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Honda Acura NSX 1991, Service Manual

The Honda Acura NSX 1991 Service Manual is an essential resource for NSX enthusiasts. This comprehensive manual provides detailed instructions and diagrams for servicing and maintaining the iconic sports car. Download it for free from manualshive.com to ensure you have all the information needed to keep your NSX in top-notch condition.

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Lighting System

-Circuit Diagram

NOTE: Several different wires have the same color. They have been given a number suffix to distinguish them (for 

ample BLU’ and 

 are not the same).

BATTERY

MAIN RELAY BOX

 

A

C

No.42

No.43

r - - - - - - - -

I

 No.44 CANADA

No.52

No.49

 

 

CONTROL UNIT

HT

E

2

RE

 

 

C

ONTRO

L 

UNIT

I

LIGHTING

10

4

7 SWITCH

RETRACTABLE

CONTROL UNIT

6401

6402

*STEREO 

CASSETTE LIGHTS 

l 

CLOCK LIGHT

*GLOVE BOX LIGHT

l 

 LIGHTER   

 LIGHTS

l 

SHIFT POSITION CONSOLE LIGHT

*CLIMATE FUNCTION CONTROL

SWITCH LIGHTS

G403

G201

23-l 70

Summary of Contents for Acura NSX 1991

Page 1: ... j s _ _ ...

Page 2: ...ot included Please note that this manual does contain warnings and cautions against some specific service methods which could cause PER SONAL INJURY or could damage a vehicle or make it unsafe Please understand that these warnings cannot cover all conceivable ways in which service whether or not recommended by HONDA might be done or of the possible hazardous consequences of each conceivable way no...

Page 3: ......

Page 4: ... Code and Vehicle Type JH4 HONDA MOTOR CO LTD JAPAN NAI ACURA NSX Transmission Type 15 5 speed Manual 26 4 speed Automatic Check Digit Model Year M 1991 Factory Code T Tochigi Factory Japan Serial Number Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number r Paint Code COLOR NH 547 ...

Page 5: ...e done by an authorized Acura dealer l To avoid rendering the SRS inoperative which can lead to personal injury or death in the event of a severe fron tal collision all maintenance must be performed by an authorized Acura dealer l Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caus ed by unintentional activation of the airbag l All SRS elec...

Page 6: ...RY CAUTION I ALB CAUTION I COOLING FAN CAUTION RADIATOR BLEED PLUG CAUTION AIR CONDITIONER R E T R A C T A B L E HEADLIGHT CAUTION I EXPANSION i a O J i I TANK CAP I j I CAUTION f i EMISSION CONTROL fiFORMATION and VACUUM HOSE ROUTING DIAGRAM 5 TIRE INFORMATION J ...

Page 7: ...low the lift manufacturer s instructions 0 Use rubber pad adapters on the lift to avoid damaging the car Spacer Installation 1 Place the rubber contact pads as shown 2 Raise the lift a few inches and rock the car to be sure it is firmly supported 3 Raise the lift to full height and inspect lift points for solid support 4 Install rubber spacers on the coil springs CAUTION Remove the rubber spacers ...

Page 8: ...When lifting the rear of the car put the gearshift lever in reverse Automatic in PARK Raise the car high enough to insert the safety stands CENTER SUPPORT POINT Adjust and place the safety stands as awn on page l 8 so the car will be approximately level then lower the car onto them 0 Always use safety stands when working on or under any vehicle that is supported by only a jack 0 Never attempt to u...

Page 9: ...etween the safety stand platforms and the car s front and rear support points to avoic damaging the car The safety stand platforms must contact the car s support points only they must not come in contact with any other part of the car SUPPORT POINTS RUBBER PADS SAFETY STANDS ...

Page 10: ...les lift that end of the car off the ground Damage to the car s suspension and body is almost certain if this method of towing is attempted If the NSX cannot be towed by flat bed it should be towed with the rear wheels off the ground If due to damage the car must be towed with the rear wheels on the ground do the following 0 Release the parking brake 0 Shift the 5 speed transmission to Neutral 0 I...

Page 11: ...lating Dacro type Gray plating Green coating on the threads Torquer type When replacing nuts and bolts use only the same ww Tighten the nuts and bolts with a torque wrench to the specifications provided in this manual Clean all thread ridges with a non wire type bristle brush Foreign matter in the threads may cause the bolt to loosen Sections on this car requiring the use Dacro nuts and bolts will...

Page 12: ...these items will require special cautions and tools and should therefore be done by an authorized Acura dealer 0 To avoid rendering the SRS inoperative which can lead to personal injury or death in the event of a severe fron tal collision all maintenance must be performed by an authorized Acura dealer l Improper maintenance including incorrect removal and installtion of the SRS can lead to persona...

Page 13: ...Component Locations RS LIGHT in the gauge assembly AIRBAG ASSEMBLY Airbag and Inflator DASH SENSOR R HORN SRS UNIT including cowl sensor AIRB ASSEMBLY CABLE REEL I 12 ...

Page 14: ... backup power unit and the cowl sensor are located inside the SRS control unit The SRS operational sequence is as follows I The cowl sensor activates and one or both dash sensors activate 2 Electrical energy is supplied to the airbag inflator by the battery or the backup power unit if the battery voltage is too low 3 Airbag deployment At least the cowl and one dash sensor must be activated simulta...

Page 15: ...RING WHEEL WARNING BEFORE INSTALLING STEERING WHEEL D BULKHEAD WARNING WARNING zizJ THIS VEHICLE IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS TAMPERING WITH OR DISCON NECTING THE SRS WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYSTEM...

Page 16: ...ECTED TEN YEARS AFTER DATE OF MANUFACTURE AS NOTED ON THE CERTIFICATION PLATE 0 ANY REPAIR INSPECTION OR NEARBY ACCESSORY INSTALLTION SHOULD BE DONE BY AN ACURA DEALER 0 IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING OR FLASHES FAILS TO LIGHT OR STAYS ON AFTER THE IGNITION IS FIRST TURNED ON SEE YOUR AUTHORIZED ACURA DEALER J STEERING WHEEL WARNING WARNING m TO PREVENT ACCIDENTAL DEPLOYMENT AND POSSIB...

Page 17: ... is an open circuit or damage to the wiring GAUGE ASSEMBLY GAUGE ASSEMBLY and FLOOR HARNESS and FLOOR HARNESS 30 P Connector 30 P Connector CABLE REEL and INFLATOR 3 P Connector FLOOR HARNESS c I DASH SENSOR RI ASH SENSOR R and FLOOR HARNESS and SRS MAIN HARNESS 4 P Connector SRS CONTROL UNIT SRS MAIN 2 P Connector 18 P Connector DASH SENSOR Ll and SRS MAIN HARNESS 2 P Connector CABLE REED and SRS...

Page 18: ...ion switch replace ment see section 23 0 Cruise control switch replacement see section 23 Airbag Assembly Do not try to disassemble the airbag assembly There are not separately serviceable parts Once an airbag has been operated deployed it cannot be repaired or reused SHORT CONNECTOR RED AIRBAG MODULE For temporary storage of the airbag assembly during service please observe the following precauti...

Page 19: ...n first disconnect the connector between the cable reel and the main SRS harness 0 If the steering column is going to be removed without dismounting the steering wheel lock the steering by turning the ignition key to O LOCK position or remove the key from the ig nition so that the steering wheel will not turn round S R S HARI 3 Steering wheel Do not replace the original steering wheel with any oth...

Page 20: ...ng equipment 0 Disconnect both the negative and positive bat tery cables l Install the short connector before performing work on the dashboard lower panel or the SRS sensors Wiring 1 2 3 Never attempt to modify splice or repair SRS wiring NOTE SRS wiring can be identified by special yellow outer protective covering Be sure to install the harness wires so that they are not pinched or interfering wi...

Page 21: ...and cable reel Connect the short connector to the airbag side of the connector Reconnect both the positive cable and negative cable to battery SHORT CONNECTOR AIRBAG MAINTENANCE LID A CABLE REEL NECTOR SHORT CONNECTOR 5 Removing the connectors at the fuse box CAUTION Avoid breaking the double locked con nectors on the fuse box The connectors are double locked to remove them first lift the connecto...

Page 22: ...Special Tools Individual tool lists are located at the front of each section ...

Page 23: ...Specifications Standards and Service Limits 3 2 Design Specifications 3 l 1 ...

Page 24: ...ion A T Automatic Transmission AIT I N E X I STANDARD NEW SERVICE LIMIT 1 373 14 0 199 981 10 0 142 196 2 28 150 95 I 51 05 5 9429 5 9468 0 05 o 15 0 002 0 006 0 050 0 089 0 002 0 004 0 015 0 0006 37 086 1 4601 38 037 1 4975 37 326 1 4695 36 559 1 4393 37 398 1 4724 36 741 1 4465 37 266 1 4672 37 665 1 4825 37 504 1 4765 36 559 1 43931 37 398 1 4724 36 741 1 4465 0 15 o 19 0 006 0 007 0 17 6 21 0 ...

Page 25: ... 0 11181 End play installed on crankshaft Ring to groove clearance Ring end gap Top Second Top Second Oil 0 15 0 30 0 006 0 012 0 40 0 018 0 030 0 055 0 001 0 002 0 13 0 005 0 030 0 055 0 001 0 002 0 13 0 005 0 25 0 40 0 010 0 016 0 60 0 024 0 35 0 50 0 014 0 020 0 75 0 03 0 20 0 70 0 008 0 028 0 80 0 03 Main journal diameter Taper out of round main journal Rod journal diameter Taper out of round ...

Page 26: ...ant capacity f US qt Imp qt M T 16 0 17 0 14 1 for overhaul I including engine heater cooling I 12 0 12 7 10 6 for coolant change line and expansion tank expansion tank capacity 2 1 P A T 16 5 17 4 14 5 for overhaul 2 2 US qt 1 8 Imp qt 12 0 12 7 10 6 for coolant change Expansion tank Opening pressure kPa kg cm psi 93 l 23 0 95 I 25 14 18 cap Thermostat Start to open 2 IoF 76 80 I 69 l 76 Fully op...

Page 27: ...ff Idle CO min STANDARD NEW 343 3 5 50 333 11 3 9 4 490 637 5 0 6 5 71 92 12 v 323 363 3 30 3 70 47 53 70 18 5 15 4 l lOO 1 900 M T800 50 AiT 7505 50 fin gear 0 1 I MEASUREMENT I S T A N D A R D N E W 1 SERVICE LIMIT Stroke Pedal olav I 1Pedal height I to floor 186 4 7 32 130 I 35 5 12 5 32 9 15 lO 35 0 591 r I Disengagement height Disc surface runout Thickness Rivet head depth Thickness Rivet hea...

Page 28: ... D I D STANDARD NEW SERVICE LIMIT 2 8 3 0 2 5 for overhaul 2 7 2 9 2 4 for oil change 30 984 31 OOO 1 2198 1 2205 42 984 43 000 I 892 l 693 32 002 32 018 1 260 1 261 0 02 0 001 min 0 14 0 21 0 006 0 008 49 009 49 025 1 9295 l 9301 0 06 0 23 0 002 0 009 35 92 35 97 11 414 1 4161 49 009 49 025 1 9295 I 9301 0 06 0 21 0 002 0 009 35 92 35 97 I 414 l 416 47 009 47 025 I 8507 l 8513 0 06 0 21 0 002 0 0...

Page 29: ...t piece clearance Diameter at the contact point with the shift piece Interlock to select alrn clearance Diameter at the contact point with the select arm Shift piece to shift forks and Bth reverse shift piece clearance Diameter at the contact point with the shift forks and 5th reverse shift niece STANDARD NEW 0 3 0 8 0 01 0 03 17 0 17 1 0 669 0 673 0 14 0 006 0 1 0 2 0 004 0 008 0 03 0 10 0 001 0 ...

Page 30: ...eturn spring free length 1st 41 4 1 630 39 4 1 551 2nd 3rd 4th 33 0 I 299 31 0 1 220 Clutch disc thickness Ist hold Ist 2nd 3rd 1 88 2 00 0 074 0 079 Until grooves wone out 4th 2 28 2 40 0 090 0 094 Until grooves wone out Clutch plate thickness 1 St hold 1 st 1 95 2 05 0 077 0 081 Discoloration 2nd 3rd 4th 2 25 2 35 0 089 0 093 Clutch end plate thickness 4 M a r k 1 2 05 2 10 0 081 0 083 Mark 2 2 ...

Page 31: ...48 1 5754 Countershaft 1 st gear 40 000 40 016 1 5748 1 5754 Countershaft reverse gear 43 000 43 016 1 693 1 694 Countershaft 4th gear 41 000 41 016 1 614 1 615 Countershaft 2nd gear Involuted spline Countershaft 3rd gear 52 000 52 019 2 0472 2 0480 Secondary shaft 2nd gear 43 000 43 016 1 693 I 694 Reverse idler gear 18 007 18 020 0 7089 0 7094 I Wear or damage Mainshaft 1st gear collar length 35...

Page 32: ... 35 440 1 3947 l 3952 35 440 35 455 1 3952 1 3959 35 455 35 470 I 3959 l 3965 35 470 35 485 1 3965 1 3970 35 485 35 500 1 3970 I 3976 35 500 35 515 1 3976 l 3982 17 90 I 7 95 0 705 0 707 1 975 2 000 0 078 0 079 2 000 2 025 0 078 0 080 2 025 2 050 0 080 0 081 2 050 2 075 0 081 0 082 2 075 Z 100 0 082 0 083 2 100 Z 125 0 083 0 084 2 125 Z 150 0 084 0 085 2 150 Z 175 0 085 0 086 2 175 2 200 0 086 0 0...

Page 33: ... o 0 039 1 o 0 039 5 7 0 224 7 6 0 299 14 7 0 579 9 6 0 378 38 4 1 512 8 4 0 331 8 4 0 331 8 4 0 331 6 4 0 252 8 4 0 331 8 1 0 319 8 6 0 339 7 6 0 299 7 1 0 280 8 6 0 339 7 0 0 276 24 3 0 957 20 0 0 787 18 0 0 709 20 2 0 795 19 0 0 748 8 6 0 339 5 6 0 220 6 6 0 260 8 1 0 319 9 4 0 370 6 8 10 268 6 6 0 260 6 1 0 240 6 1 0 240 14 6 0 575 14 8 0 583 88 6 3 488 44 0 I 732 30 3 1 193 41 8 1 646 44 4 1 ...

Page 34: ...ection at adjustment Caster o Front at inspection at adjustment Total toe Front Rear Front wheel turning angle Inward wheel Outward wheel Side slip Front Rear Rim runout End Play Axial Radial Front Rear 00 20 530 00 20 210 I0 30 30 10 30 IO 8O 00 245 8 00 215 out 3 5 21 In 6 0 I 33O 06 2O 26O 34 Out 6 0 1 In 9 0 I O O 7 O 0 028 O O 7 O 0 028 0 0 SERVICE LIMIT 0 05 0 002 0 05 0 002 r Brakes Section...

Page 35: ...ng capacity 5 hour ratio V AH MIT A K Starting capacity 5 second ratio V M T at 15OC 15OFI 300 A draw A T Alternator belt Deflection with 98 N IO kg 22 lb ft between oullevs Alternator MEASUREMENT 1 Output 13 5 V at hot A 6 000 rpm Coil resistance rotor 0 Slip ring O D Brush length Brush spring tension g 02 Starting motor 1 TvpelOutput kW M a depth Commutator runout Commutator O D Brush length Bru...

Page 36: ...SH 4 425 mm 174 0 in 1 810 mm 71 3 in 1 175 mm 48 3 in 2 530 mm 99 6 in 1 510 1 530 mm 59 4160 2 in 135 mm 5 3 in 2 1 610 kg 3 550 lb 1 610 kg 3 550 lb Water cooled 4 stroke DOHC with VTEC gasoline engine 90 VG cylinder transverse 90 0 x 78 0 mm 3 54 x 3 07 in 2 977 cm3 cc 181 6 cu in 10 2 Belt driven double 41 overhead camshafts Forced and wet sump Premium UNLEADED grade gasoline with 91 Pump Oct...

Page 37: ... h 1 800 rpm 27 C I 81 OF 50 35 oc 95 OF 4 5 m set 14 8 ft sec 420 m3 h 15 540 cu ftlh Swash plate type NIPPON DENS0 1 0 155 3 cc rev 1 94 7 cu in rev 7 600 rpm 80 cc 2 7 US oz Corruaated fin tvpe Corrugated fin type 19 5 oc 67 OF at 12V Sirocco fan 178W112V Infinity variable 460 m3 h 1 16 247 cu ftlh Air mix type Dry single plate V belt drive 40 WI12 V R 12 9505 8 g 77 9 d lb Rack and pinion Elec...

Page 38: ...ox 7 5 A 10 A 15 A In The Relay Box 7 5 A 10 A 15 A 20 A 30 A 40 A 50 A In The Main Fuse Box 7 5A IOA 15A 20A 30A 40A 120A Headlights High Low 12V 65W 5 5 W Front Turn Signal Lights 12 V 32 CP SAE 1156 Front Position Light 12 v 5 w SAE 3652 Rear Turn Signal Lights 12 v 45 CP SAE 3497 Stop Tail Lights 12 V 3212 CP SAE 2057 Tail Lights 12 v 2 CP SAE 194 Side Marker Lights Front 12 v 3 CP SAE 168 R e...

Page 39: ...Body Specifications m I 1 175 46 3 Unit mm in ...

Page 40: ...Maintenance Lubrication Points 4 2 Maintenance Schedule 4 4 ...

Page 41: ...ng column bushings 1 0 Steering ball joints 1 1 Select lever Automatic 1 2 Pedal linkage 1 3 Intermediate shaft 1 4 Brake master cylinder pushrod 15 Trunk hinges 1 6 Door hinges upper and lower 17 Door opening detents 18 Fuel filler lid 19 Front hood hinges and latch 20 Clutch master cylinder pushrod 2 1 Tilt lever 2 2 Parking brake cable end 2 3 Throttle cable end 2 4 Shift cable end and select c...

Page 42: ... 13 I 0 4 3 ...

Page 43: ... G E jJ I I 11 11 Manual 800 2 50 rpm Automatic 750 f 50 rpm 11 84 in gear Check with CO meter 1 1 l 12 1 l 12f 1 1 l 13 15 2 Red BTDC 123 91 If clicking sound is heard as you pinch the PCV hose between the PCV valve and in 11 134 take manifold valve is OK Intake 0 15 0 19 mm fO O06 0 007 in Exhaust 0 17 0 21 mm 0 007 0 008 in The rubber fuel hoses need periodic replacement since they are subject ...

Page 44: ...g kl aJnssaJd 46 warsAs ayeJq yzol vJV VP 6 1 I naJ D 146y waisAs ayeJq y3ol uV E P 6 1 uo iewJ 4uo3 leu6 s Josuas laaqM l I I l t 6 I isai uo iounj uo ieJado wa sAs ayeJq y3ol luV 69 6 1 J OAJaSaJ all1 UO SyJew 19 6 1 JaMol pue Jaddn ayl uaannlaq s laAal p nl4 8 tl IA p nl4 uralsAs awq iw vw3 vwi4 tr JO txoa AIUO asn ayeJq yc ol y V Gu pnlau pin14 ayeJg P 6 1 SY ID P L 01 o t pa6e6ua Allnd I I I ...

Page 45: ...Construction and Function Outline 5 2 Variable Valve Timing and Lift Electronic Control System VTEC 5 4 Cylinder Head 5 9 Lubrication System 5 11 Exhaust System 5 13 Cooling 5 14 ...

Page 46: ...d fuel and uses a PGM FI Multi point injection system This engine incorporates a new mechanism called Honda Variable Valve Timing and Lift Elec tronic Control System VTEC This mechanism the world s first allows the timing and lift of the intake and exhaust valves to be changed simultaneously The engine also includes a new electronically controlled intake manifold system that can change the volume ...

Page 47: ...hieved by switching the chamber volume of the intake manifold according to engine speed This is electronically controlled l Cooling system for the mid ship engine Radiator located in front compartment An aluminum alloy radiator and pipes made of aluminum alloy Engine room cooling fan Expansion tank l The cylinder block is highly rigid with deep water jackets l In order to achieve lighter weight ma...

Page 48: ...ming and lift profile at low speed and a different profile at high speed Switch over from one profile to the other is controlled electronially and is selected by monitoring current engine speed and load CAM LOBES FOR LOW RPM CAM LOBES FOR HIGH RPM PRIMARY ROCKER ARM MID ROCKER ARM SECONDARY ROCKER ARM LOST MOTION ASSEMBLY INTAKE VALVE EXHAUST VALVE 5 4 ...

Page 49: ...g and lift output improves to the level that a racing engine can offer Until now few variable valve timing systems have been commercialized In those that have only the time that both valves are open intake exhaust overlap could be changed Honda s system is the first in the world in which both the valve timing and the degree of valve lift can be changed as needed making it the most advanced valve t...

Page 50: ...TION STOPPER PISTON drive the rocker arms separately PISTON B I PRIMARY MID SECONDARY ROCKER ARM ROCKER ARM ROCKER ARM At High rpm When driving at high rpm the built in piston moves in the direction shown by the arrow in the figure below As a result the primary secondary and mid rocker arms are linked by 2 hydraulic pistons like a skewer and the 3 rocker arms move as a single unit In this state al...

Page 51: ...tus such as load rpm and vehicle speed This information is transmitted to the Control Unit Valve Timing Change Conditions Engine RPM 5 800 6 000 rpm Vehicle Speed 5 km h 3 MPH or faster Water Temperature 60 C 140 F or higher Control System w t 2 SOLENOID VALVE SPOOL VALVE 3 IL from OIL PUMP I I Water temp I cont d 5 7 ...

Page 52: ...ASSEMBLY Hydraulic Pressure Control Mechanism Spool valve hydraulic pressure switch The solenoid valve in response to a signal from the PGM FI ECU closes the oil passage to the rocker arm at low speed This cuts oil pressure to the hydraulic pistons in the rocker arms so the arms operate independently At high speed the ECU opens the solenoid valve The increased oil pressure causes the hydraulic pis...

Page 53: ...ubrication On the right end of each camshaft is a driven pulley The exhaust and intake cycles require a total of 36 cam lobes to open and close the va ves No 6 No 5 No 4 c FRONT BANK No 3 No 2 No 1 f REAR BANK n r 7 il INTAKE CAMSHAFT JOURNALS EXHAUST No 6 No 5 No 4 FRONT BANK No 3 No 2 No 1 R E A R B A N K Manual Transmission A PRIMARY B MID C SECONDARY Intake valve open Exhaust valve open Automa...

Page 54: ... while increasing valve lift thus improving intake exhaust efficiency Valve mecifications Unit mm in INTAKE EXHAUST HEAD DIAMETER SHAFT DIAMETER OVERALL LENGTH VALVE LIFT MIT A T 35 1 38 5 5 0 22 112 45 4 43 A 8 7 B 10 2 C 8 3 A 9 0 B 9 5 c 8 6 30 1 18 5 5 0 22 111 55 4 39 A 7 7 8 9 0 c 7 4 A 7 7 B 9 0 c 7 4 Indicates high speed valves I Shaft diameter 5 10 ...

Page 55: ...w CRANKSHAFT MAIN JOURNAL MAIN BEARING CAP BRIDGE t I Front No 6 No 5 No 4 No 3 No 2 No 1 t t t 1 Rear SPOOL VALVE ROCKER SHAFT ORIFICES CYLINDER HEAD LIEF VALVE OIL FILTER I ENGINE OIL COOLER CYLINDER HEAD ORIFICE ROCKER SHAFT ORIFICES 5 11 ...

Page 56: ...ressure is regulated by the pump relief valve It is then filtered through the oil filter and pumped to the cylinder block and cylinder head A baffle plate is provided inside the oil pan the baffle plate helps minimize the changes in oil level produced inside the pan while driving will affect the amount of oil go ing to the pump CAM HOLDER PIPE ROCKER SHAFT OIL FILTER OIL SiRAlNER SHAFT 5 12 ...

Page 57: ...low back pressure 0 Sound tuning has been optimized to give a sporty exhaust sound note suitable to this type of car This is done by a col lection chamber in Exhaust Pipe B SILENCER MANIFOLD CONVERTER FRONi EXHAUST MANIFOLD Exhaust gas from front bank COLLECTION CHAMBER Exhaust gas from rear bank 5 13 ...

Page 58: ... system with the radiator mounted in the front of the vehicle An air cooling system driven by fan mounted in the engine compartment BLEEDER EXPANSION TANK I DRhN RADIATOR WATER VALVE HEATER CORE elY llYC IL COOLER BLEEDER THERMOSENS THERMOSTAT THROGLE BODY BREATHER PIPE ...

Page 59: ...ks are made of resinous material for reduced weight and increased corrosion protection The engine compartment cooling fan is mounted on the right side It operates in conjunction with the radiator s electric cooling fan in high mode The expansion tank is used to separate air out of the coolant circulating through the system Radiator Specifications Radiator volume kcal h 46 000 Height mm 340 Core si...

Page 60: ...Engine Removal Installation ...

Page 61: ...I 5 18 Ref No Tool Number 0 07MAC SLOOIOO 0 07941 6920003 Description Q ty Page Reference Ball Joint Remover 1 5 24 Ball Joint Remover 1 5 24 ...

Page 62: ... l 7 I 81 1 Move the seat bottoms and backs as far forward as they will go 2 Disconnect the battery negative terminal first then the positive terminal 3 Remove the expansion tank cap to speed draining m Use care when removing the expan sion tank cap to avoid scalding by hot coolant or steam 4 Raise the hoist to full height 5 Drain the coolant See Section 10 l Loosen the drain plug from the radiato...

Page 63: ... i26 x 1 0 mm 10 N m 1 0 kg m 7 lb ft ENGINE R ROOM FAN NNECTOR a6xl Omm 10 Nom I O kg m 7 lb ft 14 Remove the rear trim panels behind the passenger s seat then disconnect four connectors from ECU and five connectors from floor wire harness ENGINE WIRE HARNESS CO HARNESS Ir CORROSION RESISTANT BOLT FUEL FUEL PUMP RESISTER PUMP RESISTER ...

Page 64: ...ce bolt on the fuel filter abo ut one turn See Sec tion 11 m Do not smoke while working on the fuel system Keep open flame away from work area Drain fuel only into an approved container CAUTION l Before disconnecting any fuel line the fuel pressure should be relieved as described above l Place a shop towel over the fuel filter to Prevent pressurized fuel from spraying over the en gine 18 Remove th...

Page 65: ...CHARCOAL CANISTER CHARCOAL CiNISTER HOSE I BRAKE BOOSTER VACUUM HOSE 24 Disconnect the two engine wire harness connec tors from the side wire harness at left side of engine compartment and remove the engine wire harness terminal and the starter cable terminal from the under hood relay box and clamps 25 Remove the ground cable from the transmission FUSE BOX 1 O kg m ENGINE GIRE HARNESS 7 lb ftl 26 ...

Page 66: ...e clutch slave cylinder from the transmission case M T See Section 12 0 Do not disconnect the clutch hose 32 Remove the lower cover then remove the shift cable and select cable with cable bracket M T See Section 13 33 Remove the cover then remove the shift cable A T See Section 14 NOTE l Take care not to bend the cable when removing it Always replace a kinked cable with a new one 0 Adjust the cabl...

Page 67: ...ion lower control arms use ball joint remover 07MAC SLOOlOO and the toe control arms use ball joint remover 07941 6920003 CAUTION Make sure that the reference marks on the control arm are aligned 38 Remove the stabilizer links and separate the damper and the suspension lower control arms Hang with l Do not remove the compressor hoses l Hang the AK compressor with wire or rope as shown Do not let i...

Page 68: ... air wrench for tightening self locking nuts on exhaust pipes or catalytic converters if the oxygen sensors are not to be removed NOTE Use new gaskets and self locking nuts when reassembling SELF LOCKING NUTS lOx1 25mm 34 N m 3 4 kg m 25 lb ft n YTIC Replace FRONT EX PIPE SELF LOCKING NUT 10 x 1 25 mm 55 N m 15 5 kg m 40 lb ft 45 Remove the half shaft heat cover 46 Remove the driveshafts NOTE o Co...

Page 69: ...ush the side engine mounting bracket into the except the four bolts shown support bracket of the body 48 Lo wer hoist attach a chain hoist to the engine 51 Remove the transmission mounting bolt 49 Install the front engine mounting bolt torque the nut temporarily BODY SUPPORT BRACKET Do not remove these bolts until step 52 TRANSMISSION MOUNTING Do not remove these bolts until step 52 ...

Page 70: ...s with the chain hoist 56 Remove the chain hoist from the engine 57 Raise the body with the hoist Roll the engine assembly from under the body 54 Check that wires and hoses are completely remov ed from the engine assembly TRUCK GUIDE HOLE BODY GUlDiHOLE SIDE BEAM SCREWDRIVER NOTE When installing align the bolt holes of the beam brackets and body with screwdriver cont d 5 27 P ...

Page 71: ...1 Install the engine in the reverse order of removal NOTE 0 Align the bolt holes of the beam brackets and body with screwdriver page 5 27 l Temporarily torque the two front beam nuts and front engine mounting bolt when installing the A C compressor 0 Combine the front beam and the rear beam rod assembly then torque the four mounting bolts 0 Check that the set ring on the end of each driveshaft cli...

Page 72: ...Adjust the A C belt See Section 22 0 Clean battery posts and cable terminals with sand paper assemble then apply grease to prevent corrosion 0 Inspect for fuel leakage l After assembling fuel line parts turn on the igni tion switch do not operate the starter so that the fuel pump is operated for approximately two seconds and the fuel is pressurized Repeat this operation two or three times and chec...

Page 73: ...que Valve Specifications 8 x 1 25 mm 10 x 1 25 mm A T TRANSMISSION HANGERS refer to Section n 8 x i 25 mm I 11 22N m 2 2kg m ALT INATOR 1 BRACKET D STIFFENER MIT TRANSMISSION HANGER8 1 12x 1 25mm 75 Nom 7 5 kg m 54 lb ft HALF SHAFT SUPPORTBASE AX BRACKET HALF SHAFT HEAT COVER 10 N m I O kg m 7 lb ft 5 30 ...

Page 74: ...N m 6 0 kg m 43 lb ft I lO x 1 25 mm 60 N m 6 0 kg m 43 lb h L REAR BRACKET IO x 1 25 mm 60 N m 6 0 kg m 43 lb 60 N m 6 0 kg m I0 x 1 25 mm 60 N m 6 0 kg m 43 lb ft v 412 x I 26 mm 95 N m 9 5 kg m 6 9 lb ft 10 x 1 25 mm 60 N m 6 0 kg m 43 lb ft T CORROSION RESISTANT BOLT NUT ...

Page 75: ...d Index 6 21 Inspection 6 22 Tension Adjustment 6 22 Removal 6 23 Installation 6 25 CRANKlCYL Sensor 6 27 Cylinder Head Removal 6 28 Rocker Arms and Shafts Location 6 35 Inspection 6 36 Clearance 6 37 Camshaft inspection 6 38 Valve and Valve Seals 6 40 Cylinder Heads 6 41 Valve Seats 6 42 Valve Guides 6 44 Valve Spring and Valve Seals 6 46 Cylinder Head Installation 6 47 Rocker Arms 6 49 Camshafts...

Page 76: ... Harness 0 07MAA PR70110 Tappet Adjuster GO 07MAA PR70120 Tappet Locknut Wrench 0 07MAJ PR70100 Test Harness 07MAJ PR70200 VTEC Plug 0 07757 PJIOIOA 8 Valve Spring Compressor Attachment 07742 0010100 Valve Guide Driver 5 5 mm my Page Reference 1 6 45 1 6 11 1 6 55 1 6 55 1 6 l 1 1 6 52 5 3 1 6 40 1 6 44 45 6 2 ...

Page 77: ...m 25 kg m 181 lb ft WASHER AND CYLINDER GROMMET HEAD COVER I CAP NUT COVER RUBER SEALS Replace when damaged or deteriorated 6x 1 0 mm 12N m 1 2 kg m 9 lb ftl 6x 1 0 m m CYLINDER HEAD RUBBER SEALS Replace when damaged or deteriorated TIMING BELT REAR MIDDLE COVER TIMING BELT inspection page 6 22 Adjustment page 6 22 Replacement page 6 23 Replace every 90 000 miles 144 000 km or 72 months TIMING BEL...

Page 78: ...eriorated 6x 1 0 mm ION m 1 0 kg m 7 lb ft CAM HOLDER 8x 1 25 mm 22N m 2 2 kg m 18 lb ft AD oil to the boIt threads D O W E L P I N m 10x 1 25 mm 70N m 7 0 kg m 51 lb ft DWEi PIN FRONT INTAKE CAMSHAFT ER SEALS FRONT EXHAUST 6 x 1 O mm RLi88ER SEALS 12N m 1 2 kg m Replace when damaged 9 lb ft or deteriorated TIMING BELT COVER PLATE I CAM PULLEY ...

Page 79: ...8 x 1 25mm 22N m 2 2 kg m 16 lb ft FRONT SPOOL VALVE Troubleshooting page 6 l 6 I a 43 lb ft OIL PRESSURE SENSOR 8 x 1 25mm 22N m 2 2 kg m 1 6 l b f t DOWEL PIN P O RING Replace RADIATOR FAN CONTROL SENSOR 1 28N m 2 6 kg m 20 lb ftt O RING Replace I ROCKER SHAFT ORIFICE RCiCKER ARM ASSEMBLY PRIMARY MID SECONDARY Inspection page 6 36 Remove with 5 mm bolt and clean kont dl 6 5 I ...

Page 80: ...m and apply lubricant to any contact parts INTAKE VALVE VALVE KEEPERS SPRING OUTER _ CYLINDER HEAD BOLTS 11 x 1 5mm 78N m 7 8 kg m 56 lb ft Apply engine oil to the bolt threads VALVE GUIDE LOST MOTION VALVE SPRING CYLINDER HEAD BOLTS 11 x 1 5m 78N m 7 8 kg m 56 Ib Apply engine oil to the bolt threads ALVE SPRING SEAT EXHAUST VALVE EXHAUST VALVE SPRING RETAINER VALVE KEEPERS VALVE SEAL LOST MOTION ...

Page 81: ...lr I 6 7 ...

Page 82: ...VTEC Electrical Connections MAIN RELAY PG2 A24 FLRl A7 FUSES t SPEED SENSOR i p l3l fM K ENGINE c2 VSP WARN Al3 0 ES All 1 EGR CONTROL SOLENOID VALVE CHAMBER VOLUME CONTROL SOLENOID VALVE ...

Page 83: ...20 VCC2 D21 SGl 022 SO2 D17 PB D5 PAOUT IG No 1 A21 IG No 2 A22 IG No 3 B6 10 No 4 66 IG No 5 84 IG No 6 83 DllBTH I I NEP C4 D15 TA AFSA Fl D13TW I AFSB F3 I FAS Al6 D9 ACGF A10 HTCNTF 014 02 F I VTSF F5 I VTSR F7 D4 KSF I IGNITER UNIT IGNITION COIL FRONT SPOOL REAR SPOOL SOLENOID VALVE SOLENOID VALVE 6 REAR FRONT KNOCK KNOCK SENSOR SENSOR TERMINAL LOCATION 6 9 ...

Page 84: ...code by blinking frequency The Check Engine light can indicate any number of simultaneous component problems by blinking separate codes one after another Problem codes 1 through 9 are indicated by a individual short blinks Problem codes 10 through 59 are indicated by a series of long and short blinks The number of long blinks equals the first digit the number of short blinks equals the second digi...

Page 85: ...et ECU NOTE Disconnecting the CLOCK fuse also cancels the radio preset stations and the clock setting Make note of the radio presets before removing the fuse so you can reset them CLOCK FUSE III Final Procedure this procedure must be done after any troubleshooting cont d 6 11 ...

Page 86: ...sted above are indicated verify the code If the code indicated is not listed above replace the ECU 0 The Check Engine light may come on indicating a system problem when in fact there is a poor or intermittent elec trical connection First check the electrical connections clean or repair connections if necessary 0 The Check Engine light and D indicator light may come on simultaneously when the self ...

Page 87: ...es the ECU test harness remove the seat back panels Unbolt the ECU n check the system according to the procedure described for the appropriate code s listed on the following pages ECU I PANELS DIGITAL MULTIMETER TEST HARNESS 07MAJ PR70100 TEST HARNESS 07LAJ PT3OlOA TERMINAL LOCATION ...

Page 88: ...ectrical connections 0 For testing at connectors other than the ECU test harness bring the tester probe into contact with the terminal from the connector side of wire harness connectors in the engine compartment For female connectors just touch lightly with the tester probe and do not insert the probe RUBBER SEAL TESTER PROBE TERMINAL ...

Page 89: ...d body ground Front or 5 1 Rear A problem in the Spool YEL Front or BLUlYEL Rear Replace the spool valve Y E S I Connect the ECU test harness F5 Front Check for continuity between YEL Front or BLU YEL Rear terminal and F5 Front or F7 Rear terminal F7 Rear YEL Front or BLWYEL Rear Does continuity exist 1 YES N O Repair open in YEL Front or BLWYEL Rear wire between ECU and spool valve connector To p...

Page 90: ...Troubleshooting Flowchart Spool Valve cont d From page 6 15 harness side and body ground J Does continuity exist N O and recheck If symptomlindica tion goes away replace the origi I YEL Front or BLWYEL Rear ...

Page 91: ...K Rear terminal and body ground I 1 011 GRN VVHT Front and Rear BLU Front or BLU BLK Rear Does continuity exist 7 Y E S Repair open in BLU Front or BLWBLK Rear wire between 2P connector and body ground Connect the ECU test harness F2 F4 I I I Check for continuity between BLU Front or BLU BLK Rear terminal and F2 Front or F4 Rear terminal Does continuity exist Repair open in BLU Front or BLUlBLK Re...

Page 92: ...e Check for continuity between the 2 terminals on the oil pressure switch I Does continuity exist 7 Replace oil pressure switch Disconnect the 2P connector from SPOOL VALVE the spool valve Attach the battery positive termi nal to the YEL Front or BLUlYEL To page 6 19 ADAPTOR 10 x 1 Omm SEALING BOLT 20N m 2 0 kg m 14 lb ft NOTE Keep measuring time as short as possible because engine is running with...

Page 93: ...eep measuring time as short as possible because engine is running with no load within one minute ADAPTOR under above condition Does continuity exist N O Replace oil pressure switch Substitute a known good ECU and recheck If symptomlindica tion goes away replace the orlgl nal ECU 6 19 ...

Page 94: ...istance is within specifications remove the spool valve assembly from the clinder head and check the spool valve filter for clogging l If there is clogging replace the engine oil filter and the engine oil SPOOL VALVE ASSEMBLY 6x l Omm 12 N m 1 2 kg m B lb ft 4 If filters are normal push the spool valve with the finger and check its movement l If spool valve is normal check the engine oil pessure 6...

Page 95: ...t the L kg m 203 lb ft loosen it retighten it to 250 rubber seal from falling of N m 25 kg m 181 lb ft 4 CAP NUT CAP NUT 6x 1 0 mm 6xl Omm El 1ON m 11 0 kg m 7 lb ft lON m 1 0 kg m _ CYLINDER HEAD COVI RUBBER SEALS Replace when damaged or deteriorated 6x 1 0 mm 12N m 1 2 kg m 9 lb ft 6x 1 0 mm 9 lb ft TIMING BELT REAR MIDDLE COVER WASHER and A GROMMET x 1 25 mm 43N m 4 3 kg m id ft For adjustment ...

Page 96: ... spring loaded to apply proper tension to the belt automatically after making the following ad justment 0 Inspect the timing belt before adjusting the belt tension l Always rotate the crankshaft clockwise Rotating it counterclockwise may result in improper adjustment of the belt tension 1 Install the timing belt with the No 1 piston at TDC page 6 25 26 2 Fix the crankshaft remove the slack in the ...

Page 97: ... strut bar page 5 19 7 Remove the intake mainifold plate 8 Remove the top cover page 5 21 9 Remove the ignition coil covers 10 Remove the injector cover and the wire harness covers 11 Remove the ignition coils and the connecters NOTE 0 There are front and rear ignition coils and covers They can be identified by the mark FF front or RR rear printed on them 0 When installing front and rear ignition ...

Page 98: ...0 Remove the alternator bracket stiffener ALTERNATOR BRACKET STIFFENER 8x 1 25 m 22N m 2 2 kg m 16 lb ftl I DIPSTICK 1 0x 1 25 mm 45N m 4 5 kg m 33 l ft 6x 1 0 mm 12N m 1 2 kg m 9 lb ft PIPE 2 1 Remove the A C adjusting pulley and belt 22 Remove the dipstick pipe mounting bolt then re 24 Loosen the timing belt adjusting bolt 180 and move the front and rear timing belt middle covers 23 Remove the c...

Page 99: ... front intake cam pulley to the pointer on the front timing belt cover plate 0 Align the TDC mark on the rear intake cam pul ley to the pointer on the rear timing belt cover plate I Advance the rear exhaust cam pulley to one half tooth from TDC 4 Install the timing belt in the sequence shown Timing belt drive pulley crankshaft Adjust ing pulley t Front exhaust cam pulley Front intake cam pulley Wa...

Page 100: ... of the cam pulleys to the top and align the TDC marks on the pulleys l Align the holes on the camshaft holder pipes to the camshaft holes insert 5 0 mm pin punches and fix them at TDC 0 Remove the pin punches after the timing belt has been reinstalled NOTE l Prior to installing the cylinder head cover apply a thin layer of liquid gasket to the mating surface of the cylinder head cover and rubber ...

Page 101: ... the front cylinder head FRONT INTAKE CAM PULLEY 10 x 1 25 mm 70N m 17 0 kg m 51 lb ft 5 Install the CRANK CYL sensor in the reverse order of removal l Refer to page 6 25 and 26 when installing the timing belt 6x1 0 mm 12N m 1 2 kg m 9 lb ft CRANKlCYL SENSOR FRONT CAMSHAFTS I 1 TIMING BELT T _ RONT EXHAUST AM DI II I CWc ir wa FRONT TIMING BELT COVER PLATE 6xl Omm 12N m 1 2 kg m 9 lb ft TltilNG BE...

Page 102: ... to be removed GASKETS Replace SELF LOCKING NUTS 10 x 1 25 mm 34N m 3 4 kg m 25 lb ft Replace REAR EXHAUST PIPE A REAR EXHAUST PIPE A SELF LOCKING NUTS 10 x 1 25 mm 34N m 3 4 kg m 25 lb ft Replace GASKETS Replace 7 Remove the under cover then remove the water pipe drain bolts and drain the coolant 8 Attach the hoses to front and rear engine drain bolts then loosen the bolts and drain the coolant 0...

Page 103: ...the harness clamps from the cylinder head and the intake manifold Front cylinder head l CRANKICYL sensor connector l A C compressor magnetic clutch connector 0 Oxygen sensor connector 0 Ground cable terminal l Ground terminal l Three injector connectors cylinders No 4 5 and 6 l TA sensor connector 0 Igniter connector 0 Condenser connector 0 Oil pressure sensor connector oil pressure gauge 0 Spool ...

Page 104: ...erials from get ting into the cylinders EGR PIPE MOUNTING BOLT 8x 1 0 m m 12N m 1 2 kg m 9 lb W 8x 1 25 m m 22N m 2 2 kg m 18 lb W PCV HOSE Remove INSECTOR CONNECTOR No 4 CYLINDER I TA SENSOR COYNECTOR I GROUND CABLE GROUtiD CABLE I 8x 1 0 mm 12N m 1 2 kg m 9 lb ftl INJECTOR CONNECTOR No 1 CYLINDER INTAKE MANIFOLD GASKET Replace EGR PIPE GASKET Replace 4 _ e ...

Page 105: ... 2 kg m 9 lb ft I KNOCK SENSOR WIRE HOLDER 28 Remove the heater hose and the water hoses WATER HOSES 29 Remove the water passage PIPE 6x 1 25 mm 22N m 2 2 kg m 16 lb ft 30 Remove the cylinder head covers 31 Turn the crankshaft so that the No 1 piston is at top dead center page 6 25 26 A 32 Install the attachment under the engine then tilt the engine approximately 5O using a jack page 6 24 33 Remov...

Page 106: ...cover 36 Loosen the timing belt adjusting bolt 180 and release the belt tension NOTE Push the tensioner to release tension from the belt then retighten the adjusting bolt ALiJUSTlNG BOLT Do not remove Loosen it 1 80 37 Remove the timing belt from the pulleys CAUTION Do not crimp or bend the timing belt more than 90 or less than 25 mm 1 in in diameter y CAUTION Do not crim bend the timing belt ifio...

Page 107: ...rifice then pull out the rocker shaft orifices fl ROCKER SHAFT 5 mm BOLT 43 Remove the spool valve assemblies 44 Remove the sealing bolts EALING BOLT BOLT 45 Bundle the rocker arms with a rubber band to prevent them from separating 46 Screw a 12 x 1 25 mm bolt into each rocker shaft Remove the rocker arms while slowly pull ing the rocker shafts out of the cylinder heads toward the transmission ROC...

Page 108: ...quence until all bolts are loosened CYLINDER HEAD BOLTS LOOSENING SEQUENCE NOTE Separate the cylinder head from the block with a flat blade screwdriver as shown 49 Remove the front and rear exhaust manifold covers then remove the front and rear exhaust manifolds CAUTION l Remove the oxygen sensors before removing the exhaust manifolds l Do not use air wrench or hammer for removing the exhaust mani...

Page 109: ...t be installed in the same position if reused s Install the rocker arms after torquing the cylinder head bolts 3 Prior to reinstalling clean all the parts in solvent dry them and apply lubricant to any contact surfaces Front Cylinder Head SEALING BOLTS 20 mm 60N m 6 0 kg m 43 lb W EXHAUST ROCKER EXHAUST ROCKER ARM ASSEMBLIES No1 6 No 5 Nd 4 RUBBER BAND RUBBER BAND INTAKE ROCKER ARM ASSEMBLIES CYLI...

Page 110: ...smoothly replace the rocker arm assembly PRIMARY Check piston movenent NOTE 0 Apply oil to the pistons when reassembling 0 Bundle the rocker arms with a rubber band to pre 2 Remove the lost motion assembly from the cylinder head and inspect it Pushing it gently with the finger will cause it to sink slightly Increasing the force on it will cause it to sink deeper If the lost motion assembly does no...

Page 111: ...o shaft diameter MICROMETER 3 Measure inside diameter of rocker arm and check for out of round condition Rocker Arm Radial Clearance Service Limit 0 08 mm 0 003 in Inspect rocker arm face for wear Repeat for all rockers I If over limit replace rocker shaft and all over tolerance rocker arms I NOTE If any rocker arm needs replacementj refilace all three rocker arms in that set primary mid and secon...

Page 112: ...forth and read the end play Camshaft End Play Standard New 0 05 0 15 mm 0 002 0 006 in Service limit 0 5 mm 0 02 in 4 Remove the bolts then remove the cam holders from the cylinder head Lift camshaft out of cylinder head wipe clean then inspect lift ramps Replace camshaft if lobes are pitted scored or excessively worn Clean the camshaft bearing surfaces in the cylinder head then set camshaft back ...

Page 113: ...r head If the total runout is out of tolerance replace the camshaft and recheck If the bearing clearance is still out of tolerance replace the cylinder head 8 Check cam lobe height wear Cam lobe height standard New M T I INTAKE j EXHAUST PRIMARY 37 086 mm 36 559 mm I 4601 in I 4393 in MID 38 037 mm 37 398 mm f 1 4975 in I 4724 in SECONDARY 37 326 mm 36 741 mm I 4695 in 1 4465 in r INTAKE PRIMARY 3...

Page 114: ...keep ers before installing the valve spring compressor PLASTIC MALLET Install spring compressor Compress spring and re move valve keeper VALVE SPRING COMPRESSOR ATTACHMENT VALVE SPRING COMPRESSOR ATTACHMENT EXTENSION I I VALVE SPRING COMPRESSOR Snap on CF711 3 Install the special tool as shown VALVE SEAL COMMERCIALLY AVAILABLE VALVE GUIDE SEAL REMOVER LISLE P N 57900 S E PU 4 Remove the valve guid...

Page 115: ... 95 mm 0 065 0 077 in D Service Limit 1 45 mm 0 057 in1 Cylinder Heads m l e I Warpage NOTE If camshaft bearing clearances page 6 38 are not within specification the head cannot be resurfaced If camshaft bearing radial clearances are within specifi cations check the head for warpage s If warpage is less than 0 05 mm 0 002 in cylinder head resurfacing is not required l If warpage is between 0 05 mm...

Page 116: ...iginal location in the head then lift it and snap it closed against the seat sever al times ACTUAL VALVE SEAT Y PRUSSIAN BLUE COMPOUND 6 The actual valve seating surface as shown by the blue compound should be centered on the seat l If it is too high closer to the valve stem you must make a second cut with the 60 stone to move it down then one more cut with the 45O stone to restore seat width l If...

Page 117: ...If measurement still exceeds limit recheck using alternate method below then replace valve and guide if necessary NOTE An alternate method of checking guide to stem clearance is to subtract the O D of the valve stem meas ured with a micrometer from the I D of the valve guide measured with an inside micrometer or ball gauge Take the measurements in three places along the valve stem and three places...

Page 118: ...it may warp the head a Do not get the head hotter than 150 C 300 F excessive heat may loosen the valve seats 0 To avoid burns use heavy gloves when handling the heated cylinder head 4 Use the driver and an air hammer working from the camshaft side to drive the guide about 2 mm towards the combustion chamber This will knock off some of the carbon and make removal easier VALVE GUIDE DRIVER 07742 001...

Page 119: ...tool Removal and Installation VALVE GUIDE DRIVER 07742 0010100 Valve Guide Installed Height Intake 13 75 14 25 mm 0 541 0 561 in Exhaust 13 75 14 25 mm 0 541 0 561 in r e EZ e Valve Guide Reaming NOTE For new valve guides only 1 Coat both reamer and valve guide with cutting oil 2 Rotate the reamer clockwise the full length of the valve guide bore 3 Continue to rotate the reamer clockwise while rem...

Page 120: ...ALVE KEEPERS INTAKE VALVE SPRING M T only VALVE SPRING a9 RETAINER VALVE SPRING _ EXHAUST VALVE SEAL BLACK SPRING Replace NOTE Place the end of valve spring with closely WO UJ ICJ coils toward the cylinder head INTAKE VALVE SEAL WHITE SPRING Replace 6 46 i SPRING SEAT NOTE Install the valve spring seats before installing the valve seals ...

Page 121: ...must be clean l Turn the crankshaft so that No 1 piston is at TDC page 6 26 1 Install the front and rear exhaust manifolds to each cylinder head then tighten the self locking nuts in a criss cross pattern in two or three steps beginning with the inner nut 0 Apply oil to the self locking nut threads l Always use new exhaust manifold gaskets CAUTION l Install the oxygen sensors after installing the ...

Page 122: ...SKET METAL CYLINDER HEAD Replace GASKET METAL HEAD ORIFICES Replace D O V O RING Replace PINS 4 Tighten the cylinder head bolts sequentially in two or three steps l Apply clean engine oil to the bolt threads and washer contact surfaces Specified Torque 11 x 1 5 mm 78 N m 7 8 kg m 56 lb ft NOTE We recommend using a beam type torque wrench When using a preset type torque wrench be sure to tighten sl...

Page 123: ...loosened and ad justing screws backed off before installation 1 After wiping down the cam and journals in cylinder head lubricate both surfaces and install camshaft 2 Turn the camshaft until its keyway is facing up NO 1 cylinder TDC 3 install the camshaft seal with the open side spring facing in 3 Lubricate cam lobes after reassembly 4 Set a new O ring and a dowel pin in the oil passage of the No ...

Page 124: ...m holder FRONT No 3 No 1 CAM HOLDER CAM HOLDER i No 2 I No 4 CAM HOLDER CAM HOLDER REAR No 4 CAM HOLDER 0 0 0 0 0 0 No 2 CAM HOI DER No 3 No 1 CAM HOLDER CAM HOLDER 8 Place the cam holder pipes 9 Tighten each bolt two turns at a time in the sequence shown below to insure that the rockers do not bind on the valves NOTE Apply clean engine oil to 8 mm bolt threads Specified torque I 8 mm x 1 25 mm bo...

Page 125: ...der pipe holes and insert 5 0 mm pin punches as shown CAM PULLEYS 5 0 mm RETAINING BOLTS 10x 1 25 mm 70 N m 7 0 kg m 51 lb ft 14 install the timing belt page 6 25 15 Adjust the valve clearance 6 54 16 Inspect the rocker arms pages 6 36 and 6 52 thru 6 541 17 After installation check that hoses and connectors are installed correctly NOTE d 0 Prior to installing the cylinder head cover apply a thin ...

Page 126: ...nd check that the pistons in the mid and primary rock er arms move smoothly 0 Replace the rocker arms as an assembly if there is any abnormality Inspection Using Special Tools 0 Before using the special tool Valve Inspection Set make sure that the air pressure gauge on the air com pressor indicates over 245 kPa 2 5 kg cm2 36 psi l Inspect the valve clearance before rocker arm in spection l Cover t...

Page 127: ...primary and secondary rocker arms are mechanically connected by pistons and that the mid rocker arms do not move when pushed manually PRIMARY ROCKER ARM SECONDARY ROCKER ARM AMPLE LOST MOTION ASSEMBLY MID ROCKER ARM a If the mid rocker arms move independently of the primary and secondary rocker arms replace the rocker arms as a set 5 Remove the special tools 6 Check for smooth operation of the los...

Page 128: ...clearance at TDC of each cylinder 1 Remove the cylinder head covers FRONT No 6 No 6 No 4 No 6 No 4 REAR No 3 No 2 No 1 No 3 No 2 No 1 2 Rotate crankshaft and set No 1 piston at TDC l TDC mark white paint on the crank pulley should align with pointer on the timing lower cover and TDC grooves on the camshaft pulleys should align with timing belt cover plates FRONT No 1 PISTON at TDC REAR PULLEY 6 54...

Page 129: ...007 0 008 in 5 Loosen locknut and turn adjustment screw until feel er gauge slides back and forth with slight amount of drag INTAKE TAPPET ADJUSTER 07MAA PR70 1 1 0 07MAA PI370120 EXHAUST NOTE Use a mirror to check if the special tool is positioned on the locknut correctly 1 6 Tighten locknut andcheck clearance again Repeat adjustment if necessary INTAKE 14 lb ft EXHAUST LOCKNUT 7 x 0 75 mm 20 N m...

Page 130: ... step 6 Number 2 piston at TDC 9 Rotate the crankhft 120 clockwise cam pulley turns 60 Check that the front intake cam pulley is positioned as shown Repeat step 3 to step 6 Number 5 piston at TDC IO Rotate the crankshaft 1 20 clockwise cam pulley turns 600 Check that the front intake cam pulley is positioned as shown Repeat step 3 to step 6 Number 3 piston at TDC 11 Rotate the c tinkshaft 120 cloc...

Page 131: ...ywheel and Drive Plate 7 6 Rod and Main Bearings 7 6 Piston Connecting Rod Assemblys and Crankshaft Removal 7 9 Crankshaft 7 11 7 12 Cylinder B1oc k Pistons Connecting Rod Assemblys 7 12 Piston Rings s 7 15 Oil Seal 7 18 Crankshaft Installation 7 18 Izl I G ...

Page 132: ...Ref No 0 0 0 Tool Number 07746 0010000 07g24 PD20003 07948 s800101 Description Driver Ring Gear Holder Driver Attachment Q ty 1 1 1 Page Reference 7 18 7 6 7 18 7 2 ...

Page 133: ... lb ft DRIVE PLATE Check for cracks I I OIL PAN Do not deform SPECIAL WASHER F OIL PAN GASKET 12xl Omm 75 N m 17 5 kg m Torque sequence p Replace gl f 5kg m 76 lb ft 6 x 110 mm 12 N m I 2 kg m Torque I sequencerpage 7 6 I 1 BAFFLE PLATE CRANK gEAL Installation page 7 18 Replace SPECIAL BOLTS 6xl Omm 12 Nom I 2 kg m 9 lb ft Replace l Sli dE COVER Apply liquid gasket to mating surface cll Replace I ...

Page 134: ...ds Replace MAIN BEARIN CRANKSHAFT End play page 7 6 THRUST WASHERS Replacement page 7 6 Grooved sides face outward NOTE Thrust washer thickness is fixed and must not be changed by grinding or shimming MAIN BEARINGS Radial clearance page 7 7 Selection page 7 8 NOTE New main bearings must be selected by matching crank and block identification OIL BREATHING 12 Nom 1 2 kg m 10x 1 25 mm 50 N m 15 0 kg ...

Page 135: ...No letter denotes A with the letter for each cvlinder stamped on the block I CONNECTING ROD ASSEMBLY End play page 7 6 Selection oaae 7 l 4 CONNECTING ROD PISTON RINGS Replacement page 7 l 5 Measurement pages 7 l 5 Alignment page 7 l 6 spect top of each cylinder bore r carbon build up or ridge vina oiston Cvlindar hnre incnection page 7 y I r Warpage inspectic T n page 7 13 CYLINDER BORE SIZES Cvl...

Page 136: ...ing Rod End Play Standard New 0 15 0 30 mm 0 006 0 012 in Service Limit 0 40 mm 0 016 in CONNECTING ROD CRANKSHAFT 0 if out of tolerance install a new connecting rod 0 if still out of tolerance replace the crankshaft pages 7 9 10 and 7 l 8 Push the crank firmly away from the dial indicator and zero the dial against the end of the crank Then pull the crank firmly back toward the indicator dial read...

Page 137: ...m or scrape the bear ings or the caps to adjust clearance If the plastigage shows the clearance is still incor rect try the next larger or smaller bearing the color listed above or below that one and check again NOTE If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings replace the crank and start over El a I Clearance 1 2 3 4 5 Remove the connecting rod ca...

Page 138: ...icken Bearing Design COLOR NOTE When the different color bearing in top and bottom are mated the color is irrespective of top or bottom Selection Rod Code Location Numbers Numbers have been stamped on the side of each con necting rod as a code for the size of the big end Use them and the letters stamped on the crank codes for rod journal size to choose the correct bearings Half of number is stampe...

Page 139: ...affle plate 4 Remove the oil pass pipe and joint 5 Remove the oil pump 6 If you can feel a ridge of metal or hard carbon around the top of any cylinder remove it with a ridge reamer Follow reamer manufacturer s instructions CAUTION If the ridge is not removed it may damage the pistons as they are pushed out RIDGE REAMER 7 Remove the bearing cap bridge BEARING CAP BRIDGE cont d 7 9 ...

Page 140: ...p on the rod after removing each piston connecting rod assembly 11 Mark piston connecting rod assemblies with cylinder numbers to avoid mixup on reassembly NOTE The existing number on the connecting rod does not indicate its position in the engine it in dicates the rod bore size 12 Remove the bearing cap bolts and bearing cap side bolts then remove the bearing caps BEARING CAP BEARI BOLT BEARING C...

Page 141: ...omplete revolutions Support with lathe type tool or V blocks Out of Round and Taper 0 Measure out of round at the middle of each rod and main journal in two places 0 The difference between measurements on each journal must not be more than the service limit Jouinal Out of Round Standard New 0 004 mm 0 00016 in min Service Limit 0 006 mm 0 00024 in Measure taper 4 L at edges I Measure out of round ...

Page 142: ...ons Inspection Check the piston for distortion or cracks NOTE If cylinder is bored an oversized piston must be used Measure piston diameter at a point 17 mm 0 67 in from bottom of skirt NOTE There are two standard size pistons A and 6 The letter is stamped on the top of the piston These letters are also stamped on the block as cylinder bore sizes Piston A Diameter Standard New 89 986 90 004 mm 3 5...

Page 143: ...mm 3 546 in Oversize 0 25 90 25 90 27 mm 3 553 3 554 in 0 50 90 50 90 52 mm 3 563 3 564 in Bore Taper Limit Difference between first and third measure ment 0 05 mm 0 002 in l If measurements in any cylinder are beyond Oversize Bore Service Limit replace the block 0 If block is to be rebored refer to Piston Clearance Inspection page 7 l 2 after reboring NOTE Scored or scratched cylinder bores must ...

Page 144: ...in cylinder bores after honing to service limit rebore the engine block ENGINE LINDER HONE NOTE 0 After honing clean the cylinder thoroughly with soapy water 0 Only scored or scratched cylinder bores must be honed Piston Connecting Rod Assemblies Selection Each rod is sorted into one of four tolerance ranges from 0 to 0 024 mm in 0 006 mm increments depen ding on the size of its big end bore It s ...

Page 145: ...d New 0 35 0 50 mm 0 014 0 020 in Service Limit 0 75 mm 0 03 in1 Oil Ring Standard New 0 2 0 7 mm 0 008 0 028 in Service Limit 0 8 mm 0 03 in El be 0 I Replacement 1 2 3 I Using ring expander remove old piston rings Clean all ring grooves thoroughly NOTE 0 Use a squared off broken ring or ring groove cleaner with blade to fit piston grooves 0 Compression ring grooves are 1 2 mm wide and oil ring g...

Page 146: ...tify top and second rings by the chamfer on the edge and make sure they are in proper grooves on piston TOP RING Arl b SECOND RING 2 3 Rotate the rings in grooves to make sure they do not bind The manufacturing marks must be facing upward MARK OIL RING S P A C E R 4 position the ring end gaps as shown SECOND RING DO NOT position any ring gap CAP at piston thrust surfaces TOP RING GAP SPACER GAP DO...

Page 147: ... ring compressor check that the bear ing is securely in place then position the piston in the cylinder and drive it in using the wooden handle of a hammer 0 Stop after the ring compressor pops free and check the connecting rod to crank journal align ment before driving rod into place 0 Install the rod caps with bearings and torque the nuts to 20 N m 2 0 kg m 14 lb ft then turn the nut 95 degrees p...

Page 148: ...the oil pump side oil seal Installation 3 Before installing the crankshaft apply a coat of engine oil to the main bearings and rod bearings 1 Insert bearing halves in the engine block and con necting rods 2 Lower the crankshaft into the block THRUST WASHERS Grooved sides face outward 3 3 Install the thrust washers on the No 3 journal Oil Install the thrust washers on the No 3 journal Oil thrust wa...

Page 149: ...95O MARK 0 Line up the marks when installing connecting rod cap 5 Check the rod bearing clearance with plastigage page 7 7 then torque the connecting rod cap nuts NOTE Reference numbers on connecting rods are for big end bore tolerance and do NOT indicate the position of piston in engine CONNECTING ROD CAP NUT TORQUING METHOD 1 Torque the connecting rod cap nut to 20 Nom 2 0 kg m 14 lb ft with a b...

Page 150: ...rter side bolts are for the front side BEARING CAP BRIDGES n CAP BRIDGE BOLT 11 x 1 5 mm 66 Nom 6 6 kg m 46 lb ft1 SIDE BOLT lOx1 25mm 50 N m 5 0 kg m 36 lb ft CAP B LT Bx1 25mm 40 N m 4 0 kg m 29 lb ft 8 Apply liquid gasket to the block mating surface of the left side cover and oil pump case and install them on the engine block NOTE The seal surface on the block should be dry Apply a light coat o...

Page 151: ...id gasket to inside of broken line OIL PdMP I Apply liquid gasket to inside of broken line 0 Do not install the parts if 20 minutes or more have elapsed since applying liquid gasket instead reapply liquid gasket after removing old residue 0 After assembly wait at least 30 minutes before filling the engine with oil 11 Install the oil pass pipe and joint 12 Install the baffle plate 13 Install the oi...

Page 152: ...ial Tools 8 2 Illustration Index 8 3 Oil Level Inspection 8 4 Oil Replacement 8 4 Oil Filter Replacement 8 5 Oil Pressure Test 8 5 Oil Pump Illustrated Index 8 6 Oil Pump Removal Inspection 8 7 Oil Cooler Oil Filter Base 8 10 ...

Page 153: ...Ref No Tool Number 0 07GAD PH70200 0 07912 6110001 Description Seal Driver Oil Filter Socket CYty Page Reference 1 8 8 1 8 5 8 2 ...

Page 154: ... J I HEAD OIL CONTROL ORIFICE Use 6 x 1 O mm bolt I Rnnlarra when removing LL r m r 6x l Omm 12 No 1 2 kg m 9 lb ttl 0 RIN I Replace O RING Replace WATER PASS PIPE ENGINE OIL COOLER 8x1 25mm 22 Nom 2 2 kg m 16 lb ftl ReDlace v OIL PUMP I 8x 1 25 OIL FILTER B E I 22 N m 2 2 kg m Illustrated Index 16 lb ft E O RINGS page 8 10 Replace Replace I OIL FILTER 22 N m 2 2 kg m 16 lb it Replacement 8 5 uJ S...

Page 155: ...in the engine oil WASHER OIL PAN DRAIN PLUG 45 N m 4 5 kg m 33 lb ft 3 Reinstall the drain plug with a new washer and refill with the recommended oil Requirement I API Service Grade SG SAE viscosity 10 W 30 recommended Fuel Efficient oil Identified by the words Energy Conserving II 5 0 P 5 3 US qt 4 4 Imp qt for change including filter 6 3 e 6 7 US qt 5 5 Imp qt for engine overhaul Every 12 000 km...

Page 156: ... 16 lb e gasket surface seal Test If the oil pressure warning light stays on with the engine running check the engine oil level If the oil level is correct 1 2 3 Remove the oil pressure sender and install an oil pressure gauge Start the engine and allow to reach operating temperature fan comes on at least twice Pressure should be Engine Oil Pressure At Idle 69 kPa 0 7 kg cm 10 psi minimum At 3 000...

Page 157: ... Omm 6 N m 0 6 kg m 4 lb fti PUMP COVER Inspection page 8 7 PUMP HOUSING Inspection page 8 7 WASHER Replace SEALING BOiT 16 mm 50 N m 5 0 kg m 36 lb ft OIL SEAL Replace VALVE SP o SEALING BOLT mm 40 N m 4 0 kg m 29 lb ft RELIEF VALVE Valve must slide freely in housing bore If valve is scored replace it 8 6 ...

Page 158: ...pump assembly Replace OIL PUMP e OIL SCREEN BAFFLE PLATE OIL PASS PIPE AND JOINT 10 Remove the nine screws from the pump housing then separate the housing and cover 11 Check the radial clearance on the pump rotor Rotor Radial Clearance Standard New 0 02 0 18 mm 0 0008 0 0071 in Service Limit 0 2 mm 0 008 in INNER RdTOR 12 Check the axial clearance on the outer pump rotor Housing to Rotor Axial Cle...

Page 159: ...at the oil pump turns freely 19 Apply a light coat of oil to the seal lip 20 Install the two dowel pins end new O ring on the cylinder block 21 Apply liquid gasket to the cylinder block mating surface of the oil pump NOTE l Use liquid gasket Part No 08718 550000 OE 0 Check that the mating surfaces are clean and dry before applying liquid gasket 0 Apply liquid gasket evenly in a narrow bead centere...

Page 160: ... lb ft Replace I D YEL P NS OIL PASS OIL PUMP Apply liquid gasket to cylinder block mating surface 6x l Omm 12 N m 1 2 kg 9 lb ft 6x l Omm 12 Nom 1 2 kg m 9 lb ft 26 Install the oil pan and gasket NOTE 0 Use the new gasket 0 If the bottom of the oil pan is deformed it should be repaired or the oil pan should be replaced with a new one so as to retain proper clearance between the screen and the bot...

Page 161: ... n 2 mm PIN O RING Replace RELIEF VALVE Valve must slide freely in bolt bore If valve is scored replace it I EYGINE _ Replace OIL FILTECBASE OIL FILTER 22 N m 2 2 kg m 16 lb ft Replacement 8 5 Replace every 12 000 km 7 500 miles or 6 months Tighten according to instructions on filter OIL PRE 18 N m 0 RING Replace 8 x l i5mm 22 Nom 2 2 kg m 16 lb ft URE SWITCH B kg m 13 lb ft l 8 in BSP British Sta...

Page 162: ...Intake Manifold Exhaust System Intake Manifold 9 2 Exhaust Manifold 9 3 Exhaust Pipe and Muffler 9 4 ...

Page 163: ...m COVER PLATE TOP COVER 6 x l Omm 12 N m 1 2 kg m 9 lb ft d EGR PORT H INTAKE MANIFOLD 5xlOmm 6 Nom 0 6 kg m 4 lb ftl 6x l Omm 12 N m 1 2 kg m 9 lb ft THROTTLE BODY 8 2 1 9 lb W 6 x l Omm 12 N m I 2 kg m B lb ft INTAKE MANIFOLD 8x 1 25mm 22 Nom 2 2 kg m 1 6 lb ft Replace 9 2 ...

Page 164: ...ter installing the exhaust manifolds OXYGEN SENSOR 45 Nom 4 5 kg m 33 lb ft Be careful not to damage I 6xlOmm 12 N m 11 2 kg m 9 lb ft EXHAUST MANIFOLD 22 Nom 2 2 kg m I t mm OXYGEN 45 N m 4 5 kg m 33 lb ft Be r to da 2 i 2 kg m 6x1 25mm 22 N m 2 2 kg m 16 lb ft SELF LOCKING NUT 8x 1 25mm 34 N m 3 4 kg m 25 lb ft Apply oil to the nut threads I Replace EXHAUST MANIFOLD SHROUD LOCKING NUTS 8x1 25mm ...

