 V indicated YES Goto step8 NO Replace the IATse...

Page 282: ...1 Stanthe engine Holdthe engineat 3 000rpm with no load in neutral untilthe radiatorfan comeson then let it idle 2 Checkthe ECTwith the scantool ls 176 212 F 80 100 C or0 5 0 8V indicated YES Intermit...

Page 283: ...with the scantool ls 150 C 302 F or higher ot H Limitin Honda mode ot PGM Tester or 0 V indicated YES Go to step5 NO Replace the ECTsensor 5 Turnthe ignitionswitchOFF 6 Disconnect ECMconnectorB 24P 11...

Page 284: ...Turnthelgnition switchON ll 1 8 9 1 0 Checkthe ECTwith the scantool ls 20 C 4 F or less or L Limitin Honda modeot PGM Tester or 5 V indicated YES Go to step8 NO Replace theECTsensor I Turnthe ignition...

Page 285: ...3P connectorterminalsNo 1 and No 3 TP SENSOR3PCONNECTOR Wiresideof femaleterminals ls thereabout5 V YES Goto step7 NO Gotostep14 Turntheignition switch OFF 1 11 60 8 At the sensorside measureresistanc...

Page 286: ...dbodyground TPSENSOR 3PCONNECTOR RED BLX Wire sideof femaleterminals ls therecontinuity YES Update the ECMif it doesnot havethe latest software or substitutea known goodECM then recheck seepage11 6 lf...

Page 287: ...connector 5 Turnthe ignition switchON ll 6 At the wire harnessside measurevoltagebetween the TPsensor3PconnectorterminalsNo 1 and N o 3 TPSENSOR 3PCONNECTOR W resideoffemale terminals ls thete about5...

Page 288: ...ailure systemis OK at this time I NO Replace theTPsensor theTPsensoris not availableseparately I DTCP1122 fP Sensor Signal Higher Than Expected 1 Turnthe ignition switchON ll 2 Checkthe throttlepositi...

Page 289: ...rol lAC valve DTCP0128 canoccasionally setwhen the hoodis opened whiletheengineis running 1 Checkthe enginecoolantlevel Is the enginecoolantlevel low VES Refillthe enginecoolant lf necessary repair th...

Page 290: ...dthe ECM I DTCP0137 Secondary HO2S Sensor 2 Circuit LowVoltage 1 Reset theECM seepageI1 4 2 Startthe engine Holdthe engineat 3 000rpm wilh no load in neutral untilthe radiatorfan comeson 3 Checkthe se...

Page 291: ...ondary HO2S Sensor 2 Circuit HighVoltage 1 Resetthe ECM seepage 11 4 2 Starttheengine Holdthe engineat 3 000rpm with no load in neutral untilthe radiatorfan comeson 3 Checkthe secondaryHO2S Sensor2 ou...

Page 292: ...then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe original ECM I NO Repairopenin the wire betweenthe ECM E2 E4 andthe secondaryHO2S Sensor2 I 9 1 0 1 1 1 2 JUM...

Page 293: ...HO2S SENSOR 214PCONNECTOR Wiresideol lemaleterminals ls thereabout3 3Q YES Goto step6 NO Replace thesecondary HO2S Sensor 2 t 5 11 68 6 Checkfor continuitybetweenbody groundand secondaryH02S Sensor2 4...

Page 294: ...l sideof male terminals ls there battety voltage YES Goto step13 NO ChecktheNo 4 ACG 10A fuseinthe under dashfuse relaybox lf the fuseis OK repairopenin the wire betweenthe secondaryHO2S Sensor2 andNo...

Page 295: ...oto step2 NO Checktheseitems lf the pressureistoo high replacethe fuel pressure regulator seepage11 152 1 lfthe pressure istoo low checkthefuel pump the fuelfeed pipe the fuelfilter and replacethe fue...

Page 296: ...reDTC s P0 107 P0108 P1128 P1129r N4anifold absolute pressure MAP sensor P0111 P0 172t Fuelsvstem P0335 P0336 Crankshaft position CKP sensor P0505 ldlecontrolsystem P1149 Pl 162 P1163 P1164 P1165 Air...

Page 297: ...ueto poor contactatthe ignition coilconnectors nomisfire atthistime Makesurethe coil connections aresecure l 11 72 8 9 1 1 1 Determine which cylinder s hadthe misfire Does the misfire occur in the cyl...

Page 298: ...ed YES Replace the faulty injector I NO Go to step19 Turnthe ignitionswitchOFF Disconnect the ignitioncoil 3Pconnectorfrom the problemcylinder Turnthe ignitionswitchON ll t7 18 19 20 22 Measurevoltage...

Page 299: ...RECOLOR No 1 P0301 YEUGR N No 2 P0302 BLU RED No 3 P0303 WHT BLU No 4 P0304 BRN 11 74 28 Checkfor continuitybetweenbody groundand ECMconnectorterminal seetable ECMCONNECTOR A 31P PROBLEM CYLINDER DTC...

Page 300: ...utes Test drive the vehiclefor severalminutesin the rangeoI thelreeze dataor undervarious condilionsif therewas no freezedata Checkfor a DTCor TemporaryDTCwith the scan tool ls DTC or TemporaryDTC P03...

Page 301: ...ep48 PROBLEM CYLINDER DTC ECM TERMINAL WIRE COLOR N o 1 P030 1 B5 B R N N o 2 P0302 B4 RED N o 3 P0303 B3 BLU No 4 P0304 82 YEL 11 76 48 Connect injector 2Pconnector terminalNo 2to bodyground withajum...

Page 302: ...Pconnector l NO Goto step7 7 Connect staner subharness 6Pconnector terminal No 5to bodyground withajumper wire 8 STARTER SUAHARNESS 6PCONNECTOR l 1 l 2 1 3 l l l5l6l _ KS IJUMPER RED BLU IW RE I Wires...

Page 303: ...Repair openlnthewirebetween PGM Fl main relay 1andtheCKP sensor IGP 1 2 3 11 78 7 MeasurevoltagebetweenCKPsensor3Pconnector terminalNo 1 andbodyground CKPSENSOR 3PCONNECTOR Wire side of female tefmin...

Page 304: ...ionswitchOFF Disconnect ECMconnectorA 31P Checkfor continuitybetweenECMconnector terminal47 and body ground ECMCONNEfiORA 31P Wiresideoffemale terminals ls there continuity YES Repair shortin the wire...

Page 305: ...en0V and battery voltage YES Update the ECMif it doesnot havethe latest software or substitutea known goodECM then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe...

Page 306: ...orE 31P Turnthe ignition switchON ll lvleasure voltagebetweenECMconnectorterminal E7and body ground 6 7 8 ECMCONNECTOR E 31P Wiresideolremale terminals ls therebattery voltage YES Goto step12 NO Goto...

Page 307: ...and42 individually ECMCONNECTOR A 3 IP IGP2 IGP1 YEI BLX YEL BLKI Wiresideof female lerminals ls there battery voltage YES Go to step18 NO Updatethe ECMif it doesnot havethe latest software or substi...

Page 308: ...substitutea known goodECM then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe original ECM NO Intermittent failure systemis OK atthis time I DTCPl107 BARO Senso...

Page 309: ...Disconnect the Ay F sensor Sensor1 4Pconnector andECMconnector A 31P ConnectA F sensor Sensor1 4Pconnector terminals No 1 andNo 2 witha jumperwire A FSENSOR SENSOR 1 4PCONNECTOR AFS BLU Wiresideof fe...

Page 310: ...goesawaywith a known goodECM replacethe originalECM NO Replace the Ay F sensor Sensor1 9 DTCPl158 Ay F Sensor Sensor 1 AFS Terminal LowVoltage 1 Resetthe ECM seepage11 4 2 Startthe engine ls DTC P115...

Page 311: ...Sensor 1 AFS Terminal LowVoltage 1 Resetthe ECM seepage11 4 2 Start the engine ls DTC P1159indicated YES Go to step3 NO lntermiftent failure systemis OK at thistime Checkfor poor connections or loose...

Page 312: ...ls DTC P1159 indicated YES Update the ECMif it doesnot havethe latest software or substitutea known goodECM then recheck seepage11 6 if the symptom indication goesawaywith a known goodECN4 replacethe...

Page 313: ...is OK atthis time Checkfor poor connections or looseterminalsat the A lFsensor Sensor1 and at the ECM t 11 88 DTCPl164 A F Sensor Sensor 1 Circuit Range Performance Problem 1 Resetthe ECI 4 seepage1t...

Page 314: ...e wire betweenthe Ay F sensorrelayandthe fuses I NO Goto step4 4 MeasurevoltagebetweenECMconnector terminalsA1 andA24 30 secondsafterthe ignition switchisturnedON ll ECMCONNECTOR A I31P Wiresrdeof lem...

Page 315: ...nsor1 4Pconnector Checkfor continuitybetweenthe Ay F sensor Sensor 1 4Pconnector terminalNo 3 andbody ground A FSENSOR SENSOR 1 4PCONNECTOR 10 1 1 12 11 90 Wiresideot Iemaleterminals t 5 14 ls there c...

Page 316: ...lay at the Ay F sensor Sensor1 andattheECM I Turnthe ignitionswitchOFF Disconnect the A F sensor4Pconnectorand ECM connectorA 31P Connectthe Ay F sensor Sensor1 4Pconnector terminals No 2 andNo 1witha...

Page 317: ...connectorterminalNo 3 ELO3PCONNECTOB GRN REDI Wiresideof femaleterminals ls thereabout5 V YES Replace theELD t NO Gotostep 8 Z 3 ELD 11 92 8 Turnthe ignitionswitchOFF 9 Disconnect ECMconnectorE 31P 10...

Page 318: ...here battery voltage YES Go to step8 NO ChecktheNo 4 ACG 10A fuse inthe under dashfuse relaybox lf the fuseis OK repairopenin the wire betweenthe No 4 ACG 10A fuseandthe ELD I 8 9 10 1 1 Turnthe ignit...

Page 319: ...the ELD3Pconnectorand ECM connectorE 31P Startthe engineand let it idle While measuringvoltagebetweenECMconnector terminals 424 andE15 turnthe headlights on thigh ECMCONNECTORS Wi esideof femaletermin...

Page 320: ...n the wire betweenthe PGM Fl mainrelay1 andtheCMPsensor I TDC sensor I IGP 1 2 3 7 l 4easure voltagebetweenCMPsensorB TDC sensor 3PconnectorterminalNo 1 and body ground CMP S NSOR8 ITDCSENSOR 3P CONNE...

Page 321: ...etweenthe ECM 426 andthe CMPsensorB TDCsensor 1 NO Updatethe ECMif it doesnot havethe latest software or substitutea known goodECM then recheck seepage11 6 lf the symptom indication goesawaywith a kno...

Page 322: ...40A Canada 50A Iuse inthe under hood fuse relaybox A iooseNo 6 ECU ECM 15A fusein theunder hoodfuse relaybox A looseNo 17FUELPUMP 15A fuse inthe under dash fuse relaybox A poorconnection at ECMtermin...

Page 323: ...heck for a blownMILbulb lf thewiresandthe bulbareOK replacethe gaugeassembly l Turnthe ignltionswitchOFF Inspectthe No 6 ECU ECIM 15A fusein the under hood fuse relaybox ls the f useOK YES Go to step2...

Page 324: ...goodECM replace theoriginal ECM Also replacethe No 6 ECU ECM 15A fuse Disconnect the connectors of allthesecomponents PGM Fl mainrelay2 ECMconnector A 31P lnjectors ldleaircontrol lAC valve CamshaftP...

Page 325: ...he symptom indication goesawaywith a known goodECM replacethe original ECM I 26 Removethe PGM Flmain relay2 A 11 100 27 Check forcontinuity between ECIVI connector terminal Egandbodyground ECMCONNECTO...

Page 326: ...inal No 5 andbodyground FUELPUMP5PCONNECTOR Wire side ol lemal rerminals ls therecontinuity YES Replace the PGM Flmain relay2 Also replace the No 17FUELPUMP 15A fuse l NO Checkthe iuel pump and replac...

Page 327: ...p41 NO Repairopenin the wire betweenthe No 6 ECU ECM 15A fuseandthe PGfM Fl mainrelay1 I Checkfor continuitybetweenPGM FI main relay1 4PconnectorterminalNo 3 and ECMconnector terminalE7 PGM FIMAIN REL...

Page 328: ...inrelay14P connector terminal No 2 andbodyground PGM FIMAINRELAY1 4PCONNECTOR ls therebattery voltage YES Go to step49 NO Repair openinthewirebetween the No 6 ECU ECM 15A fuse andthe PGM Fl main relay...

Page 329: ...4l a Measurevoltagebetweenbody groundand ECM connector terminal 421 ECMCONNECTOR A 131P Wiresideoffemale terminals ls thereabout5 V YES Go to step60 NO Go to step53 11 104 53 54 Turnthe ignitionswitch...

Page 330: ...ygroundand ECM connectorterminal420 ECMCONNECTOR A 3TP 60 1 1 2 1 3 4 5 o t I 1 011112 5 6 1189 2t 21 2 231 4 q Tln 29 vcc2 IYEL BLU Wire side otfemale terminals ls thereabout5 V YES Go to step68 NO G...

Page 331: ...st software or substitutea known goodECM then recheck seepage l1 6 lf the symptom indication goesawaywith a known goodECM replacethe original ECM t vcc2 YEL BLU 11 106 68 Measurevoltagebetweenbody gro...

Page 332: ...doesnot havethe latest software or substitutea known goodECM then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe original ECM I Wire sideof femaleterminals Wires...

Page 333: ...test software or substitutea known goodECM then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe original ECI 4 I Turnthe ignitionswitchOFF Disconnect ECMconnector...

Page 334: ...betweenDLCterminalsNo 4 and No 16 DATA LINKCONNECTOR DLCI Terminal sideofJemale terminals Is there battery voltage YES Go to step3 NO Repairopen in the wire betweenDLCterminal No 4 andbodyground l 4 5...

Page 335: ...dECM then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe original ECI 4 I NO Repairopenin the wire betweenDLCterminal No 7 andthe ECM E23 Afterrepairing thewire...

Page 336: ...eground cable B andremove thebracket C 2 2kgf m l6 lbf ftl ffi t 3 Disconnect the quick connect fittings D 4 Removethefuel railmountingnuts E fromthefuelrail F thenremovethefuel railandinjectors asan...

Page 337: ...injectors intothefuelrail theninstall thefuelrailintotheintakemanifold G 1 1 Installthe fuel railmountingnuts groundcable and bracket 12 Connect the connectors to the injectors 13 Connect the quick c...

Page 338: ...A then removethe A F sensor B I ffi B 44N m InstalltheIVFsensorin the reverseorderof removal Secondary HO2SReplacement Special Tools Fequired 02 sensorwrench Snap onYA8875 SPTools93750 or equivalent c...

Page 339: ...2kgt m 8 7 lbt ft reverse order of removal lnstallthe sensor in the with a new o ring B 11 114 CMPSensorB TDC Sensorl t 2 Replacement Remove theaircleaner seepage11 162 Disconnect the CN4P sensorB TDC...

Page 340: ...andthe IATsensor B 3 lnstallthesensorin the reverseorderof removal KnockSensorReplacement 1 Removethe intakemanifoldbracket A 2 3 4 2 4 N m 2 4kgt m 17lbt ftl Disconnect the knocksensor1Pconnector Rem...

Page 341: ...M FI System GKPSensorReplacement 1 Disconnect theCKP sensor 3Pconnector 2 Remove theCKP sensor A 12N m 1 2kgt m 8 7 tbf ftl 3 lnstallthe sensorin the reverseorderof removal with a new o ring B 1 1 1 1...

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Page 344: ...OLENOID VALVE Troubleshooting page11 118 Test page 11 l27 g l 1 ia i r l i lti tl tt CAMSHAFTPOSITION ICMPISENSOR A Troubleshooting page11 121 Replacement Pagel 128 VTCSOLENOID VALVE Troubleshooting p...

Page 345: ...rminals ls there 6 75 8 25 Q YES Goto step11 NO Go to step7 7 Disconnect the VTCoil controlsolenoidvalve2P connector 1 1 1 1 8 8 Measureresistance betweenVTCoil control solenoid valve2Pterminals No 1...

Page 346: ...the VTCoil controlsolenoidvalve l NO Replace the VTCoil controlsolenoidvalve seepage11 1211 a 4 DTCP0011 VTCSystemMalfunction 1 Reset the EClvl seepage11 4 2 Starttheengine Holdtheengineat 3 000 rpmwi...

Page 347: ...resideof temaleterminals 13 ConnectECMconnectorterminalsA3 and 81 witha jumperwiremomentarily NOTE Do notjump for morethan 1 minute ECMCONNECTORS Did the engine stall or run rough YES Test drive at a...

Page 348: ...repairopen in the wire betweenthe CN4P sensorA and No 4 ACG 10A fuse I tG1 1 2 3 7 Measure voltage between CMPsensor A 3P connector terminal No 1andbodyground CMP SENSORA 3PCONNECTOR Wiresideolfemalet...

Page 349: ...oodECM replacethe original ECM I 1 1 t2 11 122 DTCP0341 WC Phase Gap 1 Resetthe ECM seepage11 4 2 Startthe engine ls DTC P0341indicated YES Goto step3 NO Intermittent failure systemis OK at this time...

Page 350: ...1259indicated YES Goto step5 NO lntermittent failure systemis OK atthis time Checkthe oil consumptionif oil was addedin step 2 Checkfor poorconnections or looseterminalsat the VTECsolenoidvalve the VT...

Page 351: ...ECM 89 I NO Updatethe ECMif it doesnot havethe latest software or substitutea known goodECM then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe original ECN4 1 1...

Page 352: ...23 NO Inspectthe VTECsolenoidvalve seepage11 t28l a 23 24 25 26 Turnthe ignitionswitchOFF Disconnect the VTECsolenoidvalve2Pconnector Aftachthe batterypositiveterminalto VTEC solenoid valve2Pconnector...

Page 353: ...lNo 2 to body groundwith a jumperwire VTECSOLENOIDVALVL 2PCONNECTOR r r 1 t 1 t 2 l JUMPER I VtS WIRE I IGRN YEL I Wiresideoffemale terminals Checkfor continuitybetweenECMconnector terminal815andbodyg...

Page 354: ...ontaminate the cylinderhead openrng Checkthe VTCoil controlsolenoidvalvefilterfor clogging lf it is clogged replacethe VTCoil control solenoidvalve Checkthe clearance betweenthe port advance side andt...

Page 355: ...Inspection 1 Disconnect the VTECsolenoidvalve2Pconnector Measureresistance betweenVTECsolenoidvalve connector terminals No 1 andNo 2 Resistance 14 30 Q 3 lf the resistance is within specifications rem...

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Page 358: ...ldleGontrol System ComponentLocationIndex TE IDLEAIRCONTROL IAC VALVE Troubleshooting page11 131 11 129...

Page 359: ...NO lf the idlespeedis lessthan 700rpm go to step3 if it s800rpm or higher go to step4 3 Disconnect theidleaircontrol lAC valve3P connector Does the engine speed increase or fluctuate YES Checkthe idle...

Page 360: ...Goto step7 NO Repairopeninthewirebetween theIACvalve andthePGM Fl mainrelay 1 1 Turntheignition switchOFF 1 2 3 7 8 Checkfor continuitybetweenbody groundand IAC valve3Pconnector terminalNo 1 IACVALVE...

Page 361: ...rebetween theIACvalve andrheEcM A12 r Reconnect theIACvalve3Pconnector Turntheignition switch ON ll 13 14 11 132 15 Measurevoltagebetweenbody groundand ECM connector terminal A12 ECMCONNECTOR A 131P r...

Page 362: ...atethe ECMif it doesnot havethe latest software or substitutea known goodECM then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe original CM l 6 Momentarilyconne...

Page 363: ...n let it idle 7 lvleasure voltagebetweenECMconnector terminals A24andB13 Does the voltage decrease when the headlights and rear window defogger arc tutned on YES Thealternator FRsignalis OK l NO Go to...

Page 364: ...lacethe original ECM I Electrical PowerSteering EPSI SignalCircuitTroubleshooting Turnthe ignition switchON ll l 4easure voltagebetweenECMconnector terminals 424 andE16 1 2 3 4 5 Wiresideof femaleterm...

Page 365: ...l No 17andthe bodyground EPSCONTROL UNIT2OP CONNECTOR Wire side of femaleterminals ls there battery voltage YES Substitutea known goodEPScontrolunit andrecheck l NO Go to step14 Turnthe ignitionswitch...

Page 366: ...brakepedal presseo ls therebattery voltage YES The brakepedalpositionswitchsignalis oK I NO Repairopenin the wire betweenthe Eclvl E22 andthe brakepedalpositionswitch l Wiresideof lemaleterminals 4 I...

Page 367: ...connectthe HondaPGMTester C or an OBDll scantool to the datalinkconnector DLC D locatedunderthe driver ssideof the dashboard 11 138 4 3 5 6 Startthe engine Holdthe engineat 3 000rpm with no load inneu...

Page 368: ...etayDox Disconnect anyof the connectors from the under hoodfuse relaybox Disconnect the connectorbetweenthe engine compartmentwire harnessand ECMwire harness Disconnect the G2terminalfrom the transmis...

Page 369: ...K CONNECT FITTINGS Precautions page11 148 Removal page11 149 Installation page11 l50 FUELVAPORLINE i PUMP Test page11 141 FUELFILLCAP FUEL TANK Replacement page l 1 155 PGM FIMAIN RELAY1 Fleplacement...

Page 370: ...ideoffemale terminals ls there battery voltage YES Go to step5 NO Repairopen in the wire betweenthe PGM Fl mainrelay1 andthe PGM Fl mainrelay2 t 3 5 N4easure voltagebetweenPGM Flmain relay2 5P connect...

Page 371: ...14 Wiresideoffemale terminals Wiresideof female terminals 11 142 t 5 t o 1 1 1 8 ls therebattery voltage YES Updatethe ECMif it doesnot havethe latest so 1ware or substitute a known goodECM then rech...

Page 372: ...NECTOR Wiresideolfemale terminals ls there battery voltage YES Replacethe PGM Fl mainrelay2 t NO Repair openin the wire betweenthe PGM Fl main relay2 andthe fuel pump 5Pconnector l Turnthe ignitionswi...

Page 373: ...uick connect fittingfor dirt and cleanit if necessary 3 4 6 7 8 11 144 1 1 10 9 Placea rag or shoptowel overthe quick connect fitting A Disconnect the quick connect fifting A Holdthe connector B with...

Page 374: ...p4 Checkto seeif the fuel pump is running listento the fuelfill portwith the fuelfill cap removed The fuel pump shouldrunfor 2 secondswhen the ignitionswitchis firstturnedon lf the pump runs go to ste...

Page 375: ...uelLineInspection Checkthe fuel systemlines hoses andfuelfilterfor damage leaks and deterioration Replace anydamagedparts Makesurethe connection is secureandthe quick connect fittingcoverisfirmly lock...

Page 376: ...ghten if necessary A Donotdisconnect thehosefromthelineattheseioints Settheboltflange Clampin the middle Thereshouldbe no W W Clampin the middle Setthispart the fuel illtube alignthe marks on the tube...

Page 377: ...th a shoptowel whichwas usedfor wiping batteryelectrolyte Replace them if theycame into contactwith electrolyte or somethingsimilar Whenconnectingor disconnecting the fuelfeed hose B fueltube D and qu...

Page 378: ...l it comesoff easily Do not removethe retainerfrom the line once removed the retainermust be replacedwith a new one 4 Checkthe contactarea A of the line B for dirt and damage lf the surfaceis dirty cl...

Page 379: ...new retainer A intothe connector B if the retaineris damaged or after replacing thefuelrail replacingthe fuelfeed line replacingthe fuel pump replacingthe fuelfilter replacing thefuelgaugesending uni...

Page 380: ...puta smallamountof newengine oil on thelineend Connectionwith new retainer Reconnectionto existing retainer 5 lvlake surethe connectionis secureandthatthe pawlsarefirmlylocked intoplace check visuall...

Page 381: ...psi aftermakingsurethatthe fuel pump andthe fuel pressureregulatorareOK 1 Remove thefuelpump seepagell 153 2 Removethe Installin the reverseorderof removalwith a new basegasket B and a new o ring C t...

Page 382: ...thefuelfilter B thefuelgaugesending unit C thecase D thewire harness E andthe fuel pressureregulator F 10 Whenconnecting thefueltankunit makesurethe connection is secure andthesuction filter G is fir...

Page 383: ...G101 5 Raise thefuelrail 6 Place awrench A onthefuelrail B 7 Place a wrench C onthefuelpulsation damper D 8 Removethe pulsationdamper 9 Installthefuel pulsationdamperin lhe reverse orderof removalwit...

Page 384: ...s Removethe fuel pipecover A Disconnect the fuelvaporhoseand quick connect fittings Disconnect the hoses Slidebackthe clamps B thentwist the hosesasyou pullto avoiddamagingthem A 38N m 3 9 ksf m 28lbf...

Page 385: ...Turnthe ignition switchOFF 4 Removethe rearseatcushion seepage20 80 5 Removethe accesspanel A from the floor 6 Disconnect the fuel pump 5Pconnector B ztr 11 156 7 Measurevoltagebetweenfuel pump 5Pconn...

Page 386: ...uel pump 14 Usingthespecial tool loosen thefueltankunit locknut A A 9 3 N m 9 5ksf m 69 lbf ft 15 Measure resistance between the No 1 andNo 2 terminalswith the floatat E EN4PTY l12 HALF FULL andF FULL...

Page 387: ...the float at the E EMPry position lf the low fuel indicatoris on go to step4 lf the low fuel indicatoris not on referto the low fuel indicatorCircuitDiagram seepage22 58 and checkthe circuit Turnthe...

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Page 390: ...LVE Test page1 1 161 i l AIRCLEANER Replacement page11 162 AIRCLEANER ELEMENT Replacement page11 162 THROTTLE CABLE Adjustment page11 163 Removal lnstallation page 11 164 THROTTLEBODY Test pagel l 160...

Page 391: ...page11 163 thengo to step2 2 l 4ove the throttleleverby handto seeif the throftle valveand orshaftaretoo looseor too tight lf there is excessive play in the throttlevalve shaft or any bindingin the th...

Page 392: ...lf the vacuumreadingdoesnotchange checkfor theseproblems Misrouted leaking broken or clogged intake air bypasscontrolsystemvacuumlines A crackedor damagedintakeair bypasscontrol thermalvalve 4 Holdthe...

Page 393: ...Removethe air cleaner C Installin the reverseorderof removal 2 3 11 162 AirCleaner Element Replacement 1 Disconnect thePCVhose1A Opentheaircleaner housing cover B Remove theaircleaner C fromtheairclea...

Page 394: ...18 112ln l loosen the locknut B turnthe adjustingnut C untilthe free play is as specified then retightenthe locknut With the cableproperlyadjusted checkthe throttle valveto be sureit opensfully when y...

Page 395: ...load in neutral untilthe radiator fan comeson then let it idle Holdthecable removing allslack from it Setthe locknuton the cablebracket A Turnthe adjustingnut B so that itsfree play is 0 m m Theshould...

Page 396: ...lecable seepagell 163 andthecruise control cable seepage4 45 Thethrottleposition TP sensoris not removable THROTTLE LEVER Thereshouldbe noclearance THROTTLECABLE MANIFOLD ABSOLUTE PRESSURE MAP SENSOR...