Page 165: ...gen sensors after installing the exhaust pipes 6xl Omm 10 N m 1 0 kg m MUFFLER 7 lb ft w GASKET Redace y z 4 10 x 1 25 mm 34 Nom 3 4 kg m GASKET 25 lb ftl Replace Replace REAR CAiALYTlC CONVERTER b 6xl Omm 10 N m 1 0 kg m 4 GASKET Rep ace r TO REAR EXHAUST MANIFOLD 6xl Omm IO N m 1 0 kg m 7 lb ft FRONT CATALYTIC CONVERTER ENGINE MOUd REAR BEAM TO F MAN RUBBER MOUNT SELF LOCKING NUT IO x 1 25 mm FR...

Page 166: ...IO 2 Radiator Replacement 1 O 4 Refilling and Bleeding 1 O 5 Expansion Tank Cap Testing 1 O 8 Pressure Testing IO 8 Thermostat Replacement IO 9 Testing IO 9 Water Pump Illustrated Index IO IO Inspection IO I 1 Replacement IO I 1 ...

Page 167: ... 10 S Inspect soldered joints and seams for leaks Blow out dirt from between core fins with compressed air If insects etc are clogging radiator wash them off with low pressure water HEATER BLEED CAP HEATER PIPE 3 RADIATOR LOWER HOBEY f tT 1 NOTE 0 Check all cooling system hoses for damage leaks or deterioration and replace if necessary 0 Check all hose clamps and retighten if necessary 0 Use new O...

Page 168: ...m ENGINE PART EXPANSION TANK Refilling and bleeding page 10 5 Leak Test page 10 8 CAP I Test IO 8 ENGINE OIL COOLER I ENGINE OIL COOLER PIPE ATF COOLER A T only ...

Page 169: ...hoses from the radiator 5 Remove the bracket and the radiator Install the radiator in the reverse order of removal NOTE 0 Set the upper and lower cushions securely l Fill the radiator and bleed the air page 1 O 5 thru 10 7 6xl Omm 10 N m I O kg m 7 lb ftl RADIATOR BRACKET UPPER CUSHIONS RESISTOR CONNECTOR RESISTOR CONNECTOR LOWER CUSillONS A I OTOR CONNECTOR LOWER HOSE 1 o 4 ...

Page 170: ...re knob to 90 and turn off the ignition This will allow the coolant in the heater to drain out with the rest of the system WASHERS Reolace 1 Open the hood the rear hatch and the engine cover 2 Remove the cover protecting the water pipes and shift cables on the underside of the car 3 Before removing the expansion tank cap first loosen the cap to lower pressure CAUTION Do not remove the expansion ta...

Page 171: ...pe bleed cap 3 Loosen the water pipe bleed bolt 4 Loosen the engine bleed bolt on the therm0 cover 9 Mix the recommended anti freeze coolant with an equal amount of water in a clean container NOTE 0 Use only HONDA RECOMMENDED anti freeze coolant 0 For best corrosion protection the coolant con centrations must be maintained year round at 50 MINIMUM Coolant concentrations less than 50 may not provid...

Page 172: ...mpleted retighten the therm0 cover bleed bolt and fill the expansion tank up to 0 5 e 0 53 US qt 0 44 Imp qt or 30 mm 1 2 in over the MAX line BLEED PLUG 14 Install the expansion tank cap and turn it 60 degrees where the first lock tab of filler neck is engaged 15 Start the engine and let it run until warmed up until the thermostat opens and the radiator cooling fan runs 16 Turn off the engine Che...

Page 173: ...g 1 2 3 4 Wait until the engine is cool then carefully remove the expansion tank cap and fill the expansion tank with coolant to the top of the filler neck Attach the pressure tester to the radiator and apply a pressure of 93 123 kPa 0 95 I 25 kg cm 14 18 psi PRESSURE TESTER Inspect for coolant leaks and a drop in pressure EXPANFION TANK Remove the tester and reinstall the expansion tank cap NOTE ...

Page 174: ...place fjxl Omm 12 N m 1 2 kg m 9 lb ft Testing Replace thermostat if it is open at room temperature To test a closed thermostat 1 2 3 Suspend the thermostat in a container of water as shown Heat the water and check the temperature with a thermometer Check the temperature at which the thermostat first opens and at full lift CAUTION Do not let thermometer touch bottom of hot container Measure lift h...

Page 175: ...RING Apply liquid gasket 22 Nom 2 2 kg m Q W 3 3 f to the threads 18 lb ft q ii BLEED BOLT IO Nom 1 0 kg m 7 lb ft WATER PUMP O RING 22 N m 2 2 kg m 18 lb ft WATEit PASSAGE WATER PUMP Inspection page I SPECIAL BOLT 8 x 1 0 mm 7 BOLTS 1 2 Nom 1 2 kg m 9 lb ft Replace 8 x 1 25 mm 2 BOLTS 22 Nom 2 2 kg m 18 lb ft Replace IJKAIN SIJL I S 10 Nom 1 0 kg m Use rubber hoses when draining 7 lb ft a ...

Page 176: ... weeping from the bleed hole is normal Turns freely BLEED HOLE BLEE D HOLE COVERED Replacement 1 Remove the timing belt page 6 23 2 Unscrew the bolts then remove the water pump 3 Install the water pump in the reverse order of removal SPECIAL BOLTS w I WATER PUMP O RING Replace SPECiAL BOLTS 8 x 1 25 mm 2 BOLTS 22 Nom 2 2 kg m 16 lb ft Replace 10 I 1 ...

Page 177: ... l 66 System Description 11 67 Troubleshooting Flowcharts Electronic Air Control Valve 1 l 70 Air Conditioning Signal 11 72 Alternator FR Signal 11 74 A T Shift Position Signal 11 76 M T Neutral Switch Signal 11 78 Clutch Switch Signal 1 I 80 Starter Switch Signal 11 82 Fast Idle Valve 11 83 Idle Speed Setting 11 84 Fuel Supply System System Troubleshooting Guide 11 86 System Description II 87 Fue...

Page 178: ...10A 07LAJ PT30200 07MAJ PR70100 07JAZ 001 OOOA 07406 0040001 Description Vacuum Pump Gauge Digital Multimeter Test Harness Test Harness Test Harness Vacuum Pressure Gauge O 4 in Hg Fuel Pressure Gauge Page Reference 1 l 44 114 118 120 129 137 140 11 21 32 37 11 21 11 131 11 21 11 139 140 11 88 ...

Page 179: ...SENSOR Troubleshooting page 1 l 32 INTAKE AIR TEMPERATURE page 1 l 6 Troubleshooting page 1 l 52 EAR KNOCK SENSOR roubleshooting page 1 l 62 SENSOR Troubleshooting page 1 l 50 EN 02 SENSOR eshooting page 1 l 32 EACV Troubleshooting page 1 l 70 FUEL PUM P RELAY Inspection page 1 l 99 ELECTRONIC CONiROL UNIT ECU Troubleshooting page 1 l 26 ...

Page 180: ...ssembly page 11 112 AIR INTAKE DUCT FUEL PUMP Troubleshooting page 1 I 99 Testing page 1 l l 02 Replacement page 1 l l 02 FUEL CUT VALVES FUEL FILTER Replacement page 11 97 FUEL FILLER PRESSURE REGULATOR I CHARCOAL CANISTER Troubleshooting page 1 l l 37 FI EL RETURN PIPE F L INJECTORS Troubleshooting page II 89 Replacement page 11 92 FUEL TAr K Replacement page 1 l l 08 FUEi PIPE I I 4 ...

Page 181: ...NTROL B O X page 11 6 1 P U R G E C O N T R O L DIAPHRAGM I DAsHPOT w DIAPHRAGM CONTROL FUEL PRESSURE R E G U L A T O R TO iWO WAY VALVE EGR VALVE Troubleshooting page 1 I 128 Troubleshooting CHARCOAL CANISTER FRONT OF i V E H I C L E cont d ...

Page 182: ...s cont d Control Box PURGE CUT OFF SOLENOID VALVE CONSTANT VACUUM CONTROL CVC EGR CONTROL MANIFOLD ABSOLUTE PRESSURE MAP SENSOR Troubleshooting page 1 l 40 CHAMBER y VOLUME CONTROL SOLENOID VALVE Troubleshooting page 1 l 120 Y AIR CHAMBER ...

Page 183: ...RESSURE REGULATOR FUEL FILTER FUEL PUMP I FUEL TANK DASHPOT DIAPHRAGM DASHPOT CHECK VALVE CHECK VALVE AIR CHAMBER CHAMBER VOLUME CONTROL SOLENOID VALVE CHAMBER VOLUME CONTROL DIAPHRAGM PCV VALVE EGR VALVE CONSTANT VACUUM CONTROL CVC VALVE EGR CONTROL SOLENOID VALVE I CHARCOAL CANISTER PURGE CUT OFF SOLENOID VALVE PURGE CONTROL DIAPHRAGM VALVE TWO WAY VALVE II 7 ...

Page 184: ...System Description Electrical Connections MAIN RELAY L I 1 I I FUEL PUMP RESISTOR Di VSU FLRP A9 I FUSES FLANK SENSOR SPEED SENSOR I X K ENGINE c2 VSP 0 ES All EGR CONTROL SOLENOID VALVE II 8 ...

Page 185: ...D20 VCCP I IG No 2 A22 D21 SGl I IG No 3 66 D22 SG2 D17 PB D5 PAOUT Dlif3TH D6 IGADJ D12 EGRL IG No 4 66 IG No 5 84 IG No 6 83 NEP C4 TCSTB Ci2 TCFC C6 TQOUT CiO D 5 TA AFSA Fi Di3TW AFSB F3 FAS Al6 1D9 ACGF D16 02 R I VTMR F4 D3 KSR I D4 KSF I IGNITION COIL q IGNITION COIL q I FRONT SPOOL REAR SPOOL SOLENOID VALVE SOLENOID VALVE MING OIL y T RESSURE WITCH cont d II 9 ...

Page 186: ...O Dl Al 29 Dl D2 91 1 Dl 61 81 61 Bl 61 Bl 8 Bl AL 3 4 OZ 6 D1 DI 13 2 20 11 I5 r r WHTw ELK RED BLU BLK BLU YEL WHT RED YELb RED BLK 02 SENSOR Cl56 C476 C500 C527 II C160LC471 II 0101 REAR HEATED 02 SENSOR c534 Cl46 m m m CRANKlCYL SENSC Cl06 To page 11 11 ...

Page 187: ...D GlOl BLU RED YELlBLK YELlBLK f III BLU BLK WHT RED L T GRN To No 1 IGNITION COIL WHT To No 2 IGNITION COIL WHTlGRN To No 9 IGNITION COIL WHT BLK To No 4 IGNITION COIL WHT BLU To No 5 IGNITION COIL WHT YEL _ To No 6 IGNITION COIL WHT RED cl 0103 cont d II 11 a I t 4 Cl32 Cl71 Cl72 Cl61 C478 C483 1 c412 11 ALTERNATOR 1 GIOI ...

Page 188: ...I C425 Cl61 C476 PNK b I CLUTCH SWITCH A 0401 Cl41 WHT GRN 0 YELlWHT 0 Gq Cl59 c475 Cl66 BLU RED 4 pzgp q Cl60 C471 Cl07 YEL _ YEL liiEq Cl21 BLU YEL BLUlYEL G 1 Cl59 c475 Cl06 BLU BLUlBLK Cl56 C476 BLUrt I 1 Cl59 c475 _ D BLu RED BLU D BLU Cl60 C471 BLu RED BLUlRED Cl61 C476 c473 c249 C316 D G N ED G N E Ni l G302 I I 1 2 ...

Page 189: ...406 c523 YELlBL jj YEL1BLU f ACG S FUSE 20A L L Cjl MAINE 1 BLKlYEL BLK WHT GRNlBLK Cl60 C471 B L K 1 f II BLK YEL y F U E L P U M P R E L A Y BLKlYEL Ill h III A Cl61 C476 G403 C406 L BLKlYEL BLK YEL 1 No 2 FUSE 15A c404 I 1 No 7 FUSE 7SA No 5 FUSE 10A No 5 FUSE 10A Cl61 C476 L I To page 11 14 cont d II 13 ...

Page 190: ...rom page 11 13 Cl40 I YELlBLK II BRN R E D ORN WHT BLU ELK RED REDlBLK YEL I I No 6 INJECTOR I Cl60 c471 c500 c527 Cl35 Cl37 RED BLK REDlBLK Cl39 I 1 All Al4 VOLUME CONTROL RED BLU C521 BLKlYEL CONTROL BOX Cl61 C476 C466 C244 WHT YEL p WHT YEL yWHT YEL CLOCK FUSE 7 5A II 14 ...

Page 191: ... n EilEli3 A A A Cl51 c4 BLU 1 TACHO METER CONNECTOR Cl61 C478 C488 REDlYEL YELlRED J A GlOl ...

Page 192: ... START 0 0 0 DIFFICULT TO START ENGINE WHEN COLD I I I 181 I IRREGULAR IDLING FREQUENT STALLING POOR ANCE WHEN COLD FAST IDLE O U T O F S P E C 69 0 ROUGH IDLE a 0 WHEN WARM RPM TOO HIGH 69 WHEN WARM RPM TOO LOW 69 WHILE WARMING UP 0 A F T E R WARMING UP 69 GO MISFIRE OR ROUGH RUNNING 69 0 FAILS EMISSION 0 0 T E S T L O S S O F P O W E R 0 0 0 3 If codes other than those listed above are indicated...

Page 193: ... PGM FI 1 IDLE CONTROL 1 FUEL SUPPLY 1 EMISSION CONTROL II 17 ...

Page 194: ...ine light can indicate any number of simultaneous component problems by blinking separate codes one after another Problem codes 1 through 9 are indicated by a individual short blinks Problem codes 10 through 59 are indicated by a series of long and short blinks The number of long blinks equals the first digit the number of short blinks equals the second digit Separate Problems Short S e e P r o b ...

Page 195: ...et stations and the clock setting Make note of the radio presets before removing the fuse so you can reset them CLOCK FUSE 4 III Final Procedure this procedure must be done after any troubleshooting 1 Remove the Jumper Wire NOTE If the Service Check Connector is jumped the Check Engine light will stay on 2 Do the ECU Reset Procedure 3 Set the radio preset stations and the clock setting cont d II 1...

Page 196: ...he ECU 0 The Check Engine light may come on indicating a system problem when in fact there is a poor or intermittent eiec trical connection First check the electrical connections clean or repair connections if necessary 0 The Check Engine light and D indicator light may come on simultaneously when the self diagnosis indicator blinks 6 7 and 17 Check the PGM FI system according to the PGM FI contro...

Page 197: ... remove the seat back panels Unbolt the ECU bracket Connect the ECU test harness Then check the system according to the procedure described for the appropriate code s listed on the following pages ECU PANELS DIGITAL MULTIMETER a A KS 32 003 h w TEST HARNESS 07LAJ PT3010A cont d ...

Page 198: ...l connections l For testing at connectors other than the ECU test harness bring the tester probe into contact with the terminal from the connector side of wire harness connectors in the engine compartment For female connectors just touch lightly with the tester probe and do not insert the probe RUBBER SEAL TESTER PROBE I TERMINAL 11 22 ...

Page 199: ...e the failure or if the problem was a loose connection you may have unknowingly solved it while doing the tests In any event if the Check Engine light on the dash does not come on check for poor connections or loose wires at al connectors related to the circuit that YOU are troubleshooting 0 Most of the troubleshooting flowcharts have you reset the ECU and try to duplicate the problem code If the ...

Page 200: ...is on the transmission is in gear A T only or the alternator is charging the ECU controls current to the EACV to msintain correct idle speed 0 Ignition Timing Control 0 The ECU contains memories for basic ignition timing at various engine speeds and manifold pressures Ignition timing is also adjusted for coolant temperature l A Knock Control System is also used When detonation is detected by the k...

Page 201: ...r flows through the a larger chamber in order to increase airflow 7 EGR Control Solenoid Valve EGR CSV When the EGR is required for control of oxides of nitrogen NOx emissions the ECU supplies ground to the EGRCSV which supplies regulated vacuum to the EGR valve ECU Back up Functions 1 Fail Safe Function When an abnormality occurs in a signal from a sensor the ECU ignores that signal and assumes a...

Page 202: ...ignition switch ON Repair open in YEL between No 5 fuse and gauge assembly I A l 3 Replace the light bulb I s Check Engine light on Repair open In BLU wire between ECU A131 and gauge YES assembly 7 a i GlOl ground and the following ter minals individually l A23 A24 l A2B 082 Is there less than 1 V YES Repalr open in wire between ECU and in take manlfold 0101 that had more than IV Substitute a know...

Page 203: ... Measure voltage between BLU terminal and GRNlWHT f 1 terminal on service check con nectar T u r n t h e i g n i t i o n switch OFF I I Disk mact A c o n nector from the ECU 1 Substitute a known good ECU and recheck If symptomlindica tion goes away replace the original ECU 1 L rnh hNe i g n i t i o n 1 N O I Is the Check Engine light ON Is the fuse OK Replace the fuse Y E S Repair short to body gr...

Page 204: ...t the service check con nector with a jumper wire Disconnect the 3P connector of each sensor one at a time l Throttle angle sensor l Ignition timing adjuster Does Check Engine light indicate CODE 7 or IE N O I I Di9 1 1 0000000000000 000000000 0 0000000000000 ooooo Jr Joq o I J DiO Y 7 Continuity YES Replace the throttle angle sensor or ignition timing adjuster Turn the ignition switch OFF Remove ...

Page 205: ...oilowmg Cl and Repair short to body ground in YELlWHT wire between ECU D19 D20 and throttle angle sensor EGR valve lift sensor MAP sensor Ignition timing Ad juster and Accelerator Pedal angle sensor I Is there battery voltage Repair open in YELlBLK wire between ECU fA25 Cl and main relay Y E S N O Check main relay and wiring connectors at main relay I 1 1 l 29 ...

Page 206: ...folds ZIRCONIA ELEME yT SENSOR TERZAL VOLTAGE V t HEATER Check Engine light has been reported on With service check connector jumped page 11 181 CODE 1 Front Oz sensor and or 2 Rear 02 sensor are in dicated Warm up engine to normal oper ating temperature cooling fan comes on Run engine for 80 seconds I Road test with the transmission in 4th gear starting at 1200 rpm accelerate using wide open thro...

Page 207: ...II 31 ...

Page 208: ...has been reported on with service check connector jumped page ll 18 CODE 41 and or 42 are indicated Do the ECU Reset Procedures page 11 19 Y E S Stop the engine Disconnect the 4P connector from the 02 sensor Measure resistance between ter minals C and D on the Oz sensor Intermittent failure system is OK at this time test drive may be necessary Check for poor con nections or loose wires at 02 senso...

Page 209: ...SENSOR 45 Nom 4 5 kg m 33 lb ft REAR 02 SENSOR 45 Nom Is there battery Voltage NO Disconnect the A connector from the ECU I t I I Measure voltage between BLK YEL terminal and body ground BLK YEL I terminal and BLK f 1 I REAR I Is there battery voltage N O Repair short in BLK or BLKIBLW wire bet ween ECU A10 or A12 and front 02 Is t h e r e backs Turn the ignition switch OFF I I dash fuse box I To ...

Page 210: ...ector to the engine wire harness only not the ECU page 11 21 Turn the ignition switch ON REAR Measure voltage between A10 or Al 2 terminal and A23 terminal Is there battery voltage Y E S N O Repair open in ELK or BLK ELU w i r e b e tween ECU A101 and front 02 sensor Substitute a known good ECU and recheck If symptomlindica tlon goes away replace the original ECU II 34 ...

Page 211: ...I I 35 ...

Page 212: ...temperature cooling fan comes on I Hold engine at 3 000 rpm for 2 minutes A T Transmission is q or B Is the Check Engine light on and does it indicate CODE 43 or 447 1YES NO Intermittent failure system is OK at this time test drive may be necessary 1 Check for poor connections or loose wires at 02 sensor C144 Cl48 and ECU I With the ignition switch OFF wait for at least two minutes I Install a jum...

Page 213: ...connect the 4P connector decrease to below 0 1 V in from the 02 sensor less than two minutes N O I I Measure voltage between D14 I front or D16 I rear ter minal and A26 terminal wire harness side of the 02 sen sor connector between A and Replace 02 sensor N O Disconnect the D connector 21 I front or D16 rear ter 1 9 D14 1 11 sor and recheck If symptomlmdfca Is there more than 0 1 V Replace 02 sens...

Page 214: ...ition A T cruise at exactly 35 mph for at least 10 seconds Remove your foot from the throttle until the vehicle decels below 30 mph Accelerate to 35 mph and cruise at exactly 35 mph for at least 10 seconds The cruiseldecel procedure must be repeated 10 times Stop the vehicle and turn off the ignition switch Start the engine The cruise decel procedure must be repeated 5 times I Does Check Engine li...

Page 215: ...the MAP sen sor INDICATION SUBSTITUTE CODE 45 3 front injectors CODE 46 3 Rear injectors CODE 45 and 46 6 injectors 1 DotheRo Te6t 1 Does Check Engine light indicate CODE 46 and or 46 Y E S Replace the injectors as indicated Inspect fuel line between the fuel filter and the fuel injectors for 1 restrictions Remove restrictions 11 39 ...

Page 216: ...he ECU SILICON VACUUM DIAPHARAFM CAVITY Englne Is warm and running Check Engine light has been reported on With service check connector jumped page II 18 CODE 3 is indicated I I I I Do the ECU Reset Procedures page 1 l 19 Start the engine and allow it to idle does it indicate CODE 37 YES Turn the ignition switch OFF 1 Turn the igniti switch ON Topagell 41 OUTPUT VOLTAGE VI 3 51 3 0 2 5 2 0 1 6 1 0...

Page 217: ...there approx 5 VI Substitute a known good ECU and recheck If symptomlindica tion goes away replace the orignal ECU Is there approx 5V7 1YES Turn the ignition switch OFF I 1 Reconnect the 3P connector to the MAP sensor Connect the ECU test harness between the ECU and connector page 11 211 Turn the ignition switch ON To page 1 l 42 Repair open or short in WHT wire between ECU ID171 and MAP sensor If...

Page 218: ...lowchart MAP Sensor cont d From page 1 l 41 Measure voltage between D17 terminal and D21 ter minal 3v7 l l 017 I 021 1 Replace MAP sensor r Substitute a known good ECU and recheck If symptom indication goes away replace the original ECU 11 42 ...

Page 219: ... cont d II 43 ...

Page 220: ...e system is OK at this time test drive may be necessary Check vacuum hoses pipes and connections Make sure all connectors are secure I I I I Stop the engine I Disconnect 4 hose from the throttle body connect vacuum pump to the hose and apply vacuum VACUUM PUMP G A U G E A973X 041 XXXXX Does it hold vacuum NO Connect a vacuum pump to the MAP sensor and apply vacuum YES Does it hold vacuum Y E S Rep...

Page 221: ...or page 1 I 21 Turn the ignition switch ON Measure voltage between D17 I terminal and D21 1 ter a m i n a l D17 4 D21 1 I I ooooooooooooo oooooooo oooooo oooooooo o N O Replace the MAP sensor Y E S Start the engine and allow it to idle N O Is there approx 1 V Replace MAP sensor Substitute a known good ECU and recheck If symp tom indication goes away replace the original ECU I II 45 ...

Page 222: ...ensor y The CRANK sensor determines timing for fuel injection and ignition of each cylinder and also detects engine RPM The CYL sensor detects the position of No 1 cylinder for sequential fuel injection to each cylinder CRANK PICK UP CRANK PICK UP COIL 6 COIL A Check Engine light has been reported on With service check connector jumped page 11 18 CODE 4 54 8 andlor 68 are in dicated Do the ECU Res...

Page 223: ...Y E S Replace the CRANK CYL sensor page 6 27 iNSOR 1 ECU 1 WIRE 1 CYLB 59 E 1 f39 l0 N F 1 BIO IWHT Reconnect the connector Connect the ECU test harness to the engine wire harness only not to the ECU page 1 l 21 I 6SO 850 u7 1 L L I CYL 3 w r 3 Measure resistance between ter minals of the indicated sensor on ECU test harness see table 650 860 U Is there 650 850 Sa Y E S Repair open in the in dicat...

Page 224: ... service check connector jumped page 11 18 CODE 6 is indicated g r FXJy P r o c e d u r e s I Turn the ignition switch ON I THERMiSTOR WV l OS 0 12 26 0 a 4 32 66104140176212246 F COOLANT TEMPERATURE Intermittent failure system is OK at this time test drive may be necessary Ctieck for poor connections or loose wires at TW sensor Cl08 and ECU Warm up engine to normal oper ating temperature cooling ...

Page 225: ...terminal Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU _ _ 1 AIT only _ i r I I Disconnect the 22P connector from the A T control unit I I I T T N O Connect the ECU test harness to D13 I D22 1 Is there approx 5V N O Repair open in REDlWHT wire between ECU D13 A T control unit and sensor I l 49 ...

Page 226: ...SH 1 HOLDER shaft As the throttle angle changes the throttle angle OUTPUT VOLTAGE V THROTTLE Do the ECU Reset Procedures page 11 19 Trun the ignition switch ON I it indicate CODE 77 Y E S Turn the ignition switch OFF I at this time test drive may be necessary Check for poor connections or loose wires at throttle angle sen sor Cl 30 and ECU GRN WHT YELIWHT Disconnect the 3P connector from the throt...

Page 227: ...ribed voltage is now avail able replace the original ECU Repair open in GRN WHT wire between ECU D22 and throttle angle sensor I Repair open in YELI WHT wire between ECU D201 and throttle angle sensor 0 5 V at full close throttle7 to 4 8 V as the throttle is depressed I 1YES Substitute a known good ECU and recheck If symptom indica tion goes away replace the origi nal ECU Replace throttle angle se...

Page 228: ...the ignition switch ON I Is Check Engine light on and does it indicate CODE IO YES Turn the ignition switch OFF he resistance of the thermistor decreases as the intake air temperature RESISTANCE kQ 20 0 204060801001201 4 32 68104140176212248 F INTAKE AIR TEMPERATURE Intermittent failure system is OK at this time test drive may be necessaryl Check for poor con nections or loose wires at TA sensor C...

Page 229: ...ED BLK terminal and GRN WHT terminal I I Connect the ECU test harness to the ECU only not to the engine wire harness page 11 21 I I Is there approx 5 V 7 Y E S Repair open in GRNl WHT wire between ECU ID221 and TA sen sor 11 and recheck If symptomlindica Is there approx 5V7 N O Repair open in AEDISLK wire bet ween ECU D15 and TA sensor Substitute a known good ECU and recheck If symptomlindica tion...

Page 230: ...k Engine light on an does it indicate CODE 13 Y E S Intermittent failure system is OK at thls time test drive may be necessary 1 Turn the ignition switch OFF Connect the ECU test harness to the engine wire harness not to the ECU page 1 l 21 I 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 I I T Check for continuity between D5 terminal and body ground Does continuity exist N O Y E S Repair sho...

Page 231: ...ge 1 I 541 Turn the ignition switch ON Is Check Engine tight on and Replace the orfglnal TCS control unit Substitute a known good ECU and recheck If symptomlindica tion goes away replace the original ECU II 55 ...

Page 232: ...idually IGNITER I Intermittent failure system is OK at this time Check for poor connections or loose wires at Igniter unit C143 Cl 23 and ECU Does continuity exist Y E S Repair open in 8LK wire between 8P connector and G103 Disconnect the 6P connector from the igniter unit Connect the ECU test harness between the ECU and connector page 1 l 21 To page 1 l 57 NOTE Inspection of igniter unit secondar...

Page 233: ...0 0 0 0 0 0 0 0 0 A 2 2 I 84 I 66 t L r 66 I YES Repair short in each terminal wire Check for continuity between terminals of 6P connector and ECU individually See table 2 Does continuity exist YES Repair open in each terminal wire Substitute a known good igniter unit and recheck Does Check Engine warning light indicate CODE 151 1YES Replace the original igniter unit I D E F UNIT II 57 ...

Page 234: ...ent faliure system is OK at this time N O Check for poor connections or loose wires at and located at left shock tower Y E S Turn the ignition switch ON I m Make sure lifts are placed properly Sea page l 8 A26 1 c2 w Slowly rotate left rear wheel and measure voltage between C2 I terminal and A26 f 1 terminal Does voltage pulse 0 V and 5 V Y E S Substitute a known good ECU and recheck If symptom in...

Page 235: ...1 l 59 ...

Page 236: ...ht is on With service check connector jumped page 11 18 CODE 18 is indicated Do the ECU Reset Procedures page 1 l 19 it indicate CODE 181 Y E S Turn the ignition switch OFF terminal and C terminal on Igni F Is there 3 6 k97 Y E S N O Replace Ignition timing adjuster Section 23 To page 1 I 61 Intermittent failure system is OK at this time Test drive may be necessary Check for poor con nections or l...

Page 237: ...timing adjuster Connect the ECU test harness between the ECU and connector page 11 21 Reconnect 3P connector 1 Connect the ECU test harness between the ECU and connector page 11 21 Turn the ignition switch ON I I I 1 Measure voltage between D8 I terminal and D2 1 terminal Measure voltage between D20 terminal and D22 1 ter minal Y E S Substitute a known good ECU and recheck If symptomlindica tion g...

Page 238: ...rating temperature cooling fan comes on FRONT KNOCK REAR SENSOR KNOCK SENSOR Is Check Engine light on and does it indicate CODE 23 or 531 II Turn the ignition swatch OFF No K u f 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Connect the ECU test harness to the engine wire harness only not to the E...

Page 239: ...e front knock sensor Substitute a known good front or rear knock sensor and recheck Is Check Engine light on and does it indicate CODE 23 or 53 1Y E S N O Replace the original knock sensor Substitute a known good ECU and recheck If symptomlindica tion goes away replace the original ECU D4 r I ORni BdNlWHT W H T e 1 I 63 ...

Page 240: ... and PGM FI ECU I Check Engine light isn t on With service check connector jumped page 11 18 CODE 30 and or 31 are indicated Do the ECU Reset Procedures page 1 I 19 Conn c floor the E rDisco from dri 4 Iti C 91 i i e necessary u car for several miles so et ryipl ugss tx E indicate No the igniti switch OFF 1 t the test harness to the fire harness only not to J page 1 l 21 I I lect the 22P connector...

Page 241: ...ir open in WHTl Does continuity exist N O G R N o r WHT RED wire between ECU Fl Y E S or F3 and the AIT control unit From page 1 I 64 Substitute a known good A T control unit and recheck Does Check Engine light indicate CODE 30 or 31 Y E S I N O Replace the original AIT control unit and recheck If symptomlindica 11 II 65 ...

Page 242: ...o to inspection described on page 11 70 PAGE I SUB SYSTEM 1 IDLE 1 ADJUST I N G EAC SCREW 86 70 72 74 76 78 80 a2 83 l DIFFICULT TO START E N G I N E W H E N C O L D 0 WHEN COLD FAST IDLE OUT OF SPEC l OOO 2 000 rpm 8 0 0 ROUGH IDLE 0 0 WHEN WARM RPM TOO HIGH 0 0 CD 0 W H E N WARM R P M T O O L O W F R E Q U E N T STALLING I I I Idle soeed is below specified r p m no load 0 0 Idle speed does not i...

Page 243: ...trol Valve EACV The valve changes the amount of air bypassing into the intake manifold in response to electric current sent from the ECU When the EACV is activated the valve opens to maintain the proper idle speed TO MAIN c RELAY bBLUlRED 1 J YELIBLK F 11 u II SCREW IDLE VALVE cont d 14 67 ...

Page 244: ... The amount of air is increased to raise the idle speed about 150 300 rpm 2 When the coolant temperature is low the EACV is opened to obtain the proper fast idle speed The amount of bypassed air is thus controlled in relation to the coolant temperature ENGINE SPEED rpm j ELANTTEMPERATURE 2 0 0 20 40 60 80 ...

Page 245: ...page 1 I 78 l M T clutch switch signal page 1 l 80 l Starter switch signal page 1 I 82 l Fast idle valve page 1 I 83 l Hoses and connections l EACV and its mounting O rings 2 If the above items are normal substitute a known good EACV and readjust the idle speed page 11 84 0 If the idle speed still cannot be adjusted to specification and the Check Engine warning light does not blink CODE 14 after E...

Page 246: ...VE SHAFT I c Check Engine light has been reported on With service check connector jumped page 1 I 18 CODE 14 is indicated VALVE Start the engine I I I I I Is Check Engine light on and does it indicate CODE 147 Intermittent failure system Is OK at this time test driving may be necessary Check for poor con nection or loose wires at EACV C133 and ECU Connect the ECU test harness A connector to the en...

Page 247: ... Cl33 connector from the EACV and connect a jumper wire to the two pins on the wire harness connector Replace EACV CAUTION the A connector must be disconnected for this test or the ECU will be damaged EACV Measure voltage between A9 I terminal and A23 4 terminal Is there battery voltage Replace EACV N O cont d 11 71 ...

Page 248: ...r from the engine wire harness only not the ECU page 1 l 21 Measure voltage between C3 I terminal and A26 1 terminal IOV I A26 6 Substitute a known A C compressor clutch7 YES Connect the RED BLU terminal of the 4P qonnector on the A C clutch relay to body ground View from SUB RELAY 1 1 Startth j engine Is there a clicking noise from th A C compressor clutch YES See Air conditioner in spection sect...

Page 249: ...a n 1 V I c3 A26 b 4 I I Repair open in BLUl I I Is voltage less than 1 V BLK wire between ECU Air conditioning signal is OK B6 and A C switch Y E S Substitute a known good ECU and recheck If symptom indica tion goas away replace the orig inal ECU ...

Page 250: ...en D9 terminal and A26 ter minal I 5v7 D9 I A26 1 I I Is there approx 5 V7 Y E S NO Turn the ignition switch OFF Reconnect D connector to the engine wire harness Warm up engine normal oper ating temperature cooling fan comes on Measure voltage between D9 mt aterminal and A26 4 ter Does the voltage decrease when headlights and rear defogger are turned on Y E S Substitute a known good ECU and rechec...

Page 251: ... between D9 terminal and body ground Does continuity exist Y E S Disconnect GRN connector from the alternator 1NO Disconnect GRN connector from the alternator GRN CONNECTOR I Check for continuity between D9 terminal and body ground Does continuity exist NO Check for continuity between D9 terminal and body ground Does continuity exist Y E S See Alternator Inspec tion Repair short in WHTlRED wire be...

Page 252: ...he A T shift indicator and select each position separately Does the indicator light properly YES See A T Shift Position lndlcator Inspection Turn the ignition switch OFF Connect the ECU test harness between the ECU and connector Disconnect 6 connector from the engine wire harness only not the ECU page 11 2 1 Turn the ignition switch ON IOV 67 I 1 1 Turn the ignitir switch ON To page 1 l 77 11 76 ...

Page 253: ... than 1 V 1YES N O Repair open in LT GRN wire between ECU 67 and gauge assembly Repair open in GRN wire be tween the gauge assembly and shift position console switch F minal with the transmission in Is there less than 1 V N O YES I Measure voltage between 67 terminal and A26 k 1 ter minal with the transmission in gear Less than 1 V 7 l 87 I A26 l 1 ...

Page 254: ...7 I terminal and A26 1 terminal in Neutral position I I Is there voltage I Disconnect the 3P connector on the MIT neutral switch I NO Connect LT GRN terminal to BLK terminal L GRN LK Is there voltage Disconnect B connector from Is there approx 10 V engine wire harness only not the ECU I Y E S MIT neutral switch signal is OK h Replace M T neutral switch J Substitute a known good ECU and re check if...

Page 255: ...11 79 ...

Page 256: ...less than 1 V N O Turn the ignition switch OFF Y E S the A terminal and B terminal on the clutch switch Depress the clutch pedal I Measure voltage between C7 terminal and A26 H terminal I Topagell 81 BLK Replace the clutch switch Y E S 1 Turn the ignitio switch ON 1 Measure voltage between PNK terminal and body ground Is there approx 10 V Y E S Repair open in BLK wire be tween the clutch switch an...

Page 257: ...n the ignition switch ON Measure voltage between C7 W terminal and A26 1 terminal I Replace the clutch switch N O Disconnect C connector from engine wire harness only not the ECU N O Substitute a known good ECU Repair short in PNK wire between ECU C7 and the clutch switch and recheck If prescribed voltage is now available replace the original ECU 1 11 81 ...

Page 258: ...tion of Starter Switch Signal BATTERY 1 VOLTAGE cl Connect the ECU test harness between the ECU and connector page 1 l 211 NOTE Clutch pedal must be depress ed on M T models Measure voltage between Cl1 terminal and A26 ter minal Is there battery voltage Y E S Inspect No 7 fuse Is No 7 fuse OK I YES 1 I Starter switch signal is OK ...

Page 259: ...amount of air bypassing into the manifold FAST IDLE VALVE AIR BYPASS VALVE WAX Inspection NOTE The fast idle valve is factory adjusted it should not be disassembled 1 Start the engine 2 Remove the cover of the fast idle valve 3 Put your finger on the valve seat area and make sure that there is air flow with the engine cold coolant temperature below 30 C d6 F and idling l If not replace the fast id...

Page 260: ...er TACHOMETER TACHOMETER CONNECTOR 3 Disconnect the 2P connector from the EACV EACV 4 Start the engine with the accelerator pedal slightly depressed Stabilize the rpm at 1000 then slowly release the pedal until the engine idles 5 Check idling in no load conditions in which the headlights blower fan rear defogger cooling fan and air conditioner are not operating idle speed should be Manual 650 50 r...

Page 261: ...eset ECU 8 Restart and idle the engine with no load conditions in which the headlights blower fan rear defogger cooling fan and air conditioner are not operating for one minute then check the idle speed Idle speed should be Manual 800 50 rpm Automatic 750 50 rpm in gear 6 Turn the ignition switch OFF 11 85 ...

Page 262: ...isted at the top of that column If inspection shows the system is OK try the next most likely system 0 etc PAGE SUB SYSTEM FUEL PUMP FUEL INJECTOR PRESSURE FUEL FUEL MAIN RELAY CONTAMI INJECTOR RESISTOR REGULATOR FILTER PUMP RELAY FUEL PUMP NATED FUEL RESISTOR SYMPTOM 89 94 95 97 98 103 106 l ENGINE WON T START 0 0 0 0 0 DIFFICULT TO START ENGINE WHEN COLD OR HOT 0 ROUGH IDLE 0 0 0 MISFIRE OR ROUG...

Page 263: ...from the system by loosening the 6 mm service bolt at top of the fuel filter 1 Disconnect the battery negative cable from the battery negative terminal 2 Remove fuel filler cap 3 Use a box end wrench on the 6 mm service bolt al the fuel filter while holding the special banjo bolt with another wrench 4 Place a rag or shop towel over the 6 mm service bolt 5 Slowly loosen the 6 mm service bolt one co...

Page 264: ...glcmz 46 53 psi Reconnect vacuum hose to the pressure regulator Pressure should be 250 304 kPa 2 55 3 10 kg cm2 36 44 psi PRESSURE REGULATOR I FUEL PRESSURE GAUGE 07406 0040001 0 If the fuel pressure is not as specified first check the fuel pump page 1 l 99 If the pump is OK check the following If the pressure is higher than specified inspect for l Pinched or clogged fuel return hose or piping l F...

Page 265: ...f time that the valve is open i e the duration the current is supplied to the solenoid coil The injector is sealed by an O ring and seal ring at the top and bottom These seals also reduce operating noise a FUEL PIPE FILTER CGRE PLUNGER SEAL RING CUSHION RING INJECTOR Check Engine light has been reported on With service check connector jumped page 1 I 18 CODE 18 is indicated Do the ECU Reset Proced...

Page 266: ...place the injector injectors that are not 1 5 2 50 Turn the ignition switch ON Measure voltage between RED 8LK terminal on the 2P con nector and body ground I Is there battery voltage 7 Y E S Turn the ignition switch OFF I Disconnect 8P connector on the injector resistor I Turn the ignition switch ON I Measure voltage between YEL 8LK terminal and body ground To page 11 91 1 To page 11 91 II 90 ...

Page 267: ...e between A23 t j terminal and following terminals l No 1 injector Al I terminal l No 2 injector A3 terminal l No 3 injector A5 j terminal l No 4 injector A2 terminal l No 5 injector A4 terminal l No 6 injector A6 I terminal Is the injector resistor testing Replace injector resis OK tor I I Y E S Replace the injector resistor Repair open RED ELK wire 1 beiween 2P connector and resistor A2 A6 I p I...

Page 268: ...e hoses before disconnecting them 5 Disconnect the fuel hose from the fuel pipe 6 Loosen the retainer nuts on the fuel pipe and harness holder 7 Disconnect the fuel pipe O RING Replace 8 Remove the injectors from the intake manifold P CUSHION 23 F t Replace RING INJECTOR MEAL RING Replace 9 Slide new cushion rings onto the injectors 10 Coat new O rings with clean engine oil and put them on the inj...

Page 269: ...e 15 Install and tighten the retainer nuts I FUEL PIPE 16 Connect the fuel hose to the fuel pipe 17 Connect the vacuum hose and fuel return hose to the pressure regulator 18 Install the connectors on the injectors 19 Install the intake manifold covers 20 Turn the ignition switch ON but do not operate the starter After the fuel pump runs for approximately two seconds the fuel pressure in the fuel l...

Page 270: ... a faster response time of the injectors I ECU L I I J INJECTORS TOR Testing 1 Disconnect the resistor connector 2 Check for resistance between each of the resistor terminals b c d e f and g and the power terminal a Resistance should be 5 7 fl INJECTOR 0 Replace the resistor with a new one if any of the resistances are outside of the specification a a 1 l 94 ...

Page 271: ... through the return line CLOSE INTAKE MANIFOLD VACUUM t IAPHRAGM FUEL INLET OPEN INTAKE MANIFOLD VACUUM DIAPHRAGM Testing m Do not smoke during the test Keep open flames away from your work area 1 Attach a pressure gauge to the service port of the fuel filter page 1 l 88 Pressure should be 323 363 kpa 3 30 3 70 kg cm 46 53 psi with the regulator vacuum hose disconnected PRESSURE REGULATOR I FUEL P...

Page 272: ...ressure regulator PRESSURE REGULATOR P A RE RN HOSE SHOP TOWEL Replacement Do not smoke while working on fuel sys tem Keep open flame away from work area 1 Place a shop towel under pressure regulator then relieve fuel pressure page 1 l 87 2 Disconnect the vacuum hose and fuel return hose 3 Remove the two 6 mm retainer bolts NOTE 0 Replace the O ring 0 When assembling the regulator apply clean engi...

Page 273: ...53 psi with the pressure regulator vacuum hose disconnected after making sure that the fuel pump and the pressure regulator are OK 1 Place a shop towel under and around the fuel filter 2 Relieve fuel pressure page 1 I 87 3 Remove the 12 mm banjo bolt and the fuel feed pipe from the filter 4 Remove the fuel filter clamp and fuel filter 5 When assembling use new washers as shown SERVICE BOLT 12 Nom ...

Page 274: ... the impeller driven by the motor the pump casing which forms the pumping chamber and the pump cover OPERATION 1 When the engine is started the main relay actuates the pump and the motor turns together with the impeller Differential pressure is generated by the numerous grooves around the impeller 2 Fuel entering the inlet port flows inside the motor from the pumping chamber and is forced through ...

Page 275: ...temperature cooling fan comes on Inspect the fuel pump resistor page 11 108 Is the check Engine light does it indicate CODE 477 Y E S Turn the ignition switch OFF Disconnect 4 hose from the in stall pipe connect vacuum pump to the hose A p p l y vacuum 3 0 0 t o 4 0 0 mmHg Start the engine Hold engine speed at 6500 rpm for 10 seconds I I I Is the check Engine warning light y L 1 To page 1 l l 00 r...

Page 276: ...open in BLKlRED wire bet ween ECU ID61 and fuel pump resistor I A23 I J terminal and A24 terminal on the 1 I I D6 I Measure the voltage between D6 Is there voltage 2 terminal and A23 ter minal I Is there battery voltage YES N O 1Turn the ignitio switch OFF 1 Disconnect A connector from the ECU only not the engine wire harness To page 11 101 Substitute a known good ECU and recheck If symptomlindica...

Page 277: ... ignition switch ON 1 Measure the voltage between A8 I terminal and A23 1 1 ter minal 1 Remove a jumper wire YES Replace fuel pump relay Measure the voltage bet ween YEL I terminal on the fuel pump relay connec CAUTION the A connector must be discon nacted for this test or the ECU will be damaged tar and body ground t 1 YEL RE YES Repair open in RED wire bet ween ECU A81 and fuel pump relay Repair...

Page 278: ...rn the ignition switch ON for 10 seconds and measure the amount of fuel flow Amount should be 333 cm3 I 1 2 02 min in 10 seconds at 12 V REGULATOF l lf fuel flow is less than 333 cm3 Il 2 021 or there is no fuel flow check for l Clogged fuel filter Clogged fuel line Pressure regulator failure page 1 I 95 m Do not smoke while working on fuel system Keep open flames away from your work area 1 Remove...

Page 279: ...f the main relay 0 If there is continuity go on to step 3 l If there is no continuity replalce the relay and retest No No 1 No No ii No 2 TO ION 1 TO ION 1 TO ST SWITCH TO BAT 0 TO ECU CA B cl TO FUEL PUMP 3 Attach the battery positive terminal to the No 6 terminal and the battery negative terminal to the No 2 terminal of the main relay Then check that there is continuity between the No 1 terminal...

Page 280: ...U terminal and body ground Is there battery voltage Turn the ignition switch ON Is there batterv voltage No ReplaceNo 2fuse I Is there battery voltage YES MAIN RELAY I N O Replace IG COIL fuse Turn the ignition switch START position Measure the voltage between BLK WHT terminal and body ground YELlBLU I Is there battery voltage N O Replace No 7 fuse YES To page 1 l 105 1 I 104 ...

Page 281: ...tween ECU A71 and Main Relay I Y E S 1 battery voltage I n I oo oooo 6b ooo ooo o o ooooooooo 0000000000000 00000000 000000 00000000000 A25 terminal and A23 4 ter PJenasy t h e vyltage b e t w e e n 1 Is there battery voltage Replace main relay YES 1 v or less I I A7 I A23 l l Measure the voltage between A7 terminal and A23 1 ter minal Is there 1 V or less for 2 seconds 1 YES N O Substitute a know...

Page 282: ...K YEL on harness side1 and body ground 1 b Is there battery voltage for 2 seconds Y E S N O Inspect the main relay page 11 104 Turn the ignition switch OFF Turn the ignition switch to START position Y E S Does the engine start NO Replace fuel pump resistor Turn the ignition switch OFF Disconnect the fuel pump con nector 1 1Turn the ig nitio 1 switch ON To page 1 l 107 FUEL PUMP RESISTOR II 106 ml ...

Page 283: ... From page 1 l 106 Is there battery voltage for 2 seconds N O Inspect the fuel pump page 1 I 102 Repair open in BlK RED wire bet ween the fuel pump resistor and the fuel pump II 107 ...

Page 284: ...nector from the fuel tank 6 Disconnect the hoses CAUTION 0 When disconnecting the hoses slide back the clamps then twist hoses as you pull to avoid damaging them 7 Place a jack or other support under the tank 8 Remove the strap bolts and nuts and let the straps fall free 9 Remove the fuel tank NOTE The tank may stick on the undercoat applied to its mount To remove carefully pry it off the mount 10...

Page 285: ...1 l 109 ...

Page 286: ...Find the symptom in the left column read across to the most likely source then refer to the page listed at the top of that column If inspection shows the system is OK try the next system 0 etc PAGE SUB SYSTEM CHAMBER THROTTLE THROTTLE DASHPOT VOLUME CABLE BODY SYSTEM CONTROL SYSTEM SYMPTOM 113 114 117 119 WHEN COLD FAST IDLE OUT OF SPEC 0 0 0 WHEN WARM RPM TOO HIGH 0 0 0 LOSS OF POWER 0 1 1 4 1 0 ...

Page 287: ...r for all engine needs It consists of the air cleaner air intake pipe throttle body EACV fast idle mechanism and intake manifold A resonator in the air intake pipe provides additional silencing as air is drawn into the system __ 4 YELIBLK RELAY ...

Page 288: ...Air Intake System Air Cleaner Air Cleaner Element Replacement AIR CLEANER CASE I AIR CLEANER ELEMENT Replace every 2 years of 30 000 miles 48 000 km whichever comes first AIR INTAKE ...

Page 289: ...tle valve to be sure it opens fully when you push the accelerator pedal to the floor Also check the throt tle valve to be sure it returns to the idle position whenever you release the accelerator Installation 1 Fully open the throttle valve then install the throt tle cable in the throttle linkage and install the cable housing in the cable bracket 2 Warm up the engine to normal operating temperatur...

Page 290: ...es on 2 Disconnect the vacuum hose to the canister from the top of the throttle body connect a vacuum gauge to the throttle body A973X 041 XXXXX 3 Allow the engine to idle and check that the gauge indicates no vacuum 0 If there is vacuum check the throttle cable page 1 l l 13 4 Check that vacuum is indicated on the gauge when the throttle is opened slightly from idle 0 If the gauge indicates no va...

Page 291: ...ere should be no clearance THROTTLE LEVER THROTTLE STOP SCREW Non adjustable Replace the throttle body if there is excessive play in the throttle valve shaft or if the shaft is binding or sticking cont d ...

Page 292: ...Throttle Body cont d Disassembly THROTTLE CABLE 22 N m 2 2 kg m CAUTION l The throttle stop screw in non adjustable 0 After reassembly adjust the throttle cable page 1 l l 13 DASHPOT DIAPHRAGM Test page 11 118 I I 1 1 6 ...

Page 293: ... Dashpot System Description The dashpot is employed to slow the closing of the throttle valve during gear shifting or deceleration DASHPOT DIAPHRAGM CHECK VALVE II 117 ...

Page 294: ...M PUMP G A973X 041 X X 3 Apply vacuum and check the speed the vacuum goes out Vacuum should go out slowly 0 If the vacuum holds or goes out quickly replace the dashpot check valve and retest 4 Connect a vacuum pump to the dashpot dia phragm 5 Apply vacuum and check that the rod pulls in and vacuum holds 0 If the vacuum does not hold or the rod does not move replace the dashpot diaphragm and retest...

Page 295: ...ng the chamber volume control valves High torque at low RPM is achieved when the valves are closed whereas high power at high RPM is achieved by when the valves are opened CHAMBER VOLUME CONTROL SOLENOID VALVE OFF p CLOSE CHAMBER VOLUME CONTROL DIAPHRAGM CK V E To No 2 FUSE TANK VOLUME CONTROL kont d II 119 ...

Page 296: ...se on chamber volume control solenoid valve in the control box and con IES nect a vacuum gauge to the hose Is there vacuum Y E S Repair the blockage or vacuum leak between the vacuum tank and the Intake manifold Disconnect the 6P connector from the control box I Measure voltage between ELK YEL terminal and BLU 1 ter COYTROL BOX 1 m i n a i Replace the chamber Is there battery voltage volume contro...

Page 297: ...tween the 6P connector and No 2 15 A fuse Does continuity exist Y E S Substitute a known good ECU and recheck If symptom goes away replace the original ECU Repair open in RED BLU wire between ECU A14 and the 6P connector A l 4 Replace chamber vol ume control solenoid valve purn the ignitioi switch OFF 1 Disconnect A connector from ECU I Check for continuity to ground on the RED BLU wire I Is there...

Page 298: ... movement 3 Check the A of the chamber volume control valve is in close contact with the stopper when the bypass valve is fully open 4 Check that 6 of the chamber volume control valve is in close contact with the full close screw when the valve is fully closed FULL CLOSE 0 If any fault is found clean the linkage and shafts with carbuie ci iner If the problem still exists after cleaning disassemble...

Page 299: ... System Disassembly 12 Nom 1 2 kg m 9 lb ft 2 Nom 2 2 kg m 16 lb ft 22 N m 2 2 kg m GASKET Replace CHAMBER VOLUME CONTROL VALVE GASKET Rnolace 16 lb ft GASKET Replace CHAMBER WASHER Replace I 22 N m 2 2 kg m 16 lb ft 11 123 ...

Page 300: ...lumn read across to the most likely source then refer to the page listed at the top of that column If inspection shows the system is OK try the next most likely system etc PAGE SYMPTOM CATALYTIC CONVERTER 126 EGR SYSTEM 128 POSITIVE CRANKCASE VEi F I ON 134 EVAPORATIVE EMISSION CONTROLS 135 ROUGH IDLE 0 0 FREQUENT AFTER WARM STALLING ING UP 0 AFTER WARM ING UP FAILS EMISSION TEST 0 0 CD POOR PERFO...

Page 301: ... m Do not smoke during this procedure Keep any open flame away from your work area 1 2 3 4 5 Start the engine and warm up to normal operating temperature cooling fan comes on Connect a tachometer Check idle speed and adjust the idle speed if necessary page 1 l 84 Warm up and calibrate the CO meter according to the meter manufacturer s instructions Check idle CO with the headlights heater blower re...

Page 302: ...erter Description The d way catalytic converter is used to convert hvdrocarbons HC carbon monoxide CO and oxides of nitrogen NOx in the exhaust gas to carbon dioxide CO2 dinitrogen N2 and water vapor HOUSING I I l 126 ...

Page 303: ... 25 lb ft 34 N m 3 4 kg m A GASKET 25 lb ft HEAT SHIELD FRONT OF VEHICLE 10 Nom 1 O kg m 7 lb ft FiONT CATALYTIC CONVERTER Removal Installation Section 9 Inspect housing for cracks or other damage Inspect element for clogging by looking through the inside GASKET HEAT SHIELD I REAR CATALYTIC CONVERTER Removal Installation Section 9 Inspect housing for cracks or other damage Inspect element for clog...

Page 304: ...ambers It is composed of the EGR valve CVC valve EGR control solenoid valve PGM FI ECU and various sensors The ECU contains memories for ideal EGR valve lifts for varying operating conditions The EGR valve lift sensor detects the amount of EGR valve lift and sends the information to the ECU The ECU then compares it with the ideal EGR valve lift which is determined by signals sent from the other se...

Page 305: ...ne speed in the 1700 2600 range YES With the engine at idle discon nect the 5 hose from the EGR valve and connect a vacuum pump gauge to the hose Is there any vacuum Move the vacuum pump gauge to 1the EGR valve Intermittent failure system is OK at this time Check for poor connections or loose wires at EGR valve C141 and control box 0532 Disconnect 8P connector from the control box and check the 5 ...

Page 306: ...GR control solenoid valve and ECU Al 1 With the engine at idle apply 8 of Check for continuity ground on RED wire of 6P connector Does the engine stall and does th EGR valve hold vacuum 7 1YES Replace EQR valve Disconnect the 6P connector from the control box Measure voltage between BLK YEL terminal on the main wire harness and body ground Reconnect the vacuum pump gauge to the 5 hose Start the en...

Page 307: ...re the hoses OK N O Connect as necessary I TEST HARNESS 07LAJ PT30200 YE l I CVC VALVE r SOLENOID LVACUUM PU Cbl ICC I Disconnect the lower hose on I YS SVYL EGR control solenoid valve and A973X 0 Measure voltage between GRN teminal and RR f 1 terminal Is there approx 5 V 7 YES To page 1 l l 32 idle Connect the test harness between the EGR valve lift sensor and engine wire harness Is there 6 10 of...

Page 308: ...air short in WHTlGRN wire between ECU D12 and EGR valve lift sensor Substitute a known good ECU and recheck If prescrib ed voltage is now available replace the original ECU I Is the maximum voltage approx 4v7 Replace EGR valve YES I Does the voltage consistent1 increase decrease as the vacuum increases decreases Replace EGR valve 1 I YES 1 g fvce the h o s e t o t h e 1 Turn the ignition switch OF...

Page 309: ...0000000 00000000000 0000000000000 00000 0000 I I Dl I DZ 1 Is there approx 1 2 V 7 1YES N O Repair open in WHTIBLK wire between ECU D12 and the sen sor Repair open in RED wire between ECU Al II and EGR control solenoid valve LlV J ...

Page 310: ...s is drawn directly into the intake manifold PCV HOSE EATHER HOSE FRONT OF VEHICLE 7 PCV VALVE C BLOW BY VAPOR 0 FRESH AIR Inspection 1 Check the crankcase ventilation hoses and connec tions for leaks and clogging PCV VALVE PCV HOSE BREATHER PIPE 2 At idle make sure there is a clicking sound from the PCV valve when the hose between PCV valve and intake manifold in lightly pinched with your fingers...

Page 311: ...Vapor Purge Control System Canister purging is accomplished by drawing fresh air through the canister and into a port on the throttle body The purging vacuum is controlled by the purge control diaphragm valve and the purge cut off solenoid valve PURGE CUT OFF SOLENOID VALVE OFF AFTER START ING ENGINE COOLANT TEMPERATURE ABOVE 7O C I 58OF C Fuel Tank Vapor Control System When fuel vapor pressure in...

Page 312: ...s Evaporative Emission Controls cont d FUEL FILLER CAP P FUEL TANK fkn i n 6 PURGE CUT OFF SOLENOID VALVE TWO WAY 7 r d CANISTER FRESH AIR PURGE CONTROL DIAPHRAGM VALVE TO No 2 a z BLK YEL GRN _I II 136 ...

Page 313: ... vacuum gauge to the hose I VACUUM PUMP GAUGE A973X 041 XXXXX 11 u ture must be below 70 C Is there vacuum Y E S Disconnect the 6P connector I N O To page 1 l l 38 To page 1 l l 38 GRN 1 between BLKl YEL terminal and GRN ter I I I I Inspect vacuum hose Is there battery voltage routing If OK replace purge cut off solenoid valve NO Measure voltage between 8LK YEL terminal and body ground cont d II 1...

Page 314: ...way replace the original ECU Warm up the engine to normal operating temperature cooling fan comes on Check for vacuum at 6 vacuum hose after starting the engine I Is there manifold vacuum N O Disconnect the 6P connector I Y E S I I I Inspect vacuum hose routing If OK replace purge cut off solenoid valve Is there manifold vacuum YES Inspect for an open in GRN wire between ECU A201 and the connector...

Page 315: ...pm PURGE HOSE VACUUM PRESSURE GAUGE O 4 in Hg 07JAZ 001000A PURGE AIR HOSE Connect a vacuum gauge to the Does vacuum appear on gauge within 1 minute canister purge hose and raise the engine speed to 3 500 rpm Y E S See two way valve test to com pk3tS Evaporative emission control are OK Does vacuum appear on the YES Inspect the purge hose and throttle body port for pinch or blockage Replace the can...

Page 316: ...entarily at 5 to mmlig 0 2 to 0 6 in Hg 0 If vacuum stabilizes valve opens below 5 mr 0 2 in Hg or above 15 mmHg 0 6 in Hg stall new valve and retest 4 Move vacuum pump hose from vacuum to press fitting and move vacuum gauge hose from vact to pressure side as shown PRESSURI 5 Slowly pressurize the vapor line while watchin gauge Pressure should stabilize at 10 to 35 mmHg 0 1 4 in Hg 0 If pressure m...

Page 317: ...sembly 12 9 Slave Cylinder CANADA Overhaul Inspection 12 I 0 Removal Installation 12 l 1 Pressure Plate Clutch Disc Mid Plate Removal 1 f l 2 Pressure Plate i Inspection 12 13 Release Bearing Inspection 12 13 1st and 2nd Clutch Discs I Inspection 1 2 1 4 Mid Plate Inspection 12 15 Mid Plate Guide Inspection 12 15 Initialization 12 l 6 Replacement 12 17 Flywheel Flywheel Bearing Inspection 12 18 Re...

Page 318: ...ber 07LAB PVOOIOO or 07924 PD20003 07MAF PR80100 07746 0010200 07749 0010000 07936 3710100 Description Ring Gear Holder Clutch Alignment Shaft Attachment 37 x 40 mm Driver Handle my 1 1 1 1 1 Page Reference 12 12 12 20 12 19 12 l 9 12 20 L 12 2 ...

Page 319: ... 14 Installation page 12 20 DAMPER WASHER MID PLATE Removal page 12 I 2 Inspection page 12 l 5 Installation page 12 20 D WEL PIN PRESSURE PLATE 1st CLUTCH DISC Removal page 12 l 2 Removal page 12 12 Inspection page 12 I 3 Inspection page 12 14 htakhn Page 12 20 Ins tallation page 12 20 TRANSMlSSlbN SPRING I 0 0 no I MID PLATE GUIDE Inspection page 12 I 5 Initialization page 12 l 6 Replacement page...

Page 320: ...sh rod in or out to get the specified stroke and height at the clutch pedal 6 Tighten locknut A 7 Loosen locknut B and pedal switch B 8 Measure the clearance between the floor board and clutch pedal with the clutch pedal fully depressed 9 Release the clutch pedal 15 20 mm from the fully depressed position and hold it there Adjust the position of pedal switch B so that the engine will start with th...

Page 321: ...Avoid spilling brake fluid on paint as it may damage the finish 0 Plug the end of the clutch pipe and reservoir hose with a shop towel to prevent fluid from flowing out of the clutch pipe and reservoir hose after disconnecting MASTER CYLINDER RESERVOIR HOSE ASSEMBLY RESERVOIR Installation 1 Install the clutch master cylinder in the reverse order of removal NOTE Bleed the clutch hydraulic system pa...

Page 322: ...ck for signs of leaking or deterioration Installation 1 Install the slave cylinder assembly on the clutch housing SLAVE CYLINDER ASSEMBLY 10 N m 1 O kg m 8 lb ft Molybdenum Disulfide 2 Bleed the clutch hydraulic system 0 Attach a hose to the bleeder screw and suspend the hose in a container of brake fluid 0 Make sure there is an adequate supply of fluid at the master cylinder then slowly pump the ...

Page 323: ...OIR SEAL GE3 FLoAT e RESERVOIR 6 x 1 0 mm IO N m 1 O kg m 8 lb ft 22 N m 2 2 kg m 16 lb ft I WASHER Replace b 0 HOSE JOiNT 10 N m 1 0 kg m 8 lb ft 10 N m 1 0 kg m 8 lb ft MASTER CYLINDER BODY Inspect the cylinder wall for scoring and wear 18 N m 1 8 kg m 13 lb it p H ROD ...

Page 324: ...the master cylinder CAUTION 0 Avoid spilling brake fluid on paint as it may damage the finish 0 Plug the end of the clutch pipe and reservoir hose with a shop towel prevent fluid from flow ing out of the clutch pipe and reservoir hose after disconnecting 22 Nom 2 2 kg m 16 lb W RESERVOIR 6x l Omm 10 N m 1 0 kg m 8 lb t31 I RE SERVOIR HOSE CLUTCH PIPE MAiTER CYLINDER ASSEMBLY 4 Install the clutch m...

Page 325: ...with a shop towel to prevent fluid from coming out 0 Clean all disassembled parts in solvent and blow through all ports and passages with compressed air PISTON CYLINDER Plug port l Do not allow dust or water to enter the system l Do not mix different brands of brake fluid as they may not be compatible 0 Do not reuse the brake fluid which was drained out 0 Avoid spilling the brake fluid on painted ...

Page 326: ...nder wall for scoring and wear SLAVE CYLINDER SPRING Install with small end BLEEDER SCREW Y 10 Nom 1 O kg m 8 lb PlSiON CUP B PISTON CUP A PUSH ROD Check that it is fitted securely over cylinder body ft SLAVE CYLINDER PISTON Inspect for wear and damage Molyljdenum Disulfied 12 10 ...

Page 327: ...terioration Installation 1 Install the slave cylinder assembly on the clutch hou ing SLAVE CYLINDER ASSEMBLY Bx1 25mm 10 Nom 1 O kg m 22 Nom 2 2 kg m 8 lb ftl 16 lb ft I 10 N m 1 O kg m 8 lb ftl Molybdenum Disulfide 2 Bleed the clutch hydraulic system 0 Attach a hose to the bleeder screw and suspend the hose in a container of brake fluid 0 Make sure there is an adequate supply of fluid at the mast...

Page 328: ...te mounting bolts two turns at a time in a crisscross pattern then remove the pressure plate and the 1 st clutch disc 3 Remove the release bearing from the pressure plate SPEClqL BOLT 1 ST CLUTCH DISC PRESSURE LATE 4 Remove the mid plate and the 2nd clutch disc 2N0 CLUTCH DISC MID SLATE 5 Remove the spring collar and damper washer from the flywheel DAMPER WASHER 12 12 ...

Page 329: ...e using a straight edge and feeler gauge Standard New 0 03 mm 0 0012 in min Service Limit 0 15 mm 0 0059 in I Measure across the pressure plate at three points STljAICjHT EDGE FEELER GAUGE Release Bearing Inspection 1 Check the release bearing for excessive play by spinning it by hand CAUTION Do not wash it in solvent 2 Replace the release bearing with a new one if there is excessive play ...

Page 330: ...the clutch disc thickness Standard 1st Clutch Disc 8 3 9 0 mm 0 327 0 354 in 2nd Clutch Disc 7 6 8 3 mm 0 299 0 327 in Service Limit 1st Clutch Disc 5 9 mm 0 232 in 2nd Clutch Disc 5 4 mm 0 213 in 1 3 Measure the depth from the lining surface to the rivets on both sides 1st and 2nd Clutch Discs Standard 1 1 m m 10 043 in min Service Limit 0 5 m m 10 020 in 12 14 ...

Page 331: ... edge a feeler gauge Standard New 0 05 mm 0 0020 in min Service Limit 0 15 mm 0 0059 in I x I STRAIGHT EDGE he i FEELER GAUGE Inspection NOTE Make sure all parts are clean before inspection 1 Make sure the mid plate guide moves when you ap ply 1 O 60 kg per one place of pressure to the disc surface of the mid plate NOTE inspection all the mid plate guides as described above Before Pressing After P...

Page 332: ...back of the flywheel until it just touches the mid plate guide 5 x 0 8 mm BOLT Length of threads 0 39 0 47 in 12 16 2 Screw the 5 mm bolt in 150 210 further 3 Make sure that 0 The mid plate guide tg I es the back of the mid plate aim yFr 0 There is 0 4CI_ I 55 mm 0 016 0 022 in clearance b een the mid plate guide and the front of 87mid plate he remaining mid plate guides as then remove the 5 mm bo...

Page 333: ...washer GUIDE COLLAR S P R I N G Y WASHER y SCREW MID PLAiE GUIDE w 3 Remove the mid plate guide with the screw installed MID PLATE GUIDE 4 Thread and tighten a 4 mm screw into the new mid plate guide then remove the mid plate guide from the guide collar 4 x 0 7 mm SCREW 4 x 0 7 mm SCREW Length of threads Length of threads 30 mm I 18 in 30 mm I 18 in KGUIDE COLLAR GUIDE COLLAR MID PLATE GUIDE cont ...

Page 334: ... for wear or damage 2 Inspect the clutch disc mating surface on the flywheel for wear cracks or burning 3 Measure the flywheel runout using a dial indicator through at least two full turns Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance NOTE The runout can be measured with engine installed Standard New 0 05 mm 0 0020 in max Service Limit 0 15 mm 10...

Page 335: ...ng into the flywheel using the special tools DRIVER ATTACHMENT 37 x 40 mm 07746 0010200 4 Align the hole in the flywheel with the crankshaft dowel pin and install the flywheel Install the bolts finger tight 5 Install the special tool then torque the flywheel bolts in a crisscross pattern as shown 12xl dmm I RING GkAR HOLDER 106 Nom 10 5 kg m 76 lb ft 07LAB PVOOIOO ot 07924 PD20003 FLYWHEEL 12 19 ...

Page 336: ... with the mark on the mid plate Align the marks 1 Install the damper washer and spring collar SPRING 2 3 Install the ring gear holder Install the 2nd clutch disc Turn the groove to the out side NOTE The index mark on the 2nd clutch disc should face away from the flywheel I CLUTCH ALIGNMENT SHAFT 07MAF PR80100 RING GEAR HOLDER 07LAB PVOOIOO or 07924 PD20003 MiD PLATE 5 Install the 1st clutch disc N...

Page 337: ...ome off Align the marks Place the diaphragm spring fingers in the groove of the release bearing 6 Torque the bolts in a crisscross pattern as shown Tighten them two turns at a time to prevent warp ing the diaphragm spring NOTE Place the diaphragm spring fingers in the groove of the release bearing 0 m 16 lb ft 9 Remove the alignment tool and ring gear holder 10 Initialize the mid plate guides See ...

Page 338: ...sembly Reassembly 13 l 9 Change Holder Assembly Shift Fork Clearance Inspection 13 20 Shift Fork Synchro Sleeve Clearance Inspection 13 21 Shift Fork Assembly Disassembly Reassembly 13 22 Mainshaft Assembly Index 13 23 Clearance Inspection 13 24 Disassembly 13 25 Inspection 13 26 Reassembly 13 27 Countershaft Assembly index 13 29 Clearance inspection 13 30 Disassembly 13 31 Inspection 13 32 Reasse...

Page 339: ... A01 OOOA Adjustable Bearing Puller 25 40 mm 1 0 07746 0010400 Attachment 52 x 55 mm 1 0 07746 0010500 Attachment 62 x 68 mm 1 07746 0030100 Driver 40 mm I D 1 0 07746 0030400 Attachment 35 mm I D 1 07749 0010000 Driver 1 Must be used with commercially available 318 x 1 6 Slide Hammer Page Reference 13 42 13 42 13 39 13 40 13 39 13 42 13 42 13 39 ...

Page 340: ...ith a new washer and refill to proper level Reinstall the oil filler plug with a new washer NOTE The drain plug washer should be replaced at every oil change Oil Capacity 2 7 e 2 9 U S qt after drain 2 8 P 3 0 U S qt after qverhaul Use only SAEI OW 30 or 1 OW 40 that exceeds SE grade OIL FILLER PLUG 45 N m 4 5 lym 33 lb ft DRAIN PLUG 40 N m 4 0 kg m 29 lb ft Back up Light Switch Neutral Switch 1 2...

Page 341: ... 0 mm BOLTS COTTER PIN IO N m I O kg m Replace CHANGE LEVER 7 lb ft 6 x 1 O mm I A IO N m 1 0 kg m 7lb ft CHANO i I 6xl OmmBOLT IO N m 1 O kg m 7 lb ft CHANGE LEVER LINKAGE IGE LEVER SEAT CHANGE i lV0 GUIDE SHlFi CABLE I O kg m 7 lb ft CHANGE LEVER BRACKET 22 N G 2 2 kg m 16 lb ft 8 x 1 25 mm 22 N m 2 2 kg m 16 lb ft 22 N m 2 2 kg m 16 lb ftl IO Nom I O kg m 7 lb ft 13 4 ...

Page 342: ... 140 5 141 5 mm 5 53 5 57 in If distance is out of spec loosen the locknut and turn the adjuster as necessary ADJ TER LOCKNUT 10 N m 1 O kg m 7 lb4 3 Tighten the locknut NOTE After adjustment check operation of the gearshift lever 2 If distance is out of spec loosen the locknut and turn the adjuster as necessary ADJUSTER LOCKNUT 10 Nom 1 0 kg m 7 lb ft 3 Tighten the locknut C OTE After adjustment ...

Page 343: ...HOUSING BOLT BACK UP LIGHT SWITCH CONNECTO R HARNESS HOLtEFi 4 Remove the strut bar 5 Remove the air cleaner case 6 Remove the connectors from the control box and remove the control box CAUTION Do not remove the vacuum tubes from the control box 7 Remove the wire harness holder jumper connector and transmission ground cable 8 Disconnect the switch connectors then remove the back up light switch an...

Page 344: ... and the Anti lock Brake sensor wire clamp 5 Loosen the ball joint nut then separate the toe control arm from the knuckle using the special tool See Section 18 6 Remove the damper fork bolt 7 Remove the ball joint nut using the special tool and separate the lower control arm from the knuckle See Section 18 1 8 Remove the right driveshaft from the intermediate shaft DAMPER FORK BOLT CASTLE NUT CABL...

Page 345: ...re clamp 22 Scribe a reference mark on the flange of the adjusting bolt adjusting cam and lower control arm 23 Loosen the ball joint nut then separate the toe control arm from the knuckle using the special tool See Section 18 24 Remove the damper fork bolt 25 Remove the bolts and lower control arm from the side beam 26 Remove the left driveshaft from the differential 27 Pry the driveshaft out of t...

Page 346: ... transmission just enough to take weight off mounts 36 Remove the front engine mounting bolts on the transmission side and retighten the bolt on the engine side CAUTION Loosen the front engine mounting bolt on the engine side but do not remove it After removing the two bolts on the transmission side be sure to retighten the bolt on the engine side 37 Remove the rear transmission mounting bolts and...

Page 347: ...OR SENSOR DUMMY COVER O RING Replace HOLDER PLATE REVERSE SHIFT FORK ASSEMBLY l Disassembly Reassembly page 13 16 I REVERSE IDLE GEAR SHAFT ASSEMBLY l Disassembly Reassembly page 13 15 OIL GUIDE RING 90 mm WASHER BEARING OUTER RACE DIFFERENTIAL ASSEMBLY l See Section 15 I OIL GUIDE PLATE 44 x 72 x 23 mm NEEDLE BEARING BEARING RETAINING PLATE COUNTERSHAFT ASSEMBLY l Index page 13 29 I MAINSHAFT ASS...

Page 348: ...I STEEL BALL LARGE I 16 mm SEALING BOLT 42 Nom 4 2 kg m 30 lb ft I SPRING L 24 2 mm I 16 mm SEALING BOLTS 42 N m 4 2 kg m 30 lb ft I SPRING L 30 mm STEEL BALL SMALL SHIFT LEVER ASSEMBLY l Removal page 13 l 7 l Installation page 1 3 43 NEUTRAL SWITCH 25 Nom 2 5 kg m 18 lb ft TRANSMISSION HOUSING j OIL GUIDE PLATE I 82 mm THRUST SHIM l Selection page 13 41 Torque Value A 12 N m 1 2 kg m 9 lb ft B 24...

Page 349: ...ts springs and steel balls 3 Remove the upper cover then remove the transmission housing attaching bolts 4 Remove the 36 mm sealing bolt 36 mm SEALING BOLT STE EL BALL UPPER 5 Expand the snap ring on the countershaft ball bear ing and remove it from the groove using a pair of snap ring pliers 4 AP RING 6 Separate the clutch housing from the transmission housing 7 Remove the thrust shim and oil gui...

Page 350: ...eplace the reverse shift arm with a new one If the width of the groove is within the standard replace the Sth reverse shift piece with a new one 3 Measure the clearance between the reverse shift arm and reverse shift fork Standard 0 05 0 35 mm 0 0020 0 0138 in Service Limit 0 5 mm 0 020 in REVERSE SHIFT ARM I REVERSE dHlFT FORK 4 If the clearance exceeds the service limit measure the width of the ...

Page 351: ... 4 6 5 mm 0 2520 0 2559 in If the thickness exceeds the standard replace the reverse shift fork with a new one If the thickness is within the standard replace the reverse synchro sleeve with a new one NOTE The synchro sleeve and synchro hub should be replaced as a set Reverse Idler Gear Shaft Assembly Removal 1 Remove the reverse shift arm from the clutch housing SHIFT 2 Shift the reverse shift fo...

Page 352: ...T NEEDLE BEARING Inspect for wear and operation REVERSE DRIVEN GEAR Inspect for wear or damage NEEDLE BEARING Inspect for wear and operation THRUST NEEDLE BEARING Inspect for wear and operation f sYNCHRO SPRING SYNCHRO RING inspection page J 3 35 REVERSE SYNCHRO SLEEVE Inspection page 13 I 6 REVERSE IDLE GEAR SHAFT Inspect for wear or damage 3 x 6 mm SPRING PIN Repla e T NEEDLE BEARING Inspect for...

Page 353: ... mm PIN PUNCH Reassembly Install the 5 mm spring pin first then install the 3 mm spring pin Mainshaft Countershaft Differential Assemblies Removal 1 2 Remove the change holder assembly from the clutch housing CHAilGE HOLDER ASSEMBLY Remove the mainshaft assembly and countershaft assembly with the shift fork from the clutch housing NOTE Tape the mainshaft splines to protect them before removing the...

Page 354: ...DIFFERENTIAL ASSEMBLY I Removal 1 Remove the shift spring set plate and shift detent spring from the transmission housing SHIFT SPRING SET PLATE SHIFT DETENT SPRING 2 Remove the bolt and spring washer 3 Pull out the shift lever then remove the shift arm SPRING WASHER SHIFT ARM OIL SEAL ...

Page 355: ...Shift Lever Select Lever Removal cont d 4 Remove the bolt and spring washer 5 Pull out the select lever then remove the select arm SPRING WASHER SELECT ARM Replace OIL SEAL Replace SELECT LEVER 13 18 ...

Page 356: ...ngs are installed properly Prior to reassembling clean all parts in solvent dry them and apply lubricant to any contact surfaces SHIFT SHIFT PIECE SHAFT 0 INTERLOCKER CHANGE HOLDER 5thlREVERSE RETURN SPRING SELECT RETURN SPRING a 3 x 6 mm SPRING PIN f Replace LOCK COLLAR 13 19 ...

Page 357: ...replace the shift arm with a new one If the width of the shift arm is within the standard replace the shift piece with a new one 3 Measure the clearance between the interlocker and select arm Standard 0 03 0 15 mm 0 0012 0 0059 in INTERLOCKER SELECT ARM 4 If the clearance exceeds the standard measure the interlocker finger Standard 11 95 12 00 mm 0 4705 0 4724 in If the width of the interlocker ex...

Page 358: ...ece with a new one Shift Fork Synchro Sleeve Clearance Inspection 1 Measure the clearance between each shift fork ant its matching synchro sleeve Standard O 45 0 65 mm 0 0177 0 0266 in Service Limit 1 O mm 0 0394 in 2 If the clearance exceeds the service limit measure the width of the shift fork fingers Standard lstl2nd SHIFT FORK 8 9F9 0 mm 0 5504 0 3543 in 3rd14th SHIFT FORK 7 4 7 5 mm 0 2913 0 ...

Page 359: ...Remove with the 3 mm spring pin and 5 spring pin Reassembly Install the 5 mm spring pin first then install the 3 mm spring pin 5thlREVERSE SHIFT FORK SHAFT 3rd14th SHIFT FORK SHAFT COLLAR 5th SHIFT FORK 3rdl4th SHIFT 5thlREVERSE SPRING WASHER lidi d u 8x l Omm SPECIAL BOLT 32 N m 3 2 kg m 3rd14th SHIFT FORK SHAFT 5x25mm SPRING PIN 3xd5mm SPRING PIN I Replace 1 stl2nd SHIFT 1 stl2nd SHIFT FORK 3x25...

Page 360: ...d operation 3rd14th SYNCHRO HUB SYNCHRO SPRING SYNCHRO RING Inspection page 13 35 Measuremer a page _ c iiPlii 5th SYNCHRO SLEEVE inspection page 13 36 5th SYNCHRO HUB 9 SYNCHRO yJNG Inspection ij Ag 73 35 5 t h G E A R Measurement page I 3 25 A r 43 x 49 x 29 5 mm NEEDLE BEARINGS Inspect for wear and operation 42 x 47 x 29 mm NEEDLE BEARING Inspect for wear and MAINSHAFT Inspection page 13 26 EAR...

Page 361: ...rd 4th synchro hub with a new one 3 Measure the clearance between 4th gear and the spacer collar Standard 0 06 0 21 mm 0 0024 0 0083 in Service Limit 0 3 mm 0 012 in 4 If the clearance exceeds the service limit measure distance I on the spacer collar Standard 29 53 29 68 mm 1 1626 1 1646 in Service Limit 29 51 mm 1 1618 in 4th GEAR SIDE 5 If distance is more than the service limit replace the spac...

Page 362: ...tance j is within the service limit measure thickness of 5th gear Standard 34 92 34 97 mm I 3748 1 3768 in Service Limit 34 80 mm I 3700 in If the thickness of 5th gear is less than the service limit replace 5th gear with a new one If the thickness of 5th gear is within the service limit replace the 5th synchro hub with a new one Disassembly CAUTION Remove the synchro hubs using a press and steel ...

Page 363: ...nd bearing surface for wear or damage then measure the mainshaft at points A B and C Standard A Ball bearing surface 32 002 32 018 mm 1 2599 1 2605 in B Needle bearing surface 42 984 43 000 mm 1 6923 1 6929 in C Ball bearing surface 30 984 31 OOO mm 1 2198 1 2205 in Service limit A 31 95 mm 1 2579 in B 42 93 mm 1 6902 in C 30 93 mm 1 2177 in Inspect oil passages for clogging Inspect for wear or da...

Page 364: ... the mainshaft without lubrication When installing the 3rdl4th and 5th synchro hubs support the shaft on steel blocks and install the synchro hubs using a press install the 3rdI4th and 5th synchro hubs with a maximum pressure of 1 000 kg and press the 3rd 4th and 5th synchro hubs with a pressure of 2 000 kg The clutch housing ball bearing is installed when it s time to check the mainshaft clearanc...

Page 365: ...Assembly 1 Reassembly cont d I Install the 5th synchro hub using a press as shown SYNCHRO GEAR HUB 3 install the transmission housing side ball bearing using a press as shown BALL BEARING 5th SYNCHRO SLEEVE 13 28 ...

Page 366: ...press 6 SPRING WASHER SYNCHRO SPRING BALL BEARING NEEDLE BEARING 5th GEAR 4th GEAR 1st GEAR u 54 5 x 60 5 x 33 mm N E E D L E B E A R I N G Inspect for wear and operation THRUST WASHER Selection page 13 30 REVERSE GEAR lT lGG k 3rd GEAR INNER SYNCHRO RING SYNCHRO CONE Inspection page 13 32 OUTER SYNCHRO RING SYNCHRO SPRING 52 x 57 x 33 mm NEEDLE BEARING Inspect for wear and operation S P A C E R C...

Page 367: ...SS k A 23912 PR8 000 33 003T33 005 mm 1 2993 1 3012 in i 32 998 33 000 mm 23913 PR8 i OOO 2gg 2gg2 inj 3 Measure the clearance between 1st and reverse gear Standard 0 04 0 10 mm 0 0016 0 0039 in 4 If the clearance exceeds the standard select the appropriate thrust washer for the correct clearance from the chart below PART NUMBER THICKNESS A 23921 PR8 000 1 42 1 44 mm 0 0559 0 0567 in B 23922 PR8 0...

Page 368: ...shaft and remove the locknut and the spring washer NOTE Locknut has left hand threads 2 Remove the ball bearing using a bearing puller as shown BALL BEARING 3 Remove the outer bearing race of the needle bear ing then remove the needle bearing using a bearing puller as shown NEEDLE BEARING 4 Support 4th gear on steel blocks as shown and press the shaft out of 5th and 4th gears 47 ...

Page 369: ...313 1 7319 in B Ball bearing surface 33 984 34 000 mm I 3380 1 3386 in1 Service Limit A 43 92 mm 1 7291 in B 33 93 mm 1 3358 in NOTE Inspect oil passages for clogging Inspect for we and damage If any part of the countershaft is less than the ser vice limit replace it with a new one Inspect for runout Standard 0 02 mm 0 0008 in min Service Limit 0 05 mm 0 0020 in NOTE Support the countershaft at bo...

Page 370: ...e 3rd 4th and 5th gears with a maximum pressure of 1 000 kg and press the 3rd 4th and 5th gears with a pressure of 2 600 kg 1 Support the countershaft on a steel block as shown and install 3rd gear using a press 2 Install 4th gear using a press as shown GEAR 3 Install 5th gear using a press as shown GEAR 4 Install the needle bearing using a press as showr then install the bearing outer race NEEDLE...

Page 371: ...stall the ball bearing using a press as shown BALL BEARING 6 Install the spring washer tighten the locknut then stake the locknut tab into the groove NOTE Locknut has left hand threads LOCKNUT 160 0 160N m 16 0 0 16 0 kg m 116 0 4 116 lb ft 13 34 ...

Page 372: ...ect the teeth on all gears for uneven wear scoring galling cracks Coat the cone surface of the gear with oil and place the synchro ring on the matching gear Rotate the ring making sure that it does not slip Measure the clearance between the ring and gear all the way around GEpR NOTE Hold the ring against the gear evenly while measuring the clearance Ring to Gear Clearance Standard 0 85 1 1 mm 0 03...

Page 373: ...ent is required always replace the synchro sleeve and hub as a set 13 36 SLEEVE Installation Each synchro sleeve has three sets of longer teeth I 20 degrees apart that must be matched with the three sets of deeper grooves in the hub when assembled NOTE Installing the synchro sleeve with its longer teeth in the 1 st 2nd synchro hub slots will damage the spring ring SYNCHRO LONGER TEETH HUB n SYNCHR...

Page 374: ...he parts in solvent dry them and apply lubricant to any contact surfaces 6xl OmmBOLT 12 Nom I 2 kg m 9 lb ft STRAINER COVER OIL PUMP SH FT AFSEMBLY STRAINER SET OIL PUMP STRAINER Inspect for damage and OIL PUMP PLATE INNER ROTOR OUTER ROTOR RELIEF VALVE SPRING STEEL B ...

Page 375: ...Clutch Housing to Rotor Axial clearance Standard 0 03 0 1 mm 0 0012 0 0039 in Service Limit 0 15 mm 0 0059 in 3 Check the radial clearance on the pump rotor Inner Rotor to Outer Rotor Radial clearance Standard 0 14 mm 0 0055 in Service Limit 0 2 mm 0 008 in 4 Check the radial clearance between the clutch housing and the outer rotor Clutch housing to Rotor Radial Clearance Standard 0 1 0 2 mm 0 003...

Page 376: ... HOLE NEEDLE BEARING OIL GUIDE PLATE 3 Position the oil guide plate and new needle bearing in the bore of the clutch housing NOTE Position the needle bearing with the oil hole facing up 4 Drive the needle bearing in using the special tools DRIVER ATTACHMENT 62 x 66 mm 07749 0010000 a l 07 746 0010500 5 Install the bearing retaining plate and stake the bolt heads in the groove in the bearing retain...

Page 377: ... release bearing guide BEARING 3 Drive in a new oil seal from the transmission side using the special tools 2 Remove the oil seal ATTACHMENT 55 mm 6 0010400 OIL SEAL Replace 4 Install the release bearing guide 6 x 1 O mm BOLTS 12 Nom 1 2 kg m 8 7 lb ft BEARING ...

Page 378: ... of the transmission housing and mainshaft NOTE 0 Use a straight edge and feeler gauge 0 Measure at three locations and average the readings Set the mainshaft ball bearing in the clutch hous ing and measure distance or 0 between the surfaces of the clutch housing and the bearing in ner race NOTE 0 Use a straight edge and feeler gauge 0 Measure at three locations and average the readings 0 Do not i...

Page 379: ...d loosen the two hex bolts l Fit the holder over the mainshaft so its lip is towards the transmission l Align the mainshaft holder s lip around the groove at the inside of the mainshaft splines then tighten the hex bolts HEX BOLT HOLDER BOLT MAINSHAFT BASE 07GAJ PG20130 c Seat the mainshaft fully by tapping its end with a plastic hammer d Thread the mainshaft holder bolt in until it just contacts ...

Page 380: ...SEAL Replace 2 Install the shift detent spring and spring set plate 8 x 1 25 mm SPECIAL BOLT 28 Nom 2 6 kg m 19 lb ftl SET PLATE DETENT SPRING 3 Install the oil seal select arm and select lever in the clutch housing 8 x 1 O mm SPECIAL BOLT 32 N m 3 2 kg m 23 lb ftl SPRING WASHER SELECT LEVER 4 Install the housing differential assembly in the clutch DIFFERENTIAL ASSEMBLY cont d ...

Page 381: ...g NOTE Plate the interlocker finger in the groove of the select arm 6 x 1 O mm SPECIAL BOLTS 16 N m 1 6 kg m 11 lb ft INTERLOCKER FINGER 7 Lift the mainshaft assembly then install the reverse idle gear shaft assembly with the spring pin matching the groove of the clutch housing REVERSE IDLE oEAR SHAFT ASSEMBLY 8 Shift the reverse shift fork to the driven gear side Lift the mainshaft assembly and r...

Page 382: ...in 20 minutes after applying the liquid gasket and allow it to cure at least 30 minutes after assembly before filling it with oil 11 Install the dowel pins on the clutch housing 12 Place the transmission housing over the clutch housing being careful to line up the shafts NOTE Make sure the 3rd 4th shift fork shaft col lar mates with the 3rd 4th shift fork shaft 3RD14TH SHIFT FORK SHAFT COLLqR DOVi...

Page 383: ...ION HOUSING SHIFT ARM SHIFT PIECE c Check the operation of the shift lever 13 Lower the transmission housing with the snap ring expanded and set the snap ring in the groove of the countershaft bearing SNAP RING 14 Check that the snap ring is securely seated in the groove of the countershaft bearing Dimension A as installed 1 60 8 15 mm 0 0630 0 3209 in 13 46 ...

Page 384: ... with liquid gasket 18 Install the upper cover 14 x I 0 mm SEALING BOLT 33 N m 3 3 kg m 24 lb ft L 25 mm 36 mm SEALING BOLT 35 N m 3 5 kg m 25 lb it 4 5 k g m I 33 lb ft BOLTS UPPER cC0vE 6 x 1 0 mm BOLTS 12 Nom 1 2 kg m 9 lb ft 19 Install the back up light switch and neutral switch NOTE Apply Honda Genuine liquid gasket P N OY740 999863 to the threads 20 Install the speed sensor 6xl OmmBOLT 12 No...

Page 385: ...L T S 16 5 kg m 47 lb ft FRONT ENGINE MOUNTING BOLT 7 10 x 1 25 mm 60 N m 6 5 kg m 43 lb ft 8x I 25 mm 0 22 N m 2 2 kg m 16 lb ft 6x l Omm REAR TRANSMISSION M MOUNTING BOLTS TRANSMISSIOi 12 x 1 25 mm JACK 10x 1 25 mm 105N m 10 5 kg m 76 lb ftj 45 N m 4 5 kg m 33 lb ft TRANSMISSION HOUSING MOUNTING BOLT 12x 1 25 mm 65 N m 6 5 kg m 47 lb ft 8 Install the slave cylinder 9 Install the shift cable and ...

Page 386: ...nd parking brake cable holder Q SELF LOCKING NUT Reolace 18 Install the intermediate shaft and tighten the intermediate shaft mounting bolts to the intermediate shaft support sr SELF LOCKING NUT IP x 1 25 mm Replace 85 N m 8 5 kg m 82 lb ft 8 x 1 25 mm 12 x 1 25 mm 22 N m 2 2 kg m 18 95 N m 9 5 kg m 69 lb ft 812 x 1 25 mm 95 Nom 9 5 kg m 69 lb 6xl Omm 10 N m II O ko m 7 lb ftb sr SELF LOCKING N U ...

Page 387: ...CKING NUT 12x 1 25 mm 95 Nom 9 5 kg m 69 lb ftl DAMPER FORK BOLT Q CASTLE NUT 10x 1 25mm 4 4 kg m 32 lb r r CASTLE NUT 12x1 25mm 6 0 kg m 43 lb ftl Replace 12 x 1 25 mm Replace 25 Install the front exhaust pipe A 26 Install the raer beam rod 27 Install the parking brake cable SELF LOCKING NUT Replace 10 x 1 25 mm 34 N n 3 4 kg m 25 lb ft 85 N m 8 5 kg m 62 lb ft GASKET Replace IO x 1 25 mm 60 Nom ...

Page 388: ...ntrol box connectors TRANSMISSION HOUSING MOUNTING BOLTS 12xl 25mm 32 Install the air cleaner case 33 Install the strut bar 34 Refill the transmission with oil 35 Connect the battery positive and negative 1 cables to the battery 36 Inspect the rear camber See Section 18 37 Check the clutch operation 38 Shift the transmission and check for smooth operation CONTROL BOX TRANSMISSION MOUNTING BOLT 12 ...

Page 389: ...al Valve Detent Spring Parking Brake Stopper Transmission Reassembly Torque Converter Transmission Installation Shift Cable Adjustment Removal Installation Gearshift Selector Shift Indicator Panel 14 112 14 114 14 116 14 118 14 119 14 120 14 121 14 122 14 123 14 126 14 127 14 128 14 131 14 133 14 137 14 138 14 139 14 139 14 140 1 I8 14 149 i 14 153 14 154 14 155 14 156 _ SUPPLEMENTAL RESTRAINT SYS...

Page 390: ...pressor Attachment Clutch Spring Compressor Attachment ECU Test Harness A T Oil Pressure Gauge Set A T Oil Pressure Gauga Replacement Hose A T Low Pressure Gauge Adjustable Bearing Puller 25 40 mm Attachment 62 x 68 mm Attachment 72 x 75 mm Driver Mainshaft Holder Attachment must be used with commercially available 3 B x 16 thread Slide Hammer O ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Page Reference 14 107...

Page 391: ...alve body and the 2nd accumulator body They are bolted to the torque converter case as an assembly The main valve body contains the manual valve 1 2 shift valve 2 3 shift valve 3 4 shift valve relief valve one way relief valve and oil pump gears The secondary valve body contains the 3 2 kick down valve CPC clutch pressure control valve 2nd orifice control valve 3rd orifice control valve modulator ...

Page 392: ...n to stop The lock up mechanism comes into operation in 2nd 3rd and 4th Driving in 3rd gear stays in 3rd gear does not shift up and down For climbing or downhill and light engine braking on high speed condition Driving in 2nd gear stays in 2nd gear does not shift up and down For engine braking or better traction starting off on loose or slippery surface Driving in 1st gear stays in 1st gear does n...

Page 393: ...m O0 TORQUE CONVERTER I LOCK UP CONTROL SOLENOID VALVE ASSEMBLY I ATF COOLER IST I 3RD CLUTCH 1 ST HOLD CLUTCH I LSD DIFFERENTIAL ASSEMBLY END CLUTCH cont d 14 5 ...

Page 394: ...he secondary shaft The second clutch is supplied clutch pressure through the secondary shaft by a circuit connected to the 2nd accumulator body 3rd Clutch1 The third clutch engages disengages third gear and is located at the end of the countershaft opposite the end cover The third clutch is supplied clutch pressure by its oil feed pipe within the countershaft 14th Clutch The fourth clutch engages ...

Page 395: ...TH CLU TCH MAINSHAFT 4THlREVERSE GEAR I MAINSHAST IST GEAR IST CLUTCH 1 ST HOLD CLUTCH ONE WAY CLUTCH II COUNTERSHAFT 1 ST GEAR PARKING GEAR COUNTERSHAFT REVERSE G COUNTERSHAFT 4TH GEiR SECONDARY SHAFT END FEAR SECONDARY SHAFT 3RD GEAR 2ND CLUTCH RY SHAFT FINAL DklVEN GEAR cont d 14 7 ...

Page 396: ...o bypass the converter thereby placing the car in direct drive The power flows by way of Engine 1 Drive plate 1 Torque converter cover 1 Lock up piston 1 Damper spring 1 Turbine 1 Mainshaft LOCK UP PjSTON DAMPER SPRING TORQUE CONVERTER COVER COMP c To oil cooler 2 Operation clutch off With the lock up clutch off the oil flows in the reverse of CLUTCH ON As a result the lock up piston is moved away...

Page 397: ... transmitted as the one way clutch slips COUNTERSHAFT MAINSHAFT IS COUNTERSHAFT 1 ST HOLD CLU 3RD CLUTCH ONE WAY CLUTCH COUNTERSflAFT 1ST GEAR PARKING GEA COUNTERSHAFT REVER CDNTERSHAFT 4TH G AR 2ND CLUTCkl TCiRQUE CONVERTER SECONDARY SHAFT SECONDARY SHAFT 3RD GEAR FINAL DRIVEN GEAR cont d 14 9 ...

Page 398: ...ic pressure is applied to the 1st hold clutch but the countershaft is rotated by the one way clutch The power flow when decelerating is as follows 1 Rolling resistance from the road surface through the rear wheels to the final drive gear then to the countershaft 1st gear via the Ist hold clutch which is applied during deceleration 2 The one way clutch becomes free at this time because of the count...

Page 399: ...secondary shaft 2nd gear drives the countershaft 2nd gear Power is transmitted to the final drive gear and drives the final driven gear NOTE 0 At 2 position hydraulic pressure is also applied to the 1st clutch but since the rotation speed of the 2nd gear exceeds that of 1st gear power from 1st gear is cut off at the one way clutch l Power flow in D position 2nd speed is the same as 2 position MAIN...

Page 400: ... the final drive gear and drives the final driven gear NOTE l At 3 position hydraulic pressure is also applied to the 1st clutch but since the rotation speed of the 3rd gear exceeds that of 1st gear power from 1st gear is cut off at the one way clutch 0 Power flow in D position 3rd speed is the same as 3 position TORQUE CONVERTER MAINSHAFT IST GEAR IST CLUTCH I I 1 gzz _ _ _ z COUNTERSHAFT ONE WAY...

Page 401: ... clutch which rotates together with the mainshaft and the mainshaft 1st gear rotates 2 Power is transmitted to the countershaft 1st gear and drives the countershaft via the one way clutch 3 Power is transmitted to the final drive gear and drives the final driven gear NOTE In the D position hydraulic pressure is not applied to the Ist hold clutch TORQUE CONVERTER IST CLUTCH J MAINSHAFT IST GEAR ONE...

Page 402: ...ntershaft 4th gear to the countershaft 3 Power is transmitted to the final drive gear and drives the final driven gear NOTE At D position 4th speed hvdraulic pressure is also applied to the 1st clutch but since the rotation speed of 4th gear exceeds that of 1st gear power from 1st gear is cut off at the one way clutch TORQUE CONVERTER 1 ST CLUTCH MAINSHAFT 4TH GEAR ONE WAY CLU UNTERSHAFT FINAL DRI...

Page 403: ...T control unit detects the appropriate gear shifting and activates shift control solenoid valves A and or B The combination of driving signals to shift control solenoid valves A and B is shown in the table below Shift control sol valve A B Range gear pJ 1st OFF ON q 2nd ON OFF q q 3rd q 1st ON OFF q 4th q 2nd OFF OFF Lock up control From sensor input signals the A T control unit detects whether to...

Page 404: ...trol Unit 14 I I I I I II I I EPS Control Unit IdI I I I I I I Engine RPM t I Ii 1 Brake Light Switch Signal 1 1 I I 1 I I I 1 I I 1 Vehicle Speed Signal I I I I I I I II L I NM Speed Signal 1 1 I 1 Linear Solenoid I Electronic Control System cont d Il El El El El 4 Self Diagnosis Indicator I 14 16 ...

Page 405: ...LE SWITCH SHIFT CONTROL SOLENOID VALVE A SHIFT CONTROL SOLENOID VALVE B LOCK UP CONTROL SOLENOID VALVE A A K CONTROL UNIT LOCK UP CONTROL SOLENOID VALVE B LINEAR SOLENOID I BRIGHTNESS REDUCTION CIRCUIT EPS CONTROL UNIT INTERLOCK CONTROL UNIT TCS CONTROL UNIT TERMINAL LOCATION ...

Page 406: ...r body The oil pump is driven by splines on the left end of the torque converter which is attached to the engine Oil flows through the regulator valve to maintain specified pressure through the main valve body to the manual valve and the servo body directing pressure to each of the clutches CUMULATOR BODY EGULATOR VALVE BODY LOCK UP VALVE BODY LINEAR SOLENOID THROTTLE VALVE BODY 14 18 ...

Page 407: ...anges in the throttle opening to changes in transmission hydraulic pressure to determine transmission shift quality and lock up operation Throttle valve B also operates on accumulator back pressure to make smooth changes from one gear to another The end of the valve contacts the linear solenoid which is controlled by the A T control unit The throttle pedal load has been reduced by eliminating the ...

Page 408: ... with the regulator valve lock up control valve and cooler relief valve built in The stator shaft arm contacts the end of the regulator valve The hydraulic pressure line pressure is controlled by the regulator Valve REGULATOR VALVE REGULATOR VALVE BODY COOLER RELIEF VALVE LOCK UP VALVE CONTROL STATOR SHkT ARM 14 20 ...

Page 409: ...ure ENGINE NOT RUNNING ENGINE RUNNING To TORQUE CONVERTER From OIL PUMP 4 d To RELIEF VALVE Stator Reaction Hydraulic Pressure Control Hydraulic pressure increase according to torque is performed by the regulator valve using stator torque reaction The stator shaft is splined in the stator and its arm end contacts the regulator spring cap When the car is accelerating or climbing Torque Converter Ra...

Page 410: ...d one way relief valve are all built into the main valve body The primary function of this valve body is switching on and off oil passages and controlling the hydraulic pressure going to the hydraulic control system OIL PUMP DRIVEN GEAR TORQUE COVERTER I CHECK VALVE RELIEF VALVE ONE WAY RELIEF VALVE OIL PUMP DRIVE GEAR MANUAL VALVE DETENT SPRING mqi VALVE S DY VALVE 2 3 SHiFT VALVE MANUAL VALVE l ...

Page 411: ...pump s driving force is transmitted by the torque converter pump directly connected to the engine to the pump shaft The gears are provided in the housing The intake and exhaust lines and the torque converter line are provided in the housing One way Relief Valve The one way relief valve is used at times of high speed or high temperature to send relief oil to the oil cooler so that cooling of ATF wi...

Page 412: ...odulator valve 4th exhaust valve 2nd exhaust valve servo control valve and 4 3 kick down valve built in Primarily it regulates shift valve operation timing and clutch pressure for shock reduction during shifting MODULATOR VALVE 3RD ORIFICE CONTROL VALVE 2ND ORIFICE CONTROL VALVE 4TH EXHAUST VALVE SERVO CONTROL VA1 3 2 KICK DOWN VALVE i CPC VALVE SECONDARY VALVE BODY 4 3 KICK DOWN VALVE 2ND EXHAUST...

Page 413: ...alve For smooth shifting between the 2nd and 3rd gear the open pressure on the 2nd gear side is relieved through a fixed orifice The valve also moves to equalize pressure differences between the 2nd and 3rd gear 2nd Exhaust Valve The 2nd exhaust valve is installed to release 2nd clutch pressure quickly when shifting from the range at which hydraulic pressure is applied to the 2nd clutch to the N p...

Page 414: ...everse switching and control The 2nd accumulator body is mounted on the torque converter housing with the 1 St hold accumulator 2nd accumulator and LSD relief valve built in IST HOLD ACCUMULATOR PISTON LSD RELIEF VALVE 2ND ACCUMULATOR PISTON 2ND ACCUMULATOR BODY 4TH ACCUMULATOR 3RD ACCUMULAT PISTON 1ST ACCUMULATOR PISTON STRAINER SERVO BODY LSD Relief Valve When the resistance of oil flow inside t...

Page 415: ... is mounted on the regulator valve body with the lock up shift valve and lock up timing B valve built in The capacity of the lock up clutch is controlled by the lock up valve body LOCK UP SHIFT VALVE LOCK UP VALVE CK UP TIMING B VALVE a 14 27 ...

Page 416: ...or Valve Torque Converter Pressure Lubrication Pressure Distribution of Hydrualic Pressure t to select Line Pressure Throttle B Pressure 0 Manual Valve l Throttle Valve B l l 2 Shift Valve 0 2 3 Shift Valve l 3 4 Shift Valve 0 Line Pressure Clutch Pressure Servo Valve Throttle Valve 14 28 ...

Page 417: ...ressure is controled by the regulator valve and becomes line pressure 1 The torque converter inlet pressure I enters 94 of torque converter through the orifice and discharges into 90 The torque converter check valve prevents the torque converter pressure from falling Under this condition the hydraulic pressure is not applied to the clutches cont d ...

Page 418: ...nd 2 3 shift valves are moved to the left side because the shift control solenoid valve A is turned ON and B is OFF by the A T control unit The line pressure 18 is supplied to the 3 4 shift valve and it is moved to the left side The line pressure 4 is the 1 st clutch pressure IO then the 1st clutch is engaged The line pressure 4 becomes the Ist hold clutch pressure 16 via the 1 2 shift valve 2 3 s...

Page 419: ...lves are moved to the left side end the 2 3 shift valve is moved to the right side because the shift control solenoid valve A and B are turned OFF by the A T control unit The line pressure 4 goes through the line 20 to the 2nd clutch then the 2nd clutch is engaged The line pressure 4 also flows to the throttle valve and the line pressure 1 flows to the 1st clutch However no power is transmitted by...

Page 420: ...hift control solenoid A is turned ON and B is OFF by the A T control unit The line pressure 4 becomes the clutch pressure control 5 and the 3rd clutch pressure 31 Then it goes to the 3rd clutch The 3rd clutch is engaged The line pressure 4 also flows to the throttle valve and line pressure 1 flows to the 1st clutch However no power is transmitted by means of the one way clutch as in 2nd speed NOTE...

Page 421: ...cumulator consequently the vehicle will move as the engine power is transmitted The line pressure 1 becomes the modulator pressure 6 by the modulator valve and travels to each shift valve The 1 2 shift valve is moved to the right side because the shift control solenoid valve A is turned OFF and 6 is ON by the A T control unit The line pressure I also flows to the throttle valve NOTE When used left...

Page 422: ...e is moved to the left side and uncovers the port leading to the 2nd clutch the 2nd clutch is engaged Fluid flows by way of Line Pressure 4 CPC Valve Clutch Control Pressure 4 l 2 Shift Valve Clutch Pressure Control 5 t 2 3 Shift Valve 2nd Clutch Pressure 21 Orifice 2nd Clutch Pressure 20 2nd Clutch The hydraulic pressure also flows to the 1 st clutch However no power is transmitted by means of th...

Page 423: ...h Since the 3 4 shift valve is moved to the right side to cover the oil port to the 4th clutch the 3rd clutch is engaged Fluid flows by way of Line Pressure 4 CPC Valve Clutch Pressure Control 4 l 2 Shift Valve Clutch Pressure Control 5 t 2 3 Shift Valve Clutch Pressure Control 5 3 4 Shift Valve 3rd Clutch Pressure 31 3rd Clutch The hydraulic pressure also flows to the 1st clutch However no power ...

Page 424: ...ince the 1 2 and 2 3 shift valves are kept on the left side the fluid flows through the 4th clutch the power is transmitted through the 4th clutch Fluid flows by way of Line Pressure 4 CPC Valve Clutch Pressure Control 4 l 2 Shift Valve Clutch Pressure Control 5 2 3 Shift Valve Clutch Pressure Control 5 3 4 Shift Valve 4th Clutch Pressure 41 Manual Valve 4th Clutch Pressure 40 4th Clutch The hydra...

Page 425: ...speed As a result the 1 2 shift valve is also moved to the left side The fluid 3 will flow through the servo valve and manual valve to the 4th clutch power is transmitted through the 4th clutch Reverse Inhibitor Control When them position is selected while the vehicle is moving forward at a speed over 6 MPH the control unit outputs 1st signal A OFF B ON the l 2 shift valve is moved to the right si...

Page 426: ...c Flow cont d cl P Position The flow of fluid through the torque converter is the same in INI position The line pressure 1 is intercepted by the manual valve and is not supplied to the clutches The power is not transmitted ...

Page 427: ...trol the control unit optimizes the timing of the lock up system Under certain conditions the lock up operation is applied during deceleration in 3rd and 4th speed The lock up shift valve body controls the range of lock up according to lock up control solenoid valves A and B and throttle valve B When lock up control solenoid valves A and B activate modulator pressure changes Lock up control soleno...

Page 428: ...f the lock up shift valve are equal and the shift valve is moved to the right side by the tension of the valve spring alone The fluid from the oil pump will flow through the left side of the lock up clutch to the torque converter i e the lock up clutch is in OFF condition NOTE When used left or right indicates direction on the flow chart THROTTLE B PRESSURE OFF LOCK UP CONTROL t 1 VI NTROL II i MO...

Page 429: ...e B is determined by the throttle B pressure tension of the valve spring and pressure regulated by the modulator Also the position of the lock up control valve is determind by the throttle valve B pressure back pressure of the lock up control valve and torque converter pressure regulated by the check valve In low speed range the throttle B pressure working on the right side of the lock up control ...

Page 430: ...ssure is still low at this time consequently the lock up timing valve B is kept on the right side by the spring force With the lock up control solenoid valve B turned ON the lock up control valve is moved somewhat to the right side causing the back pressure F2 to lower This allows a greater amount of the fluid Fl to work on the lock up clutch so as to engage the clutch The back pressure F2 which s...

Page 431: ...r check valve Under this condition the throttle B pressure working on the right end of the lock up control valve becomes greater than that on the left end modulator pressure in the left end has already been released by the solenoid valve B i e the lock up control valve is moved to the left side As this happens the torque converter back pressure is released fully causing the lock up clutch to be en...

Page 432: ...ol unit switches the solenoid valve B to ON and OFF alternately at high speeds under certain conditions The slight lock up and half lock up regions are maintained so as to lock the torque converter properly NOTE When used left or right indicates direction on the flow chart THROTTLE B PRESSURE n n ONTROL VALVE E M O D U L A T O R P R E S S U R E I 1 I l 14 44 ...

Page 433: ...rATF Cooler The radiator is mounted at the front of the vehicle The ATF cooler is installed directly on the transmission housing ATF is cooled by the engine coolant OUTLET HOSE INLET HOSE ER ...

Page 434: ...t 14 46 ...

Page 435: ... SPEED SENSOR LOCK UP CONTROL SOLENOID VALVE SHIFT CONTROL SOLENOID VALVE FRflNT TW SENSOR ACCEL PEDAL SENSOR v T NC SPEED SENSOR THROTTLE ANGLE SENSOR Engine Compartment A T CYNTROL UNIT I PGM FI ECU TCS CdNTROL UNIT 14 47 ...

Page 436: ...ADIO CASSETTE SPEED BRAKE LIGHT ALB CONTROL UNIT TCS CONTROL UNIT R E LK W EL GRI IHT I A23 A24 A20 LIGHTING SWITCH A T CODfiTROL UNIT REI I A10 AB A18 A21 I BRI LU m N 1 ORNlBLK LT BLU RN I ILK GRI LT G EL NHT GRi B LK rRED DASHLIGHT BRIGHTNESS CONTROLLER BLI SHIFT POSITION CONSOLE SWITCH G401 G401 G401 6402 6402 G402 14 48 ...

Page 437: ...9 GRN R 1 D7 A22 D3 D9 D16 A2 D13 Dil D16 A T CONTROL UNIT 01 Al D17 015 D19 D12 D5 A25 A26 I i f BLK BLUlYEL GRNlWHT I I RED BLK HT WH A c RN BL EL U GRY BLKlWHT t t YEL YEL BL REI riE l LINEAR SOLENOID L e I I e J NC SPEED NM SPEED SENSOR SENSOR bookxLp SE D T A B SHIFT CONTROL EF D a II TACHOMETER GlOl TERMINAL LOCATION View from terminal side 14 49 ...

Page 438: ...s 1 through 9 are indicated by individual short blinks Problem codes 10 through 16 are indicated by a series of long and short blinks One long blink equals 10 short blinks Add the long and short blinks together to determine the problem code After determining the problem code refer to the electrical system Symptom to Component Chart on page 14 52 short t l A See Problem CODE 1 See Problem CODE 2 Se...

Page 439: ...3A25 D1 D 3 D5 D J OS DllD13D15D1JD19D21 A2 A4 A6 ASA1QA12A14AMA1SA20A22A24A26 02 D4 D6 DSD10D12D14Dl6DlSD2OD22 NOTE o l Only the A and D sections of the ECU test harness are used for All troubleshooting l Unless otherwise noted use only the Digital Multimeter KS AHM 32 003 for testing ...

Page 440: ... connector l Open in shift position console switch wire l Faulty shift position console switch l Disconnected shift control solenoid valve A connector l Short or open in shift control solenoid valve A wire l Faulty shift control solenoid valve A 9 Disconnected shift control solenoid valve B connector l Short or open in shift control solenoid valve B wire l Faulty shift control solenoid valve B Sym...

Page 441: ...tor light is on steady not blinking whenever the ignition is on 14 76 I Lock up clutch does not have duty operation ON OFF Lock up clutch does not engage Fails to shift from 2nd to 1st gear after releasing the brake pedal from a stop when in the D position Check A C signal with A C on Check brake light signal 14 77 14 78 l If a customer describes the symptoms for codes 3 6 or 11 yet the D indicato...

Page 442: ...id valve Check for continuity between the A 6 RED WHT a n d A 2 5 BRNIWHT terminals Is there continuity NO Connect the 2P connector to the lock up control solenoid valve as sembly I I Measure the resistance between Check for loose control unit con nectors If necessary substitute a known good control unit and Repair short to ground in REDIWHT wire be tween the A6 terminal and the lock up control so...

Page 443: ...n the A4 terminal and the lock up control solenoid valve B Check for open in WHTlBLK wire be tween the A4 terminal and the lock up control solenoid valve B If wire is OK check the Lock up Control Solenoid Valve g Check for continuity between the A 4 W H T I B L K a n d A 2 5 BRN WHT terminals Is there continuity N O Repair short to ground Y E S in WHTlBLK wire be tween the A4 terminal and the lock...

Page 444: ...ure the voltage between the D18 BLU and A25 BRN WHT terminals NO Is the voltage 4 75 5 25 V Y E S Turn the ignition switch OFF Connect the ECU test harness be tween the connectors and the control unit Turn the ignition switch ON Measure the voltage between the D7 and A25 terminals Is the voltage 0 44 0 56 V Check for loose control unit con NOTE View from terminal side BRN 4 76 5 25 V LBL _1 Repair...

Page 445: ...on to q I Disconnect the 26P and 22P con nectors from the control unit 1 1 Turn the ignitr switch ON m Make sure lifts are placed properly See page l 6 BRNiWHT YELIRED o 5 V 1 OS Rotate the rear wheel and check Check for loose control unit con NOTE View from terminal side cont d 14 57 ...

Page 446: ...osition Measure the voltage between the A21 and A25 terminals Is there battery voltage Y E S Shift to other than q and q position I V PI A 2 1 A25 4B ECU TEST HARNESS TERMINAL Check for short in SKY BLU wire between the A21 terminal N O end the shift position console switch or shift position indi cator If wire is OK check for loose connectors If neces sary substitute a known good control unit and ...

Page 447: ...LK wire between the Al 5 terminal and the shift position console switch or shift position indi cator If wire is OK check for loose connectors If neces sary substitute a known good control unit and recheck A l 3 A25 Check for short in GRNlYEL wire between the Al 3 terminal and the shift position console switch or shift position indi cator If wire is OK check for loose connectors If neces sary subst...

Page 448: ...ction 23 Turn the ignition switch OFF Connect the ECU test harness be tween the control unit and con nectors Turn the ignition switch ON A21 A26 Shift to q position Measure the voltage between the A21 and A25 terminals ECU TEST HARNESS TERMINAL Is there voltage N O Repair open in SKY BLU wire between the A21 terminal and the shift position console switch I I Shift to q or q position A l 9 A Measur...

Page 449: ...Is there voltage N O I I Repair open in BRNlBLK Y E S wire between the Al5 terminal and the shift position console switch Shift to q position r 7 A l 3 A25 Measure the voltage between the 1 Shift to y position Ar s y Measure the voltage between the Is there voltage Y E S N O Check for loose control unit con nectors If necessary substitute a known good control unit and recheck Repair open in LT GRN...

Page 450: ...12 24 D Y E S Disconnect the 2P connector from the shift control solenoid valve as sembly Check for continuity between the A 5 BLU YEL a n d A25 BRN WHT terminals Is there continuity N O Connect the 2P connector to the shift control solenoid valve as sembly Check for loose control unit con nectors If necessary substitute a known good control unlt and recheck Check for open in BLUlYEL wire between ...

Page 451: ... between the A 3 GRN WHT a n d A 2 5 BRN WHT terminals Repair short to power source in GRN WHT wire between the A3 terminal and shift con trol solenoid valve B Check for open in GRNlWHT wire be tween the A3 terminal and the shift control solenoid valve B If wire is OK check the Shift Control Solenoid Valve B Y E S N O Connect the 2P connector to the shift control solenoid valve as sembly Check for...

Page 452: ...isconnect the 2P connector from the NC speed serr coupler 1 Measure the resistance of the NC speed sensor Replace the NC speed sensor 1Reconnect the NC speed sensor 400 600 C Disconnect the 22P connector pqq BLWGRN Measure the resistance between L y133U GR a n d D15 1 I s t h e r e s i s t a n c e 4 0 0 6 0 0 No ohms 2OW nector If necessary substitute a NOTE View from terminal side To page 14 65 1...

Page 453: ...ensor Is there continuity Repair open in BLWGRN wire between D17 terminal and NC speed sensor Is there continuity Repair open in BLUNEL between D15 terminal and NC speed sensor Y E S Check for loose control unit con nectors If necessary substitute a known good control unit and recheck cont d 14 65 ...

Page 454: ... BRNIWHT terminals BRNIWHT Is the voltage 4 75 5 25 NO 3 Connect the ECU test harness be r 1 I I Repair open or short in BLU wire between the 018 terminal and the D18 terminal of the PGM FI ECU t 8LU 4 NOTE View from terminal side I Start the engine and warm it up to normal operating temperature I ECU TEST HARNESS TERMINAL Measure the voltage between the D5 and A25 terminals 1 I N O Is the voltage...

Page 455: ...T GRN Measure the voltage between the A9 GRN and A25 BRN WHT terminals Is there battery voltage Y E S Repair open or short in GRN wire between the A9 terminal and the gauge assembly Check for loose control unit con nectors If necessary substitute a known good control unit and recheck NOTE View from terminal side a cont d 14 67 ...

Page 456: ...NESS TERMINAL Is there approx 5 V for over five NO Y E S _ Refer to PGM FI A T e 4 V approx every four seconds Signal Section 11 seconds YES Raise the car I I NO Is the Check Engine light on Repair the PGM FI Sys tem Section 11 I NO Start the engine Turn the ignition s itch OFF Shift to q position Raise the engine to over 2 000 rpm over 40 mph in 4th gear for five seconds Disconnect the A connecto...

Page 457: ...recheck 1 I I Turn the ignition switch OFF I Disconnect the A connector from the PGM FI ECU Check for continuity on the PNK wire between the D16 terminal on the A T control unit and the A 16 terminal on the PGM FI ECU h NO Repair open in PNK Is there continuity wire Y E S I Check for continuity on the PNK wire between the D 16 terminal on Is there continuity N O Repair short in PNK wire Check for ...

Page 458: ...the NM speed sensor Disconnect the 22P connector from the control unit I NOTE View from terminal side 1 Measure the resistance between 1 Dl a RN and Dl2 WHT ter I I Check for continuity between Is the resistance 400 SO D19 ORN terminal and body ground Y E S Disconnector the 2P connector I zEjip Measure the resistance of the NC speed sensor Check for continuity between D19 ORN terminal and the NM s...

Page 459: ... resistance 400 60 ohms 20 C Repalce the NC speed sensor n Y E S P BLUIYEL I I Measure the resistance between D 1 7 BLUIGRN a n d D 1 5 BLUIYEL terminals I BLUlGPN Disconnect the 26P and 22p con nectors from the control unit Measure the resistance between the Al BLK WHT and the Dl GRY terminals Is the resistance approximately 5 i l llun Check for loose control unit connectors If necessary substitu...

Page 460: ...N or BLUlYEL wires between D 17 terminal and the NC speed sensor I I 1 I Is there continuity N O Repair open in BLWGRN wire between 017 terminal and the I Y E S Check for continuity between D15 BLUIYEL terminal and the NC speed sensor NC speed sensor f y Y Is there continuity Y E S NO Repair open in BLWYEL wire between D15 ter minal and the NC speed smsor 1 Check for loose control unit con nectors...

Page 461: ...ontrol unit Check for continuity between the A8 YELIBLK terminal and the gauge assembly Repair open or short BLKlYEL wire between the A23 andlor A24 terminals and dash fuse box Check for open or short in YELlBLK wire be tween the A8 terminal and the gauge assem bly If wire is OK check the D indicator light and the shift position in dicator Check for loose control unit con nectors Check the shift p...

Page 462: ...e lgnitton NOTE View from terminal side Measure voltage between the A8 til YElJBLK Is there voltage Replace the A l control unit Y E S I I Measure voltage between the YELIBLK wire at the gauge assem bly and body ground Is there voltage Y E S N O Replace faulty shift po sition indicator 14 76 ...

Page 463: ...ls A C com pressor OFF Is there battery voltage NO Repair open in REDlBLU wire be tween A22 terminal and Auto AIC control unit I I A C signal is OK 1 Lock up Control Solenoid Valve A B i Test NOTE Lock up control solenoid valves A and B must be removed replaced as an assembly 1 Disconnect the connector from the lock up control Replacement 1 Remove the mounting bolts and lock up control sole noid v...

Page 464: ...ts ON N O Faulty brake light circuit Y E S Disconnect the 26P and 22P con nectors from the control unit Measure the voltage between D2 GRNIWHT and A25 BRNNVHT terminal with the brake pedal pushed Repair open in GRN WHT wlre be Is there battery voltage tween D2 terminal and brake light switch Y E S Brake light signal OK A26 BRNIVVHT NOTE View from terminal side 14 78 I I I A I A _ I ...

Page 465: ...ace the linear solenoid assembly if there is con tinuity between the Al or Dl and body ground NOTE Select the appropriate shim when the linear sole noid is replaced 1 Remove the linear solenoid and shim from the trans mission housing 2 Clean the mounting surface 3 Measure the distance between the mounting surface of the linear solenoid and the throttle valve body Measurement of distance YEARSOLENO...

Page 466: ...10 minute of applying the liquid gasket l After installation wipe off any liquid gasket that squeezed out from around the linear solenoid shlm NOTE l Check that the mounting surfaces are clean and dry before applying liquid gasket Degrease if necessary 0 Apply the liquid gasket evenly 0 Do not install the parts if 10 minutes or more has passed since you first applied the liquid gasket If 10 minute...

Page 467: ... bolt from the transmission housing and remove the A T speed sensor 2 Replace the O ring with a new one before reassembling the AK speed sensor 6 x l Omm 12 N m I 2 kg m 9 lb ft NC SPEED SEN NM SPEED SENSOR 6xl Omm 12 N m 1 2 kg m 9 lb ft m O0 14 83 ...

Page 468: ...t 1 4 L V Erratic shifting 14 2 6 V Harsh shift up and down shifting 2 4 15 23 24 27 47 A E H I L V Harsh shift I 2 2 9 C D V Harsh shift 2 3 2 10 23 24 C D H L V Harsh shift 3 4 2 11 23 25 C D I L V Harsh kickdown shifts 2 23 27 28 L v Q Harsh kickdown shift 2 1 48 0 Harsh downshift at closed throttle 1 5 E T Harsh shift when manually shifting to a 3 3 L Axle s slips out of trans on turns 43 50 L...

Page 469: ...accumulator defective 3rd clutch accumulator defective 4th reverse accumulator defective 1st hold clutch accumulator defective Servo valve stuck Lock up clutch timing valve stuck Lock up clutch shift valve stuck Lock up clutch control valve stuck Shift fnrk NOTES L M If the oil screen is clogged with particles of steel or aluminum inspect the oil pump and differential clutch and planetary gear ass...

Page 470: ...check valves not installed I R12 Shift fork bolt not installed I B NOTES Set idle rpm in gear to specified idle speed If still no good adjust motor mounts as outlined in en gine section of service manual I c 1 If the large clutch piston O ring is broken inspect the piston groove for rough machining I D E G If the clutch pack is seized or is excessively worn inspect the other clutches for wear and ...

Page 471: ... minutes for cooling then repeat same test in 1 3 D and R position NOTE Stall speed test must be made only for checking the cause of trouble Stall Speed RPM Specification 1 950 2 250 rpm TROUBLE Stall rpm high in 2 position PROBABLE CAUSE l Low fluid level or oil pump output l Clogged oil strainer l Pressure regulator valve stuck closed l Slippage of 2nd clutch Stall rpm high in 1 position Stall r...

Page 472: ... hole A T OIL PRESSURE GAUGE SET 0 7 4 0 6 0 0 2 0 0 0 3 A T OIL PRESSURE GAUGE REPLACEMENT HOSE 0 7 4 0 6 0 0 2 0 2 0 1 HOSE BITTING A T LOW PRESSURE GAUGE 07406 0070000 Start the engine and measure the respective pressure as follows 0 Line Pressure Clutch Pressure 0 Clutch Low High Pressure l Throttle B Pressure Install a new washer and the sealing bolt in the inspection hole and tighten to the ...

Page 473: ...TCH PRESSURE INSPECTION HOLE I 3RD CLUTCH PRESSURE INSPECTION HOLE PROBABLE FLUID PRESSURE CAUSE Standard Service Limit Torque converter 834 883 kPa oil pump pressure 785 kPa 8 5 9 0 kg cmz 8 0 kg cm 114 psi regulator torque I 121 128 psi converter check valve oil pump 1st Clutch 1st Hold Clutch 2nd Clutch 3rd Clutch 2nd Clutch 3rd Clutch 4th Clutch Servo valve or 4th Clutch 490 kPa 5 0 kg cm2 7 1...

Page 474: ...th Clutch SELECTOR PROBABLE FLUID PRESSURE POSITION SYMPTOM CAUSE Standard Service Limit D No or low 2nd Clutch 490 883 kPa 441 kPa 2nd pressure 5 0 9 0 kg cm2 4 5 kg cm2 64 psi No or low 3rd Clutch 71 128 psi with accelerator pedal varies with throttle released 3rd pressure opening 785 kPa No or low 4th Clutch 8 0 kg cm2 1 I4 Ps 4th pressure with accelerator ped more than 218 opens 6 With the eng...

Page 475: ...ery voltage to the linear solenoid LINkAl SOLENOID 7 Measure full opened throttle B pressure CONNECTOR wWhile testing be careful of the rotat ing rear wheels THROTTLE PRESSURE INSPECT10 LINEAR SOLENOID PRESSURE Throttle B SELECTOR FLUID PRESSURE POSITION SYMPTOM PROBABLE CAUSE Standard Service Limit D Pressure too Linear Solenoid O 1 5 kPa O 1 5 kPa high O O 15 kg cm2 10 O 15 kg cm O 2 psi O 2 psi...

Page 476: ... Fluid or an equivalent DEXRON II type automatic transmission fluid FULL Changing 1 Bring the transmission up to operating temperature by driving the car Park the car on level ground turn the engine off then remove drain plug 2 Reinstall the drain plug with a new washer then refill the transmission to the full mark on the dipstick Automatic Transmission Fluid Capacity 2 9 L 3 1 US qt 2 6 Imp qt at...

Page 477: ...14 95 ...

Page 478: ...ir cleaner case See Section 11 I 6 Remove the connectors from the control box and remove the control box 7 Remove the wire harness holder disconnect the speed sensor wire connectors solenoid valve wire connectors starter motor cables and transmission ground cable 8 Remove the ATF cooler as it is connected by the hoses CAUTION Do not remove the hoses from the ATF cooler 9 Remove the starter motor m...

Page 479: ...ove the parking brake cable holder and the anti lock brake system sensor wire clamp 15 Remove the castle nut and separate the control arm from the knuckle See Section 18 16 Remove the damper fork bolt 17 Remove the castle nut and separate the lower control arm from the knuckle See Section 18 18 Remove the right driveshaft from the intermediate shaft Corrosion resistant bolt nut DAMPER FORK BOLT PA...

Page 480: ... brake cable holder and the anti lock brake system sensor wire clamp 32 Make a reference mark on the flange of the adjusting bolt adjusting cam and lower control arm 33 Remove the castle nut and separate the control arm from the knuckle See Section 18 34 Remove the damper fork bolt 35 Remove the bolts and lower arm from the side beam 36 Pry the driveshaft out of the differential Pull and remove it...

Page 481: ... 43 Remove the front engine mounting bolts on the transmission side and retighten the bolt on the engine side CAUTION Loosen the front engine mounting bolt on the engine side but do not remove it After removing the two bolts on the transmission side be sure to retighten the bolt on the engine side 44 Remove the rear transmission mounting bolts 45 Remove the transmission housing mounting bolts 46 P...

Page 482: ...Illustrated Index L Side Cover 14 100 ...

Page 483: ...eplace BREATHER JOINT BREATHER CAP TRANSMISSION HANGER NC SPEED SENSOR O RING Replace ATF COOLER ATF COOLER FILTER GASKET Replace SPEED SENSOR COVER LINEAR SOLENOID SHIM O RING Replace LINEAR SOLENOID CONNECTOR STAY NM SPEED SENSOR O RING Replace ATF LEVEL GAUGE ATF LEVEL GAUGE PIPE O RING Replace RETAINER PLATE BALL BEARING TORQUE SPECIFICATION JO TORQUEVALUE BOLT SIZE REMARKS A 12 N m 1 2 kg m 9...

Page 484: ...Illustrated Index Transmission Housing 14 102 ...

Page 485: ...ING SECONDARY SHAFT 2ND GEAR NEEDLE BEARING THRUST NEEDLE BEARING SECONDARY SHAFT SEAL RING 35 mm DIFFERENTIAL OIL SEAL Replace REVERSE IDLER GEAR SHAFT HOLDER REVERSE IDLER GEAR SHAFT SPRING STEEL BALL NEEDLE BEARING TRANSMISSION HOUSING REVERSE IDLER GEAR CONNECTOR STAY SEALING WASHER Replace THRUST SHIM BEARING OUTER RACE SNAP RING SECONDARY SHAFT BALL BEARING COUNTERSHAFT BALL BEARING MAINSHAF...

Page 486: ...Illustrated Index Torque Converter Housing Valve Body ...

Page 487: ...g m 13 lb ft 8 x 1 25mm OIL PRESSURE CHECK BOLT C 14 Nom 1 4 kg m 10 lb ft 6 x l Omm Special bolt D 30 N m 3 0 kg m 22 lb ft 8 x 1 25mm MAIN SEPARATOR PLATE TORQUE CONVERTER CHECK VALVE TORQUE CONVERTER CHECK VALVE SPRING ATF LUBRICATION PIPE 2ND ACCUMULATOR BODY LSD RELIEF VALVE SPRING LSD RELIEF VALVE CONTROL SHAFT CONTROL LEVER OIL SEAL Replace LOCK WASHER Replace CHANGE SHAFT CHANGE SHAFT CAP ...

Page 488: ...oil seal lip 2 Slip the special tool onto the mainshaft and engage the parking brake pawl with the parking gear 3 Remove the transmission L Side Cover in the following numbered sequence NOTE Remove the special tool from the mainshaft after removing the locknuts Reinstall 3 bolts around the driveshaft oil seal CAUTION Protect the lip of the driveshaft oil seal by reinstalling three bolts after remo...

Page 489: ...in reverse idler gear shaft is under spring pressure take care not to let it pop out 1 Remove the transmission housing in the following numbered sequence CAUTION Set the special tool with b6lts as shown 7HAC PK4 NOTE Align the control shaft spring pin with the groove in the transmission housing a NOTE Remove three shafts together OUNTERSHAFT SECONDARY SHAFT MAINSHAFT ...

Page 490: ...re spring loaded to prevent stripping the threads in the torque converter housing press down on the accumulator covers while unscrewing the bolts in a crisscross pattern 1 Remove the valve body in the following numbered sequence CAUTION Do not use a magnet to remove the check balls it may magnetize the balls 4 Bolts 6 2 Bolts P a Replace Q RF Replace 14 108 ...

Page 491: ...I 2 Set the spring in the valve and install it in the valve body Push the spring in with a screwdriver then in stall the spring seat SPRING VALVE BODY 3 Set the spring in the valve and install it in the valve body Install the spring with a screwdriver then install the valve cap with the cutout aligned with the screw driver VALVE BODY VALVE SPRING CAP SCREinrDRlVER _ f _ 14409 ...

Page 492: ... solvent and dry it with compressed air Roll up half a sheet of ATF soaked paper and insert it in the valve bore of the sticking valve Twist the paper slightly so that it unrolls and fits the bore tightly then polish the bore by twisting the paper as you push it in and out CAUTION The valve body is aluminum and doesn t require much polishing to remove any burrs ATF soaked E abrasive Repair 5 Remov...

Page 493: ...ance of the drive and driven gears Pump Gears Side Radial Clearance Standard New Drive gear diameter 0 210 0 265 mm 0 0083 0 0104 inl Driven gear radius 0 035 0 063 mm 0 0014 0 0025 in DRIVE GEAR Inspect teeth for wear or damage 3 Measure the thrust clearance of the driven gear to valve body Drive Driven Gear thrust Axial Clearance Standard New 0 03 0 05 mm 0 001 0 002 in Service Limit 0 07 mm 0 0...

Page 494: ... freely see Valve Body Repair on page 14 1 10 0 Coat all parts with ATF before reassembly 0 Adjust and select the manual valve detent spring when the manual valve or manual valve detent spring is replaced See page 14 142 CAUTION Do not use a magnet to remove the check balls it may magnetize the balls 5 P 2 3 StjIFT VALVE CHECK BALLS MANUAL VALVE LOCK PLATE Replace VALVE CAP BxlOmm 14Nin 1 4 kg m 1...

Page 495: ...ft spring 0 9 0 0 035 8 6 2 313 4 shift spring 0 339 40 4 1 591 14 5 0 8 0 0 031 7 0 Relief valve spring 0 276 43 7 1 720 21 2 1 1 0 0 043 8 4 One way relief valve 0 331 44 4 1 748 19 5 0 9 0 spring 0 035 6 4 2 313 4 shift spring 0 252 25 1 0 988 11 9 0 8 0 0 031 7 0 Torque converter check 0 276 43 7 valve 1 720 21 2 spring 1 1 0 043 8 4 0 331 41 8 1 646 15 7 14 113 ...

Page 496: ...ts are worn or damaged 0 Check all valves for free movement If any fail to slide freely see Valve Body Repair on page 14 1 IO l Coat all parts with ATF before reassembly C A U T I O N DO not use a magnet to remove the check balls it may magnetize the balls 4TH VALVE I A 3 2 KICK DOWN VALVE FILTER Replace 4 3 KICK DOWN VALVE Q Q aCRV0 GUN I I UL MODULATOR VALVE I 2ND ORIFICE CONTROL SLEEVE VALVE 3R...

Page 497: ...wn valve spring 4 3 kick down valve spring I Wire Dia 1 o 0 039 1 o 10 039 0 8 0 031 0 9 0 035 1 4 0 055 0 8 0 024 1 o 0 039 1 o 0 039 0 9 0 035 CHEdK BALL r W 3RD CiiECK BALL Standard New Unit of length mm in 0 0 6 1 0 240 6 8 0 268 8 1 0 319 8 6 0 339 9 4 0 370 7 6 0 299 8 1 0 319 6 1 0 240 6 6 0 260 Free Length 27 1 1 067 32 1 1 264 47 9 1 886 48 3 7 902 33 0 1 299 24 4 0 967 53 5 2 106 27 1 7 ...

Page 498: ...rts are worn Or dama9ed 0 Check all valves for free movement If any fail to slide freely sea Valve Body Repair on page 14 110 l Coat all parts with ATF before reassembly I R mlace the O rings 0 l Omm 12 Nrn 1 2 kg m 9 lb ftl ACCUMULATOR S E R V O B A S E 6xl Omm 12 Nvn 1 2 kg m 9 lb ft Replace ATF MAGNET 6 x l Omm SEP i a2r 0 Ihe ERVO VALVE _ _ _ _ _ RD ACCUMULATOR 1ST ACCUMULATOR A lW5 I UN Repla...

Page 499: ... spring 3 0 0 118 18 0 0 709 84 5 3 327 12 8 0 1 st accumulator spring 2 3 0 091 20 0 0 787 104 6 4 118 14 8 NOTE 0 After disassembly of the ATF strainer check that it is in good condition and the inlet opening is not clogged Replace the strainer with a new one if it is clogged or damaged 0 The strainer can be reused if it is not clogged Clean the inlet opening thoroughly with compressed air befor...

Page 500: ...e reverse order of disassembly NOTE l Coat all parts with ATF 0 Align the hole in the regulator cap with the hole in the valve body press the spring cap into the body and tighter the lock bolt c REGULATOR SPRING CAP VALVE ROLLER J R PAD LOCK UP CONTROL REGULATOR VALVE COOLER RELIEF VALVE 6 x l O m m 12Nin 1 2kgm 9Ib ft I SPRING SPECIFICATIONS No Spring g 0 c9 0 Stator reaction spring Regulator val...

Page 501: ...Check all valves for free movement If any fail to slide freely see Valve Body Repair on page 14 1 IO 0 Coat all parts with ATF before reassembly LOCK UP TIMING VALVE B LOCK UP SHIFT VALVE C A P ROLLER SPRING SPECIFICATIONS Unit of length mm inI Standard New No Spring Wire Dia O D Free Length No of Coils 0 Lock up shift valve spring 1 o 0 039 8 6 0 339 51 3 2 0201 19 8 0 Lock up timing valve B spri...

Page 502: ...pair on page 14 110 0 Coat all parts with ATF before reassembly 6 x l Omm 12 N m 1 2 kg m 9 lb ft VALVE SEAT LSD RELIEF VALVE 2ND ATOR PISTON O RING Replace SNAP RING wIST HOLD ACCUMULATOR PISTON O R I N G Replace SNAP RING SPRING SPECIFICATIONS Unit of length mm in Standard New No Spring Wire Dia O D Free Length No of Coils 0 LSD relief valve spring 0 8 0 031 8 4 0 331 37 3 1 469 12 1 0 Ist hold ...

Page 503: ... needle and needle bearings for galling and rough movement LOCKNUT Replace 140 0 140 N m 14 0 0 14 0 kg m 101 0 101 lb ft DISC SPRING MAINSHAFT Check splines for excessive wear or damage Check bearing surface for scoring scratches or excessive w e a r SNAP YNG THRUST NEEDLE wAsHER l jqJ BEARING 1ST GEAR I THRUST WASHER HRUST WASHER THRUST NEEDLE BEARING 4TH CLUTCH SEAL RINGS NEEDLE BEARING SET RIN...

Page 504: ...RUST WASHER DISC SPRING e REVERSE GEAR 4 NEEDLE BEARING 37 x 43 x16mm tkd Use needle bearing ot same color O RINGS Replace THRUST WASHER THRUST NEEDLE BEARING 1 ST HOLD CLUTCH HUB Lc IST GEAR NEEDLE BEARING Separate type CATION AINER TER OUNTEhSHAFT Check splines for excessh heck bearing surface for excessive wear 2ND GEAR 2ND GEAR SPACER THRUST NEEDLE BEARING 3 R D G E A R NEEDLE BEARING 44 x 52 ...

Page 505: ...needle bearing with a feeler gauge NOTE Take measurements in at least three places and take the average as the actual clearance STANDARD O 0 03 mm O 0 001 in 3RD GEAR _ iND GEAR FEELER GAUGE 3RD GEAR COLLAR 3RD GEA R 2ND GEAR 3RD GEAR COLLAR 3RD GEAR COLLAR N o Part Number Length mm in 1 90413 PR9 000 35 425 35 440 1 3947 I 3952 2 90414 PR9 000 35 440 35 455 1 3952 1 3959 3 90415 PR9 000 35 455 35...