Page 397: ...IntakeAirSystem ThrottleBodyDisassembly Reassembly EVAPORATIVE EMISSION EVAP CANISTER PURGE VALVE A V 2 N m 0 2kgt m 1 lbf ft 3 5N m 0 35kgf m 2 5lbf ft MAPSENSOR THROTTLE BODY L TPSENSOR 11 166...

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Page 400: ...ral untiltheradiator fancomeson Drivefor aboutl0 minutes withoutstopping Your speeocanvary With the transmissionin 4th gear drive at a steady speedbetween50 62 mph 80 100km h for 30 seconds Repeatstep...

Page 401: ...d inneutral untilthe radiator fancomeson 3 Letthe engineidletor al least40secondswith the throttlefully closed 4 Checkfor a DTCP1505 with the scantool ls DTC P1505indicated YES Check thesepartsfor vac...

Page 402: ...tweenthe PCVvalve andintake manifold is lightlypinched A withyour fingers or pliers lf there is no clickingsound checkthe PCVvalve grommetfor cracksor damage lf the grommet is OK reDlace the PCVvalvea...

Page 403: ...page l1 175 step1on page11 180 FUELTANK VAPORCONTROLVALVE Test page11 187 Replacement page11 189 FUELTANKPRESSURE SENSOR Troubleshooting page 11 171 EVAPORATIVE EMISSION EVAPI CANISTER Troubleshooting...

Page 404: ...vacuumpumpto the openend of the hose Turnthe ignitionswitchON ll l 4onitor FTPsensorvoltagewith the HondsPGM Tester or measurevoltagebetweenECM connector terminals E4andE14 andcarefully squeeze thevac...

Page 405: ...TOR E131PI 1 2 t 3 t 4 5 o 8 9 114 t c 61 18 2C21 22123 241 t 26 271 29 31 TP LTGRN Wiresideof femaleterminals ls thete about2 5 V YES Intermittent failure systemis OK at thistime Checkfor poorconnect...

Page 406: ...check seepage11 6 lf the symptom indication goesawaywith a known goodEClvl replacethe original ECM I DTCP0453 FTPSensor CircuitHighVoltage 1 Checkthe vacuumlinesat the FTPsensorfor misrouting leakage...

Page 407: ...M E4 11 174 11 MeasurevoltagebetweenFTPsensor3Pconnector t e r m i n a l s N o 2a n dN o 3 FTPSENSOR3PCONNECTOR FTPILTGRN Wiresideoffemale terminals ls thereabout5 V YES Replace the FTPsensor l NO Got...

Page 408: ...creates greaterpressure vacuum The optimum condltlonfor testingis freshfuel and must be lessthan a full tank lf possible to assistin leakdetection add 1 gallonof freshfuelto the tank aslong asit will...

Page 409: ...ECI 4 821 1 NO Updatethe ECMif it doesnot havethe latest software or substitutea known goodECM then recheck seepage11 6 lf the symptom indication goesawaywith a known goodECM replacethe original ECM...

Page 410: ...to step 18 NO Repair open in the wire bet iveen the EVAP bypasssolenoidvalveandthe ECM E20 1 Turnthe ignition switchON ll 2 tG l 19 MeasurevoltagebetweenEVAPbypasssolenoid valve2PconnectorterminalNo 1...

Page 411: ...Repair theleakfromtheEVAPbypass solenoidvalve EVAPtwo way valve or FTPsensor l 11 178 Wiresideof female terminals EVAPCanister Vent Shut Valve Test 22 Disconnect the vacuumhosefrom the EVAP canisterv...

Page 412: ...rolvalvetest seepage 11 1 8 7 ls the fuel tank vapotcontrol valve OK YES Go to step31 NO Replace thefueltankvaporcontrol valve l Tightenthe fuelcap3 clicks then monitorthe FTPsensorreadingswith the Ho...

Page 413: ...ionfor testingis freshfuel andthere must be lessthan a full tank lf possible to assistin leakdetection add I gallon of freshfuelto the tank aslong as it will not fill the tank just beforestartingthese...

Page 414: ...t 10 Disconnect bothvacuumhosesfrom the EVAPtwo way valve A andconnecta vacuumpumpto the canisterport on the two way valve Turntheignition switchON ll Applyvacuumto the hose Doesthe valvehold vacuum Y...

Page 415: ...ginal ECM I EVAPBYPASS SOLENOID VALVE2PCONNECTOR l l l 2 l I t l 2WBS BLU REo I Wire side of femaleterminals 11 182 EVAPCanisler Vent Shut Valve Test 18 Disconnect the vacuumhosefrom the EVAP canister...

Page 416: ...ENTSHUT VALVE 2PCONNECTOR Wlreside oflem rerm na s ls therebattery voltage YES Replace the EVAPcanistervent shutvalve A andtheo ring B I NO Repairopenin the wire betweenthe EVAP canister ventshutvalve...

Page 417: ...hOFF 35 Discon nectthe quick con nectfitting A fromthe EVAPcanister and plugthe canisterport B 36 Turnthe ignition switchON ll 11 184 42 Turnthe ignition switchON ll I 38 39 37 While monitoringFTPsens...

Page 418: ...out 1 5V Makesurethe enginecoolant temperatureis still above95 F 35 C andyour vacuumpumphasno leak Monitorthe voltagecontinuouslyfor 20 seconds Does the voltage drop to 1 5 V and hold for at least20 s...

Page 419: ...8 2 1kPa 6 16mmHg 0 2 0 6in Hg lf the vacuumstabilizes valveopens below0 8kpa 6mmHg 0 2in Hg or above2 1kPa 16mmHg 0 6in Hg installa new valveand retest 11 186 4 Movethe vacuumpump hosefrom the vacuum...

Page 420: ...uumholds replacethe fueltankvapor control valve seepage11 189 lf the vacuumdoesnot hold the float is OK Do the valvetest 5 A973X 041 XXXXX ValveTest 1 N4ake surethefueltankis lessthanhalffull 2 Remove...

Page 421: ...vapor recirculation hose B NOTE At eitherlocation tiny dropletsof fuel are normal lf fuel runsout of the hosesat eitherlocation replacethe fueltankvaporcontrolvalve lfthefuel doesnotrunoutof the hoses...

Page 422: ...ethe EVAPcanister C 4 Installin the reverseorderof removal FuelTankVaporControlValve Replacement 1 Remove thefueltank seepagell 155 2 Remove thefueltankvaporcontrol valve A from thefueltank B Installt...

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Page 424: ......

Page 425: ......

Page 426: ...ls 12 2 Comoonent Location Index 12 3 Clutch Pedal Clutch Pedal Position Switch and Clutch Interlock Switch Adiustment 12 4 CfutchMaster Cylinder Rep acement 12 5 Slave Cylinder Replacement 12 7 Clutc...

Page 427: ...ialTools o tt o Clutch I 12 2 Ref No ToolNumber Description Oty 1 o OTJAF PM7O11A 07LAB PV001 00or07924 PD20003 07zAF PR8A100 07936 3710100 l 1 1 1 Clutch Alignment Disc RingGearHolder Clutch Alignmen...

Page 428: ...s O RING Replace UTCHPEDAL Adjustment Page124 CLUTCH MASTER CYLINDER Replacement pagel2 5 CLUTCHDISC Bemoval page12 9 Installation page 12 12 PRESSURE PLATE Removal page 12 9 lnstallation page 12 12 F...

Page 429: ...ifiedheight F stroke G free play H and disengagement height l attheclutchpedal ClutchPedalStroke 130 140mm 5 12 5 51in l ClutchPedalFreePlay l0 16mm 0 39 0 63in ClutchPedalHeight 193mm 7 60in Disengag...

Page 430: ...movethe clutchlineclip Removethe clutchmastercylinder A and pull it towardthe middleof the enginecompartment Removethe retainingclip B Disconnect the clutch line C Plugthe endof the clutchlinewith a s...

Page 431: ...penthe tip of the retainingclip B with a screwdriver Tightenthe mastercylindermountingnutsto 13N m 1 3kgfm 9 4lbf ft Bleedthe clutchmasterhydraulicsystem seestep 11 on page12 8 NOTE Thereservoir filli...

Page 432: ...2 Removethe intakeair duct seestep8 on page5 3 Removethe clutchlinebracket A 4 5 6 Removethe mountingbolts A andtheslave cylinder B Removethe roll pins C Disconnect the clutchline D andremovetheO ring...

Page 433: ...t the movementof the releasefork B with a blockof wood to remove all the air from the system Tightenthe bleedscrewto I N m 0 8kgf m 6 lbf ft do not ovenightenit Refillthe clutchmastercylinderwith flui...

Page 434: ...thanthe servicelimit replacethe pressure ptate StandardlNewl 0 6mm 0 02in max ServiceLimit 0 8mm 0 03in 07zAF PR8A100 07936 3710100 OTJAF PM7O11A 2 Installthe special tools A A nl I ffim 9fra I tP 07L...

Page 435: ...he liningofthe clutchdiscfor signsof slipping or oil lf theclutchdiscis burnedblackor oil soaked reolaceit 1 d 12 10 9 lvleasu rethe clutchdiscthickness lfthethickness is lessthanthe servicelimit repl...

Page 436: ...ethanthe servicelimit replacethe flywheeland recheck the runout Resurfacing the flywheelis not recommended Standard New 0 05mm 0 002in max ServiceLimit 0 15mm 0 006in FlywheelReplacement 1 Installthe...

Page 437: ...uperhightemp ureagrease P N08798 9002 to lhe splines A of the clutchdisc B then installthe clutchdiscusingthe specialtools Installthepressureplate A andthe mounting bolts B finger tig ht v 07936 37101...

Page 438: ...B therelease bearing C andthe release bearing guide D intheshadedareas 1 0 1 6g 10 04 0 06oz l ac 0 4 1 0g 10 01 0 04o 7 re IL l E 6 0 t 1 09 0 01 0 04 oz With the releasefork slid betweenthe release...

Page 439: ......

Page 440: ...ion Countershaft Disassembly Countershaft Inspection Countershaft Reassembly Synchro Sleeve andHub Inspection andReassembly Synchro RingandGear Insoection 13 39 Mainshaft Bearing andOilSeal Replacemen...

Page 441: ...000015 vs802c000018 07GAJ PG20 10 07GAJ PG20130 07JAD P190100 07NAD P20A100 07736 A01000B 07746 0010300 07746 0030100 07746 0030300 07749 0010000 l l l EngineHanger Adapter 2 0to 2 4Liter EngineHanger...

Page 442: ...operlevel Oil Capacity 1 50 1 6US F at tluid change 1 70 1 8US qt at overhaul Always useHondaManualTransmissionFluid MTF Usingmotor oil cancausestiffershifting and noisebecauseit doesnot containthe pr...

Page 443: ...Disconnect the negative cablefirst thenthe positive cablefrom the battery Removethe battery Removethe intakemanifoldcover seepageg 3 Remove theaircleaner housing seepage11 162 Removethe intakeair duct...

Page 444: ...scover A by liftingup on the locktab B thenslidethe harness forwardofftheaircleaner housing mounting bracket C 1 1 12 Attachthe specialtool to the threadedhole in the cylinderhead vsB02c00001s Install...

Page 445: ...d Drainthetransmission fluid Reinstall thedrainbolt witha newwasher seepage13 3 Remove thesplash shield Ds t o 1 7 1 8 1 9 db qF 13 6 20 21 22 23 Removethe threeway catalyticconverter TWC assembly see...

Page 446: ...akereference marks A on the front suspension subframe B and mountingbolts C then remove the front suspension subframe 27 Removethe clutchcover 28 Remove thefrontenginemount Place thetransmission iacku...

Page 447: ...ls Required Enginehangeradapter 2 0to 2 4literVS802C000015 EnginehangerVS802C000018 Enginesupporthanger A RedsAAR T 12566 subframe adaDterEoS02c000011 Availablethroughthe HondaTool and Equipment Progr...

Page 448: ...12x 1 25ftrn 64N m 6 5kgf m 47 lbf ft bolts 12x 1 25mm 64N m 6 5kst m 47 lbf ft 7 lnstalltheclutchcover 6 x 1 0 m m 12N m 1 2kgI m 9 lbf ftl 8 Supportthesubframewith the subframeadapter anda jack Inst...

Page 449: ...page 16 17 lnstallthe threeway catalyticconverter TWC assembly seestep17on page5 12 10x 1 25mm 13 10 6 x 1 0 m m 1 2 N m 15 Installthe transmissionmount bracket A andthe transmission mountingbolt B 12...

Page 450: ...lthebrakeboosterand EVAPline bracket mountingbolts A and air cleanerhousingbracket mountingbolt B Tighten theaircleaner housing bracketmountingbolt C and installthe water pipemountingbolt D A 9 8N m 1...

Page 451: ...to bend the clutch line 8 x 1 25mm 22 N m 2 2kgf m 16lbf ft 6 x 1 0 m m 9 8N m 1 0kgf m 7 2 tbt ftl a _ _gEEa9En P N08798 9002 24 Installthe harness clip 13 12 25 Installthe cablebracket A andcables B...

Page 452: ...seestep39on page 5 15 Installtheintakemanifoldcover seestep41 on page5 15 Installthe battery Connectthepositive cable first thenthe negative cable to the battery Reflllthe transmission fluid seepage13...

Page 453: ...TASSEMBLY U 28 mm WASHER t 4 i 28 mm SPRINGWASHER iO BALLBEARING l 28 x 43 x 7 mm OILSEAL Replace D REVERSE GEARSHAFT 1 REVERSE IDLER GEAR f lr 6 mm SPECIALBOLT 15N m 1 5kgt m 11lbf ft I REVERSE SHIFT...

Page 454: ...KET rai o f dd O rl F z O TRANSMISSION HOUSING O 10mm WASHER Replace 10mm FLANGEBOLT 44 N m 4 5kgf m 33lbf ft O 8 mm FLANGEBOLT 27 N m 12 8 kgf m 20lbl ft TRANSMISSIONHANGERA O INTERLOCK BOLT 39N m 4...

Page 455: ...ainshaftfrom hittingthe workbench 1 Removethe detentbolts A springs steelballs and back uplightswitch B Removethe vehiclespeedsensor VSS A and O ring B 13 16 3 Removethe interlockbolt A the changeleve...

Page 456: ...erB Remove the32mm sealing cap A Expand the72 mm snapring B onthe countershaft ballbearing and removeit from the grooveusinga pairof snapring pliers Remove thetransmission housing C and 14x 20mm dowel...

Page 457: ...splinesto protect the seal then removethe mainshaftassembly A andcountershaft assembly B with the shiftforks C fromtheclutchhousing D 14 Remove the28 mm springwasher E and28mm washer F t7 t 1 I 13 18...

Page 458: ...ne lf distanceis within the standard replacethe reversegearwrln a new one Standard 13 4 13 7mm 0 527 0 539in l I ChangeLeverClearance Inspection 1 Measurethe clearancebetweenchangelever Al andthe sele...

Page 459: ...dinstall it SELECT LEVER Becareful notto damage thedustseal wheninstalling it 1 I l L r l r r l I DUST COVEB a 7 Fr irr6 rooa P N 08798 9002 ROLLER 6 x 1 0 m m 12N m 1 2kgl m 8 7lbf ft E Fl d 1sr 2No...

Page 460: ...rd replacethe shiftforkwith a new one lfthethicknessof the shiftforkfingeriswithin the standard replacethe synchrosleevewith a new one Standard 7 4 7 6mm 0 29 0 30in 2 3 Measurethe clearance betweenth...

Page 461: ...ManualTransmission Shift ForksDisassembly Reassembly Priorto reassembling cleanallthe partsin solvent dry them andapplylubricantto anycontactparts sTHSHIFTFORK 13 22 PINDRIVER 5 mm...

Page 462: ...of 3rdgearislessthanthe service limit replace 3rdgearwitha newone lfthethickness of 3rdgeariswithintheservice limit replacethe 3rd 4thsynchrohub with a new one Standard 23 92 23 97 mm 0 941 0 944in Se...

Page 463: ...orethanthe servicelimit go to step 8 lf theclearance iswithintheservice limit go to steD10 Standard 0 06 0 16mm 0 002 0 006in ServiceLimit 0 25mm 0 010 in 13 24 Standard Standard Service Limit 8 Measu...

Page 464: ...0 947 in E f MainshaftDisassembly 1 Remove the angular ballbearing A andthe taperedcone ring usinga commerciallyavailable bearing separator B anda commercially available bearing puller C Besurethe be...

Page 465: ...any partof the mainshaft is lessthanthe servicelimit reDlace it with a new one Standard A Ballbearingsurface transmission housingside 27 987 28 000 mm 1 1019 1 1024in B Distancecollar surtace 31 984...

Page 466: ...oth endsof the mainshaft Rotatethe mainshafttwo complete revolutions when measuringthe runout lf the runoutis morethanthe servicelimit reolacethe mainshaftwith a new one Standard 0 02mm 0 001in max Se...

Page 467: ...Notethe directionof installation 3RD 4TH SYNCHRO SLEEVE 3RD 4TH SYNCHRO HUB SYNCHRO SPRING SYNCHRORING TAPEBED CONERING MBS DISTANCECOLLAR SYNCHROSLEEVE NEEDLE BEARING Checkfor wearandoperation GEAR...

Page 468: ...hro spring Installthe 3rd 4th synchro hub A by aligning the synchroringfingers B with 3rd 4thsynchrohub grooves C A lnstallthe3rd 4thsynchrohub A usingthe special tool 07746 0030100 6 Installthe3rd 4t...

Page 469: ...C Installthe 5thsynchro hub A usingthespecial tools 07746 0030100 07746 0030300 13 Installthe 5thsynchro sleeve 12 13 30 14 Installthe synchro spring A Installthe synchro ring B by aligning thesynchr...

Page 470: ...ance collarwitha newone lf the thicknessis within the standard go to Standard 23 03 23 08 mm 0 907 0 909 in l 3 Measurethe thicknessof the 1stoear lfthethicknessof lst gearislessthanthe service limit...

Page 471: ...earislessthan the servicelimit replace2nd gearwith a new one lfthethicknessof 2ndgeariswithintheservice limit replacelhe 1sV2nd synchrohubwith a new one Standard 27 92 21 97 mm 1 099 1 r01in l Service...

Page 472: ...servicelimit replaceit with a new one Standard A Ballbearingsurfaceltransmissionhousingsidel 30 020 30 033mm 1 1819 1 1824in B Distancecollarsurface 39 937 39 950mm 11 5723 1 572A in l C Needlebearing...

Page 473: ...eration Notethe directionof installation 35 mm SHIM REVERSE GEAR 1ST 2ND SYNCHRO HUB SPRING TRIPLECONESYNCHRO 1ST GEAR NEEDLE BEARING Check forwear anoopera on DISTANCE COLLAR ANCECOLLAR GEAR 4THGEAR...

Page 474: ...hroassembly A by aligningthe synchroconefingers B with lstgear grooves C then installthe synchrospring D 3 Installthe 1st 2nd synchro hub A by aligning the synchroconefingers B with 1sV2ndsynchrohub g...

Page 475: ...nstall the3rdgear B usingthespecial tool anda press C Do not exceedthe maximum Dressure 14 700 N 1 500 kgf 3 307lbflmax 07746 0030100 13 36 L 12 Install the4thgear A usingthespecialtool anda press B D...

Page 476: ...23983 PPP 9001 07mm 0 0421n 23984 PPP 0001 1 1mm 0 0437 n 11 23984 PPP 9001 15 mm 0 0453 n J 23985 PPP 0001 19 mm 0 0469n K 23985 PPP 9001 23 mm 0 0484 n L 23986 PPP 0001 27 mm 0 0500 n M 23986 PPP 9...

Page 477: ...D to press the countershaft E outoftheballbearing lf necessary installthe 35mm shimselected in step 16 then recheck the clearance Installthe distancecollar A 35mm shim and new ballbearing B usingthes...

Page 478: ...synchrohub Do not installthe synchrosleevewith its longerteeth in the 1sv2ndsynchrohub slots E becauseit will damage thespringring NOTE lf replacement is required alwaysreplace the svnchrosleeveand s...

Page 479: ...arance betweeneachgear A and itssynchro ring B alltheway around Holdthe synchroring againstthe gearevenlywhile measuringthe clearance lf the clearance is less thanthe servicelimit replacethe synchrori...

Page 480: ...he differential assembly 2 Remove theballbearing A fromtheclutch housing B usingthespecialtool anda commercially available 3 8 l6 slidehammer C Removethe oil seal A from the clutchside Be carefulwhen...

Page 481: ...ingsetplate A from the clutch housing B Removethe needlebearing A usingthe special tool and a commerciallyavailable3 8 16slide hammer B then removethe oil guideplateC 07736 A010008 13 42 3 Positionthe...

Page 482: ...the reading 5 Measuredistance betweenthe end of the clutch housing A andthebearing innerrace B witha straightedgeand depthgauge Measureat three locationsand averagethe readings A Shim Selection Formul...

Page 483: ...2 mm 0 0520 n z 23956 P21 000 1 35 mm 0 0531 in 23957 P21 0001 38 mm 0 0543 in AB 23958 P21 0001 41mm 0 0555n AC 23959 P21 0001 44 mm 0 0567 n AD 23960 P21 0001 47mm 0 0579n AE 23961 P21 000 1 50mm 0...

Page 484: ...in until it just contactsthe wide surfaceof the mainshaftbase 16 Zeroa dialgauge A on theendofthe mainshaft Turnthe mainshaftholderbolt B clockwise stop turningwhen the dialgauge A hasreachedits maxim...

Page 485: ...er A and 28 mm washer B overthe ball bearing C Notethe installation directionof the springwasher A Applyvinyl tapeto the mainshaftsplines D to protectthe seal Installthe mainshaft and countershaft E i...

Page 486: ...and 72 mm shimintothetransmission housing C 7 8 Removethe dirt and oil f rom thetramsmission housing sealing surface Applyliquidgasket P N 08718 0001 to the sealingsurface Besureto seai the entirecirc...

Page 487: ...C Release the snapring so it seatsin the grooveof the countershaft bearing 12 Checkthatthe 52 mm snapring is securelyseated in the grooveof the countershaft bearing DimensionO as instalted 3 3 6 0mm...

Page 488: ...acket B andchange leverassembly C 12N m 1 2 kgf m 9lbt ft 18 Applyliquidgasket Pi N 08718 0001 to thethreads of the interlockbolt D and installit on the transmission housing 6 x 1 0 m m 19 Installthe...

Page 489: ...Manual Transmission Transmission Reassembly cont dl 22 Installthevehiclespeedsensor VSS A and O ring B 22N m 2 2kgf m r6 lbf ft 13 50...

Page 490: ...2 N m 2 2kgf m 16 lbt ftl SHIFT LEVER KNOB 8 N m 0 8ksr m 5 8lbf ft l SHIFTLEVER HOUSING P N 08798 9002 r Ll Rotatethe shiftcable towardtheopening 6 x 1 0 m m 9 8 N m 1 0kgf m 7 2 tbf fr COTTERPINS qr...

Page 491: ...M T Differential ComponentLocationIndex DRIVENGEAR Beplacement page13 53 Backlash Insoection oaoe13 53 Feplacemeni paoe I 3 5 3 BALL BEARING Beplacemenl page13 54 I c1 l 13 52 I...

Page 492: ...0 05 0 15mm 0 002 0 006in FinalDrivenGear Carrier Replacement 1 Removethe bolts left hand threads in a crisscross patternin severalsteps then removethe final drivengear A from the differential carrie...

Page 493: ...show no signsof wear the bearingsareOK 2 Removethe carrierbearing A with a commercially available bearing puller B 13 54 3 Installthe new bearings A with the specialtool and a press Presseachbearingon...

Page 494: ...AD P20A100 1 Removethe differential assembly 2 Removethe oil seal A from thetransmission housing B 3 Removetheoil seal A fromtheclutchhousing B 4 Installthe newoil sealin thetransmission housinq with...

Page 495: ...h housing 13 56 5 Installthe transmissionhousingontothe clutch housing thentightenthe 8 mm flangeboltsin a crisscross patternin severalsteps seestep 15on page13 48 8 x 1 25mm 27 N m 2 8kgf m 20 lbf ft...

Page 496: ...551 n F 41446 PL3 8001 1 5mm 0 0591n 41447 PL3 800 1 1 6mm 0 0630n rt 41448 PL3 B001 1 7mm 0 0669n J 41449 PL3 8001 1 8mm 0 0709n 41450 PL3 8000 1 05mm 0 0413n 41451 PL3 80001 15mm 0 0453n l tvl 41452...

Page 497: ......

Page 498: ...Removal 16 3 Driveshafts Disassembly 16 5 Dynamic Damper Replacement 16 8 Driveshafts Reassembly 16 9 Driveshafts lnstallation 16 17 lntermediate ShaftRemoval 16 19 Intermediate ShaftDisassembly 16 20...

Page 499: ...o t9 6 o D 07GAD PH70201 07MAC S100200 07NAF SR30101 07xAc 001010A 07746 0010400 07746 0030400 07749 0010000 07947 S800100 OilSealDriver BallJointRemover 28 mm HalfShaftBase ThreadedAdapter 22 x 1 5mm...

Page 500: ...cial Tool Required Balljointremover 28 mm 07MAC S100200 1 Loosenthe wheel nutsslightly 2 Raisethe front of the vehicle and supportit with safetystandsin the properlocations seepage1 8 3 Removethe whee...

Page 501: ...on page18 19 Becarefulnotto dislodgethe lower balljoint from the knuckle Pullthe knuckleoutward and removethe driveshaftoutboardjoint from the front wheel hub usinga plastic hammer 9 8 16 4 10 Leftdri...

Page 502: ...ethe setrlngfrom the inboardjoint Removethe boot bands Becarefulnotto damage the boot anddynamicdamper lf the boot bandis a weldedtype A cutthe boot band B lf the boot bandis a doublelooptype C lift u...

Page 503: ...eparating them from the inboard Jornt N4ake a mark A on the rollers B andspider C to identifythe locationsof rollerson the spider then removethe rollers Remove thecirclip D Markthe spider C and drives...

Page 504: ...t A to the inboardiointside Becarefulnotto damaoethe boot 2 4 Wipe off the greaseto exposethe driveshaftand theoutboard jointinnerrace Makea mark A on the driveshaft B at the same positionof the outbo...

Page 505: ...ldedtype cutthe boot band lfthe bootbandisa doublelooptype liftupthe bandbend and pushit intothe clip lfthe boot bandis a low profiletype pinchthe bootbandusinga commercially available boot bandpincer...

Page 506: ...ootset UsethegreaseIncludedin the inboard boot set 7 I I t 1lg n r 9 l I 1 I l r VL A y DYNAMTC DAMPER DOUBLE LOOP BAND Replace EARCLAMPBANDS OUTBOARD JOINT STOP RING Replace cont d ROLLER Usethe grea...

Page 507: ...D Replace Boot bandreplacement only Usethe greaseincluded in the nboardbootset Y _ Usethe greaseincluded in the inboardbootset LOWPROFILE BAND Beplace DOUBLE LOOPBAND Replace DYNAMIC DAMPER OUTBOARDJO...

Page 508: ...bootontothe driveshaft then removethe vinyltape Becarefulnot to damage inboardboot Ine 4 5 3 Installthespider A ontothe driveshaftby aligning the marks B on the spiderandthe end of the driveshaft Fitt...