Page 506: ...f the clearance is out of tolerance select and install a new totters COlTER 31 5 mm 1 No 1 Part Number 1 Thickness mm Iin I 1 90441 PR9 000 1 975 2 000 0 078 0 079 2 90442 PR9 000 2 000 2 025 lO O79 0 080 3 90443 PR9 000 2 025 2 050 0 080 0 081 4 90444 PR9 000 2 050 2 075 0 081 0 082 5 90445 PR9 000 2 075 2 100 0 082 0 083 6 90446 PR9 000 2 100 2 125 0 083 0 084 7 90447 PR9 000 2 125 2 150 0 084 0...

Page 507: ...05 0 16 mm 0 002 0 006 in A FEELER GAUGE COTTER RETAINER i 4TH GEAR REVERiE SELECTOR HUB 10 If the clearance is out of tolerance select and install a new cotter retainer THICKNESS COTTER RETAINER 1No 1 Parts Number 1 Thickness I 1 I I 90432 PR9 000 3 00 3 03 mm 0 118 0 119in I 2 I I 90433 PR9 000 3 03 3 06 mm 0 119 0 120in 3 I I 90434 PR9 000 3 06 3 09 mm 0 120 0 122in 4 I I 90435 PR9 000 3 09 3 1...

Page 508: ...trips if you break a strip the clutch will not work properly COUNTERSHAFT 1 ST GEAR COPPER FRICTION STRIP ONE WAY CLUTCH SCREWdRIVER Inspect the parts as follows PARKING GEAR inspect for wear or scoring 6 1 ST GEAR COLLAR NEEDLE ROLLER BEARINGS Inspect for galling and rough movement ONE WAY CLUTCH Inspect for damage or faulty movement COUNTERSHAFT IST GEAR Inspect for wear or scoring 3 After the p...

Page 509: ... washer 0 Inspect thrust needle and needle bearings for galling and rough movement LOCKNUT iLO N m 14 0 0 14 0 kg m 101 0 r101 lb ft SPACER 31 mm SECONDARY SHAFT Check splines for excessive wear or damage Check bearina surface for scoring scratches or exces sive wear 3RD GEAR SEAL RINGS 35 mm THRUST WASHER THRUST NEEDLE BEARING I 2ND GEAR NEEDLE BEARING 37x43x22mm THRUST NEEDLE 14 127 ...

Page 510: ...G RETAINER CIRCLIP CLUTCH DISCS Standard thickness I 94 mm 0 076 in CLUTCH END PLATE SNAP RING CLUTCH PLATES Standard thickness 2 3 mm 0 091 in SNAP RING CLUTCH END 2 34 mm 0 092 in CIRCLIP SPRING RETAINER RETURN SPRING CLUTCH PISTON O RINGS Replace CLUTCH DRUM CLUTCHPLATES Standard thickness 2 0 mm 0 079 in a ...

Page 511: ...N DISC SPRING CLUTCH DISCS Standard thickness 1 94 mm 0 076 in1 I Y CLUTCH END PLATE b SNAP RING 4 3RD CLUTCH SNAP RING CLUTCH END PLATE CLUTCH DISCS Standard thickness 1 94 mm 0 076 in CLUTCHPLATES Standard thickness 2 0 mm 0 079 in wCIRCLiP m SPRlNG RETAINER ucRETURN SPRING 7I CLUTCH PISTON io z C L U T C H D R U M cont d 14 129 ...

Page 512: ...ING RETAINER ClRCLlP s 63 CLUTCH PLATES Standard thickness 2 3 mm 0 091 in O RINGS Replace CLUTCH PISTON Clutch Illustrated Index 2ND CLUTCH CLUTCH END PLATE SNAP RING CLUTCH DISCS Standard thickness 1 94 mm 0 076 in ...

Page 513: ...he special tools as shown CLUTCH CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07HAE PL50100 RING lh COMPRESSOR w BOLT ASSEMBLY 07GAE PG40200 CAUTION If either end of the compressor attach ment is set over an area of the spring retainer which is unsupported by the return spring the retainer may be damaged RETAINER Set here DO not set here cont d 14 131 ...

Page 514: ...e special tool spring retainer and return spring 6 Wrap a shop rag around the clutch drum and apply air pressure to the oil passage to remove the piston Place a finger tip on the other end while applying air pressure OIL PASSAGE COMPRESSED AIR HOSE NOZZLE OSHA Approved 30 psi type only a a a 14 132 ...

Page 515: ...ring is securely staked NOTE For Ist 3rd and 4th clutches q O RINGS n CLUTCH PISTON O RING 3 Install the piston in the clutch drum Apply pressure and rotate to ensure proper seating NOTE Lubricate the piston O ring with ATF before in stalling CAUTION Do not pinch O ring by installing the piston with force PISTON CLUTCH DRUM 4 Install the return spring and spring retainer and position the circlip o...

Page 516: ...PL50100 I CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY 07GAE PG40200 CAUTION If either end of the compressor attach ment is set over an area of the spring retainer which is unsupported by the retainer spring the re tainer may be damaged RETAINER set here Do not set here 6 Compress the clutch return spring 7 Install the circlip 8 Remove the special tools 14 l 34 ...

Page 517: ...a minimum of 30 minutes 11 Starting with a clutch plate alternately install the clutch plates and discs Install the clutch end plate with flat side toward the disc NOTE Before installing the plates and discs make sure the inside of the clutch drum is free of dirt or other foreign matter CLUTCH END PLATE LUTCI I DISC 12 Install the snap ring SCREWDRIVER SNAP RING cont d ...

Page 518: ...hin the service limits select a new clutch end plate from the following table NOTE If the thickest clutch end plate is installed but the clearance is still over the standard replace the clutch discs and clutch plates 2ND 3RD 4TH and IST HOLD CLUTCH PART No 22551 PX4 003 22552 PX4 003 22553 PX4 003 22554 PX4 003 22555 PX4 003 22556 PX4 003 22557 PX4 003 22558 PX4 003 22559 PX4 003 1 ST CLUTCH PART ...

Page 519: ...ove the Ist hold clutch bearing using a bearin puller G PULLEF IST HOLD ITCH BEARING lST HOLD CLUTCH 2 Install a new bearing using the special tools NOTE Drive in the bearing until it fully bottoms DRIVER 07749 0010000 ATTACHMENT 72x75mm 07746 0010600 ...

Page 520: ...7749 0010000 ATTACliMENT 07947 6340500 TORQUE CONVERTER HOUSING 2 Drive in the new mainshaft bearing until it bottoms in the housing using the special tools DRIVER 07749 0010000 ATTACHMENT 62x68mm 07746 0010500 3 Install the new oil seal flush with the housing using the special tools DRIVER 07749 0010000 ATTACHMENT 72x75mm 07746 0010600 14 138 ...

Page 521: ... the new bearing into the housing using the spe cial tools DRIVER 07749 0010000 BEARING ATTACHMENT 72x75mm 07746 0010600 OIL GUIDE PLATE Secondary Shaft Bearing Replacement Commercially Available 318 x 16 Thread Slide Hammer c ADJUSTAB E BEARING PULLER 25 40 mm 07736 AOIOOOA SECONDARY SHAFT NEEDLE BEARING Replace with new bearing if removed 2 Replace the oil guide plate 3 Drive the new bearing int...

Page 522: ...earings from the transmission housing expand the new bearing part way into it then release the pli each snap ring with the snap ring pliers then push the ers Push the bearing down into the transmission until bearing out the ring snaps in place around it NOTE Do not remove the snap rings unless it s necessary to clean the grooves in the housing Remove install ...

Page 523: ...ing in the reverse idler shaft Push the spring in with the steel ball then install the needle bearing NOTE The steel ball is under spring pressure Take care not to let it pop out VERSE SPRIN STEEL BALL IDLER SHAFT NEEDLE ROLLER BEARING 3 Install the reverse idler shaft holder into the transmis sion housing then tighten the bolts 6x l Omm 12 N m 1 2 kg m 9 lb ft ERSE IDLER SHAFT HOLDER I REVERSE ID...

Page 524: ...LVE I II I II DISTANCE MANUAL VALVE W L f DETENT SPRING M A N U A L VAlcE LEVER N positicn 6 If the measurement is out of tolerance select the appropriate manual valve detent spring using table below then install it and recheck MANUAL VALVE DETENT SPRING No Part Number Length 1 24618 PR9 000 103 5 mm 4 07 in 24619 PR9 000 104 0 mm 4 09 in I 3 24620 PR9 000 104 5 mm 4 11 in LENGTH r I Parking Brake...

Page 525: ...0 lb ft 7 Bolts NOTE Install the oil pump driven gear with its chamfered side facing down DRIVEN GEAR DRIVE GEAR Ill SHAFT 4 DRIVEN GEAR Qill Chamfered side faces separator plate NOfE Make sure the pump drive gear rotates smoothly in the normal operating direction and the pump shaft moves smoothly in the axial and normal operating directions CAUTION If the pump gear and pump shaft do not move free...

Page 526: ...e faces bolt hole 17 Bolts 10x 1 25mm 55 N m 5 5 kg m 40 lb ft 0 6xl Omm 14N m 1 4 kg m 10 lb ft w u ure J6xl Omm 12 N m 1 2 kg m 9 lb ft J NOTE Install the three shafts together COUNTERSHAFT SECONDARY SHAFT MAINSHAFT NOTE Align the control shaft spring pin with the groove in the transmission housing a NOTE Torque bolts to 55 N m 5 5 kg m 40 lb ft in order of thru in two or more steps ...

Page 527: ...3 Assemble the transmission in the following numbered sequence Replace cont dl ...

Page 528: ...ropriate parking brake stopper using the table below and install it on the parking shift arm PARKING BRAKE STOPPER 7 Install the special tool as shown and shift to PARK position MAINSHA 07924 P 8 Install and torque the new locknuts Tighten to speci fied torque then loosen and retighten to specified torque TORQUE 140 t 0 140 N m 14 0 0 14 0 kg m 101 0 101 lb ft NOTE Countershaft locknut has left ha...

Page 529: ... sensor cover and linear solenoid TORQUE 12 N m 1 2 kg m 9 lb ft SPkEEED SENSOR COVER NM SPEED SENSOR LINEAR SOLENOID 6x l Omm 10 N m 1 0 kg m 7 lb4 14 Install the control lever new lock washers change shaft and change shaft cap on the other end of the control shaft Tighten the bolts and then bend the tab over against the bolt head 6x l Omm 12 N m I 2 kg m 9 lb ftl CHANGE SHAFT CAP CONTROL CONTROL...

Page 530: ... Disassembly 6x l Omm DRIVE PLATE 12 N m I 2 Kg m 9 lb ftl Inspect for cracks 12x l Omm 75 N m 7 5 Ka m 54 lb W Replace Torque in cris oss pattern 14 148 ...

Page 531: ...SMISSION MOUNTING BOLT 10x 1 25mm 60 N m 6 0 kg m 43 lb ft TRANSMISSION JACK 65 N m 6 5 kg m 47 lb f 7 Attach the torque converter to the drive plate with 8 bolts to 12 N m 1 2 kg m 9 lb ft Rotate the crankshaft as necessary to tighten bolts to l 2 of specified torque then final torque in a crisscross pattern Check for free rotation after tightening the last bolt 8 Install the torque converter cov...

Page 532: ... brake system sensor wire clamp and parking brake cable holder CORROSION RESISTANT BOLT NUT DAMPER SELF LOCKING NUT CASTLE NUT FORK BOLT Replace 12x 1 25mm Ranlaca 85 Nem p C Is f 3 IL U I SELF LOCKING NUT Replace vr 12x 1 25mm 95 N m 9 5 kg m 69 lb ft D 3 ny lll L I 711 6x l Omm IO N m 11 0 kgm 7 lb ft CONTROL ARM SET RING SELF LOCKING NUT I 4 ADJUSTING NUT 14x 1 5 mm Replace 125 N m ADJUSTING BO...

Page 533: ...9 5 kg m 69 lb ft DAMPER FORK BOLT 6xl Omm 10 N m I O kg m 7 lb ft 10 N m 1 O kg m 7 lb R CASTLE NUT Replace 10x 1 25mm 44 N m 14 4 kg m 32 lb ft CASTLE NUT Replace 24 Install the front exhaust pipe A 25 Install the rear beam rod 26 Install the parking brake cable 0 Corrosion resistant bolt nut SELF LOCKING NUT Replace 12 x 1 25 mm 65 N m 6 5 kg m 62 lb ftl COTTER PIN Replace 12x 1 25mm 60 N m 6 0...

Page 534: ...m 28 lb ftj Corrosion resistant bolt nut c 34 Refill the transmission with ATF 35 Connect the battery positive j and negative j ca ble to the battery 36 Inspect the rear camber See Section 18 37 Start the engine Set the parking brake and shift the transmission through all gears three times Check for proper shift cable adjustment 38 Check the ignition timing See Section 23 39 Let the engine each op...

Page 535: ...rd to the front of the car 8 Check that the hole in the control lever is perfectly aligned with the hole in the shift cable CONTROL LEVER SHIFT CABLE END Cable Cable Exact Too Short Too Long Alignment 9 If not perfectly aligned loosen the locknut on the shift cable and adjust as required ADJUST NUT LOCKN NOTE Left hand LOCKNUT threads 11 Install the control lever pin and lock pin NOTE 0 If you fee...

Page 536: ...e cotter pin and selector lever pin from the selector lever and mount ing bolts from the bracket beam 3 Remove the shift cable clamps 4 Remove the shift cable holder and shift cable cover 5 Remove the shift cable by removing the lock pin and control lever pin from the control lever CAUTION Take car not to bend the cable when removing it 6 Install the shift cable in the reverse order of removal 7 C...

Page 537: ...3 N m I 0 3 kg m 2 lb ft GQA SILICONE GREASE 3 N m 0 3 kg m 2 lb ft Apply non hardening thread lock sealant SHIFT INDICATOR PANEL KEY CYLINDER 3 N m 0 3 kg m 2 lb ft SILICONE F_PEbCC LEVER COVER SHIFT INDICATOR 3 N m 0 3 kg m 2 lb ft SHIFT CABLE I LOCK PIN CONTROL LEVER PIN SHIFT CABLE HOLDER Install in this direction ETENT COVER 10 N m 1 0 kg m 7 lb ft DETENT PLATE 5 N m 0 5 kg m 4 lb ft I SHIFT ...

Page 538: ... ness when servicing the shift indicator panel INDICATOR LIGHT S RS UNIT 1 Check that the index mark of the indicator aligns with the N mark of the shift indicator panel with the trans mission in NEUTRAL 2 If not aligned remove the center console panel See section 20 3 Remove the shift indicator panel mounting screws and adjust by moving the panel NOTE Whenever the shift indicator panel is re move...

Page 539: ...on 15 4 Bearing Replacement 15 5 Differential Disassembly 15 6 Clutch Disc Clutch plate Replacement 15 8 Differential Reassembly 15 9 Oil Seal Replacement 15 11 Bearing Outer Race Replacement Clutch Housing Side 15 12 Bearing Preload Adjustment 15 12 Oil Seal Installation 15 14 ...

Page 540: ...SA00600 Description Attachment 78 x 70 mm Clutch Spring Compressor Bolt Assembly Clutch Spring Compressor Attachment Clutch Spring Compressor Attachment Pilot 32 x 60 mm Attachment 45 x 55 mm Differential Inspection Tools Attachment 62 x 68 mm Driver Driver Attachment Page Reference 15 12 15 6 15 l 0 15 6 15 l 0 15 6 15 l 0 15 14 15 5 15 4 15 6 15 11 15 13 15 12 15 12 15 14 15 14 ...

Page 541: ... cement page 15 8 CENTRAL GEAR BEARING OU Replacement page 15 12 13 Inspect for wear or damage Inspect for wear or damage 162 mm WASHER w CLUTCH PLiITE Inspection page 15 4 Replacement page 15 8 CLUTCH PLATES Inspection page 15 4 Replacment page 15 8 CARRIER ASSEMBLY Inspect for wear or damage 112 mm THRUST SHIM Selection page 15 8 Replacement page 15 8 TAPER ROLLER BEARING Replacement page 15 5 I...

Page 542: ...e clutch discs are replaced See page 15 8 Assembly 1 Place one special tool in a vise Place the left side of the differential assembly on the special tool then preset the differential with 3 5 rotations both clockwise and counterclockwise DIFFERENTIAL INSPECTION TOOL 07MAJ PR90100 2 Measure preset torque clockwise using a torque wrench as shown Standard 60 140 N m 6 14 kg m 43 101 lb ft Service Li...

Page 543: ... bearing is replaced 1 Remove the bearings using standard bearing pullers BEARING PULLER PULLER 2 Install the bearings using a press as shown NOTE Press the bearings squarely until they bot tom against the case Transmission Housing Side STEEL PLAY R TAPER RO BEARING Clutch Housing Side STEEL PLATE r4 ATTACHMENT 45 x 55 mm 07MAD PR90300 ...

Page 544: ... special tools on the stopper plate as shown CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE PX40100 STOPPER PLATE CLUTCH SPRING COMPRESSOR ATTACHMENT 07GAE PG40200 CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY 07HAE PL50100 3 Compress the spring plate 4 Remove the stopper clip 5 Remove the special tools and then remove the stopper plate spring plate and 60 mm washer STOPPER PLATE SPRING PLATE 60 mm WASHER Y D...

Page 545: ...m WASHER 7 Remove the carrier assembly central gear clutch plate and clutch disc CARRIER ASSEMBLY C E N T R A L G E A R CLUTCH DISC 8 Remove the ring gear by installing the differential housing mounting bolts into the threaded holes and tightening them RING GEAR DIFFERENTIAL HOUSING COVER DIFFERENTIAL HOUSING MOUNTING BOLTS ...

Page 546: ...lutch plates and a stan dard shim 112 mm THRUST SHIM OStandard shim J 4 1270 PR8 000 3 0 mm 0 1181 in Reference Measure 41 7 41 9 mm 1 6417 1 6496 in 4 install the differential case NOTE Tighten the bolts evenly in several steps then torque them in a criss cross pattern Torque 40 N m 4 0 kg m 29 lb ft 5 Make sure the preset torque is within the standard See page 15 4 6 If preset torque is beyond t...

Page 547: ...sing cover v h the mark on the ring gear AMARK 3 Install the 102 mm washer clutch discs clutch plate and 112 mm thrust shim NOTE 0 Lubricate the clutch discs with transmission oil 0 Position the 112 mm thrust shim with the thickness size mark facing away from the clutch discs Thickness Size mark 112 mm THRUST SHIM CLUTCH DiSCS CLUTCH PLATES 102 mm WASHER 4 Install the 60 mm washer spring plate and...

Page 548: ...R ATTACHMENT 07GAE PG40200 CLUTCH SPRING COMPRES OR SEMBLY PL50100 6 Cohpress t spring plate then install the stopper c l i p 7 Install the differential housing NOTE Align the fingers of the clutch plates and clutch discs DIFFERENTIAL HOUSIW 8 Make sure the differential housing touches the final driven gear DIFFERENTIAL _ FINAL DRIVEN GEAR I CLUTCH PLATE ...

Page 549: ...he bolts two turns at a time then torque them in a crisscross pattern 8 x 1 O mm SPECIAL BOLTS 407 m 4 0 kg m 29 lb ft DIkFERENTIAL INSPECTION TOOL 07MAJ Pi 901 00 Oil Sea Removal 1 2 3 Remove the differential assembly Remove the oil seal from the transmission housing Remove the oil seal from the clutch housing Replace ...

Page 550: ...ING 0 DIFFERENTIAL 0 TAPER ROLLER BEARING and OUTER RACE 0 75 mm THRUST SHIM 0 90 mm WASHER 0 OIL GUIDE RING 1 Remove the bearing outer race and 75 mm thrust shim from the transmission housing by prying up on the bearing outer race or by heating the housing to about 100 C 212OF CAUTION Do not reuse the thrust shim if the outer race was pried out NOTE l Let the transmission cool to the room tempera...

Page 551: ......

Page 552: ...ation 1 Install the oil seal in the transmission housing DRIVER DRIVER ATTACHMENT 07749 0010000 4 l 07965 SA00600 PILOT 3i x 60 mm 07MAD PR90200 2 Install the oil seal in the clutch housing PILOT 32 60 mm 07MAD PR90200 ...

Page 553: ...Driveshafts Special Tools 16 2 Driveshafts Removal 16 3 Disassembly 16 6 Inspection 16 7 Reassembly 16 8 Intermediate Shaft Replacement 16 12 Disassembly 16 13 Index Inspection 16 15 Reassembly 16 16 ...

Page 554: ...O 0 7 7 4 6 0 0 1 0 4 0 0 0 07749 0010000 8 0 7 9 4 1 6 9 2 0 0 0 3 Description crty Page Reference Hub DidAssembly Base 2 16 13 14 16 Hub Driver Attachment 1 16 16 Attachment 1 16 16 Oil Seal Driver Attachment 1 16 16 Ball Joint Remover 1 16 5 Attachment 52 x 55 mm 1 16 14 Driver 1 16 14 16 Ball Joint Remover 1 16 4 ...

Page 555: ...OTE It is not necessary to drain the transmission oil when the right driveshaft is removed 4 Raise the locking tab on the spindle nut and loosen it NOTE Before installing the wheel clean the mating surfaces of the brake disc and inside of the wheel 26x1 5mm SPINDLE NUT Replace 335 Nom 33 5 kg m 242 lb ft After tightening use a drift to stake spindle nut shoulder WHEEL NUT ainst the driveshaft 110 ...

Page 556: ...ll joint Be sure that the 10 mm hex nut is flush with the ball joint pin end or the threaded section of the ball joint pin might be damaged by the ball joint remover Position the special tool between the knuckle and control arm as shown then separate the toe con trol arm CAUTION Be careful not to damage the ball joint boot COTTER PIN Replace On reassembly bendIthe cotter pin a a 10 x 1 25 mm CASTL...

Page 557: ...T REMOVER 07MAC SLOOIOO On reassembly bend the cotter pin as shown 12 x 1 25 mm CASTLE NUT 60 Nom 6 0 kg m 43 lb ft 15 Pry the driveshaft assembly with a screwdriver as shown to force the set ring past the groove SCREWDRIVER A 7mm 16 Pull the inboard joint and remove the driveshaft and CV joint from of the differential case or interme diate shaft as an assembly CAUTION l Do not pull on the drivesh...

Page 558: ...e the boots 2 Remove both joints 0 Outboard joint side only Remove the circlip from the outboard joint groove Remove the outboard joint and spring Outboard joint only 3 Remove the rollers from the spider ROLLER 4 Remove the set ring then remove the spider with a bearing remover NOTE Before disassembly mark the spider and driveshaft so they can be reinstalled in their original positions SET RING BE...

Page 559: ...ing reassembly Spline direction Check splines for wear or damage Check inside bore for wear Inspect for cracks SET RING Pack cavity HOLDER Section AA INBOARD JOINT BOOT JOINT BOOT BOOT BAND Check splines for wear or damage Check inside bore for wear Inspect for cracks Pack cavity with grease NOTE Stagger the inboard joint spider and outboard joint spider 60 apart To ease assembly mark alignment ma...

Page 560: ...ing the marks on the spider and end of the driveshaft 4 install the set ring into the driveshaft groove SET RING al 5 Fit the rollers to the spider with their high shoulders facing outward CAUTION l Reinstall the rollers in their original positions on the spider 0 Hold the driveshaft assembly with the rollers up to prevent them from falling off SPIDER ROLLER High shoulder faces toward outside 6 Pa...

Page 561: ...P inboard joint side NOTE Wrap the splines with vinyl tape to prevent damage to the boot 9 Install the inboard boot to the driveshaft then remove the vinyl tape INBOARD BOOT I IO Install the set ring into the driveshaft groove 11 Install the spider on the driveshaft by aligning the marks on the spider and end of the driveshaft 12 Install the set ring into the driveshaft groove SET RING M a r k SET...

Page 562: ...rease included in the new joint boot set Grease Quantity 120 130 g 15 Fit the inboard joint onto the driveshaft INROARD JOINT ilign the roller holders with the nboard joint as shown kelow HOLD ER 16 Adjust the length of the driveshafts to the figure below then adjust the boots to halfway between full compression and extension NOTE The ends of the boots seat in the grooves of the driveshaft and joi...

Page 563: ...rmediate shaft groove 20 Install the inboard end of the driveshaft into dif ferential or intermediate shaft CAUTION l Always use a new set ring whenever the drive shaft is being installed 0 Make sure the L driveshaft locks in the differen tial side gear groove and the CV joint subaxle bottoms in the differential 0 insert the Ft driveshaft CV joint subaxle into the intermediate shaft until the inte...

Page 564: ... support base CAUTION To prevent damage to the differential oil seal hold the intermediate shaft horizontal until it is clear of the differential NOTE Mark the support base and bearing support during disassembly to ensure proper positioning during reassembly CAUTION The bearing support and support base are made of aluminum Be careful not to damage them when servicing Corrosion resistant bolt nut S...

Page 565: ...outer seal from the bearing support 2 Remove the external circlip and internal circlip LIP EXTERNAL CklCLIP 3 Press the intermediate shaft out of the shaft bear ing using the special tool Hydraulic press HUB DWASSEMBLY BASE 07GAF SD40700 INTERMEDIATk SHAFT 4 Remove the intermediate shaft inner seal from the bearing support INNER SEAL Replace Icont d 16 13 ...

Page 566: ...sassembly cont d 5 Press the intermediate shaft bearing out of the bearing support using the special tools Hydraulic Press DRIVER J 077494010000 ATTACHMENT 52 x 55 mm 07746 0010400 HUB DlSlASSEikBLY BASE 07GAF SD40700 16 14 ...

Page 567: ...upport and support base are fitted and must be replaced as an assembly Corrosion resistant bolt nut SUPPORT BASE Check for damage INNER SEAL Replace AEiGii 3 4g ARING SUPPORT EXTERNAL CIRCLIP Check for damage o Check for damage or distortion B x 1 25 mm FLANGE BOLT 22 Nom 2 2 kg m 16 lb ft INTERMEDIATE SHAFT BEARING Replace SET RING Replace 16 15 ...

Page 568: ...earing support CAUTION Install the circlip with the tapered end facing out INTERNAL CIRCLIP 3 Drive the intermediate shaft inner seal into the bearing support using the special to HUB DIWASSEM L INNER SEAL BASE 07GAF SD40700 4 Press the intermediate shaft into the shaft bearing using the special tools Hydraulic press INTERMEDIATE SHAFT HUB DIRVER ATTACHMENT 7 07GAF SE00200 hflflM Fit the inner rac...

Page 569: ...5 Seat the external circlip in the groove of the in termediate shaft CAUTION Install the circlip with the tapered end facing out EXTERNAL CIRCLIP 6 Install the outer seal into the bearing support 16 17 ...

Page 570: ...Gear Box Inspection Ball Joint Boot Replacement Power Unit Installation and Removal EPS Control Unit Installation and Removal 17 31 17 31 17 32 17 33 17 34 17 40 17 41 17 42 17 43 17 45 17 46 17 47 17 52 17 63 17 64 17 68 17 69 17 72 17 73 17 74 SUPPLEMENTAL RESTRAINT SYSTEM SRS The NSX includes a driver s side Airbag located in the steering wheel hub as part of a Supplemental Restraint System SRS...

Page 571: ...ionBallJointHarnessScrewBootWrenchAClipGuide 8 07MAZ SL00200 Test Harness B 0 07MAZ SL00300 Test Harness C 03 07MAZ SL00400 EPS power unit checker 0 07941 6920003 Ball Joint Remover 0 07973 6920001 P S Adjustment Guide 0 07974 SD90000 Steering Inspection Arm O ty Page Reference 2 17 24 1 17 7 70 1 17 7 28 1 17 23 27 1 1 1 17 23 17 30 17 45 26 48 722750 5 53 54 55 56 59 60 61 1 17 45 53 55 1 17 45 ...

Page 572: ...the portion of the column between the steering wheel and this joint is adjustable up and down When the tilt lever is operated the lock gears are detached from the column gear to release the lock The column moves upward or downward on two pivot bolts When the tilt lever is returned to a fixed position after selecting the steering wheel height the lock gear is engaged with the column gear to secure ...

Page 573: ...opic lever is lowered the lever pivot turns in a direction to loosen the stopper shim at the tip of the lever pivot allowing the shaft to make telescope The telescopic stroke is limited by the slot and stopper on the movable shaft After selecting a steering wheel position and returning the telescopic lever to the fastening position the stopper shim is pressed against the movable shaft the lever pi...

Page 574: ... into a lower holder Due to this construction the steering column will slide in its axial direction when a large impact is given in the axial direction of the column Since the U shaped plate is fastened to the body the U shaped plate is bent and deformed along the guide when the column slides in its axial direction Through the deformation of the plate the energy is absorbed and the column slides f...

Page 575: ...teering Only 1 Raise the front wheels off the ground see sec tion 1 2 Turn the steering wheel with a spring scale and check its reading 3 If the reading exceeds the service limit adjust the steering gearbox as shown on the next page Service Limit 20 N 2 kg 4 4 lb Power Assist Check With Car Parked Electrical Power Steering Only Turn the steering wheel with a spring scale Read the measurement when ...

Page 576: ...m 6 8 kg m 49 lb ft Indicated 52 N m 5 2 kg m 38 lb ft RACK GUIDE SCREW 43 inm LOCKNUT WRENCH 07MAA SL0020A Electrical Power Steering 1 Loosen the rack guide screw locknut 2 Tighten loosen and retighten the rack guide screw two times to 4 N m 0 4 kg m 2 9 lb ft then back it off 20 Eo 3 Tighten the locknut on the rack guide screw with the special tool 4 Check for tight or loose steering through the...

Page 577: ...improperly handled such as dents cracks or deformation l Always keep the short connector on the airbag con nector when the harness is disconnected l Do not disassemble or tamper with the airbag as sembly 1 Disconnect both the negative cable and positive ca ble from the battery 2 Remove the maintenance lid form the steering wheel lower cover then remove the short connector 3 Disconnect the connecto...

Page 578: ...pel the unit with enough force to cause serious injury NOTE If an intact airbag assembly has been re moved from a scrapped car or has been found defec tive or damaged during transit storage or service it should be deployed See section 23 CAUTION l Carefully inspect the airbag assembly before install ing Do not install an airbag assembly that shows signs of being dropped or improperly handled such ...

Page 579: ...sitioning the steering wheel m Confirm that the airbag assembly is secure ly attached to the steering wheel otherwise severe per sonal injury could result during later airbag deployment 1 Before installing the steering wheel center the ca ble reel Do this by first rotating the cable reel clockwise un til it stops Then rotate it counterclockwise approximately two turns until The yellow gear tooth l...

Page 580: ...er cover I MAINTENANCE t I LID SHORT CONNECTOR RED 10 Connect the battery positive terminal and then con nect the negative terminal 1 1 After installing the airbag assembly confirm proper system operation 0 Turn the ignition to II the instrument panel SRS warning light should come on for about 6 seconds and then go off 0 Confirm operation of horn buttons 0 Confirm operation of cruise control set r...

Page 581: ...TER DASHiOARD KNEE B OLSTER LOWER PANEL PAD 4 Remove the column lower face Disconnect the con nector between the cable reel and the SRS main har ness then remove the connector holder N FACE 5 Remove the column lower cover and column upper cover NOTE Be careful not to damage the column covers COLUMN UPPER COVER if 5 COVER 6 Disconnect the TCS sensor TCSCONNECTOR GREEN SRS MAIN HARNESS YELLOW CABLE ...

Page 582: ...BINATION SWITCH 8 Remove the steering joint cover STEERING JOdT COVER 9 Remove the steering joint bolts and washers from the joints LOCK WASHERS STEERlNG JOlNT BOLTS 10 Disconnect the ignition switch connectors and re move the column holder then remove the column assembly by removing the attaching nuts HOLDER FLANGE NUTS 8x1 25 mm BOLT WASHERS 17 13 ...

Page 583: ...and damage Replace as an assembly if damaged or faulty l If either the steering column assembly or TCS sensor is removed select the appropriate shim and adjust the distance between the steering shaft and TCS sensor Refer to Section 19 for shim selection Attach a spring scale to the knob of the telescopic lever If the force measured is not within the specification loos Measure the force required to...

Page 584: ...t are aligned the joint should slip on freely If not reposition the steering rack to correct the misalignment STEERING JOINT Slip the upper end of the steering joint onto the steering shaft line up the bolt hole with the groove around the shaft and loosely install the upper bolt STEERING SHAFT Pull down while tightening bolt TOOTHED LOCK STEERlNG JOlNT BOLTS 23 N m 2 3 kg m 17 lb ft 4 Install the ...

Page 585: ...OR GREEN Tcs ENBOR 9 Install the column upper cover and column lower cover NOTE Be careful not to damage the column covers COLUMN UPPER COVER COMUN LOWER COVER 10 Connect the harness from the cable reel to the SRS main harness below the pedal bracket then attach the connector holder to the column lower face 11 Install the column lower face HOLDER m 0 ...

Page 586: ...rning chime to the driver under cover then install the dash board lower panel KNEE BOLSTER DASHbOARD KNEE HOLSTEIN LOWER PANEL PAD 0 14 Install the steering wheel and SRS airbag assembly to the column 17 10 0 12 Install the knee bolster and pad 17 17 ...

Page 587: ...Disassembly page 17 9 Installation page 17 10 STEERING COLUMN Removal page 17 l 2 Inspection page 17 14 Installation page 17 I 5 STEERING GEARBOX Removal installation page 17 19 Disassembly page 17 22 Inspection page 17 21 Reassembly page 17 25 17 18 ...

Page 588: ...nut and remove the nut 6 Install the 12 mm hex nut on the ball joint Be sure that the 12 mm hex nut is flush with the ball joint pin end or the threaded section of the ball joint pin might be damaged by the ball joint remover 7 Separate the tie rod ball joint and knuckle using the special tool CAUTION Avoid damaging the ball joint boot NOTE If necessary apply penetrating type lubricant to loosen t...

Page 589: ...f OX ASSEMBLY QCorrosion resistant bolt nut 13 Installation is the reverse order of removal 0 Install the gearbox assembly and spare tire holder plate frame 0 Install the steering joint 14 Connect the battery positive terminal and then con nect the negative terminal 15 After confirm proper system operation 0 Turn on the ignition to II the instrument panel SRS warnig light should go on for about 6 ...

Page 590: ...age PINION DUST SEAL GEAR HOUSING r STEERING GROMMET B Check for damage LOCK NION BEARING NUT 60 N m 6 0 kg m 43 lb ft 10 mm NUT 60 N m 6 0 kg m 43 lb ft SCREW PRESSURE SPRING PRESSURE PLATE STEERING RACK Inspect surface for damage STOP WASHER COTTER PIN Q CASTLE NUT Replace IA F kn m Ih ftl I BOOT Check for d a m a a e TUBE CLAMP m SILICOI STEERING GREASE Coat thL Honda P N 08733 B070E surface of...

Page 591: ...eck the preload If the preload is out of the specification adjust the rack guide page 17 27 If the preload is still out of the specification disas semble the gearbox and check each part NOTE Slide the steering rack in the cylinder until the end of the projects rack 60 mm 2 34 in from the cylinder end Inspection is made near this rack position 5 Check the pinion preload with a spring scale Preload ...

Page 592: ... WRENCH 07MAA SL0040A 9 Move the rack toward the gearbox side i e in the direction of the arrow as far as it goes and out the pinion assembly pull when the pinion gear contacts the cutout in the rack NOTE The rack cannot be removed from the rack end side STEERING PINION Arrow direction 0 Check the bearing movement while pulling the bearing outer race as shown NOTE This type of the bearing has play...

Page 593: ...ner race with the tool securely Ezl Bearing mark BEARING El Y W HtiB DIS ASSEMBLY BASE 07GAF SD40700 10 Remove the steering rack from the cylinder STEERIN RACK 0 Check the gearbox lower bearing and replace it if it is damaged Remove the bearing by lightly tapping with a plas tic hammer as shown If the bearing is hard to re move by tapping heat the gearbox by soaking it in 100 C 212OF water CAUTION...

Page 594: ...ng Hydraulic press P S ADjUSTMEN GUIDE 07973 6920001 1 1 lnser the steering rack into the cylinder housing be ing careful not to damage the steering rack sliding surface STEERING RACK 12 Install the steering pinion into the gearbox NOTE Do not engage the steering pinion with the steering rack this time TEERING PINION 13 If the dust seal was removed drive in the new dust seal until it bottoms on th...

Page 595: ...ighten the set screw using a torque wrench of the different length obtain the torque value using the following formulas A A B Y Y x Actual torque X X Torque wrench reading IO cm PINION SCREW WRENCH 7MAA SL0040A Indicated 5 7 7 1 N m 57 71 kg cm 49 62 in lb Actual 8 0 10 N m 80 100 kg cm 82 87 in lb PINON SCREW WRENCH 07MAA SL0040A 18 Turn the pinion right and left several times to make set it then...

Page 596: ...las shown in the step 17 Actual 70 90 N m 7 9 kg m 50 65 lb ft indicated 54 69 N m 5 4 6 9 kg m 39 50 lb ft Tool length B 15 cm 6 in 50 mm LOCKNUT WRENCH PINION SCREW WRENCH 07HAA SL0030A 07MAA S L0040A 21 Turn the pinion shaft slowly then insert the rack and engage the rack and pinion gears 22 The system is in neutral when the rack end projects 60 mm 2 34 in from the cylinder end 23 Install the r...

Page 597: ...0020A 26 Screw each rack end into the rack while holding the lock washer so its tabs are in the slots in the rack end NOTE Install the stopper washer with the cham fered side facing out LOCK WASHER RACK END 27 Tighten the rack end securely then bend the lock washer back against the flat on the flange as shown NOTE Coat the stopper washer with grease suffi ciently 28 Install the boots on the rack e...

Page 598: ... and left to be certain that the boots are not deformed or twisted 31 If the tie rod ends were removed install the tie rods on the right and left rack ends and screw them in until the threaded section is 11 mm 0 43 in in length 11 mm 10 43 in Hand tighten TIE ROD END 32 Install the gearbox on the cross beam page 17 20 33 Check the wheel alignment and adjust if necessary Section 18 ...

Page 599: ...ed section of the ball pin l Dvnot allow dust dirt or other foreign materi als to enter the boot BALL PIN TAPERED SECTION BOoT INSTALLATION SECTION 4 Install the boot in the groove of the boot installation section securely then bleed air 5 Insert the special tool into the threads in the ball pin and align the end of the tool with the groove in the boot Slide the clip over the tool and into positio...

Page 600: ... the steering gearbox driven by the con trol unit and power unit Its distinctive features are described below l Minimized loss of engine horsepower are decreased fuel consumption 0 A linear steering feel and the reduction of kick back 0 Since it requires no complicated hydraulic piping etc the system is compact and light in weight EPS CONTROL UNIT I POWER UNIT STEERING WHEEL I ALTERNATOR AT YPEED ...

Page 601: ... into account steering torque steering speed and vehicle speed Selfdiagnosis functions are included l A power unit that drives the motor according to the signals from the control unit A current sensor is built in to give feedback information to the control unit Two relays shut off the power if a problem in the system occurs l Two speed sensors the speedometer and the automatic transmission sensor ...

Page 602: ...ansmits a signal to the control unit when it receives a steering input The control unit calculates an adequate motor control with addition of speed sig nals the two speed sensors then transmits a control signal to the power unit Based on the signal from the control unit the power unit drives the motor inside the gearbox The torque generated by the motor is transmitted to ball screw through gears a...

Page 603: ...slider core is installed on the pinion shaft on grooves and turns with the pin ion shaft When there is little resistance the input shaft tot don bar pinion shaft and the slider core turn together to the same angle The slider core does not move up down INTERFACE CIRCUIT TRANSFORME PINION GEAR When there is resistance on the input shaft hard to steer situation and the slider pin is turned at an angl...

Page 604: ...portionately with the rotational speed of the pinion When the steering direction is reversed the voltage is generated in the opposite direction No power is generated when driving straight ahead without turning the steering wheel Interface Circuit The interface circuit is housed inside the steering gearbox near the pinion It rectifies and amplifies the signals from the torque sensor and the rotatio...

Page 605: ... sensor 4 Determination of motor torque data from the prescribed assisting force map based on the car speed data steering rotational speed data and the steering torque data 5 Changeover of control modes and output of control signals to the power unit based on data on car speed direction of torque and rotational direction of steering Normal Control Mode The rotational direction of motor is determin...

Page 606: ...an over current flows to the motor and the power unit The control unit detects this and reduces the current flow to the motor Average Moving Current Control The electric current flow to the motor is estimated from the current values detected by the current sensor and the aver age current is obtained at two second intervals The motor driving current is suppressed when the average current value exce...

Page 607: ... mode to con trol the flow of current from the battery Steering FET FET FET FET condition I 2 3 4 Motor operation h ing to ON oFF oFF PWM Operates in direction steerrng to the rrght Straight ahead OFF OFF OFF OFF Stops St3tering to oFF ON PWM oFF Operates in direction steerrng to the left PWM in the table indicates PWM control based on CURRENT FEED BACK I I IT I GROND F A I L S A F E FET ISRIVE _ ...

Page 608: ... the steering wheel Recirculating Ball Screw The recirculating ball screw is constructed so that balls roll between the screw shaft and the nut and those coming out of the screw face enter the screw groove again through a tube for recirculation The rotation torque on the shaft is con verted into thrust in axial direction as the slope of the screw shaft presses against the nut throught balls Since ...

Page 609: ...I I I I I FET 2 83 b i ORNdA I I I I I I I IIII I I I IFET IO WHT LI I Llj I BLKlRED I F S RLY B6 b PNK II F s SLD GND2 pzi i3 BATTERY ALT L ERNATOR SCKE CONNECTOR PNKlBLU HEEL SPEED SENSOR A l 8 A 1 7 A l 8 A l 5 A l 4 A 1 3 A 1 2 A i l A10 A9 B12 Bli BID B9 B8 B7 B8 CONTROL UNIT CONNECTOR 17 40 ...

Page 610: ...S INDICATOR LIGHT ALTERNATOR 4 P CONNECTOR EPS CONTROL UNIT POWER UiUlT DASH FUSE B6X TORQUE SENSOR 6 P CONNECTOR STEERING WHEEL SPEED SENSOR 4 P CONNECTOR STEERING GEARBOX TORQUE SENSOR STEERING WHEEL SPEED SENSOR 17 41 ...

Page 611: ...he connector terminals 0 Make sure that the terminals are not bent or damaged in any way when a test harness is installed l A digital circuit tester must be used to perform the inspections An analog circuit tester must be used only when this procedure is indicated in the specification figures l The EPS system connector should not be disconnected except when necessary l Inspect the connection condi...

Page 612: ...PS INDICATOR LIGHT When the EPS control unit senses an abnormality in the system the control unit memorizes the problem the EPS indica tor light blinks at equal intervals and the power steering assist is turned off When the EPS indicator light has been reported on connect the two terminals of the service check connector with a jumper wire Then turn on the ignition switch and observe the blinking f...

Page 613: ...inks together to determine the problem code then refer to the Troubleshooting Chart on page 17 51 Example G 6 6 seconds 1 I seconds 0 36 seconds The control unit can memorize any number of simultaneous problems The problem codes are repeated sequentially be ginning with the lowest number The problem code is stored in the control unit memory even when the ignition switch is turned off After repairi...

Page 614: ... SL00200 STEERING GEARBOX Test Harness C 0 Pull the carpet back from the passenger s side and re move the power unit cover Disconnect the connector and connect test harness C POWER UNIT TEST HARNESS c 07MAZSL00300 Power Unit Checker 0 Pull the floor carpet back from the passenger s side and remove the power unit cover Disconnect the connector and connect the power unit checker 0 Remove the cigaret...

Page 615: ...ation standard I Condition Stationary swing operation load Without power 12 kg 24 46 lb assist engine off maximum With power assist 4 2 kg 9 26 lb engine running maximum 1 wheal alignment 1 Are they normal 1Y E S Correct the air pressure or wheel alignment Park the vehicle on a level surface 1 ahead with the wheels pointing straight 1 Measure the stationary swing operetion load Refer to the chart ...

Page 616: ... indicator light on 1YES NO Check the tire pressure wheel alignment and steering mechani cal system Refer to the Troubleshooting Chart see page 17 51 The EPS indicator light does not come on when the ignition switch is turned ON Turn the ignition switch ON I To page 17 48 cont d 17 47 ...

Page 617: ...Check the continuity between ter minals 82 and Al 1 and the body ground If continuity is present replace the EPS control unit If there is no continuity check the ground of terminals B2 and A 11 Replace the indicator light bulb Turn the ignition switch ON I Ground the No 8 PNK BLU ter minal of the 30 P gauge assembly connector to body PNKlBLU WIRE Is the EPS indicator light on Y E S The circuit in ...

Page 618: ...m see section 23 Y E S Stop the engine Short the service check connec tor and turn the ignition switch CONNECTOR ISLUI Is a problem code displayed 1NO Y E S Refer to the Troubleshooting Chart see page 17 51 Turn the ignition switch OFF SERVICE CHECK CONNECTOR SW Disconnect EPS control unit con nectors A and B I To pagi 17 50 I I cont d ...

Page 619: ... and Start the engine and check the voltage between the A9 terminal and body ground Is there more than 12 V IYES Repair open in the WHTlBLU wire between the EPS control unit and the alternator Check the EPS control unit pow er supply see page 17 59 If it is O K substitute a known good EPS control unit and recheck ...

Page 620: ... Related corn nents I it is c 5 0 0 0 0 0 0 0 0 I z z In T hl z I System indicated b f v 2 P t 0 AZ 8 E u 2 z 1 1 1 2 a 1Torque sensor VT VT2 0 1 Toraue sensor VT3 0 1Torque sensor WTA 0 Torque sensor REF 2 5 0 Steering wheel speed sensor 0 EPS Dower unit 0 0 0 __ 1 3 14 2 1 22 3 1 33 3 3L I 42 3 41 0 0 0 0 17 54 0 0 0 17 56 0 0 0 0 0 0 0 Power supply ECU ignition input 0 Speed sensor signal input...

Page 621: ...he chart on the right and A10 f 1 terminal Turn the steering wheel to the right and use the same method to check the voltage Chart of Standard Output Values I Test harness Standard Value V A terminal No Name Straight Turned to Turned to ahead the left the right Al6 VT 1 2 82rfO 55 1 f 0 25 I 0 25 A 6 WTz 2 2 82 0 55 2 0 25 2 0 25 A l 7 VTJ 3 2 5kO 30 1 3 f 2 5 3 2 5 A l 4 REF 2 5 2 52 0 1 7 2 5 k ...

Page 622: ...t on TEST HARNESS B O MAZ SL00200 fypJxpppJxd ly IO II 1213 1415161718 7 8 9 IO II 12 Terminal Test harness A Name terminal No Test harness B terminal No 12v A 7 3 VT1 A l 6 2 VT2 A6 1 VT3 Al7 5 REFZ 5 A l 4 4 GND A10 6 I N O Is there continuity I Repair in the wire with no con tinuity 1YES I Check the continuity on terminals A6 A7 A10 A14 A16andA17 individually to body ground Y E S Repair short i...

Page 623: ...tage between the A5 and A 15 terminals pJGJ 1011 12131415161718 7 8 9 IOII 12 Turn the steering wheel to the left and check the voltage between the A5 I and Al5 t f ter minals NOTE l Turn the steering wheel at an approx speed of 180 per secpnd l Use an analog tester Standard Output Values Steering wheel operation Standard Straight ahead o v Turned to the left Approx 0 1 V Turned to the right Appro...

Page 624: ...d rn the chart on theright Is there continuity Y E S Repair open in the wire with no continuity Check the continuity on terminals A5 and Al 5 individually to body ground TEST HARNES 07MAZ SL002 Is there continuity Repair short in the wire with con tinuity to body ground Faulty steering wheel angle sensor Replace the steering gearbox as sembly cont d ...

Page 625: ...the test harness A and C as indicated in the chart on the right I TEST HARNESS C 07MAZSL00300 PWRRLYI Bl 11 F E T 4 1 BE 4 F E T 3 1 B9 1 5 E F T 2 1 83 1 1 F E T 1 1 El0 1 2 VIS 812 6 VIS 84 6 SLO GND B7 9 I Is there continuity Repair open in the wire with no YES Check the continuity on terminals as indicated in the chart individu ally to body ground YES Repair short in the wire with con tinuity ...

Page 626: ...Remove the RED and BLU wires from the EPS motor on the steer ing gearbox Is there continuity 3 to the power unit terminals and I Is there battery voltag Y E S To page 17 58 Check for continuity RED and BLU wires individually to body ground Is there continuity N O Faulty EPS motor Replace the steering gearbox assembly Repair short in RED or BLU wire with continui ty to body ground wire between the ...

Page 627: ... page 17 54 Connect to the cigarette lighter POWER UNIT CHECKER 07MAZ SL00400 OUTPUT Connect CAUTION Be careful because the steering wheel will rotate if the FET drive switch is turned ON Power Unit Checker Operation Sequence VIS output of sequence 1 NOTE 0 When the steering wheel is turned to the left and right lock point in sequence 4 and 5 turn on the FET drive swtich 0 This operation must be c...

Page 628: ... Y E S Check the No 5 15 A fuse and replace if necessary Turn the ignition switch OFF TEST HARNESS A 07MAi SLOOl OO Connect test harness A to the wire harness only Turn the ignition switch ON Check the voltage between the A8 and All terminals of the test harness A Substitute a known good EPS control unit and recheck cont d 17 59 ...

Page 629: ...g see section 14 TEST HARNESS A Check the speed sensor signal Vo 07MAZSLOOIOO I Disconnect the 3 P connector from the speed sensor Check for continuity between the lVt teqG alof t h e 3 P connector and the Al 2 termi YELlRED A 1 21314 51617 8 9 1011 1 12 13 14 15 16 17 18 View from terminal side I A I N O Repair open in the YELlRED wire Is there continuity between the EPS control unit and Y E S sp...

Page 630: ... unit and recheck NOTE Do not connect the connec tor on the control unit side of test harness A Turn the ignition switch OFF TEST HARNESS A 07MAZ SLOOlOo 1 Remove the test harness A from the EPS control unit only Check for continuity between the A4 terminal of the test harness A and No 18 fPNK BLK terminal of the 22 P connector I rr 101112131415161718 7 8 9101112 I I PNK BLK WIRE Repair open in th...

Page 631: ...ing Flowcharts cont d Problem code 23 34 41 42 43 and 44 0 EPS control unit related problem Check for poor connections or loose wires at the EPS control unit If there is no abnormality replace the EPS control unit ...

Page 632: ...ng the gearbox check the wheel alignment and adjust if necessary POWER UNIT Replacement page 17 73 CONTROL UNIT Replacement page 17 74 I S T E E R I N G G E A R B O X STEERING WHEEL 1RBAG A S S E M B L Y _ I Removal Installation page 17 64 Illustrated Index page 17 68 Pinion Preload inspection page 17 69 Rack Guide Screw Adjustment page 17 69 Al Removal page I 1 8 Disassembly 1 m page I I Y I Inst...

Page 633: ...oint Be sure that the 12 mm hex nut is flush with the ball joint pin end or the threaded section of the ball joint pin might be damaged by the ball joint remover 7 Separate the tie rod ball joint and knuckle using the special tool CAUTION Avoid damaging the ball joint boot NOTE If necessary apply penetrating type lubricant to loosen the bail joint BALL JOINT REMOVER 0794y 6920003 r l CASTLE NUT 45...

Page 634: ...he steering shaft l After installing the gearbox check the wheel alignment and adjust if necessary CONTROL UNIT POWER UNIT Replacement page 17 73 Replacement page 17 74 I STEERING COLUMN Removal page 17 12 Inspection page 17 14 Installation page 17 15 STEERING GE Removal Installation page 17 64 AIRBAG ASSEMBLY Illustrated Index page 17 68 Removal page 17 8 Pinion Preload Inspection page 17 69 Disa...

Page 635: ... ball joint Be sure that the 12 mm hex nut is flush with the ball joint pin end or the threaded section of the ball joint pin might be damaged by the ball joint remover 7 Separate the tie rod ball joint and knuckle using the special tool CAUTION Avoid damaging the ball joint boot NOTE If necessary apply penetrating type lubricant to loosen the ball joint BALL JOINT REMOVER 0794 6920003 P 7 sr CAST...

Page 636: ...ound cable 14 Remove the terminal nuts and the wires from the gearbox terminals TERMINAL NUTS 1 0 kg m 7 lb ft NOTE After tight ening the terminal nuts bend up the terminal tabs against the nuts securely TERMINAL GUARD 15 Remove the radiator pipe bracket at the firewall RADIATOR PIPE 16 Remove the radiator pipe bracket at the floor and space the radiator pipe away from and gearbox RADIATOR PIPE co...

Page 637: ...g m 43 Gearbox to FI cross beam QlOx6B mm FLANGE BOLT 60N m lb ft ont RIGHT SIDED 6 0 kg m 43 lb ft Front cross beam to cross beam bracket AlOxB4mm FLANGE BOLT 60N m 6 0 kg m 43 lb ft Gearbox to Front cross beam 10x66 mm FLANGE BOLT 60N m 6 0 kg m 43 lb ft Front cross beam to cross beam bracket 18 Lower the gearbox and cross beam with care so as not to interfere with the radiator pipe NOTE The cro...

Page 638: ...After installation turn the ignition switch ON and check the Electrical Power Steering warning light for operation Check and adjust the wheel alignment Section 18 l Turn on the ignition to II the instrument panel SRS warning light should go on for about 6 se conds and then go off l Confirm operation of horn buttons l Confirm operation of cruise control set resume switch l Turn the steering wheel c...

Page 639: ...t 610x97 mm FLANGE BOLT 60N m 6 0 kg m 43 lb MOUNT BASE SiEERlNG GROMMET Check for damage lOmmNU 60N m 6 0 kg m 43 lb ft R E HARNESS ST MOUNT COLLER I A I a A GROUND CABLE 3 lb ft ftj MUUIY I DU3llllUU Check for damage STOP WASHER BOOT BAND CASTLE NUT 45N m 4 5 kg m 33 lb ft COTTER PIN Replace STEERING GREASE Honda P N 08733 B070E Coat the inside of the boot x 1 ROD SILICONE GREASE LOCKNUT Coat th...

Page 640: ...cylinder until the end of the rack projects 60 mm 2 34 in from the cylinder end Inspection is made near this rack position Install the special tool on the pinion shaft and check the preload with a spring scale If the preload is out of the specification adjust the rack guide Preload 30N 3 kg 6 6 lb1 60 mm 2 34 in STEERING INSPECTION ARM 07974 SD90 OOO l Rack guide screw adjustment Remove the rack g...

Page 641: ...ng formulas AI A B Y Y x Actual torque X X Torque wrench reading 40 mm LOCKNUT WRENCH 07MAA SLOOIOA Actual 25N m 2 5 kg m 18 lb ft Indicated 19N m 1 9 kg m 14 lb ft Tool length 8 15 cm 6 in 40 mm LOCKNUT WRENCH 07MAA SLOO 1 OA Tie rod installation 5 Screw each rack end into the rack while holding the lock washer so its tabs are in the slots in the rack end NOTE Install the stopper washer with the ...

Page 642: ...e sliding surface of the rack end 8 Install the new boot bands on the boot and bend both sets of locking tabs Lightly tap on the doubled portions to reduce their height NOTE After assembling slide the rack right and left to be certain that the boots are not deformed or twisted LOCKING TABS BOOT BAND 9 If the tie rod ends were removed install the tie rods on the right and left rack ends and screw t...

Page 643: ...tapered section of the ball pin l Do not allow dust dirt or her foreign materi als to enter the boot L PIN TAPERED TION BOOT INSTALLATION SECTION 4 Install the boot in the groove of the boot installation section securely then bleed air 5 Insert the special tool into the threads in the ball pin and align the end of the tool with the groove in the boot Slide the clip over the tool and into position ...

Page 644: ...move the power unit bracket Remove the terminal nuts and disconnect the cables from the power unit terminals TERMINAL NUT IO N m 1 O kg m 7 lb ft 5 Remove the power unit by disconnecting the con nector 10N m 1 O kg m 7 lb ft 10i m I 1 0 kg m POWER 7 lb ft UNIT Installation is the reverse order of removal NOTE Turn the ignition switch ON and check the EPS warning light for operation I 17 73 ...

Page 645: ...ER DUCT 3 Disconnect the connectors from the control unit by removing the wire harness band CONTROL UNIT 4 Remove the power window control unit by pulling it toward you then remove the control unit e POWER WINDOW CONTROL 10LIl 1 0 kg m 7 lb ftl UNIT Installation is the reverse order of removal NOTE Turn the ignition switch ON and check the EPS warning light for operation ...

Page 646: ...Specification 18 14 Hub Replacement 18 l 5 Illustrated Index 18 20 Knuckle Control Arms Compliance Pivot Removal 18 2 1 Ball Joint Boot Replacement 18 25 Front Damper Removal 18 24 Disassembly Inspection 18 27 Reassembly 18 28 Installation 18 28 Rear Suspension Torque Specification 18 29 Hub Replacement 18 30 Illustrated Index 18 34 Knuckle Control Arms Removal 18 35 Ball Joint Boot Replacement 18...

Page 647: ...int Boot Clip Guide 0 07MAB SLOOI 00 Front Hub Holder 8 07MAC SL09100 Ball Joint Remover 0 07MAG SLOO200 Bali Joint Boot Clip Guide 8 07941 6920003 Ball Joint Remover 0 07965 SD90100 Hub Dis Assembly Base 07974 SA50800 Ball Joint Boot Clip Guide O ty Page Reference 1 18 32 3 3 1 18 18 3 3 2 18 18 3 2 1 18 38 1 18 17 19 1 18 21 22 23 36 1 18 25 1 18 21 3 5 1 18 18 3 3 1 18 38 c 3 0 0 0 0 0 0 0 0 0 ...

Page 648: ...PENSION ASSEMBLY l Knuckle Control Arms Compliance Pivot Removal page 18 21 l Illustrated Index page 18 20 l Ball Joint Boot Replacement page 18 25 Installation page 18 28 Disposal page 18 43 0 Rear Suspension HUB ment page 18 l 5 REAR DAMPER Removal page 18 39 Disassembly Inspection page 18 40 Reassembly page 18 42 Installation page 18 42 Disposal page 18 43 page 18 30 REAR SUSPENSION ASSEMBLY l ...

Page 649: ...and improved ride It also allows the individual suspension components to be designed in detail for maximum strength and rigidity FRONT STABILIZER LOWER CONiROL ARM w REAR UPPER CONTROL A R M LOWER CONTROi ARM i To further increase suspension link rigidity and to obtain optimum knuckle geometry the knuckles and ball joints are con tained within the wheel profile At each corner of the car the indivi...

Page 650: ...eel to move rearward by a controlled amount thus absorbing energy The result is an outstanding ride quality with only minimal changes to track width and wheel geometry In Corning the compliance pivot does not come into play and the lateral suspension stiffness required for maximum roadholding and optimum control response is maintained Rear Toe Control Arm Many conventional passenger car independen...

Page 651: ...ht and left to check for wobbling 0 Check the height of each suspension see below Standard value Tire size Tire pressure psi kpa Standard height mm in empty car1 Front Rear 205150 ZRI 5 33 230 170 180 mm 6 7 7 1 in 225 50 ZRI 6 40 275 213 223 mm 8 4 8 9 in Front Ground clearance to the center of the lower control arm bolt Rear Ground clearance to the center of the toe con trol arm bolt Height insp...

Page 652: ...adjusted for camber caster front only and toe However because each of them relates to the other the camber changes when the toe is adjusted for example Therefore the total adjustment of the front rear wheel alignment is required whenever either one of the elements i e camber caster or the toe is adjusted Front wheel alignment adjusting procedure Check the ride height 1 Measure camber 1 1 1 1Adjust...

Page 653: ...eck the tire pressure and ride height as described on page 18 6 3 Center the steering wheel Toe 1 Measure the lelpgth of the threaded section on the right and left r ck ends Standard 11 mm for shoulder Difference between right and left 1 mm max 2 If the measurement is out of the specification loosen the locknut and adjust properly _ LOCKNUT 44 Nom 4 4 kg m 32 lb ft Camber 1 Loosen the locknut on t...

Page 654: ...e at the same time on one side of the car Repeat for the other side of the car NOTE 0 One graduation on the camber adjusting cam equals approximately 10 minutes of camber change 0 One full turn of the tie rod equals approximately 8 mm 6 Measure the caster according to the alignment equipment manufacture s instructions 7 Adjust the caster NOTE One graduation on the caster adjusting cam equals appro...

Page 655: ...one of the turning radius gauges then lower the car NOTE Be sure that the car is parallel to the ground with the wheels on the turning radius gauges and boards Remove the lock pin on the gauge Turn the steering wheel fully to the right and left while applying the brake and measure the turning angle of both wheels Turning angle inward 33OO6 2O Outward 26 34 Reference value TURNIG RAblUS GAUGE 3 If ...

Page 656: ...m Rear Wheel Alignment Adjusting Procedure Rear wheel alignment adjusting procedure Check the ride height 1 Measure camber and toe 1 1 Adjust camber I 1 Adjust toe cont d 1841 ...

Page 657: ...ngth of the threaded section on the right and left toe control arms Standard 40 mm Difference between right and left 1 mm max 2 If the measurement is out of the specification loosen the locknut and adjust properly Loosen the nuts 40 Nom 4 0 kg m 29 lb ft 2 Mark the arm in the position which aligns with the dial center of the adjusting cam Graduation in contact with groove wall GROOVE WALL Loosen t...

Page 658: ... Front and Rear Wheel Axial Runout Standard O O 7 mm O 0 028 in1 Front and Rear Wheel Radial Runout Standard O O 7 mm O 0 028 in Turn the wheel slowly by hand and check for excessive axial and radial runout Bearing End Play Front Wheel End Play Standard 0 mm 0 in Service limit 0 05 mm 0 002 in max Replace Rear Wheel End Play Standard 0 mm 0 in Service limit 0 05 mm 0 002 in max Replace w 13 ...

Page 659: ...SELF LOCKING NUT h lOx1 25mm 44 N m 4 4 kg m 32 lb ft Replace FLANGE BOLT 10 x 1 25 mm 60 Nom 6 0 kg m 43 lb ft ft CASTLE NUT 1 2 x 1 25 mm 60 Nom 6 0 kg m 43 lb ft SELF LOCKING NUT 1 2 x 1 25 mm l m 12 5 kg m 90 lb ft 0 CASTLE NUT 12 x 1 25 mm 60 N m 6 0 kg m 43 lb ft I I SELF LOCKING NUl SELF LOCKING NUTS l 2 x 1 25 mm 1 12x 1 25mm FLANGE BO 10x 1 25mm 60 N m 6 0 kg m Q SELF LOCK1 Sr FLANGE BOLT...

Page 660: ...t the point you are going to pry because aluminum alloy wheels can be easily damaged Corrosion resistant bolt nut SELF LOCKING NUT 10 x 1 25 mm Replace 65 N m 16 5 ka m 47 lb ft 2 6 x 1 5mm 335 Nom 33 5 kg 242 lb ft NOTE After tightening use a drift to stake the spindle nut shoulder against HUB BEARING ASSEMBLY Inspect for faulty movement and wear Reolacement oaae 18 l 7 I FRONT HUB Check for dama...

Page 661: ...istant bolt nut 7 lb ft 5 Remove the speed sensor from the knuckle and front lower control arm but do not disconnect it NOTE Be careful when installing the sensors to avoid twisting wires IO N m II O kg m 7 lb ft ftl b Corrosion resistant bolt nut 6 Remove the caliper bracket mounting bolts and hang the caliper assembly to one side CAUTION To prevent accidental damago to the caliper assembly or br...

Page 662: ...om the knuckle 3 SELF LOCKING NUT 4 10x 1 25mm Replace 65 N m 6 5 kg m 47 lb ft 1 FRONT fiU8 UNIT Corrosion resistant bolt nut 1 2 Attach the special tool to the hub and tighten the nuts then set the special tool in a vise and secure it Pry the spindle nut stake away from the spindle then remove the spindle nut SPINDLE NUT 26 x 1 5 mm Un stake FRONT HUB HOLDER 07MAB SLOOlOO Remove the special tool...

Page 663: ...y available bearing puller CAUTION To prevent damage to the tool make sure the threads are fully engaged before pressing NOTE Wash the bearing and hub thoroughly in high flash point solvent before reassembly NOTE Replace the bearing with a new one after removal 7 Press a new wheel bearing into the hub using the special tools shown and a hydraulic press HUB ASSEMBLY DRIVER ATTACHMENT 07GAF SD4t200 ...

Page 664: ... vise and secure it 10 Tighten the new spindle nut to specified torque then stake the spindle nut shoulder against the spindle 335 N m 33 5 kg m 242 lb ft After tightening use a drift to stake spindle nut shoulder against the spindle FRONT HUB HOLDER 07MAB SLOOIOO 11 Remove the special tool ...

Page 665: ...UPPER CONTROL ARM Check for damage or cracks T _ II y Ly I Check for damage or cracks Check for deterioration or damage i I I jI UPPER ARM BALL JOINT Inspect for faulty movement and w e a r COMPLIANCE PIVOT LOWER BRACKET Check for damage or cracks FRONT KNUCKLE Check for damage I LOWER CONTROL ARM Check for damage or cracks LOWER LOWER CONTLOL ARM BALL JOINT Inspect for faulty movement and wear BA...

Page 666: ...cant to loosen the ball joint Q CASTLE NUT BALL JOINT REMOVER 55 N m 07941 6920003 15 5 ka m 40 lb ft I PIN 7 8 9 Replace On reassembly bend the pin as shown Corrosion resistant bolt nut Remove the cotter pin and lower control arm ball joint nut Install the 12 mm hex nut on the ball joint Be sure that the 12 mm hex nut is flush with the ball joint pin end or the threaded section of the ball joint ...

Page 667: ... Avoid damaging the ball joint boot NOTE If necessary apply penetrating type lubri cant to loosen the ball joint d COTTER PIN Replace On reassemblv BALL JOINT REMOVER 07MAC SLOOlOO I bend the cot pin as shown I I CASTLE NUT 12x 1 25mm 60 Nom Corrosion resistant bolt nut 13 Remove the knuckle assembly KNU CKLE ASSEMBLY 14 Separate the lower control arm and damper by removing the damper mounting bol...

Page 668: ...esh grease 5 Insert the new retainer lightly into the ball joint pin NOTE When installing the ball joint press the re tainer into the ball joint pin BALL PIN TAPERED SECTION BOOT INS SECTION TAL RETAINER CAUTION l Keep grease off the boot installation section and the tapered section of the ball pin l Do not allow dust dirt or other foreign materials to enter the boot 6 Install the boot in the groo...

Page 669: ...nufacturer s instruc tions then remove the self locking nut CAUTION Do not compress the spring more than necessary to remove the nut LOCKING NUT 10 x 1 25 mm Replace COMMERCIALLY AVAILABLE 2 Remove the spring compressor then disassemble the damper as shown on the next page Inspection 1 2 3 4 Reassemble all parts except the spring Push on the damper assembly as shown Check for smooth operation thro...

Page 670: ...r weakness compression or damage DAMPER PLATE STOP BUMP S TOP BUMP S TOP Check for weakness or Check for weakness or damage damage DENT in DAMPER UNIT l Check for leaks and faulty operation l Check for rust l Disposal page 18 43 3 8 mm FLANGE NUT 13 Nom 1 3 kg m B lb ft I I d aJ BRAtiE HOSE BRACKET NOTE Align the brake hose bracket bolt with the dent in the damper and loosely tighten the brake hos...

Page 671: ...d tighten the 10 mm self locking nut 30 Nom 3 0 kg m 22 lb ftl 1 Reposition the damper on the frame with the weld ed nut of the hose bracket facing outside as shown tr DAMPER MOUNTING BOLT 2 install the damper end on the lower arm and loosely tighten the mounting nut NOTE The bolts and nuts should be tightened with the vehicle s weight on the damper 3 Secure the damper mounting bolt using a new se...

Page 672: ...KING NUT 10x 1 25mm sr FLANGE BOLT 12x1 25mm 95 Nom 9 5 kg m 69 lb ft I Replace 54 Nom 5 4 kg m 39 lb ft CASTLE NUT 10 x 1 25 mm SELF LOCKING NUT 14x 1 5mm 44 N m 4 4 kg m 32 lb ft Replace 125 N m 12 5 kg m 90 lb ft CASTLE N U T 12 x 1 25 mm 60 N m FLANGE BOLTS 6 0 kg m 43 lb ft 10 x 1 25 60 N m 6 0 kg m 43 lb ft SPiNDLE NUT 26x 1 5mm FLANGE BOLT 12 x 1 25 mm __ 9 5 kg m 69 lb ft Q CALIPER BRACKET...

Page 673: ...Before installing the wheel clean the mating surfaces of the brake disc and inside of the wheel CAUTION Use a rag at the poini you are goint to pry because aluminum allov wheels can be easilv darhaaed 47 lb ft Y FLANGE B oLT IO x 1 25 mm Replace 66 Nom 6 5 kg m HUB BEARING ASSEMBLY KNUCKLE Inspect for faulty movement and wear Replacement page 18 32 s I 11 111 10 N m 1 0 kg m Replackment page 18 32...

Page 674: ...nd rear lower control arm but do not disconnect it NOTE Be careful when installing the sensors to avoid twisting wires SPEED SENSOR a Corrosion resistant bolt nut 10 1 O kg m 7 lb ft 6 Remove the banjo bolt and disconnect the brake hose then remove the brake hose clamp from the knuckle CAUTION Avoid spilling brake fluid on painted plastic or rubber surfaces as it can damage the finish Wash spilled...

Page 675: ...lt nut Rear Wheels Bearing Replacement 1 Separate the wheel bearing from the hub using the special tools and a hydraulic press CAUTION 0 Hold onto the hub to keep it from failing when pressed clear Hydraulic press DIS ASSEMBLY HUB DlSlASSEMBLY EEL BEARING HljB 2 Remove the outboard bearing inner race from the hub using the a commercially available bearing puller CAUTION To prevent damage to the to...

Page 676: ...s a new wheel bearing into the hub using the special tools shown and a hydraulic press Hydraulic press HUB ASSEMBLY DRIVER ATTACHMENT 07GAF SD40200 WHEEL BEARING HUB D SSEMBLE H DlSlASSEMBLY PIN BASE 07GAF SD40100 07965 SD90100 4 Install in reverse order of removal a ...

Page 677: ...spect for faulty I fl STABILIZER BAR Check for damage FLANGE BOLTS REAR KNUCKLE Check for damage or cracks LOWER CONTROL BALL JOINT lnsoect for faultv movement 6x1 25mm 23 N m 2 3 kg m 17 lb ftl TOE CONTROL ARM BUSH Check for deterioration or damage a n d w e a r I LOWER CONTROL ARM Check for damage or cracks TOE CONTROL ARM Check for damage or cracks BALL JOINT Inspect for faulty movement and wea...

Page 678: ...toe control arm as shown and separate the toe control arm CAUTION Be careful boot not to damage the ball joint COlTER PIN Replace On reassemblv CASTLE NUT 10 x 1 25 mm 44 Nom 4 4 kg m 32 lb ft bend the cotter pin as shown BALL JOINT REMOVER 07941 6920003 TOE C bNTROL ARM Q Corrosion resistant bolt nut 6 Hold the stabilizer link with the wrench and remove the damper mounting nut Q DAMPER MOUNTING N...

Page 679: ...t b 11 Remove the cotter pin from the castle nut of the upper control arm ball joint and remove the nut 12 Install the 12 mm hex nut on the ball joint Be sure that the 12 mm hex nut is flush with the ball joint pin end or the threaded section of the ball joint pin might be damaged by the ball joint remover 13 Position the special tool between the knuckle and upper control arm as shown CAUTION Be c...

Page 680: ...e 125 N m 12 5 kg m 90 lb ft LOWER CONTROL ARM ASSEMBLY a 17 Remove the upper control arm by removing the flange bolts UPPER CON TROL ARM ASSEMBLY FLANGE BOLT 10x 1 25mm 60 N m 6 0 kg m 43 lb ft a Corrosion resistant bolt nut 18 Remove the toe control arm FLANGE BOLT 12x 1 25mm 95 Nom 9 5 kg m 69 lb ft TOE CONTROL A M ASSEMBLY CAUTION Make sure that the reference marks on the toe control arm are a...

Page 681: ... BOOT INSTAL iATlON SECTION CAUTION Do not contaminate the boot installa tion section with grease BALL PIti TAPERED SECTION RETAINER INSTALL O N ATION CAUTION 0 Keep grease off the boot installation section and the tapered section of the ball pin 0 Do not allow dust dirt or other foreign materials to enter the boot 6 Install the boot in the groove of the boot installation section securely then ble...

Page 682: ...LF LOCKING NUT 10 x 1 25 mm Replace Corrosion resistant bolt nut 5 Hold the stabilizer link with a wrench and remove the damper mounting nut DAMPER MOUNTING NUT 12 x 1 25 mm Replace Corrosion resistant bolt nut 6 Remove the stabilizer link from the stabilizer bar and knuckle 7 Remove the rear damper assembly SELF LOCKING NUT 12 x 1 25 mm Replace STAtilLlZER LINK r Corrosion resistant bolt nut 18 3...

Page 683: ... 10 mm Replace AVAILABLE Remove the spring compressor and disassembly the damper as shown on page 18 41 Insoection I Reassemble all parts except the spring 2 Push on the damper assembly as shown 3 Check for smooth operation through a full stroke both compression and extension NOTE The damper should move smoothly If it does not no compression or no extension then gas is leaking and the damper shoul...

Page 684: ... MOUNTING RUBBER SPRING M NTING RUBBER Check for damage or crack DAMPER SPiiNG Check for weakened compression or damage Corrosion resistant bolt nut BASE BUMP S6 PLATE BUMP STOP PLATE DUST COVER SLEEVE BUMP S OP Check for weakness or damage DAMPER UNIT l Check for oil leak or faulty operation l Check for rust l Disposal page 18 43 f8 41 a ...

Page 685: ... damper mounting rubber and damper mounting washer and loosely install a new 10 mm self locking nut Hold the damper shaft and tighten the 10 mm self locking nut 30 N m 13 0 kg m 22 lb ft Installation 1 Reposition the damper assemble between the frame and knuckle 2 Install the stabilizer link and connect the stabilizer bar 3 Loosely tighten the new self locking nut I SELF LOCKING NUT 12 x 1 25 mm 8...

Page 686: ...self locking nuts 9 InstalMhe rear hatch glass garnish TAPPING SCREW REAR HATCH GL GARNISH ASS m The dampers contain nitrogen gas and oil under pressure The pressure must be relieved before disposal to pre vent explosion and possible injury when scrapping Place the damper on a level surface with its rod extend ed and drill a hole of 2 3 mm 0 078 0 118 in diameter in the body to release the gas Fro...

Page 687: ...e be done by an authorized Acura dealer 0 To avoid rendering the SRS inoperative which can lead to personal injury or death in the event of a severe frontal collision all maintenance must be performed by an authorized Acura dealer 0 Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the airbag 0 All SRS ele...

Page 688: ...19 20 Rear Caliper Disassembly 19 20 Reassembly 19 23 Brake Hoses Pipes 19 26 Parking Brake 19 27 ALB Description Features Construction Operation 19 28 Circuit Diagram 19 38 Wiring Connector Location 19 40 ALB Checker Function Test 19 41 Wheel Sensor Signal Confirmation 19 43 Troubleshooting Anti Lock Brake System Indicator Light 19 44 Symptom to System Chart 19 46 Flowcharts 19 47 Hydraulic Syste...

Page 689: ...AA SGOOIOO or Bleeder T Wrench 1 19 62 6 9 07HAA SG00101 0 07HAE SGOOI 00 Brake Spring Compressor 1 19 21 2 4 0 07JAG SD40100 Pushrod Adjustment Gauge 1 19 15 07HAJ SGOOIOO ALB Checker US 1 19 41 43 6 9 07HAJ SG00200 ALB Checker Canada 1 19 41 43 6 9 0 07KAZ OOIOOOA Window Switch 1 19 65 13 NOTE Use 07HAJ SGOOI 00 US or 07HAJ SG00200 Canada ALB Checker only a 19 2 ...

Page 690: ...or or it may explode severe personal injury may result HYDRAULIC SYSTEM Relieving Accumulator MASTER CYLINDER Index Torque page 19 I 2 inspection page 19 l 3 BRAKE BOOSTER Tests page 19 l 3 14 Pushrod clearance adjustment Index Torque page 19 67 b MODULAT R SOLENOID UNIT m n a eg 72 Index Torque page 19 63 Solenoid Leak Test page 19 64 19 3 ...

Page 691: ...y CAUTION Check that the brake lights go off when the pedal is released Brake Pedal Play Inspection END Stop the engine and inspect the play by pushing the pedal by hand Brake Pedal Play 1 5 mm l 16 13 64 in NOTE Do not adjust the pedal height with the pushrod depressed CAUTION If the pedal free play is out of specifica tion brake drag may occur 2 3 4 5 6 7 ADLUSTING NUT NOTE After rear brake cali...

Page 692: ...the hose joints with rags or shop towels 0 Clean all parts in brake fluid and air dry blow out all passages with compressed air 0 Before reassembling check that all parts are free of dust and other foreign particles 0 Replace parts with new ones whenever specified to do so 0 Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid 0 Do not mix different brands of brake f...

Page 693: ... greater pedal stroke immediately after the brake pads have been replaced as a set Several applica tions of the brake pedal will restore the normal pedal stroke BtiAKE PADS 3 Remove the two brake hose bracket bolts Remove the two caliper bolts and move the caliper out of the way CAUTION Support the caliper with a piece of wire so that it does not hang from the brake hose CALIPER BOLTS BRAKE HOSE B...

Page 694: ...pe excess grease off the shims 10 Install the brake pad shims correctly WEAR INDICATOR INNER PAD SHIMS I OUTER PAD INNER PAD 11 Push in the pistons so that the caliper will fit over the pads 12 Set the caliper down into position then install the brake hose bracket bolts and the caliper bolts Tighten the bolts to the specified torque CALIPER BRACKET BOLTS 10 x 1 0 mm FLANGE BOLT 50 Nom 5 0 kg m 36 ...

Page 695: ...ately with water 1 Remove the banjo bolt and disconnect the brake hose from the caliper 2 Remove the caliper bolts then remove the caliper BANJO BOLT CALIPER BOLTS 3 Remove the pad spring from the caliper body PAD SPRING 4 If necessary apply compressed air to the caliper fluid inlet to get the pistons out Place a shop rag or wooden block as shown to cushion the pistons when there are expelled Use ...

Page 696: ...grooves PISTON 4 Lubricate the caliper cylinders and pistons with brake fluid then install the pistons in the cylinders with the dished end facing in PISTONS 5 Reinstall the caliper in the reverse order of removal m Always reinstall the brake pads in their original positions to prevent loss of braking efficiency 6 Fill the brake reservoir up and bleed the brake system page 19 101 Front Brake Disc ...

Page 697: ...ake sure no dirt or other foreign matter is allowed to contaminate the brake fluid l Do not mix different brands of brake fluid as they may not be compatible 0 Do not spill brake fluid on the car it may damage the paint if brake fluid does contact the paint wash it off immediately with water NOTE The reservoir on the master cylinder must be full at the start of bleeding procedure and checked after...

Page 698: ...9 Nom 0 9 kg m 7 lb ft REAR 9 Nom 0 9 kg m 7 lb ft ...

Page 699: ...age 19 15 I I 8 x 1 25 mm 13 N m I 3 kg m 9 lb ft I MASTER CYLINDER Inspection page 19 I 3 12 x 1 0 I I I 19 Nom 1 9 Master Cylinder and Brake Booster Index Torque To Modulator w _ I 11 I I Solenoid Unit 19 12 8x i 25mm 15 Nom 1 5 kg m 11 lb f t IO x l O mm 19 N m 1 9 kg m 14 lb ft ...

Page 700: ...the master cylinder assembly Replace the master cylinder assembly with a new part if necessary 0 Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid 0 Do not mix different brands of brake fluid as they may not be compatible 0 Do not reuse the drained fluid Use only clean DOT3 or 4 Brake fluid l When connecting the brake pipes make sure that there is no interference ...

Page 701: ...ary while depressed for 30 seconds the vacuum booster is OK If the pedal rises the booster is faulty CAUTION Do not try to disassemble the booster Replace the booster assembly with a new one With the engine stopped depress the brake pedal several times using normal pressure When the pedal is first depressed it should be low On con secutive applications pedal height should gradual ly rise If the pe...

Page 702: ...djusting nut as shown Clearance O O 4 mm O 0 016 in Preferred O O 2 mm O 0 008 in VACUUM GAUGE Commercially 15 N m 1 5 kg m 11 lb ft Available FEELER O 30 in Hg ADJUSTER LOCKNUT 7 Tighten the star locknut securely Remove the special tool and install a new master cylinder rod seal in the booster STAR LOCKNUT 22 N m 2 2 kg m 16 lb ft PUSHROD ADJUSTMENT GAUGE 07JAG SD401 OO O O 4 mm O 0 016 in O O 2 ...

Page 703: ...uid 0 Do not mix different brands of brake fluid as they may not be compatible 0 Do not reuse the drained fluid Use only clean DOT3 or 4 Brake fluid NOTE 0 Coat piston piston seal and caliper bore with clean brake fluid 0 Reolace all rubber parts with new ones ever disassembled I2 x 1 25 when 110 Nom 11 kg m 80 lb ft PIN BOOT Check for deterioration or damage CALIPER BRACKET C h e c k f o r 10 mm ...

Page 704: ...om the arm CLEVIS A CABLE CLIP PARKING BRAKE CABLE 4 Remove the two caliper mounting bolts and the caliper from the bracket CAUTION l Thoroughly clean the outside of the caliper to prevent dust and dirt from entering inside 0 Support the caliper with a piece of wire so that it does not hang from the brake hose CALIPER MOUNTING BOLTS If lining thickness is less than service limit at step 6 replace ...

Page 705: ...reinstall the brake pads in their original positions to prevent loss of braking efficiency l A contaminated brake discs or pads reduces stopping ability Keep grease off the discs and pads NOTE 0 Apply a Molykote 77 to the shims page 1 Q l 6 Wipe excess grease off the shims 0 Install the inner pad with its wear indicator fac ing upward 0 Make sure that the pad spring is installed onto the caliper b...

Page 706: ... Inspection 1 2 3 4 5 Raise each side of the car and support on safety stands page l 6 through 81 Remove the rear wheels Remove the brake pads page 19 l 7 Inspect the disc surface for grooves cracks and rust Clean the disc thoroughly and remove all rust Use suitable nuts I 2 x 1 5 mm and plain washers to hold the disc securely against the hub then mount a dial indicator as shown Brake Disc Runout ...

Page 707: ...he rotor Disassembly CAUTION 0 Make sure all parts are clean before reassembly 0 Use only new replacement parts l Use only DOT3 or 4 clean brake fluid l Do not allow dirt or other foreign matter to con taminate the brake fluid l Do not mix different brands of brake fluid l Avoid spilling brake fluid on painted plastic or rubber surfaces as it can damage the finish Wash spilled brake fluid off imme...

Page 708: ...STbN SEAL 9 Adjust the special tool as shown 95 mm 3 74 in BRAKE SPRING COMPRESSOR 07HAE SGOOIOO 10 Install the special tool between the caliper body and spring guide as shown 11 Compress the adjusting spring B by turning the shaft of the special tool then remove the retaining ring with snap ring pliers RETAINING RING SNAP RING PLIERS 07914 SA50001 BRAKE SPRING COMPRESSOR 07HAE SGOOIOO cont d 19 2...

Page 709: ...g spring B spacer bearing A and cup from the adjusting bolt ADJUSTING BEARING A BOLT ADJUSTING BOLT 14 Remove the sleeve piston and remove the pin from the cam CAM SLEEVE PISTON 15 Remove the return spring parking nut lock washer lever cam and cam boot RETURN SPRING LOCK a WASHER PARKING NUT LEVER ...

Page 710: ...mercially available assembly lube and install in the caliper 3 Install the cam with threaded end facing up CAUTION 0 Avoid damaging the cam boot since it must be installed before the cam 0 When installing the cam do not allow the cam boot lips to turn outside in CAM Assembly lube I NEEDLE ROLLER BEARING 4 Install the lever lock washer and parking nut then tighten the parking nut 5 Install the retu...

Page 711: ...taining ring then remove the brake spr ing the spacer ing compressor ADJUSTING BOLT BEARING A I CUP I ADJUSTING SPRING B SPRlliUG COVER ADJUSTING BOLT 11 Adjust the special tool as shown 95 mm 3 74 in BRAKE SPRING COMPRESSOR 07HEA SGOOIOO 12 Install the special tool as shown 13 Compress the spring until it bottoms out NOTE Check that the retaining ring is seated in the groove properly SNAP RING PL...

Page 712: ...ke pads 20 Install the pad spring on the caliper 21 Install the caliper on the caliper bracket and tighten the caliper mounting bolts 22 Connect the brake hose to the caliper with new sealing washers and tighten the banjo bolt 23 Connect the parking brake cable to the arm on the caliper 24 Fill the brake reservoir up and bleed the brake system page 19 l 0 25 Operate the brake pedal several times t...

Page 713: ...es 3 Check for leaks at hose and line joints or connections and retighten if necessary CAUTION Replace the brake hose clip whenever the brake hose is serviced BRAKE HOSE TO CALIPER MASTER CYLINDER TO LINE 19 N m 1 9 kg m 14 lb ft BLEED SCREW 9 N m 0 9 kg m 7 lb ftl 15 N m I 5 kg m BRAKE HOSE TO CALIPER 35 Nom 3 5 kg m 25 lb ft BRAKE HOSE 6 WAY JOINT 19 N m 1 9 kg m 14 lb ft 19 26 ...

Page 714: ...NG BRAKE LEVER Check for smooth opera tion 8x l Omm 22 Nom 2 2 kg m 16 lb ftl CLEVIS PIN SWITCH I e6iiL Sliding surface Check for faulty movement ADJUSTING I EQUALIZER 3 8xl Omm 22 N m 2 2 kg m 16 lb ft 22 N m 2 2 kg m LOCK PIN 16 lb ft BRAdKET Check for faulty movement 19 27 ...

Page 715: ...ur wheels The system has a fail safe function that allows normal braking if there s a problem with the anti lock brake system 0 DIFFERENCES BETWEEN THE 3 CHANNEL AND 4 CHANNEL ANTI LOCK BRAKE SYSTEM Items 3 Channel 4 Channel Gear Pulser Front 50 Front 47 Rear 50 Rear 50 Control Unit 12 and 18 pins 18 and 20 pins Modulator Solenoid 4 Pistons 4 Pistons Unit 3 Solenoid Valves 4 Solenoid Valves I Serv...

Page 716: ...g movement of the primary piston is provided at the side of the master cylinder body A reed switch for detecting the brake fluid volume is also provided on the cap of the reservoir tank 2 Operation When the brake pedal is depressed the secondary piston is pushed through the brake booster and the center valve B is closed so that the fluid pressure is generated on the secondary side At the same time...

Page 717: ... spring until the end hits on the cylinder the braking is per formed by the fluid pressure on the secondary side 2 In case of leaking from the secondary system PRIMARY SECONDARY PISTON u v w u AR RIGHT FRONT LEFT The secondary piston does not produce fluid pressure keeps moving ahead hits on the end surface of the primary piston so that the primary piston is pushed under the same condition as an o...

Page 718: ...wheel rear wheel outboard joint of the driveshaft front hub bearing unit turn the magnetic flux around the coil in the speed sensor alternates generating voltages with frequency in proportion to wheel rotating speed These pulses are inputted into the control unit and the control unit identifies the wheel speeds PERMANENT MAGNET ad OUTPUT t GEAR PULSER at HIGH SPEED VOLTAGE OW SPEED I SPEED SENSOR ...

Page 719: ... h 6 mph the self diagnosis function monitors the main system functions When an abnormality is detected the anti lock brake system indicator light goes on There is also a check mode of the self diagnosis system itself when the ignition switch is first turned on the anti lock brake system indicator light comes on and stays on for a few seconds after the engine starts to signify that the self diagno...

Page 720: ...t and outlet valves are integrated in the solenoid valve unit SOLENOID VALVE MODULATOR PISTON Accumulator The accumulator is a pneumatic type which accumulates high pressure brake fluid fed from the pump incorporated in the power unit When the anti lock brake system operates the accumulator feeds high pressure brake fluid to the modulator valve via the inlet side of the solenoid valve PRESSURE SWl...

Page 721: ...ed off Upon receiving this signal the control unit activates the motor relay to operate the motor Power Unit c SENSING LEVER The power unit is composed of a motor and a plunger type pump This unit transmits the revolution of the motor to the plunger by way of an eccentric bearing and supplies high pressure brake fluid to the accumulator by the effect of the reciprocating movement of the plunger Wh...

Page 722: ...hrough the outlet valve which is normally open It is also connected to the hydraulic pressure source pump accumulator pressure switch etc via the inlet valve which is normally clos ed The chamber D serves as an air chamber Under these conditions the pressures of the chambers C and D are maintained at about the atmospheric pressure permitting regular braking operations RESERVOIR CHAMBER D I OUTLET ...

Page 723: ...ic Hydraulic Electric Hydraulic Power Circuit Power Circuit I I I Downy O N Close ON Open Caliper pressure constant H o l d O N Caliper pressure increasing Up O F F Close Open OFF OFF Close Close Slide Piston Function When the car is used on rough roads where the tires sometimes lose adhesion the anti lock brake system may function excessively causing an excessively large volume of brake fluid to ...

Page 724: ...19 37 ...

Page 725: ...HT SWITCH ALTERNATOR I wHT BLu f ciixq YEL GRNIRED m CANADA jmij USA YEL BLUIWHT WHTlGRN GRNlWHT G551 WHTIGRN I TCS CONTROL UNIT 1 JUNCTION CONNECTOR YELlBLK I I 1 WHTlBLU REDlWHT GRN t 7 BLK BLK Y E a to I II YELIGRN ER SAFE RELAY SUB RELAY BOX B R N L G BRNlBLK a BLU BLK YELlBLK G302 G202 YELlRED 20P CONNECTOR 18P CONNECTOR CONTROL UNIT TERMINAL SIDE 19 38 ...

Page 726: ...7 83 11 FR IN 1 FR OUT 13 FL IN 3 FL OUT 16 RR IN 8 RR OUT 18 RL IN IO RL OUT 23 FSR 25 PMR GND FLP 15 FRP 14 RLP 6 RRP 5 PSW 35 COM 26 FRW 3 6 FRW t 31 FLW 37 FLW t 32 1 RRW 27 1 RRW t 20 RLW 28 NW t 21 I IG2 30 1 GND om D ORNIRED J GRY WHT I wow D YEL BLU TCS CONTROL UNIT 0 GRNlWHT scs SGi PGM FI ECU 6101 INSPECTION CONNECTOR r REAR t u YELlBLK ...

Page 727: ...R PARKING BRAKE S IITCH CONNECTOR LEFT FRONT SENSOR CONNECTOR PRESSURE SWITCH CONNECTOR RIGHT FRONT SOLENOID CONNECTOR LEFT FRONT SOLENOID CONNECTOR 1 LEFT REAR SOLENOID CONNECTOR RIGHT REAR SOLENOID CONNECTOR PUMP MOTOR CONNECTOR RIGHT REAR SENSOR CONNECTOR LEFT REAR SENSOR CONNECTOR I MOTOR ALB RELAY 40 A FUSE 19 40 ...

Page 728: ... A collision can result from a reduction or complete loss of braking ability causing severe per sonal injury or death 1 With the ignition switch off disconnect the 6 P in spection connector from the connector cover located under the glove box and connect the 6 P in spection connector to the ALB checker W LOCK BRAKE SYSTEM Y 43 CONNECTOR COVER ALBCHECKER 6 P INSPECTION 07HAJ SGOOl OO WS CONNECTOR G...

Page 729: ... 4 Sends the driving signal of each wheel then sends the lock signal of the front left wheel to the control unit There should be kickback Mode 5 Sends the driving signal of each wheel then sends the lock signal of the front right wheel to the con trol unit There should be kickback NOTE If little or no kickback is felt from the brake pedal in modes 2 5 repeat the function test of modes l 5 several ...

Page 730: ...Rear m B Power ON Start Test Mode Selector 5 With the transmission in neutral rotate each wheel briskly one revolution per second by hand and confirm that its respective monitor light on the checker blinks as the wheels rotates NOTE 0 Rotating a wheel too slowly will produce only a weak blink of its monitor light that may be dif ficult to see 0 In bright sunlight the monitor light may be dif ficul...

Page 731: ...er the engine is stopped and restarted However after recharging the battery the problem code must be cleared from the control unit s memory by disconnecting the ALB 2 3 No 32 fuse for at least 3 seconds Anti lock Brake System Indicator Light Circuit CAUTION Use only the digital multimeter to check the system 1 The indicator light does not go on when the igni tion switch is turned on Check the foll...

Page 732: ... check connector or else the Check Engine light will stay on when the engine running Turn the ignition switch on PROBLEM CODE PROBLEM PROBLEM CODE 4 2 CODE 1 7 2 Indicator light on Indicator light off t 12 Second 1 Second 1 1 II 5second 11 Connect the pause Fazsyd 1 1 11 Second jumper wire 1 pause pause pause 1 Second NOTE 0 The control unit can indicate three problem codes one two or three proble...

Page 733: ...or relay Pressure Switch Accumulator Modulator See page r L Hydraulic Controlled Components Parking brake switch related p r o b l e m _ 11g 5o I l i g h t Brake fluid level switch 0 0 0 I I PulserW 19 51 0 0 19 52 Modulator 0 0 0 0 O Speed sensor I i I 1 S p e e d s e n s o r s I I 0 Front or rear fail safe relay IQ 8 I I I I t I 19 53 Fail safe relay I I I I 1 1 Fc n 44 41 0 4 7 4 2 Solenoid pro...

Page 734: ...s l Check the ALB 40A Fuse l Check all brake system hoses and pipes low and high pressure for signs of leaking bending or kinking l Check reservoir fluid level and if necessary fill to the MAX level Disconnect the pressure switch connector and check the con tinuity between the No 1 BLK and No 2 YEL terminals N O See page 19 62 I Bleed high pressure fluid from the maintenance bleeder with the Bleed...

Page 735: ...a known good control unit and recheck If prescribed voltage is now availa ble replace the original control unit 1 VEL 3 8 3 7 3 6 3 5 3 4 3 2 31 3 0 2 3 2 2 21 2 0 19 VEL RED JUMPER WIRE 1 F View from control unit terminal side 7 MOTOR RELAY L Does it work properly Y E S Faulty pump motor relay Connect the No 2 WHT BLU and No 4 terminals using a jumper wire MAIN RELAY BOX Does the pump motor run Y...

Page 736: ...servoir t a n k I ES System is OK recheck pump motor to confirm no intermittent problem l If level stays the same and there are bubbles in the modulator reservoir tank check the accumulator fluid quantity by bleeding the high pressure line with the Bleeder T wrench If over 160 cc upper limit faulty accumulator If under 100 cc lower limit modulator inlet solenoid leak or accumulator leak l If level...

Page 737: ... known good control unit and recheck NOTE Before Troubleshooting Problem Code 2 remove the ALB 2 3 No 32 fuse for three seconds to clear the control unit s memory then test drive the car If the anti lock brake system indicator light stays off the probability is that the car was driven with the parking brake applied c l The parking brake is applied for more than 30 seconds while driving l The brake...

Page 738: ... GRN BLK Front Right Positive GRNIBLU Front Left Positive GRN YEL Rear Right Positive LT BLU Rear Left Positive GRN Front Right Negative BRN Front Left Negative BLU YEL Rear Right Negative GRY Rear Left Negative v Check for continuity to ground BRN FL 0 GRN FR 0 GRN BLU FL 0 GRNIBLK FR GRY RNIYEL RR View from control unit terminal side Repair open in sensor wire GRNIBLK Front Right Positive GRN Fr...

Page 739: ... the sensor and control unit GRN YEL Rear Right Positive LT BLU Rear Left Positive BLWYEL Rear Right Negative GRY Rear Left Negative Y E S Check for continuity to ground 38 3 7 36 3 5 b 3 4 3 2 3 1 30 L GRY RL 0 BLUIYEL RR LT BLU RL 0 GRNIYEL RR 0 View from control unit terminal side Reconnect the 20P connector to the control unit and connectors Connect the ALB checker to the inspection connector ...

Page 740: ...or ground 6202 HARNESS SIDE CONNECTOR View from terminal side CONNECTOR FRONT RIGHT FRONT LEFT BRNlBLK Disconnect the 3P connectors from the front solenoids Check BRNlBLK wire for con tinuity between the solenoids and the front fail safe relay Is there continuity Y E S View from terminal side Repair open in BRNlBLK wire be tween the solenoids and the front fail safe relay Turn the ignition switch ...

Page 741: ...NOID SIDE CONNECTOR View from terminal side w connector from the control unit Check each wire for continuity to ground RED BLK Front Right Inlet YELIBLK Front Right Outlet REDIBLU Front Left Inlet YEL BLU Front Left Outlet 1 I YEL BLK Y E L BLK HARNESS SIDE CONNECTOR FRONT LEFT FRONT RIGHT REDIBLU YELIBLU il ei Y r T View from terminal side Repair short in wire l YES 1 REDIBLK Front Right Inlet Is...

Page 742: ... View from terminal side EAR OLENOID ONNECTOR Y E S Disconnect the 3P connectors from the rear solenoids I REAR RIGHT BLUlBLK REAR LEFT I 2 BLU BLK JTb 3 4 I V i e w f r o m t e r m i n a l s i d e tmurty between the solenords I I I Is there continuity 1YES Repair open in BLWBLK wire be tween the solenoids and rear fail safe relay Turn the ignition switch ON I q1 NO 1 YELIBLK termrnal I and YELIBL...

Page 743: ...ire for continuity between the control unit and rear solenoid RED WHT Rear Right Inlet YELIWHT Rear Right Outlet RED GRN Rear Left Inlet YEL GRN Rear Left Outlet itT Check YEL GRN wire for con tinuity between the rear fail safe relay and control unit REAR LEFT REAR RIGHT REDlGRN YELlGRN RED WHT YELIWHT View from control unit terminal side Repair open in wire between the solenoid and control unit R...

Page 744: ...t and 1 FRONT LEFT View from terminal side FRONT RIGHT RED BLt D7 F RED B pDp b n Y E S 1 Check each wire continuity be front solenoid RED BLK Front Right Inlet YELIBLK Front Right Outlet RED BLU Front Left Inlet YEL BLU Front Left Outlet tween control unit and body ground RED BLK Front Right Inlet YELIBLK Front Right Outlet REDIBLU Front Left Inlet YELIBLU Front Left Outlet I Repair open in wire ...

Page 745: ...een the fail safe relay and ground or poor ground 6202 Y E S I FRONT RIGHT FRONT LEFT I 2 fJ b 3 4 JBLK I T View from terminal side I BRNlBLK BRNIBLK Check BRN BLK wire for con tinuity between the solenoids and front fail safe relay J n 1 BRNlBLK View from terminal side Is there continuity YES NO Repair open in BRN BLK wire be tween the solenoids and front fail safe relay Check for loose control u...

Page 746: ...ear Left Outlet I I I Is there 1 3 C Faulty solenoid Disconnect the 18P connector I from the control unit Check each wire for continuity between the control unit and body ground RED WHT Rear Right Inlet YEL WHT Rear Right Outlet REDIGRN Rear Left Inlet YELIGRN Rear Left Outlet YELlGRN REDIWHT YELlWHT View from control unit terminal side Repair open wire between the YELIWHT Rear Right Outlet RED GR...

Page 747: ...heck for continuity between the No 4 BLK terminal body ground Is there continuity N O Y E S Repair open in BLK wire between the relay and ground or poor ground 62021 REAR RIGHT REAR LEFT I 2 dBLK 3 4 sz I z View from terminal side Check BLUlBLK wire for con tinuity between the slenoids and rear fail safe relay Repair open In BLUlBLK wire be View from terminal side tween the solenoids and rear fall...

Page 748: ...id on the car it may damage the paint if brake fluid does contact the paint wash it off immediately with water BRAKE BOOSTER MASTER CYLINDER RESERVOIR TANK To right rear brake To rear brake left front brake MODULATOR RESERVOIR POWER UNIT MODULATOR SOLENOID UNIT _ e 19 61 ...

Page 749: ...unit 3 Install the special tool on the bleeder screw and turn it out slowly 90 to collect high pressure fluid into reservoir Turn the special tool out one complete turn to drain the brake fluid thoroughly 4 Retighten the bleeder screw and discard the fluid 5 Reinstall the red cap BLEEDER T WRENCH 07HAA SGOOIOO 07HAA I 000 1 0 1 MODULATOR RESERVOIR I HIGH PRESSURE HOSE I SOLENOID HEAD ACCUMUL PRESS...

Page 750: ...int if brake fluid does contact the paint wash it off immediate ly with water Q CORROSION RESISTANT BOLT 19 N m 1 9 kg m 14 lb ft MODULATOR SOLENOID UNIT Do not disassemble Solenoid leak test page 19 64 Solenoid flushing page 19 65 I I0 x 1 0 mm 19 Nom 1 9 kg m 14 lb ft1 I OIL BOLT 35 N m 3 5 12x l Omm 19 Nom I 9 kg m kg m 14 lb ft 14 lb ft 19 N m 1 9 kg m 14 lb ft B x 1 25 mm 15 N m I 5 kg m 11 l...

Page 751: ...b ftl 4 Start the engine and release the parking brake 5 Turn the Mode Selector to 1 and press the Start Test button 6 While the ALB pump is running place your finger over the top of the solenoid return tube in the modulator reservoir SOLENOID RETURN TUBE Feel for brake fluid here SOLENOID RETURN TUBE PUhP SUPPLY l If you can feel back fluid coming from the return tube one of the solenoids is leak...

Page 752: ...the same solenoid to the battery negative 1 terminal with a jumper lead as shown FRONT RIGHT REAR LEFT REAR RIGHT TERMINAL 6 Press the auxiliary switch to run the pump After the pump has run for about five seconds press and release the remote starter switch three or four times to open and close the solenoid Continue run ning the pump for about 30 seconds then release the auxiliary switch and open ...

Page 753: ... air BANJO BOLT l Before reassembling check that all parts are free of dust and other foreign particles l Replace parts with new ones whenever specified to do so l Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid 0 Do not mix different brands of brake fluid as they may not be compatible 0 Do not reuse the drained fluid Use only clean DOT 3 or 4 brake fluid SEALIN...

Page 754: ...e high pressure brake fluid out from the system us ing the Bleeder T Wrench page 19 62 0 Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid 0 Do not mix different brands of brake fluid as they may not be compatible 0 Do not reuse the drained fluid Use only clean DOT 3 or 4 brake fluid NOTE Replace the O ring with a new one before rassembly m The accumulator contain...

Page 755: ...I RESSURE JOINT ACCUMliLATOR Accumulator Disposal m The accumulator contains high pressure nitrogen gas do not puncture expose to flame or at tempt to disassemble the accumulator or it may ex plode severe personal injury may result 1 2 3 Secure the accumulator in a vise so that the relief plug points straight up Slowly turn the plug 3 I 2 turns and then wait 3 minutes for all pressure to escape Re...

Page 756: ... the modulator reservoir to the MAX level NOTE Do not reuse aerated brake fluid that has been bled from the power unit 3 Bleed high pressure fluid from the maintenance bleeder with the special tool BLEEDER T WRENCH 07HAA SGOOIOO Or SOLENOID HEAD Y k 4 PRESSURE SWITCH UNIT 4 0 lb ft 4 Start the engine and release the parking brake NOTE Depress the brake pedal firmly while test in pro gress light in...

Page 757: ...nect the connectors from the control units ANTI LOCK BRAKE SYSTEM CONTROL UNIT SECURITY DbOR LOOK CONTROL UNIT CONTROL UNIT 2 Remove the four control unit bracket bolts then remove the bracket with the control units 3 Remove the control unit from the bracket ANTI LOCK BRAKE SYSTEM CONTROL I BOLT 4 Install the new control unit in the reverse order of removal NOTE Check the anti lock brake system in...

Page 758: ...inals and 0 There should be continuity between terminals I and 0 1 Check the pulser for chipped or damaged teeth 2 Measure air gap between the sensor and pulser all the way around while rotating the driveshaft by hand A B Standard 0 4 1 O mm 0 016 0 039 in NOTE If the gap exceeds 1 O mm 0 039 in the probability is a distorted knuckle which should be replaced PtiLSER SENSOR 19 71 ...

Page 759: ... BOLT 6x l Omm 10 N m I O kg m 7 lb ftl 6x l Omm 10 Nom I O kg m 7 lb ft 22 N m 2 2 kg m 16 lb ft Rear Sensor Replac ement NOTE 8x 1 25mm 22 Nom 2 2 kg m 16 lb ft 0 Be careful when installing the sensors to avoid twisting the wires 0 After sensor replacement confirm proper opera tion page 19 43 Q6 x 1 0 m m 10 N m 1 O kg m 7 lb it ORdOilON RESISTANT BOLT 6xlOmm 10 Nom 1 O 7 lb ft kg m kg m a a 19 ...

Page 760: ...omponent Location Index 19 7 4 System Description 19 7 5 Outline 19 7 5 Construction and Function 19 76 Circuit Diagram 19 8 0 Troubleshooting 19 8 2 TCS Switch 19 137 Fail Safe Relay 19 137 Steering Angle Sensor Replacement 19 138 ...

Page 761: ... Location Index 1 TCS INDICATOR LIGHT THROTTLE ANGLE SENSOR ITCSOFF INDICATOR LIGHT TCSl ACTIVATION LIGHT TCSCONTROL MAIN FUSE BOX MAIN ANTI LOCK BRAKE CONTROL UNIT DASH FUSE BOX SHIFT POSITION CONSOLE SWITCH Aft ...

Page 762: ... needs and if necessary will then signal the throttle actuator and PGM FI control unit to reduce engine power The system is automatically ready whenever the engine is started but can be manually canceled with the TCS switch However once activated the system cannot be canceled until it is once again in the ready state STEERING WHEEL SENSOR THROTTLE ANGLE SENSOR REAR RIGHT BODY WHEEL SEhiSOR TCi CON...

Page 763: ...the control unit signals the throttle actuator which closes the throttle valve thus reducing engine power and maintaining the expected line Rough Road Control Based on signals from the wheel sensors the control unit detects a rough road based on frequency of wheel rotational vibration The control unit then signals the throttle actuator to relax engine power thus improving acceleration efficiency G...

Page 764: ...nnector termi nals are connected with a jumper wire Steering Angle Detection Steering angle is detected by the steering angle sensor located on the steering column The sensor uses two magnetoresistor elements to determine steering angle and direction of rotation When the driver turns the steer ing wheel a magnet in the steering shaft generates waves in the MR elements These waves are ampli fied an...

Page 765: ...le valve is automatically relaxed to achieve optimum traction THROTTLE DRUM THROTTLE VALVE LOST MOTION SPRING INSIDE RETURN SPRIJG TLE THROTTLE VALVE y RETURN SPRINGS A ACCELERATOR PE DAL OPENING SENSOR DU R I N G NORMAL mlvibm LEVER 1 THiOTTLE RETURN SPRING THROTiLE VALVE TLE THROTTLE ACTUATOR STEP MOTOR VALVE OPENING SENSOR YHROTTLE ACTUATOR STEP MOTOR DURING TCS ACTUATION Movement of parts whil...

Page 766: ...19 79 ...

Page 767: ...N1 37 23 24 2 11 scs VP2 VP1 FSR 101 TCS CONTROL UNIT STVC SIRGA STRQB LGEl LGEP PG2 PGl Ma4 Me2 ME3 Ms1 COMI COM2 RLP RRP FLP FRP 5 1 4 18 15 38 29 30 26 21 25 22 28 27 20 18 9 7 p Y E L R T ORNlRED J I l W t R N HT BLI t t r u I IT 7 I I I I GRN I i THROTTLE ACTlJATOR STEP MOTOR L L SPEED SENSOR GlOl G405 TEERING ANGLE SENSOR 10 P CONNECTOR 20 P CONNECTOR 12 P CONNECTOR CONTROL UNIT CONNECTOR 19...

Page 768: ...ERLOCK CONTROL UNIT GR PGM FI ECU A T CONTROL UNIT J L 19 40 6 34 35 TCSW TCSW ATPN STOP VSU LAMP TCS CONTROL UNIT eACP TCFC TCINH TQOUT TCFS PA NEP TH VREF ATSP 32 1 0 39 1 3 1 3 33 I J 36 TCOFF LAMP GR D r NiRED I GRN PGM FI ECU GRN RE PEDAL ANGLE SENSOR THROTTLE ANGLE SENSOR I BL I OR EL AIT CONTROL UNIT 1 A T only 19 81 ...

Page 769: ...ast 3 seconds to clear the problem code from the TCS control unit memory TCS Problem Code Indication 1 2 3 4 5 6 7 Stop the engine Turn the ignition switch on and confirm that the TCS indicator light comes on Turn the ignition switch off Connect the two terminals of the Service Check Connector with a jumper wire Turn the ignition switch on but do not start the engine Record the blinking frequency ...

Page 770: ...lem occurrence the two existing problem codes are moved up one register and the third problem code is stored in the first register If problems continue to occur the oldest problem code is moved out of the last register and lost and the most recent problem code is stored in the first register l The TCS indicator light will not come on again after the engine starts unless another problem occurrence ...

Page 771: ...on light do not go off two seconds after the ignition switch is turned on The TCS indicator light does not go off after the engine starts The TCS OFF indicator light does not go off after the engine starts tays on TCS control unit or battery voltage too low l 2 TCS conrol unit 2 Parking brake signal 2 l Steering angle sensor 3 l PGM FI ECU 0 0 0 00 3 2 NeP Signal engine speed signal 3 3 Abnormal T...

Page 772: ...n for two seconds when the ignition switch is first turned on no bulb check NOTE The TCS indicator light stays on until the engine starts Turn the ig 7 switch ON 1 Do the other indicator lights ALB Check Engine SAS etc come on Y E S N O I To page 19 86 Turn the ignition switch OFF Replace the fuse and recheck Y E S I DASii FUSE BOX cont d 19 85 ...

Page 773: ...ound and turn the ignition switch ON Check the lights TCS indicator light No 8 or No 42 terminal TCS OFF indicator light No 36 terminal View from terminal side GRYIBLK LlBLK WIRE WIRE TCS activation light No 31 terminal TCS switch indicator light No 40 terminal LT GRNlYEL WIRE Y E S N O l Replace defective bulb l Repair open in the wire be tween the TCS control unit and gauge assembly Check the AL...

Page 774: ...on nector and body ground with the ignition switch ON Is there battery voltage Y E S 1 Turn the ignitio switch OFF 1 I 1 Check for continuity to body ground between the No 15 ter minal of the 20 P connector and No 38 terminal of the 12 P con nector individually l Is there continuity I T Repair open in the YEL wire be tween the TCS control unit and dash fuse box View from terminal side 12 P CONNECT...

Page 775: ...T1 12 P CONNECTOR Turn the ignition switch OFF I I Disconnect the 12 P connector 1 form the TCS cyntrol unit 1 Turn the ignition switch ON View from wire side I LT GRNlYEL WIRE From TCS SWITCH INDICATOR LIGHT GRYlBLK WIRE From TCS INDICATOR LIGHT Do the indicator lights go off Repair short to ground in the wire between the TCS control unit and Substitute a known good TCS control unit and recheck I...

Page 776: ...stay on after See page 19 85 2 sec Y E S Start the engine Check the Check Engine light Is the light ON N O Check the problem code in the PGM FI ECU system Perform the procedures for troubleshooting the PGM PI sys tern and recheck Y E S Perform the procedures for cate code 35 or 36 problem code 3 1 see page 19 100 N O NOTE l Problem code 35 A short or open circuit in the GRY wire between the No 1 T...

Page 777: ...ol untt l Use the 10 V range a similar range in the analog Confirm that the analog tester pointer swings to approximately To page 19 91 1Turn the ignition switch OFF 1 connectors from the TCS control 1 Turn the ignitioi switch bN mm m1 I Is the TCS indicator light on N O Y E S Repair short to ground in the YELIBLK wire between the TCS control unit and the gauge as sembly 19 90 ...

Page 778: ... WHTlBRK wire between the TCS control unit and PGM FI ECU Check for continuity between the No 10 terminal of the 20 P con nector and the C6 terminal of the PGM FI test harness NOTE Use the PGM FI test har ness connect the test harness to 1 the PGM FI ECU Is there continuity Y E S N O Repair open in the WHTlBLK wire between the TCS control unit and PGM FI ECU Check for poor connection or loose wire...

Page 779: ...rcuit Measure the voltage between the No 10 terminal of the 20 P con nectar for TCS control unit and body ground NOTE l Check when engine is warmed up l Use the 1 OV range or a similar range in the ana Confirm that the analog tester pointer swings to approximatly L log tester 5 ov J l 20 P CONNECTOR 123451 16 7 8 9 Q I I 12 I3 14 5 16 i l7 I8 I9 20 I P View from terminal side V WHTl6i K WIRE TCINH...

Page 780: ...r the EPS control unit and body ground Y E S Is there battery voltage See Alternator and Regulator Test Section 23 NOTE The TCS OFF indicator light comes on if the TCS control unit back up power VW is more than 18V a Check for poor connections and loose wires at the TCS control unit l Substitute know good TCS Control unit and recheck cont d 19 93 ...

Page 781: ... on TCS Control Unit NOTE l If the TCS indicator light indicates problem code 1 2 replace the TCS control unit 0 If the TCS indicator light stays on check for a short to body ground in the YEL BLK wire between the control unit and the TCS indicator light If the wire is OK replace the TCS control unit ...

Page 782: ...s disconnected or cut the input signal becomes low No 5 IO A Release the oarkina brake lever FUSE switch OFF and t t the ignition 1 switch ON I 1 BRAKE SYSTEM LIGHT 0 in the gauge assembly r I I GRNlRED 4 r GRNlYEL Check the BRAKE system light BRAKE FLUID LEVEL SWITCH p PARKING BRAK E S W I T CH Is the BRAKE system light come YES on l Check for Parking brake switch test or INIl brake fluid level s...

Page 783: ... wheel has moved approximately one turn NOTE 0 Always maintain the same number of rotations 0 Step 1 to 4 are the steering angle sensor check proce dures for actual rehicle operating condition This will be called the steering anlge sensor system check in the following sections NOTE 0 Start checking after the steering wheel moves at least 1 5 turns from the right to the left 0 Turn the steering whe...

Page 784: ... _ I NOTE Use the digital mul l W I R E ISTVC Check for resistance between the No 1 and No 5 terminals timeter Resistance is approx imately 40 kD YELlRED I l Substitute a known good con trol unit and recheck l Check for poor connections or poor wires Repair open or short circuit in the YELlRED wire between the No 1 terminal and TCS control unit View from terminal side LT GRNlBLK WIRE LOElI View fr...

Page 785: ...0 C N O To page IQ 991 Check for open or short in the LT GRN RED and LT GRNlWHT wire between the steering angle sen sor and TCS control unit Refer to 5 and 6 If there is no open or short circuit check for poor connections or loose wires If the connections substitute a known good TCS control unit and recheck 1 1 Turn the ignition switch OFF 1 Disconnect the 5 P connector from the steering angle sen...

Page 786: ...ystem see page 19 96 Does it flash 5 times Y E S Turn the ignition switch OFF Steering angle sensor Replace the steering column as system is OK sembly 1 Start the engine 1 Perform the steering angle sensor system check see page 19 96 I Does it flash 5 times YES Inspect each part again I Steering angle sensor system is OK I cont dl 19 99 ...

Page 787: ...heck for a PGM FI problem code Are problem codas 35 TCF open or short circuit or 36 TCFC open or short circuit indicated YES a Check the TCFS signal when FM F1 system problem code 35 is tdicated TCFS signal check see lelow 7 Check the TClNH signal if no problem coda is indicated saa page 19 1031 Perform the PGM FI troublaahoot ing procedure if problem codes other than 35 and 36 are in dicatad D Ch...

Page 788: ...1 Repair short in the GRY wire be tween the TCS control unit and PGM FI ECU CONNECTOR View from terminal side I 71 l Substitute a known good con trol unit and recheck l Check for poor connections or loose wires N O Is there OV TCS in operation Y E S Turn the ignition switch OFF NOTE Use the PGM FI test har I ness see section 11 I I I I Disconnect the 20 P connector 20 P CONNECTOR J from the TCS co...

Page 789: ... terminal side Y E S Turn the ignition switch OFF Disconnect the 12 P connector from the TCS control unit and the Turn the ignition switch OFF Check for continuity between the TCS control unit No 32 terminal end body ground Disconnect the 12 P connector from the TCS control unit and the 12 P connector from the PGM FI ECU Is there continuity Y E S l Substitute a known good TCS control unit and rech...

Page 790: ... TCINH signal check see blow Start the engine Measure the voltage between the and body grounii TCS control unit No 10 terminal Check if the analog tester needle pulses in small increments in the range below 5 V z approximately 2 5V 20 P CONNECTdR J I 2 3 4 qtarls 7m 0 I I 12 13 14 5 16 17 I8 I9 20 I View from terminal side NOTE Use the 10 V range or a similar range in the analog tester I To page 1...

Page 791: ... WHTlBLK wire between the TCS control unit and PGM FI ECU 20 P CONNECTOR S 7 8 9 15116il7 18 I9 20 WHTlBLK WIRE TCINH View from terminal side I PGM FI TEST HARNESS NOTE Use the PGM FI test harness see section 1 I Is there an open or short N O Y E S Repair open or short in the WHTI BLK wire between the TCS con trol unit and PGM FI ECU 1 l ZZYZod 1 l Check for poor connections or a ...

Page 792: ...ana log tester l Check with the engine idling and warmed up Is there approximately 6 0 V Y E S 2 N O l Check for poor connections or Disconnect the 12 P connector from the TCS control unit the 12 P connector from the PGM FI ECU and the 26 P connector from the A T control unit I Check for continuity between the 1 and body groun d 1 TCS control unit No 41 terminal I N O 7 tween the TCS control unit ...

Page 793: ...e voltage between the TCS control unit No 41 terminal and body ground is there approximately 6 0 V l Substitute a known good PGM Fi ECU and recheck Y E S l Check for poor connections or loose wires Disconnect the 26 P connector to t h e tromle ntgine GRN WIRE NEP l l 12 P CONNECTOR View from terminal side eGRN WIRE NW Measure the voltage between the TCS control unit No 41 terminal l Substitute a k...

Page 794: ...engine Measure the voltage between the TCS control unit No 39 terminal and body ground N O Is there appproximately 3 3 V Y E S l Substitute a known good TCS control unit and recheck 0 Check for poor connections or loose wires WiE To page 19 I 08 NOTE 0 Use the 10 V range or a similar range in the ana log tester 0 Check with the engine idling and warmed up High torque Low torque 12 P CONNECTOR View...

Page 795: ...the TCS control unit and the PGM FI ECU NOTE Use the PGM FI test harness see section 11 I Is there continuity Repair open in the WHTIRED wire between the TCS control unit and Check for continuity between the 1 6 n l niT9 connec PGM FI TEST HARNESS 12 P CONNECTOR View from terminal side J WHTlRED WIRE F TQOUT Repair short in the WHTlRED wire between the TCS control unit and l Check for poor connect...

Page 796: ...problem code 3 4 indicated Intermittent failure Check for poor connections or Y E S loose wires Measure the voltage between the TCS control unit No 13 terminal 20 P CONNECTOR and body ground I I Check for poor connections or Is there approximately 5 V Turn the ignition switch OFF I To page 19 1 IO BLU WIRE 4 View from terminal side VRFE V cont d 19 I 09 ...

Page 797: ... control unit PGM FI ECU and the A T control unit Check for continuity in the BLU I wire between the TCS control unit BLU WIRE VREF 1 J NOTE Use the PGM FI test harness see section 11 PGM FI TEST HARNESS I 20 P CONNECTOR I Repair open in the BLU wire be tween the TCS control unit and PGM FI ECU View from terminal side BLU WIRE VREF I I I Connect the 22 P connector to 1 the PGM FI ECUi 1 Turn the i...

Page 798: ... voltage between the TCS control unit No 13 terminal and body ground Y E S l Substitute a known good TCS control unit and recheck l Check for poor connections or loose wires 20 P CONNECTOR I View from terminal side L tiLU WIRE 7 VREF Substitute a known good AK control unit and recheck Internal short circuit of the A T control unit cont d 19 I 11 ...

Page 799: ...or loose wires Does the check engine light indi cate problem code 13 Y E S Repair according to the PGM FI troubleshooting guide Measure the voltage between the TCS control unit No 12 terminal and body ground 20 P CONNECTOR I s t h e v o afr matelv NC Check for poor connections or I Turn the ignition switch OFF To page 19 113 View from terminal side RNIRED WIRE L PA 19 112 ...

Page 800: ...ew from terminal side I2e ORNlRED WIRE T PA 20 P CONNECTOR View from terminal side ORNlRED WIRE PA l TPA IJ oooooooooooooooooooooooooooooeroooooooo 00000000000000000000000000000000000000 z PGM FI TEST HARNESS 20 P CONNECTOR Measure the voltage between the and body grounii L TCS control unit No 12 terminal I l Substitute a known good I s the voltage approximately PGM FI ECU and recheck l Check for ...

Page 801: ...er minals m I YEL wH T W RE GRN JVHT WIRE r I BLUlRED WIRE Is there approximately 5V Measure the voltage between the No 1 terminal and body ground Y E S I Connect the 3 P connector to the pedal angle senr r 1 Turn the ignition switch ON I ew from terminal side Check for open or short in the YELIWHT wire between the PGM FI ECU and pedal angle sensor If the wire is OK substitute e known good PGM FI ...

Page 802: ...CU 3 P connector from the pedal an gle sensor and the 22 P connec tor from the A T control unit Check for contrnurty between the 20 P CONNECTOR BLUlRED WIRE BACP I II I I 2 3 44 51 IO I I 12 13 14 15116 View from terminal side BLUlRED WIRE BACP I 20 P CONNECTOR View from terminal side I 1 BLLVRED WIRE I I OACP Check for continuity in the BLU RED wire between the TCS control unit and pedal angle se...

Page 803: ...tions or poor wires When the throttle is completely closed and open measure the vol tage between the TCS control unit No 3 terminal and body ground l Approximately 0 5 V when completely close l Approximately 4 5 V when completely open l Between the 0 5 V closed and 4 5 V open N O Y E S l Substitute a known good TCS control unit and recheck l Check for poor connections or loose wires Turn the ignit...

Page 804: ...ide b 32 I REDIYEL WIRE WTH THROTTLE ANGLE SENSOR Repair open in the REDIYEL wire between the TCS control unit and Y E S l Substitute a known good TCS control unit and recheck l Check for poor connections or loose wires the throttle angle sensor Problem codes are displayed by the PGM FI and the A l indicators when there is a short cont d 19 117 ...

Page 805: ...heck the Anti lock brake system for a problem code Are problem codes 4 1 4 Z 4 and 4 8 indicated Y E S Perform the repair according to the Anti lock brake control unit troubleshooting chart Measure the voltage between the TCS control unit 20 P connector No 7 9 18 and 20 terminals and body ground Make sure that the there is 0 V when the wheel is stopped and approximately 2 V when the wheel is rotat...

Page 806: ...m terminal side ORNlRED WIRE FRPI 1 B P CONfiECTOR Y E S Turn the ignition switch OFF Disconnect the 20 P connector from the TCS crtrol unit 1 Check for continuity in the ORNl RED ORNIBLK BLWORN and GRYIWHT wires between the TCS control unit and the Anti lock brake control unit I I L 1 I Disconnect the 20 P connector Ilommirmr rllulri Is there continuity 1YES N O l Substitute a known good control ...

Page 807: ...or more than 3 seconds to reset the TCS control unit I Start the engine Intermittent failure Check for poor connections or loose wires Y E S Check the ANTI LOCK ALB light Y E S Perform the procedures indicated in the Anti lock brake trouble shooting NO Turn the ignition switch OFF I Check for poor connections or loose wires at the Anti lock brake control unit and check the com ponent ground at the...

Page 808: ...and 18 P con nector No 7 ORNIRED and No 14 terminals No 9 ORNIBLK and No 15 terminals No 18 BLU ORN and No 5 terminals No 20 GRY WHT and No 6 terminals I Vire from terminal side 1 L RN WIRE Gf YlWHT WIRE Rb 1 1 I I I ORN RED WIRI a Check for poor connections or loose wires at TCS control unit l Substitute known good TCS control unit and recheck wire between the TCS control unit cont d 19 121 ...

Page 809: ...ystem and the throttle actuator system for more than 3 seconds to reset yiE zi it foq g 23 Is problem code 5 l indicated Check the throttle body see section 11 I I s it normal Substitute a known good throttle actuator and recheck Y E S Check for poor connections or loose wires 19 122 ...

Page 810: ... 1 terminal of the 4 P connec 1body ground 1 tor for the fall safe relay and TCS 15 A FUSE Repair open the YEL wire between the fail safe relay and dash fuse box GRNlRED WIRE From TCS I 5 A FUSE v I Y E S I Measure the voltage between the No 2 terminal of the 4 P connec tor for the fail safe relay and body ground 4 P CDNNECTOR I NO Is there battery voltage Y E S View from terminal side Repair open...

Page 811: ... P connector from the TCS control unit Turn the ignition switch ON Measure the voltage between the No 2 RED BLK terminal of the 20 P connector and body ground REDlBLK WIRE FSR 2ojP CONNECTOR Uo page 19 125 Y E S View from terminal side Turn the ignition switch OFF I Connect the 20 P connector to the TCS control unit I I To page 19 l 25 1 9 4 2 4 ...

Page 812: ...ls of the 1 O P connector for the TCS con trol unit and body ground fail safe relay system is f rctioning properly LT GRNlBRK WIRE Is there battery voltage YES 10 P CONNECTOR To page 19 l 27 NO Turn the ignition switch OFF I Disconnect the 1 O P connector from the TCS control unit and 4 P connector from the fail safe relay Check for continuity between the 1 NO 1 Repair open in the LT GRN BRK wires...

Page 813: ...o 2 terminal of the 20 P con nector for the TCS control unit and No 3 of the 4 P connector for the fail safe relay I REDIBLK s o p CONNECTOR 6 4 P CONNECTOR Repair open in the REDlBLK wire between the TCS control unit and fail safe relay Check for continuity between the cj NO Repair short in the RED BRK wire to the body ground Check for poor connections or View from terminal side 19 l 26 ...

Page 814: ...O View from terminal side BLK WIRE PG Turn the ignition switch OFF BLK WIRE PG IL Disconnect the 1 O P connector from the TCS control unit I Check for continuity between the No 29 BLK the No 30 BLK terminals of the 10 P connector for the TCS control unit and body 1g r o u n d To pa From FAIL SAFE RELAY I LT GRNlBLK I zTROL UNIT fm W H T THROTTLE ACTUATOR Y E S 19 l 28 N O l Repair open in the BLK ...

Page 815: ...minal and body ground No 22 BRN terminal and body ground No 25 ORN terminal and body ground HTIGRN wire View from terminal side No 26 YEL terminal and body ground No 27 WHT GRN terminal and body ground No 28 GRN terminal and body ground Repair wire between the TCS con to body ground trol unit and throttle actuator that is defective View from terminal side Y E S Check for continuity internal NOTE I...

Page 816: ...ntinuity Y E S Replace the throttle actuator nectar to the TCS control unit and 6 P connector to the throttle ac O P CONNECTOR Turn the ignition switch ON Measure the voltage between the No 3 RED YEL and the No 4 BLWRED terminals of the 20 P connector for the TCS control unit when the accelerator pedal is released View from terminal side Y E S Substitute a known good throttle actuator assembly and...

Page 817: ... come on Shift the shift lever a range then slowly increase the speed up to 50 km h 31 mph and maintain this speed for 30 seconds To page 19 132 N O 20 P CONNFCTOR LT GRN WIRE AT PN Measure the voltage between the No 6 LT GRN terminal of the 20 P connector for TCS control unit and body ground View from terminal side I When the shift position is q or q is there no voltage yyi h e tl JyJ yg jif tery...

Page 818: ...the shift position is q or q is there continuity n h j n ZZ A Y E S l Check for poor connections or loose wires l Substitute a known good TCS control unit and recheck I N O View from terminal side l Repair open or short to ground in the LT GRN wire betinreen the TCS control unit and shift position indicator l The shift position indicator or shift position console switch is defective cont d 19 131 ...

Page 819: ...Measure the voltage between the No 33 ORN BLU terminal of the 12 P connector for TCS control I 12 P CONNECTOR T View from terminal side To page IS I 33 NO Is there approximately 5 0 V To page 19 134 Y E S Turn the ignition switch OFF I Disconnect the connectors from the A T control unit Measure the voltage between the No 33 fORN BLU terminal of the 12 P connector for TCS control unit and body grou...

Page 820: ... D14 terminal of the teSt Is there an open or short 1 NO Y E S Repair open or short in the ORNl BLU wire I Reconnect the 22 P connector to the A T control unit I ORNlBLU WIRE AT SP I Start the engine 2 P CONNECTOR No 33 ORNIBLU terminal of the 12 P connector for TCS control unit and body ground Vew from terminal side Is there voltage N O Y E S l Check for poor connections or loose wire l Substitut...

Page 821: ... there approximately 2 3 V loose wires l Substitute a known good TCS N O control unit and recheck Turn the ignition switch OFF I Disconnect the 20 P connector from the TCS control unit Start the engine Measure the voltage between the No 33 ORN BLU terminal of the 12 P connector for TCS control unit and body round when the shift position iskl 3 or q in 4th ORNlBLU WIRE IAT SP 12 P CONNECTOR View fr...

Page 822: ... LIGHT SWITCH 12 P CONNECTOR I I Perform the procedures indicated in the troubleshooting guide Y E S Shift the transmrssron Into q Press the accelerator pedal all the way down Make sure that the speedometer display change to approximatly 20 mph 30 km h and the engine speed is 1 OOO 2 000 rpm Check if the TCS activation light flashes at the same time To page 19 136 View from wire side NOTE The TCS ...

Page 823: ... switch is pushed and there is no voltage Shift the transmission into q when the switch is released I I Is it normal I 1 Press the accelerator pedal I Y E S I I I Make sure that the traction con trol does not operate and the TCS activation light does not flash Replace the TCS control unit Is it normal Y E S N O Replace the TCS control unit I Press the brake pedal and stop the rear wheels NOTE Stop...

Page 824: ...Light From Form No 5 15 A FUSE LIGHTING SWITCH YELlGRN LT GRNlYEL CONTROL UNIT 1 1 UNIT 1 Fail Safe Relay Test There should be continuity between the A and B termi nals when the battery is connected to the C and D ter minals There should be no continuity between the A and B ter minals when the battery is disconnected From TCS 15 A FUSE From No 5 15 A FUSE GRNiRED I Y E L A C 8 B D I LT GRNlBLK TCS...

Page 825: ... by tightening 2 bolts and make sure the adjusting shim is installed properly CAUTION Do not apply any grease or oil to the ad justing shim Detect part STEERING BOLTS 10 N m 1 0 kg m 7 2 lb ft ANGLE SENSOR 2 Connect the 5 P connector to the steering angle sensor 3 Install the steering column covers 4 Perform the steering angle sensor system check See page 19 96 If there is an abnormalty check the ...

Page 826: ...teering column Adequate air gap can be kept by select ing the adjusting shim with the reference number Selection of The Adjusting Shim Adjusting Shim Reference Number Shim P N Thickness 1 Not used 0 mm 2 A 0 1 mm 3 B 0 2 mm 4 A B 0 3 mm 5 C 0 4 mm 6 A C 0 5 mm 7 B C 0 6 mm 8 D 0 7 mm Reference Number Locations NUMBER STEERING COLUMN 1A 53395 SLO A01 Parts Number I 0 1 mm I llo l 1Thickness 1 Color...

Page 827: ... Opener Latch Replacement 20 58 Opener Cable 20 56 Windshield Rear Window Glass Rear Hatch Glass Index 20 21 Windshield 20 22 Rear Window Glass 20 26 Molding Replacement 20 30 Rear Hatch Glass Glass 20 32 Glass Molding Replacement 20 35 SUPPLEMENTAL RESTRAINT SYSTEM SW The NSX includes a driver s side Airbag located in the steering wheel hub as part of a Supplemental Restraint System SRS Informati...

Page 828: ... spoiler is made of SMC 1 Straight line front side frame for excellent absorption of front impact energy 2 Extruded molded side sills with high strength and rigidity 3 Lower part of center pillar is designed as flare type and united solidly to main frame thus greatly improving rigidity 4 All main frame parts are joined smoothly providing high impact strength and improving body rigidity 5 Large cro...

Page 829: ...gs Alloy Non heat treated alloys 5000 Aluminum Magnesium AI MS Heat treated 6000 Aluminum Magnesium Silicone Part Material properties Body composites Good corrosion resistance HA51 82P 0 Weldability and mallability Exterior surface skin Excellent mallability and corrosion HAZ6083P T4 resistance Roof panel HAZ6083P T4 HAZ6083 T4 is particularly resis Side sills HACF60 T5 tant to corrosion 20 3 ...

Page 830: ...Types and Materials of Exterior Resin Parts Fuel filler lid HAS 2148 Gnylon PPO alloy Page 20 57 20 4 ...

Page 831: ...Adiustment page 20 I 6 G L A S S REAR GLASS GUIDE FRONT GLASS STRIKER c Adjustment page 20 18 OUTER MOLDING HiNGE ASSY LATCH y LOWER WEATHERSTRIP INSIDE DOOR HANDLE 7 Passenger s side SWITCH PANEL irOWER WINDOW s SWITCH 20 5 ...

Page 832: ...h a shop towel 2 Remove the trim plate by pulling it backward and remove the inside door handle screws MOUNTING SCREWS Remove the 2 mounting screws while pulling the handle RIM PLATE 3 Disconnect the connector and the handle cable then remove the inside door handle by pulling it forward HANDLE CABLE 4 Carefully remove the front and rear sash covers A FRONT SASH COVER CLIP REAR SASH COVER 20 6 ...

Page 833: ...s required CONTROL SWITCH PANEL AIR DUCT I DOOR PANEL 7 Remove the mounting screws and disconnect the connectors then remove the power window con trol unit and speaker POWER WINDOW CONTROL UNIT SPEAKER UNIT 8 Remove the lower door weatherstrip retaining clips then pull off the lower door weatherstrip Remove the screw grommets and carefully remove the plastic cover b Clip location 3 Clip location T...

Page 834: ... original adjustment FRONT SASH LOCKNUT ADJUSTING BOLT urn 3xl Omm QB x 1 25 mm 3 N m 0 8 kg m 22 Nom 2 2 kg m Q CORROSION RESISTANT BOLT NUT 12 Remove the mounting bolt and locknut Remove the rear sash then disconnect the latch rod NOTE 0 Hold the adjusting bolt with a hex wrench when removing the locknut i Scribe a line around the locknut to show the original adjustment I LOqKNUT LATCH ROD I I R...

Page 835: ...he lock rod out its joint using a flat tip screwdriver then carefully remove the lock cylinder 17 Disconnect the rod and remove the inside crank Remove the cable and harness clips Remove the mounting screws then remove the latch assembly through the hole in the door NOTE Take care not to bend the lock rod LATCH ASSEMBLY INSIDE CRANK 18 Lower the window and remove the mounting nuts then remove the ...

Page 836: ...cribe a line around the locknuts to show the original adjustment FRONT GLASS_OUlD LOCKNUT I I ADJUSilNG BOLT i LOCKNUTS a8x1 25mm 22 N m 2 2 kg m 16 lb ft Q CORROSION RESISTANT BOLT NUT 21 Remove the 4 regulator mounting bolts and looser the 3 motor bolts then take out the regulator ass embly through the window slot NOTE 0 Scribe a line around the mounting bolts to show the original adjustment 0 T...

Page 837: ...8 and molding mounting screw 0 Starting at the front and sliding the molding forward STABILIZER t CORROSION RESISTANT SCREW Removal 1 Lower the window fully 2 Remove the seat page 20 38 3 Disconnect the door harness connectors 4 Remove the door assembly by removing the hinge bolts detent rod pin and pulling out the wire harness CAUTION Place a shop towel and rubber pad on the jack to prevent damag...

Page 838: ...ing Also make sure that there is no clearance between the glass and door upper weatherstrip when the glass is closed Adjust the position of the door glass as necessary pages 20 I 3 to 17 3 Attach the wire harness correctly on the door NOTE Make sure the wires are not pinched 4 When reinstalling the plastic cover apply adhesive along the edge where necessary to maintain a con tinuous seal and preve...

Page 839: ... Glass Adjustment Adjusting bolt locations G L A S S 1 0 0 0 r ____ se STOPPER PLATE 0 FRONT SASH FRONT GLASS GUIDE REGULATOR ASSEMBLY REAR GLAiS GUIDE cont d 20 13 ...

Page 840: ... 6 Connect the connector of the control switch panel to the door harness NOTE Take care not to scratch or score the con trol switch panel 7 Carefully close the door while holding the window glass to prevent it from contacting the body panel 8 Close the door glass fully NOTE Check the door fit to the body opening 9 Measure and record the clearance H and B between the glass and body at the locations...

Page 841: ...ody at the front and center pillars 3 Loosen the nuts securing the rear glass guide and adjust the glass fore and aft by moving the glass guide NOTE Hold the adjusting bolts with a hex wrench when loosening the lower glass guide locknuts I BOLT 4 Loosen the nut securing the stopper plates and adjust so that the clearance H at the loca tions is within the specified value NOTE Check that the stopper...

Page 842: ...E DOOR LkKNUT 2 Align the front sash and rear sash with the glass with the adjusting bolts at the bottom of the sashs FRONT out A 8 m n c r h mrarl AYI LOCKNLJT REAR SASH ADJUSTING BOLT 3 Adjust and set the front and rear stabilizers in the positions which will ensure correct clearance B then retighten the stabilizer bolts securely DE BILIZER 4 Move the glass up and down to seat it then measure th...

Page 843: ... not pinched by the door glass Section I WINDSHIELD G L A S S RETAINER A S S DOOR TRIM WEAhERSTRIP Section Section 16 With the door and glass closed fully check for water leaks NOTE Do not use high pressure water 17 install the control switch panel in the door panel 18 Install the door harness 19 Attach the plastic cover and install the door panel 20 Check for air leaks 20 17 ...

Page 844: ...ge to make the door edges PARALLEL with the body Q CORROSION RESISTANT BOLT The door and hod edges should be parallel NOTE Check for water and air leaks Door Striker Adjustment Make sure the door latches securely w ithout slamming If it needs adjustment 1 2 3 Draw a line around the striker plate for reference Loosen the striker screws and move the striker IN or OUT to make the latch fit tighter or...