Page 509: ...llers Holdthe driveshaftsothe inboardjoint is pointingup to preventit trom fallingoff 7 16 12 1 1 8 Makesurethe endsof the boot aresealedin the groovesin the driveshaftandjoint then installthe boot ba...

Page 510: ...bandthroughthe nose sectionof the commerciallyavailableboot band tool KD 3191 or equivalent A and intothe sloton thewindingmandrel B Placea wrenchon the winding mandrelof the boot bandtool andtightent...

Page 511: ...0mm 0 2 0 4 in tail protrudingfrom the clip 19 Bendthe bandend A by tappingit down with a nammer NOTE Makesurethe bandandclip do not interferewith anythingandthe banddoes not move Removeany greaserema...

Page 512: ...the new stop ring intothe driveshaftgroove A 3 t 4 Insertthe driveshaft A intothe outboardjoint B untilthe stopring C is closeto the joint To completelyseatthe outboardjoint pickup the driveshaftandjo...

Page 513: ...ardioint 105 115g 3 7 4 1ozl r llt 0 A g fff l f o o 16 16 8 Adjustthe lengthof the driveshafts to the figure below then adjustthe bootsto halfwaybetween full compressionandfull extension Makesurethe...

Page 514: ...Repeat steps10and11forthe bandon theother end of the boot 6 0mm10 24 in MAX 3 0mm 0 12in MAX Driveshafts Installataon 1 Installa new set ringontothe setring grooveof the driveshaft leftdriveshaft App...

Page 515: ...Becarefulnotto damagethe ball joint boot Wipe off the greasebeforetightening the nut at the balljoint Torquethe new castlenut C to the lowertorquespecification thentightenit onlyfarenoughto alignthes...

Page 516: ...ts 10 Turnthe front wheel by hand and makesurethe clearance betweenthe driveshaftand circumference parts 1l Refillthe transmission with recommended transmission fluid seepage13 3 12 Checkthe frontwhee...

Page 517: ...ventdamage to the differentialoil seal B 16 20 Intermediate ShaftDisassembly Special Tools Required Oil sealdriver07947 5800100 Halfshaftbase07NAF SR30101 1 Removetheset ring A outerseal B andexternal...

Page 518: ...3 Removethe internalsnapring 4 Pressthe intermediate shaftbearing A out of the bearing support B usingthespecial toolsanda oress 07947 s800100 07NAF SR30101 16 21...

Page 519: ...Driveline Axle Intermediate ShaftReassembly Exploded View INTERMEDIATE SHAFTRING FLANGEBOLT 10x 1 25 mm 39IVm 4 0kgf m 29lbt ftl tto o p E 7 BEARING SUPPOBT Packthe interiorof the outerseal 16 22...

Page 520: ...with compressed air Do not washthe rubber partswith solvent 2 Pressthe intermediate shaftbearing A intothe bearing support B usingthespecial toolsanda press 07746 0010400 Install thenseattheinternal s...

Page 521: ...tion 1 Usesolvent or brakecleaner to thoroughly clean the areaswherethe intermediate shaft A contacts the transmission differential and dry with compressed air Insertthe intermediate shaft assemblyint...

Page 522: ...3 Installthe heatshield andtightenthe three bolts 4 Installthe rightdriveshaft seepage16 17 8 x 1 25mm 2 2 N m 12 2 16 25...

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Page 524: ...k 17 4 Steering Linkage andGearbox Inspection 17 5 Steering Wheel Removal 17 6 Steering WheelDisassembly Reassembly 17 7 Steering WheelInstallation 17 8 Steering Column Removal andInstallation 17 9 St...

Page 525: ...Steering SpecialTools Ref No ToolNumber Description Oty o 07MAA S100200 LocknulWrench 43 mm E tt L 2 r V 6Y o I 17 2...

Page 526: ...13 STEERING WHEEL Removal page17 6 Disassembly Reassembly page 17 7 Installation page17 8 STEERING COLUMN SteeringColumnRemovaland Installation page17 9 SteeringColumnInspection page17 1 l SteeringLoc...

Page 527: ...ackguideadjustment inspectthe steering linkage andgearbox seepage17 5 BOTATIONAL PLAY 0 10mm 0 0 39in l 17 4 PowerAssistCheck Startthe engine and let it idle Attacha commerciallyavailablespringscaleto...

Page 528: ...t for looseness STEERING COLUMN Inspect for loose column mounting hardware STEERING GEARBOX Inspect for loosemountinghardware GEARBOXMOUNTINGCUSHIONS Inspect for deterioration STEERING JOINTS Check fo...

Page 529: ...B i 17 6 3 Installa commerciallyavailablesteeringwheel puller A on the steeringwheel B Freethe steeringwheelfrom the steeringcolumnshaftby turningthe pressure bolt C ofthe puller Note these items when...

Page 530: ...SteeringWheelDisassembly Reassembly CONTACTPLATE MOOULE SETBRACKET STEERING WHEEL REAB COVER STEERING WHEEL ACCESSPANELA 75 offi ffi Y f b accEss PANEL B CRUISECONTROLSWITCH CONNECTOR HOLDERS 17 7...

Page 531: ...ve Do nottap on the steeringwheelor steeringcolumn shaftwhen installingthe steeringwheel 17 8 3 Installthe steeringwheelnut A andtightenit to the specified torgue A _ B 39N m 4 0 kgfm 29lbtftl Connect...

Page 532: ...s dashboard lowercover see page20 59 andundercover see page20 60 4 Removethe columncovers A I x 1 25mm 16N m 1 6kgf m 12lbl fr b 5 6 Disconnect the wire harnessconnectors from the combinationswitchass...

Page 533: ...ringjointto makesurethatthe steering jointisfullyseated Theninstallthe upper joint bolt andtightenit to the specifiedtorque Tightenthe lowerjoint boltto the specifiedtorque Finishthe installation and...

Page 534: ...B forplayandpropermovement lfany bearingis noisyor hasexcessive play replacethe steeringcolumn asan assembly Checktheabsorbingplates C absorbingplateguides D stop E andcoatingplates F for distortion...

Page 535: ...heir headsoff with a 5 mm 3i16in drill bit Becarefulnotto damagethe switchbodywhen removingthe shearbolts 3 Removethe shearboltsfrom the switchbody 4 Installtheswitchbody withoutthe key inserted 5 Loo...

Page 536: ...therackguidescrew A ro25N m 2 5 kgf m 18lbf ft thenloosen it 5 Max j i rrrr I 4il N m a 5 kgf m 33lbt ft Retighten the rackguidescrewto 6 N m 0 6kgf m 4 lbf ft then backit off to the specifiedangle Sp...

Page 537: ......

Page 538: ...Troubleshooting Index 17 23 System Description 17 24 Circuit Diagram 17 26 DTC Troubleshooting 17 28 EPS lndicator Circuit Troubleshooting 17 47 MotorRemoval lnstallation 17 49 Steering Gearbox Remov...

Page 539: ...omponents Rel No Tool Number Description otv at o 07MAC S100200 070AD P0A0100 07zAA S5A0100 BallJointRemover 28 mm Attachment 42 mm LocknutWrench 1 1 l SpecialTools G C _ 1t h5 d u_r c_ t t L t I 17 1...

Page 540: ...itRemoval lnstallation page17 67 UNDER DASH FUSE RELAY BOX i X DATA LINKCONNECTOR I16P TOROUE SENSOR STEERING GEARBOX SteeringGearboxRemoval page17 51 SteeringGearboxOverhaul page17 55 SteeringGearbox...

Page 541: ...S However when thesame DTC isdetected morethanonce themostrecent DTC iswritten overthepriorDTC therefore onlyone occurrence ismemorized TheDTCS areindicated repeatedly untiltheignition switch is turne...

Page 542: ...checkfor looseconnectors poorterminal contact etcin the affectedcircuit beforeyou start troubleshooting 3 Aftertroubleshooting clearthe DTCandtest drive the vehicle Besurethe EPSindicatordoesnot comeo...

Page 543: ...n The ignitionswitchis turnedON ll The engineis stopped The SCScircuitis shortedto body groundbefore the ignitionswitchis turnedON ll Example of DTC23 Longblinks Short blinks two times threetimesl 6 7...

Page 544: ...he EPSindicatorgoesoff returnthe steeringwheelto the straightahead drivingpositionand release the steeringwheel The EPSindicatorcomeson again4 secondsafter releasing the steeringwheel Within 4 seconds...

Page 545: ...blemwith the motor voltage seepage1736 DfC 42 A problemwith the motor drivencurrent opencircuitor shortto grounol seepage 17 38 DTC 43 A problemwith the motor drivencurrent shortto power seepage17 41...

Page 546: ...47 EPSindicatordoesnot go off and no DTCis stored EPSIndicatorCircuitTroubleshooting seepage17 47 EPSindicatordoesnot stay on no DTCis stored and thereis no powerassist 1 Checkthe motorwires betweent...

Page 547: ...or Terminalsign Terminal namel Description Measurement Terminals Conditions lqnitiqr switchON lll Voltage WHT BLU BAT Plus bafterv Power source forthe actuatormotor l Ground Constant Battery voltage 2...

Page 548: ...ECM 4pulse Raise thevehicleoffthe groundandspinthe Alternating voltage about O V 5 V O V 5 V BRN SCS Servjco check siqnal Detects servicecheck 8 Ground SCSnotgrounded Batteryvoltage 1 0 YEL IG1 llqnit...

Page 549: ...a EPSComponents CircuitDiagram SPE DSENSOR 3PCONNECTOR TOFOUESENSOR 6P CONNECTOR l l i 2 l 3 F r T T I J_ _LvJ Wn ide ot f m l r fmin ls GAUGEASSEMBLY 22PCONNECTON GAUGEASSEMATY 22PCONNECTOR 17 26...

Page 550: ...EPS COI IFOIUNIT cou EcToR A 2P F l A EPSCONTNOL UNIT co lNEcTofi 8 2P l l t2 Wir le ol l m l t tman r MOTOF CONNECTOR riTt OATA IN CONN CTOA T6P vTTrvaEvnrv wwzna T rmin l id oll m l r rmin l 17 27...

Page 551: ...s therecontinuity YES Repair shortto bodygroundinthewire between thetorque sensor andEPS control unit l NO Goto step7 5 17 28 1 8 Turnthe ignitionswitchON ll Measurethe voltagebetweenEPScontrolunit co...

Page 552: ...comeon YES Goto step4 NO Checkfor loosewiresor poorconnnections lf the connections are good the systemis OK at this time l 4 Stopthe engine andverifythe DTC ls DTC16 indicated YES Go to step5 NO Perfo...

Page 553: ...OR C 2OP Wiresideof femaleterminals 17 30 9 1 0 Turnthe ignitionswitchOFF Checkfor continuitybetweenthe appropriateEPS controlunitconnectorC 20P terminalandthe torquesensorterminal seetable TOROUE SEN...

Page 554: ...cc2 1 Clear theDTC 2 Starttheengine 3 Wait at least10seconds 4 Doesthe EPSindicatorcomeon YES Goto step4 NO Checkfor loosewiresor poorconnections lf the connections aregood the systemis OK at this t i...

Page 555: ...ol lemaleterminals 17 32 9 Checkfor continuitybetweenEPScontrolunit connectorC 20P terminalNo 11andthe torque sensor6PconnectorterminalNo 3 EPS CONTROL UNITCONNECTOR C 2OP Vcc2 GRN YEL Wiresideof fema...

Page 556: ...eandtheengineis running at 280rpmor belowfor 3 seconds 1 Startthe engineandcheckthetachometer ls the tachometer working correctly YES Goto step2 NO Go to step9 2 Test drive the vehicleabove15km h 9 3m...

Page 557: ...recheck l NO Repairopen in the wire betweenthe EPS controlunitandthe ECM I Turnthe ignitionswitchOFF and disconnect EPS controlunitconnectorC 20P Startthe engine and letit idle 9 10 Wiresideof emalete...

Page 558: ...er connector the gaugeassembly andthe ECM I NO Checkfor looseECMcontrolunitconnectors lf necessary substitutea known goodECMcontrol unitandrecheck I 1 5 DTC 37 EPS Control UnitInternal Circuit lnputCi...

Page 559: ...nector B 2P terminalNo 1 andbodyground EPSCONTROL UNITCONNECTOR B 2P M1 RED H F t I t r f T L Wiresideoffemale terminals ls therecontinuity YES Repairshortto body groundin the REDwire betweenthe EPSco...

Page 560: ...minals ls there battery voltage YES Repair shortto power in the circuitwire betweenthe EPScontrolunitandthe motor NO Goto step11 1 1 Turnthe ignitionswitchis OFF Substitutea known goodEPScontrolunit a...

Page 561: ...it connector B 2P terminal No 1 andbodyground EPS CONTROL UNITCONNECTOR BI2P M1IRED H I f2 l C T I Wiresideof femaleterminals ls there continuity YES Repairshortto body groundin the REDwire betweenthe...

Page 562: ...tor B 2P terminal No 2 andbodyground EPS CONTROL UNIT CONNECTOR B 2P mzrcnrur ll l A v Y I Wiresideof female terminals ls therebattery voltage YES Repair shortto powerinthe circuitwire betweenthe EPSc...

Page 563: ...l Checkfor loosewiresor poorconnections if the connections are good substitutea known good EPScontrolunit andconnectallthe disconnected connectors Startthe engine andturn the steeringwheelfrom lockto...

Page 564: ...andbodyground EPSCONTROL UNITCONNECTOR B 2P M1 REo H T t I I I t r v T L WiresideotIemale terminals ls thercbattery voltage YES Repairshortto powerin the circuitwire betweenEPScontrolunitand motor l...

Page 565: ...the DTC ls DTC 43 indicated YES Replacethe steeringgearboxmotor and recheck tl NO Perform the appropriate troubleshooting for the code indicated l 13 17 42 DTC 47 EPS Control Unitlnternal Circuit Powe...

Page 566: ...eplacethe originalEPScontrolunit l NO Performthe appropriate troubleshooting for the codeindicated t DTC 51 EPS Control UnitInternal Circuit EEPROM 1 Clear the DTC 2 Startthe engine Does the EPS indic...

Page 567: ...r Voltage FallOff 1 Clear the DTC 2 Startthe engine Doesthe EPS indicatotcomeon YES Goto step3 NO Checkfor loosewiresor poorconnections lf the connections aregood the systemis OK at this t r m e l 3 S...

Page 568: ...the originalEPScontrolunitand recheck I NO Performthe appropriate troubleshooting for the code indicated t DTC67 TorqueSensorl FCircuit 1 Clearthe DTC 2 Starttheengine 3 Turnthe steeringwheelfrom lock...

Page 569: ...p 4 NO Check for loosewiresor poorconnections lf the connections aregood the systemis OK at this time l 4 Stopthe engine andverifythe DTC ls DTC 69 indicated YES Check for looseor poor connections at...

Page 570: ...e EPSindicatorcomeon YES Go to step5 NO Inspect theEPSindicator bulb if thebulbis OK replace the bulbcircuitboardin thegauge assembly l 3 4 5 Turnthe ignitionswitchOFF 6 Disconnect EPScontrolunit conn...

Page 571: ...2P terminalNo 1 and body ground EPS CONTROL UNITCONNECTON A 2P B WHT BLUI H I t r v L 1 7 1 8 1 9 20 Wire side of femaleterminals ls therebattery voltage YES Go to step17 NO Check for a blown No 18 60...

Page 572: ...et buttons 2 Disconnect the negativecablefrom the battery and wait 3 minutesbeforebeginningwork 3 Removethe aircleanerassembly A 4 Removethe connectorbracket A onthegearbox housing and disconnect the...

Page 573: ...eetimes rightand leftabout45degrees lvlake surethe motor is evenlyseatedon the steering gearboxandthatthe O ringis not pinchedbetlveen the matingsurfaces InstalltheremovedDartsin the reverseorderof re...

Page 574: ...page20 60 Removethe steeringjoint bolts A and disconnect the steeringjoint by movingthe steeringjoint B towardthe column 4 5 6 7 i l _ t l a L 8 Removethe cotterpin A from the tie rodballjoint nut B a...

Page 575: ...theground cable terminal A fromthe steering gearbox housing a b H ry T lt 13 _ 1 1 a zi i F _1 17 52 14 Remove theengine wire harness clamps A from the threemountingbrackets Removethe heaterhose B fro...

Page 576: ...e leftside of the steeringgearbox 18 19 Removethe steeringstiffenerB from the rightside of the steeringgearbox i t1 20 Lowerthe steeringgearbox and rotateit so the pinionshaftpointsupward 21 Removethe...

Page 577: ...an assemblyto the wheelwellopeningon the passenger s side 23 Carefullyraisethe driver sside pinionside ofthe steeringgearbox A andtie rod B untilclearsthe mastercylinderand under hood fuse relaybox th...

Page 578: ...ttc J Renrace LocKscREw 162 N m lto srgf m 119lbf ft BOOTBAND Beqtace Replace I I ASHER rtE 54 TIE ROD END CONNECTOR SteeringGearboxOverhaul ExplodedView RACKGUIDE 6 BOOTBAND Beplace sPRrNG DISC WASHE...

Page 579: ...lsto enterintothe steeringgearbox Eemoval 1 Removethe steeringgearbox seepage17 b1 Disassembly 2 Unbendthe lockwasher A i Holdthe bracket A with onewrencn anq unscrew bothtie rodends B with anotherwre...

Page 580: ...with bolts Securely clampthe yokein a viseasshown Do not clamp the steeringgearboxhousingin the vise 1 10 8 Installthespecialtool A on the lockscrew B securely then loosenand removethe lockscrew from...

Page 581: ...ddiscard thestopring A onthe cylinder byexpanding itwithsnapringpliers Remove anddiscard thelockscrew B 13 Installthe new lockscrewon the rackhousing 14 Installthe newstopringin thegroove C onthe cyli...

Page 582: ...the steering gearboxhousing Attachthe yoke A of a universalpullerto the gearboxhousingmountswith bolts thensecurely clampthe yokein a viseas shown Do notclamp the steeringgearboxhousingin a vise 11 18...

Page 583: ...ingsurfaces Slidethe steeringrackall theway to left and place thesliderguideon thesteering rackby aligning the bolt holes B 1 1 17 60 29 25 Centerthesteeringrackwithin its stroke and align theslidergu...

Page 584: ...g Expandthe boot A by removingthe vinyltape andfit the bootends B in the installation grooves on thecylinder housing 5 t 3 2 74N m 7 5kgf m 5irlbf ft 34 Close theearportion A ofthe bands B with commer...

Page 585: ...EPSComponents SteeringGearboxOverhaul cont dl 36 Bendthe lockwasheragainstthe flat spotson the bracketwitha Iargepairof pliers 37 Adjustthe rackguidescrew seepage17 13 17 62...

Page 586: ...ox and move it toward thedriver s sideuntilthesteering gearbox is ln Dosition Becarefulnotto damagethe hoses lines andwire harnesses 3 Installthe pinionshaftgrommet A 4 Insertthe pinionshaftup through...

Page 587: ...the bulkhead and connectthe heatervalvecableend B to the heater valvearm C Readjust the heatervalvecable see page21 46 9 8N m 1 0 kgfm 7 2tbf ftl L t i t 17 64 9 Reinstall the heaterhose A on the hos...

Page 588: ...hield A 6 f 14 1 5 Centerthe steeringrackwithin its stroke Wipe off anygreasecontamination from lhe ball joint taperedsectionandthreads Then reconnect the tie rodends1A tothe dampersteeringarms lnstal...

Page 589: ...lly seated Theninstallthe upperjoint bolt andtightenit to the specified torque Tightenthe lowerjoint boltto the specifiedtorque 8 x 1 25 mm 28 N m 2 9kgf m 21 tbt ft 19 20 Installthedriver sdashboardl...

Page 590: ...Removethe bootfrom the tie rodend andwipe the old greaseoff the ballpin 2 Pack thelowerareaof the ballpin A wilhfresh mulr purposegrease 3 Packthe interiorof the new boot B and lip C with freshmultipu...

Page 591: ......

Page 592: ...ent BallJoint BootReolacement Stabilizer BarRep acement Stabilizer LinkRemoval lnstallation LowerArm Removal lnstallation Damper Spring Replacement RearSuspension HubBearing UnitReplacement Knuckle Re...

Page 593: ...l I Ref No Tool Number Description otv o o G 07GAF SE00100 07MAC S100200 07746 0010500 07749 0010000 07965 SA50500 07965 SD90100 Hub Dis Assembly Tool BallJointRemover 28 mm Attachment 62 x 68 mm Driv...

Page 594: ...0 STABILIZER BAR Replacement page18 17 STABILIZER LINK Removal lnstallation page1818 STABILIZER BAR Replacement page18 30 KNUCKLE HU8 WHEEL BEARING Replacement page18 1 1 Ball Joint Boot Replacement p...

Page 595: ...tiresizeandtirepressure Tiresize Front rear 195 60R15 Tire pressure Front 230kPa 2 3kgf cm 33 psil Rear 210 kPa 2 1kgf cm 30 psi Checkthe runoutof the wheelsandtires Checkthe suspensionballjoints Hold...

Page 596: ...chbolt hole diameter allowsa smallrangeof adjustment DamDer PinchBolt AdiustingBoh P N 90188 55A 000 Raisethe front of the vehicle andsupportit with safetystandsin the properlocation seepage1 8 Remove...

Page 597: ...owerthe front of the vehicleto the ground and bouncethe vehicle severaltimesto stabilize the suspension Checkthe camberangle lf it is within the specification checkthe fronttoe and adjust it if necess...

Page 598: ...oeInspection Adiustment Usecommercially available computerized four wheel alignment equipment to measure wheelalignment caster camber toe andturningangle Followthe equipmentmanufacturer s instructions...

Page 599: ...rd 28 00 reference Checkthe toe lf it is correct butthe turningangle is notwithin the specification checkior bentor damagedsuspension components 18 8 WheelBearingEndPlayInspec tion 1 Raiselhe vehicle...

Page 600: ...Servicelimit 2 0mm 0 08in l 4 Reset thedialgaugetotheposition shown and measurethe radialrunout Frontand rearwheel radialrunout Standard Aluminum wheel 0 0 7mm 0 0 03io Servicelimit 1 5mm 0 06in lf th...

Page 601: ...0 3 Loosenthe pressurebolt A and installthespecial tool asshown Insenthe jaws carefully making surenotto damagethe balljoint boot Adjustthe jaw spacingby turningthe adjustingbolt B 10mm HEXNUT 5 07MAC...

Page 602: ...for corrosion delormation and damage Replace if rusted WHEELBEARING Replace 5 mm SCREWS Replace FLAT SCREWS 6 x 1 0 m m 9 8 N m 1 0 kgf m 7 2 lbf ft BRAKE DISC SPINDLE NUT 22x 1 5mm 1 8 1 N m 18 5kgf...

Page 603: ...A 8 x 1 25 mm 22N m 12 2ksl m 26tbf ftl B 12x 1 25mm 108N m 11 0kgf m 80 rbf ftl 4 Removethe caliperbracketmountingbolts B and removethe caliperassembly C from the knuckle To preventdamageto the calip...

Page 604: ...nsertthe lockpin into the balljointpinfromthe lnside to theoutside of the vehicle Theclosedend of the lockDinmust be inthe rangeshown 07MAC SL00200 12x 1 25 mm 59 69N m R 1 1 12 6 0 7 0 kgl m 43 51 lb...

Page 605: ...oldontothe hubto keep it from fallingwhen pressedclear a s Pressthe wheel bearinginnerrace A off of the hub B usingthespeiialtool a commercially available bearing separator C anda press 1 5 07GAF SE00...

Page 606: ...and notetheseitems Becareful notto damagethe balljointbootwhen installing the knuckle Tightenall mountinghardwareto the specified lOrque values Torquethe castlenutto the lowertorque specification the...

Page 607: ...B 6r rffi l B Wipe the greaseoff the taperedsectionof the pin C and packfreshgreaseontothe base D t I 18 16 Inst llthe boot ontothe balljoint pin then squeeze it gentlyto forceout any air Do not let d...

Page 608: ...bolts A and bushingholders B then removethe bushings C andthe stabilizer bar D FORWARD A 10x 1 25mm 3 9 N m 4 0ksf m 29lbl ftl i i i i l I r i r j r 1 _ i i ii i 4 llt j 4 lnstallthestabilizer bar in...

Page 609: ...erof their rangeof movement 18 18 4 Installthe self locking nut andflangenut and lightlytightenthem NOTE Usea new self locking nut on reassembly 5 Placethe floor jackunderthe lowerarm balljoint and ra...

Page 610: ...rm from the knuckleusing thespecial tool seepage18 10 5 Removethe flangebolts A and removethe lower arm B 14x 1 5mm 83N m 8 5 kgf m 61 lbf ft 6 Installthelowerarm in the reverseorderof removal and not...

Page 611: ...PER SPRING MOUNTING CUSHION Check fordeterioration anooamage DAMPER SPRING Check forlreelength SELF LOCK NG NUT 12x 1 25inm 44N m 4 5kgt m 33lbf ftl neDtace a ta e9 DAMPER MOUNTING BASE 1 checkfor del...

Page 612: ...UT 07MAC S1002000 Disconnectthe tie rodendfrom the steeringarm on thedamperusingthespecialtool seepage18 1 0 Removethe bolts and removethe wheelsensor harnessbracket A and brakehosebracket B from the...

Page 613: ...essary to removethe nut Release the pressure from the strutspring compressor then disassemble the damperas shown in the ExplodedView 18 22 4 Reassemble all the pans exceptfor the upper springseatandsp...

Page 614: ......

Page 615: ...shaftwith a hexwrench C and tightenthe 12mm nutto the specifiedtorque 4 5kgt m 33 lbf ft Remove thedamper assembly fromthestrutspring compressor 10 18 24 Installation 1 Lowerthe lowerarm and positiont...

Page 616: ...ifiedtorque Tightenthe damperpinchnutsto the specified torque Installthe brakehosebracket A andthe wheel sensorharnessbracket B ontothe damper and tightenthe boltto the specified torque 5 1 9 8N m 11...

Page 617: ...ormation x 1 0mm 9 8N m 1 0kgf m 1lbf ftl HUBBEARING UNIT Check forfaultymovement andwear 6 x 1 0 m m 9 8N m 1 0kgf m 7 lbf ft u n Y HUBCAP Replace SPINDLE NUT 22x 1 5mm 181N m 18 5kgt m 134lbf ft Bep...

Page 618: ...akehosemountingbolt A B 10x 1 25 mm 5 5 N m C 5 6 kgfm 41lbf ft 2 2 kgtm 16lbt ftl Removethe caliperbracketmountingbolts B and hangthe caliper C to one side To preventdamage to the caliperor brakehose...

Page 619: ...e Usea new hub capon reassembly Beforeinstallingthe wheel cleanthe mating surfaceof the brakediscandthe insideof the wneel 10 18 28 Raisethe rearof the vehicle andsuppon it with safetystandsin the pro...

Page 620: ...e boltsand nuls then placea floorjackunderthe lower arm and raisethe suspension to loadit with the vehicle sweight beforefullytighteningthe boltsand nutsto the specified torquevalues Alignthe cam posi...

Page 621: ...25mm 38 N m 3 9kgf m 28 lbf ft Removethe flangebolts A and bushingholders B then removethe bushings C andthe stabilizer bar D 18 30 4 Inslallthestabilizerbar in the reverseorderof removal and notethes...

Page 622: ...C withthejointpins D setatthe centerof eachmoving range 4 lnstallthe self locking nut andflangenut and lightlytightenthem NOTE Usea new self locking nut on reassembly Placea jackunderthe trailingarm...

Page 623: ...gf m ir3lbf ft 12x 1 25 mm 59 N m 16 0 kgf m 43 tbf ft 18 32 5 Installtheupperarm in the reverseorderof renloval and notetheseitems Firstinstall allthesuspension components and lightlytightenthe bolts...

Page 624: ...m 11 0kgt m 80 tbf ft a r 7 Removethe trailingarm rearmountingbolt A Do not loosenthe specialbolts B on the trailingarm A 12x 1 25mm 59N m ttg 1 r 1 Lowerthe jack and removethe trailingarm Installthe...

Page 625: ...ened compression anddamage 9 I tI SELF LoCK NG NUT t J 10x 1 25mm 29 N m 3 0kgf m 22lbf ft Replace DAMPER MOUNlING COLLAR DUSTCOVER t 9 r qnJ E Z n BUMP sroPPLArE l t t BUMP STOP Check torweakness a n...

Page 626: ...dsin the properlocation seepage1 8 Removethe rearwheels 2 Removethe flangebolt A from the bottomof the damper Removethe rearbulkheadcover seepage20 51 Removethe flangenuts A from the top of the damper...

Page 627: ...ressionand extension The damper shouldextendsmoothlyandconstantlywhen compressionis released lf it doesnot the gasis leakingandthe dampershouldbe replaced 4 Checkfor oil leaks abnormalnoises or bindin...

Page 628: ...he damper A 10x 1 25mm 59N m 16 0kgt m ia lbt ft 3 Looselyinstalltheflangebolt A on the bottomof thedamper 12x1 25 mm 61N m 6 2 kgf m 45lbf ft Raisethe suspension with a floor jackto loadthe vehiclewe...

Page 629: ......

Page 630: ...10 Front Brake Pads lnsoection and Replacement 19 11 Front Brake DiscInspection 19 13 Front Brake Calioer Overhaul 19 14 Master Cylinder Replacement 19 15 Master Cylinder Inspection 19 16 Brake Booste...

Page 631: ...Conventional BrakeComponents SpecialTools Ref No ToolNumber DescriDtion Qty o 07JAG SD40 100 PushrodAdiustmentGauoe 1 I 19 2...

Page 632: ...Brake Cable Replacement page1926 REARDISCBRAKE RearBrakePads Inspection and Replacement page l9 20 RearBrakeDisc Inspection page19 22 RearBrake Caliper Overhaul page19 23 PARKING BRAKE LEVER Parkino B...

Page 633: ...nts Modulator BrakeSystemInspection andTests BrakeSystemTest Brakepedal sinks fades when braking 1 Startthe engine and let it warm up to operatingtemperature 2 Attacha 2 inchpieceof maskingtapealongth...

Page 634: ...akedrag ls therc brake dtag at any ot the wheels YES Go to step4 NO Replace the brakebooster I 4 Without removingthe brakelines unboltand separate the mastercylinderfrom the booster then spinthe wheel...

Page 635: ...the locknutfirmly Do not adjustthe pedalheightwith the pushrodpressed 15N m 1 5kgl m 11lbl ft 19 6 7 Check the brakepedalfreeplayasdescribed below PedalFreePlay 4 With the engineoff inspectthe play A...

Page 636: ...nt wheels then raisethe rearof the vehicle and supportit with safetystandsin the properlocation seepage1 8 Makesurethe parkingbrakearm A on the rear brakecalipercontacts the brakecaliperpin B NOTE The...

Page 637: ...to contaminate the brakefluid 1 Makesurethebrakefluidlevelin the reservoir isat the MAX upper levelline A Slidea pieceof clearplastichoseoverthe flrst bleedscrew and submergethe otherend in a containe...

Page 638: ...GRN ORN tk o o o b 3s1E8 I oPEN Leve down I I A Y BtK csor BrakeSystemIndicatorCircuitDiagram UNDER OASH FUSE FELAYBOX EBAK FLUID IEVELSwlICH 19 9...

Page 639: ...hereshouldbe continuity With the brakeleverdown thereshouldbe no continuity R dFu E UF Y 19 10 BrakeFluidLevelSwitchTest Checkfor continuitybetweenthe terminals A with the float in the down positionan...

Page 640: ...the properlocation seepage1 8 Removethe front wheels 2 Checkthe thickness of the innerpadiA and outer pad B Donotinclude thethickness of the brake pad backingplate Brakepadthickness Standard 9 5 10 5m...

Page 641: ...sand padshim correctly Installthe padswith the wear indicators C on the inside lf you are reusingthe pads alwaysreinstall the brakepadsin theiroriginalpositionsto preventa momentarylossof brakingeffic...

Page 642: ...w discshouldbe refinishedif its runoutis greater than0 10mm 0 004 in Thickness andParallelism 1 Raisethe front of the vehicle and supportit with safetystandsin the properlocation seepage1 8 Removethe...

Page 643: ...reusingpads alwaysreinstallthemin their originalpositionsto preventlossof brakingefficiency Do not reusedrainedbrakefluid A l w a y s u s e H o n d a D O T 3 b r a k e f l u i d N o n H o n d a b r a...

Page 644: ...rcylindermountingnuts H and washers 8 Removethe mastercylinderfrom the brakebooster Becarefulnotto bendor damagethe brakelines when removingthe mastercylinder 9 Removethe rod seal l from the mastercyl...

Page 645: ...otment 19 16 BrakeBoosterPushrodClearance Adjustment SpecialToolsRequired Pushrodadjustmentgauge07JAG SD40100 NOTE Brakeboosterpushrod to piston clearance must becheckedand adjustmentsmade if necessar...

Page 646: ...learance 0 0 t mm 0 0 02 in lf the clearance is incorrect loosenthe starlocknut A andturn the adjuster B in or out to adjust Adjustthe clearance whilethe specifiedvacuum is appiiedto the booster Holdt...

Page 647: ...while pressedfor 30 seconds the vacuumbooster is OK lf the pedalrises the boosteris faulty 2 With the enginestopped pressthe brakepedal severaltimes usingnormalpressure Whenthe pedalis first pressed...

Page 648: ...rakeboostermountingnuts C Removethe brakebooster A from the engine comparlmenr INdAdEI Becarefulnot to damagethe booster surfacesandthreadsof the boosterstud bolts Becarefulnotto bendor damagethe brak...

Page 649: ...with safetystandsin the properlocation seepage1 8 Removethe rearwheels 2 Checkthe thickness of the innerpad A andouter pad B Do not includethe thicknessof the brake padbackingplate Brakepadthickness...

Page 650: ...nstallthe brakepadsin their originalpositionsto preventa momentarylossof brakingefficiency 11 Rotatethe caliperpistonclockwiseintothe cylinder then alignthe cutout A in the pistonwith the tab B on the...

Page 651: ...it refinishthe brakedisc Max RefinishLimit 9 0mm 0 35in NOTE lfthe brakediscis beyondtheservice limitfor refinishing replaceit seepage18 26 A new discshouldbe refinishedif its runoutis greater than0 1...

Page 652: ...usingpads alwaysreinstallthemin their originalpositionsto preventlossof brakingefficie ncy Do not reusedrainedbrakefluid UseonlycleanHondaDOT3 brake fluid Non Honda brake fluidcancausecorrosion andsho...

Page 653: ...geand leakage NOTE Replace the brakehoseclipwheneverthe brakehoseis serviced 15N m 1 5kgf m 11lbf ftl ABSMODULATOR UNIT Io BRAKE LINE 15N m 1 5 kgfm 11lbf ftl BRAKE HOSE to CALIPER lBANJOBOLTI 3il N m...

Page 654: ...Removethe flangebolt A and removethe brake hosebrackets from the damper Remove anddiscard thehoseclip B Removethe banjobolt C and removethe brake hose D romthecaliper 4 I x 1 25mm 6 Installthebrakehos...

Page 655: ...Conventional BrakeComponents 1 ParkingBrakeCableReplacement Exploded View PARKING BRAKE swtTcH ADJUSTING NUT L PARKING BRAKE CABLE Check forstiffness binding anddamage e 8 x 1 25 22 N m 12 2kgl 19 26...

Page 656: ...ole seepage20 57 Removethe parkingbrakecableclip A from the brake cable B 4 6 Disconnectthe parkingbrakecablefrom the lever c Removethe parkingbrakecablemounting hardware then removethe cable 7 lnstal...

Page 657: ......

Page 658: ...DTC Troubleshooting Index 19 34 Symptom Troubleshooting Index 19 35 System Description 19 36 Circuit Diagram 19 42 DTC Troubleshooting 19 45 ABSIndicator CircuitTroubleshooting 19 52 Brake System Indi...

Page 659: ...e19 59 UNDER OASH FUSE RELAY BOX L LEFT REAR WHEEL SENSOR Inspection page19 59 Replacement page19 59 DATALINKCONNECTOR I16PI RIGHT FRONT WHEEL SENSOR Inspection page19 59 Replacement page19 59 ABSMODU...

Page 660: ...TheABS indicatorgoesoff when the vehicleis drivenagain andthe systemis OK afterthe ignitionswitchis turnedfrom OFFto ON ll Diagnostic TroubleCode DTCI The memorycan holdthreeDTCS However when the sam...

Page 661: ...drive but troubleshooting is donebasedon the DTC checkfor looseconnectors poorterminal contact etc beforeyou starttroubleshooting 3 Aftertroubleshooting clearthe DTC disconnect the HondaPGMTester and...

Page 662: ...pressed The ignitionswitchis turnedON ll The SCScircuitis shortedto body groundbefore the ignition switchisturnedON ll Example ot DTC 15 Longblink Shortblinks fivetimesl Examole of DTC22 Longblinks tw...

Page 663: ...nal seepaqe19 46 DTC 17 Left rear wheelsensor open short to bodv qround short to power seeDaoe 19 45 DTC 18 Faultvleft rear wheelsensorDulsesiqnal seeDaqe 19 46 Drc 2l Continuous oDeration chioDed Dul...

Page 664: ...e 19 52 ABS indicatordoesnot go off and no ABS DTCis stored ABS IndicatorCircuitTroubleshooting seestep1 on Daqe19 53 Brakesystemindicatordoesnol come on BrakeSystemlndicatorCircuitTroubleshooting see...

Page 665: ...h ON ll Voltage BLU YEL RRS Detects righfrear wneetsensor srgnal a _ l 6 7 Wheel Spin wheelat I turn second AC 0 053 V or above Oscilloscope 0 15 Vp p or above GRN YEL RRS BLU F R S Detects right fron...

Page 666: ...forthe 0umD motor 16 GN D Below 0 3 V WHT RED B MR Powersource for theoumD motor 17 GND Atalltimes Battery voltaoe 1 8 WHT GRN B FSR Powersource for thevalve relav 18 GND Atalltimes Battery voltaoe 19...

Page 667: ...cedif the rearwheelsare locked creatingan extremelyunstablecondition TheABS precisely controlsthe slip rateof the wheelsto ensuremaximum grip forcefrom the tires therebyensuringthe maneuverability and...

Page 668: ...ensifying Self diagnosis Function 1 T h e A B S c o n t r o l u n i t i s e q u i p p e d w i t h a m a i n C P U a n d a s u b C P U E a c h C P U c h e c k s t h e o t h e r f o r p r o b l e m s 2...

Page 669: ...The hydrauliccircuitis an independent four channeltype onechannel for eachwheel Pressure intensifyingmode Inletvalveopen outlelvalveclosed Master cylinder fluidis pumpedoutto thecaliper Pressure reta...

Page 670: ...t LOW SPEED Wheel Speedand Modulator Control 8E EEETqE VEJ q ESPEEq 5 PRESSURE OUTLET VALVE 9p OFF INLET VALVE oN OFF MoroR I l t l OFF Whenthe wheelspeeddropssharplybelowthe vehiclespeed the inletval...

Page 671: ...ABSGomponents CircuitDiagram L lJ I 5 l r t l I r l I l o s N Gu csl LqF G50l 19 42...

Page 672: ...ffrre riq r srbm r l q_ md Y4 I L 7 19 43...

Page 673: ...NECTOR B I22PI 1 l 2 l 3 l 1 5 GAUGE ASSEMBLY CONNECTORS CONNECTOR A I22P WHEEL SENSOR 2PCONNECTORS FRONT J T l L t q t t l l L_ J r r Tr e l RIGHT REAR LEFT REAR tslTt t J 1T 1 I t L t r l z i J Term...

Page 674: ...re betweenthe ABS modulator control unitandthe appropriate wheelsensor I NO Goto step4 4 Turnthe ignitionswitchOFF 5 Check forcontinuity between theappropriate wheelsensor circuit terminal andbodygrou...

Page 675: ...uitwire betweenthe ABS modulator control unitandthewheelsensor l NO Replace thewheelsensor l 19 46 DTC12 14 16 18 Wheel Sensor Putse Signal NOTE lf theABS indicatorcomeson for the reasons describedbel...

Page 676: ...or control unit l Disconnect the harness2Pconnectorfrom the appropriate wheelsensorandcheckthe resistance between the sideandthe sideofthe wheel sensor ls there lessthan450 Q YES Replace the wheelsens...

Page 677: ...tthistime t 19 48 DTC51 MotorLocked 1 Check the No 10 40A fuse in theunder hoodfuse retayDox ls thetuse OK YES Reinstallthe fuse and go to step2 NO Replace the fuse and recheck l 2 Disconnect the ABSc...

Page 678: ...Sindicatorcomeon and is DTC 51 indicated YES Replace the ABS modulator control unit l NO The systemis OK at thistime l 6 7 DTG52 MotorStuckOFF 1 Check theNo 10 40A fuseintheunder hood fuse relay box l...

Page 679: ...ABS controlunitandbodyground G202 1 19 50 3 DTC53 MotorStuckON 1 Clear the DTC thendisconnect the HondapGM Tester 2 Test drive the vehicle DoestheABS indicatotcomeon and is DTC 53 indicated YES Goto s...

Page 680: ...tandthe under hood fuse relaybox I DTC 61 lG2Voltage NOTE Check theNo 11 7 5A fusein theunder dash fuse relaybox beforetroubleshooting 1 Clear theDTC thendisconnect theHondaPGM tesler 2 Test drivethe...

Page 681: ...p2 Pullup the parkingbrakelever Does the btake system indicator come on YES Goto step3 NO Repairopenin the indicatorpowersource circuit lf necassary substitute a known goodABS modulator control unit a...

Page 682: ...dbodyground G501 1 10 1 1 3 ABSindicatordoesnot go off 1 Checkthe No 8 20Alfuse intheunder hood fuse relaybox andreinstall thefuseif it isOK ls thefuseOK YES Goto step2 NO Replace thefuse andrecheck l...

Page 683: ...dy ground G202 t 9 Turnthe ignition switchON ll 1 8 19 54 10 Connect the ABScontrolunit3lPconnector terminalNo 20andbodygroundwitha jumper wire ABSCONTROL UNIT31PCONNECTOR Wire side of femaleterminats...

Page 684: ...2 172 a Brakesystemindicatordoesnot go off 1 Turnthe ignition switchON ll 2 Release the parking brake Doesthebrake systemindicatotgo ofl after severalseconds YES The systemis OK at this time l NO Goto...

Page 685: ...Turnthe ignitionswitchOFF Connect the multiplexcontrolunit 13Pconnector terminalNo l andbodygroundwitha jumperwire MULTIPLEX CONTROL UNIT13P CONNECTOR JUMPER WIRE Wiresideoffemale terminals Turnthe ig...

Page 686: ...mthe brakelinesduringremovaland installation To preventthe brakefluid from flowing plugand coverthe hoseendsandjointswith a shoptowel orequivalent malenal Removal 1 Turnthe ignitionswitchOFF 2 Pullupt...

Page 687: ...ushinthelockoftheABScontrol unit31Pconnector untilyou hearit clickintoplace thenconnect theconnector 4 Connect the six brakeIines 5 Bleedthe brakesystem startingwith the front wheels 6 Connectthe PGMT...

Page 688: ...the gap exceeds 1 0mm 0 04 in check for a bentsuspension arm Standard Front 0 4 1 0mm 0 02 0 04 in Rear 0 2 1 0mm 0 01 0 04in l Front 0 4 1 0 mm 10 02 0 0 lin l I t Bear 0 2 1 0mm 0 01 0 04 in WheelS...

Page 689: ......

Page 690: ......

Page 691: ...rd Instrument Panel Removal lnstallation Driver s Dashboard LowerCover Removat Installation Driver s Dashboard UnderCover Remova t Insta llation Oriver s Pocket Removal lnstallation ShiftLever TrimRem...

Page 692: ...nt Fuel FillDoorOpener Cable Replacement HoodLatch Rep1acement Fuel FillDoorOpener Replacement Hatch Handle Replacement Hatch Latch Replacement Hatch Lock Cylinder Replacement Frame Subf rameReplaceme...

Page 693: ...a DOORSASHTRIM Replacement page20 10 DOOR GLASS OUTER WEATHERSTRIP Replacement page20 10 DOOR Position Adiustment page 20 12 t POWER DOOR LOCKSWITCH Driver s DOOR OUTER TRIM K p IJ A A dq W2 Ya J ait...

Page 694: ...ge 20 9 CYLINDER ROO PROTECTOR GLASS Replacement page20 9 Adjustment page20 11 6X W STRIKER Adjustment page20 13 LATCH Replacement page20 7 RETAINER CLIP POWERDOOR LOCKACTUATOR OUTER HANDLE PROTECTOR...

Page 695: ...e B Pushthe door grip cover C out to release the hook D andtab E andpulloutthe coverto releasethe tabs F and hook G by hand then removethe cover 20 4 3 Removethe armrestcover A Takecarenotto scratchth...

Page 696: ...r breakingit FastenerLocations 95mm 3 74 in l 12mm r q i 0 17in l r _ r Clip 9 ffi EtA l m m 0 04 in l 45mm 1 77 in l 7 Disconnect the innerhandlecable A from the innerhandle B anddisconnectthe powerd...

Page 697: ...ctor B 3 Pullthe protectordown to release the hook C from the door Fastener Location Screw 1 2 5 20 6 4 Disconnect the cylinderrod A and release the retainerclip B then removethe lockcylinder C Discon...

Page 698: ...nstallthe lockcylinder Besurethe clipisfullyseated inthesloton the lockcylinder Whenreinstalling thedoorpanel makesurethe plasticcoveris installedproperly and is sealed aroundthe coversDerimeter DoorL...

Page 699: ...ghthe holein the door Takecarenotto bend the outerhandlerod B cylinderrod C lockrod D andinnerhandle cable E Fastener Locations 8 Screw U 6 x 1 0 m m 5 N m 0 5kgf m 4 tbf ft 20 8 9 Installthelatchin t...

Page 700: ...0 m m 8 N m 0 8 kgf m 6 rbf ftl Remove thebolts C andloosen thebolts D then remove theregulator E through theholeinthe door Applymultipurpose grease to allthesliding surfaces oftheregulator A wheresho...

Page 701: ...im lnstallthetrim in the reverseorderof removal 3 20 10 DoorGlassOuterWeatherstrip Replacement NOTE Puton glovesto protectyour hands Takecarenotto scratchthe door 1 Remove thepowermirror seepage20 15...

Page 702: ...stallation Checkfor water leaks seestep7 on page20 121 Test drive andcheckfor wind noase 14 r o tL rrt DoorGlassAdjustment NOTE Checkthe weatherstrips and glassrun channelfor damageor deterioration an...

Page 703: ...nel seepage20 4 9 Test drive andcheckfor wind noise 300mm 12in l 20 12 DoorPositionAdiustment NOTE Checkfor equalgapsbetweenthe front rear and bottomdoor edgesandthe body Checkthatthe door and body ed...

Page 704: ...r A The strikernuts arefixed butthestriker canbe adjusted slightly up or down andin or out 1 Loosenthe screws B rhen inserta shoptowel C betweenthe body and striker Lightlytlghtenthe screws Wrapthe st...

Page 705: ...ndex POWER MIRROR Replacement page 20 15 a b r J 4 1 TWEETER TWEETER MIRROR MOUNTCOVER MIRROR HOLDER Replacement page20 15 __ Q MOUNT REARVIEW MIRROR Replacement page 20 16 POWER MIRROR ACTUATOR Repla...

Page 706: ...f removal and notetheseitems Makesurethe connectoris pluggedin properly Attachthe harnessclip Mirror HolderReplacement 1 Carefully pulloutthebottomedgeofthe mirror holder A by hand Takecarenotto scrat...

Page 707: ...iewmirror A down towardthe bottomof the windshield then detachit from the spring B in the mount C and removethe rearviewmirror Takecarenotto scratchthe mirror Dase 3 lf necessary removethe springfrom...

Page 708: ...STENER 2 Self adhesive type glassside SIDERUBBER DAM WINDSHIELD SIDETRIM m _ lny S RErA NER 6 f N tJ e N8 CLIP 4 Blue CLIP WINDSHIELD Beplacement page20 19 SPOILER FASTENER 2 Selt adhesive type LOWER...

Page 709: ...ont d OUARTER GLASS UPPER CLIP FRONT SEAL tsetladhesive typel n iT J n l l l Pl v I LowERcLrp _ Self adhesive type b I R ARCLIP Self adhesive type OUARTER GLASS Beplacement page 20 29 LEV EMBLEM 03mod...

Page 710: ...s seepage20 95 Removethe molding A from the upperedgeof the windshield B lf necessary cutthe moldingwith a utilityknife lf the old windshieldisto be reinstalled make alignmentmarksacrossthe glassand b...

Page 711: ...ntirewindshieldopening flange Do not scrapedown to the paintedsurfaceofthe body damagedpaintwill interferewith proper bonding Removethe rubberdam andfasteners from the oooy 11 Cleanthe body bondingsur...

Page 712: ...E Becarefulnotto touchthewindshieldwhere adhesive will beaoolied t 3 14 Gluethemolding A withadhesive tape B 3M4212 or equivalent to the upperedgeofthe windshield C Besurethealignment mark D of the mo...

Page 713: ...aroundthe edgeof the windshield A betweenthe dams B andmolding C asshown thenlightly wipe it off with gauzeor cheesecloth Applyglassprimerto the molding Do not apply body primerto the windshield and d...

Page 714: ...the cartridgewithout air pockets to ensurecontinuousdelivery Putthe cartridgein a caulkinggun and run a beadof adhesive A aroundthe edgeof the windshield B betweenthe dams C andmolding D asshown Apply...

Page 715: ...s seepage20 95 NOTE Thecowl coverclipsmay not setproperlyif the windshieldadhesiveistoo wet Installthe clips A B on bothsidetrim C lf the clip D is damaged replacethe sidetrim andclips as an assembly...

Page 716: ...tors A 4 lf the old rearwindow is to be reinstalled make alignmentmarksacrossthe glassand bodywith a grease pencrl Apply protective tapealongthe insideand outside edgesof thehatch Usingan awl makea ho...

Page 717: ...ngsurfaceis kept free of water oil and grease 10 20 26 11 Gluethesideupperfasteners A andsidelower fasteners B with adhesivetape 3M 5312 or equivalent Gluetheupperrubberdams C with adhesive tape NITTO...

Page 718: ...d 14 Remove the rearwindow 15 Witha sponge applya lightcoatof glassprimer alongthe edgeof the rearwindow A upper rubberdams B and lower rubberdam C as shown then lightlywipe it off with gauzeor cheese...

Page 719: ...20mm 10 79 in l 2 m m 0 08in 1 7 Beforefilling a cartridge cuta V in the end ofthe nozzle A asshown 20 28 7 mm 0 27in I 18 Packadhesiveintothe cartridgewithout air pockets to ensurecontinuousdelivery...

Page 720: ...e vehiclestandfor at least4 hoursafterrearwindow installation lf the vehiclehasto be usedwithin the first 4 hours it must be drivenslowly 22 Reinstallall remaining removed parts NOTE Advisethe custome...

Page 721: ...yremovethe quarterglass 20 30 6 With a putty knife scrapethe old adhesivesmooth to a thickness of about2 mm 0 08in on the bondingsurfacearoundthe entirequanerglass opening flange Do not scrapedown to...

Page 722: ...terglass 11 Alignthe upperclip A andlowerclip B withthe edgeof the quarterglass C then anachthem with adhesive tape NITTO571 or equivalent to the insidefaceof the quarterglass andalignthe center of th...

Page 723: ...mm 3 9i1in 45 mm 1 77 in 3 5mm 0 r4in l 30mm 11 18 in l 50mm I 1 97in 1 t 6 mm 0 24in n L v 20 32 13 With a sponge applya lightcoatof glassprimer alongthe edgeof the rubberdam A andfront seal B asshow...

Page 724: ...cartridge cut a V in the end ofthe nozzle A asshown 10mm 0 39in 20mm 0 79 in t 5 7 mm 10 27 in 20 33 16 Packadhesiveintothe cartridgewithout air pockets to ensurecontinuousdelivery Putthe cartridgein...

Page 725: ...erglass usea softshoptowel dampenedwith alcohol 19 Letthe adhesivedry for at leastt hour thenspray water overthe quarterglassandcheckfor leaks Markthe leakingareas letthe quarterglassdry then sealwith...

Page 726: ......

Page 727: ......

Page 728: ...andOoenino Drao Check page20 48 DRAINCHANNEL Replacement page20 39 5 a t c _ a BR CKEI COVER LIMITSWITCH AUTO STOP SWITCH Adjustment page 20 46 E R I CABLE TUBE REAR BRACKET E ESTOP a MOONROOF CONTRO...

Page 729: ...etweendeflectorsealand roof panel 2 Checkfor a insufficient deflectorextension 3 Checkfor a deformeddeflector Motor noise 1 Checkfor a loosemotor 2 Check for a worngearor bearing 3 Checkfor a deformed...

Page 730: ...d A 6 x 1 0 m m I N m 0 9 kgf m 7lbt ft 3 lf necessary repeaton the oppositeside B GlassReplacement L Close theglassfully Slidethesunshade alltheway back Removethe screws A then removeboth bracket cov...

Page 731: ...derof removal and checkthatlhe deflectorarm base B and deflectorlink pivotbase C line up with the samealignment lines D lf necessary adjust them forwardor backwardso the edgeof the deflector seal E to...

Page 732: ...cations Screw 2 Release the drainchannel A from both hooks B of thedrainchannel sliderby pulling thedrain channelforward 4 Remove thedrainchannel A Installthe channel inthe reverse orderof removal and...

Page 733: ...erspacers B Fastener Locations Screw 4 tF 3 Removethe screws then removebothspacers 20 40 4 While liftingthe front portionofthe sunshade A movethe sunshadeforwarduntilyou canseeboth sunshade rearhooks...

Page 734: ...Letthe water run freelyfrom a hosewithout a nozzle Do not usea high pressure spray 1 Motor Replacement Removethe headliner seepage20 54 Puton glovesto protectyour hands Disconnecl the connector A and...

Page 735: ...es Ei and removethe moonroof relays F FastenorLocations Bolt 10 um 6 x 1 0 m m 9 8N m 1 0 kgf m 7 2lbf ft 4 5 2 irl Removethe interiorharness G by detaching the harnessclips H With an assistantholding...

Page 736: ...the reverse order of removal and notetheseitems Before installing theframe clearthedraintubes and drainvalvesusingcompressed air Checkthe frame seal Clean thesurface ofthe frame When installingthe fra...