Page 845: ...emove the 2 mounting nuts from the hole in the door while holding the mirror NOTE Do not drop the mounting nuts inside the door POWER MIRROR CONNECTOR aMOUNTiNG NUTS 4 Install the door mirror in the reverse order of removal 5 With the door closed fully check for water and air leaks NOTE Do not use high pressure water Q CORROSION RESISTANT NUT 2 Pull the actuator and glass out from the mirror housi...

Page 846: ...the door glass page 20 I 3 l If necessary Replace any damaged clips I I I FRONT PILLAR RETAINER I REAR PILLAR PA 1 Open the rear hatch and remove the trim panel page 20 37 2 __ Remove the 2 mounting nuts from the hole in the REAR PILLAR I body panel and pull the panel out by hand PANEL NOTE Do not drop the nuts inside the body panel SCREW 9 I FRONT PILLAR R TAINER adhesive OUTER RETAINER L I _ i L...

Page 847: ...LAk Removal page 20 3 installation page 20 UPPER RUBBER DAM NNER RUBBER OUTER RUBBER DAM UPPER MOLDING LOWER MOLDING Molding Replacement page 20 30 REAR WINDOW GLASS Removal page 20 26 Installation page 20 27 WlNDSHlELb Removal page 20 22 Installation page 20 23 UPPER MOLDING A UPPER FASTENER RUBBER DAM LOW ER SPACER 21 ...

Page 848: ...E DAM l w E I AdHESlVE 4 Using an awl make a hole thrugh the windshield adhesive from inside the car Push piano wire through the hole and wrap each end around a piece of wood I AlhiESlVE DAM 5 With a helper on the outside pull the wire back and forth in a sawing motion and carefully cut through the adhesive around the entire windshield CAUTION l Hold the piano wire as close to the glass as possibl...

Page 849: ...If the old glass is to be reinstalled use a putty knife to scrape off all traces of old adhesive then clean the glass surface with alcohol where new adhesive is to be applied NOTE Make sure the bonding surface is kept free of water oil and grease CAUTION Avoid setting the glass on its edges small chips may later develop into cracks Clean the shadowed 4 Glue the lower spacers and defrost panel seal...

Page 850: ...Keep water dust and abrasive materials away from the primed surface v h Apply glass primer here 2 m m 8 Thoroughly mix all the adhesive and hardener together on a glass or metal plate with a putty knife NOTE 0 Clean the plate with a sponge and alcohol before mixing l Follow the instructions that come with the adhesive 9 Before filling a cartridge cut off the end of the noz zle at the angle shown C...

Page 851: ...rfaces with your hands 0 Mask off the dashboard before painting the flange v A Apply body primer here 1 2 Glue the upper fastener to the body as shown UPPER FASTENER UPPER FASTENER ADHESIVE TAPE 13 Use suction cups to hold the glass over the open ing align it with the marks made in step 5 and set it down on the adhesive Lightly push on the glass until its edge it fully seated on the adhesive all t...

Page 852: ...lowly 0 Keep the glass dry within the first 1 hour after installation 0 Check that the ends of the molding are set under the air scoop 16 Reassemble all removed parts Removal CAUTION 0 Wear gloves to remove and install the glass 1 2 3 To remove the rear glass first remove 0 Seats page 20 38 0 Rear pillar trim panel page 20 37 l Rear upper trim panel page 20 37 0 Rear hatch glass assembly page 20 5...

Page 853: ... the painted surface of the body damaged paint will interfere with pro per bonding 0 Remove all traces of the rubber spacer material from the body 0 Mask off surrounding surfaces before applying primer Clean the body bonding surface with a sponge dampened in alcohol NOTE After cleaning keep oil grease or water from getting on the surface If the old glass is to be reinstalled use a putty knife to s...

Page 854: ... wipe it off with gauze or cheesecloth NOTE 0 Do not apply body primer to the glass and do not get body and glass primer sponges mixed up 0 Never touch the primed surfaces with your hands If you do the adhesive may not bond to the glass properly causing a leak after the glass is installed 0 Keep water dust and abrasive materials away from the primed surface v b Apply glass primer here Upper Moldin...

Page 855: ...I 13 mm ADHESIVE LL I 0 5 in L l 8 mm 0 3 in Make a slightly thicker bead at each corner f 12 Use suction cups to hold the glass over the open ing align it with the marks made in step 4 and set it down on the adhesive Lightly push on the glass until its edges are fully seated on the adhesive all the way around NOTE Do not close or open the doors until the adhesive is dry L ALhwvlENT MARK8 13 After...

Page 856: ...to scrape all traces of old adhesive thoroughly 5 Clean the glass surface with alcohol where the new moldings are to be installed NOTE Make sure the surface is kept free of water oil and grease 6 With a brush apply a light coat of glass primer around the edge of the glass NOTE Scrape off excess glass primer with a putty knife after installing the new moldings OUTER GLASS INNER GLASS EXCESS PRIMER ...

Page 857: ...LDING 10 Scrape or wipe the excess adhesive off with a put ty knife or gauge NOTE Use a soft shop towel dampened with alcohol to remove adhesive from a painted surface upper seal lower fastener or glass 11 After the adhesive is dry install the rear defogger sub harness and ground cable antenna lead in the upper molding Right Side Left Side Ground cable Rear defogger Antenna lead sub harness 20 3 1...

Page 858: ...ol where new adhesive is to be applied NOTE Make sure the bonding surface is kept free of water oil and grease Apply the protective tape along the edge of the rear CAUTION Avoid setting the glass on its edges hatch frame as shown small chips may later develop into cracks With a helper holding the glass pull the wire back and forth in a sawing motion and carefully cut through the adhesive along the...

Page 859: ...ame then center it in the opening Mark the location by mark ing lines across the glass and body with a grease pencil at the four points shown NOTE Put several spacers between glass and rear hatch air scoop to prevent glass from sliding down ALIGNMENT MARKS I 8 mm 0 3 in I 4 L 8PeCER 5 With a brush apply a light coat of glass primer of the glass as shown then lightly wipe it off with gauze or chees...

Page 860: ... before mixing 0 Follow the instructions that came with the adhesive Before filling a cartridge cut off the end of the noz zle at the angle shown Cut off nozzle end A as shown 10 mm 0 4 in 1 9 Pack adhesive into the cartridge without air a pockets to ensure continuous delivery Put the car tridge in a caulking gun and run a bead of adhesive around the edge of the glass as shown 4 m m 0 15 in l r 12...

Page 861: ...nd for at least 4 hours after glass installation If the car has to be used within the first 4 hours it must be driven slowly 13 Remove the spacers 14 Install the support struts Rear Hatch Glass Molding Replacement 1 Remove the rear hatch page 20 53 2 Place the glass on its surface as shown CAUTION Avoid setting the glass on its edges small chips may later develop into cracks 3 With a helper holdin...

Page 862: ...ng the new molding Degrease the inner surfaces of the new molding thoroughly then apply a light coat of glass primer to the surfaces NOTE 0 Apply glass primer around the entire groove of the new molding l Do not apply glass primer to the outer surface 9 Run a bead of adhesive in the groove of the molding 10 Press the molding into position around the entire edge of the glass NOTE Check that the mol...

Page 863: ...m Disassemble in numbered sequence J Clip Locations NOTE L SUN VISOR l When removing the rear trim panels take care not to damage the control units and relays 0 Take care not to scratch or score the trim panels l If necessary replace any damaged clips EAR PILLAR TRIM PANEL A IM PANEL FRONT PILLAR TRIM PANEL fl SIDE SILL L REAR TRIM PANEL A IPENER 2 1 REAR SIDE TRIM CENTER ARMRESl Replacement page ...

Page 864: ...a caps l Take care not to scratch the interior trim dashboard and center armrest l On reassembly replace the anchor bolt and use li quid thread lock 0 N m 4 0 kg m seat belt rower ancnor 011 Q SEAT MOUNTING BOLTS 10 x 1 25 mm 40 Nom 4 0 kg m 29 lb ft LOWER ANCHOR i 20 UNF y a p t3 2 kg m DOWER ANCHOR BOLT tiAP LOWER ANCHOR Q CORROSION RESISTANT BOLT NOTE Grease the moving surface of the slide INNE...

Page 865: ...el and side panel page 20 37 UPPER ANCHOR BOLT 7 l 6 20 UNF 5 Remove the upper anchor bolt and retractor bolts RETRACTOR BOLT 7 l 6 20 UNF REAR PILLAR TRIM Replacement page CENTER ANCHOR BOLT 7 l 6 20 UNF 32 N m 3 2 kg m 23 lb ft 6 Check that the retractor locking mechanism func tions as described on page 20 40 7 Install the front seat belts in the reverse order of removal NOTE TOOTHED 0 Make sure...

Page 866: ...d water to clean Check that the belt does not lock when pulled out slowly The belt is designed to lock only during a sudden stop or impact Make sure that the belt will retract automatically when released Replace the belt with a new one if there is any abnormality 1 Adjust the passenger seat fully forward to make room behind the seat back 2 Using the dimensions shown measure and mark the location o...

Page 867: ... the lock bolt then slide the mirror stay fron the lug MIRR STA I Counter clockwise CdVER 3 Remove the lock bolt then remove the toothed lock washer and hold spring from the mirror stay LOCK BOLT Clockwise ED LOCK WASHER HOLD SPRING MIRROR STAY Installation is the reverse order of removal 20 41 ...

Page 868: ... page 20 37 0 Side sill trim page 20 37 0 Center console panel page 20 43 2 Pull up the retainers and carpet clips at the front edge passenger s side then remove the floor carpet 3 Remove the console carpet attaching screw from the heater unit passenger s side 4 Remove the carpet hooks from the dashboard inside screws then remove the console carpet FOOTREST M NTlNO BOLTS L DASH SENSOR R I SEkovn I...

Page 869: ...UTION Be careful not to damage the SRS wire harnesses when servicing the dashboard NOTE 0 Take care not to scratch or score the dashboard l Do not drop the screws inside the dashboard Disassemble in numbered sequence SHOP TOWEL 3 CENTER ARMREST INNER PANEL f CENTER AIR VENT Lift up he parking brake lever TER CONTROL UNIT CASSETElRADlO TRUNK LID OPENER MAIN SWITCH Y 0 I PANEL Passenger s side GLOVE...

Page 870: ...CAUTION Be careful not to damage the SRS wire harnesses when servicing the steering column Driver s Side NOTE Take care not to scratch or score the dashboard and steering column Dlsassemble in numbered sequence I L DASH 1 I R DASH 1 SENSOR SENSOR I CABLE REEL and MAIN HARNESS SRS UNIT _ ____ RETRACTOR SW BRIGHTNESS CO I DASHBOARD LOWER PANEL Driver s sl e KNEE BOLSTER PAD b y w INSTRUMENT PANEL IE...

Page 871: ...0 Center armrest page 20 43 0 Clock center air vent and console panel page 20 43 0 Heater control unit and stereo cassette radio page 20 43 0 Dashboard lower panel passenger s side 0 Glove box lid and glove box page 20 43 m To avoid accidental deployment and possible injury always install the protective short connector on the inflator connector when the harness is disconnected 2 Lower the steering...

Page 872: ...icator panel A T wrap with a shop towel Reassembly NOTE 0 Make sure the dashboard fits onto the guide pin and defrost panel correctly 0 Before tightening the dashboard bolts make sure the dashboard wires are not pinched If necessary remove the defrost panel Sr MOUNTING BOLT I DASHBOAW J I TTAINEA 4 M UNT NG BXT GlJlriE PIN Q DASHBOARD MOUNTING BOLTS JROTECTIVE A rAPE kP TI Im END PLATE ff a DASHBO...

Page 873: ...connect the washer hose horn connecters and ambient sensor connector 0 An assistant is helpful when removing the front bumper 0 Take care not to scratch the bumper SKIRT MOUNTING BOLTS BUMPER MOUNTING NUTS HOOK QBxl Omm 0 x 1 0 mm Bumper beam side HOLE 10 N m 1 0 kg m 10 N m 1 0 kg m Bumper bracket side NER FENDER FRONT BUMPER SIGNAL LIGHT SKIRT COVER BUMPER MOUNTING BOLTS 8 x 1 25 mm 22 N m 2 2 k...

Page 874: ... BUMPFR BEAM aam ABSORBER I BUMPER FACE I UPPER FRAME SIDE PLATE k yg BUMPER LOWER E 1 SlDE FRAME lXTENTlON QJ Spoiler installation Jd T Q d BUMPER SKIRT SKIRT SPOILER PLATE NUT FRONT UNbER SPOILER LICENSE a e PLAIt 43 I UlNl MOUNTING BOLT 131 T 20 48 ...

Page 875: ...n each side 6 Remove the bumper assembly by sliding it to the rear NOTE 0 Disconnect the license light connector 0 An assistant is helpful when removing the rear bumper 0 Take care not to scratch the bumper MOUNTING NUT 6x l Omm 10 N m 1 O kg m 7 lb W BUMPER MOUNTING NUT 6x 1 25mm 22 Nom 2 2 kg m A I B ll 7x M 16 lb ft FLOOR TRIM PANEL 10 N m I O kg m 7 lb ft INNER FENDER REAR BUMPER ASSEMBLY UNDE...

Page 876: ...UPPER FRAME Rear Bumper Disassembly BUMPER BEAM UPPER LICENSE PLATE SUPPORT SUMP R SKIRT 20 50 ...

Page 877: ...ust the height of the hood at the rear edge l Adjust the hood latch to obtain the proper height at the forward edge page 20 52 4 Install the new hood After installing adjust the hood fit to the opening SHIM Use shims as required to make the hood fit flush with the bumper at the f ront edge I STRIKER MOUNTING BOLTS Q6 x 1 0 mm 10 N m 1 0 kg m STRIKER I Adjust the striker right or left to align it w...

Page 878: ... care not to bend the cable 6x l Omm IO N m II O kg m 7 lb ft HOOD SWITCH Be careful not to damage the HOOD RELEAiE Y HANDLE To remove the handle first remove the side sill trim page 20 37 6xl Om 10 N m I 7 lb ft s kg m HOOD LATCH A l COVER Q6 x l Omm 10 N m 1 0 kg m 7 lb ft HOOD EDGE ClJSHItiN Turn as necessary to make the hood fit flush with the bumper and headlight lid I 4 After installing adju...

Page 879: ...emoval NOTE 0 Before tightening the mounting bolts adjust the rear hatch and striker 0 With the rear hatch closed fully check for water and air leaks I I I I LE 1 CONNECTOR REAR DEFOGGER CONNECTOR NC ROD HOLDER Turn the holder 45O to remove it I SHIM Use shims es required to make the latch fit flush with the body at the rear edge I I 6xl Omm 0 Nm I O kg m lb ft iTRlKER ADJUSTMENT Adjust the rear h...

Page 880: ...Nom I O kg m 7 lb ft HINGE MOUNTING BOLTS 6 x 1 0 mm 10 N m 1 0 kg m 7 lb ft HIGH MOUNT STOP LIGHT HARNESS SUPPORT STRUT SUPPORT STRUT BOLT TRUNK LIi3 HINGE Adjust the hinges fore and aft and right and left as necessary REAR HATCH AIR SCOOP to equalize the gap between the trunk lid and the body _ LIDi STOP LIGHT HARNESS SHIM Use shims as required to make the trunk lid fit flush with the body at th...

Page 881: ...nnector HIGH MOUNT STOP LIGHT HARNESS TRUNK LID ADHESIVE TAPE NOTE Clean the trunk lid bonding surface with a sponge dampened in alcohol TRUNK LID SPOILER MOUNTING NUTS Q6xl Omm 10 N m 1 0 kg m 7 lb ft SCREW SIDE TRIM PAiiELY Pry out the 3 clips and disconnect the connector CLIP II FLOOR TRW i PANEL Pry out the 5 clips and lossen the screws then pry out the clips f wTRuNK 5 TRIM PANEL Pry out the ...

Page 882: ...stalling check that the cables are routed and connected properly 0 If necessary adjust the cable by changing the position of the cable housing Standard cable housing position REAR GLASS HATCH OPENER Replacement page 20 57 REAR HATCH LATCH y Replacement page Replacement pag Replacement page 20 57 r FUEL OPEiGER FUEL LID iATCH Lower the rear inner TRUNK tiD LATCH Replacement page 20 58 fender and re...

Page 883: ...FUEL LID AS I check for 2GiGii he bodv REAR SIDE TRIM PANEL Removal page 20 37 Replacement handle and rear side trim panel Fuel Lid Opener Latch OPENER CABLE MOUNTING BOLTS 6x l Omm 10 N m 1 0 kg m 7 lb ft 3PE NER K N O B I t 1 10 Nom I O kg m 7 lb L OPENER CABLE Replacement page 20 56 J iz LL p ___ Push and turn the fuel lid latch to oftain a flush fit between the fender and lid 02 To remove the ...

Page 884: ...MOUNTING BOLTS 6xl Omm 10 N m I O kg m 7 lb ft REAR PANEL MOUNTING LE I Fe OPENER CABLE h TRUNK KEY SWITCH Be careful not to damage the trunk key switch LOCK CYLINDER _ Remove the rear panel and turl the lock cylinder 45 O Remove the lock rod and lock jq l i rn the hole in the LOCK CYLINDER HARNESS I 0 TRUNK LID OPENEd EAB E REAR PANEL BOLT r REAR PANEL TRUNK LID LAT s 9 I 0 and disconnect the loc...

Page 885: ... clips SPECIAL MOUNTING NUT INSIDE CLIP 1 SIDE AIR SCOOP DUCT ASSEMBLY SPECIAL MOUNTING NUT SPEClAL BO l21 ti y SIDE SILL PANEL A FRONT INNER FE I A 7 INNER FENDER SIDE SILL PANEL Remove the side sill panel by sliding it forward Turn the side clips 45O then pull them out of the side sill I C SIDE SILL PANEL 6 A L O W E R S C R E W w LOWER CUP 2 S E CLIP 9 20 59 ...

Page 886: ...ROSS BEAM 10x 1 25mm 39 Nom 3 9 kg m 28 lb ftl 012 x 1 25 mm l b x 1 25 mm 95 N m 9 5 kg m 69 lb W 60 Nom 6 0 ka m 43 lb ft 10x 1 25 mm 60 N m 6 0 kg m 43 lb ft 10x 1 25 mm 39 Nom 3 9 kg m 28 lb W I 6xl Omm I 10 Nom 1 O ka m 71 lb ft w SPARE TIRE HOLDER BATTERY HOLDER I I 76x l Omm 10 N m 1 0 kg 71 lb ft 8x 1 25mm 25 N m 2 5 kg m 18 lb ft 4 CORROSION RESISTANT BOLT NUT 20 60 ...

Page 887: ...I 60 N m 6 0 kg m 43 lb ft I 10X 1 25ml 60 Nom 6 0 43 lb ft 1 69 lb ft FRO Id x 1 25 mm 60 Nom 6 0 kg m 43 lb ft 60 Nom 6 0 kg m IO x 1 25 mm 3 A 60 Nom 6 0 kg m 43 lb ft CENTER ROD 1 2 x 1 25mm V 95 Nom 9 5 kg m 69 lb ft QlO x 1 25 mm 60 Nom 6 0 kg m 43 lb t Q CORROSION RESISTANT BOLT N1 20 6 1 ...

Page 888: ...Frame Repair Chart 20 62 ...

Page 889: ...ar Temperature Sensor 22 87 Ambient Temperature Sensor 22 87 Coolant Temperature Sensor 22 88 Evaporataor Temperature Sensor 22 88 Sunlight Sensor 22 89 Recirculation Control Motor 22 89 Air Mix Control Motor 22 90 22 90 22 9 1 22 9 1 22 92 22 92 Vent Door Control Motor Mode Control Motor Aspirator Fan Relay Control Unit Adjustment A C System Service Discharge Evacuation Leak Test Charging Procedu...

Page 890: ...Special Tools r Ref No Tool Number Description O ty 1 Page Reference I I I 0 07LAJ PT301 OA ECU Test Harness 1 22 57 58 22 2 ...

Page 891: ...erant and then forces it through the condenser DEF DOOR VENT DOOR CONTROL Adjustment page 22 72 HEAT DOOR Adjustment page 22 72 RECIRCULATION CONTROL MOTOR Replacement page 22 64 BLOWER Serves as a reservoir which filters and removes moisture from the refrigerant ISOR 22 85 1 AMBIENT TEMPERAiURE SENSOR Removal Replacement page 22 86 V COOLAN Test page 22 87 DUAL CONDENSER TEMPERATURE SENSOR Remova...

Page 892: ...Heater Evaporator Door Position a C O L D KA type only VENT DOOR DEFROSTER EVAPORATOR HEATEd CORE CORE 22 4 ...

Page 893: ...22 5 ...

Page 894: ... below High temperature high pressure gas Section compression Radiation of heat COMPRESSOR 1 bCONDENSER High temperature High temperature high presure liquid high pressure liquid Dust removed RECEIVER TANK CONDENSER EXPANSION VALVE H E A T E R C O R E R E C E I V E R TANK CONDENSER EVAPORATOR COMPRESSOR a a a 22 6 ...

Page 895: ...ling fan control unit to prevent the compressor from operating 25kPA 588kPA 0 25kg cm2 4psi 6kg cm2 85 psi _ Operate the compressor Stop the compressor 231kPA 2059kPA 2 35kg cm2 34 psi 21 kg cm2 299 psi l Middle pressure switch If the refrigerant pressure goes above or below 1520 kpa 15 5kg cm 220 psi the tripple pressure switch sends a signal to the PGM FI ECU then the PGM FI ECU operates the idl...

Page 896: ...l unit operates Trl ON and radiator fan at low speed When radiator coolant temperature is above 194OF 90 C the control unit operates Trz ON radiator fan at high speed and engine compartment fan When radiator coolant temperature is above 266OF 1 30 C the control unit operates Tr3 OFF and stops the condenser fan Then it operates Tr4 OFF and stops the compressor ON OFF ON OFF ON OFF 172OF 78 C 282OF ...

Page 897: ...AMBIANT TEMPERATURE SENSOR TRIPLE PRESSURE SWITCH I MODE CONTROL IN CAR MOTOR TEMPERATURE AIR MIX MOTOR SENSOR MAIN FUSE BOX COOLING FAN CONTROL UNIT Fan radiator and con denser fans inside car SRS wire harness is routed near the air conditioner harness m All SRS wire harnesses and connectors are colored yellow Do not use electrical test equipment on these circuits CAUTION Be careful not to damage...

Page 898: ...LK ED tl ___ 4 s BLKlBLl 1BLOWER HI RELAY GRY BLI 0RNIWH BLK L LT POWER I TRANSISTOR BLK 0 8 No 37 1 JA WHT WH WH T G R N t YEL BLK No 36 1 OA BL No 21 lOA r CONDENSER FAN RELAY N B RED R E D B 1 7 v PGM FI ECU 1EO P ESSOR RELAY BL BL OR r 3 FI I BLUlBLK c a r GRNlB BRNiBtK PCESSURE BLK G302 6301 G201 G302 22 l 0 ...

Page 899: ...K WHTI 1 No 33 7 5A fEL ASUNLIGHT SENSOR B COOLANT TEMPERATURE SENSOR C EVAPORATOR TEMPERATURE SENSOR D AMBIENT AIR TEMPERATURE SENSOR E IN CAR TEMPERATURE SENSOR z 30 27 30 28 14 13 14 12 30 19 I so 22 CL M TE CONTROL l T 991 i so 13 14 14 14 7 10 12 14 3 10 B 14 8 IO 24 RN 11 ...

Page 900: ...ion switch OFF the indicator light memory will be lost B A C I I I F I D E H INDICATOR COMPONENT WITH PROBLEM POSSIBLE CAUSE Refer to PAGE A M O D E IN CAR TEMPERATURE SENSOR Open or short circuit 22 l 6 B w AMBIANT TEMPERATURE SENSOR Open or short circuit 22 l 8 C e3 SUNLIGHT SENSOR Open or short circuit 22 20 D s COOLANT TEMPERATURE SENSOR Open or short circuit 22 22 E OS EVAPORATOR TEMPERATURE ...

Page 901: ... while you start the engine The control unit will then automatically run the check in eight steps one step every 5 seconds To stop at one of those steps push the MODE button to continue push it again for each st ep after that Pushing the OFF button or turning the ignition OFF will turn off the check Check the temperature volume and source of this air flow and compare it to what the chart shows it ...

Page 902: ...N TURE SENSOR S r M O T O R M O T O R SPEED A C DENSER A C ON CLIMATE CONTROLS SYSTEM FAN PRESSO CONTROL SENSOR SENSOR M O T O R M O T O R UNIT SYMPTOM 22 38 23 7 6 22 18 22 20 22 22 22 24 22 26 22 30 22 32 22 34 22 40 22 46 22 50 22 52 22 56 Xmate control system does lot work at ail 0 Uo air from blower 0 0 0 40 cold air from blower 0 0 0 Vo hot air from blower 0 0 4ctual rsmperature is differ nt...

Page 903: ...1 Small Light 2 VENT mode I I 12 Blower High Relay 3 Fresh Position Signal 13 A C Signal 4l 14 1Asperator Fan I I 5 Air Mix Motor HOT 6 MODE 3 16 DEF 7 MODE 4 17 Recirc Position Signal 8 Power Transistor Base I I 1 8 9 RECIRC I I 1g Vent Motor OPEN 10 FRESH I I 20 MODE 1 14 P ature Sensor ...

Page 904: ...ensor circuit Remove the center console panel page 22 841 then disconnect the 1 g gt y t h e i n c a r 1 Measure resistance between the No 1 terminal and No 2 terminal in the sensor half of the con nector Is there l 1 2kD7 Y E S Replace in car temperature sensor Turn the ignition switch ON Measure voltage between the RED GRN wire 1terminal in the other half of the connector and body ground NO Is t...

Page 905: ... back of the 14 P con nector measure voltage between No 9 terminal and No 14 terminal 7 I s t h e r e apF Repair open in RED GRN wire between con N O I trol unit No 91 and in car temperature sensor I I I I Disconnect the 14 P connector from the climate control unit Check for continuity between No 9 terminal and body ground I I I I Is there continuity NO Repair short in RED GRN wire between con tro...

Page 906: ...ermistor decreases as the temperature outside the car increases AMBIENT Problem in the ambient tempera ture sensor circuit I TEMPERATURE Turn the ignition switch OFF Disconnect the 2 P connector from the ambient temperature sensor behind the front grille Measure resistance between the 2 terminals in the temperature sensor half of the connector Is there l 7 kD YES NO _ Replace ambient temperature s...

Page 907: ...original control unit Repair open in BLKI Remove the climate control unit page 22 84 Leave the wire con nected I I Repair open in BRN Is there approx 5 V No 81 wire between control unit and am N O bient temperature sen sor Disconnect the 14 P connector from the climate control unit I Substitute a known good control unit and recheck If symptom indi 1cag acvmoer y wiwlace the No 8 No 14 22 19 ...

Page 908: ...t increases Problem in the sunlight sensor circuit Disconnect the 2 P connector from the sunlight sensor I Measure resistance between the as shown 2 terminals in the sunlight sensor ORNl 7 N U Is there approx 7 5 kg Replace sunlight sen I Isor I Turn the ignition switch ON I Measure voltage between GRN RED wire terminal in the con nector and body ground I NO Is there approx 5 VI Y E S Turn the ign...

Page 909: ...m ptomlindication goes away replace the original control unit From the back of the 14 P con nectar measure voltage between No 1 1 I terminal and No 2 terminal Disconnect the 14 P connector from the climate control unit Check for continuity between No 11 terminal and body ground I I I I L 8 NO Substitute a known good control unit and recheck If symptom lndi cation goes away replace the original con...

Page 910: ...ster decreases as the coolant temperature increases Problem in the coolant tempera ture sensor circuit I Disconnect the 2 P connector Measure resistance between the Is there 5 30 kg Y E S Turn the ignition switch ON Measure voltage between LT BLU wire terminal in the other half of the connector and body ground Is there approx 5 V Turn the ignition switch OFF I I Y E S Measure voltage between LT BL...

Page 911: ...rol unit and recheck If sym ptom indication goes away replace the original control unit J nectar measure voltage between Is there approx 5 V N O JYES Disconnect 14 P connector from the control unit Substitute a known good control unit and recheck If symptomlindi cation goes away replace the original control unit No 7 No 14 22 23 ...

Page 912: ...or outlet air temperature increases Problem in the evaporator temper ature sensor circuit Disconnect the 2 P connector from the evaporator temperature sensor Measure resistance between the 2 terminals in the temperature sensor half of the connector Turn the ignition switch ON Measure voltage between LT GRN wire terminal in the other half of the connector and body ground NO Replace evaporator tempe...

Page 913: ... nector measure voltage bet ween No 3 terminal and No 14 C 1terminal NO Repair open in LT GRN wire between control unit No 31 and evapo rator temperature sensor Disconnect 14 P connector from the control unit Substitute a know good control unit and recheck If symptomfindi cation goes away replace the original control unit Repair short in LT GRN wire between control unit No 31 and evapo rator tempe...

Page 914: ... sure the linkage is free of obstructions I Remove the climate control unit netted page 22 84 Leave the wire con Turn the ignition switch ON Set the temperature control dial at TEMP display 18 then measure battery voltage between the No 15 terminal and body ground when turning temperature control dial at TEMP display 32 After measure battery voltage between the No 1 terminal and body ground when t...

Page 915: ...al and body ground when turning tempera ture control dial at TEMP display 18 I N O Is there battery voltage Repair o p e n i n t h e GRNlBLK or GRNlBLU Y E S wires between the air mix control motor and the control unit Turn the ianition switch OFF Dis the control unit connect the 30 P connector from 1 e I Check for continuity between GRN BLK or GRN BLU terminals and body ground Is there continuity...

Page 916: ...l unit and recheck If symptomlindi cation goes away replace the original control unit Repair open in the GRNlRED wire between the air mix control Y E S motor and control unit Turn the ignition switch OFF I Disconnect the 14 P connector from the control unit Check each wires for continuity l GRN wire l BLKlGRN wire I I I BLKlGRN wire s between the air I s there 1 03 1 dG2t I 1 I To pag 22 29 22 28 ...

Page 917: ... o r BLKlGRN wire s and body ground or BLKlGRN wire s between the air mix control motor and control Test the air mix control motor at the heater page 22 90 Y E S Replace the air mix control motor Substitute a known good control unit and recheck If symptomlin 22 29 ...

Page 918: ...ge is free of obstructions Remove the climate control unit page 22 84 Disconnect the both connectors LY from the climate control unit No 14 IBLKIGRN Connect battery power to the No 16 terminal of the 30 P con nector and connect the No 2 terminal to body ground The mode control motor should run If it doesn t try reversing the connections L 00 CONTROL I Does the motor run Y E S Test the mode control...

Page 919: ...ontrol unit N O Repair short in the wireN 1 be tween the mode control motor and control unit CL2 control door is stuck repair it Y E S a known good control unit and recheck If sym ptom indication goes away replace the original control unit GRY GRNlWHT PNKlBLK BLKlGRN MCDE CONTROL MOTOR CONNECTOR 22 31 ...

Page 920: ...tch OFF I Make sure all wires in the recircu lation control motor connector are securely attached Make sure the linkage is free of obstructions Remove the climate control unit page 22 84 Disconnect the both connectors from the climate control unit Open the hood Disconnect the 8 P connector from recirculation control motor at the blower Check each wires for continuity l BLU GRN wire l LT GRNlRED wi...

Page 921: ...epair any short in wire s be tween the recirc motor and con trol unit Test the recirculation control mo tor at the blower page 22 89 Is the motor OK NO Replace the motor Y E S Substitute a known good control unit and recheck If symptomlindi t ac gcooenstr gfirwlace the LT RECIRCULATIO CONTROL MOTOR 22 33 ...

Page 922: ... connector are securely attached Make sure the linkage is free of obstructions Remove the climate control unit page 22 84 Leave the wire connected I Turn the ignition switch ON Set the temperature control dial at TEMP display 18 then measure battery voltage between No 5 ter minal and body ground when turning temperature control dial at TEMP display 32 After measure battery voltage between No 19 te...

Page 923: ...re battery voltage between the YEL BLU terminal and body ground when turning the temperature control dial at TEMP display 18 Is there battery voltage Repair open in YEL BLK or YELlBLU wires between the vent Y E S door control motor and control unit Turn the ignition switch OFF Disconnect the 14 P connector from the control unit Check for continuity between YEL BLK or YEL BLU terminals and body gro...

Page 924: ... GRN RED terminal and body ground Substitute a known good control unit and recheck If symptomlindi I Is there approx 5V Y E S N O Repair open in the GRNlRED wire between the vent door control motor and control unit Turn the ignition switch OFF p q Disconnect the 14 P connector Check each wires for continuity l YEUWHT wire l BLKIGRN wire I I e ffffKLE2xz vent door control motor and con To page 22 3...

Page 925: ... in the GRNIRED YELANHT or BLKlGRN wire s be tween the vent door control mo tor and control unit Test the vent door control motor at the heater page 22 W Y E S Replace the vent door control motor Substitute a known good control unit and recheck If symptom in dication goes away replace the original control unit 22 37 ...

Page 926: ...it Turn the ignition switch ON Measure voltage between the No 30 WHT YEL terminal and body ground Y E S Repair open in WHTlYEL No 301 wire between the control unit and No 33 7 5 A fuse Measure voltage between l No 28 YEL BLK terminal and body ground l No 27 YEL BLK terminal and body ground Is there battery voltage I NO Repair open in YELlBLK No 27 or No 281 wire between the control unit and No 4 1...

Page 927: ...nd body ground l No 24 BLK and body ground Is there continuity NO Substitute a known good control unit and recheck If symptomlindi Repair open BLK No 24 or No 251 wire between the control unit and body ground If wires are OK check for poor ground at G401 22 39 ...

Page 928: ...sub kelay box A and re I Turn the ignition switch ON Measure voltage between the BLU WHT wire terminal and body ground 1 Is there battery voltage Y E S NO Repair open in BLWVHT wire be tween the No 28 30AI fuse and blower relay Measure voltage between the YELlBLK wire terminal I and body ground 1 I Is there battery voltage Y E S T To page 22 41 1 22 40 ...

Page 929: ...r disconnected Y E S Replace the blower relay Check for continuity between the BLK wire terminal and body ground Y E S Repair open in BLK wire between the blower relay and body ground If wire is OK check for poor ground at 0301 Turn the ignition switch OFF I Reinstall the blower relay Disconnect the 2 P connector from the blower motor Turn the ignition switch ON I To page 22 42 BLOWER MOTOR C O N ...

Page 930: ...ry voltage Y E S Repair open in BLUlRED wire be tween blower motor and blower relay Inspect the blower motor NOTE Connect the battery power to the BLWRED wire terminal and connect the BLK BLU wire ter minal to body ground The blower motor should runs Does the blower motor run Replace the blower motor I YES ntx mi h O F F Reconnect the connector to the SUB RELAY f _ e 22 42 ...

Page 931: ...high relay Turn the ignition switch OFF 1 the BLK BLU wire terminal and 1 Turn the ignitio switch ON 1 Measure voltage between the YEL BLK wire terminal and body ground Repair open in BLK wire between 1 t zLJL Repair open in YELIBLK wire be tween ignition switch and blow er high relay YES To page 22 44 j cont d 22 43 ...

Page 932: ...ls A and 6 with power connected no continuity with power discon nected Y E S Replace the blower high relay I Turn the ignitio switch OFF i Reinstall the blower high relay Remove the climate control unit page 22 84 Disconnect the 30 P connector from the climate control unit Connect a jumper wire between the ORN WHT wire terminal and body ground Turn the ignition switch ON To page 22 45 No 1 2 ORNIW...

Page 933: ...e 22 44 Repair open in ORNMfHT wire be tween blower high relay and cli mate control unit Substitute a known good control unit and recheck If symptom indi cation goes away replace the original control unit a 22 45 ...

Page 934: ... motor speed does not change Open the hood disconnect the 3 P power transistor connector from the blower harness connector LT Connect a voltmeter between the Y E S Turn the FAN switch to the mid dle of its range v B To page 22 47 GRNlBLK To 22 46 ...

Page 935: ... the blower motor I Check for continuity in the BLK BLU wire Is there continuity N O 1YES S e e troubleshooting page Repar open in the BLK BLU wire between the blower motor and control unit Check for continuity between the BLK BLU terminal and body ground Is there continuity N O Replace the power transistor Repair short in the BLKlBLU wire between the blower motor and control unit No 22 BLKIBLU do...

Page 936: ...continuity in the LT GRN BLK wire I I Is there continuity Y E S NO Repair open in the LT GRNlBLK wire between the power transis tor and control unit Check for continuity between the No 8 LT GRN BLK wire terminal and body ground 1 NO Substitute a known good control unit and recheck If symptomlindi cation goes away replace the original control unit ...

Page 937: ...22 49 ...

Page 938: ...sure voltage between the No 13 GRY BLK terminal and body ground I Is there battery voltage NO Y E S Check for continuity between l No 25 BLK terminal and body ground l No 24 BLK terminal and body ground Y E S Substitute a known good climate control unit and recheck If sym ptomlindication goes away replace original control unit To paw 22 51 Repair open in one of the two BLK wires between the climat...

Page 939: ...From page 22 50 1 Turn the ignition switch OFF 1 I Disconnect the 12 P connector from cooling fan control unit I Substitute a known good cooling replace the original control unit 22 51 ...

Page 940: ...1 z e cover from sub elay box A and re Using a jumper wire connect the VV l T RNwireterminaltobody l Do both condenser fans run L Y E S Connect a jumper wire between the WHT GRN wire terminal and ELK wire terminal Do both condenser fans run Y E S Turn the ignition switch ON To page 22 53 To page 22 55 22 52 ...

Page 941: ... Connect battery power to relay terminal C then connect terminal D to body ground There should be continuity between terminals A and B with power connected no continuity with power discon nected Replace the condenser fan relay Turn the ignition switch OFF and reinstall the condenser fan relay Disconnect the 12 P connector from the cooling fan control unit Turn the ignition switch ON To page 22 54 ...

Page 942: ...ween the ORN BLU terminal and body ground t 1 NO I Is there battery voltage Repair open in the ORNlBLU wire between the condenser fan relay and cooling fan control unit fan control unit and recheck If symptom indication goes away replace the original control unit 22 54 ...

Page 943: ...side WHT Left side WHTIBL Y E S Test both condenser fan motors Connect battery power to the WHT and WHT BLU wire termi nals and connect the WHT GRN terminal to body ground Both fans should run Repair open in WHT wire between the No 37 fuse 10 A and the right fan or in the WHTIBLU wire between the No 36 fuse IOA and the left fan Does the fan motor s OK I NO Replace the faulty fan motor Y E S r betw...

Page 944: ... lay from sub relay box A Is there battery voltage Y E S NW Repair open in the PNKlORN wire between the No 21 IO A fuse and compressor clutch relay I c Turn the ignition switch ON Measure voltage between the YEL BLK wire terminal I and body ground NO Repair open in the YELlBLK wire Is there battery voltage between the No 4 16 A fuse and compressor clutch relay Y E S To page 22 57 22 56 ...

Page 945: ...he compressor clutch relav Y E S I I I I 1Turn the ignition switch OFF 1 p Remstall the compressor clutch Remove the panel from behind the passenger seat Disconnect the 4 connectors from PGM FI ECU Connect teh ECU test harness connectors to the ECU Turn the ignition switch ON I ECU TEST HARNESS Measure battery voltage between Is there battery voltage Y E S NO Repair open in the REDlBLU wire betwee...

Page 946: ...ESS A l 5 c3 I I Turn the ignition switch OFF I Does compressor clutch engage Y E S Using a jumper wire connect C3 test harness terminal to body ground Does compressor clutch engage Y E S NO Turn the ignition switch OFF I A B L7 To page 22 61 Substitute a known good PGM FI ECU and recheck If symptomiindi cation goes away replace the original ECU To page 22 59 22 58 ...

Page 947: ...erant pressure If Does compressor clutch engage pressure good replace AIC pres sure switch N O Turn the ignition switch OFF I Check for continuity between the 8LK wire terminal and body ground Is there continuity N O Y E S Repair open in the BLK wire be tween the pressure switch and body ground or poor ground 0302 BRNlBLK BLK To page 22 60 cont d 22 59 ...

Page 948: ... n i t a n d prey s w i t c h Y E S Repair open in the BRNIBLK wire between the cooling fan control unit and pressure switch 11Start the enginei NO Does compressor clutch engage Repair open in the BLWBLK wire between PGM F ECU and cooling Y E S fan control unit Substitute a known good cooling symptom indication goes away replace the original control unit 22 60 ...

Page 949: ...the connector from compressor Turn the ignition switch ON 1 g r o u n d t 1 RED Repair open in the RED wire be Is there battery voltage tween the compressor clutch re lay and compressor Y E S Replace the compressor clutch 1 22 6 1 ...

Page 950: ...Blower 22 62 ...

Page 951: ...ERY BRACKET 4 Remove the sub relay box A and the water drair duct Disconnect the connectors from the blower motor power transistor and recirculation contra motor Q CORROSION RESISTANT BOLT I r 6 mm bolt DUCT BLOWER POWER TRANSISTOR and RECIRC MOTOR CONNECTORS 6 mm bolt 5 Remove the blower mounting bolts then remove the blower 2 CORROSION RESISTANT BOLT 6 Install the blower in the reverse order of ...

Page 952: ...MOTOR COVER 3 Remove the recirculation control motor I connec tor and 3 screws RECIRCULATION CONTROL MOTOR L 4 Install the recirculation control motor in the reverse order of removal Apply battery voltage page 22 89 and watch the door movement Make sure that the recirculation door moves smooth ly without binding Make sure the motor doesn t pull the door too far 22 64 ...

Page 953: ...b ft Condenser line A both side 23 N m 2 3 kg m 17 lb ft Condenser line C to left side condenser 14 N m 1 4 kg m 10 lb ft Receiver dryer 14 N m 1 4 kg m 10 lb ft Receiver line and suction line to heater assembly 22 N m 2 2 kg m 16 lb ft Compressor hose mounting bolts 22 N m 2 2 kg m 16 lb ft Compressor mounting bolts a 25 N m 2 5 kg m 18 lb ft Compressor bracket mounting bolts 50 N m 4 5 kg m 36 l...

Page 954: ...ng and run for up to 30 minutes even after the engine is turn ed off CAUTION Radiator coolant will damage paint Quickly rinse any spilled coolant off painted surfaces Disconnect the heater hoses at the heater Coolant will run out when the hoses are disconnected drain it into a clean drip pan Disconnect the heater valve cable from the heater valve HEAiER VALVE CABLE 5 Remove all refrigerant from th...

Page 955: ...lant mixture Bleed the air from the cooling sys tem Section IO CAUTION Follow the sequence described in the air bleed procedure If you don t you may leave air in the system which could damage the engine 15 If necessary adjust the heater valve cable l Set the air mix control motor at COLD position page 22 90 l Connect the end of the cable to the heater valve arm l Gently slide the cable outer housi...

Page 956: ...e connector and remove the coolant tem perature sensor clip and the sensor COOLANT TEMPERATURE SENSOR Evaporator Temperature Sensor Removal Give the evaporator temperature sensor a quarter turn and then pull out it EVAPORATOR TEMPERATURE SENSOR 22 68 ...

Page 957: ... l Make sure that the vent door moves smoothly without binding l Make sure the motor doesn t pull the vent door too far Replacement 1 Remove the mounting screws then remove thl mode control motor MODE CONTROL MOTOR 2 install the mode control motor in the reverse order of removal Then apply battery voltage page 22 91 and watch the doors move l Make sure that the HEAT and DEF doors moves smoothly wi...

Page 958: ...90 and watch the door move Make sure that the air mix door moves smoothly without binding Make sure the motor doesn t pull the air mix door too far 4 If necessary to adjust the heater valve cable 0 Set the air mix control motor at COLD position page 22 90 0 Hold the end of the cable housing against the stop on the cable Then snap the clamp down over the housing 0 After adjusting the cable make sur...

Page 959: ... evaporater 3 Remove the expansion valve if necessary HEATER CORE PIPE CLAMP AIR MIX DOOR 1 EXPANSION VALVE TAPE Replace CAPILLARY TUBE must be touching the suction line LOWER HALF OF THE HOUSING 4 Assemble the heater evaporator unit in the reverse order of disassembly Hold the expansion valve capillary tube down against the suction line and wrap it with tape to hold it there 22 7 1 ...

Page 960: ...od to he clip 0 Turn this lever all the way clockwise and hold it there 0 Turn this Ieve clockwise and hold it against its stop HEAT Door Adjustment Reposition gear 2 so this mark lines up with the mark on gear 1 0 Loosen this screw in gear 2 GEAR 1 GEAR 2 a 22 72 ...

Page 961: ...d behind the right and left side of the front bumper as shown The cooling efficiency of parallel dual condensers is as good as or better than a single condenser mounted in front of radiator Description RECEIVER DRYER RIGHT CONDENSER 22 73 ...

Page 962: ...SCHARGE LINE C Left Condenser CONDENSER CONDENSER LINE A 4 Disconnect the connector from the condenser fan motor remove the mounting belts 2 and nut then remove the condenser CORROSION RESISTANT BOLT Right Condenser NUT V RIGHT CONDENSER MOUNTING BOLTS 10 N m 1 0 kg m 7 21 lb ft Left Condenser NUT Q MOhNTlNG BOLTS 10 N m 1 0 kg m 7 2 lb ftl 5 Install the condenser in the reverse order of removal l...

Page 963: ...condenser Remove the fan mounting screws 31 then remove the fan from the shroud CONDENSER I NUT 10 N m CONDENSER DUCT 1 0 kg m 7 2 lb it SCREW SPACER SHROUD CONDENSE6 FAN 3 Assemble the condenser in the reverse order Be careful not to damage the tabs on the condenser shroud when you attach it to the air intake duct 22 75 ...

Page 964: ...evolving inclined disc drives the surrounding 10 reciprocating pistons As the inclined disc revolved it pushes the pistons protected by a ceramic shoe thus compressing the refrigerant 4 CENTER BOLT PRESSURE PLATE _e SHIMS 4e SNAP RING B PULLEY SNAP RING A 22 76 FIELD COIL ...

Page 965: ... hoist Make sure it s properly supported Section I 5 Remove the front beam Section 5 6 Disconnect the suction and discharge hoses from the compressor Cap the open fittings immediately to keep moisture and dirt out of the system DISCHARGE HOSE SUCTION f 3 7 Loosen the idler pulley center nut and adjusting bolt then remove the belt from compressor ADJUSTING BOLT 12 N m 11 2 kg m IDLER PULLEY CENTER ...

Page 966: ... if it s noisy or has ex cessive play or drag o 12 N m 0 1 2 kg m 8 7 lb ftt 11 Install in the reverse order of removal If you re installing a new compressor drain all the refrigerant oil out of the old compressor and meas ure its volume Subtract the volume of old oil from 80 CC 2 l 3 floz the result is the amount of oil you should drain from the new compressor through the suction fitting 12 Adjus...

Page 967: ...than 5 minutes on a running engine 0 Used belt refers to a belt which has been used or a running engine for 5 minutes or more l s L d NOTE Check for belt damage If necessary replace the belt ADJUSTING BOLT 12 N m 1 2 kg m 8 7 lb ft PULLEY CENTER NUT 45 N m 14 5 kg m 32 5 lb ft 22 79 ...

Page 968: ...0 2 ohm at 2o c 68OF If resistance is not within specifications replace the 3 Measure the clearance between the pulley and pres sure plate all the way around If the clearance is not within specified limits the pressure plate must be removed and shims added or removed as required following the procedure on the next page CLEARANCE 0 5 0 15 0 020 _ 0 006 in NOTE The shims are available in three sizes...

Page 969: ...olt CENTER BOLT 12 N m 1 2 kg m 9 lb ft P N 10204 2 Remove the pressure plate and shim s taking care not to lose the shims PRESSURE PLATE SHIMS 3 Use circlip pliers to remove snap ring B then remove the pulley SNAP RING B PULLEY cont d 22 81 ...

Page 970: ...lay 0 Make sure the circlip fits in its groove properly l Apply locking agent to the threads on the center bolt l Make sure that the pulley turns smoothly after it s reassembled Relief Valve Replacement 1 Remove the relief valve and O ring Don t let any compressor oil run out O RING RELIEF VALVE 13 5 N m I 35 kg m 9 8 lb ft RE EF VALVE CAP 2 3 4 5 Clean off the mating surface Apply compressor oil ...

Page 971: ...22 83 ...

Page 972: ... console 1 Carefully pry the clock out of the dash and discon nect it CAUTION Be careful not to damage the center con sole panel and the dashboard 2 Remove the center dash vent 2 screws 3 Remove the 2 screws from the top of the console panel CLOCK IFNT 4 Remove the ashtray lift up on the door to pop it out then remove the 2 screws behind it ASHTRAY 5 Remove the console storage box lift out the bot...

Page 973: ...y includes a small fan aspirator fan to draw air past the sensor SRS wire harness is routed near the console m All SRS wire harnesses and connectors are colored yellow Do not use electrical test equipment on these circuit CAUTION Be careful not to damage the SRS wire harnesses when servicing the console 1 Remove the center console panel as described in step 1 7 in the first column Climate Control ...

Page 974: ... temperature sensor Be careful not to damage the front grille and front bumper AMilENT TEMPERATURE SENSOR Sunlight Sensor With a small screwdriver carefully pry the sunlight sen sor out of the dashboard and disconnect its wire harness Protect the dashboard cover it with a shop towel before you pry against it SUNLIGHT SENSOR 22 86 ...

Page 975: ...pplied to it during test ing Therefore use a circuit tester that puts out a measuring current of 1 mA or less Ambient Temperature Sensor Compare the resistance reading between terminals of the ambient temperature sensor with specificatoins shown in the following graph It should be within specification o OF 35 32 50 68 86 104 122 OC 10 0 IO 120 130 40 i501 TEMPERATUER CAUTION The sensor uses a ther...

Page 976: ...se a circuit tester that puts out a measuring current of 1 mA or less C 0 10 20 80 40 601 60 70 80 Oc 0 IO 201 301 TEMPERATURE TEMPERATURE CAUTION The sensor uses a thermistor which can be damaged if high current is applied to it during testing Therefore use a circuit tester that puts out a measuring current of 1 mA or less Evaporator Temperature Sensor Compare the resistance reading between termi...

Page 977: ...nnector disconnected 0 1 0 2 V Recirculation Control Motor 1 Connect battery power to No 1 terminal of the recir culation control motor and connect to the No 2 ter minal to ground The motor should run If it doesn t reverse the con nections the motor should then run 2 Check for continuity between the terminals of the recirculation control motor according to this table 22 89 ...

Page 978: ...rminal and the No 4 terminal The reading should be 4 7 kO 7 V at HOT position 0 3 kO 7 V at COLD pcosition Vent Door Control Motor 1 2 Connect battery power to the No 1 terminal of the vent door control motor and connect to the No 2 terminal to ground the vent door control motor should run and stop at CLOSE If it doesn t reverse the connections then the mo tor should run and stop at OPEN Apply 5 V...

Page 979: ...e connectinos the motor should run and stop at DEF Plug the connector back in to the motor Then oper ate the MODE switch on the control panel and in each mode probe the back of the connector to check for continuity between terminals according to the table Aspirator Fan Connect battery power to the BRN YEL terminal of the connector and connect the BLK terminal to ground The fan should run BLK 22 9 ...

Page 980: ... connected to the C and D ter minals There should be no continuity when the battery is dis connected A C E v v B D Control Unit Adjustment The calibration switch can raise or lower the set temper ature by f3OF 1 5OC in relation to the digitally displayed temperature Calibration switch 5 3OF 1 53 22 92 ...

Page 981: ...ozone layer Always use UL listed refrigerant recovery recycling equipment to extract the refrigerant before you open an A C system to make repairs Follow the equip ment manufacturer s instructions Refrigerant Recovery Recycling System Evacuation 1 2 When an A C System has been opened to the at mosphere such as during installation or repair it must be evacuated using a vacuum pump If the system has...

Page 982: ...he chlorofluorocarbons CFCs used in conventional refrigerant R 12 may damage the earth s ozone layer Always use UL listed refrigerant recovery recycling equipment to extract the refrigerant before you open an A C system to make repairs Follow the equipment manufacturer s instructions 1 Attach an Air Conditioning Service Station as shown 2 Open high pressure valve to charge the system to about 100 ...

Page 983: ...when charging the system CAUTION Do not overcharge the system the compressor will be damaged Attach an Air Conditioning Service Station as shown Follow the equipment manufacturer s instructions HIGH SIDE ADAPTER Kent Moors P N J25499 P N ACT135 Charging Procedures 22 95 ...

Page 984: ...ditioning for 10 minutes un der the above conditions read the delivery temper ature from the thermometer in the dash vent and the high and low system pressure from the AK gauges 5 To complete the charts 0 Mark the delivery temperature along the vertical line 0 Mark the intake temperature fair temperature along the bottom line 0 Draw a line straight up from the air temperature to the humidity 0 Mar...

Page 985: ... 1 5 HUMIDITY 80 EMPERATURE 8 u 2000 E K CM t C 1 PSI kPa 3 lilw 501 4 0 0 a n1000 Mol 300 Psi kPa 50 400 I I 40 3 0 0 i 3Ol 200 I f 2017 100 2 lo 0 TEMPERATURE 3 2 6 8 7 7 8 6 8 5 1 0 4 0 20 26 30 35 MO 0 120 251 130 351 MO INTAKE TEMPERATURE INTAKE TEMPERATURE 22 97 ...

Page 986: ...rozen expansion valve Replace expansion valve low pressure line is not cold Low l Faulty expansion valve pressure gauge indicates vacuum Discharge temperature is low and Frozen evaporator Run the fan with compressor the air flow from vents is restricted off then check capillary tube Expansion valve frosted Clogged expansion valve Clean or Replace Receiver dryer is cool should be Clogged receiver d...

Page 987: ... Control 23 91 Indicator High Beam Indicator 23 l 30 Safety Indicator 23 145 Shift Lever Position Indicator 23 152 Turn Signal Indicator 23 209 Integrated Control Unit 23 l 58 Interlock System 23 140 Lights Exterior Back up Lights 23 200 Brake Lights 23 203 Daytime Running Lights CANADA 23 190 Front Side Marker Lights 23 191 Hazard Lights 23 209 Headlights 23 187 Brake Lights 23 203 License Plate ...

Page 988: ...ntenna Nut Wrench 1 23 236 0 07MAi SL00500 SRS Test Harness A 1 23 329 0 07LAZ SL40200 SRS Test Harness B 1 23 33 1 0 07LAZ SL40300 SRS Test Harness C 1 23 334 0 07LAZ SL40400 SRS Test Harness D 1 23 33 1 0 07HAZ SG00500 Deployment Tool 1 23 340 0 KS AHM 32 003 Digital Multimeter 1 23 78 23 2 ...

Page 989: ...ake sure multiple pin connectors are packed with grease except watertight connectors Since new type connectors are used connection and disconnection of them should be done paying attention to the following precautions 0 Because all the connectors except terminal of 1 P are equipped with push down type locks unlock them first before disconnecting the connectors 0 On the connectors installed on the ...

Page 990: ...t off from the mating connector by holding on both connectors 0 Never try to disconnect connectors by pulling on their wires GOOD 0 NO GOOD 0 Place the plastic cover over the mating connector after reconnecting Also check that the cover is not distorted NO GOOD x 0 Before connecting connectors check to see that the terminals are in place and not bent or distorted NO GOOD GOOD 0 Check for loose ret...

Page 991: ...nectors fully until they will no longer go 0 The connectors must be aligned and engaged securely 0 Do not use wire harnesses with a loose wire or connector NO GOOD x 0 Before connecting check each connector cover for damage Also make sure that the female connector is tight and not loosened from the previous use 0 Insert male connectors into the female connectors fully until they will no longer go ...

Page 992: ...ted parts NO GOOD x Keep sufficient distance1 0 GOOD 0 Do not bring wire harnesses in direct contact with sharp edges or corners 0 Also avoid contact with the projected ends of bolts screws and other fasteners NO GOOD x 0 Route harnesses so they are not pulled taut or slackened excessively xNO GOOD GOOD 0 Protect wires and harnesses with a tape or a tube if they are in contact with a sharp edge or...

Page 993: ...ng check that the wire harnesses are not twisted or kinked 0 Wire harnesses should be routed so that they are not pulled taut slackened excessively pinched or in terfering with adjacent or surrounding parts in all steering positions l When using the Service Tester follow the manufac turer s instructions and those described in the Shop Manual l Always insert the probe of the tester from the wire ha...

Page 994: ... the circuit operation identify one or more possible causes of the problem Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2 Keep in mind that a logical simple pro cedure is the key to efficient troubleshooting Test for the most likely cause of failure first Try to make tests at points that are easily accessible 4 Fix The Problem Once the speci...

Page 995: ... to identify wire colors in the circuit schematics RELAY In normal condition Normal open relay 1Normal closed relay e WHT White YEL Yellow BLK Black BLU Blue GRN Green RED Red ORN Orange PNK Pink BRN Borwn GRY Gray PUP Purple LT BLU Light Blue LT GRN Light Green Wire insulator has one color or one color with another color stripe The second color is the stripe CONDENSER i IlIt y a i 1 T I I I I SWI...

Page 996: ...IATOR FAN RIGHT RETRACTOR CUT RELAY LOW RELAY RADIATOR FAN ULUWtK RELAY HIGH RELAY CONDENSER FAN RE WER HIGH RELAY INTERMITTENT WIPER RELAY ALB REAR FAIL SAFE RELAY LlGHTlNd RELAY MAIN RELAY ALB FRONT FAI ICI nv POWER WINDOW RELAY TAILLIGHT RELAY ALB MOTOR RELAY Y BOX LEFT RETRACTOR RELAY 23 10 ...

Page 997: ... Dashboard AUTOMATIC CLIMATE CONTROL STARTER warning system I N T E G R A T E D CONTROL UNIT DASH FUSE BOX ...

Page 998: ... Door and Floor DRIVER S DOOR INNER PANEL I ANTI LOCK BRAKE CONTROL UNIT I POWER DOOR LOCK I CONTROL UNIT CONTROL UNIT ME RUNNING CONTROL CAhlAnd 1 SriCURlTY CONTROL UNIT SRS CONTkOL UNIT FOOT WELL BASk SPEAKER RIGHT F NT FLOOR PANEL i 2 3 1 2 ...

Page 999: ... rl Rear Bulkhead PG PGM FI MAIN RELAY RETRACTABLE HEADLIGHT aQcoNTRoLuNiT INTERLOCK CONTROL UNIT FUEL PUMP RELAY Ll I TNESS 9OL TCS CONTROL UNIT TCS FAIL SAFE RELAY 23 13 ...

Page 1000: ...Relay and Control Unit Locations Engine Compartment ENGINE COMPARTMENT FAN RELA REAR WINDOW DEFOGGER IGNITER UNIT 23 14 ...

Page 1001: ...C250 C301 thru C321 T201 thru T20B G201 and G202 G301 and G302 Right Retractor Sub Harness C281 thru C283 Left Retractor Sub Harness C381 thru C383 Floor Wire Harness C401 thru C471 C472 thru C508 G401 and G402 G403 thru G405 Side Wire Harness C521 thru C545 Rear Wire Harness C551 thru C564 G551 Trunk Wire Harness C581 and C582 Trunk Sub Wire Harness C591 and C592 Driver s Door Wire Harness C601 t...

Page 1002: ...ompartment area To Body ground via battery ground wire Battery To Battery negative terminal Engine Ground Wire A T5 G2 Middle of engine compartment To Transmission housing Left side of engine compartment To Body ground via engine ground wire A Engine Ground Wire B T6 G3 Right front corner of engine compartment Right front corner of engine compartment To Front head cover To Body ground via engine g...

Page 1003: ... JND WIRE EN NE GROUND WIRE B ...

Page 1004: ...ine Engine Engine Engine Engine Engine Left side of engine compartment Engine compartment Where the Wires Go To Side wire harness C530 To Side wire harness C530 To Side wire harness C531 To Starter solenoid To Engine oil pressure sensor To Radio noise condenser To Front oil pressure switch B To Front spool solenoid valve To Coolant temperature sensor TW To Coolant temperature gauge sender To Back ...

Page 1005: ... lzl A ENGINE W I R E H A R N E S S cont d 23 l 9 ...

Page 1006: ...er rear engine com partment To Rear oxygen sensor Cl49 8 Right side of engine com partment To Engine compartment fan resister C l 5 0 2 Right side of engine com partment To Engine compartment fan Cl51 2 Right side of engine com partment To ignition Ne service connector Cl52 2 Right front engine compartment To Fuel pump resister Cl53 20 Right bulkhead To Junction connector Cl54 26 Middle of behind ...

Page 1007: ... rl p173 5 Cl34 Cl32 Ti03 23 21 ...

Page 1008: ...rea To R Retractor sub harness C281 6 Behind Right headlight To R Retractor relay 6 Behind Right headlight To L Retractor relay 4 Sub relay box B To Power amplifier relay 4 Sub relay box B To Anti lock brake Front fail safe relay 4 Sub relay box B To Washer motor relay 4 Sub relay box 6 To Anti lock brake Rear fail safe relay 5 Sub relay box B To Intermittent wiper relay 4 Sub relay box B To Winds...

Page 1009: ...C2bl c262 I C203 cont d 23 23 ...

Page 1010: ...nder dash To Anti lock brake inspection connector C240 20 Right under dash To Anti lock brake control unit C241 1 8 Right under dash To Anti lock brake control unit C242 18 Right under dash To EPS control unit C243 1 2 Right under dash To EPS control unit C244 2 0 Behind right kick panel To Floor wire harness C468 C245 1 8 Behind right kick panel To Floor wire harness C469 C246 16 Behind right kic...

Page 1011: ... rl SUB RELAY BOX A cont d 23 25 ...

Page 1012: ...e left front solenoid 3 Left front compartment area To Anti lock brake left rear solenoid 2 Lefr f ront compartment area To Anti lock brake motor 3 Left front compartment area To Anti lock brake right front solenoid 3 Left front compartment area To Anti lock brake right rear solenoid 1 4 Left front compartment area To Retractor sub harness C381 4 Left front compartment area To Auto cruise actuator...

Page 1013: ...FRONT COMPAR 23 27 J ...

Page 1014: ...Front compartment wire harness C208 To Right headlight To Right retractor motor Left Retractor Sub Harness C381 C382 C383 1 4 Left front compartment To Front compartment wire harness area C314 6 Behind Left headlight To Left headlight 6 Left front compartment area To Left retractor motor 23 28 ...

Page 1015: ...e RIGHT RETRACTOR SUB HARNESS I LEFT RETRACTOR SUB HARNESS I ...

Page 1016: ...ge To Junction connector C418 1 4 Under middle of dash To Automatic climate control unit c419 30 Under middle of dash To Automatic climate control unit C420 1 6 Under middle of dash To Stereo radio cassette player C421 2 Under middle of dash C422 4 Under center console To Cigarette lighter relay C423 2 Under center console To Shift position console light A T C424 2 Under center console To Shift po...

Page 1017: ...FLOOR WIRE HARNESS I Lx C 4 1 6 I C4b5 c 2 I LEFT KICK PANEL I I c422 C425 C424 C426 C423 I 0404 6701 kont d 23 31 ...

Page 1018: ...dash To Foot well bass speaker 2 Right under dash To Foot well bass speaker 4 Center under dash To Starter cut relay 4 Right under dash To Daytime running light control unit CANADA 8 Right under dash To Daytime running light control unit CANADA 2 Right under dash To Service check connector 2 Right under dash 1 6 Right under dash To Security control unit 22 Right under dash To Security control unit...

Page 1019: ...C466 C465 C468 C464 c473 FLOOR WlFiE HARNESS co d 23 33 ...

Page 1020: ...500 c501 C502 c503 c504 c505 C 506 c507 C508 G403 G405 18 6 8 4 1 0 12 2 0 2 2 2 6 7 4 12 20 Left rear bulkhead To Retractable headlight control unit Left rear bulkhead To Fuel tank wires C771 Left rear bulkhead To Interlock control unit Left rear bulkhead To Fuel pump relay Left rear bulkhead To TCS control unit Left rear bulkhead To TCS control unit Left rear bulkhead To TCS control unit Left re...

Page 1021: ... ITI RETRACTABLE HEADLIGHT CONTROL UNIT i FLOOR WIRE HARNESS 23 35 ...

Page 1022: ... 1 2 Left rear bulkhead To Floor wire harness C499 Left rear window To Rear defogger wire C81 I 1 4 Left front engine compartment To Engine wire harness C 10 I A T 6 Left front engine compartment To Engine wire harness Cl 01 I M T 2 Left front engine compartment To Engine wire harness C 102 6 Left front engine compartment To Emission control box 3 Left front engine compartment To Emission control ...

Page 1023: ...MAIN FUSE BOX I 23 37 ...

Page 1024: ...o Trunk opener solenoid 8 Left trunk area To L Taillight assembly 2 Left trunk area To L Rear turn signal light 3 Center trunk area To Trunk latch switch 4 Center trunk area To License plate lights 2 Center trunk area To Security trunk key cylinder switch 8 Right trunk area To R Taillight assembly 2 Right trunk area To R Rear turn signal light 2 Right quarter panel area To R Rear anti lock brake s...

Page 1025: ...es Go i C581 2 C582 Left front trunk area 2 Above center trunk are s To Side wire harness C536 To Trunk sub wire harness C59 1 Remark Trunk Sub Wire Harness c591 c592 2 Above center trunk area 2 Above center trunk area To Trunk wire harness C582 To High mount brake light c NK SUB WIRE HARNESS ...

Page 1026: ... 3 Left door To Driver s door courtesy light C612 8 Left door To Driver s door key cylinder switch and door lock motor C613 4 Left door To Driver s door power window motor C614 5 Left door To Security indicator C615 2 Left door To Driver s door switch Passanger s Door Wire Harness C651 1 4 Behind right kick panel C652 1 0 Behind right kick panel C653 3 Right door C654 8 Right door C655 3 Right doo...

Page 1027: ...DRIVER S DOOR WIRE HARNESS PASSENGER S DOOR WIRE 23 41 ...

Page 1028: ...dash Left under dash Right under dash Center floor Where the Wires Go To Dash fuse box C908 To Floor wire harness C429 To SRS control unit To Cable reel To Left dash sensor To Right dash sensor To Body ground via floor wire harness Remark Fuel Tank Wires c771 6 Left rear bulkhead To Floor wire harness C489 C772 3 Fuel tank area To Fuel gauge sending unit c773 2 Fuel tank area To Fuel pump 23 42 ...

Page 1029: ...SRS CONTROL UN FUEL TANK WIRES 23 43 ...

Page 1030: ... Remark To Side wire harness C525 To Power seat sliding switch To Power seat reclining switch To Power seat reclining motor To Power seat sliding motor To Belt switch Passenger s Power Seat Wire Harness c791 c792 c793 c794 c795 4 Under passenger s seat To Floor wire harness C474 5 Right passenger s seat To Power seat sliding switch 5 Right passenger s seat To Power seat reclining switch 2 Left pas...

Page 1031: ... rl DRIVER S SEAT I DRIVER S POWER SEAT WIRE HARNESS PASSENGER S SEAT PASSENGER S POWER SEAT WIRE HARNESS 23 45 ...

Page 1032: ...ndow Defogger Wire C811 1 Left front engine compartment To Side wire harness C529 C812 1 Rear window area To Rear window defogger 1 Hatch Wires Rear window area To Rear window defogger 1 RigKt rear bulkhead To Floor wire harness C504 Rear window area To Rear window glass antenna I I I G801 I I Right engine compartment I To Body ground via hatch wires I I REAR ROOF WIRE C752 cl301 HATCH WIRES WINDO...

Page 1033: ... Main relay box is located in the front compartment right side c935 ITo Lighting relay C938 To Power window c939 brake Motor Relay 940 To Junction connector c941 To Junction connector cable T 211 Not used C A N A D A with EPS 23 47 ...

Page 1034: ...se box is located in the engine compartement left side JUMP START TERMINAL T l 1 BATTERY To Starter cable STARTER MOTOR To Stater cable1 I c921 ITo Rear defogger relay ALTERNATOR To Engine wire harness TlOl l Not used Option a a 23 48 ...

Page 1035: ...arness C522 I C906 ij ITo Side wire harness C908 To SRS wire C909 To Integrated contrc ChNADA C911 Option fIG2 A 1 C912 Option BATT e C905 To Floor wire harness C405 l 1 u u n nl X21 11 C904 To Floor wire harness IC402 l To Floor wire harness C406 l To Floor wire harness To Floor wire harness C404 l fC403 l 23 49 ...

Page 1036: ... I T o I MAIN RELAY BOX T o Page23 54 MAIN FUSE BOX aBLK Starter motor I lo g lPOA Rear window detogger t B N o 1 B 20A I I I I YELlBLU 7 Security control unit No 22 20A I t Voltage regulator S P G M F I m a i n relay t 8 WHTIGRN Passenger s power seat sliding motor No 23 20A I WHTlBLU Passenger s power seat reclining motor 823 51 4 a a 23 50 ...

Page 1037: ...compressor clutch No 24 10A WHTlGRN Engine compartment fan motor No i5 20A BLUlGRN Cigarette lighter No i6 15A GRNlRED TCS control unit t 6 No l7 0ption YEllBLU Option COlP Dash fuse box No t3 30A i BLKlYEL PGM FI main relay lG1 No 1 Ignition coil No 2 Ignition coil No 3 Ignition coil No 4 Ignition coil No 5 ignition coil No 6 Ignition coil Radio noise condenser lcont d 23 51 ...