Page 737: ...bletube sidebracket F andthe cable tube mountingscrews G from bothsidesof the frame H Fastener Locations A rScrew 2 B Screw 2 r Position switch side 6 x 1 0 m m A c g aN m No switch sidel o E Bolt 2 S...

Page 738: ...sshouldbe replaced Apply multipurposegreaseto the glassbracket A andguiderailportionof theframe B indicatedby the arrows Beforereinstalling the motor makesureboth linklifters areparallel andinthefully...

Page 739: ...hown Checkthe glassfit to the roof panelandthe glassheight seepage20 37 5 x 0 8 m m 5 N m 0 5kgf m 4lbf ft 3 Withan open end wrench loosen the limitswitchmountingbolts C 4 Adjustthe limit switch D Mov...

Page 740: ...ereyouhearafaintclickwhenthe switchcam F pushesthe switch auto stop Checkthatthe switchplatecontactsthe switchbracket G Checkthe operationof the glassby operatingthe moonroofswitch Fromthe tilt upposi...

Page 741: ...eepage20 41 then check The gearportionandthe innercablefor breakage and damage lf the gearportionis broken replace themotor lf the innercableis damaged removethe frame seepage20 42 and replace the cab...

Page 742: ...SHELF page20 5l REARSIDETRIM PANEL page20 51 B PILLARUPPEBTRIM page20 50 DOOROPENING TRIM page20 50 A PILLAR TRIM page20 50 Removal lnstallation page2054 KICKPANEL page20 50 DOORSILLTRIM page20 50 Rep...

Page 743: ...epage20 51 2 Installthetrim in the reverseorderof removal and notetheseitems Replace anydamaged clips Apply liquidthreadlockto the anchorboltsbeforereinstallatior Beforeinstallingthe anchorbolts makes...

Page 744: ...tconnectoris pluggedin properly lfthethreadsontherearsidetrimpanel mounting self tapping ETscrewsareworn out useanoversized self tappingETscrew P N90137 S1A Eo1 1 madespecifically forthisapplication W...

Page 745: ...renotto bendor scratchthe trim and panels 1 To remove the reartrim panel remove thechildseattetheranchor seepage23 11 2 Removethe trim as shown 3 Installthe trim in the reverse orderof removal andrepl...

Page 746: ...Removethe trim in the sequenceshown Hatchuppertrim panel Lefthatchsidetrim Righthatchsidetrim Hatchlowertrim panel 2 Installthe trim in thereverse orderof removal andreplace anydamaged clips FastenerL...

Page 747: ...2 C pillar trim bothsides seepage20 51 Moonroofswitch seepage22 112 Spotlights seepage22 961 Ceilinglight seepage22 96 Removethe sunvisor A and holder B from both srdes 1 Removethe caps C 2 Removethe...

Page 748: ...ace anyclipsthatremaininthe roofduring removal Reinstallthe clipsbackinthe headliner beforeinstallation F C l i p 2 H C l i p 2 CarpetReplacement SRScomponentsare locatedin this area Reviewthe SRScomp...

Page 749: ...and notetheseitems Takecarenotto damage wrinkle ortwistthe carpeL Makesurethe seatharnesses are routed correctly Slipthecarpetundertherearsidetrim panelon eachsideproperly Replace theclipif it sdamage...

Page 750: ...earconsole up then removeit Fastener Locations B Screw 2 C Clip 2 2 Removethe front console A 1 Pulloutthedashboard centerlowercover B to detachthe clips C 2 Dlsconnect the accessory power socket conn...

Page 751: ...Consoles FrontConsoleDisassembly Reassembly NOTE Takecarenotto scratchthe consoleand relatedparts FastenerLocations Screw 8 C FRONTCONSOLE a BEVERAGE HOLDER ASSEMBLY CONSOLE BOX 20 58...

Page 752: ...he clips B andhooks C 2 Gentlypull out the upperportionto release the clips D andhooks E FastenerLocations B clip 2 DD Clip 2 4 Installthepanelin the reverseorderof removal and pushthe clipand hookpor...

Page 753: ...erin the reverseorderof removal and pushthe clip portioninto placesecurely 20 60 Driver sPocketRemoval lnstallation NOTE Puton glovesto protectyour hands Takecarenotto scratchthe dashboardand related...

Page 754: ...ift levertrim C from underthe trim to releasethe clips D and hooks E of the leftside Fastener D clip i F V Locations 2 E Hook 2 a7 r t1 u 4 Pulloutthe shift levertrim A by handto release the remaining...

Page 755: ...ver sdashboardIower coveropenings loosenthe bolts A securingthe centerpanel B 2 FastenerLocations A Bolt 2 x 0 8mm 5 N m 20 62 4 Pullout the centerpanel A to release the clips B and hooks C and remove...

Page 756: ...onionsinto place securety GloveBoxRemoval lnstallation SRScomponentsare locatedin this area Reviewthe SRScomponent locations seepage23 13 andthe precautions andprocedures seepage23 14 intheSRS section...

Page 757: ...fromthedashboard B Fastener Locations Screw 7 6hD t 4 Remove the screws lhen remove the slde vent A FastenerLocations Screw 4 5 lnstallthe sideventin thereverse orderof removal 20 64 Beverage HolderR...

Page 758: ...ons Screw 3 4 lnstallthe tray in the reverseorderof removal Passenger s TrayRemoval Installation NOTE Take carenotto scratch thedashboard Putongloves to protect yourhands 1 2 3 4 Removethe dashboard s...

Page 759: ...requencies for the preset buttons Disconnect the negativecablefrom the battery and wait at leastthreeminutesbeforebeginningwork Removetheseitems Driver sdashboardlowercover seepage20 59 Driver sdashbo...

Page 760: ...nginecompartmentwire harnessconnectors l from the under dash fuse relavbox J Middleportion 8 Disconnect the floor wire harnessconnectors A andcombination subharness connector B Passenger s side 9 From...

Page 761: ...rd mountingboltsof the middleportionbefore reinstallation Beforetighteningthe bolts makesureeachwire harnessandcontrolcablesare not pinched Makesurethe connectorsarepluggedin properly andthe antennale...

Page 762: ...E andcruisecontrolmain switchconnector F Separate thedashboard andsteering hangerbeam Faslener Locations A r B o l t 4 B S c r e w 9 5 N m 0 5kgf m 4lbf ftl 5 Installthe beamin thereverse orderof rem...

Page 763: ...ent page20 81 Seat back StrikerReplacement page20 81 Seat back CoverReplacement page 20 82 SeatCushionCoverReplacement page20 84 FRONTSEAT Removal lnstallation page20 i1 Disassembly Reassembly Driver...

Page 764: ...protective tapeto preventdamage Takecarenotto scratchthe body or tearthe seat covers Puton glovesto protectyour hands 1 Makesureyou havethe anti theft codefor the radio thenwrite down the frequencies...

Page 765: ...shown thedriver s seatis similarexceptit hasno OPDSunitconnector With the helpof an assistant carefullyremovethe front seatthroughthe front door opening Installthe seatinthe reverse orderof removal a...

Page 766: ...renotto tearthe seamsor damagethe seatcovers Puton glovesto protectyour hands Whenpryingwith a flat tipscrewdriver wrap it with protective tapeto preventdamage Apply multipurposegreasetothe moving por...

Page 767: ...ntdamage Apply multipurposegreaseto the moving portionof the seattrack To Drevent wrinklesin the seatcushioncover stretchthe materialevenlyoverthe pad lvlake surethe rearseataccess cableis connectedpr...

Page 768: ...yfrom oil Oil cancorrodethe sensorcausingit to fail Puton glovesto protectyour hands Seat back Cover Removethe front seatiseepage20 71 Withsideairbag Fromundertheseatcushion detachthe sideairbagconnec...

Page 769: ......

Page 770: ...iB andremovethe cover A installthecoverin the reverseorderof removal and notetheseitems Fitall the hooksof the headrest front trim intothe holesin theheadrest reartrim thenpushon the headrest trim un...

Page 771: ...ltbuckle seestep4 on page23 6 3 From undertheseatcushion detachthe side airbagconnectorclip and on the passenger s seat detachthe OPDSunitconnectorclip Release the hookspringsfrom the seatcushionframe...

Page 772: ...r r 8 Installthecover in the reverseorderof removal and notetheseitems To preventwrinkleswhen installlnga seat cushioncover makesurethe materialis stretchedevenlyoverthe pad beforesecuring theclipsan...

Page 773: ...i t h t h e c e n t e r s h o u l d e r b e l t m a k e s u r e t h e r e a r e n o twistsor kinksin the belt Makesurethe seat backs locksecurelv FastenerLocations A Bolt 2 B rBolt 1 C Bott 1 D Clip...

Page 774: ...pivot pin C of the latchlever D from the seat backf rame Fastener Locations lnstallthelatchin the reverseorderof removal and makesurethe seat back locksand unlocksproperly RearSeat back StrikerReplac...

Page 775: ...eedgeof the latchlevercover A to releasethe clips and release the coverfrom the pivotpins B ofthe latchlever C whilepulljng the latch lever FastenerLocations D Clip 2 i r rJ 20 82 5 On rightseat backi...

Page 776: ...ith centershoulder belt passthe centerbelt C throughthe holein the seat bacl cover lnstallthecoverin the reverseorderof removal and notetheseitems To preventwrinkleswhen installinga seat back cover ma...

Page 777: ...tcushioncoverall the way around and release the clips A then remove the seatcushioncover i w F 1 1 L t s i l 1 r l J l l 20 84 4 Installthecoverin the reverseorderof removal and notetheseitems To prev...

Page 778: ...Makesurebothfront sidemarkerlightconnectors are pluggedin properly Makesurethe front bumperengagesthe hooksof the sidespacersand upperbeamson bothsidessecurely Replace anydamaged clips Fastener Locat...

Page 779: ...reboth rearsidemarkerlightconnectorsare pluggedin properly M a k e s u r e t h e r e a r b u m p e r e n g a g e s t h e h o o k s o f t h e s i d e s p a c e r s s i d e b r a c k e t s a n d u p p e...

Page 780: ...he hoodhinge B Turnthe hoodedgecushions C as necessary to makethe hoodiit flushwith the body at the front and side edges 6 x 1 0 m m 9 8N m 1 0kgf m 7 2lbf ft Adjustthe hoodlatch D to obtainthe proper...

Page 781: ...ltipurposegreaseto eachlocationof the hoodlatchand hood hingeas indicatedby the arrows I 20 88 HoodSealReplacement 1 Usinga clip remover detachthe clips then remove the hoodseal A Takecarenotto scratc...

Page 782: ...Locations Clip 10 t 2V H Usinga clip remover detachthe clips Release the hooks B thenremove the hoodinsulator C Take carenot to scratchthe hood Installthe insulator inthe reverse orderof removal and n...

Page 783: ...l seepage20 52 4 Slightlylooseneachboltand nut 5 Adjustthehatch A alignment inthefollowing sequence Adjustthe hatchhinges B rightand left aswell asforwardand rearward usingthe elongatedholes T u r n t...

Page 784: ...9 1 0 HatchSupportStrut Replacement 1 With the helpof an assistant usea flat tip screwdriver A to pry the supportstrutclips B from eachend of the supportstrut C at the hatch and body then release the...

Page 785: ...Locate the painted alignment mark B onthehatch weatherstrip Allgn the paintedmarkwith the alignmenttab in the the centerof the hatchopening andinstall thehatchweatherstrip alltheway aroundin the dire...

Page 786: ...s necessary to a r r l i 7 a t h a n n c Tighten the hingemountingbolts Reinstallthe fuelfilldoorspring Checkthatthefuel fill door opensproperlyand lockssecurely and checkthatthe rearof the door is fl...

Page 787: ...ws C 2 Removethe clips D 3 Release the bottom hooks E ofthe grille 4 Pullout the boftomof the grilleto release the upperhooks F 5 Pulloutthegrilleto release the slits G from the ribs H then removethe...

Page 788: ...clips C by carefullypullingthe passenger s cowl cover D upward to release the hooks E and pull outthe coverforwardto release the hooks F then removethe cover Takecarenotto scratchthe body Detachthe c...

Page 789: ...he upperclip and detachthe clipby pryingon theA pillar cornertrim A Take carenot to scratchthe body and relatedparts Fastener Location Closethe door half way Pullthe A pillercornertrim A out to detach...

Page 790: ...bodv Pullup andslidethe roof moldingto release the front bracket D from the pin E Pullup the front portionof roof molding 4 Pullup and release the rearbracket A from the pin B then removethe roof mold...

Page 791: ...chlockcylinder B Fastener Locations Bolt 2 6 x 1 0 m m 9 8N m 1 0kgf m 7 2lbf ftl 20 98 3 Frominside thehatch release theclips A B while holding therearlicense trim C thenremove lhe trim Takecarenotto...

Page 792: ...ase theclips while pulling the hatchspoiler A away andrelease the fasteners B then removethe spoiler Takecare notto scratchthe body Fastener Locations Clip 2 t Installthe spoilerinthe reverse orderof...

Page 793: ...hereshown Wheninstalling thesidei VTEC emblemon the body alignthe application tapewiththeedgeof thewheelarch then pressthe emblem into place and removethe application tape 03model Wheninstalling the L...

Page 794: ...EM LEVEMBLEM Ontoinside face of the guarterglass REARSiREMBLEM ilg 1 93 t 50 CIVICEMBLEM Edgeofthe hatch SIDEi VTECEMBLEM 9 SIDE i WEC EMBLEM ADHESIVE TAPE Edge of the hatch RightSide 63 2 5 F l 6 l r...

Page 795: ...nd removethe clip E securingthe front air spoiler front bumper andfront innerfender 3 Fromthewheelarch remove theclips F G securing thefrontinnerfender andsplash shield onthebody 4 Release the hook H...

Page 796: ...heelarch removethe clip A and releasethe clip B then removethe front fender fairing C Fastener Locations A C l i p 1 B C l i p 1 J Installthe fenderfairing in the reverseorderof removal and notethesei...

Page 797: ...FastenerLocations Clip 4 4 Installthe protector inthe reverse orderof removal and notetheseitems Replace anydamaged clips Pushtheclipsintoplacesecurelv 20 104 RearAir OutletReplacement 1 Remove the re...

Page 798: ...l 1 HATCH HANDLE Replacement page 20 110 FUELFILLDOOROPENER Replacement page20 109 HATCHLATCH Replacement page20 110 FUELFILLDOOR LATCH page 20 107 FUELFILLDOOROPENEB CABLE Replacement page20 107 I O...

Page 799: ...hoodopenercable A from the hood latch B see removethe hood releasehandle D from the body Fastener Locations C B o l t 2 E C l i p 3 page20 108 and removethe bolts C then 6 x 1 0 m m 9 8N m 11 0 kgl m...

Page 800: ...necessary seepage20 55 Disconnect the fuelfill door openercable A from the opener B seestep3 on page20 109 Fastener Locations C Cushiontape 1 D Clip 1 E Clip 2 4 KCmodel Removethe leftmiddlefloorcros...

Page 801: ...latch Takecarenotto bendthe cable 6 x 1 0 m m 9 8N m 1 0kgf m 7 2lbf ft 20 108 Installthehood latchin the reverseorderof removal and notetheseitems Apply multipurposegreaseto eachlocationof the hoodla...

Page 802: ...filldooropener 6 x 1 0 m m 9 8N m 11 0 kgf m 7 2 lbf ft Removethe leftdoor silltrim seepage20 50i Remove theopener Alfromthe bolt B 2 3 4 Disconnect the fuelfill door openercable A then removethe open...

Page 803: ...properly 1 0kg m 7 2 tbt t a t 20 110 HatchLatchReplacement NOTE Puton glovesto protectyour hands 1 Removethe hatchlowertrim panel seepage20 53 2 Disconnect the hatchopenercable A cylinderrod B hatch...

Page 804: ...A Fromoutsidethe hatch removethe boltsecuring the lockcylinder A Frominsidethe hatch pull the lockcylinder out by releasing the hook B FastenerLocation Bolt 1 rS l u ar 6 x 1 0 m m 9 8 N m 1 0kgfm 7...

Page 805: ...em with new ones Reference holesalignment SUBFRAME REFERENCE HOLE Body Side INSTALLATION REFERENCE HOLE Subframe side INSTALLATION REFERENCE HOLE FRONTSUSPENSION SCREWDRIVER or TAPERED PUNCH INSTALLAT...

Page 806: ...the followingsequence to avoiddamageto the quarterpanel MIDDLE FLOOR CROSS MEMgER BRACE GUSSET SIDEFRAME STIFFENER 8 x 1 25 mm 29 N m 3 0kgf m 22 lbf ft U S model 10x 1 25 mm 38 N m 3 9kgf m 28lbf ftl...

Page 807: ...to13 0 51 Forengine mountrl3 0 51 Formanual transmission mouoto13 0 5 Formanual transmission mounto1310 5 Formanual t ansmission mo nt d13 0 51 o I g h Fordampermounts11 5 0 45 Fordampercentero78 3 07...

Page 808: ...981 Locatingholes20 0 79 Trailingarm center Reardampercenter Forupperarmo13 0 51 Fortrailingarmd13 0 511 Forupperarm bracketcenterrl5 0 59 Locating holes13 0 51 Foruppe armo13 0 511 Forrearlower arm...

Page 809: ...engine mount113 0 511 Formanual transmission mount013 0 51 Formanual trensmission mount613 0 51 Formanual trrnsmission mounro13 0 51 Fordampermounto11 5 0 45 Fordampercenterr78 3 07 Fordampermounto11...

Page 810: ...Locatingholer20 0 79 Trailingarm center Reardampercentel Forupperarmo13 0 51 11 t2 Fortrailingarms13 0 51 Forupperarm bracketcentero15 0 591 Locating holeo13 0 51 Forupperarmd13 0 51 Forrearlower arm...

Page 811: ......

Page 812: ...Troubleshooting 21 32 AirMixControl Motor TestandReolacement 21 34 ModeControl Motor TestandReplacement 21 35 Recirculation Control Motor TestandReolacement 21 36 Evaporator Temperature Sensor Reolac...

Page 813: ...HVAC Heating Ventilation andAir Conditioning SpecialTools Ret No ToolNumber DescriDtion Otv o 07sAz 001000A Backprobe Set 2 2 att KCe Tt t e t T 21 2...

Page 814: ...in theheater unit Beplacement page 2142 COMPRESSOR Beplacement page21 47 ClutchCheck page21 48 Clutch Overhaul page21 49 ThermalProtector Check page21 48 ThermalProtector Replacement page21 51 Relief...

Page 815: ...ocationIndex cont dl CONDENSER FAN Test page 22 51 RADIATOR FANRELAY Test page22 51 Tesl page 22 51 CLUTCH RELAY MOTOR RELAY Test page 22 5I UNDER HOOD FUSE RELAY BOX A C PRESSURE SWITCH RADIATORFAN t...

Page 816: ...ent page 21 39 RECIRCULATION CONTROL MOTOR Test page 21 36 Replacement page 21 36 MODECONTROLMOTOR Test page21 35 Replacement page21 35 AIRMIXCONTROL MOTOR Test page 21 34 Replacement page 21 34 POWER...

Page 817: ...iustbe oreyou reconnecteachline Before connecting anyhoseor line applya few drops of relrigerantoil to the O ring Whentightening or loosening a fitting usea second wrenchto supportthe matchingfitting...

Page 818: ...r 6x 1 0mm 9 8N m 1 0kgf m 7 2lbf ft Receiver lineA to the receiveilineB 13N m 1 3kgr m 9 4lbf ft Receiver lineB andthe suctionlineto the evaporator 6x 1 0mm 9 8 N m 11 0 kgf m 7 2lbf ft Suction line...

Page 819: ...nosis will begin About 10secondslater the self diagnosis will finishandthe A C indicatorgoesoff lfanytroubleisfound therecirculationindicatorblinksthediagnostictroublecode DTC toindicateafaulty circui...

Page 820: ...8 A shortln the air mix controlmotor circuit seeDaoe 21 16 9 A problemin theairmix control linkaqe door or motor seepaqe21 17 1 0 An openor shon in the modecontrolmotorcircuit seeoaqe21 18 1 1 A probl...

Page 821: ...uit Troubleshooting seepage21 28 Poorgroundat G301 Cleanliness andtightness of all connectors Bothfansdo not run with the A C on Radiator andCondenser Fans Common Circuit Troubleshooting see page 21 2...

Page 822: ...TU YEL BLK MODEVENT REAR WINDOWDEFOGGER RELAY OUTPUT INPUT BLK GROUND OUTPUT 1 4 BLK YEL lG2 Power INPUT B on Cavity Wire color Siqnal 1 T 2 3 BLIVRED REAR WINDOWDEFOGGER SWITCH LED INPUT 4 LT GRN A C...

Page 823: ...vehicleusesHFC 134a R 134a refrigerant which doesnot containchlorofluorocarbons Payattentionto the followingserviceitems Donotmix refrigerants CFC 12 R 12 andHFC 134a R 134a Theyarenotcompatible Useon...

Page 824: ......

Page 825: ...SWTCfi lG2 HoIii 0l lllll C F BLK RED rG2 I I I I I n G301 A C PnESSUEt swTOt t iCF RADIATOS oT0n NADIATOS tAl swtlcll j 19S F 193 C l CONDEN N MOTOB I 8u I I BLX I G301 l I IHEFMAI Y PBorEcro8 lTl n...

Page 826: ...ERATUNESENSOR sn 4 Lrenil ffftH F u YEUBLU YEL NED BED YEI RED 8LU WHT 8LU YEL GRN LTGRI l GNNMHT GRN YEL 8LK l coNNEcroFrir Pt f mxr EcroB 2P G5 1 8U I G602 m a c M DEF MODEl Mq EI M00 2 M00t3 MOOE3...

Page 827: ...oesaway replacethe originalair mix controlmotor lf the symptom indication continues substitutea known goodheatercontrolpanel and recheck lf the symptom indication goesaway replacethe originalheatercon...

Page 828: ...ontrol motor and recheck lf the symptom indication goes away replacethe originalair mix controlmotor lf the symptom indication continues substitutea known goodheatercontrolpanel and recheck lf the sym...

Page 829: ...ANEL CONNECTOR A 14PI 2 3 Wire side ol lemaleterminals ls therecontinuity YES Repair anyshorttobodygroundinthe wire s betweenthe heatercontrolpanelandthe mode controlmotor l NO Goto step5 HEATER CONTR...

Page 830: ...aregood substitutea known good modecontrolmotor and recheck lf the symptom indicationgoesaway replacethe originalmode controlmotor lfthe symptom indication continues substitute a known goodheatercont...

Page 831: ...connect the jumperwire 6 Disconnect the powertransistor4Pconnector 21 20 8 7 Checkfor continuitybetweenthe No 3 terminalof the powertransistor4Pconnectorand body ground POWERTRANSISTOR4PCONNECTOR Wire...

Page 832: ...trolpanelandthe powertransistor l 1 4 BLU YEL 15 l o 1 7 1 8 1 9 Reconnect heatercontrolpanelconnectorA 14P Testthe powertransistor seepage21 38 ls thepower transistorOK YES Checkfor loosewiresor poor...

Page 833: ...ketand body ground BLOWER MOTORRELAY 4PSOCKET ls therebatteryvoltage YES Goto step25 NO Repair openinthewirebetween theNo 14 fuseintheunder dash fuse relay boxandthe blowermotorrelay I 21 22 25 26 Tur...

Page 834: ...thin thespecificationsshown on thegraph YES Go to step3 NO Replace the evaporatortemperature sensor I 3 Disconnect heatercontrolpanelconnectorB 22P 86 F 30 c Terminal sideof maleterminals 4 Checkfor c...

Page 835: ...NO Reoairooen in the wire betweenthe heater controlpanelandthe evaporatortemperature sensor I 21 24 4 DTC15 A ShortintheEvaporator Temperature Sensor Circuit 1 Removethe evaporator temperaturesensor...

Page 836: ...controlmotor OK YES Goto step7 NO Replace the recirculation controlmotor or repair the linkage anddoors I Disconnect heatercontrolpanelconnectorA 14P 5 6 8 Checkfor continuitybetweenthe No 5 and No 6...

Page 837: ...A 14P Wiresideoltemale terminats RECIRCULATION CONTROL MOTOR 5PCONNECTOR Wiresideol lemale terminals ls there continuity YES Checkfor loosewires or poor connections at heatercontrolpanelconnectorA 14...

Page 838: ...wire betvveen the No 14 fuse in the under dash fuse relaybox andthe heatercontrolpanel l Turnthe ignitionswitchOFF 6 Checkfor continuitybetweenthe No l3terminal of heatercontrolpanelconnectorA 14P an...

Page 839: ...terminalof the condenserfan relay4Psocketand body ground CONDENSER FAN RELAYilP SOCKET ls thete battery voltage YES Go to step4 NO Replace the under hood fuse relaybox l 21 28 4 Connect the No landNo...

Page 840: ...ns CommonCircuitTroubleshooting NOTE lf bothfansandthe Ay C compressorclutchdo not work when the Ay C switchis on go to Ay CPressure SwitchCircuitTroubleshooting seepage21 32l 1 Checkthe No 1 20A and...

Page 841: ...y box andthe No 14 10A fuse inthe under dash fuse relaybox Are the tuses OK YES Goto step2 NO Replace the fuse s and recheck I 2 Checkthe enginecoolanttemperature the throttle positionsensor andthe id...

Page 842: ...e ignitionswitchOFF 10 Reinstallthecompressorclutchrelay 11 l 4ake surethe Ay C switchis OFF 12 Turnthe ignition switchON ll 13 Uslngthe Backprobe Set measurethe voltage betweenthe No 18termina of ECI...

Page 843: ...the wire betweenthe compressorclutchrelayandthe compressor clutch l 21 32 A C Pressure SwitchCircuit Troubleshooting 1 Turnthe ignitionswitchON ll 2 Turnthe blowerswitchon and checkfor blower motor o...

Page 844: ...d lf no codesarefound subsititutea known 9ood multiplex controlunitanda ECMoneat a time Disconnect the Ay C pressureswitch2Pconnector and under dash fuse relayboxconnectorF 12P 1 0 13 21 33 11 Checkfo...

Page 845: ...runssmoothly go to step3 AIRMIXCONTROL MOTOR 3 4 Measurethe resistance betweenthe No 4 and No 5 terminals lt shouldbe between2 1kto 3 9k Q Reconnect the air mix controlmotor 5Pconnector thenturnthe ig...

Page 846: ...modecontrolmotor runssmoothly go to step4 Usea digitalmultimeterwith an outputof 1 mA or lessat the 20 kQ range With the modecontrol motor runningas in step2 checkfor continuity between the No 4 5 6...

Page 847: ...t cyclethe recirculation controlmotor or a longtime RECIRCULATION CONTROL MOTOR lf the recirculation controlmotor doesnot run in step2 removeit then checkthe recirculation controllinkageand doorsfor s...

Page 848: ...efullypull outthe evaporator temperature 4 Installthe sensorin the reverseorderof removal Evaporator Temperature Sensor Test l Dipthe sensorin icewater and measurethe resistance betweenitsterminals EV...

Page 849: ...upply12voltsto the No 4 cavitywitha jumper wire Turnthe ignition switchON ll andcheck thatthe blowermotorruns lf the blowermotor doesnot run replacethe powerrranstsror lfthe blowermotorruns thepowertr...