Page 1038: ...relay Blower high relay Radiator fan low relay Radialor fan high relay Condenser fan relay A C compressor clutch relay t Y E L l B L K E n g i n e conpartment f a n r e l a y F Y E L l B L K Radiator fan control unit lG2 YELlBLK Y E L I B L K Climate control unit lG2 t Y E L I B L K Power door mirrors Y E L l B L K k Rear window defogger indicator light R E A R W I N D O W D E F O G G E R R E L A ...

Page 1039: ...id No l lOA BLKlYEL P N K SRS c o n t r o l unit VA I No P lSA r 2 R E D SRS c o n t r o l unit VB Fuel pump resistor and fuel pump 1 r 4 i IIa tIi SeneOre 0 BLK YEL V A T control unit lG1 I BLKlYEL t Emission control box BLKIYEL I No S lOA t_ _ YEL Integrated control unit lG1 I YEL t Back up lights Shift lock solenoid AIT 41 YEL Gauges and indicator lights P TCS SWITCH I Turn signal lights EPS co...

Page 1040: ...ts player t B Clock t B EPS control unit t B Climate control unft t B No 34 15A No 35 20A W HTlBLU 7 pT o Hp 3 r Passenger s door courtesy light I ORNrT Power door lock control unit t I dIc ZerItIr Key less control unit option WHTlBLK R Condenser fan motor No 42 15A 01 I I ERN WHTI R Headlight retractor motor I HEADLIGHT RETRACTOR SWITCH No 43 15A I I WHTlBLK L Headlight retractor motor HEADLIGHT ...

Page 1041: ...ay coil Horns Brake lights Security indicator light Integrated control unit Key interlock solenoid I RED WHTz nar igl a arard relay No 46 0 0 Not used No 51 20A GRNlBLK E Passenger s door speaker t B Driver s door speaker t B ANTI LOCK BRAKE MOTOR RELAY Foot well bass speaker tB WHTIBLU Anti lock brake motor I I I I YELlRED 0 ANTI LOCK BRAKE CONTROL UNIT I POWER WINDOW RELAY I lBLKl G201 No 26 40A...

Page 1042: ...AILLIGHT RELAY y k tr ys oL N T y k tr ys oL N T License plate lights Dashlight brightness control unit Rashlight brightness contraller Hazard switch light Lighting switch light Power door mirror switch light Driver s power window switch light Rear wimdow defogger switch light Cruise main switch light TCS switch light Stereo radio cassette Clock Glove box light Cigarette lighter light G a u g e l ...

Page 1043: ...BLK FiTl yrIYx fiJ WHT I I I FET2 H ORN I I I I I I FETI I I JWHT BLU I I I I I I FET4 LB H ORNlBLU _ m m J R MOTOR m BLU t 1 L J IPS power unit 62 BLK Transmission housing Engine head 63 A 64 q Battery ground wire q Engine ground wire B q Engine ground wire A q EPS ground wire q Front compartment wire harness S h i e l d e d w i r e cont d 23 57 ...

Page 1044: ... WHT Front knock sensor I Rear knock sensor PGM FI ECU LG 1 TCS control unit LG 1 Sl C 7 L L T GRNlBLK Steering sensor TCS PGM FI ECU LG2 Front oxygen sensor B REDlBLU L J BRNlWHT I 7BRNIWHT Rear oxygen sensor Knock sensor I BRNIwHT BRNIWHT jRT lNECTOR n K li TJMBRN WHT c urn n 1 IA T c o n t r o l u n i t S p e e d sensor A T q Engine wire harness q Floor wire harness a Side wire harness q Knock ...

Page 1045: ... locatons From Page23 53 Neutral switch M T Speed sensor PGM FI ECU PG1 TCS control unit PG1 PGM FI ECU PG2 TCS control unit PG2 n GlOl a BLK Engine compartment fan motor G102 A BLK fgniter unit 6103 q Engine wire harness q Floor wire harness cont d 23 59 ...

Page 1046: ...tching 41 Dimmer relay Switching C 0 II G201 a B L K Intermittent wiper relay 0 tm B L K Windshield wiper high relay Switching 0 q BLK Radiator fan HI relay Switching 0 A BLK k z o 1 I 0 BLK Anti lock brake front fail safe relay Anti lock brake rear fail safe relay 0 RItetractor c u t relsy Switching L Retractor c u t relay Switching n 6202 q Engine wire harness q Front compartment wire harness 23...

Page 1047: ...301 41 0 41 0 0 IlTJ BLK Radiator fan resister A B L K A n t i l o c k b r a k e m o t o r fl BLK i Iiyessure s w i t c h FTil BLK p h switch Anti lock brake pressure switch fl BLK Condensor fan relay 4 6 3 0 2 q Front compartment wire harness kont d 23 61 ...

Page 1048: ... c o n t r o l unit option Shift position console switch AIT C l u t c h switch M T Interlock control unit A T Daytime running C A N A D A light control unit Gauges and indicator lights Cruise control unit Power door lock control unit Security control unit C l o c k Passenger s door switch Passenger s door lock switch Passenger s door key cylrnder switch Passenger s door lock actuator Integrated c...

Page 1049: ...mBLK E Driver s door switch Driver s door lock switch Driver s door key cylinder switch Driver s door lock actuator pm BLK Chime lights on warning DASH FUSE BOX a BLK Windshield wiper switch BLKV l l n nsf wU h lrd relay q BLK G402 To Page23 64 6 4 0 1 q Floor wire harness J Driver s door wire harness cont d 23 63 ...

Page 1050: ...te player r q ttT R FRONTO I I Stereo radio cassette playe I I q O R N I R FRONT 0 L I r B q I I I W H T L FRONT 0 I I Foot well bass q ORN L FRONT 0 speaker I L SHORT CONNECTOR Rear 0 Rear speaker 0 Car telephone system option q BLK Driver s door speaker q L fi m BLK Passenger s door speaker l7 J BLK Foot well bass speaker JBLK d li lroPlm Page23 63 q Floor wire harness q Driver s door wire harne...

Page 1051: ...fan control unit STEREO RADIO CASSETTE PLAYER CONNECTOR I I I q BLKlLT GRN I mBLK BRN Security control unit A G404 TCS control unit G405 q Engine wire harness q Front compartment wire harness q Floor wire harness q Passenger s power seat wire harness q R Retractor headlight wire harness q L Retractor headlight wire harness q Fuel tank wires Throttle actuator cont d 23 65 ...

Page 1052: ...3 and 46 for illustrated ground locations sa BLK R Taillight assembly 1L jRsar s i d e m a r k e r l i g h t s BLKT Torn signal lights BLK Power antenna motor IC IC IC n 6501 I TJBLK Rear window defogger h GE01 q Hatch wires q Rear wire harness q SRS main wire harness 23 66 ...

Page 1053: ...SHIELD 70D23L 80D26L INDICATOR Replacement 1 Remove the spare tire and the spare tire holder 2 Disconnect both the negative cable and positive cable from the battery 3 Remove the battery holder then take out the battery RE TIRE HOLDER SPARE TIRE 23 67 ...

Page 1054: ...e This may force electrolyte to spray out of the battery vents Follow the charger manufacturer s instructions and charge the battery at a proper rate If you re using a computerized battery tester follow the test procedure provided with it If you don t have a computer ized tester follow this conventional test produre To get accurate results the temperature of the electrolyte must be between 21 OC 7...

Page 1055: ... charged here hrs charged I Test Load Capacity 2 l Apply 300 amp load for 15 seconds to remove surface charge l Allow 15 seconds recovery period l Apply test load see Test Load Chart l Record voltage at the end of 15 seconds t Stays above 9 6 volts battery is OK 1 t I Drops below 9 6 volts battery is no good 80D28L MF t BATTERY CODE LOAD TEST CHART Use the test load or l 2 the cold cranking amps C...

Page 1056: ...E LID A 3 Disconnect the connector between the airbag and cable reel 4 Connect the short connector to the airbag side of the connector STEERING WHEEL I AIRBAG CONNECTOR I SHORT CONNECtOR RED 5 Remove the door sill molding 6 Remove the kick panel trim pieces as necessary 7 Remove the fuse box mounting bolts 8 Disconnect the fuse box connectors NOTE The SRS main harness connector is double locked To...

Page 1057: ... Install the kick panel trim pieces 4 Disconnect the short connector from the airbag SHORT CONNECTOR RED LID A CABLE REEL SHORT CONNECTOR 5 Connect the airbag 2 P connector and cable reel 2 P connector 6 Attach the short connector to the lid A and attach to the steering wheel 7 Connect both the negative cable and positive cable to the battery 8 After installing the dash fuse box confirm that all s...

Page 1058: ...inals in each switch position according to the table 0 I 0 0 II 0 0 0 0 Ill Q 0 7 j P CONNECTOR I WHTiBLK BAT B WHTlRED IACC Electrical Switch Replacement 1 Remove the dashboard lower panel See page 23 l 281 2 Disconnect the 7 P connector from the floor wire harness 3 Insert the key and turn it to 0 4 Remove the 2 screws and replace the switch LOCIi CYLINDER SWITCH 23 72 ...

Page 1059: ...d center panels 2 Remove the steering column covers 3 Remove the knee bolster and dash lower frame 4 Disconnect the 7 P and 6 P connectors KNEE BOLSTER 4 Remove the column holder mount bolts 5 Remove the mounting nuts 12 lb ft 39 N m 13 9 kg m 28 lb ft 6 Lower the steering column assy 7 Center punch each of the shear bolts and drill their heads off with a 3 16 in drill bit CAUTION Do not damage th...

Page 1060: ...steering lock assembly into the steering column un til the clicks into place 12 Loosely tighten the new shear bolt NOTE Make sure the projection on the ignition switch is aligned with the hole in the steering column 13 Insert the ignition key and check for proper opera tion of the steering wheel lock and that ignition key turns freely 14 Tighten the shear bolts until the hex heads twist off SHEAR ...

Page 1061: ...LKlGRN Test page 23 80 SHIFT POSITION CONSOLE SWITCH NEUTRAL SAFETY SWITCH A T l Test page 23 156 l Replacement page 23 l 57 CLUTCii INTERLOCK SWITCH M T Test page 23 80 S T A R T E R l Test page 23 76 l Solenoid Test page 23 81 l Replacement page 23 81 l Overhaul page 23 82 l Reassembly page 23 87 23 75 ...

Page 1062: ... pedal is fully depressed The clutch interlock switch turns on at the position where the clutch disengages 15 20 mm 0 59 0 79 in from fully depressed position NOTE Full stroke of clutch pedal is 135 145 mm 5 3 5 7 in from fully released position r d CLUTCH INTERLOCK SWITCH Fullv Ralaarari I Position IS 20 mm 0 59 0 79 in Fully Deprksed 23 76 ...

Page 1063: ...Diagram BATTERY IGNITION MAIN RELAY BOX SWITCH Z WHT RED I BLKlWHT B L 1MAIN riUoSXE C i 7 r SLKlBLU DASH FUSE BOX N0 7 7 5A BLKlWHT BLKlWHT l LMA M A I N l PGM FIECU GAUGE ASSEMBLY 1 K W f K G1 HT mm STARTER 23 77 ...

Page 1064: ... 2 Check the starter engagement Press the clutch pedal all the way M T only and turn the ignition switch to Start The starter should crank the engine NOTE On cars equipped with manual transmission the engine will not crank unless the clutch pedal is fully depressed l If the starter still does not crank the engine check the battery battery positive cable ground and the wire connections for loosenes...

Page 1065: ...hen the armature is rotated with the drive gear held Replace the gears if damaged 4 Check cranking voltage and current draw Voltage should be no less than 8 5 volts Current should be no more than 350 amperes If voltage is too low or current dravy too high check for 0 Battery fully charged l Open circuit in starter armature commutator segments l Starter armature dragging l Shorted armature winding ...

Page 1066: ...he battery is connected to the C and D terminals There should be no continuity when the battery is disconnected A T Clutch Interlock Switch Test M T 1 Remove the dashboard lower panel and knee bolster then disconnect the 2 P connector from the switch 2 Check for continuity between the terminals accord ing to the table Terminal Clutch Pedal A B RELEASED PUSHED A B CLUTCH INTERLOCK 3 If necessary re...

Page 1067: ... IN COIL HOLD IN COIL Starter Replacement Disconnect the battery negative cable Remove the engine wire harness from the harness clip on the starter motor I Disconnect the starter cable from the B terminal on the solenoid and the BLK WHT wire from the S terminal I Remove the 2 bolts holding the starter and remove the starter UPPER MOUNTING BOLT 45 N m 4 5 kg m 32 lb ft BmTERMINAL MOUNTING NUT 9 N m...

Page 1068: ... 23 81 CLUTCH ASSY BRUSH END COVER O RING Replace ARMATURE PlNlbN GEAR HARNESS CLIP fjLd Test PINIOV GEAR L ROLLER BEARIN and CAGE Prevent rollers from being scattered and lost MOLYBDENUM DISULFIDE NNING CLUTCH ASSY SOLENOlD HOUSING STEEL BALi When reassembling install steel ball from clutch side MOLYBDENUM DISULFIDE MOLYBDENUM I DISULFIDE GEAR HOUSING COVER 23 82 ...

Page 1069: ... the spring lifts off the brush Spring Tension 19 24 N 1 9 2 4 kg 4 2 5 3 lb SPRING SCALE ING BRUSH Starter Brush Inspection Measure the brush length If not within the service limit replace the armature housing and brush holder assembly Brush Length Standard New 15 0 15 5 mm 0 59 0 61 in Service Limit 10 0 mm 0 39 in NOTE To seat new brushes after installing them in their holders slip a strip of 5...

Page 1070: ...I4 in VERNIER CALIPER Commutator Runout Standard New O 0 02 mm O 0 0008 in Service Limit 0 04 mm 0 0016 in II D I A L INDICATOR COMMUTATOR 3 If the commutator runout and diameter are within limits check the commutator for damage or for carbon dust or brass chips between the segments 4 If surface is dirty recondition it with a 500 or 600 sandpaper Then check mica depth If neces sary undercut mica w...

Page 1071: ...ksaw blade on the armature core ARMATURE TESTER HACKSAW BLADE ARMATURE If the blade is attracted to the core or vibrates while core is turned the armature is shorted Replace the armature 7 With an ohmmeter check that no continuity exists between the commutator and armature coil core and between the commutator and armature shaft If continuity exists replace the armature SHAFT COIL CORE COMdUTATOR 2...

Page 1072: ...ugh recordition with a strip of 500 or 600 sandpaper SOLENOID PLUNGER PO T CONTACTING FACE Starter Field Winding Test 1 2 Check for continuity between the brushes If there s no continuity replace the armature housing Check for continuity between each brush and the armature housing ground If continuity exists replace the armature housing BRUSHES ARMATURE HbUSlNG GROUND 23 86 ...

Page 1073: ...ywheel or tor que converter ring gear if the starter drive gear teeth are damaged Starter Reassembly Reassemble the starter in the reverse order of disas sembly 1 2 3 Pry back each brush spring with a screwdriver then position the brush about halfway out of its holder and release the spring to hold it there Install the armature in the housing Next pry back each brush spring again and push the brus...

Page 1074: ...89 RADIO NOISE CONDENSER Test oaoe 23 97 SPARK PLUGS 6 Inspection page 23 96 TACHOMETER CONNECTOR Engine revolyion detected SERVICE LOOP IGNITER UNIT l Replacement page 23 92 l Input Test page 23 93 l Troubleshooting Section 11 IGNITION COILS 61 l Removal page 23 94 l Test page 23 95 CYLlCRANK SENSOR l Troubleshooting section 11 l Replacement section 5 23 88 ...

Page 1075: ...asic Control Determination of ignition timing current duration The control unit has stored within it the optimum basic ignition timing for operating conditions based upon engine speed and intake manifold pressure With compensation by signals from sensors the system determines optimum timing for ambient conditions and sends voltage pulses to the igniter unit Compensation of ignition timing Compensa...

Page 1076: ...ifferent wires have the same color They have been given a number suffix to distinguish them for ex ample WHT and WHT are not the same IGNITION MAIN RELAY BOX SWITCH I IGNITOR UNIT I BLK G103 No 3 BLI EL BL EL 1 EL BLKlYEL 6 PGM FI MAIN 1 CONDENSER ...

Page 1077: ...timing adjuster in con trol box 5 Remove the control box cover 6 Remove the 2 screws from the control box then dis connect the 3 P connector from the ignition timing adjuster IGNITION TIMING CONTROL BOX v 2 i CONNECTOR 7 Remove the ignition timing adjuster from the con trol box 8 Drill the 2 rivets off with a 3 16 in drill bit then separate the stay cover from the adjuster CAUTION Do not damage th...

Page 1078: ...0 min 1 rpm in gear 3 Ajust the idle speed if necessary see section 1 1 Igniter Unit Replacement 1 2 3 B P Disconnect the 8 P and 6 P connectors from the ig niter unit Remove the 2 mounting bolts from the igniter unit Pry or slide the igniter unit pull out of the front side CAUTION Be careful not to damage the vacuum hose when removing igniter unit MOUNTING BOLTS 12 N m 1 2 kg m 8 7 lb ft PCONNECT...

Page 1079: ...tion system and fuel emission system 0 The tachometer should operated nomally IGNITER UNIT BLK WHTlGRN View from wire side 8 P CONNECTOR WHTIYEL BLK2 No Wire Test condition Test desired result 1 8LKl Under all conditions Check for continuity to ground 2 8LK2 There should be continuity 3 WHT Ignition switch ON Check for voltage to ground There should be battery voltage 5 WHTIBLK 6 WHTIBLU 7 WHTIYEL...

Page 1080: ...overs are used not touch them handle the ignition coils and plugs for the front side and rear side Be sure to use torrent carefully ones when mounting them 1 2 3 4 Remove the ignition coil covers Disconnect the 2 P connectors from the ignition coils Remove the ignition coils Remove the plugs IGNITION COIL COVER PLATINUM ilP PLUG CYLlNDEk HEAD COVER 23 94 ...

Page 1081: ...tance will vary with the coil tempera ture specification is at 25OC 77OF Primary Winding Resistance between the A and B terminals 0 9 1 1 ohms l If primary winding resistance is OK substitute a known good ignition coil and check the system operation If the system is normal replace the orginal igni tion coil A TERMINAL B TERMiNAL k IGNITION COIL B A V SECONDARY WINDING TERMINAL BECONDARY WINDING TE...

Page 1082: ...er CAUTION The plug cleaner should be used with the air pressure of lees then 6 kg cm 66 PSI and for less than 20 seconds 3 Replace the plug if the center electrode is rounded as shown below NOTE Do not use spark plugs other than those list ed below because these plugs are a new type IS0 standard Spark plug These marks are sealed on the air cleaner cover _ 7 PFRGG 1 1 NGK PKZOPR Lll ND For all nor...

Page 1083: ... probes and measure the condenser capacity Condenser capacity 0 47 f 0 09 microfarads uF BODYGROUND NOTE The radio noise condenser is intended to reduce ignition noise However condenser failure may cause the engine to stop running 2 If not within the specifications replace the radio noise condenser 23 97 ...

Page 1084: ...Component Location Index CHARGE SYSTEM LIGHT in the gauge assembly Test page 23 104 BATTERY Test page 23 68 ALTERNATOR l Alternator and Regulator Test page 23 100 l Replacement page 23 106 l Overhaul page 23 107 23 98 ...

Page 1085: ...N FUSE BOX 1 No 9 120A No Z9 50A WHTlRED WHT r m RECTIFIER K YE B I ILIB LU 5 BL r BLKiYEL BLKlYEL I I INTEGRATED I ll ANTI LOCK BRAKE VI I BLKlYEL rTRoL K M NG UNll LIGHT 1 4W Y WHilBLU WHflBLU I I VOLTAGE REGULATOR FIELD WINDING ALTERNATOR 23 99 ...

Page 1086: ...nd and between the S YEL BLU terminal and body ground B S YELIBLU 0 If there is no voltage check for Blown No 2 15 A fuse in the dash fuse box or No 18 20 A fuse in the main fuse box An open in the BLK YEL wire between the dash fuse box and the voltage regulator or the YELlBLU wire between the main fuse box and the voltage regulator 0 If there is battery voltage go to step 3 NOTE Test use the SUN ...

Page 1087: ...ter negative lead Attach the negative tester cable and the voltmeter nega tive lead to the top of throttle body NEGATIVE TESTER CABLE VOLTMETER NEGATIVE LEAD Inductive pick up Attach the inductive pick up to the B terminal at the al ternator ALTERNATOR INDUCTIVE PICK UP B TERMINAL I I ALTERNATOR NOTE The arrow is pointing opposite direction from the alternator B terminal INDUCTIVE From the alterna...

Page 1088: ...aximum amperage reading and compare with the chart below FULL FEILD ACCESS HOLE 140 130 120 110 100 90 80 70 60 50 40 30 20 1 0 REGULATOR Located inside the end Cover 7 Move the test selector switch to the STARTING No I position 8 Start the engine Raise engine speed to 2 000 rpm and hold make sure cooling fans are off 0 2 4 6 810 12 14 16 18 Alternator Speed x 1000 rpm I I I I I I I I I I 0 2000 4...

Page 1089: ...x 1 Turn the ignition switch on The charge system light should come on If it does not come on disconnect the alternator con nector and short the pin of the L WHT BLU termi nal to ground View from terminal side a If the light still does not come on check for Bad bulb An open in the WHT BLU wire between the light and voltage regulator An open in the BLKIYEL wire between the light and the dash fuse b...

Page 1090: ... does not go off there is a short to ground in the WHT BLU wire between the light and the control unit 5 Remove the glove box See section 20 and discon nect the 20 P connector from the ALB control unit With the engine running the charge system light should go off ALB CONTROL UNIT 20 p CONNECTOR 0 If the light goes off there is a short in the ALB control unit 0 If the light does not go out there is...

Page 1091: ...ere is a short to ground in the WHT BLU wire between the charge system light and the EPS control unit 2 Disconnect the 4 P connector from the alternator 3 Remove the terminal nut and the BLK wire from the B terminal Alternator Replacement BLK WIRE I B TERMINAL NUT 9 N m 0 9 kg m 6 5 lb ftl 4 P 4 Remove the pulley cover from the alternator PULLEY COVER cont d 23 l 05 ...

Page 1092: ...ulley 6 Remove the adjusting bolt and through bolt then al ternator from the bracket ALTERNATOR NUT 22 N m 2 2 kg m 16 lb ftl ADJUSTING BOLT 8 N m 0 8 kg m 6 lb ft ALTERNATOR THROUGH BOLT 46 N m 4 5 kg m 33 lb ft 7 Alternator installation is the reverse order of removal NOTE Adjust the alternator belt tension after install ing See page 23 l IO 23 l 06 ...

Page 1093: ...END COVER BRUSH HOLDER VOLTAGE REGULATOR I BRUSH HOLDER a1 ew PULLEY LOCKNUT 115 N m I 1 5 kg m 83 lb ft INSULATOR I REAR HOUSING ASSY BRUSHES Inspection page 23 108 SPACER RING REAfi BEARING DIODE RECTIFIER ASSY Test page 23 l 08 INSULATOR SLEEVE WEARING RETAINER STdTOR THROUGH BOLT Do not disassemble STATOR ASSYlDRlVE END HOUSING Test page 23 109 I R O T O R 1 Test page 23 109 FRONT BEARING PULL...

Page 1094: ... between the E ground and P of each diode pair terminals All diodes should have continuity in only one direc tion P2 B P l 0 Pl Pl 0 0 P2 P2 t 0 P3 P3 P 4 IE P 4 2 If any of the 8 diodes fails replace the rectifier as sembly Diodes are not available separately I Alternator Brush Inspection 1 Remove the end cover then take out the brush holder by removing its 2 screws 2 Measure length of the brushe...

Page 1095: ...the rotor or rotor shaft ROTOR SHAFT SLIP RINGS ROTOR 3 If the rotor fails either continuity check replace it Stator Test 1 Check that there is continuity between each pair of leads 2 Check that there is no continuity between each lead and the coil core LEADS COIL CORE 3 If the coil fails either continuity check replace the stator 23 1 09 ...

Page 1096: ...b ft Tension gauge method Attach the belt tension gauge to the belt and measure the tension of the belt Tension 392 492 N 40 50 kg 88 121 lb NOTE l On a brand new belt the tension should be 784 882 N 80 90 kg 176 198 lb when first measured l See the instruction for the belt tension gauge l If there are cracks or any damage evident on the belt replace it with a new one ALTERNATOR THROUGH BOLT ADJUS...

Page 1097: ......

Page 1098: ...BLK and ORNlBLU CLIMATE CONTROL UNIT Troubleshooting see section 22 SUB RELAY BOX A A C P R E S S U R E SWITCH See section 22 DIAlOR FAN T Tz est page 23 118 IA fc f I l n eplacement see section IO L E F T C O N D E N S E R FAN Test page 23 119 Replacement see section RIGHT CONDENiER FAN MOTOR Test page 23 119 Replacement see section 22 Test page 23 119 Replacement see section B 22 23 l 12 ...

Page 1099: ...PGM FI ECU See Section 11 ENGINE COMPARTMENT FAN RELAY Test page 23 121 I COOLANT TEMPERATURE SENSOR Test page 23 l 22 ENGINE COMkARTMENT FAN MOTOR Test page 23 120 Replacement page 23 l 20 23413 ...

Page 1100: ...E BOX No 9 120A No l2 30A No 24 10A WHT BLKeWHT BLU H F WHTIGRi A D ILK ILK YELlBLK COOLING FAN CONTROL UNIT PGM FI ECU 7 RED GRN BRNlBLK GRYlBLK BLUlBLK iGiTRE 4 CLIMATE SFITRoL PG i CU A C SYSTEM COMPRESSOR CLUTCH RELAY l ATE CONTROL 12 GRNlBLK a 4 i BLUIRED B 1 ORNlBLU t A 6302 6403 A C PRESSURE SWITCH A HI LO ON between 210 kpa 2 1 kg cm2 30 psi and 2700 kpa 27 kg cm2 384 psi 6 MID ON below 12...

Page 1101: ...TER B B L K jL 6302 L ELK 4RADIATOR M i OR YELlE ILK YE LUZ i c RADIATOR FAN 1 HIGH _ 14 R E L A Y D B BL IED PR L U i B L Y I ED Wt B L I E D PGM E C U 6202 6 3 0 2 LK Wt A fl E N G I N E PARTMENT R E L A Y B lLU ENGtNE O PARTMENT MOTOR IT I 1 M I B L K 1 6102 iRN i 23415 ...

Page 1102: ...nsor and A C pressure switch A and B on the A C system to determine when the fans should run and at what speed Additionally the temperature switch shuts down the A C system if the coolant temperature exceeds 1 30 C 266OF If the pressure in the A C system is higher than normal pressure switch A closes and the fans will run at high speed only See the A C section for description and specification of ...

Page 1103: ...4 2 3 Compressor cluch does not engage as 1 necessary 1 Refer to section 22 for A C pressure inspection of the A C system c s a G z E 2 2 IL 3 5 5 3 WHT2 WHT BLU2 WHT3 WHT BLU3 VVHTIGRN WHTI MN or WHT BLUl YELIBLK BLU WHT or LT GRN YEL BLK WHT2 WHTIBLU RED SRNIBLK BLUNVHT or LT GRN YEL BLK WHT BLU2 BLU RED WHT GRN WHT BLU BLUiWH or LT GRN GRY BLK BLU BLK BRN BLK BLU WHT or LT GRN G403 G302 or G 4 ...

Page 1104: ...ORN BLU Condenser fan relay coil 0 1 0 BLU BLK PGM FI ECU AC9 1 1 YELIBLK IG2 power supply 1 2 GRN BLK Radiator fan low relav coil 0 Resistor Test 1 Disconnect the 3 P connector from the resistor 2 Using an ohmmeter measure resistance between the A and B termianls Replace the resistor if the resistance is not within specifications NOTE Resistance will vary with the resistor tem perature specificat...

Page 1105: ...e to the B termianal 3 If the motor fails to run smoothly replace it Condenser Fan Motor Test 1 Disconnect the 2 P connector from the radiator fan motor 2 Test motor operation by connecting battery positive to the A terminal and negative to the B terminal 3 If the motor fails to run smoothly replace it terminal side NOTE The illustration shows right condenser 23 119 ...

Page 1106: ...tive to the B terminal 3 If the motor fails to run smoothly replace it terminal side Engine Compartment Fan Motor Replacement 1 Disconnect the 2 P connector from the engine com partment fan motor 2 Remove the engine compartment fan motor relay tachometer connector and engine wire harness from the engine compartment fan stay 3 Remove the 3 mounting bolts 2 P CONNECTOR ENC3lNE COMPbRTMENT FAN RELAY ...

Page 1107: ...y Test There should be continuity between the A and B termi nals when the battery is connected to the C and D ter minals There should be no continuity when the battery is dis connected A TYPE B TYPE A C 23 121 ...

Page 1108: ...ge 1 Remove the coolant temperature sensor from the thermostat housing 2 Suspend the coolant temperature sensor in a con tainer of coolant as shown THERMOMETER TEMPERATURE 3 Heat the coolant and check coolant temperature with a thermometer see table below 4 Measure the resistance between the A and I3 termi nals according to the table Resistance 1 047 0 872 0 519 0 489 tKQ 1 255 1 024 0 573 0 541 5...

Page 1109: ...WIRE HARNESS SPEEDOMETER indicates 60 mdh I60 km h1 at 1 026 6371 rpm of the speed sensor FUEL GAUGE l Gauge Test page 23 134 l Sending Unit Test page 23 135 VOLTAGE METER The No 5 15A fuse and other gauges are OK but if the TACHOMETER Indicates lOOr min at 300 pulses per minute of the igniter unit COOLANT TEMPERATURE GAUGE l Gauge Test page 23 136 l Sender Test page 23 136 pointer of the voltage ...

Page 1110: ...3 HIGH BEAM CATOR 1 4W I All ILU w t 7 1 KiYEL BLKiYEL I I SPEED SENSOR YEL 415 CHARGING EHTTEM 1 AW 827 ILU VOLTAGE REGULATOR BiK GlOl GAUGE ASSEMBLY I Bll I YELlRED 812 I I 114 YE R N BLI H T COOLANT TEMPERATURE SENDING UNIT f OIL 1ERAEUPRE SENDING UNIT E t BiK I 113 I 829 PGM FI ECU 6401 6402 23 124 ...

Page 1111: ...E I I I YELIRED Y E ED GA ED CNSTCONTROL DASHLIGHT BRIGHTNESS T i RA ED CONTROLLER UNIT OIL SSURE 1 T GRNlRED I GR L R t t R i Ir I GRNlRED I GA l i i I PARKING I II I Q i I I BRAKE Sl2 P 1 4W FAILURE Dcl Y ED ANTI LOCK BRAKE CONTROL UNIT TCS CONTROL UNIT 1 i A U S A i I T CANADA 1 0302 cont d I BLK 23 125 ...

Page 1112: ...FROM PREVIO PAGE 4W ECU CONTROL UNIT BAIT CONTROL UNIT l EPS A T CONTROL UNIT YELlRED 9 IED A21 I SPEEDOMETER 1 1 I I I I I I As b I h I IHT YELiSLU ELUlYEL Eliu 47 G401 G402 YEI I 1 I ILK BLK I L I I FUEL GAUGE UNIT T i BLK d 6403 INTEGRATED CONTROL UNIT 23426 ...

Page 1113: ... PNI EPB W ATOR 1 4W I I I I CRUISE CONTROL DIMMING CIRCUIT BLU GR Al4 IEL A 1 0 R TURN SIGNAL Dl ATOR 1 4W LK GRYjBLK RED BLUlBLK W OCK DASHLIGHT CRUISE EPB CONTROL TCB CONTROL UNIT BRIGHTNESS EPITTRoL FKfTRoL UNIT A T CONTROLLER 23427 ...

Page 1114: ... light A CONNECTOR Carries in the SRS indicator signal SRS MAIN WIRE HARNESS 1 Remove the dashboard lower panel and disconnect the two connectors from the floor wire harness 2 CON6ECTORS I LOWER FOOT WHEEL LIGHT PANEL LIGHTS ON CHIME 2 Remove the 2 screws then remove the dashboard center panel from the dashboard DASHBOARD CENTER PANEL 3 Disconnect the TCS switch and the retractor switch connectors...

Page 1115: ...from both sides from the gauge assembly 6 Remove the 8 screws then remove the steering column upper and lower covers 8 Use a protective cloth on the combination switch to prevent scratching the gauge assembly Remove the 4 screws then take out the gauge assembly as shown COLUMN LOWER COVER COiUMN UPPER COVER 23429 ...

Page 1116: ...GH r 1 4W x 21 SRS INDICATOR LIGHT 1 4WI HIGH BEAM INDICATOR LIGHT 1 4W1 TCS INDICATOR LIGHT 1 4W TURN SIGNAL INDICATOR LIGHT 1 4W ANTI LOCK BRAKE SYSTEM CHECK ENGINE OIL PRESSURE LIGHT 1 4WI GAUGE Lll 3 OW GHT 3 OW GAUGE LIGHT 3 OW 23 l 30 ...

Page 1117: ... 1 2 Speedometer and tripmeter operate but odometer does not operate 2 4 3 1 Speedometer and odometer operate but tripmeter does not operate 1 2 Speedometer operates but odometer and tripmeter do not operate 1 Speedometer odometer and tripmeter do 1 3 2 not operate PRINTED CIRCUIT PANEL A JOINT COTNECTOR PRINTED CIRCUIT PRINEL B View from the back of the gauge assembly ...

Page 1118: ...PEEDOMETER MOUNTING SCREWS x3 TACHOMETER MOUNTING SCREWS x3 VOLTAGE FUEL GAUGE I I HOUSING MOUNTING SCREWS x5 COOLANT TEMP OIL PRESSURE A GAUGE MOUNTING SCREWS x0 Test page 23 136 and 137 FUEL VOLTAGE GAUGE Test page 23 123 and 134 Specificaton page 23 123 l SHIFT LEVER POSITION 1 lMruFATrm LIGHT CASE SPi Rj d L Specification page 23 123 T tAGt FANtL VISOR TRIPMETER PRINTED CIRCUIT PANEL COVER PRI...

Page 1119: ...ire 0 If there is battery voltge go to step 4 4 Check for voltage between the YEL RED terminal and body ground with the ignition switch ON There should be approximately 5 V 0 If there is no voltage check for Defective gauge assembly check for the A21 terminal of the A connector See page 23 123 l If there is approximately 5 V go to step 5 5 If all continuity and voltage tests are normal but the spe...

Page 1120: ...for An open in the YEL YELNVHT or BLK wire Poor ground G403 4 Turn the ignition switch OFF Attach a jumper wire between the B YEL WHT and C BLK terminals Turn the ignition switch ON Check that the pointer of the fuel gauge starts mov ing toward F mark CAUTION Turn the ignition switch OFF before the pinter reaches F mark on the gauge dial Failure to turn the ignition switch OFF before the pointer r...

Page 1121: ... unit 3 Remove the 5 nuts then take out the fuel gauge sending unit assembly from the fuel tank 4 Measure the resistance between the A and B termi nals at E EMPTY l 2 HALF FULL and F FULL by moving the float Float Position E 112 F 1Resistance 9 1105 I 10 125 5 39 5 2 5 bottom of the fuel tank E I 2 F 25 0mm 144mm 275mm 0 98in 5 67in I 0 8in 5 If unable to obtain the above readings replace the fuel...

Page 1122: ...kly enough may cause damage to the gauge 0 If the pointer of the gauge does not swing at all check for An open in the YEL or YELIGRN wire Repalce the coolant temperature gauge if the fuse and wiring are normal l Inspect the gauge sender if the gauge is OK Sending Unit Test 1 2 3 4 Disconnect the YEL GRN wire from the sender With the engine cold use an ohmmeter to measure resistance between the pos...

Page 1123: ...e gauge does not swing at all check for An open in the YEL or BLU WHT wire Replace the oil pressure gauge if the fuse and wiring are normal l Inspect the engine oil pressure if the gauge is OK 3 Cheek the oil pressure of the engine See section 8 l Replace the oil pressure sending unit if the engine oil pressure is OK Oil pressure Warning System III Oil Pressure Switch Test 1 Raise the car and plac...

Page 1124: ...oes not function perform input test for daytime running light control unit see page 23 176 Brake Fluid Level Switch Test 1 Remove the reservoir cap Check that the float moves up and down freely Replace the reservoir cap assembly if the float does not move freely 2 Check for continuity between the terminals with the float up and down There should be continuity with the float and no con tinuity with...

Page 1125: ...ea Drain fuel only into an approved container 2 Drain fuel tank into an approved container Then install the drain bolt with a new washer 3 Add less than 11 e 2 4 U S Gal 2 9 Imp Gal of fuel and turn the ignition switch on The low fuel Indicator light should come on within 4 minutes 4 Then add one more gallon of fuel japprox 4 L I 1 U S Gal 0 9 Imp Gal11 The light should go out within 4 minutes 0 I...

Page 1126: ... to damage the SRS wire har nesses when servicing the interlock system TCS CONTROL OCK CONTROL UNIT est page 23 142 u I SRS MAIN WIRE UNIT HARNESS SHIFT POSITION CONSOLE SWITCH Test page 23 156 Replacement page 23 157 KEY INTERLOCK SOLENOID and KEY INTERLOCK SWITCH in the steering lock assembly Test page 23 143 PT LOCK SOLENOID Test page 23 144 Replacement page 23 144 23 l 40 ...

Page 1127: ... AIT CONTROL UNIT YE1 1 YEL a k kup K SOLENOID ON UNLOCK E T YELlBL KEY CNIl M CK d I ___ ______________ 1 SHIFT LOCK RELAY 0 me wmp_m k l w INTERLOCK CONTROL UNIT GRYlWHi SHIFT LEVER c POSITION INDICATOR Y GRYIWHT GRYlWHT 0 SHIFT POSITION EeT LE 0N Posiiion in P BLK 6401 0402 23 141 ...

Page 1128: ...ol unit and the accelerator at l An open in the wire the same time Shift lever position in P Check for continuity to ground l Faulty shit position console switch SRYIWHT should be continuity l Poor ground G401 G402 l An open in the wire Ignition switch ON Check for voltage to ground l Blown No 5 IO A fuse YELIBLK should be battery voltage l Faulty shift lock solenoid l An open in the wire Key Inte...

Page 1129: ...ion according to the table Terminal A B C Position c c Q Ignition Key pushed in switch ACC Key released o 4 4 Check that the key cannot be removed when the bat tery is connected to the A and C terminals l If the key cannot be removed the key interlock solenoid is OK 0 If the key can be removed replace the steering lock assembly key interlock solenoid is not avail able separately View from wire sid...

Page 1130: ...t the lock pin is blocked by the shift lock lever 0 If not adjust the position of shift lock solenoid View from wire side Replacement 1 Remove the E ring and the solenoid pin 2 Remove the self looking nuts and shift lock solenoid E RING SELF LOCliNG NUTS Replace 10 N m 1 0 kg m 7 2 lb ft 3 Install the shift lock solenoid in the reverse order of removal and adjust the position of shift lock solenoi...

Page 1131: ...Indicator System LED s are used to indicate when the turnk lid or a door is not fully closed or when a brake light is faulty the LED s will remain ON for about 2 seconds after the ignition switch has been turned ON to show that the system circuit is fun citoning Brake Light Bulb Failure Indicator If all brake light bulbs are OK the Indicator light stays off because the ORNANHT wire is constantly b...

Page 1132: ...I Y REDlYEL BLKlYEL WHTIGRN 812 In the gauge assembly I WHTlBL I ti L WH IRIVER S fOL TESY 1 3 4W L GRI WH GRI iL WH ASSENGER S flO rTESY 1 3 4W E D GRI WHT BL DOME LIGHT I I O I I j313 T I KBLK WHT I 3 4W 818 VII3LK GRNiBL I GRI GRNlRED BiK I BL I BLK A LK GRNiBL SWITCH G401 6401 0401 6402 G401 6402 6402 6402 23 l 46 ...

Page 1133: ...RATED CONTROL GRNlWHT f RITY CONTROL I I GRNlWHT 6 dXl BE CONTROL TXSTCONTROL ANTI LOCK BRAKE CONTROL UNIT P t TCONTROL HIGH MOUNT BRAKE LIGHT r LED I 1 ORNjWHT NiW BLk L 1 6401 6402 HT I L TAILLIGHT LJAILUR SENSOR EEE 43CP I R TAILLIGHT air BiK 6501 23 147 ...

Page 1134: ... har nesses when servicing the safety indicator system Remove the dashboard lower panel center panel and in strument panel Disconnect the B connector 30 P from the gauge assembly See page 23 128 Make the following input tests at the harness pins If all tests prove OK yet the indicator still fails to work replace the safety indicator A CONNECTOR B CONNECTOR View from terminal side YEL BLK 23 148 ...

Page 1135: ...uity l An open in the wire NOTE Before testing remove No 34 15 A fuse Lighting switch ON Check for voltage between l Faulty dashlight brightness control 8 RED BLK and and dashlight bright RED BLK 1 and RED 1 system RED ness control dial in terminals l An open in the wire full bright should be battery boltage GRN BLU Driver s door opened Check for continuity to ground l Faulty door switch should be...

Page 1136: ...ight not lit with trunk lid opened Brake Indicator light not lit with blown brake light bulb Brake Indicator light remains on with good brake light bulbs Dome light not on with door opened When switch position is in MIDDLE Retractor motor Indicator light remains on with good retractor motor Retractor motor Indicator light not lit with faulty retractor motor Stuck by foreign matter 1 2 Et Y E L 1 R...

Page 1137: ...oes not come on when the ignition switch is turned OFF to ON with the B GRN terminal of the 8 P connector grounded and the brake pedal pressed 0 If the BRAKE LAMP comes on replace the right failure sensor l If the BRAKE LAMP does not come on go to step 4 4 Remove the rear trim panel that covers the left tail light Make sure the 1 BRAKE LAMP 1does not come on when the ignition switch is turned OFF ...

Page 1138: ...ses when servicing the shift lever position indicator l GAUGE ASSEMBLY Removal page 23 l 28 Disassembly pages 23 132 l INTERLOCK SYSTEM See page 23 140 A T CONTROL SYSTEM See Automatic Transmission section 14 SRS MAIN WIRE HARNESS I SHIFT LEVER POSITION INDICATOR Input Test page 23 154 A T CONTROL UNIT See Automatic Transmission section 14 SHlF i POSITION CONSOLE SWITCH Test page 23 l 58 Replaceme...

Page 1139: ...FT LEVER POSITION INDICATOR DIMMING CIRCUIT z iLiB 1 iLiB J i24 823 GPN BR NjBLK 1 LT GR N WHT B sBLU GRN YEL 10 a 313 325 HT Ll t fTE fK UNIT GRI Y GRYlWHT I 0 I N D 3 A T CONTROL UNIT LT BLU GRN BLU BRN BLK GRN YEL L T GRNlWHT REDlBLK I SHIFT POSITION RED BLK CONSOLE SWITCH I DASHLIGHT BRIGHTNESS CONTROLLER DASHLIGHT BRIGHTNESS CONTROLLER A 6401 G401 6402 6402 23 153 ...

Page 1140: ...ing the Indicator input test Remove the gauge assembly from the dashboard and dis connect the 30 P connector from the gauge assembly Make the following input tests at the harness pins If all tests prove OK yet the indicator still fails to work replace the main printed circuit panel speedometer tachome ter and odo tripmeter A CONNECTOR Carries the SRS indicator signal SRS MAIN WIRE HARNESS A CONNEC...

Page 1141: ...Check for continuity to ground should be continuity l Faulty shift position console switch l Faulty A T control system l Poor ground G401 G402 l An open in the wire Lighting switch ON and dashlight brightness con trol dial on full bright Check for voltage between RED BLK and RED terminals should be battery voltage l Faulty dashlight brightness control system l An open in the wire Ignition switch O...

Page 1142: ...the shift lever View from wire side l If there s no continuity within the range of free play adjust the installation position of the con sole switch Back up Neutral Shift Position Console Switch Light Switch Safety Switch R 0 0 0 3 P 0 0 0 0 Adjustment 1 2 3 Shift to the P position then loosen the bolts Slide the switch in the direction of D position wi thin 2 0 mm 0 079 in 1 so that there is cont...

Page 1143: ... con sole switch into position Attach the switch with the 2 bolts Test the console switch in the P and N positions see page 23 l 56 NOTE The engine should start when the shift lever is in the N position within the range of free play Connect the 12 P and 2 P connectors clamp the har ness and install the console Bulb Replacement CAUTION 0 All SRS electrical wiring harnesses are covered with yellow o...

Page 1144: ... RELAY BOX WHTlRED WH t WHT BLKlYEL N o 5 DASH IdA iE A 5 T WHTlBLU W H t WHTlBtK WHTlBLK 49 I 813 Y E zl1 N 1 4W 7 H T TURN SIGNAL HAZARD RELAY LIGHTING SWITCH L R I GRNIBLti I ENTRY LIGHT REAR WINDOW I LIGHTS ON f I DEFOGGER I REMINDER I rAE KER I TIMER CIRCUT I TIMER CIRCUIT CIRCUIT I CIRCUIT I I I I I I ILK Et A3 I POWER WINDOW I I KEY OFF TIMER I I CIRCUIT I I I I G401 6402 0301 0401 6402 23 ...

Page 1145: ...one circuit board sharing common circuit functions SEAT BELT REMINDER LIGHT Y I r BEEPER I I I EL L BLL 812 REDlBLU BL DRIVER S TE ELT BLK BLK KEY 6401 SWITCH 6402 BLL HT Al I WlNDSHlLD WIPER WASHER SWITCH ED 84 COMBINED OPERATION WIPER WASHER CIRCUIT LOW OIL PRESSURE INDICATOR LIGHT Y YELlRED c 87 I I I OIL PRESSURE INDICATOR I FLASHER CIRCUIT I I I I I I I Bm P i 611 A1 A2 86 RN BRNlRED BRNlYEL ...

Page 1146: ...e bracket to disconnect the 16 P con nector from the integrated control unit Remove the integrated control unit from the dash fuse box Make the following input tests at the harness pins If all tests prove OK yet the system still falls to work replace the control unit NOTE Several different wires have the same color They have been given a number suffix to distinguish them for example YEL and YEL2 a...

Page 1147: ...he wire Check for continuity to ground l Faulty left door switch should be continuity l An open in the wire NOTE Before testing remove No 34 15A fuse Key on Riminder System No Terminal Test condition Test desired result Possible cause if result is not obtained 1 A8 Under all conditions Check for continuity to ground l Poor ground G401 G402 should be continuity l An open in the wire 2 A9 Under all ...

Page 1148: ...ge to ground should be battery voltage l Blown No 38 15 fuse l Faulty lighting switch l An open in the wire l Faulty taillight relay Check chime operation Chime should activate each time the l Faulty chime l An open in the wire battery is connected Seat Belt Reminder System No Terminal Test condition Test desired result Possible cause if result is not obtained 1 2 3 14 5 48 A9 A5 BLU YEL Al3 Under...

Page 1149: ... bulb indicator light should come on l An open in the wire Oil Pressure Indicator System No Terminal Test condition Test desired result Possible cause if result is not obtained 1 A8 Under all conditions Check for continuity to ground l Poor ground G401 G402 should be continuity l An open in the wire 2 A9 Under all conditions Check for voltage to ground l Blown No 34 15A fuse should be battery volt...

Page 1150: ...turn signal system in left position l An open in the wire Ignition switch ON 6 A3 and turn signal switch in right position Connect the A9 termi Check marker light operation 7 PNK BLU nal to the PNKlBLU left or right front side or BLU WHT termi marker light should come on 8 BLUMIHT n a l l Blown bulb l Poor ground G301 l An open in the wire Power Window key off Timer System No Terminal Test conditi...

Page 1151: ... wire Ignition switch ON Check for voltage to ground l Blown No 26 4OA fuse 4 BLU RED should be battery voltage l Faulty intermittent relay l An open in the wire Ignition switch ON Check for voltage to ground l Blown No 6 7 5A fuse 5 YEL and wiper switch INT should be battery voltage l Faulty wiper switch l An open in the wire ignition switch ON Check for voltage to ground l Blown No 6 7 5A fuse 6...

Page 1152: ...the closed door switch With voltage at the A6 terminal ground at the B2 terminal and no voltage at the A5 terminal the chime is activated to remind the driver to turn off the lights Chime Test 1 Remove the dashboad lower panel then disconnect the 2 P connector from the foot light 2 Disconnect the 2 P connector from the floor wire harness 3 Test chime operation by connecting battery positive to the...

Page 1153: ...cuit senses ground through the closed door switch With ground at thee Al 1 and B2 terminals the beeper sounds El Ignition Key Switch Test 1 2 3 4 Remove the dashboad lower panel and dashboard center panel If necessary remove the knee bolster Disconnect the 8 P connector from the floor wire harness There should be continuity between the No 8 and No 7 terminal when the ignition key is inserted in to...

Page 1154: ...HEADLIGHT CONTROL UNIT lnout Test page 23 1 j4 HIGH BEAM INDICATOR LIGHT in the gauge assembly Gauge Assembly page 23 130 h LIGHTING SWITCH Test page 23 177 Replacement page 23 178 DAYTIME RUNNiNG LIGHT CONTROL UNIT CANADA Test page 23 178 SECURITY CONTROL UNIT Input Test page 23 312 23 l 68 ...

Page 1155: ...page 23 185 I R RETRACTOR RELAY Test page 23 186 FLDAYTIME RIjNNlNG LIGHT CANADA Replacement page 7 L L RETRACTOR RELAY Test Daae 23 186 L RETRkTOR MOTOR V HEADLIGHTS Ajustment page 23 l 88 Replacement page 23 l 89 L DAYTIME RUNNING LIGHT CANADA Replacement page 23 l 90 23469 ...

Page 1156: ...o 44 CANADA LWA 9 No 52 No 49 20 4 20A REDIYE ry q RED GR p RETRACTAsiEADLlGHT REDIYEf REDIGR CONTROL UNIT HT REDjBLK E BLK 2 t D W RE I L TAILLIGHT BLlJ RED y RED YE 113 sEcu wY CONTROL UNIT I t LIGHTING 10 4 7 SWITCH iHTS RETRACTABLE CONTROL UNIT 6401 6402 STEREO RADIO CASSETTE LIGHTS lG l CLOCK LIGHT 1 GLOVE BOX LIGHT l f f TTE LIGHTER ASHTRY GAUGE LIGHTS l SHIFT POSITION CONSOLE LIGHT CLIMATE ...

Page 1157: ... EL diDI UlBLK BLU r J R ED BLI I A B C W H RN YE1 W H RN r GRNiYEL BLUiRED BLI YE ADLIGHT ARCTOR HT Ll I WHTIBLK RETRACTABLE HEADLIGHT WHTIGRN 2 LIGHTING SWITCH 3 14 Ii PNKIBLK REDIGRN BLUYGRN R HEADLIGHT RETRACTOR CUT RELAY BLK BLK I PNKIBLK I LIGHT control CANADA 6202 cont d 6202 6401 6201 G403 6402 23 171 ...

Page 1158: ...TIME RUNNING LIGHT CONTROL UNIT FUSE I No 5115AI I 7 YEL 4 GI BRAKE EilM 1 4W GFiNlRED GRNIRED l TCS CONTROL UNIT ANTI LOCK BRAKE CONTROL UNIT E D RN R E D KDE LEVEL SWITCH BLK c 6302 G R IR No 3 7 5A E D m BOX EL KKK NG SWITCH I YELlBLK l YELlBLK YELlBLK pAY iE 4 oME LIGHT bb 32CP 32CP LIGHT BLK BLK 6301 G40i 23472 ...

Page 1159: ...ion switch system is comprised of 7 switches and the turn signal cancel unit CRUISE CONTROL MAIN SWITCH REAR WINDOW DEFFOGGER SWITCH LIGHTING SWITCH TURN SlGNALlDlMMEk SWITCH TURN SIGNAL CANCEL SWITCH WIPER WASHER SWITCH 23 173 ...

Page 1160: ...nections between the 13 P connector and control unit then replace the control unit if all in put tests prove OK l Several different wires have the same color They have been given a number suffix to distinguish them for example RED YELl and REDNEL4 are not the same REAR BULKHEAD I CONTROL UNIT I BULKHEAD PANEL 18 P CONNECTOR View from wire side YELIGRN I I WHTlGRN BiK YEL BLU Y E L YELiWHT LT GR N ...

Page 1161: ...eadlights on should be battery voltage l Faulty lighting switch l An open in the wire Lighting switch l Check for voltage to ground l Faulty lighting relay or lighting switch RED YELl headlights on should be battery voltage l Blown No 52 20 A fuse 6 l An open in the wire l Faulty lighting relay or lighting switch RED GRN l Blown No 49 20 A fuse l An open in the wire Passing switch ON Check for vol...

Page 1162: ... 3 BLK RED Ignition switch ON Check for voltage to ground l Blown No 3 7 5A fuse should be battery voltage l An open in the wire Lighting switch ON Check for voltage to ground l Blown No 43 15Aj fuse 4 PNK BLK should be battery voltage l Faulty lighting switch l An open in the wire Under all conditions Check for continuity to ground l Blown daytime running light 5 YELIBLK should be continuity bulb...

Page 1163: ...knee bolster 3 4 Disconnect the 16 P connector from the floor wire harness Check for continuity between the terminals in each switch position according to the table KNEE_BOLSTER DASHBOARD CENTER PANEL DASHBOARD LOWER PANEL I Lighting Dimmer Passing Switch Turn Signal Switch Terminal 5 8 9 Position R 0 LI rl 0 NEUTRAL 23477 ...

Page 1164: ...S wire har nesses when servicing the lighting system 1 Remove the dashboard lower panel and disconnect the 2 P connectors from the floor wire harness LOWER PANEL 2 Remove the dashboard center panel DASHBOARD CENTER PANEL 3 Remove the tilt cover l lLT COVER 4 Remove the steering column lower cover and upper cover 5 Disconnect the 16 P connector and 10 P connector P NNECTOR 16 P CONNECTOR 23 l 78 ...

Page 1165: ...NSEL SWITCH 8 If necessary remove the cancel unit and cancel switch TlJR N SIGNAL CANCEL SWITCH TURN iiGNAL CANCEL UNIT Lighting Switch Light Bulb Replacement 1 Remove the steering coloumn covers 2 Remove the 2 screws 3 Slide the lighting switch out of the housing as shown 4 Remove the bulb from the lighting switch by turning the bulb 45 LIGHTING SWITCH I HOtiSlNG BULB 0 91 W 23 179 ...

Page 1166: ...connectors from the floor wire harness P ON LOWER PANEL FOO LIGHT LIGHTS ON CHIME 2 Remove the dashboard center panel DAsHBOARDCENTER PANEL 3 Remove the tilt cover TILT COVER 4 Remove the steering column lower cover and upper cover 5 Disconnect the 5 P and IO P connectors from the each switch TCS SWITH P CONNECTOR 1 O P COiiNECTOR RETRACTOR SWITCH 6 Remove the 6 screws then remove the instrument p...

Page 1167: ...terminals in each switch position according to the table Retractor Switch Switch lights terminals F and E RETRACTOR SWITCH Retractor Switch F E C D Retractor Switch Light Bulb Replacement 1 Remove the retractor switch 2 Turn the socket 45O counterclockwise to remove it SWITCH I BULB 0 84W 23 181 ...

Page 1168: ...r motor fuses in the main relay box 15A 15A W MAIN RELAY BOX 2 Turn the knob clockwise to raise the headlight 3 Remove the 2 caps and 4 screws and cowl clips COWL CLIP CAYS I 4 Slide the headlight garnish upward to remove it NOTE Be careful not to damage the front bumper or the headlight garnish when upward to remove it HEADLIGHT GARNISH PROTECTIVE TAPE 5 Disconnect the 6 P connector from the head...

Page 1169: ...r of the removal and l Make sure there is no interference between the wire harness and linkage 0 Coat the joint with grease and make sure the link age moves smoothly Adjustment 1 Remove the stopper caps STOPPER CAPS w a K STOPPER BOLT C 2 Adjust the stopper bolt A and B 3 Adjust the stopper bolt C fore or aft until the head light garnish fits flush with the front fender when the headlights are clo...

Page 1170: ...or Test 1 Remove the retractor motor 2 Test motor operation by connecting battery positive wire to the A terminal and negative to the D terminal The motor should run continuously 3 If the motor fails to run smoothly replace it 4 Disconnect the power supply and check for continui ty between the terminals according to the table while turning the knob clockwise as shown above T e r m i n a l B C t F ...

Page 1171: ...ter minals There should be no continuity when the battery is disconnected B D al t A C Dimmer Relay Test Remove the dimmer relay from the main relay box There should be continuity between the F and E ter minals and between the B and C terminals There should be continuity between the A and C ter minals when the battery is connected to the E and F terminals There should be no continuity when the bat...

Page 1172: ...er minals when the battery is connected to the E and F terminals There should be no continuity when the battery is disconnected A CE Retractor Cut Taillight Relay Test 1 2 3 Remove the retractor cut relay from sub relay box A There should be continuity between the C and D ter minals There should be continuity between the A and B ter minals when the battery is connected to the C and D terminals The...

Page 1173: ...r being inter rupted by the interrupter plate and passed through the convex lense The interrupter plate determines the form The outer lense distributes the light into the pattern B 1 L 4 a 9 Y 3 CONVEX LENSE INTERRUPTER PLATE BULB REFLECTOR OUTER LENSE Screen I 23 l 87 ...

Page 1174: ...idjust the beadlights to local requirements JOTE Be careful not to damage the front fender or the leadlight garnish when adjusting HEADLIGHT HORIZONTAL ADJUSTING POINT PROTECTIVE TAPE IIEAVLIWI I Vtli I IGAL ADJUSTING POINT 23 l 88 ...

Page 1175: ...ctor motor fuses in the main relay box A No 43 15A FUSE No 42 15A FUSE MAIN RELAY iOX 2 Turn the knob clockwise to raise the headlight CAP NOB COWL CLIPS CA SCFiEWS 4 Slide the headlight garnish upward to remove it NOTE Be careful not to damage the front bumper or the headlight garnish when removing it HEADLIGHT GARNISH 5 Disconnect the 6 P connector from thee headlight unit 6 Remove the 4 mountin...

Page 1176: ...se do not touch them or the attaching hardware immedi ately after they have been turned off Do not try to replace or clean the headlights with the lights on Remove the cover cap Disconnect the 2 P connector then remove the re taining spring and bulb NOTE If necessary remove the headlight garnish Do not touch INING SPRING BULB HI B6WIL 55W 2 P COiUNECTOR BOLT UNIT BULB 32CPl SOCKET 2 If necessary r...

Page 1177: ... LIGHT FRONT POSITION LIGHT BULB 5WI TURN SIGNAL HOUSING Front Side Marker Lights III Replacement 1 Carefully pry out the front side marker light from the front fender NOTE Be carefully not to damage the front side marker light or the front fender when prying out the front side marker light PROTECTIVE CLOTH RUBBER 2 3 Disconnect the 2 P connector from the front side marker light Turn the bulb sock...

Page 1178: ...uts and the taillight as sembly NEW GASKET REAR PANEL TAILLIGHT ASSEMBLY NOTE l inspect the gasket replace if it is distorted or overly compressed 0 Make sure that there is no weter leakage in the taillights after installing the taillights Bulb Replacement 1 2 Open the trunk lid and rear trim panel Turn the socket 45O counterclockwise to remove it from the taillight housing TURN SIGNAL LIGHT BULB ...

Page 1179: ...VE CLOTH 2 Disconnect the 2 P connector from the rear side mar ker light 3 Turn the bulb socket 45O counterclockwise to re move it from the rear side marker light HOUSING r 2P CdNNECTOR License Plate Lights rl Replacement 1 Remove the 8 screws and disconnect the 4 P con nector LICENSE PLATE LIGHTS REAR JUMPER 2 Turn the bulb socket 45 counterclockwise to re move it from the housing 8W HOliSlNG 3 I...

Page 1180: ...nect the 2 P connectors then remove the glove box I GLOVE BOX LOWER PANEL 4 Remove the 2 screws from the glove box light GLOVE BOX 5 Theres should be continuity between the A termi nal and B terminal with a bulb installed There should be no continuity when the switch is pushed From FUSE No 38 15 Al 0 To GROUND 401 0402 23 l 94 ...

Page 1181: ... Index DOME LIGHT Test Replacement page 23 197 I R COURTESY LIGHT Test Replacement page 23 l 98 R DOOR SWITCH L COURTESY LI Test Replaceme Test Replacement page 23 199 L DOOR SWITCH Test page 23 198 I TRUNK LIGHT Test Replacement page 23 I 99 23 l 95 ...

Page 1182: ...CONTROL UNIT SAFETY INDICATOR INTEGRATED CONTROL UNIT in the gauge assembly Y GRNlBLU GRI L SECURITY CONTROL UNIT Y GRNlRED LU GR 4c b lNT SWITCH BLI t BLI a 6401 7 I ED GRNJBLK K TNT SWITCH ILU WHTlBLU I 1 I WHTjBLU WHTjBLU WHTlBLU GRN SLU GRNlBLK D DOME LIGH I d B L F G HT SAFETY INDICATOR in the gauge assembly b 23 l 96 ...

Page 1183: ...e lens Remove the 2 bolts and the housing Disconnect the 4 P connector from the housing HOUSING LENS Check for continuity between the terminals in each switch position according to the table n 1 ll n I I I I I View from terminal side O F F B E F G 1 AT MOUNTING BOLTS 23 l 97 ...

Page 1184: ...ind the door trim panel Make sure that the bulb is in good condition Check for continuity between the terminals NOTE Do not connect the tester probes in the wrong polarity because there is a diode inside the courtesy light DOOR TRIM PANEL RETAINER PLATE LENS HOtkING From N0 34 15A FUSE 3 4W To DOOR SWITCH 2 Disconnect the 2 P connector from the door switch DOOR iWITCH microswitch type 3 There shou...

Page 1185: ...Do not connect the tester probes in the wrong polarity because there is a diode inside the trunk light TRUNK SIDE PANEL RETAINER HOUSING FromN034 15A FUSE m 3 4W To GROiND G501 1 Open the trunk lid and remove the trunk rear trim panel 2 Disconnect the 3 P connector from the trunk latch 3 There should be continuity between the A terminal and body ground Theree should be continuity when the latch is...

Page 1186: ...Back up Lights Component Location Index SHIFT POSITION CONSOLE SWITCH A T back up light switch Test page 23 202 BACK UP LIGH Test page 23 202 BACK UP FIGHTS Bulb replacement page 23 192 23 200 ...

Page 1187: ... YEL L 10 9 BLK BLK FLOOR WIRE HARNESS i I I I i I SIDE WIRE HARNESS I I I I I I I I I I I I I I I I I I I I I FLOOR WIRE HARNESS SIDE WIRE HARNESS ENGINE WIRE HARNESS SIDE WIRE HARNESS YEL tYE1 tYE1 NO 5 10A DASH FBEE MIT L I I I I I I I I I 1 I ILK I I 3LK I I I I I I I A GdBLK REAR WIRE HARNESS 6501 23 201 ...

Page 1188: ...und G 501 An open in the YEL or GRNIBLK wire Automatic Transmission NOTE Check the No 5 10 A fuse in the dash fuse box before testing 1 Test the back up light switch by shifting the select lever to R and turning the ignition switch ON 2 If the back up lights do not go on check the back up light bulbs in the taillight assembly 3 If the fuse and bulbs are OK remove the center con sole then disconnec...

Page 1189: ...nent Location Index BRAKE LIGHT SWITCH Test page 23 205 HIGH MOUNT BRAKE LIGHT l LED Replacement page 23 206 l Replacement page 23 206 9 Test page 23 205 ement page 23 192 L TAILLIGHT Bulb Replacement page 23 192 23 203 ...

Page 1190: ...HT I GRNlWHT l CRUISE CONTROL UNIT l TCS CONTROL UNIT ANTI LOCK BRAKE CONTROL UNIT A T CONTROL UNIT l INTEGRATED CONTROL UNIT HIGH MOUNT BRAKE LIGHT rI LED L T N W m BLK 1 G401 H T I I I GRNiWHT GRN GRNiWHT I r ID m w 1 i I L L FAILURE I SENSOR KiKE I 43CP I BRAKE LIGHT i 43CP 3 tKE 43CP I L I L TAILLIGHT SAFETY INDICATOR K ORNIWHT G501 R TAILLIGHT K 23 204 ...

Page 1191: ...ght Test 1 Open the trunk lid and engine cover 2 Disconnect the 2 P connector from the trunk wire harness View from terminal side 3 4 5 Connect voltmeter positive probe to the GRN WHT terminal negative probe to BLK terminal When the brake pedal is pushed check for voltage between GRN WHT and BLK terminals There should be voltage 0 If there is no voltage check for Blown No 45 20 A fuse in the main ...

Page 1192: ...om the rear spoiler then disconnect the 2 P connector from the high mount brake light REAR SPOILER 2 P CONNECTOR Rear Spoiler Replacement CAUTION Be careful not to damage the high mount brake light rear spoiler and trun lid 1 Open the trunk lid 2 Remove the 6 mounting nuts 3 Carefully pull out the spoiler assembly from the rear trunk lid 4 Disconnect the 2 P connector from the trunk sub wire harne...

Page 1193: ...g the flasher system S R S MA N WIRE HARNESS TURN SIGNAL INDICATOR LIGHTS in the gauge assembly HAZARD SWITCH Gauge Assembly page 23 123 Removal page 23 214 Test page 23 215 LIGHT SWITCH Test page 23 177 Replacement page 23 178 TURN SIGNAL H Input Test page DASH FUSE BOX l TURN SIGNAL SWITCH Test page 23 177 Replacement page 23 178 l TURN SIGNAL CANCEL UNI Input Test page 23 213 MARKER FLASHER CIR...

Page 1194: ...L RED WHT REDlWHT RED SLK DASHLIGHT y ti Ess 7 UNIT v TURN SIGNAL CANCEL UNIT To Next Page RE dIDE REDfELK TURN SIGNAL HAZARD RELAY From Next Page ILK GA 96 MARKEF he integ 96 PN 6401 6402 x7 7 c Y BLU GRNlYEL R E 3CP 3CP 4 ELK d 6301 LK RE ILK iRoEEAR ARKER IGHT CP I I T SLK d G501 1 REDiWHT REDlBLK 1 REDiWHT REDlBLK I I DASHLIGHT T ESS UNIT 23 208 ...

Page 1195: ... I ELI 7 3 c5 1 Cl0 mm I 1 BLI K 1 G401 0402 1 L L 0 C8 c7 TURN SIGNAL CANCEL UNIT t HT BL DiW f E REI BLUlGRN BLUlYEL r TURN SIGNAL HAZARD RELAY v BLK r7 GRNJBLU GRNjBLU GRNJYEL GRNjYEL L TURN SIGNA LIGHTS 1 jAiK 1 R TUAN lGNAL LIGHTS GRNlYEL i jf D TO RO GfEAEARp BLK BLK BLK BLK BLK d 1 6501 G301 0301 G501 ...

Page 1196: ...er and the cancel mechanism are separated mechanically and connected electrically instead The system cancels the turn signals electrically by means of a solenoid when a turn is accomplished To monitor the steering a sensor mechanism which consists of cancel cams on the steering shaft and a switch is used Steering shaft Cancel cam Cancel switch Turn signal lever Solenoid 23 210 ...

Page 1197: ...witches A and B are installed When the steering is turned in direction of the arrow switch A turns on first Then switch B turns on 60 A III B By this pattern steering rotation is monitored R turn signal c Cancel signal output L turn signal 3 I I c Cancel signal output 23 211 ...

Page 1198: ...ge l An open in the REDiWHT wire SR Ignition switch ON and Check for voltage to ground l Blown No 5 IOA fuse turn signal switch in R should be battery voltage l Faulty turn signal switch or can 3 Ignition switch ON and ccl unit SL turn signal switch in L l An open in the YEL BLU GRN or BLU YEL wire SR Hazard switch ON Check for voltage to ground l Faulty hazard switch 4 should be battery voltage l...

Page 1199: ...be battery voltage relay l An open in the wire c 2 Turn signal switch R 1 Check for continuity between l Faulty turn signal switch BRN the C2 and C6 terminals l An open in the wire 4 _ C6 should be continuity GRY c2 Turn signal switch L 1 Check for continuity between l Faulty turn signal switch BRN the C2 and C9 terminals l An open in the wire 5 c9 should be continuity GRN BLK c 3 Under all condit...

Page 1200: ...ng the lighting system 1 Remove the dashboard lower panel and disconnect the 2 P connectors from the floor wire harness LOWER PANEL 2 Disconnect the 18 P connector from floor wire harness 3 Remove the tilt cover COVER 4 Remove the steering column lower cover and upper cover NOTE Be careful not to damage steering column covers 5 Remove the 4 screws then remove the hazard switch and wiper washer swi...

Page 1201: ...f the housing as shown Remove the bulb from the hazard switch by turning the bulb 45O HAZAFD SWITCH HOUSING 1 Remove the dashboard lower panel see page 23 214 2 Disconnect the 18 P connector from the floor wire harness 3 Check for continuity between the terminals in each switch position according to the table ABCD EFGH XJ K L MN 0 P OR View from wire side M Not used F H 0 91 W h M E D G 23 215 ...