Page 850: ...tersin the reverseorderof removal BlowerUnitRemoval and lnstallation Forsome models SRScomponentsare locatedin this area Reviewthe SRScomponentlocations seepage 23 13 and precautions and procedures se...

Page 851: ...r then removethe wire harnessclips B andthe connectors C Removethe self tapping screwsandthe bracket D A 21 40 10 Disconnectthe connector A from the recirculation controlmotor then removethe wire harn...

Page 852: ...rolmotor A the powertransistor B the blowermotor C andthe dustand pollenfiltefs D canbe replacedwithout removingthe blowerunit Beforereassembly makesurethatthe recirculation controllinkageanddoorsmove...

Page 853: ...hout bendingthe pipes Installthecore in the reverseorderof removal and notetheseitems lfyou re installinga new evaporatorcore add refrigerant oil KElHlN SP 0 seepage21 6 Replace the O ringswith new on...

Page 854: ...the heatervalvecable B from the heatervalvearm C Turnthe heatervalvearm to the fully openedpositionasshown Whentheengineis cool draintheengine coolant from the radiator seepage10 6 6 Slidethe hosecla...

Page 855: ...ontrolmotor then removethe wire harnessclips B andthe connector C Removethe self tapping screwand the cover D Disconnect the heatervalvecable E 10 7 t 21 44 11 Remove the mounting bolts themountingnut...

Page 856: ...tallthehoseclampssecurely Refillthecoolingsystemwith enginecoolant see page10 6 Adjustthe heatervalvecable seepage2 l 461 Makesurethatthereis no coolantleakage Makesurethatthereis no air leakage Refer...

Page 857: ...llinkage C t l r2t Setthe temperaturecontroldialon Max Coolwith the ignitionswitchON ll Attachthe heatervalvecable B to the air mix controllinkage C as shownabove thensnapthe heater valvecablehousing...

Page 858: ...inthe reverse orderof removal and notetheseitems Beforeinstallingthe new compressor checkfor metalor othercontamination inthe line Replace any contaminated parts lf you re installinga newcompressor y...

Page 859: ...ge21 49 and add or remove shimsas neededto increaseor decrease clearance Clearance 0 510 15mm 0 02010 006 in NOTE Theshimsareavailable infourthicknesses 0 1m m 0 2m m 0 4m m a n d0 5m m 21 48 a 4 Rele...

Page 860: ...essof shimsas necessary then reinstallthearmatureDlate and recheckits clearance seepage21 481 NOTE Theshimsareavailable in fourthicknesses 0 1mm 0 2mm 0 4mm and0 5mm 9 g 3 lf you are replacing the fie...

Page 861: ...gnthe bosson the fieldcoilwith the holeinthecompressor Cleanthe rotorpulleyandcompressorsliding surfaceswith contactcleaneror other non petroleum solvent Install newsnaprings notethe installation dire...

Page 862: ...7 4N m 0 75kgf m 5 rbf ftl Compressor ReliefValve Replacement 2 1 4 Recover the refrigerant with a recovery recycling chargingstation seepage21 53 Removethe reliefvalve A andthe O ring B Plug the open...

Page 863: ...r finswhenremovino the condenser 6 x 1 0 mm 9 8N m 1 0 kgf m 7 2tbl ftl 5 lnstallthe condenser inthe reverse orderof removal and notetheseitems lf you reinstalling a newcondenser add refrigerant oil K...

Page 864: ...occurs ventilatethe work areabeforeresumingservice Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricant manufacturers 1 l r i t i r 1 Connecta R 134a refrigerantrecove...

Page 865: ...cycling charging station lfthe system hasbeenopenfor severaldays the receiver dryer shouldbe replaced andthe systemshouldbe evacuated for severalhours Air conditioningrefrigerantor lubricantvapor can...

Page 866: ...nnecta R 134a refrigerantrecovery recycling charging station A to the high pressure service pon B andthe low pressure serviceport C as shown followingthe equipmentmanufacturer s instructions 2 3 4 Eva...

Page 867: ...ent or vehicle airconditioning systemsshouldnot be pressure testedor leaktested with compressedair Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricant manufacturers 2...

Page 868: ...Frozen evaporator Runthefanwith compressor off then checkevaooratottemoerature sensor Exoansion valveisfrosted eanor reolace Receivetdryer outletiscool andinlet iswarm should bewarmduring ooeralton C...

Page 869: ...rviceport andthe low pressure serviceport followingthe equipmentmanufacturer s instructions Determine the relative humidityandair Iemperaru re Compressed air mixedwith R 134a forms a combustiblevapor...

Page 870: ...temperature The delivervtemperature shouldfall betweenthetwo lines Completethe low sidepressure testand high sidepressure testin the sameway Anv measurements outsidethe line may indicatethe needfor fu...

Page 871: ...74 22 79 22 AO 22 41 22 82 22 42 22 43 22 43 22 44 22 84 22 85 22A6 22 87 22 88 22 104 22 105 22 106 22 107 EntryLightscontrol system Component Location Index 22 89 Circuit Diagram 2290 lgnitionKeySwi...

Page 872: ...ircuit Diagram 22 149 AccessoryPowerSocket TesVReplacement 22 1 49 Keyless Power Door Lock System Component Location Index 22 150 CircuitDiagram 22 151 Keyless Receiver UnitInputTest 22 153 ControlUni...

Page 873: ...BodyElectrical SpecialTools Ref No ToolNumber Description Otv Q o o 07wAz 001010A O7 LAJ PT3 O 2OA 07TAz 001020A MPCSServiceConnector 1 TestHarness 1 BackProbeAdaotet 1 22 2...

Page 874: ...esurethe connectors arecleanand haveno loosewireterminals Makesuremultiplecavityconnectors are packedwith dielectricgrease exceptwatertight connectors All connectorshavepush downreleasetype locks A So...

Page 875: ...s Securewires andwire harnesses to lhe frame with their respective wire tiesat the designated locations Removeclipscarefully don tdamagetheir locks A Slippliers A undertheclipbaseandthroughthe holeat...

Page 876: ...t no wiresare oinched underthem When usingelectricaltest equipment followthe manufacturer s instructions andthosedescribedin thismanual lf possible inserttheprobeof thetesterfromthe wire side exceptwa...

Page 877: ...heckthe diagnosisyou made in step2 Keepin mindthata logical simple procedureis the keyto efficienttroubleshooting Testfor the most likelycauseof failurefirst Try to maketestsat pointsthat areeasilyacc...

Page 878: ...RelayandControlUnit Locations Engine Compartment RADIATOR FAN RELAY BLOWER MOTOR RELAY HORNRELAY CONDENSER FAN RELAY UNDER HOOD FUSE RELAY BOX 1 ELDUNIT 22 7...

Page 879: ...ecolorsr RED RED YEL I LRED BLK andRED 8LU I _LOW BEAMCUTRELAY lcanada _ lWirecolors REDMHT RED BLK I LBEDA EL andRED BLU I KEYLESS RECEIVER UNIT CRUISE CONTROL UNIT POWERWINOOWRELAY TURNSIGNAL HAZARD...

Page 880: ...cont d 22 9...

Page 881: ...cont d L SRSUNIT EPSCONTROL UNIT PGM FI MAINRELAY 1 lWirecolors YEUBLK LWHT BLK WHT BLK andRED YEL PGM FI MANRELAY 2 fwirecolors YEUBLK I LYEUGRN YEUBLKandGRN YEL I AIR FUEL RATIO SENSOR RELAY Wire co...

Page 882: ...arandRoof MOONROOF OPEN RELAY Wirecolors GRNI EL GRN I LRED YEL BLK andYEL GRN I MOONROOF CLOSE RELAY REAR WINDOWWIPER INTERMITTENT CONTBOL UNIT fwirecolors GRN BLK GRN l IGRN AtVHT BLKandYEL GRNI 22...

Page 883: ...Relay andControlUnitLocations DoorandSeat Driver sDoor Passenger s Seat l POWER WINDOWMASTER SWITCH lHasbuilt in control unit 22 12...

Page 884: ...G402 seepage22 18 EPS subharness C 1 5 1a n dC 1 5 2 G 151 seepage22 241 Dashboard wireharness A lleftbranch C504 through C510 G501 andG503 seepage22 26 Leftsideturn signallight c506 seepage22 26 Dash...

Page 885: ...3 Leftsideof enqinecompartment Leftsideof enginecompartment Bodygroundviabattery qround car le 2 Batterv Battervneoativeterminal EngineGroundCable Connector or Terminal Cavities focation Connec sto No...

Page 886: ...Middleof enginecompartment Frontof enginecompartment Frontof engane compartment Engine wireharness see page22 16 Engine wireharness see oaae 22 16 T1 r2 2 4 L ttsideof enginecompartment Middleorenoin...

Page 887: ...gine Under glovebox Underglovebox Leftsideof engine BightsideoI engine Leftsideof intakemanifold Leftsideof intakemanifold Middleof engine compartment Middleof engine compartment Middleof engine compa...

Page 888: ...1 0 1 1 1 3 1 4 22 17...

Page 889: ...wash rfluidlevel switch Windshield washer motor 8 1 2 1 1 0 1 1 2 7 2 2 2 2 2 2 I 2 2 Bightsideo engine compartment Behind rightsideof rontbumper Rightsideot engine compartment Behind rightsideof fron...

Page 890: ...ENGINE COMPARTMENT WIRE HARNESS cont d 22 19...

Page 891: ...Under hood fuse relay box Frontof engine companment Leftsideof engine compartment Leftsideof engine compartment Leftsideo engine compartment Frontof engine compartment Underrightsideof cowlcover Unde...

Page 892: ...l ENGINECOMPARTMENTWIRE HARNESS conr d 22 21...

Page 893: ...dermaddle of dash Underleftsideof dash Underleftsideof dash Underleftsideof dash Underleftsideof dash Underleftsideol dash Underrightsideof dash Underrightsideot dash Underrightsideot dash Underrights...

Page 894: ...D i ifa j 1_ 1 g t a UNDER DASH FUSE RELAY BOX ENGINE COMPARTMENT WIRE 22 23...

Page 895: ...nector B EPS control unitconnector C EPS motor EPS torquesensor c 1 5 1 c152 2 l 3 1 6 4 2 2 20 2 6 2 I Underrightside ofdash Underrightsideof dash Underrighrsideof dash Middleof engine companment Mid...

Page 896: ...EPSSUBHARNESS 22 25...

Page 897: ...dash 14 Underlettsideof dash 4 Underlettsideof dash 22 I Behind gauge assembly 22 i Behind gauge assembly 10 Behind hazard warnning switch 22 Behind heater control panel 14 Behind heater control panel...

Page 898: ...DASHBOARD WIRE HARNESS A 1 9 20 34 I LEFTSIDETURN SIGNALLIGHT SUBHARNESS u 2s t 30 cont d 22 27...

Page 899: ...h Engine compartment wire harness seepage22 18 Engine companmentwire harness see page22 18 Engine compartment wire harness seepage22 18 Engine compartment wire harness seepage22 18 ECN4 wireharness se...

Page 900: ...DASHBOARO WIBE HARNESS A T I 22 29...

Page 901: ...relay box connectorX see page2245 c401 c402 c403 G510 reel 2 1 1 7 1 6 t9 1 8 I 3 5 6 1 8 1 0 1 2 1 1 1 4 5 4 1 1 4 1 8 1 4 5 6 1 4 2 8 1 0 4 1 2 Insteering column cover Insteering column cover Inste...

Page 902: ...OASHBOARD WIRE HARNESS B 22 31...

Page 903: ...2 3 4 1 I I 1 0 1 4 1 2 4 4 6 20 8 4 6 Eehind glovebox Undermiddleof dash Behind glovebox Behind glovebox Behind glovebox Intheunder dash fuse relay box Intheunder dash fuse relay box Intheunder dash...

Page 904: ...ECMWIREHARNESS 22 33...

Page 905: ...2 1 4 1 6 3 I Underdriver s seat 2 i Underdriver s seat 2 I Leftsideoffloor 4 Underdriver s seat 2 Underdashfuse relay box 1 1Middleoffloor 3 Underpassenger s seat 2 Underpassenger s seat 2 Rightsideo...

Page 906: ...10 1 1 FLOOR WIREHARNESS cont d 22 35...

Page 907: ...or Rightrearsidemarker light Rightrearspeaker Right sideseatbelttensioner c554 Fueltank Fueltank Fueltank Lefttaillight Leftrearoffloor Behind leftsideof rearbumper Leftquarter panel Lefttaillight Lef...

Page 908: ...FLOOR WIREHARNESS 22 37...

Page 909: ...roof motor Moonroot openrelay Moonroof position sensor 1 N4oonroof positionsensor2 Moonroofswitch Rear ceiling light SpotlighVceiling light c507 6 I 7 8 5 1 2 1 0 5 5 2 5 2 4 5 3 4 8 Middleof roof Mid...

Page 910: ...nectorB Rear windowde ogger connector A Bear windowdetogger connector B Bear window wiper moto c553 c554 7 8 I 3 1 0 6 2 l 2 2 2 2 2 1 1 4 12 2 Middleo hatch Middleof hatch Behind highmountbrake light...

Page 911: ...kswitch Driver s doorspeaker Driver spowerwindow motor Leftpowermirroractuator Lefttlveeter Powerwindow masterswitch c504 c505 9 1 0 1 7 2 3 8 5 6 2 3 3 2 6 2 20 t3 Driver s door Driver s door Driver...

Page 912: ...tor Passenger s powerwindowswitch Rightpowermirroractuator Righttweeter c514 6 I 5 1 4 3 2 1 2 2 2 5 6 2 1 3 6 Passenger s door Passenger s door Passenger s door Passenger s door Passenger s door Pass...

Page 913: ...ctor to Harness lndex cont dl OPDS Unit Harness Connoctor orTorminal Cavitios Location Connectsto Notes OPDS unit 2 1 I Infrontpassenger s seat Under frontpassenger s seat Floor ware harness seepage 2...

Page 914: ...lation control motor c851 c852 c853 I 2 8 3 4 1 1 6 5 5 2 2 1 0 5 1 21 Undermaddle of dash Underrightsideof dash Undermiddleof dash Underrightsideof dash Underrightsideof dash Underrightsideof dash Un...

Page 915: ...ay Radiator fan relay Rearwindow defoqqerrelay 1 4 2 1 5 9 1 1 1 t o 5 6 1 0 l J 2 4 5 4 4 1 4 7 3 4 4 4 4 Enginecompartmentwire harness seepage22 18 Enginecompartmentwire harness seepage22 18 Enginec...

Page 916: ...inecompartmentwire harness see page22 181 Engine compartment wire harness seepage22 18 Enginecompartmentwire harness see page22 18 Enginecompartmentwire harness seepage22 18 Dashboard wire harnessA se...

Page 917: ...rolunit 9 10A WHT RED Audiounit Datalinkconnector DLC Gaugeassembly lmmobilizer controlunit receiver lmmobilizerindicatorlight Keylessreceiverunil lvlultiDlex controlunit 1 0 40A WHT REDABSmodulator c...

Page 918: ...tcontrolunit 1 0 7 54 YEL Back uplights Cruiseindicatorlight EPScontrolunit Gaugeassembly Keylessreceiverunit Multiplexcontrolunit Securitycontrolunit connector optional 1 1 7 5A BLIVORN ABS modulator...

Page 919: ...wasfrer sr virch G402 Leftand riqhtairbaqsensors SRSunit G451 Datalinkconnector DLC G501 ClutchinterlockswitchmClutchpedalpositionswitch forcruisecontrol Cruisecontrolmain switch Cruisecontrolunit Da...

Page 920: ...sesideof the under dash fuse relaybox 5 Removethe mountingbolt and slidethe under dashfuse relaybox A down from the bracket B 6 Disconnect the backsidefrom connectors from the backof the under dash fu...

Page 921: ...the surfacecharge 5 Wait 15seconds then applya testloadof 280amps for 15seconds 6 Recordbatteryvoltage lf voltageis above9 6volts the battery isOK l lf voltageis below9 6volts gotostepT 7 Charge the b...

Page 922: ...t relaV Daytime runninglightsrelay Canada PGM FI mainrelav 1 PGM Fl mainrelav2 Blowermotor relav Normally open tvpe B Rearwindow defoqoerrelav Moonroofcloserelay Fiveterminal type MoonroofoDenrelav Lo...

Page 923: ...itybetweenthe No l and No 3 terminalswhen power is disconnected Blower motor relay type 1 type2 tF gr t J 1 l Rearwindow defonn O 6 rc V r n Ft s3 22 52 Five terminal type Check for continuity between...

Page 924: ...ver see page20 59 2 Disconnect the 5Pconnectorfrom the under dash fuse relaybox WHT RED Wiresideof female terminals BLK WHT BLK YEL BLK RED Checkfor continuitybetweenthe terminalsin each switchpositio...

Page 925: ...ILPRESSURE SWITCH page 8 4 GAUGEASSEMBLY SelJ diaqnostic Procedure page22 56 Gauqedulb Replacement page22 63 Rep6cement page22 64 CoolantTemperature Gauge TroLrbleshooting page22 64 BRAKE FLUIDLEVEL S...

Page 926: ...CONNECTOR A bluel CONNECTOR B lgreenJ SPEEDOMETER Vehicle Speed Signal Circuit Troubleshooting page 22 65 TACHOMETEB FUEL GAUGE Test page11 156 7 t i _ _ ODO TRIP METER 22 55...

Page 927: ...ng switchOFF thenON andOFFagain 5 Within 5 sec release the trip resetbutton then pushand release the buttonfour times reDeatedlv NOTE While in the self diagnosis mode the dashlightsbrightnesscontrolle...

Page 928: ...Self diagnosis mode Trip Reset switch ON OFF ON r r r r r r 1 r r r r lll u u l_lL__l I l l 5 sec Faulty The needles sweepfrom the minimum positionto the maximum position then return to theminimumposi...

Page 929: ...Gauges CircuitDiagram No20ioAl USA ECM PCM V I r r l l J I ii ciorurnn I 8 coNNECron Norll0AlFUSE UflOENfiOOO FUSE 8ILAY 8OX COOLANI TEMPfNAIUFT SPIEDOMEIEN TACHOMEIIR FUTLGAUGI GAUGE 8L o 22 58...

Page 930: ...ti lTomxr I MAi IIiIANCE ft0unlD 0tcaTo8 LIGH LEDI cont d 22 59...

Page 931: ...J a Gauges I No2il5AlFUSE ilnlh undi hooq DASH llu rcl ybox r LGHTS Y Y t l t l CircuitDiagram cont dl ls 2 I BLUIYEL I J cSutsE m n0L t WASHEF Itut0 I VEL 6t0tcToR UGHT tDl 22 60...

Page 932: ...t I DAYTIME I BUNN NG i LIGHTS I I NTROL I UNII i L I icmadd ib n rnoL tNGniEorL UNIT PRESSUBE swtTcH lCld d Eisin 3topp d l iopd Ersin runni s i cont d 22 61...

Page 933: ...rcuitDiagram cont dl CoME NAT ON tMf tOBtUZEn LtctlTswtTclt l tTRoL UN I ftCtIVER GRNIfiED I 7 V LEFTTUN SIGI IAL II DICATOR GAUGIASSEi BLY LTCHTS HIGHSEAM IMMOBITIZER ltDtcATon r tilucaToB f il vll9i...

Page 934: ...lacement CRUISE HIGHBEAMINOICATOR LIGHT 1 4W ITOR LIGHT I 4W LEFT TURNSIGNALINDICATOR LIGHTl1 il wl GAUG LIGHT 1 4 WI IMMOBILIZEN INDICATOR LTGHT 1 4 Wl GAUGELIGHT 1 4W RIGHTTURN SIGNALINDICATOR LIGHT...

Page 935: ...multiplexcontrolunitDTC seepage 22 168 ls a DTC indicated YES Troubleshooting the causeof the multiplex controlunitDTC seepage22 168 and recheck NO Goto step3 3 Dothecommunication linecheck withthese...

Page 936: ...ness clipandbodyground ls there continuity YES Goto step5 NO Repair openin the BLKwire between theVSS a n dG1 0 1 I 3 4 5 Connectthe WHTtest harnesscliD B to the positiveprobeof a voltmeter and connec...

Page 937: ...Does voltage pulse ttom 0 to about 5 V ot morc YES Goto step14 NO Replace the VSS I t2 t 5 22 66 14 Disconnect the 22Pconnector 8 from the gauge assemDry GAUGE ASSEMBLY CONNECTOR B 22P Wiresideot fem...

Page 938: ...J VSSReplacement 1 Removethe intakeresonator 2 Disconnect the 3Pconnectorfrom the vehicle speedsensor VSS A 4 Removethe mountingbolt then removethe VSS lnstalltheVSSin the reverseorderof removal 22 6...

Page 939: ...ment page22 81 HEADLIGHT RELAY 1 Test page22 51 HEADLIGHT RELAY 2 Test page22 5 l 0 FRONT SIDEMARKER LIGHT BulbReplacement page22 83 BRAKEPEDALPOSITION swtTcH Test page22 84 Adjustment pagel9 6 SIDETU...

Page 940: ...t page 22 83 HIGHMOUNTBRAKE LIGHT Replacement page 22 82 LICENSE PLATE LIGHTS Replacement page 22 83 BACK UPLIGHT Replacement page22 82 TAILLIGHTSsnd BRAKELIGHTS Replacement page22 82 REAR TURNSIGNALL...

Page 941: ...BEAMCUTRELAY Canadal_ Wirecolorsr REDMHT RED BLK I LREDryEL andRED BLU I Test page22 51 DASHLIGHTSBRIGHTNESS CONTROLLER COMBINATION LIGHT SWITCH TesVReplacement page 22 80 oAYTIME RUNNINGLIGHTSCONTROL...

Page 942: ...I ucEr 6E I PI ATE fiIli I 8L l _o IETT NEANSIDE MAircN IIGHT f IGHT TSONT s 0E MANXtF IJGIIT LET FBOIII SIDE MAiKEE L IGHT 22 71...

Page 943: ...I BED ED RED I I 2 I 01 I fifili 1l H I I I tU RED l _ l orrro INDICAIOF l lcli BLU l RE A DNL No12 i l7 5Al DAYTIME BUNNINC LIGHTS EfLAY y I I HT BI I n TIGHT luDl 12 RE t0 t1 t l T oorr rr ro r I I...

Page 944: ...LAII I LIGNTS twr2l 8LI I I G552 NEHI IAILUOHI RIGHT RIAF SIDI I IAFrc8 UCHT LEFT BEAF SIDE LJGHT LEFT TAIILGlT FIGIIT FBONT SIDE MAfircF LJGHT l5w BIGHT PANKNG LIGIIT TTFT TRONT 3r0E MABKER LIG IT LE...

Page 945: ...Exterior Lights CircuitDiagram BrakeLights UiDENHOOD FUSE NEUYBOX SATIISY I r o7l15A r T v rrni citr 22 74...

Page 946: ...CircuitDiagram Back upLights UiDEN H DFUSI 8EIAY 80 22 75...

Page 947: ...do the controlunit inputtest NOTE Whenthedaytimerunninglightsareon the highbeamindicator will glowat halfitsnormalintensity 1 Removethe driver sdashboardlowercover seepage20 60 2 Disconnectthe l4Pconn...

Page 948: ...nlightswitch An open in the wire 1 RED B LU Combination lightswitchON iD and dimmer switch i n H I G H Connecta jumperwire between No 3 andNo 1terminals Bothheadlights HIGH and highbeamindicator light...

Page 949: ...Thedriverorsomeone whoweighs thesameshould sitinthedriver s seat 1 Cleanthe outerlenssothatyou canseethe center of the headlights A Headlights becomevery hot duringuse do not touchthem or any attachin...

Page 950: ...necessary adjustthe headlights to local requirements by turningthe verticaladjuster i HeadlightReplacement Removethe front bumper seepage20 85 Disconnect the connectors A from the headlight B Removet...

Page 951: ...reall makinggoodcontact lf the terminalsare bent looseor corroded repair them as necessa ry and recheck the system l f t h e t e r m i n a l s l o o k O K c h e c k f o r c o n t i n u i t y b e t w e...

Page 952: ...new bulb in the reverseorderof removal Makesurethe notchesin the bulb alignwith the tabsln theheadlight 2 FrontTurnSignalLight Parking Light 1 Remove the innerfender seepage20 102 2 Disconnectthe con...

Page 953: ...rclockwise to removethe bulbsocket When installingthe taillight checkthe gasket if it is distortedor stayscompressed replaceit After installingthe taillight run wateroverthe taillightto makesureit doe...

Page 954: ...2 3 4 J f t lo tiP t J f l Separate thelens B andhousing C thenremove the bulb lnstallthe lightinthe reverse orderof removal SideMarkerLightReplacement 1 Carefully prythelight A outoftherearbumper and...

Page 955: ...ed Checkfor continuitybetweenthe No 3 and No 4 terminals withcruisecontrol Thereshouldbe no continuity whenthebrake pedalis pressed Thereshouldbecontinuity whenthe brakepedal is released lf necessary...

Page 956: ...RN SIGNAL SWITCH Test page 22 80 Beplacement page 22 80 TURNSIGNAL INDICATOR LIGHTS lnthegauge assembly BulbReplacement page 22 63 HAZARD WARNINGSWITCH Test page 22 88 Replacement page 22 88 TURNSIGNA...

Page 957: ...TurnSignal Hazard Flasher UNDff HOOD FUSUftIIY 8OX Circuit Diagram No20lr0A USA Ut toEB DASH No 2 l50A Cmada TUSVRILAY 8OX J INDICATON IIGHT 11 1W fiIGHT T FBONT 22 86...

Page 958: ...be continuiw Poor ground G201 Anooeninthewire 3 lgnitionswitchON ll Hazard warningswitch OFF Checkfor voltageto ground Thereshouldbe batteryvoltage Blown No 19 7 5A fusein the under dash fuse relaybox...

Page 959: ...onnector A from the hazard warningswitch B 4 Pushout the hazardwarningswitchfrom behind thecenterpanel C Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table lf the conti...

Page 960: ...ONKEYSWITCH lest page22 91 DRIVER SDOORSWITCH CEILING LIGHT SPOTLIGHTS Test page22 96 Replacement page22 96 REAR CEILING LIGHT Test page 22 96 Replacement page 22 96 FRONTPASSENGER S DOORSWITCH HATCHL...

Page 961: ...0A USA CircuitDiagram CEILING UGHT Y I I J j IGNIlx N KEY SWtTCH PASSTNGERS DOOB SWITCH i9r d l ORIVEBS DOOR SWITCH DtrVTN S DOOR Locx NOB s t tTc8 l BU I G t lGlHoTin 0Nilll nd STAnT 0D EiIIpN SMTqI...

Page 962: ...upperand lower covers seepage 17 9 2 Disconnect the 6Pconnector 3 Checkfor continuitybetweenthe No 1 and No 2 termrnars Thereshouldbe continuitywith the keyin the ignitionswitch Thereshouldbe no conti...

Page 963: ...BOXCONNECTOR K Il7PI UNDEB DASIJ FUSE RELAY BOXCONNECTOR O I2PI UNDEB DASH FUSE RELAY BOXCONNECTOR P 18PI GRN LTGRN REO UNOER DASH FUSE REI AY BOXCONNECTOB X I8PI 1 1 3 4 5 7 8 8ED WHT WHT BLK UNDER D...

Page 964: ...sired result Posq c sq ej1 9 j d P 1 8 RED Hatchopen Checkfor voltageto ground Thereshould be 1 V or less Poorground G552 Fauhy hatch latchswitch An openinthewire Hatchclosed Check forvoltage to groun...

Page 965: ...cationIndex CEILING LIGHT SPOTLIGHTS Test page 22 96 Replacement page22 96 REAR CEILING LIGHT Test page 22 96 Replacement page 22 96 v J HATCHLATCHSWITCH Test page22 97 CARGO AREALIGHT fesl page 22 97...

Page 966: ...CircuitDiagram STAB ctu G LIGHT MUITIPLEX c0NTlot UIIIT J HATCH LATClI swtTcH 22 95...

Page 967: ...o a 4 o SPOTLIGHTS I Ceilinq lioht r o F F i R ON o F O OFF L ON G OFF lf the continuityis not asspecified checkthe bulb lf the bulbis OK replace theceilinglighvspotlig hts 22 96 1 2 3 4 RearCeilingL...

Page 968: ...f thereis no continuitv checkthe bulb lf the bulb is OK replacethe cargoarealight 1 HatchLatchSwitch Test Openthe hatch Removethe hatchlowertrim panel seepage20 s3 Disconnect the 2Pconnector A from th...

Page 969: ...0 Connector Terminals pa ge 22 101 RIGHT DOOB TWEETER Replacement page 22 102 ANTENNASUB LEAD DRIVER S DOOR SPEAKER Replacement page 22102 ROOFANTENNA Replacement page22 1 03 RIGHT REAR SPEAKER Replac...

Page 970: ...iagram No 20ioA USA 8AT F f t WHT FED ACC ACC HoTinACC lllmd0Nllll AUDIO UflIT t r a r r a O e a DRIVER S DOORSPEArcF IEFITWEETER PASSE GIF S SIGIITTWEETEB DOOB SPEAKES LEFTFEAB NrcBTREAF SPEA I8 SPEA...

Page 971: ...ll out the centerpanel A 4 Disconnect the audioconnector B and antenna lead C heatercontrolpanelconnectors D and HAVCpushswitchassembly E then removethe centerpanel 22 100 7 Removethe heatercontrolpan...

Page 972: ...eaker Riqhttweeter 8 GRN BLK Driver sdoor speaker Lefttweeter 9 RED BLK Liqhtson siqnal 1 0 WHT RED Constantpower 1 1 Not used 12 Not used Not used 1 4 Notused t a BLU YE L Riohtrearsoeaker t o BLU BL...

Page 973: ...o far you will damagethe lowerclips C Thenlifi the speakerstraightup to release the lowerclips 3 Disconnect the 2Pconnector B and removethe speaKer Tweeter Carefullypry the tweeter A out of the mirror...

Page 974: ...RoofAntennaReplacement 1 Removethe rearpartof headliner seepage20 54 2 Disconnect the antennaleadconnector A and 1P connector B from the roof antenna C 3 Removethe mountingnut andthe antenna 22 103...

Page 975: ...witchis builtintothe heatercontrolpanel UNDER HOOD FUSE RELAY BOX REAR WINDOW DEFOGGER SWITCH t REAR WINDOWDEFOGGER RELAY Test page 22 51 u NOISE CONDENSER CapacityTest page 22 107 REAR WINDOWDEFOGGEB...

Page 976: ...t J Circuit Diagram J Hl lj fl 1fl1fi BEATERcoNrf oLpANrL T f rAiwrxDow 74 DEfOGGES I SWrcfl iP INDIATOR L ILEDI 22 105...

Page 977: ...intof eachdefoggerwire andthe negative probeto the negativeterminal Thereshouldbe about6 V with the ignitionswitch andthe defoggerswitchON lf thevoltage is asspecified thedefoggerwlre is oK lf the vol...

Page 978: ...Pconnector A from the noise condenser Noise condensercapacity 0 47 a 0 09microfarads Wiresideolfemale terminals 4 Usea commerciallyavailablecondensertester Connectthe condenser testerprobes andthe mea...

Page 979: ...ement page 22 1 12 Test page22 112 Replacement page 20 41 MOONROOFLIMITSWITCH Test page22 113 MOONROOFAUTO STOPSWITCH Test page22 113 MOONROOF OPEN RELAY lwirecolors GRN YEL GRN I LRED YEL BLK andYEUG...

Page 980: ...lOAl US No 20150 Canda A Clos dfom lh ruto nop poshio tolh doed porhion B Clo d inth lilt ordo3 d poilion C Clo d inanyop n io riltl posirion D Clos dinth tilt po6iiion UNDIR OAS8 FUSE NILAY MX BL G50...

Page 981: ...omthecontrol unit B Wire sideof female terminals Inspectthe connectorandsocketterminalsto be surethey areall makinggoodcontact lf the terminalsare bent looseor corroded repairthemasnecessary and reche...

Page 982: ...d Faulty moonroof auto stop switch Disconnectthe moonroof control unit5Pconnector andmakethese nputtests attheconnector lfanytestindicatesaproblem findandcorrectthecause thenrecheckthesystem lf allthe...

Page 983: ...the table Terminal Pi iti 1 4 5 CLOSE FO TILT OPEN o lf the continuityis not asspecified replacethe moonroofswitch 4 22 112 MotorTest 1 Remove the headliner seepage20 54 2 Disconnect the 2Pconnectorfr...

Page 984: ...t asspecified replacethe moonrooflimit switch 1 2 Auto stopSwitchTest Removethe headliner seepage20 54 Disconnect the 2Pconnectorfrom the moonroof auto stopswitch Checkfor continuitybetweenthe termina...

Page 985: ...Index POWERMIRRORS Function Test page22 116 Replacement page20 15 ActuatorTest page22 117 ActuatorReplacemenl page22 1 18 POWER MIRROR and MIRRORDEFOGGER SWITCH lesl page22 111 Replacement page22 1 17...

Page 986: ...CircuitDiagram UiIDTS rcOD R SE R LAY 8OX rcilmoN s1 vtTcH 1 ih a i 0At Usa UiD DASH N SUnIIAY 8OX J t 22 115...

Page 987: ...wingleft withthe ignition switchON flr lfthemirrordoesnottiltdown ordoesnotswing left checkfor an openin the GRN WHT or BLU Wl lT wirebetweenthe leftmirrorandthe 13P conneclor lf the wire is OK checkt...

Page 988: ...il tlf I 8 ON o o OFF lf the continuityis not asspecified replacethe power mirrorswitch 5 22 117 1 2 PowerMirrorActuatorTest Removethe door panel seepage20 4 Disconnect the 6Pconnector A from the pow...

Page 989: ...the cover then removethe two Torx screwsfrom the mirror connector Recordtheterminallocationsandwire colors Cutthe wire harnesswith the wire cutter 7 Removethe threescrews andseparate the mirror housin...

Page 990: ...CONNECTORRIGHT MIRROR CONNECTOR Wiresideoffemale terminals Canada l 1 Reassemble inthe reverseorderof disassembly Becarefulnotto breakthe mirror holderwhen reinstalling it to the actuator Reinstallth...

Page 991: ...Horns ComponentLocationIndex HORN RELAY Test page 22 51 HORNS Test page22 122 Beplacement page22 122 UNDER HOOD FUSE RELAY BOX HORNSWITCH fesl page22 122 CABLEREEL Replacement page23 119 22 120 r...

Page 992: ...J Gircuit Diagram J 22 121...

Page 993: ...failsto sound replaceit 22 122 1 HornSwitchTest Removethe steeringcolumncovers seepage 17 9 Disconnecl the dashboardwire harnessB 5P connector A from the cablereel B Usinga jumperwire connectthe dash...

Page 994: ...tor B to ground lf the hornssound go to step6 lf the hornsdo notsound replacethecable reel Reconnect the hornswitchpositive1Pconector B 6 22 123 1 Usingajumperwire connent thesteering wheelto bodygrou...

Page 995: ...RELAY BOX POWER WINDOWRELAY Iest page 22 51 FRONT PASSENGER S WINDOW MOTOR Test page 22 132 t J POWERWINDOW MASIER SWITCH InputTest Daqe22 126 Test page22 128 Replacement page22 133 FRONTPASSENGER S W...

Page 996: ...CircuitDiagram tGt TtoitswtTcfi No 20il0A USA UNOERHMOFUSI 8tLAY 8OI r o F BTTYEL U lGl HOT in0N ll tndSTABT llll WHT BU 22 125...

Page 997: ...s windowoperations 1 Remove thewindowmaster switch A seepage22 133 2 Disconnect the14P connector B fromthemaster switch GRN WHT 3 Inspectthe connectorand socketterminalsto be surethey areall makinggoo...

Page 998: ...the under dash fuse relay box Blown No 22 23 l2OA tuse in the under dash fuse relayDox Faultypowerwindow relay Poorground G201 An open in the wire 2 GRN BLK 1 RED YEL Connect the No l 1 and No 7 term...

Page 999: ......

Page 1000: ...e o DOWN e lf the motor doesnot run or failsto run smoothly replacerL 1 Pulser Test Reconnect the 4Pconnectorto the driver swindow motor and reconnect the 20Pconnectorto the powerwindow masterswitch...

Page 1001: ...em Cavitv Wire Test condition Test Desired result Possible causeif resultis not obtained 3 GRN BLK lgnitionswitchON l l Checkfor voltageto grouno Thereshouldbe battery voltage BlownNo 6 7 5A fuse inth...

Page 1002: ...ctthe No 2 terminal to the No 1terminal andthe No 4 terminal to the No 5 terminal andturnthe ignitionswitchON ll and pressthe down buttonon the powerwindow masterswitchfor the passenger s window Check...

Page 1003: ...sspecified replacethe swtlcn tfiTtTtT Etl l r r Jl Torminal Poiition 1 2 4 UP OFF DOWN 22 132 Passenger s Window Motor Test 1 Removethe passenger s door panel seepage20 4 Disconnect the 2Pconnector A...

Page 1004: ...the 14Pconnector B from the switch Removethe threescrewsandthe switchfrom the switchpanel 3 22 133 Passenger s Window Switch Replacement Removethe door grip seepage20 4 Removethe powerwindow switch A...

Page 1005: ...t page22 143 Replacement page22 145 WINDSHIELD WIPER ARMSand LINKAGE Replacement page22 145 WIPER WASHER SWITCH Test page22 140 Replacement page 22 140 UNDER DASH FUSE RELAY BOX INTERMITTENT WIPER CIR...

Page 1006: ...placement page 22 147 CONDENSER CapacityTest page22 107 BEARWINDOWWIPER ARM Replacement page 22 146 WASHER RESERVOIB Replacement page 22 146 WASHERFLUIDLEVELSWITCH Canada TesI page22 144 Replacement p...

Page 1007: ...Wipers Washers CircuitDiagram Windshield UNOEN HOOD FL SE 8ELAY BOX IGNITIONSWITCN 7 F il I 6 U I u Hr o f 1 L MULTIPIIX coiln0L UNIT 22 136...

Page 1008: ...iagram RearWindow UI IOIF H OFUSE RELAY MX GNMOIIISW ICH No2olaoAl USA BATTERY r i l No g soA ro2o 1 1_ l _ _fww l y l E r H o r b 0 N i l I andsra8r 0 ffAnw tDow wtPEE INTE ITTEI IT C NNOL UI IT f li...

Page 1009: ...onnector A fromtherearwindow wiDer intermittent control unit B Inspect theconnector andsocket terminals to besuretheyareallmaking goodcontact lftheterminals arebent loose orcorroded repairthem asneces...

Page 1010: ...orground G553 An openin thewire 6 WHT RED lgnitionswitchON ll andrear window washer switchON Checkfor voltageto ground Thereshouldbe battery vortage BlownNo 9 10A fuseinthe under dash fuse relaybox Fa...

Page 1011: ...l out the wiper washerswitch Inspect the connectorterminalsto be surethey are all makinggoodcontact lf the terminalsare bent looseor corroded repairthemas necessary and recheck the system lfthetermina...

Page 1012: ...CONNECTOR BI6PI UNDER DASH FUSE RELAY BOX CONNECTOR G 1OP 2 3 UNDER DASH FUSE RELAY BOX CONNECTOR J 8PI l 1 llTtl F_j JF 1 4 1 5 1 6 7 l 8 l WHT BLU l 1 l rl l l l s l r l z l o l BLU RED UNDER DASH F...

Page 1013: ...ON ll andwasher switchON Checkfor voltageto ground Thereshouldbe battery vortage BlownNo 20 20A fusein the under dash fuse relaybox Faultywiper washerswitch An open in the wire E 0 BLU RED lgnitionswi...

Page 1014: ...een theNo 5 terminal andground andrunthemotorat low or highspeed Thevoltmeter shouldindicate 12V and4 V or less alternately lf it doesnot replacethe motor l j J 22 143 RearWindow 1 Openthe hatch and r...

Page 1015: ...motor doesnot run replaceit 22 144 WasherFluidLevelSwitchTest Replacement Canada 1 3 4 Partiallyremovethe right innerfender seepage 20 102 Disconnect the 2Pconnector A from the washer levelswitch Rem...

Page 1016: ...idesoff of the pin E then removethe assembly 5 Scribea line A across the linkandwlndshield wiper linkageto showthe originaladjustment Separate thewindshield wiperlinkage B from the wipermotor C N m 3...

Page 1017: ...Installin the reverseorderoI removal and note theseitems Apply multipurposegreaseto the moving parts Beforereinstalling the wiper arm turn the wiper switchON thenturn OFFto returnthe wiper shaftto th...

Page 1018: ...WasherTubesReplacement Remove therightinnerfender seepage20 102 Remove thewasher nozzles andclips thenremove thetubes 1 2 r L cont d 22 147...

Page 1019: ...Wipers Washers WasherTubesReplacement cont dl 3 Install inthe reverseorderof removal Takecarenotto plnchthewashertubes Check thewasheroperation 22 148...

Page 1020: ...onnectorterminalsto be surethey are all makinggoodcontact lf the terminalsare bent looseorcorroded repairthemas necessary and recheck the system lf the terminalslookOK go to step4 Turnthe ignitionswit...

Page 1021: ...161 Programming page22 161 PASSENGER S DOOR LOCK ACTUATOR Test page 22158 RECEIVER UNIT lnputTest page22 153 IGNITIONKEYSWITCH Test page22 91 DRIVER SDOORSWITCH HATCHLATCHSWITCH Test page22 97 HATCHLO...

Page 1022: ...DENHooD FUSE RETIY 8OX UI IDE8 DASH fUSE RETAY 80X 8Ar cl lG1 lG1 HoT in0N lllaidSTAfft llll J I 000R Loc KNOE tl xtY 2 t F Li___J cont d 22 151 l 3 IT I BLK I G502 MULTIPUX CONTNo Uflfi PASSTNGtrS 00...

Page 1023: ...HOOD FU8E BELAY MX l br t15a FUSE CircuitDiagram cont dl J t HORN SWTCH UNDEN DAS I FUSE 8ELAY 8OX t J Y Df IVEB S 0008 swtrcH plo d l DFIVES S DOOB TOCK 6WTCH tGtltot t IGY stvrTcH mMErNAllofl LIGHI...

Page 1024: ...22 100 3 Disconnect the 5Pconnector A from the keylessreceiverunit B WHT RED Wiresideoffemale terminals 4 Inspecttheconnectorandsocketterminalstobesuretheyareall makinggoodcontact lf the terminalsare...

Page 1025: ...sultis notobtained 2 BLU ORN Underall conditions Checkfor continuitybetween the No 2 terminalandthe No 2 terminalofthe under dash fuse relaybox connectorK 17P Thereshouldbe continuitv An open in the w...

Page 1026: ...SE RELAY BOX CONNECTOR J 8PI UNDER OASH FUSE RELAY BOX CONNECTOR PI18PI UNDER DASH FUSE RELAY BOX CONNECTOR K 17PI BLU ORN UNDER DASH FUSE RELAY BOX CONNECTOR O 8P YEL BLKYEL BLK YEL YEL UNDER DAsH FU...

Page 1027: ...iver s doorswitch An ooeninthewire Driver s doorclosed Checkfor voltageto ground Thereshould be 5 V or more Faulty driver s doorswitch Shortto oround o4 LTGRN RED Passenger s dooropen Check forvoltage...

Page 1028: ...disconnected There should becontinuitv An openinthewire M7 YEUBLK Connect J7terminal to 47 lMgl terminal andMg lMTl terminalto J4 Check actuator operation Thedriver s doorlockactuator should lock lun...

Page 1029: ...tteryvoltageonly momenlanry Terminal ilil lll l 2 LOCK e e UNLOCK e e lf the actuatordoesnot operateasspecified reprace rr 4 22 158 Passenger s door 1 Remove the passenger s doorpanel seepage20 4 2 Di...

Page 1030: ...age20 53 3 Disconnect the 2Pconnectorfrom the hatchlock actualor 4 Checkactuatoroperationby connectingpowerand groundaccordingto the table To preventdamage to the actuator applybatteryvoltageonly mome...

Page 1031: ...knobswitchis in the UNLOCKED position Thereshouldbe no continuitywhen the door lock knobswitchis in the LOCKED position lf the continuityis not asspecified replacethe door locl actuator 5 22 160 1 Doo...

Page 1032: ...erased NOTE lt is importantto maintainthe time limits betweenthe steps Makesurethe doorsandthe hatch are closed 1 Turnthe ignition switchON lli 2 Within 1to 4 sec pushthe transmitterlockor unlockbutto...

Page 1033: ...INOICATOR LIGHT BulbReplacement page22 63 ECM Replacement page11 4 Substitute known good for testing page11 5 IMMOBILIZER CONTROL UNIT RECEIVER Troubleshooting page 22 165 Replacement page 22 167 TRA...

Page 1034: ...iliii tlun oona r KEYCYLTNDER lf the properkeyhasbeenused the immobilizerindicatorlightwill come on for about2 seconds then go off lf the wrong key hasbeenusedor the codewas not receivedor recognized...

Page 1035: ...SE RELAY 8OX rGNtTt0i swlrcH lct HoT in0N ll ndSIAnT l l 0R8 itAWStY tct tGPl tGPz LG3 M0CD EC LGI LG2 t No20 LAl rUSA CircuitDiagram F G N 8ELAY1 YEUBIJ t DATA PA8 II IG LIN SMIG CONNECIOR SWITCH 0Lc...

Page 1036: ...eiver then go to step9 NO Checkfor theseproblems then go to step3 Blown No 9 10A fusein the under hood fuse relaybox I An openin the wire betweenthe gaugeassembly andthe immobilizer controlunit receiv...

Page 1037: ...izer controlunit receiver 7PconnectorNo 2 terminal andECMterminalE27 ls therecontinuity YES Go to step13 NO Repair theopeninthe RED BLU wire I Reconnect the 7Pconnectorto the immobilizer controlunit r...

Page 1038: ...17 Disconnect the 7Pconnector A from the immobilizercontrolunit receiver B 5 Removethe two screwsandthe immobilizer controlunit receiver from the ignitionkeycylinder c Installthe immobilizercontroluni...

Page 1039: ...x IGNITION KEYLIGHT Test page22 91 lr J REAR CEILING LIGHT Test page 22 96 LIGHT SPOTLIGHTS Test page22 96 GAUGE ASSEMBLY ECM MULTIPLEX CONTROL UNIT Builtinto the under dash fus6 relav boxl Troublesho...

Page 1040: ...tDiagram I 10 20 a0AJ usA ib a l50A C nd IGNITiON SWITCH BAI _to oJ BLI YEL tcl J G201 HAICII LATCH SWITCH cont d UiIDM HOOD IUSE NEUY BOX MULTIPLEX c0NT80r tNsPECTror CONNECIOF UNDEf DASH FUSE NEUYBO...

Page 1041: ...tiplexControlSystem J J CircuitDiagram cont d l 1o 3 l7 5AJ tUSt lln uidt hoodr itutefd4bor I V I wHTPLU l 0 t t lrfl lElnv ucHT lA l t Y l I CIILING LIGHT I l MOBItEER NTIOL UIIIT RECEIVEE V I I 22 1...

Page 1042: ...onlinesbetween the ECM the gaugeassembly andthe under dash fuse relaybox Wake up andSleep The multiplexcontrolsystemhas wake up and sleep functionsto decrease parasiticdraw on the batterywhen the igni...

Page 1043: ...d ceiling light indicate mode 1 YES Go to step8 NO Goto step7 22 172 7 Checkfor continuitybetweenterminal4ofthe under dash fuse relaybox connectorJ and body ground ls therecontinuity YES Replace the u...

Page 1044: ...andthe gaugeassembty 1 Faultypoweror groundto the ECM Faulty ECM I Before replacinga FaultyECM PCM makesureit hasthe latestsoftwarerevision UDdateif necessary beforeswappingor replacing DTCs Multiplex...

Page 1045: ......

Page 1046: ...ECTOR C 14P CONNECTOR EI13P 1 2 CONNECTOR F 12P GRN RED USAI GRN ORN Canada coNNECTOR P 18P CONNECTOR J 8PI WHT RED 1 2 3 4 5 6 1 BLK cont d GRN ORN BLU CONNECTOR K 17P I CONNECTOR OI12P CONNECTOR X 8...

Page 1047: ...hcwire Cavitv Testcondition Tesi Oesired result Possible cause ifresult isnotobtained o3 GRN Driver s dooropen Checkfor voltageto ground There should be 1 V or less Faulty driver s doorswitch Anooenin...

Page 1048: ...o 2 15Aifuse intheunder hood fuse relaybox Faulty taillight relay An ooeninthewire F8 GRN RED Brake fluidreservoir floatin down position brake fluid Checkfor voltageto ground There should be lessthan...

Page 1049: ......

Page 1050: ...ion 23 23 DTC Troubleshooting Index 23 28 Symptom Troubleshooting Index 23 30 System Description 23 31 Circuit Diagram 23 34 DTC Troubleshooting 23 36 SRSIndicator Circuit Troubleshooting 23 105 Compo...

Page 1051: ...SAZ 0010004 Backprobe Set o o ro J Gl 07HAZ SG00500 DeploymentTool SCSServiceConnector SRSInflator Simulator SRSSimulator LeadC Backprobe Adapter 17mm SRSSimulator LeadE SRSSimulator LeadF 8t oTPM oo1...

Page 1052: ...11 REAR CENTER BELT and REAR SEATBELTBUCKLES step1onpage 23 8 Inspection page 239 SHOULDER ANCHOR ADJUSTER step8 onpage 23 4 FRONT SEAT BELT Replacement page 23 4 Inspection page 239 I REAR SEAT BELT...

Page 1053: ...et buttons Disconnect the negativecablefrom the battery and wait at least3 minutesbeforebeginningwork Slidethe front seatforwardfully Removethe loweranchorcap A and removethe loweranchorbolt B 3 1 5 R...

Page 1054: ...the seatbelttensionerhasbeendeployed replacethe front seatbeltprotectorwith a new one Applyliquidthreadlockto theanchorbolts beforereinstallation Beforeinstallingthe anchorbolts makesure thereare no t...

Page 1055: ...0 UNF 32N m 3 3 kgfm 24lbf ft 6 Pulltheseatbeltswitch tensioner harness C out throughthe holeon the seattrack a 23 6 7 Installthebucklein the reverseorderof removal and notetheseitems Assemblethe wash...

Page 1056: ...and retractor D B 7 16 20 UNF 3 4 A 6 x 1 0 m m 3 4N m 0 35kgl m 2 5 lbf ftl A 7 16 20UNF 32N m 3 3kgf m 24 tbf ftl N m 3 3kgf m 2irlbf ft 5 Installtheseatbeltin the reverseorderof removal and notethe...

Page 1057: ...k cover seepage20 82 5 Removethe seat back padfrom the seat back frame seestep3 on page20 81 6 Removethe screw and releasethe hooks A then removethe retractorcover B Fastener Location B 23 8 t 7 Remov...

Page 1058: ...withseatbelttensioners reviewthe SRScomponent locations see page23 13 andtheprecautions andprocedures see psge23 14 in theSRSsection before performing repairs or service Retractor FrontandRear 1 Befor...

Page 1059: ...el if necessary Useonly soapandwaterto clean NOTE Dirt build upin the loopsof the upper anchorscancausethe seatbeltsto retractslowly Wipe the insideof the loopswith a cleancloth dampened in lsopropyl...

Page 1060: ...he toothed washer E from thetetheranchor Installthe anchorinthe reverse orderof removal I J 23 11 Side 1 Removethe rearbulkheadcoversfrom bothsides seepage20 51 2 Removethe anchorbolt A then removethe...

Page 1061: ......

Page 1062: ...23 116 SENSOR SEAT BACK Replacement page20 75 FRONT PASSENGER S SIDE AIRBAG Replacement page 23 1 15 Disposal page 23 116 FRONT PASSENGER S SEAT BELT TENSIONER Beplacement page 23 4 Disposal page 23 1...

Page 1063: ...e system lf it is not a Hondamultimeter makesureits outoutis 10 mA 0 01A or lesswhen switchedto the lowestvalue in the ohmmeterrange A testerwith a higheroutput couldcauseaccidental deploymentand poss...

Page 1064: ...dsurfaceup Neverput anythingon the airbag To preventdamageto the airbag keepit freefrom any oil grease detergent or water 23 15 Store theremoved airbag ona secure flatsurface awayfromanyhighheatsource...

Page 1065: ...yedsideandthe SRSunit Aftera collisionin whichthe airbagsor the sideairbagsdid not deploy inspectfor any damageor any deformationon the SRSunit front impactsensors andthe sideimpact sensors lf thereis...

Page 1066: ...SRSgroundlocations areclean and groundsare securely fastenedfor optimum metal to metalcontact Poorgroundingcancauseintermittent problemsthat aredifficultto diagnose Precautions for Electrical Inspecti...

Page 1067: ...sleeve side connectorin the directionshown As the two connectorhalves are pressedtogether the sleeve A is pushedback by the pawl C Do nottouchthe sleeve Whenthe connectorhalvesarecompletelV connected...

Page 1068: ...h SideAirbags Seatswith sideairbagshavea SIDEAIRBAG labelon the seat back Because the componentpans seat back cover cushion etc of seatswith andwithout airbags aredifferent makesureyou installonly the...

Page 1069: ...ect the negativecablefrom the battery andwait at least3 minutesbefore beginningthe followingprocedures BeforedisconnectingSRSunitconnectorA 1 fromtheSRSunit disconnectthedriver sairbag4Pconnector 3 th...

Page 1070: ...el A from the steering wheel then disconnecl the driver sairbag4P connector B from the cablereer Front Passenger sAirbag 3 Disconnect the front passenger s airbag4P connector A from dashboard wire har...

Page 1071: ...sconnect bothseatbelttensioner 2Pconnectors A fromthefloorwireharness Seat Belt BuckleTensioner 6 Disconnect bothseatbeltbuckletensioner4P connectors A 23 22 J 4 SRSUnit 7 Disconnect SRSunitconnectorA...

Page 1072: ...amultimeter makesure its outputis 10mA 0 01A or lesswhenswitched to thesmallest valueintheohmmeterrange A tester witha higher outputcoulddamage theairbagcircuit or cause accidental airbagdeployment an...

Page 1073: ...the HondaPGMTesterfrom the DLC 7 Dothe troubleshootingprocedure for the DTC Patteins of DTCIndications The DTCconsistsof a main code and subcode S Second 2 5 3 5 6 S o N l t l oFF l I l Ll l I First e...

Page 1074: ...f the SRSindicatordoesnotcome on as indicatedabove alwayscheckfor an openor a shortto groundin the SCS circuitbeforetroubleshooting the system Exampleof DTCIndications 1 Continuous failure SRSIndic6to...

Page 1075: ...nnectorwithin 4 seconds 7 TheSRSindicator will bllnktwo timesindicating thatthe memory hasbeenerased 8 Turnthe ignitionswitchOFF andwait for 10 seconds 9 Turnthe ignition switchON ll again TheSRSjs OK...

Page 1076: ...connectorwithin 4 secondsafterthe SRSindicatorwent off 6 The SRSindicatorcomeson again Reconnect the SCSserviceconnectorto the MESconnectorwithin 4 seconds afterthe SRSindicatorcomeson 7 The SRSindic...

Page 1077: ...tbeltbuckletensioner seepaqe23 54 Shortto anotherwire or decreased resistance in driver sseatbelt buckletensioner see page23 55 2 t 4 Shortto Dowerin driver sseatbeltbuckletensioner seepaqe23 56 2 t 5...

Page 1078: ...dairbag s andfront passenqer s sideairbaqdeDloved 10 6 Driver sandfront passenqer s sideal 10 7 Seatbeltandseatbeltbuckletensioners andairbag s and driver s andfront passenger s side airbagsdeployed 1...

Page 1079: ...ffindicatorstays on afterbulbcheck lfthe indicatorstayson it doesnot set a DTC Sideairbagcutoff indicatoris flashing Makesurenothing is on thefronl passenger s seat lf the sideairbagcutoffindicator st...

Page 1080: ...one sideairbagwill deployduringa side impacl lf the impactis on the passenger s side the passenger s sideairbagwill deployevenif thereis no passenger Seat Belt and Seat Belt BuckleTensioners The seatb...

Page 1081: ...impactsensormusl activate andsendelectricsignalsto the microprocessor 2 The microprocessor mustcomputethe signals and dependingon the severityof the collisionandwhetherthe seat beltbuckleswilch is ON...

Page 1082: ...n or doesnot go off after6 seconds or if il comeson while driving it indicatesan abnormalityin the SRS The SRSmust be inspected and repairedassoon as possible Forbetterserviceability the SRSunit memor...

Page 1083: ...SRS CircuitDiagram rrssfc s srarsftr rrl 0 n J 4 i _ _ _ _ 1 r Tr i 23 34 J...

Page 1084: ...I J I J tr ozr tr ul ar NJfl t l 1i tzl I J 23 35...

Page 1085: ...irbag4Pconnector A from the cablereel 07sAz TB4011A 07xaz s230100 5 Connectthe SRSinflatorsimulator 2 Q connectors andthe simulatorleadFto the cable reet 23 36 6 Reconnect the batterynegativecable 7 E...

Page 1086: ...C1 3 Shortto AnotherWireor Decreased Resistance in Driver s AirbagInflator SpecialToolsRequired SRSinflatorsimulator07SAZ T8401 1A SRSsimulatorleadF 07XAZ S230100 1 ErasetheDTCmemory seepage23 26 2 Tu...

Page 1087: ...isconnectthe specialtool from the cablereel 23 38 I J 14 Checkresistance betweenthe No 7 andthe No 16 terminals andbetween the No 6 andthe No 15 terminals of SRSunitconnectorA 18P There shouldbe an op...

Page 1088: ...lereel 07sAz T84011A Connect theSRSinflator simulator 2 0 connectors andthe simulatorleadFto the cable reel Reconnect the batterynegativecable Erasethe DTCmemory 6 1 9 10 t4 1 1 1 2 Readthe DTC ls DTC...

Page 1089: ...ody ground Thereshouldbe 0 5V or less ls the voltage as specitied YES Replace thecablereel l NO Replacedashboard wireharness B l 1 8 1 9 20 23 40 1 I J L DTC1 5 Short to Ground in Driver s Airbag lnfl...

Page 1090: ...ce betweenthe No 7 terminalof SRSunitconnectorA 18P and body ground the No 16terminalandbodyground the No 6 terminalandbodyground andtheNo 15terminal and body ground Thereshouldbe an opencircuit or at...

Page 1091: ...nger s airbag4P connector A from dashboardwire harnessB 07sAz T84011A 07xAz s230100 Connectthe SRSinflatorsimulator 2 0 connectors andthe simulatorleadFto dashboard wire harness B Reconnect the batter...

Page 1092: ...lnJlator SpecialToolsRequired SRSinflator simulator 07SAZ T8401 1A SRSsimulatorleadF07XAZ S230100 1 Erasethe DTCmemory seepage23 261 2 Turnthe ignition switchON ll andcheckthatthe SRSindicatorcomeson...

Page 1093: ...rom the floor wire harness seestep5 on page23 221 9 10 23 44 T J qJ 12 Disconnect SRSunitconnectorA 18P from the SRS unit seestep 7 on page 23 22l 13 Disconnectthe specialtool from dashboard wire harn...

Page 1094: ...es 4 Disconnect thefront passenger s airbag4P connector A from dashboard wire harnessB 07sAz T84011A 07xAz s230100 Connectthe SRSinflatorsimulator 2 Q connectors andthe simulatorleadFto dashboard wire...

Page 1095: ...board wireharness B replace dashboard wireharness B 15 to 23 46 J DTC2 5 Shortto Groundin FrontPassenger s AirbagInflator SpecialToolsRequired SRSinflatorsimulator07SAZ T84011A SRSsimulatorleadF07XAZ...

Page 1096: ...floor wire harness seestep5 on page23 22 I I I 12 13 t4 Disconnect SRSunitconnectorA 18P from the SRSunit seestep7 on page23 221 Disconnectthe specialtool from dashboardwire harness B Checkresistance...

Page 1097: ...011A 5 ConnecttheSRSinflatorsimulator 2 0 connector andsimulatorleadC to the floor wire harness 07TAZ 52501 lA 23 48 t 5 J 6 Reconnect the batterynegativecable 7 Erasethe DTCmemory 8 Readthe DTC ls DT...

Page 1098: ...ethe SRSunit seepage23 1221 a NO Openor increased resistance in dashboard wireharness B replace dashboard wire harness B t 1 8 I I t o DTC3 3 Shortto AnotherWireor Decreased Resistance in Driver s Sea...

Page 1099: ...placethe floor wire harness l Turnthe ignitionswitchOFF Disconnect the batterynegativecable andwait for 3 minutes 1 1 13 14 23 50 t J 16 Disconnect the driver sairbagconnector seestep 2 on page23 211...

Page 1100: ...5 Connectthe SRSinflatorsimulator 2 J connector and simulatorleadCto the floorwire harness I 6 Reconnect the batterynegativecable 7 Erasethe DTCmemory 8 Readthe DTC Is DTC 3 4 indicated YES Goto step9...

Page 1101: ...SRSunit see page23 122 a NO Shorttopowerin dashboard wireharness B replace dashboard wireharness B l 23 52 L J DTC3 5 Shortto Groundin Driver s SeatBelt Tensioner SpecialTools Required sRS inflalorsim...

Page 1102: ...rness replacethe floorwire harness l Turnthe ignitionswitchOFF Disconnect the batterynegativecable andwait for 3 minutes 1 1 1 4 I 23 53 16 Disconnectthedriver sairbagconnector seestep 2 on page23 211...

Page 1103: ...adthe DTC ls DTC21 1indicated YES Goto step9 NO Openor increased resistance in the driver s seatbeltbuckletensioner replacethe driver sseat beltbuckle I 9 Turnthe ignitionswitchOFF Disconnect the batt...

Page 1104: ...wtrenarness Reconnect the batterynegativecable Erasethe DTCmemory 6 7 8 Readthe DTC ls DTC 21 3indicated YES Go to step9 NO Shortin the driver sseatbeltbuckle tensioner replacethe driver sseatbeltbuc...

Page 1105: ...F Disconnect the batterynegativecable andwait for 3 minutes 4 Disconnect the driver sseatbeltbuckletensioner 4Pconnector A from the floor wrrenarness ConnecttheSRSinflatorsimulator 2 0 connectors andt...

Page 1106: ...nd in Driver s Seat BeltBuckle Tensioner SpecialTools Required SRSinflatorsimulator07SAZ TB4011A SRSsimulatorleadF 07XAZ S230100 1 Erasethe DTCmemory seepage23 26 2 Turnthe ignitionswitchON ll and che...

Page 1107: ...nceasspecilied YES Faulty SRSuniureplace theSRSunit see page23 122 a NO Short toground inthefloorwireharness replace thefloorwireharness l 23 58 J L DTC4 1 Openin Front Passenger s SeatBelt renstoner...

Page 1108: ...1 12 1 4 I 15 Turnthe ignitionswitchOFF Disconnect the batterynegativecable andwait for 3 minutes 16 Disconnect the driver sairbagconnector seestep 2 on page23 211 tront passenger s airbag connector s...

Page 1109: ...he floor wire narness 07TAZ S25011A Connectthe SRSinflatorsimulator 2 Q connector andsimulatorleadCto the floor wire harness Reconnect the batterynegativecable Erasethe DTCmemory 6 7 23 60 1 5 J 8 Rea...

Page 1110: ...reharness B I RED YEL I t 6 r8l P T 2 3 4 5 6 8 10 t l 12 t 3 15 16 1 7 RED BLK DTC4 4 Shortto Powerin FrontPassenger s SeatBeltTensioner Special Tools Required SRSinflatorsimulator07SAZ T84011A SRSsi...

Page 1111: ...floor wire harness l 1 1 t J 1 4 23 62 1 1 15 t o 1 8 1 9 20 21 Turnthe ignitionswitchOFF Disconnect the batterynegativecable andwait for 3 minutes Disconnect the driver sairbagconnector seestep 2 on...

Page 1112: ...onnect the SRSinflatorsimulator 2 e connector andsimulator leadC to thefloorwireharness Reconnect the batterynegativecable Erasethe DTCmemory 7 8 Readthe DTC ls DTC 4 5 indicated YES Go to step9 NO Sh...

Page 1113: ...page 23 1221 1 NO Short to groundin dashboard wire harnessB replace dashboard wireharness B I 23 64 DTC22 1 Openor Increased Resistance in FrontPassenger s SeatBeltBuckle Tensioner SpecialToolsRequir...

Page 1114: ...ontactat SRSunit connector B 18P andtheSRSunir Check the connection if the connectionis OK replacethe SRSunit seepage23 122 a NO Openor increased resistance in the floor wire harness replacethe floorw...

Page 1115: ...esideoIfemale terminals ls the resistanceas specified YES FaultySRSunit replacethe SRSunit see page 23 1221 a NO Shortin the floor wire harness replacethe floorwire harness I GRN 23 66 J DTC22 4 Short...

Page 1116: ...eatbelt buckletensioner4Pconnector seestep6 on page 1_r Disconnect SRSunitconnectorB 18P from the SRSunit seestep7 on page23 221 Disconnect the specialtool from the floor wire harness Reconnect the ba...

Page 1117: ...batterynegativecable Erasethe DTCmemory 5 6 1 23 68 U 8 Readthe DTC ls DTC 22 5 indicated YES Go to step9 NO Shortto groundin the front passenger s seat beltbuckletensioner replacethe front passenger...

Page 1118: ...if the batteryeverwent oeao 1 Erasethe DTCmemory seepage23 26 2 Turnthe ignitionswitchON ll andcheckthatthe SRSindicatorcomeson for about6 secondsand thengoesoff Doesthe SRSindicatotstay on YES Replac...

Page 1119: ...rmittent failure systemis OK at thistime Goto Troubleshooting Intermittent Failures see page 23 261 23 70 I J DTC14 1 14 2 Internal Failure oftheFront Passenger s Sidelmpact Sensor 1 Erasethe DTCmemor...

Page 1120: ...atbeltbuckleswitch3P connector A from the floor wire harness 4 5 t I 6 Bucklethe driver sseatbelt Checkresistance betweenthe No 1 and No 3 terminalsofthe driver sseatbeltbuckleswitch3P conneclor There...

Page 1121: ...side oI male terminals ls the rcsistance as specified YES Goto step8 NO Replace the driver sseatbeltbuckleassembly then clearthe DTC I 23 72 J 8 Checkresistance betweenthe No 1terminalofthe floor wire...

Page 1122: ...nitconnectorC 8P andthe No 3 terminalof the floor wire harness3Pconnector Thereshould b e 0 1 Q FLOORWIRE HARNESS SRS UNITCONNECTORC I8P 3PCONNECTOB Wire side of femaleterminals ls the resistance as s...

Page 1123: ...front passenger s seatbeltbuckle switch3Pconnector A from the floor wire harness 23 74 J 6 Bucklethe front passenger s seatbelt Checkresistance betweenthe No 1 and No 3 terminalsof the front passenge...

Page 1124: ...s ls the resistanceasspecilied YES Goto step8 NO Replace the front passenger s seatbeltbuckle assembly thenclearthe DTC I 9 1 0 8 Checkresistance betweenthe No 1terminalofthe floor wire harness3Pconne...

Page 1125: ...step13 NO Shortto groundin the floor wire harness replacethe floorwire harness I 23 76 J 13 Checkresistance betweenthe No 7 terminalof SRSunitconnector C 8P andtheNo 3 terminalof the floor wire harnes...

Page 1126: ...Disconnect the batterynegativecable andwait for 3 minutes Disconnect the driver sairbag4Pconnectorfrom the cablereel seestep2 on page23 21 Disconnect the front passenger s airbag4P connectorfrom dashb...

Page 1127: ...torsimulator jumper connector andsimulatorleadHto the engine compartmentwire harness2Pconnector A 07YAZ S3AA100 07SAZ TB O11A 1 4 t 5 23 78 r1 16 Checkresistance betweenthe No 10and No 11 terminalsof...

Page 1128: ...connect the batterynegativecable andwait for 3 minutes Disconnect the driver sairbag4Pconnectorfrom the cablereel seestep2 on page23 21 Disconnect the front passenger s airbag4P connectorfrom the dash...

Page 1129: ...dH to the engine compartmentwire harness2Pconnector A 1 4 07YAZ S3AA100 23 80 16 Checkresistance betweenthe No 1 and No 12 terminalsof SRSunitconnectorA 18P There shouldbe 1 O or less SRS UNIT CONNECT...

Page 1130: ...erynegativecable andwait for 3 minutes 4 Disconnect the floor wire harness2Pconnector A from the driver ssideairbag 07sAz T84011A 5 Connectthe SRSinflatorsimulator 2 Q connector and simulatorleadEto t...

Page 1131: ...wire harness replacethe floor wire harness l 23 82 DTC11 3 Short to Another Wireor Decreased Resistance in Driver s SideAirbag lnflator SpecialToolsRequired SRSinflator simulator 07SAZ T84011A SRSsim...

Page 1132: ...ale terminals ls the resistance as specified YES FaultySRSunit replacethe SRSunit see page23 t221 a NO Shonto another wire inthefloorwire harness replacethe floor wire harness I WHT BLU WHT BLK DTG11...

Page 1133: ...connector seestep4 on page23 21 and bothseat beltbuckletensioner4Pconnectors seesteD6 on page 23 221 9 10 23 84 J 1 1 Disconnect SRSunitconnectorB 18P from the SRSunit seestep7 on page23 22l Turnthe...

Page 1134: ...ethe DTCmemory 6 7 I 8 Readthe DTC ls DTC 11 5indicated YES Goto step9 NO Shortto ground in the driver ssideairbag inflator replacethe driver ssideairbag seepage 2 3 1 1 5 t 9 Turnthe ignitionswitchOF...

Page 1135: ...nectthe batterynegativecable andwait for 3 minutes 4 Disconnect the floor wire harness2Pconnector A from the front passenger s sideairbag 07xAz s1A0200 5 Connect the SRSinflatorsimulator 2 Q connector...

Page 1136: ...eharness I I WHT RED DTC12 3 Short to Another Wireor Decreased Resistance in Front Passenger s SideAirbagInflator SpecialToolsRequired SRSinflator simulator 07SAZ T84011A SRSsimulatorleadE o7XAZ S1402...

Page 1137: ...WHT RED r r Jl 8 l e l n i tl Bl S T 2 3 6 10 l l 15 WHT GRN Wiresideof emale terminals ls the resistance as specilied YES Faulty SRSunit replace the SRSunit see page23 1221 a NO Shortto anolher wire...

Page 1138: ...ector seestep4 on page23 21 and bothseatbeltbuckle tensioner 4Pconnectors seestep 6 on page 23 22l t 1 1 Disconnect SRSunitconnectorB 18P from the SRSunit seestep 7 on page 23 221 Turnthe ignitionswit...

Page 1139: ...ethe DTCmemory 8 Readthe DTC ls DTC 12 5indicated YES Goto step9 NO Short to groundin the front passenger s side airbaginflator replacethe front passenger s side airbag seepage23 1 15 1 9 Turnthe igni...

Page 1140: ...chOFF Disconnect the batterynegativecable andwait for 3 minutes 4 Checkthe connectionbetweenthe floor wire harness2Pconnectorandthe driver ssideimpact sensor ls theconnectionOK YES Go to step5 NO Repl...

Page 1141: ...seepage23 122 1 NO Openinthefloorwireharness replace the floor wire harness l 23 92 DTC13 4 FaultyPowerSupplyto theDriver s Sidelmpact Sensor 1 Erasethe DTCmemory seepage23 261 2 Turnthe ignitionswit...

Page 1142: ...step8 NO Shortto groundinthefloorwireharness replace thefloorwireharness I BRN YEL 8 Checkresistance betweenlhe No 8 and No l5 terminalsof SRSunil connectorB 18P There shouldbe an opencircuit or at l...

Page 1143: ...andwait for 3 minutes 4 Checkthe connectionbetweenthe floor wire harness2Pconnectorandthe front passenger s sidelmpactsensor Is the connectionOK YES Go to step5 NO Poorcontactbetweenthe floor wire ha...

Page 1144: ...theFront Passenger s Sidelmpact Sensor 1 Erasethe DTCmemory seepage23 26 2 Turnthe ignitionswitchON ll andcheckthatthe SRSindicatorcomeson for about6 secondsand then goesoff Does the SRS indicator sta...

Page 1145: ...ge23 125 lf the problemis stillpresent replace theSRSunit seepage23 122 I NO Shortin the floor wire harness replacethe floorwireharness l PNK BLU 23 96 7 Turntheignition switchON ll DTC15 1 Faulty OPD...

Page 1146: ...step12 Replace the No 9 l0A fuse 9 10 1 1 14 t o 1 1 13 Disconnect OPDSunit harness8Pconnector A from the OPDSunit Turnthe ignitionswitchON ll for 30 seconds then turn it off Check theNo 9 10A fuse ls...

Page 1147: ...NITCONNECTOR B I18PI Wiresideottemale terminals ls the resistance as specified YES Goto step22 NO Shortto ground in the floor wire harnessor OPDSunit harness replacethe faultyharness l GRN ORN 23 98 2...

Page 1148: ...3 26 3 Turnthe ignition switchON ll andcheckthatthe SRSindicatorcomeson for about6 secondsand then goesoff Doesthe SRSindicatorstay on YES Turn the ignitionswitchOFF and go to step NO Intermittent fai...

Page 1149: ...minalof the OPDSunit harness8Pconnectorand body ground Thereshouldbe batteryvoltage OPDSUNtTHARNESS 8PCONNECTOR Wiresideof female terminals ls therebattety voltage YES Goto step11 NO Goto step23 9 10...

Page 1150: ...placethe gaugeassembly l NO Goto step19 A t I 1 9 20 22 Turnthe ignitionswitchOFF Disconnect floor wire harness6PconnectorC509 A from the dashboardwire harness Turntheignition switchON ll Checkfor vol...

Page 1151: ...el Checkforvoltage between the No 4 terminalof dashboardwire harnessA 6Pconnector C509and body ground Thereshouldbe battery vorlage 03 model Checkfor voltagebetweenthe No 5 terminalof dashboardwire ha...

Page 1152: ...oard wire harnessA replace dashboard wireharness A I YEL 1 2 3 4 5 X 6 8 9 10 1t 12 I J 1 1 1 1 21 22 32 33 35 36 34 Turnthe ignitionswitchOFF Disconnect the OPDSunit harness8Pconnector A from the OPD...

Page 1153: ...tay on YES Go to step3 NO Intermittent failure systemis OK atthis time Goto Troubleshooting Intermittent Failures see page23 26 NOTE Aftermarketdevices fluorescent lights laptopcomputers etc usedneart...

Page 1154: ...CTOR B I22PI 1 2 3 4 5 X 6 8 9 1 0 11 12 l 3 x1 1 1B 21 22 BLK o Wiresideoffemale terminals Is the resistance as specified YES Goto step4 NO OpenintheBLKwireof dashboard wire harness A or faultybodygr...

Page 1155: ...Go to step10 NO Goto step9 23 106 J 9 Connecta voltmeterbetweenthe No 2 terminalof gaugeassemblyconnectorB 22P andbody ground Turnthe ignition switchON ll and measurethe voltage Thereshouldbe battery...

Page 1156: ...relaybox lsthe f useOK YES Goto step 19 NO Go to step3 Replacethe No 13 10A fuse Turnthe ignition switchON ll andwaitfor 30 seconds Thenturn the ignitionswitchOFF Check rheNo 13 10A fuse ls the fuseOK...

Page 1157: ...ct the driver sairbag4Pconnector see step2 on page23 2 l Disconnect the front passenger s airbag4P connector seestep3 on page23 21 Disconnect bothseatbelttensioner2Pconnectors seestep 5 on page23 22 D...

Page 1158: ...B I Turnthe ignitionswitchOFF Disconnect SRSunitconnectorC 8P from the SRS unit seestep 7 on page 23 22 29 30 I SRSUNITCONNECTOR C I8P 31 Connect the No 3 terminalofSRSunitconnectorA 18P andthe No 5 t...

Page 1159: ...or in dashboard wire harnessA replacethe faulty harness l 23 110 40 Removethe gaugeassembly seepage22 64 then disconnect gaugeassemblyconnectorA from the gaugeassembly Checkresistance betweenthe No 14...

Page 1160: ...the SCS menu seethe Tester soperating manual t r9 I l IL 23 111 47 Check resistance between theNo 6terminal of SRSunitconnector C 8P andbodyground There should be0 1 0 Q SRSUNIT CONNECTOR C I8P Wires...

Page 1161: ...ors After a collisionwherethe sideairbag s deployed replacetheseitems SRSunit Deployed sideairbag s Sideimpactsenso s for the side s that deployed Duringthe repairprocess inspecttheseareas lnspectallt...

Page 1162: ...e driver sairbag C 5 l f c 23 113 Installation 1 Connectlhe horn switchconnector 1P to the driver sairbag 2 Placethe new driver sairbag A inthesteering wheel and secureit with new Torx bohs B and inst...

Page 1163: ...he front passenger s airbag B outofthe dashboard NOTE The airbaglid haspawlson itssidewhich 4 aftachit to the dashboard 23 114 t r r Installation 1 Placethe new front passenger s airbag A intothe dash...

Page 1164: ...torque Makesurethatthe seat back coveris installed properly lmproperinstallation may preventproper deployment Besureto installthe harnesswires sothatthey are not pinchedor interferingwith other parts...

Page 1165: ...e deolovedwhile still in the vehicle The airbags sideairbags seatbelttensioners andseatbeltbuckletensionersshouldnot be considered as salvageable partsand shouldneverbe installedin anothervehicle 1 Tu...

Page 1166: ...maged ComDonents lf the red lighton the tool comeson the componentis readyto be deployed 11 Pushthetool sdeployment switch Theairbags and tensionersshoulddeploy deploymentis both highlyaudible andvisi...

Page 1167: ...3 115 seatbelttensioner see page23 4 and seatbeltbuckletensioner 2 In all cases makea shortcircuitby cutting stripping andtwistingtogetherthe two inflator wires NOTE The driver sand passenger s airbag...

Page 1168: ...onnector Alfrom the cruise controlsevresumeswitch then removethe steering wheelbolt B Alignthe front wheelsstraightahead then remove the steeringwheelwith a steeringwheel puller see step3 on page 17 6...

Page 1169: ...ab B thenpulloffthecablereel A 23 120 J Installation 1 Beforeinstallingthe steeringwheel alignthe front wheelsstraightahead 2 lf not alreadydone disconnect the batterynegative cable andwait at least3...

Page 1170: ...ith the noleson the steeringwheel and installthesteering Ai eelwith a new steeringwheel bolt A c 23 121 8 lnstallthe driver s airbag seepage23 113 9 Reconnect the batterynegativecable 10 After install...

Page 1171: ...nit 23 122 lnstallation 1 Installthe newSRSunit A withTorxbolts B then connectthe connectors C to the SRSuniu push them into positionuntiltheyclicks NOTE Whentighteningthe Torx boltsto the specified t...

Page 1172: ...onnect the floor wire harness2Pconnector from the sideimpactsensor 6 RemovetheTorx bolt A usinga Torx T30bit then removethe sideimpactsensor B lnstallation 1 Install the newsideimpactsensor witha newT...

Page 1173: ...nit 5 Removethe two screws C andthe OPDSunit D 23 124 Installation 1 Placethe new OPDSunit A on the seat back frame Tightenthe two screws B andconnectthe OPDS unit harness8Pand sensorconnectors C to t...

Page 1174: ...e front innerfender seepage 2O 1O21 Disconnect the enginecompartmentwire harness 2Pconnector A and removethe two Torx bolts B usinga TorxT30bit then removethe front impact sensor C 2 Installation 1 In...

Page 1175: ......

Page 1176: ...erSockets Fuse Relay lndexes toharness Connector andWireHarness lndexes Component Connectors Circuit Oiagram 22 149 Air Cleaner 2214 Rep1acemen1 11 162 Air MixControlMotor Meintenence section Section...

Page 1177: ...tion 20 64 Dashboard Bemoval 1nsta11ation 20 66 Oashboard CenterPanel Removal 1nstaf 1ation 2062 Dashboard LowerCover Removal lnstallation 20 59 63 Dashboard UnderCover Removal lnstallation 2060 Diffe...

Page 1178: ...m Component Location lndex 11140 A d j u s t m e n t 1 1 1 4 4 Test 11 145 FuelTank B e p l a c e m e n l 1 11 5 5 FuelTankVaporControlValve Test 11 187 Replacement 11189 Fuses See firstpageofthisInde...

Page 1179: ...22 121 20 110 20 110 Hatch Latch Replacement K Hatch Latch Switch 1 11 1 3 Hubs Replacement 1A26 Test Test Replacement HatchSupportStruts Beplacement HatchWeatherstrio Replacement Hazard WarningSwitch...

Page 1180: ...lSeesection 3 MIL Howto Informatron 11 46 MILCircuit Troubleshooting 1197 Mirrors ComponentLocation Index 20 14 ModeControlMotor Replacement MoonroolSunshade Rep1acement 2040 MoonroofSwitch TesVRep1a...

Page 1181: ...emb1y 20 74 Seat Rear Removal lnstallation 20 80 Seat back Cover Reer StartingSystem Component Location Index 4 3 CircuitDia9ram 4 4 r0 4 RadiatorFanCircuit Troubleshooting RadiatorFanSwhch Replacemen...

Page 1182: ...11164 Removal 1 127 HowtoIn ormation 22 Belay andControl Unit Locations 22 7 4 11 12 Beplacement 1767 ComponentLocationlndex 11 117 Tie rodBallJoint Boots lnstallation Replacement TurnSignal Hazard R...

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