Page 1202: ...Dashlight Brightness Control Component Location Index A T CONTROL U DASHLIGHT BRIGHTNESS CONTROL UNIT Input Test page 23 2 18 LIGHTING SWITCH Test page 23 177 Replacement page 23 178 23 216 ...

Page 1203: ... RED HAZARD SWITCH LIGHT O SlW LIGHTING SWITCH LIGHT O QlW REAR DEFOGGER SWITCH LIGHT O QlW CRUISE MAIN SWITCH LIGHT O QlW l TCS SWITCH LIGHT O 34W l POWER DOOR MIRROR SWITCH LIGHT O QlW DRIVER S POWER WINDOW SWITCH LIGHT O QlW l GAUGE LIGHTS WXS I WX l SHIFT POSITION CONSOLE LIGHT 1 4W CLIMATE FUNCTION CONTROL SWITCH LIGHTS 23 217 ...

Page 1204: ...r all conditions Lighting switch ON Lighting switch ON Adjusting dial rotated Test desired result Possible cause if result is not obtained Check for continuity to l Poor ground G401 G402 ground should be continuity l An open in the wire Check for voltage to ground l Blown No 38 I 5A fuse should be battery voltage l Faulty taillight relay l Faulty lighting switch l An open in the wire Attach to gro...

Page 1205: ...floor wire harness DASHBOARD LOWER PANEL 2 Remove the dashboard center panel DiSHBOARD CENTER PANEL 3 Remove the tilt cover TILT COVER 4 Remove the steering column lower cover and upper cover UPPEF COVER LOWER C VER 5 Disconnect the TCS switch connector and dashlight brightness controller connector KS SWITCH 10 P CONNECTOR DASHLIGH BRIGHTNESS CONTROLLEF 6 7 Remove the 6 screws then remove the inst...

Page 1206: ...rotating the adjusting dial Resistance should vary from 0 to 24 000 ohms as the dial is rotated NOTE Resistance will vary slightly with tem perature RETRACTOR SWITCH BRIGHTNESS CONTROLLER Dashlight brightness controller 1 Controller Light Bulb Replacement 1 Remove the dashlight brightness controller 2 Turn the socket 45 counterclockwise to remove it BULB iO B4W 23 220 ...

Page 1207: ...ry light timer system Description If the driver s door has been opened by the outer handle a foot light and a light at the ignition switch go on and stay on for about 8 seconds after the driver s door is closed FOOT LIGHT Replacement page 23 223 IGNITION KEY LIGHT Replacement page 23 223 D RIVER S DOOR SWITCH fin the door retch Test page 23 198 DASH FUSE BOX ENTRY LIGHT TIMER CIRCUIT in the integr...

Page 1208: ...uit Diagram BATTERY I ILU WHT BLU WHTlBLU 1 I FOOT P IGNITION LIGHT KEY 1 4W LIGHT 1 4W WH BtK wHTiBLK l POWER DOOR LOCK CONTROL UNIT in INTEGRATED CONTROL UNIT GRNiBLU A 4 V tB DOOR B BLb BLK t l GRNiBLU A3 92 Bti 1 G401 6402 23 222 ...

Page 1209: ...ashboard lower panel FOOi LIGHT 4 Remove the foot light bulb Ignition Key Light Replacement 1 Remove the dashboard lower panel 2 Remove the dashboard center panel 3 Remove the bulb socket from the key light case by turning the socket 45 KEY SWITCH KEY LIGHT CASE 4 Remove the key light case from the key cylinder by removing the attaching screw 23 223 ...

Page 1210: ...Clock Circuit Diagram BATTERY MAIN RELAY BOX NO 33 f NO 29 7 5A 50A I WHTlRED EL t WHT 6 BA E i A BLKlYEL YEL CLOCK LIGHTING FUASSEH SWITCH BOX B REDJLK ELK d 6401 G402 23 224 ...

Page 1211: ...hown 2 Disconnect the 4 P connector from the clock PROTECTIVE CLOTH CENTER AIR VENT 4 P CONNECTOR I PROTECTIVE CLOTH rl Terminals A B C 0 Terminal Wire Destination A BLK Ground 1 B 1 RED BLK 1Light on signal I C WHT YEL Constant power Time memory D YEL IGI Main clock power supply 23 225 ...

Page 1212: ...ircuit Diagram BATTERY B L r LIGHTING SWITCH i tf _ BANlYEL I REDlBLK I CIGARETTE LIGHTER WHTlBLU I MAIN FUSE BOX No 9 120A 1 No 15 2 JA iRN WH W H Y E BiK d G 4 0 1 G402 No 12 3OA ILK E D No 3 I D A S H 10A iE E D 23 226 ...

Page 1213: ...om the floor wire harness CENTER AIR VENT CENTER ARMREST 6 Disconnect the therm0 fuse case from the socket end 7 Remove the ring nut and separate the cigarette iight er socket from the thermal protector 8 When installing the cigarette lighter align each lug on the face panel illumination ring and cigarette lighter socket with the groove of the hole then po sition the bulb case on the thermal prote...

Page 1214: ...or from the cigarette lighter relay Wire colors of 4 P conneclor BLU GRN YEL RED BRN YEL BLK There should be continuity between the A and B ter minals when the battery is conencted to the C and D terminals there should be no continuity when the battery is dis conencted 23 228 ...

Page 1215: ...eo sound system POWER AMPLIFIER RELAY Test page 23 234 STEREO RADIO CASSETTE PLAYER l Removal page 23 232 l Terminals page 23 234 SUB RELAY BOX BH ASSENGER S D O O R S P E A K E R eplacement page 23 237 DRIVER S DOOR SPEAKER Component Location Index qt page 23 237 REAR SPEAKER Replacement page 23 238 POWER ANTENNA MOTOR l Test page 23 235 l Replacement page 23 237 ANTENNA MAST WINDOW ANTENNA ANTEN...

Page 1216: ...CURTY KiTRoL i 3 15A CAR TELEPHPNE SYSTEM Optlon BLK BRN REDlBLK ORN WHT wt E D I 5 PNK WHT A 6 VEL Y E A 4 MUTE STEREO RADIO CASSETTE PLAYER WINDOW ANTENNA GRN POWER AMPLIFIER POWER AMPLIFIER POWER AMPLIFIER PASSENGER S DOOR SPEAKER CAR TELEPHONE SYSTEM Option B L K 4 REAR SPEAKER A h 6401 6401 G402 G402 Y 6404 6401 0401 6402 G402 23 230 ...

Page 1217: ... rl MAST ANTENNA I GRNYBLK PNI PNK WHT 0201 L POWER ANTENNA MOTOR with the antenna retracted fully LIMIT I I SWITCH 1 BLE 6551 23 231 ...

Page 1218: ... SRS harness assembly if there is an open circuit or damage to the wiring SRS hAIN WIRc HARNESS 1 Remove the clock PROTECTIVE CLOTH 2 Remove the 2 screws then remove the center air vent CENTER AIR VENT 3 Take out the ashtray Remove the 2 screws under the ashtray AiHTRAY 4 Remove the 4 screws then remove the center armrest PAD I CENiER ARMREST 23 232 ...

Page 1219: ...ve the 4 screws then disconnect the 14 P and 30 P connectors from the floor wire harness Take out the climate control unit CLIMATE CONTROL UNIT 16 P 7 Remove the 4 screws then disconnect the 16 P con nector mast antenna lead and window antenna lead Take out the stereo radio cassette player STEREO RADIO 16 P CONNECT MAST ANTENNA LEAD WINDOW ANTENNA LEAD 23 233 ...

Page 1220: ... bass speaker Passenger s 0 A9 O R N Passenger s door speaker amplifier 1 A10 ORN 1 Drivers door speaker amplifier Al 1 ORN WHT Telephone mute signal A l 2 BLK BRN Security IN Al3 BLKlLT GRN Security OUT I Al4 I BLK 1 Ground G401 402 I Al 5 O R N 1 Foot well bass speaker Driver s 0 A l 6 O R N Foot well bass speaker Passenger s 0 Power Amplifier Relay Test 1 Remove the power amplifier relay from t...

Page 1221: ...and 3 mount ing nuts to take out the motor 1 Remove the door trim panel see section 20 2 Remove the door speaker assembly from the door panel by removing the 5 screws SPECIAL NUT ANTENNA NUT WRENCH OWAA 001 OOOB SPAC BUSHlbG 3 ITENNA AN IC MOiOR i BRACKET DAIN HOSE install in reverse order of removal NOTE Tighten the special nut then tighten 2 mount ing nuts to motor bracket DOOR SPEAKER ASSEMBLY ...

Page 1222: ...EL 2 p CONNECTOR i BULKHEAD PANEL 4 Remove the 4 screws then take the rear speaker out of the center bulkhead panel CENTER BULKHEAD PANEL Foot Well Bass Speaker Replacement 1 Pull the right front floor carpet back 2 Remove the foot well bass speaker cover CARPET 3 Disconnect the 2 P and 6 P connectors then remove the 2 bolts from the EPS power unit Remove the foot well bass speaker assembly EPS PO...

Page 1223: ... Test page 23 242 CABLE REEL Test page 23 243 I HORN SWITCH SRS MAIN WIRE HARNESS Test page 23 242 Overhaul section 17 I LEFT HORN MAIN FUSE BOX I I Test page 23 241 SECURITY CONTROL RIGHT HORN UNIT Input Test page 23 311 Test page 23 241 I Description Security Alarm System The security alarm system is an anti theft alarm system If someone tries to open the trunk hood or either door without the ig...

Page 1224: ... I WHTlGRN WHTlGRN I I WHTlGRN WHTlGRN 4 TLlGHT SECURITY INDICATOR N E LjCK HORN RELAY A T only BLlJlRED I 4 BLUlRED BLUlRED 4 CRUISE P HoRN SWITCH Ei L A ORI I L K ORNlBLK YE E 6301 0302 ORNjBLK 1 RN B 0 iLfGF LK SECURITY HORN H ELK 23 240 ...

Page 1225: ...he horn 2 Remove the right and left horns 2P CONNECTOR RIGHT HORN Security Horn 2P CONNECTOR I SECiJRlTY HORN 3 Test the horn by connecting battery voltage to the A and B terminals The horn should sound 4 If the horn fails to sound replace it 23 241 ...

Page 1226: ...re install ing Do not install an airbag assembly that shows signs of being dropped or improperly handled such as dents cracks or deformation Always keep the short connector on the airbag con nector when the harness is disconnected Do not disassembly or tamper with the airbag as sembly Disconnect the battery negative terminal and then disconnect the positive terminal Make sure the wheels are aligne...

Page 1227: ...ed There should be continuity l If there is continuity the horn switch is OK l If there is no coutinuity go to step 7 7 Remove the TORX bolts using TORX T30 bit then remove the airbag assembly MAINTENANCE L T X BOLT 10 N m 1 O kg m 7 lb ft Replace 8 Check for continuity between the horn positive ter minal and the steering column shaft with the horn switch pressed There should be no continuity STEE...

Page 1228: ... the cable reel 0 If there is no continuity remove the nut and the 4 screws then remove the steering wheel cover Replace the horn switch STEERING WHEEL NUT 50 N m IS 0 kg m 30 lb ft Replace I STEERING WHEEL COVER 9 Install the steering wheel Section 17 23 244 ...

Page 1229: ...Trunk Opener El Component Location Index TRUNK OPENER MAIN SWITCH test page 23 246 I TRUNK LATCH TRUNK OPENER SOLENOID Test Replacement 23 247 23 245 ...

Page 1230: ... BLK TRUNK OPENER SOLENOID BiK 6501 Main Switch Test 1 Remove the glove box to disconnect the 2 P con nector from the switch 2 There should be coutinuity between the No 1 ter minal and No 2 terminal with the main switch ON There should be no continuity with the main switch OFF MAIN SWITCH 3 If necessary replace the switch I MAIN SWITCH 23 246 ...

Page 1231: ...ty when the switch is released Solenoid Test Replacement 1 Open the trunk lid and remove the trunk side trim panel 2 Disconnect the Z P connector from the solenoid 3 Test the solenoid operation by connecting battery voltage to the A and B terminals momentarily TRUNK OPENER SET CABLE BOLT 4 If necessary remove the 2 bolts then disconect the trunk opener cable from the solenoid assembly OPENER CABLE...

Page 1232: ...r Door Mirrors Component Location Index R DOOR MIRROR ASSEMBLY Test page 23 252 Replacement page 23 252 L DOOR MIRROR ASSEMBLY Test page 23 252 Replacement page 23 252 250 MAIN FUSE BOX DASH FUSE BOX 23 248 ...

Page 1233: ...Q IGNITION G2 SWITCH BLUIWHT YELfBLK LIGHTING SWITCH I Y D I 3LK YEL BLK RE I 9 POWER DOOR MIRROR SWITCH r I UP r REAR WINDOW DEFOGGER RIGHT _ I DOWN 0 LIGHT 1 12W ILK BiK V DASHLIGHT BRIGHTNESS CONTROL UNIT G401 6402 YEI BLUlGRN N 1 1 LEFT 1 YELIWHT BLUlBLK ...

Page 1234: ...t mirror should tilt down or swing left when the ignitin switch is turned ON 0 If the mirror does not tilt down or does not swing left remove the left door trim panel and check for open in the YELANHT or YELIBLK wire between the left door mirror and switch If the wire is OK check the left door mirror 0 If the mirror neither tilts down nor swings left repair the YELIRED wire 0 If the mirror operate...

Page 1235: ...n 20 2 Remove the 3 screws then remove the mirror switch from the armrest DOOR TRIM PANEL I SCREW MIRROR SWITCH Switch Test 1 Remove the power door mirror switch from the arm rest 2 Check for continuity between the terminal in each switch position according to the table Mirror Switch R O F F C O O 0 UP 0 0 8 BULB SOCKET 23 251 ...

Page 1236: ...on TILT UP Connect battery positive to the No 3 terminal and negative to the No 2 terminal TILT DOWN Connect battery positive to the No 2 terminal and negative to the No 3 terminal SWING LEFT Connect battery positive to the No 2 terminal and negative to the No 1 terminal SWING RIGHT Connect battery positive to the No 1 terminal and negative to the No 2 terminal 4 If the mirror fails to operate pro...

Page 1237: ...ECK SW ITCH Test page 23 260 POWER DOOR LOCK CONTROL UNIT Input Test page 23 256 R DOOR SWITCH Test page 23 198 L DOOR L Test page R I DOOR LOCK ACTUATOR and LOCK KNOB SWITCH L DOOR SWITCH Test page 23 259 Test page 23 198 Replacement section 20 L DOOR LOCK ACTUATOR and LOCK KNOB SWITCH Test page 23 258 Replacement section 20 23 2 53 ...

Page 1238: ...LU RED and BLU RED2 are not the same BATTERY SECURITY CONTROL UNIT OiN IT TRUNK OPENER CIRCUIT I I 0 LDOOR I LbCK 1 ACTUATOR I I _ _ A LOCK UNLOCK Po8SER LOCK KiTRoL SWITCH L DOOR LOCK SWITCH DOOR KNOB u U G t I BLH I j R i ACTUATOP BL kYT o SWlTCH I GRNIYEL GRN wHT dgi __A 2 GRNiRED GRI BLK I R DOOR LOCK SWITCH n 1BLK L DOOR SWITCH K _ 6401 G402 G401 6401 G402 G401 23 254 ...

Page 1239: ...or lock switch IEither door lock switch I I2 door lock knob I door 2 The door is not supposed to be locked but it is locked When the ignition key is inserted and the door is opened 5 E 24 B b 0 i 1 s e z a 5 l ci u 2 2 3 2 3 2 3 3 G401 G402 ORN G401 G402 WHTIYEL or YEL RED WHT RED or YEL RED BLKIRED or BLKiWHT WHT RED or YEL RED G401 G402 BLUNVHT or BLUlRED WHT RED or YELlRED G401 G40i BLU GRN or ...

Page 1240: ... 18 P con nector from the control unit Make the following input tests at the harness pins NOTE l Recheck the connections between the 18 P connector and the control unit then replace the control unit if all input tests prove OK POWER DOOR LOCK CONTROL UNIT View from wire side 23 256 ...

Page 1241: ...ft door lock switch l Poor ground G401 402 l An open in the wire RNiWHT Check for voltage to ground should be 1 V or less uVHT YEL 3LKWHT Check for voltage to ground should be 1 V or less l Faulty right door lock switch l Poor ground G401 402 l An open in the wire BLK RED l Faulty left door lock actuator l Poor ground G401 402 l An open in the wire 3LUMIHT Check for voltage to ground should be 1 V...

Page 1242: ...cted to the No 8 terminal connect negative to the No 7 terminal momentarily CAUTION To prevent damage to the motor apply battery voltage only momentarily View from wide side ACTUATOR 4 If the actuator fails to operate properly replace it 5 Check for continuity between the terminals in each switch position according to the table KEY CYLINDER SWITCH Terminal P o s i t i o n 1 2 3 UNLOCK 0 0 NEUTRAL ...

Page 1243: ...OCK With battery positive connected to the No 8 terminal connect negative to the No 7 terminal momentarily CAUTION To prevent damage to the motor apply battery voltage only momentarily View from wide side 4 If the actuator fails to operate properly replace it 5 Check for continuity between the terminals in each switch position according to the table KEY CYLINDER SWITCH DOOR LOCK KNOB SWITCH Termin...

Page 1244: ... 1 Remove the door grip assembly 2 Disconnect the 3 P connector of the switch 3 Check for continuity between the terminals in each switch position according to the tables Terminal 1 2 Position 3 from DOOR LOCK SWI DOOR GRIP ASSEMBLY 23 260 ...

Page 1245: ... page 23 264 f KEY OFF TIMER CIRCUIT in the integrated control unit Input test page 23 164 DASH FUSE BOX Description Power Window Key off Timer Operation The power windows can still be operated for about 10 minutes after the ignition switch is turned from the II to the I or 0 position as long as neither of the doors has been opened this provides a convenience to parked occupants while offering a d...

Page 1246: ...TTERY I No 34 15A No 47 No 50 2OA 20A I I WHT YEL BLU IBLK P 1 ILK 9 GI L DOOR SWITCH R DOOR SWITCH 6401 6402 LIGHTING SWITCH 1LK E BLI BLI I I 9 9 11 11 10 10 BLlJlYEL BLUlGRN BLUlYEL BLUlGRN DASHLIGHT BRIGHTNES SiiliTRoL Bil K 1 G401 G402 I DN AUT0 1 BLKiYEL Btg iDrNWH Et 1 I POWER WINDOW CONTROL UNIT 6401 G402 23 262 ...

Page 1247: ... windows do not oprate 1 2 3 G201 YEL Driver s window does not operate in any position Driver s window does not operate in AUTO 1 4 2 3 5 ztz WHTNEL 3 1 2 RED GRN or BLU Passenger s window does not operate 1 2 3 4 5 G40 BLU BLK BLUNEL G402 BLUIGRN BLU RED or BLUiWHT Both windows do not oper ate within minutes after 1 2 3 4 G401 WHT BLU or the ignition switch is OFF G402 GRN RED 23 2 63 ...

Page 1248: ...or continuity to ground l Poor ground G401 402 should be continuity l An open in the wire Ignition switch ON Check for voltage to ground l Blown No 50 2OA fuse should be battery voltage l Faulty power window relay 2 W H T N E L l Faulty key off timer system l Poor ground G201 l An open in the wire 3 BLKNEL Ignition switch ON and Check for voltage to ground l Faulty driver s switch driver s switch ...

Page 1249: ...st 1 Remove the door trim panel see section 20 2 Check for continuity between the terminals in each switch position according to the tables View from wire side Driver s Switch Passenger s Switch Switch Light 8 7 0 n w 0 23 265 ...

Page 1250: ... between the terminals in each switch position according to the table View from wire side Terminal 3 8 1 2 7 Position I Driver s Switch Replacement 1 Remove the door trim panel see section 20 2 Remove the 4 screws then remove the power win dow switch from the door panel DOOR TRIM PANEL I SWliCH e 23 2 66 ...

Page 1251: ...ve the power win dow switch from the door trim panel DOOR TRIM PANEL I SWITCH Switch Light Bulb Replacement 1 Remove the door trim panel see section 20 2 Remove the 4 screws then remove the power win dow switch from the door trim panel DOOR TRIM PANEL 3 Remove the power window switch bulb BULB 0 91W w 23 267 ...

Page 1252: ...er Test Using an analog ohmmeter running the motor by con necting battery voltage to the No 1 and No 2 terminals check for needle movement when connecting the test leads to the No 3 and No 4 terminals The analog ohmmeter needle should move back and forth alternately 1 Remove the door trim panel see section 20 2 Disconnect the 2 P connector from the motor 3 Test motor operation by connecting batter...

Page 1253: ...ay in the main relay box There should be continuity between the A and 6 ter minals when the battery is connected to the C and D terminals There should be no continuity when the battery is disconnected A A C C aI 33 ii km km B B D D rl 23 269 ...

Page 1254: ...Component Location Index DRIVER S SEAT PASSENGER S SEAT MAIN FUSE BOX I RECLINING MOTOR Test page 23 273 POiVER SEAT SWITCH Test page 23 272 1 1 1 11 1 S L I D I N G M O T O R h7 T e s t p a g e 2 3 2 7 3 I ID 23 270 ...

Page 1255: ... r m RN W H BLU PASSENGER S POWER SEAT SWITCH I m ItIDE DRIVER S POWER SEAT SWITCH 2 RECLINE 2 BLF L lECLlNE I I REDlWHT BLKlWHT RECLINING MOTOR E 5 F B REDlYEL BLKlYEL REDlWHT BLKlWHT REDlYEL BLKlYEL SLIDING MOTOR RECLINING MOTOR SLIDING MOTOR E 3ir 1 BLK d 6403 BLK J 6401 6402 F FORWARD B BACKWARD 23 271 ...

Page 1256: ...erior trim or the body 1 Remove the 2 screws then remove the power seat switch from the power seat 2 Disconnect the 5 P connectors from the power seat each switch 3 Check for continuity between the terminals in each switch position according to the table 6 RECLINING SLIDING 23 272 ...

Page 1257: ... stops running discon nect a battery terminal immediately FORWARD SLIDING Connect battery positive to the No 6 terminal and negative to the No 7 terminal BACKWARD SLIDING Connect battery positive to the No 7 terminal and negative to the No 6 terminal FORWARD RECLINE Connect battery positive to the No 4 terminal and negative to the No 1 terminal BACKWARD RECLINE Connect battery positive to the No 1...

Page 1258: ...moval page 23 277 Test page 23 279 INTEGRATED REAR WINDOW DEFOGGER Function Test page 23 280 DASH F E BOX f GER I AIN FUSE BOX Description Function The rear window defogger is controlled by the integrated control unit When the defogger switch in the combination switch is pushed it sends a signai to the defogger timer in the integrated control unit and the defogger stays on for 25 minutes or unit1 ...

Page 1259: ...fG ER 1 T R ED Y B I 18 15 A 9 DEFOGGER TIME CIRCUIT in INTEGRATED CONTROL UNIT A8 I A C tb p m REAR I WINDOW KZGER I B D II i YELjBLK I 3LKIGRN YELlBLK t I LIGHTING LIGHTING SWITCH SWITCH 7 YELlBLK RED l 3LK J I4 LIGHT 0 9lW L G YELlWHT I K BLK I K 1 YELlWHT r REAR WINDOW RiI DEFOGGER 1 DASHLIGHT K my Ess UNIT GE01 6401 6402 23 275 ...

Page 1260: ...perates but indicator light does not go on Defogger does not operate and indicator light does not go on Defogger does not operate but indicator light goes on Operate time is too long or too short Normal operation time is 25 minutes 3 1 2 1 x B 5 s u 2 3401 3801 YELIWHT YELIBLK BLKIGRN YELIBLK or YELNVHT YEL or YELIWHT WHT RED or BLK 23 2 76 ...

Page 1261: ...2 P connectors from the floor wire harness 2 P CONNECTORS l S ON CHIME L FOOT LIGHT 2 Disconnect the 18 P connector from the floor wire harness CAUTION Be careful not to damage SRS wire TCH 18 P CONNECTOR 3 Remove the tilt cover TILT COVER 4 Remove the steering column lower cover and upper cover NOTE Be careful not to damage steering column covers 5 Remove the 4 screws then remove the rear window ...

Page 1262: ...r switch 4 Remove the rear window defogger switch bulb REAR WINDOW DEFOGGER SWITCH Relay Test I Remove the defogger relay in the main fuse box 2 There should be continuity between the C and D ter minals 3 There should be continuity between the A and B ter minals when the battery is connected to the C and D terminals There should be no continuitv when the battery is disconnected 23 278 ...

Page 1263: ...board lower panel 2 If necessaly remove the knee bolster 3 Disconnect the 18 P connector from the floor wire harness 4 Check for continuity between the terminals in each switch position according to the table View from wire side 23 279 ...

Page 1264: ...POSITIVE TERMINAL NEGATIVE TERMINAL Check for continuity between the negative terminal and body ground If no continuity check for open in the defogger ground wire Connect the voltmeter positive probe to the middle of each defogger wire and the negative probe to the negative terminal The should be approximately 6 V with the ignition switch and the defogger switch ON 0 If the voltage is as specified...

Page 1265: ... Replacement page 23 285 I SRS MAIN WIRE HARNESS l WIPER LOW RELAY Test page 23 284 l WASHER RELAY Test page 23 284 INTEGRATED CONTROL UNIT Test page 23 165 WASHER FLUID WINDShELD RESERVOIR WASHER MOTOR Replacement page 23 289 Test page 23 289 WlNbSHlELD WIPER MOTOR Test page 23 285 Replacement page 23 286 Description The system is equipped with an intermittent relay a low relay and a high relay T...

Page 1266: ...I I BLUiGRN EL ED BLK 6201 3LU HT I EL GRNiBLK BLUiYEL YELiRED B LK YELiRED WINDSHIELD flPE WASHER IF IA 16 BLUiRED f 0 I I BLK l 1 BLUlWHT INTERMITTENT DWELL TIME I MiST SWITCH G I YEL GRN BRNlRED R N I BR BLUiRED HT I YkL YE1 I A INTERMITTENT WIPER CIRCUIT in INTEGRATED CONTROL UNIT BLK BLK BLK 6202 G401 6402 G301 6201 23 2 82 ...

Page 1267: ...turned OFF YELIRED BLlJ WHT BLU RED BRNlRED o r BRNNEL Erratic intermittent cycle or wipers do not operate inter mittently PINK or YELIGRN Little or no washer fluid is pumped 2 BLU RED Wipers do not operate simultane ously with washer 1 Intermittent Relay Test I rsxz ve the wiper intermittent relay from sub relay 2 There should be continuity between the A and C ter minals when the battery is conne...

Page 1268: ...hen the battery is connected to the C and D terminals There should be no continuity when the battery is disconnected Low Relay Test 1 2 Remove the wiper low relay from sub relay box B There should be no continuity between the A and B terminals when the battery is connected to the C and D terminals There should be continuity when the battery is dis connected A C I I 8 D 23 284 ...

Page 1269: ... than 4 V al tor assembly ternately Test motor operation LOW SPEED Connect battery positive to the B GRN BLK terminal and negative to the Lo BLUIRED terminal HIGH SPEED Connect battery positive to the B GRN BLK terminal and negative to the Hi BLU GRN terminal 5 If the motor fails to run smoothly replace it Hi BLU GRN L o BLUIRED z BLUIWHT B GRNIBLK Hi BLUIGRN Lo BLUIRED 6 Reconnect the 5 P connect...

Page 1270: ...ly WIPER LINKAGE ASSEMBLY 5 P COidNECTOR 4 Remove the 3 mounting bolts and 1 nut from the wiper linkage assembly to remove the wiper motor assembly NUT 18 N m 1 8 kg m 12 8 lb ft MOUNTING WlPEk MOTOR 5 Install the wiper motor assembly in the reverse ord er of removal Wiper Washer Switch Replacement CAUTION a All SRS electrical wiring harnesses are covered with yellow outer insulation a Replace the...

Page 1271: ...WIPER WASHER SWITCH TCH 3 Remove the tilt cover TILT tiChER 4 Remove the steering column lower cover and upper cover UPPER COVER LOWER COVER NOTE Be careful not to damage the steering column covers 5 Remove the 4 screws then remove the hazard switch and wiper washer switch assembly WINDSHIiLD WIPER WASHER SWITCH 23 287 ...

Page 1272: ...r wire harness 3 Check for continuitv between the terminals in each switch position according to the table WIPER WASHER SWITCH P CONNECTOR View from wire side B R 0 P C Terminal A B C N 0 P Q Ft Positoin INT 0 0 LO 0 IA IT 0 HI 0 IA IT 0 Mist switch ON Washer switch ON Intermittent dwell time 0 8A N 0 controller turned 7 O 25KP 23 2 88 ...

Page 1273: ...onnecting the battery positive to the terminal and the nega tive to the terminal Remove the washer nozzles NOTE 0 Clamp the hose at the front harness l Take care not to pinch hoses during reinstallation 0 Install the grommets firmly l After installation adjust the washer nozzles WASHER FLUID RESERVOIR MOTOR l If the motor fails to run smoothly replace it l If the motor runs smoothly but little or ...

Page 1274: ...UTION Be carefull not to damage the SRS wire har nesses when servicing the cruise control system SRS MAIN WIRE MARNESS MAIN SWITCH Test page 23 299 Replacement page 23 298 CRUISE CONTROL UNIT placement page 23 300 SOLE SWITCH A T acement page 23 157 CLUTCH SWITCH M T Test page 23 301 C A B L E R E E L Test page 23 243 Replacement page 23 342 ...

Page 1275: ...1 ACTUATOR ASSEMBLY SPEED SENSOR 23 l 33 ...

Page 1276: ...e to close Operation The cruise control system will set and automatically main tain any speed above 30 mph 45 kph To set make sure that the main switch is in the ON position After reach ing the desired speed press the set switch The cruise control unit will receive a set signal input and in turn will actuate the cruise control actuator When the set switch is depressed and the cruise control system...

Page 1277: ... attracts the clutch plate then power is transmitted to the output link by the gear directly connected to the clutch plate and the output gear The output link rotates clockwise then the actuator cable opens the throttle and the car accelerates Deceleration The motor rotates in the reverse direction of acceleration then in the same way the power is transmitted to the output link The output link rot...

Page 1278: ... IT G IRN 1 i HORN RELAY I LT GRhllWHT I I ORNlBLK BLUlRED 8 l KLLE HORNS BLUlRED a 1YEL t YEL f MAIN SWITCH Ll r REDIBLK DASHLIGHT BRIGHTNESS CONTROLLER BLK BL GRNlWHT I k 77 CRUISE CONTROL UNIT BRAKE LIGHTS BRN BLU WHT BLU O Acceleration I 0 Deceleration I I R N YELlRED SPEED PULSER M T CSLJl i AIT SHIFT POSRW N EK iLE JTUATOR ASSEMBLY d G401 6402 G302 0401 6402 23 294 ...

Page 1279: ...dicator light does not go on 1 2 1 2 Cruise speed noticeably higher or lower than what was set Excessive overshooting and or undershooting when trying to set soeed 2 Steady speed not held even on a flat road with cruise con trol set Car does not decelerate or ac celerate accordingly when SET or RESUME button is pushed 1 T GRNIBLK T GRNIRED 1 1 2 Set speed not cancelled when clutch pedal is pushed ...

Page 1280: ...re is an open circuit or damage to the wiring Remove the glove box then disconnect the 14 P con nector from the control unit Make the following tests at harness pins NOTE Recheck the connections between the 14 P con nector and the control unit then replace the control unit if all input tests prove OK SRS MklN WIRE HARNESS CRUISE CONTROL 4 WHT GRN BLK l l L I ll lll wire side 23 296 ...

Page 1281: ...d be 0 5 O 5 V repeatedly Check for voltage to ground should be 0 V with the pedal pushed and battery voltage with the pedal released Check for voltage to ground should be battery voltage with the pedal pushed and 0 V with the pedal released Attach to ground Indicator light in the gauge assembly comes on Check the operation of the ac tuator motor should be able to hear motor Check the operation of...

Page 1282: ...hting system 1 Remove the dashboard lower panel and disconnect the 2 P connectors from the floor wire harness S R S TAIN WIR H RNESS L FOOT LIGHT 2 Remove the dashboard center panel DASHBOiiRD CENTER PANEL 3 Remove the tilt cover TILT COVER 4 Remove the steering column lower cover and upper cover 5 Disconnect the 16 P connector and the 10 P con nector P NNECTOR 16 P CONNECTOR CAUTION Be careful no...

Page 1283: ...tch LIGHTING SWITCH IO P CONNECTOR 16 P CONNEdTOR Main Switch Test 1 Remove the dashboard lower panel and dashboard center panel 2 If nesessary remove the knee bolster 3 Check for continuity between the terminals in each switch position according to the table 16 P CONNECTOR 6 5 4 15 14 13 12 11 5 7 LIGHT 0 91W 0 91W 15 1 16 23 299 ...

Page 1284: ...onnector SRS T E S T HARNESS C 07LAZ SL40300 2 Check for continuity between the terminals in each switch position according to the table I Termina I 3 I 2 I 1 I 0 If there is no continuity check the cable reel l If OK go to step 3 3 Remove the switch cover from the SET RESUME switch then separate the SET RESUME switch by removing the 2 screws 4 Check for continuity between the terminals in each sw...

Page 1285: ...D PUSHED 0 0 0 0 BRAKE LIGHT SWITCH I P CONNECTOR BRAiE PEDAL 3 If necessary replace the switch or adjust pedal height see section 12 Clutch Switch Test 1 Disconnect the 3 P connector from the switch 2 Check for continuity between the terminals accord ing to the table CLUTCH CLLdCH I PEDAL BRAKE PEDAL 3 If necessary replace the switch or adjust pedal height see selection 12 23 30 1 ...

Page 1286: ...ition u I 1 2 0 0 3 0 0 D 0 0 1 N 1 I I II II R P 6 1 Disconnect 4 P connector from the actuator 2 Check the output linkage moves smoothly 3 Connect the battery positive to the D terminal and negative to the A terminal 4 Check for a clinking sound from the magnetic clutch and that the output linkage is locked You should be able to hear the motor 5 If the output linkage is not locked replace the ac...

Page 1287: ...output linkage should be located at the full close position Free play should be 11 1 5 mm 0 43 f 0 06 in ADJUSTING NUT ADJUSTING NUT ACTUATOR ACTUATOR LOCKNUT LOCKNUT FREE PLAY FREE PLAY 11 11 1 5 mm 0 43 0 06 in 1 11 1 5 mm 0 43 0 06 in 1 II FUiL CLOSE POSITION 4 If the free play is not within specs loosen the lock nut and turn the adjusting nut as required NOTE If necessary check the throttle co...

Page 1288: ... Test page I I R DOOR KEY CYLINDER SWITCH Test page 23 315 Replacement section 20 23 72 I Test page 23 242 SUB RELAY I I KEY SWITCH Test page 23 318 HORN RELAY OXA Test page 23 68 SECURITY HORN Test page 23 241 R DOOR LOCK KNOB and DOOR SWITCH Test page 23 315 CONTROL UNIT page 23 311 DIMMER RELA L FRONT POSITION LIGHT Replacement 1 Test page 23 317 LIGHTING RELAY Test page 23 185 page 23 l 89 I R...

Page 1289: ...page 23 174 TP INK KEY CYI 3 3 L FRONT SIDE MARKER LIGHT Replacement page 23 l 91 Test page 23 301 SECURITY INDlCATdR Replacement page 23 316 I L DOOR KEY CYLINDER SWITCH Test page 23 315 Replacement section 20 L REAR SIDE MARKER LIGHT Replacement page 23 l 93 I L DOOR LOCK KNOB and DOOR SWITCH Test page 23 315 and 198 Replacement section 20 TAILLIGHTS Replacement page 2 CLUTCH SWITCH M T _ 23 305...

Page 1290: ...oved and reconnected Engine starter circuit and battery circuit are bypassed by breaking the ignition switch Hood engine cover trunk lid opener in the vehicle is operated Flowchart of the security alarm system operation 1 Remove the key from the ignition switch l I g n i t i o n k e y swit O F F Close all the doors hood engine cover and trunk lid Both door switches OFF l Engine cover switch OFF l ...

Page 1291: ...removed and reconnected or 6 Engine starter circuit and battery circuit are bypassed by breaking the ignition switch or 7 Hood engine cover trunk lid opener in the vehicle is operated or I Alarm 0 The horns headlights side marker lights and tail lights sound and flash repeatedly for 2 minutes l Engine starter circuit interrupted I N O About 2 minutes passed t YES Either door is unlocked by using t...

Page 1292: ...No 9 12 3A MA N SXE No 18 20A WHTiGRN I I W IWHT R N Y E LIJ HORN RELAY BLKIYELeBLKIWHT No 5 7 DASH 10A iE sCTUATRTER RELAY SECURITY INDICATOR 1 2W ORI I I D LT GRNlWHT LK HORN SWITCH SE CONTROL r I v SECURITY CONTROL UNIT I BLUlGRN rOR YELlGRN OR 3 H iiUNRITY BLK 1H I SAFETY INDICATOR v BLU I 1 BL 3LK I BLK ORNjBLK YEI R N BR T B ARTucNHK SWITCH C BLK BLK BLK BiK 1 G501 6302 6301 G401 G402 6404 2...

Page 1293: ...LlGnTlNEM I RE ED REI BLK SECURITY CONTROL UNIT Ed GR LT GRNIRED I GRNlW I U R I GRNlYEL Ed GR POWER DOOR LOCK CONTROL UNIT GR N YE i GR r LucFci I 4 3 BLK d 6201 BLU BL HT UiR BL HT SAFETY INDICATOR GRNlRED K BLK SAFETY INDICATOR OT ED UNIT v GRNlBLU RETRACTABLE ETRoL LOCK UN LOCK LOCI 3DOOR SWITCH K I G403 6401 G402 6401 G402 23 309 ...

Page 1294: ...IGHT PASSENGER S DOOR WIRE HARNESS SHIFT POSITION COINSOLE SWITCH lATl _ _ _ _ SECURITY CONTROL UNIT FRONT W I R E HARNESS HOOD SWITCH R FRONT POSITION I R P lTlON LIGHT LIGHT MAIN RELAY BOX R HEADLIGHT LIGHTING TAILLIGHT DIMMER RELAY RIGHT HiGHI HORN FRONT COMPARTMENT WIRE HARNESS LEFT L6Wl HC SIDE IGHT ONT rlON r RN 23 310 ...

Page 1295: ...IWHT BLKIGRN or BLKNEL Starting ststem is not operated 2 1 NHTIGRN 3RN BLK fEL GRN or T GRNiWHT Security alarm can be set but alarm not ope rated when the trunk hood or either door is unlocked without the key Horn alarm T GRNIRED 3LU RED or 3ED YEL Headlight alarm Both alarms Alarm not cancelled when the door keylock is un locked with the key Alarm not cancelled when the key is inserted the igniti...

Page 1296: ... the wire 2 Y E L B L U Under all conditions Check for voltage to ground l Blown No 18 ZOA fuse should be battery voltage l An open in the wire Under all conditions 3 GRN Connect to ground security l Blown No 45 ZOA fuse indicator should come on l Faulty security indicator l An open in the wire 4 YEL Ignition switch ON Check for voltage to ground l Blown No 5 lOA fuse should be battery voltage l A...

Page 1297: ... in the wire Ignition key is inserted Check for voltage to ground l Faulty ignition key switch into the ignition switch should be 1 V or less l Poor ground G401 G402j 1 2 BLU GRN Ignition key is removed Check for voltage to ground l An open in the wire from the ignition switch should be 5 V or more Engine cover opened Check for voltageto ground l Faulty engine cover switch should be 1 V or less l ...

Page 1298: ...ty left or right door key switch l Poor ground G401 G402 l An open in the wire 21 GRNNVHT Left door key in LOCK Check for voltage to ground l Faulty left or right door key should be 1 V or less as the switch door keylock is turned in 22 GRY VVHT Right door key in LOCK LOCK l Poor ground G401 G402 l An open in the wire Left door lock knob in Check for voltage to ground l Faulty left door lock knob ...

Page 1299: ... There should be no continuity with the trunk latch in LOCK trunk lid closed position lrl Door Switch Test NOTE Be careful not to damage the door trim panel when remove it 1 Remove the door trim panel See section 20 2 Disconnect the 2 P connector from the door switch DOOR SWITCH microswitch type 3 There should be continuity between the A terminal and B terminal with the door opened 4 There should ...

Page 1300: ...OR INDICATOR I A ED B Trunk Key Cylinder Switch Test 1 Open the trunk lid and remove the trunk rear trim panel 2 Disconnect the 2 P connector from the trunk key cylinder switch 3 There should be continuity between the A and B ter minals when the trunk keylock is turned to UNLOCK with the key There should be no continuity when the keylock is released 2 P CONNECTOR View from wire side 23 316 ...

Page 1301: ...over opened There should be no continuity with the lever pushed down cover closed LEVER View from terminal side rl Hood Switch Test 1 Open the hood 2 Disconnect the 2 P connector from the hood switch 3 There should be continuity between the A and B ter minals with the lever released hood opened There should be no continuity with the lever pushed down hood closesd LEVER terminal side B n 23 317 ...

Page 1302: ...r Disconnect the 8 P connector from the floor wire harness There should be continuity between the No 8 and No 7 terminals when the ignition key is inserted into the ignition key cylinder There should be no continuity when the ignition key is removed c iew from wire side DASHBOARD LOWER K N E E B O L S T E R P A N E L DASHBOhD CENTER P A N E L 23 3 18 ...

Page 1303: ...2 1 Circuit Diagram 23 322 Wiring Locations 23 323 Troubleshooting 23 324 Airbag Assembly Removal 23 338 Installation 23 339 Disposal 23 340 Cable Reel l Removal 23 342 Installation 23 344 Dash Sensor Removal 23 346 l Installation 23 347 SRS Unit Removal 23 348 l Installation 23 349 ...

Page 1304: ...mental Restraint System SRS Component Location Index DASH SENSOR L Removalllnsta DASH SENSOR RI Removal Installation FUSE BOX SRS UNIT including cowl sensor Removal Installation page 23 348 CABLE REEL 23 320 ...

Page 1305: ...The backup power unit and the cowl sensor are located inside the SRS unit The SRS operational sequence is as follows 1 Cowl sensor activates and one or both dash sensors activate 2 Electrical energy is supplied to the airbag inflator by the battery or the backup power unit if the battery voltage is too low 3 Airbag deployment At least the cowl and one dash sensor must be activated simultaneously f...

Page 1306: ...No 5 lOA I II I DI SRS CONTROL UNIT No 2 15A No i 1gA SRS L I I 6401 1 I VOLTAGE REGULATOR COWL SENSOR Bl Et B wt E D 1I No 29 RELAY 7 50A BOX iT R K R I c i BATTERY BL E D IGNITION SWITCH CABLE REEL I AIR BAG INFLATOR B DRH J DASH SENSOR RI 4 DRC LI SADH T sv CCHK tYH SENBoR 0 SRS UNIT GROUND G701 I 23 322 ...

Page 1307: ...embly if there is an open cirucit or damage to the wiring GAUGE ASSEMBLY GAUGE ASSEMBLY and FLOOR HARNESS and FLOOR HARNESS 30 P Connector 30 P Connector I CABLE REEL and INFLATOR 3 P ConFector I FLOOR HARNESS I Y W h 7 P Connector I SRS MAIN I SRS MAIN HARNESS m C A a I ana ru3c tsu 2 P Connector I SR6 MAIN HARNESS DASH SENSOR IL and SRS MAIN HARNESS 2 P Connector CABLE REED and SRS MAIN HARNESS ...

Page 1308: ... probes directly on component connector pins or wires you may damage them or the control unit l Always keep the short connector on the airbag connector when the harness is disconnected SRS Indicator light troubleshooting Possible conditions 1 SRS light does not come on at ail see page 23 326 2 SRS light stays on constantly see page 23 330 3 SRS light comes on in combination with a failure of anoth...

Page 1309: ...RNESS A 07MAZ Sl 00500 12 3 4 5 9 10 11 12 13 14 15 16 SRS test harness B SRS UNIT PRS TEST HARNESS B 7JAZ SL40200 A SIDE SRS UNIT SIDE SRS test harness C 07LAZ SL40300 CONNECTOR SRS test harness D SRS MAIN WIRE SRS TEST HARNESS D 07LAZ SL40400 B SIDE WIRE HARNESS SIDE Cont d 23 325 ...

Page 1310: ... 23 324 Connect the battery positive terminal and then connect the negative terminal Turn the ignition switch ON Is another indicator light TCS AL etc ON in the dash panel YES inspect No 5 fuse Turn the ignition switch OFF Disconnect the SRS main har ness 18 P connector from the SRS control unit Repair open in floor harness between the No 5 fuse and gauge assembly Turn the ignition switch ON SRS M...

Page 1311: ...O 1 the indicator YES Replace bulb Connect a voltmeter between the No 9 terminal of the 30P connector and body ground Turn the ignition switch ON Measure the voltage between the No 9 terminal and body ground LOOR WIRE ARNESS 30 P I I CONNECTOR l l To page 23 329 View from terminal side kont d 23 327 ...

Page 1312: ...nd the No 7 terminal 1 j of the floor harness s 30P connector Measure the voltage between the No Gterminal and the No 7 terminal FLOOR WIRE CONNECTOR l 1 YEL BLK View from terminal side Check for continuity between the No 7 terminal and body ground Turn the ignition switch OFF To page 23 329 YES N O Repair open in the No 6 ter minal YEL wire of the floor wire harness Repair open in the No 7 termin...

Page 1313: ...or to the gauge assembly and SRS unit then connect the SRS test harness A to the SRS unit Measure the voltage between the No 6 terminal and body SRS UNIT SRS HAR 07M SRS MAIN HARNESS 1 2 3 4 5 6 7 8 SRS unit assembly is faulty Kont d 23 3 29 ...

Page 1314: ...t connector to the airbag connector when checking these voltages SRS UNIT SRS TEST IARNESS A SRi MAIN 07MAZ SL00500 HARNESS 0 03 0 0 63 vcc sv CCHKl S A D C EUC 1 G N D I D C MI Normal 5 1 6 9 4 0 5 5 10 0 14 0 9 06 14 0 5 1 6 9 o 2 0 O 2 0 lO O 14 0 9 0 14 0 A Cowl sensor open or dash i sensor short I 9 Cowl sensor short or dash sensor open G SRS unit ground and SRS unit mounting bolts GND open l...

Page 1315: ...4 2 Kg for either sensor go to step 3 l If resistance is less than 3 8 4 2 KQ for either sensor go to step 4 3 Check to make sure there is no continuity between body ground and each terminal of both dash sensors l If there is no continuity the SRS unit is faulty Substitute a known good SRS unit and recheck the voltages according to the chart on page 23 330 l If there is continuity at any of the te...

Page 1316: ... is faulty replace and recheck the voltages according to the chart on page 23 330 0 If there is no continuity replace the SRS main wire harness and recheck the voltages according to the chart on page 23 330 Mode B Cowl sensor short or dash sensor open Mode C One dash sensor open CAUTION Disconnect the battery negative termi nal and then disconnect the positive terminal Connect the short connector ...

Page 1317: ...el open 1 Disconnect the battery negative terminal and then disconnect the positive terminal 2 Connect the SRS test harness B between the SRS unit and SRS main harness s 18 P connector Measure the resistance between the B 1 and the 87 terminal SRS UNIT SRS TEST HARNESS B 07LAZ SL4020 SRS MAIN HARNESS 1 B P CONNECTOR w 0 2 KQ 0 If resistance is more than 0 2 KD go to step 3 l If resistance is less ...

Page 1318: ...nflator is faulty replace the airbag assembly and recheck the voltages according to the chart on page 23 330 Mode E SRS No 1 fuse open CAUTION Disconnect the battery negative termi nal and then disconnect the positive terminal Connect the short connector to the airbag assem bly See page 23 3241 1 Connect the SRS test harness B between the SRS unit and SRS main harness 18 P connector 2 Reconnect th...

Page 1319: ...ess 4 P connec tor side with the ignition switch ON FLOOR HARNESS SRS MAIN HARNESS 4 P CONNECTOR View from terminal side 0 If voltage is less than 9 V go to step 4 a If voltage is more than 9 V go to step 6 4 Connect the SRS test harness B between the SRS unit and SRS main harness s 18 P connector Check for continuity between the Bl 1 terminal and body ground SRS UNIT SRS TEST HARNESS B 07LAZ SL40...

Page 1320: ... on page 23 330 6 Connect the SRS main harness s 4 P connector to the floor harness then disconnect the floor harness s 30 P connector from the gauge assembly and meas ure the voltage between the No 9 terminal and body ground with ignition switch on FLOOR HARNESi 30 P CONNECTOR r BLU view from terminal side l If voltage is less than 9 V the floor wire harness is faulty repair open or short in BLU ...

Page 1321: ...k for continuity between the 85 B15 terminal and body ground SRS UNIT SRS MAIN HARNESS 18 P CONNECTOR ITI a If there is continuity the SRS unit is faulty replace and recheck the voltages according to the chart on page 23 330 0 If there is no continuity the SRS unit ground the control unit component grounds or the main har ness is faulty check the ground check wire and control unit mounting bolts a...

Page 1322: ...r improperly han died such as dents cracks or deformation l Always keep the short connector on the airbag connector when the harness is disconnected l Do not disassemble or tamper with the airbag as sembly Disconnect the battery negative terminal then dis connect the positive terminal Remove the maintenance lid A below the airbag then remove the short connector MAINTENANCE LID A 3 Disconnect the c...

Page 1323: ...tor from the airbag con nector MAINTENANCE SHORT CONNECTOR 3 Connect the airbag 3 P connector and cable reel 3 P connector 4 Attach the short connector to lid A then reinstall the lid on the steering wheel 5 Connect the battery positive terminal and then con nect the negative terminal 6 After installing the airbag assembly confirm proper system opration a Turn on the ignition to II the instrument ...

Page 1324: ...rapped the airbag should be deployed while still in the car It should not be considered a salvageable part and should never be installed in another car Confirm that the airbag assembly is securely attached to the steering wheel otherwise severe personal injury could result during airbag deployment 1 2 3 Disconnect both the negative cable and positive cable from the battery Confirm that the special...

Page 1325: ...ce up outdoors on flat ground at least thirty feed from any obstacles or people 1 Confirm that the special tool is functioning properly by following the check procedure on this page or on the tool box label of the Tool Box 2 Disconnect the short connector from the airbag harness Follow the remaining steps 5 6 7 and 8 of the in car deployment procedure Damaged Airbag Special Procedure 1 2 3 4 5 m I...

Page 1326: ...e harness is disconnected 0 Do not disassemble or tamper with the airbag as sembly Disconnect the battery negative terminal then dis connect the positive terminal Make sure the wheels are aligned straight forward Remove the dashboard lower panel then disconnect the foot light connector and lights on chime connec tor from the dashboard lower panel FOOT L GHT CAME WASHBOARD LOWER PANEL 4 Remove the ...

Page 1327: ...steering wheel nut STEERING WHEEL NUT TORX BOLT I AIRBAG ASSEMBLY 8 Disconnect the connectors from the horn and cruise control set resume switches then remove the airbag connector from its clips CRUISE CONTROL SET RESUME 9 Remove the steering wheel from the column 10 Remove the cable reel and cancel sleeve CABLE REEL CANCEL SLEE 23 343 ...

Page 1328: ... sleeve grooves with the cable reel projections PROJECTIONS 2 Carefully install the cable reel and the cancel sleeve to the steering column shaft CABLE REEL CANCEL SLEEVE I STEERING COLUMN SHAFT 3 Install the steering column upper and lower covers 4 Center the cable reel Do this by first rotating the cable reel clockwise un til it stops Then rotate it counterclockwise approximately two turns until...

Page 1329: ...irbag con nector and connect the cable reel and airbag harness NOTE Attach the short connector to lid A then in stall the lid 12 Connect the battery positive terminal then connect the negative terminal 13 After installing the cable reel confirm proper sys tem operation 0 Turn on the ignition to II the instrument panel SRS light should go on for about 6 seconds and then go off l Confirm operation o...

Page 1330: ...maintenance lid A below the airbag then remove the short connector SHORT CONNECTOR RED MAlniTENANCE LID A AIRBAG CONNECTOft fl SHORT CONNECTOR CONNECTOR 3 Disconnect the connector between the airbag and cable reel 4 Connect the short connector to the airbag side of the connector 5 Remove the dashboard lower panel 6 Pull back the carpeting and disconnect the conr tor between the dash sensor and SRS...

Page 1331: ...ess SENSOR BRACKET V DASHSENSOR MOUNTING BOLTS 8 mm x 1 25 22 N m 12 2 kg m 16 lb ft Replace NOTE Make sure the sensor is installed securely 3 Disconnect the short connector from the airbag con nector and connect the cable reel and airbag harness NOTE Reinstall the short connecter then put the maintenance lid A back in position 4 Connect the battery positive terminal then connect the negative term...

Page 1332: ...nect the battery negative terminal then dis connect the positive terminal Remove the maintenance lid A below the airbag then remove the short connector SHORT r 3 MAINTENANCE LID A AIRBAG CABLE REEL CONNECTOR SHGRT CONNECTOR 3 Disconnect the connector between the airbag and cable reel 4 Connect the short connector to the airbag side of the connector 5 Pull down the carpeting from the front console ...

Page 1333: ...ector push it into posi tion until it clicks 3 install the carpet 4 Disconnect the short connector from the airbag con nector and connect the cable reel and airbag harness NOTE Attach the short connector to lid A then in stall the lid CABLE REEL CONNECTOR I CONNECTOR MAINTENANCE LID A SHORT CONNECTOR 5 Connect the battery positive terminal then connect the negative terminal 6 After installing the ...

Page 1334: ...ted Control Unit 6 Interlock System 5 L i g h t s E x t e r i o r Back up Lights 9 Brake lights 4 Front Side Marker Lights 6 Daytime Running Lights 7 Hazard Lights 9 Headlights 7 License Plate Lights 8 Rear Side Marker Lights 8 Taillights 8 Turn Signal Lights 9 Lights Interior Ashtray Lights 10 Courtesy Lights 4 Dashlight Brightness Control 8 Dome Light 4 Entry Light Timer 6 Foot Light 6 Glove Box...

Page 1335: ...No 29 50A EPS r iEA 19 c 3 IATTERY 1 WI f E f C Gl HT STARTER CUT RELAY RN k b_________ _ 1 L BLKiBLU BLI t N0 7 7 5A C G I HT BLK BLI HT BLKiYEL 1 3 SECURITY control 18 B BLK I 0103 I WHT WHTIGR MAIN FUSE BOX I 1 I 7 v i apGM FIECU STARTER r j tAY BULB CHECK CIRCUIT in the I t J SSEMBLY Btl A No 1 ...

Page 1336: ......

Page 1337: ...LlB I YI BL E L I EL BLKIYEL 8 11 BBBB 1 WHrU WH YfL I BL 1 i NG LIGHT 2 C 1 RA ED UNIT D ANTI LOCK BRAKE CONTROL UNIT 17 C EPS CONTROL UNIT lS C L e FUNIT i i 1 WHTJBLK WHTIBLU WHTIYEL WHTlRED BlKlY 13 v I I P C ECU KlYEL WHTIBLU 14 7 WHTfRED I YELM BLl VOLTAGE REGULATOR FIELD WINDING 2 RECTFIER i CONDENSER ALTERNATOR ...

Page 1338: ......

Page 1339: ...ED COOLANT of ATURE YE p76 37 LT GRN BLUlWHT YE GR LK WI LIB I N B1 LK WH TiGl 6 i 1 f ITIBl ED WH ED BLK 1 0102 LK YE BiK BLI ED ORI 1 SDENSER RELAY a LK I BLI BLUlRED b COOLING FAN CONTROL UNIT BLU RED BL BLK IzAToR RESISTER A A 6302 6403 6302 6202 A C PRESSURE SWITCH A HI LO ON between 210kpa 2 lkgl m 30psi and 2700kpa 27kgfdm 384psi B MIDJ ON below 1250kps i2 5kg cd 17gpsi ...

Page 1340: ......

Page 1341: ...UNIT M6i TROL UNIT P S9 CBO TROL UNIT 1 E BLKlYEL 15A 8 B 25 Y REDlBLK i i 9 20A 7 A it Y REDfGRN BL I GRN L GAUGE ASSEMBLY B m I YEL I I L CHARGIN I I y 1 4W U HIGH BEAM ND jATOR 1 4W OOLANT ik RATURE OIL PRESSURE GAUGE A 1N IT c L REDlGRN RED YE OIL EURE SENDING UNIT 1 COOLANT TEMPERATURE SENDING UNIT DIMMER VOLTAGE RELAY 7 A yTCONTROL DASHLIGHT BRIGHTNESS 18 D N R OLLER 6401 6492 GiOi ...

Page 1342: ......

Page 1343: ...OIL I I 1 KiYE ODO TRIPMETER SPEEDOMETER ARGE FUEL DRIVE CIRCUIT DRIVE CIRCUIT GAUGE 1 4W BRAKE CHECK 1 4W dsQs tow FU KllAT 1 4W YE I YELIRED Y E t7 27 lN ifM ED UNIT O D i v SPEEDOMETER ED GRNiRED YEtiRED ANTI LOCK BRAKE io t UNIT C O TRDL UNIT II I 0302 SPE D FSOR YELiWHT YELhU 6401 0402 0403 ...

Page 1344: ......

Page 1345: ...lOA N 8 15AI 8 B SRS i TROL UR C lGNAL 20 B Q C 25 Y 36 Y REDlBtK BLU 01 LU GI L TURN f poR 1 4W BLUiWHT PNKiBlU YELiBtK GRYiBLK RiD BLUiBLK 444 ii MI E OCK EPB CONTROL CONTROL CONTROL DASHLIGHT CRUISE z TRoL UNIT A T BRIGHTNESS 19 c 18 B 13 D C M OLLER TRoL 13 c 17 B ...

Page 1346: ......

Page 1347: ... BtU 639 3 4W I PASSENGER S fTESY INTEGRATED C N R OL UNIT 0 IGNiTION KEY LIGHT A O lGHT POWER ANTENNA MOTOR lO D I OFF d 8 ONb IRIVER S C TESY ILU Gf IED Gi Gl INTEGRATED S UMT POWER DOOR LOCK c M t UNIT SECURITY c MIo L UNIT J BLKIWHT INTEGRATED C OsN R OL UNIT PO iER DOOR LOCK tii L UNIT SECURITY CM L UNIT II y y 41 P GRNIRED GRNIBLU NIB ED GR 1 ENGER S SWITCH LU GR GA LK 4 BAT h No 9 120AJ WHT...

Page 1348: ......

Page 1349: ...R in I Built in i i Eifll wt iRN KEV INTERLOCK SWITCH AIT CONTROL UNIT lB C 3 Ei SOLENOID 0N UNLOCK ITIRIED BLKiRED ORNiBlK V I I IVEL i EL ELI SHIFT LOCK RELAY w m T I INTERLOCK CONTROL UNIT BLK GRVlWHT n 6401 6402 SHIFT L GR HT Ll 8 15A B B 25 v REDjBLK I SHIFT POSITION I AEO CONSOLE SWilCH BLK DASHLIGHT BRIGHTNESS M R OLLER A 640 G402 ...

Page 1350: ...j ...

Page 1351: ...g lZOA WHTIAED ACC W H T 162 BLKlYEL IGi BLKIYEL No Z i5A Y E L I B L K No 4 15A YEL NaS 10A m e gauge assenbly iVER POSITION INDICATOR DIMMING CIRCUIT YE1 I BRN IBLK 1 LT GA NIWHT BLK 6401 6402 I il YELIBLU YELlBLK 5 ...

Page 1352: ......

Page 1353: ...3 7 v L W HT Rf LK OFIN16 i 1 7 I LO GA E t U YE WHifBtK i I I I I C I I I I I I i i i ENTRY LIGHT I REAR WINDOW I LIGHTS ON I I DEFOGGER I REMINDER I I T MER C RCUT I TIMER CIRCUIT I CIRCUIT I I I I I SIDE MARKER E rR I I I I I GRNIBLU WHTlRED ORN PNKIBLU BLUfWHT 0 55 REAR WINDOW ER 12 D RSRONT SIDE MARKER LIGHT WP 6401 0402 ...

Page 1354: ......

Page 1355: ...GHT bA E t P BL Fi BEEPER I I I I I I I 3WER WINDOW I SEAT BELT I ziY F TIMER I BEEPERITIMER I ljEEEyPEoRN CIRCUIT 1 CIRCUIT I I I I I I I ED YE RN YEI COMBINED OPERATION WIPER WASHER ClRCUlT 1 I I I fVlllR SURE I FLASHER CIRCUIT I I ED I t GRYfBLK REDIBLU t t I BRNIRED BRNIYEL WHTIBLU 7 IGER S POWER kFsw 12 A DRIVER S SEAT BELT SWITCH BLK 0401 0402 k 1 1 INTERMITTENT VOlTAGE REGULATOR DWELL TIME ...

Page 1356: ......

Page 1357: ...T RED REDlGRN LK I BLUIRED 6 65 UNIT i B d fFREDfGRNi7iJ W H DASHLIGHT BRIGHTNESS CONTROL UNITO A rWHTIGR Na LIGHTING SWITCH BLK LRED BLuy REdi I I lf HT B 15A 8 A 8 B I HI I I _PNK2BLK RED GRN vi I No 52 No 49 G I LT iyll 4 DAJHT RETRACTABLE SECURITY SIGNAL BRIGHTNESS HEADLIGHT CONTROL UNIT f CEt UN T CONTROL UNIT 16 B 9 D 1 DAYTIME U lNG 1 TROL I I L 1 CANADA ...

Page 1358: ......

Page 1359: ...ELIBLK YELIBLK YELIBLK I I I I 1 I I I I I I 1 I I I I I I I I I I I I I I I I I I I I I I I I I I r m I I I I I I I 1 I I I I 1 BL I I I I I 1 B HEADL GHT CTOR i YE 7 RN YELIWHT 1 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I WG SWITCH I BLUIGRN I ED I I HT BLI BLK BLK BLK DA E LIGHT 32CP 1 I RETRACTABLE HEADLIGHT CONTROL UNIT 1 I I SAFETY TOR I I I I BLUIBLK K B K B K BllK Bt...

Page 1360: ......

Page 1361: ...GHT S B 1 POWER DOOR MIRROR SWITCH LIGHT ll B POWER WINDOW SWITCH LIGHTS i2 A TCS SWITCH LIGHT i9 B GAUGE LIGHTS Z D 3 C 1 SHIFT POSITION CONSOLE LIGHT B 1 CLIMATE FUNCTION CONTROL SWITCH LIGHTB 20 C 1 LIGHTING SWlTCH LIGHT 7 B DEFOGGER SWITCH LIGHT lP D CRUISE MAIN SWITCH LIGHT l D 8 DASHLIGHT BRIGHTNESS CONTROLLERI RETRACTOR SWITCH LIGHT 7 B RED 1 STEREO RADIO1 CASSETTE PLAYER lO B 1 CLOCK S A 1...

Page 1362: ......

Page 1363: ... i20A WHTIRED ACC B L K I Y E L 101 BLKIYEL No 2 15A 7 Y E L No S lOA RI _ L LK I 1 4W ECi B BLK 1 0301 LK LK R ILK A ILK RI zYiE LIGHTS 8WX2 REAR 1 SIDE MARKERS 3CPX2 1 tilLLIGHTS BCPXO H T I J IGHTS 3CPX2 6501 ...

Page 1364: ......

Page 1365: ...Y No 120A ACC WHTlRED lOi BLKlYEL No 2 15A BLKIYEL No 4115A YELlElK 8 15A 3 E 12 7 REDIBLK CLOCK No 33 7 5A wt 0401 6402 WHTlYEL EL LK GSOi L CK UP 45CPJ ...

Page 1366: ......

Page 1367: ...ITCH YEL No 5ilOAj W H T I Y E L No 33 7 5A COlllBlNATlON SWITCH m 1 VMHTTG SWITCH 1 I I CANCEL SWITCH I BLUiGRN BLUiYEL BLK TURN SIGNAL HAZARD RELAY REAR IFRONT 45CP 32CP BLK BLK GRNIBLU YURN Sl i jBLu jYY I Ll RTj yEL GRNjBLU 0501 0301 TURN SiGNAL M TOR LIGHT INTEGRATED CM UNIT 1 FRONT REAR 32CP 45CP BLK 6301 G5Ol ...

Page 1368: ......

Page 1369: ...AIN HARNESS OR BLUiRED 0 r 4 BLUIRED BLUIRED 8 71 HORN SUME f SWITCH 13 c RN B I LK ORNIBLK YE BiK I BLK 6301 6302 I 01 No 6 iOA W CIGARETTE LIGHTER e I SECURITY HORN RN YE LUIGI b 1 _ 4 RNIY t HTIB Et I BLK t BLK 0401 6402 B NO 15 I20A ID 1flGA TE RELAY a UNIT N 6 15A CAR TELEPHONE 16 A 6 B SYSTEM Oplion v v Y BLKlBRN REDlBLK ORNlWHT MUTE STER 00 0 WINDOW ANTENNA REAR SPEAKER h n 6404 6401 0402 B...

Page 1370: ......

Page 1371: ... 51 4 A 20A MAST 1 ANTENNA H NNA I L A Y 1LIMIT SWITCH PNKIWHT ANTENNA LEA0 PNKkHT ILK PNI IO RADIO CASSETTE PLAYER IFIER KER NE 4 a BLK LiR ED I POWER AMPLIFIER w I POWER AMPLIFIER I L POWER ANTENNA MOTOR with the antenna retracted fully PASSENGER S DOOR SPEAKER 6401 6401 6401 6402 6402 G402 h 0401 G402 ...

Page 1372: ......

Page 1373: ...HTIYEL t r L YEI L YE LEFT r L f I I L NoJS 15A FUSE 8 B 25 Y NoB 20A LK AED BLK POWER DOOR MIRROR SWITCH UP r d c _ J P BLUiGRN i r YELlWHT GLUIBLK B LI IL1 R LK OG RiD 4 25 DASHLIGHT BRIGHTNESS C R OL UNIT OiN WHTIRI 0 WH TIBI L 001 G501 TRUNK I iER SWITCH LK I TRUNK OPENER SOLENOID ...

Page 1374: ......

Page 1375: ... L No S lOA WHTlYEL No 33 7 5A SECURITY CJT OL UNIT DOOR KNOB I c ORN n LOCK UNLOCK KR LOCK IYTTRoL Y ELK G401 1BLI IBLI t URITY T UN T GRATED itot UN T 7 WHTlRED YELIRED RN BlU GRN RN DOOR KNOB s s r 9 I I GT DN SWITCH cp 1 R DOOR LOCK SWITCH I IBLK 6402 6401 ...

Page 1376: ......

Page 1377: ...6 40A INTEGRATED W UNIT I I 56 I iRYlE DRIVER SEAT S POWER zLKW I m No30 20A No 47 20A NoJB i5A FUSE 8 B REDIBLK WH Et r UNIT 9 B SLID k i BlKl REDlYEL BLKlYEL BLKiG J 4 81 J YEL I REDfGRN I POWER WINDOW CONTROL UNIT SLIDING MOTOR BiK L F FORWARD B BACKWARD PASSENGER S MOTOR A _ _ 0201 6401 0402 ...

Page 1378: ......

Page 1379: ... 7 ED GRA TROI B 25 I Y YELlBLK RED ELK WI YELIWHT RED LK REAR WINDOW EVGGER HT PASSENGER S POWER SEAT SWlTCH LlDE 1 RECLINE I B f REDlWHT BLKIWHT ti M RECLINING MOTOR BLK 1 K n 0401 0402 YE IN 1 T 1 B F it REDlWHT BLKlWHT 1BLK L RECLINING MOTOR I YEL WHT DASHLIGHT GgESS UNIT B INTEGRATED C jM R OL UNIT REAR WINDOW DEFOGGER SLIDING MOTOR BiK 1 GE01 0401 6402 ...

Page 1380: ... e ...

Page 1381: ...K r BLK i LIGRN E L YE t I BLUIWH 8LUfRED G R BLUlYEL YEI BLK YEILlRl I t YEI RI BLUiG RN OR INTEGRATED N R OL UNIT LK WIPER LAY ID _ _ _ r r 181 ELK l la K 1 I iD WINDSHIELD jWASHER M I S T SWITCH LK YEL BLK YE1 t INTEGRATED N R OL UNIT ED 81 54 f BLUlWHT 8LUlRED L Et INTEGRATED N R OL UNIT YEL 6201 6202 0401 INTEGRATED M R OL UNIT 6301 6201 ...

Page 1382: ......

Page 1383: ...E L I G H T YTCc H 3 D LT IN CRUISE CONTROL UNIT Acceleration I i PGM FI ECU I I 14 c I I I YELIRED I I I I RN I SHIFT SPE D EESOR 1 POSITION LE I I ACTUATOR ASSEMBLY I BiK 1 6302 I El I I I I I I I I I I I I I I I I I I T bR t i T GR d 3 15A 8 B 2 5 Y R E D I B L K _ ELK BLK 6401 0402 RED DASHLIGHT BRIGHTNESS N R OLLER KtiSE SWITCH 13 ...

Page 1384: ......

Page 1385: ... 2115AI BLKIYEL fF I d 7 5A l A 2 EL L BLKlWHT BLI VEL UMP IESISTOR E t L b 3 KlRE I YELIBLK YE 1 iRN BLK BLKIRED INJECTOR RESISTORS AIT CONTROL UNIT l6 B FUEL PUMP 11 e ELK T T Y E L HLUIYEL L 0403 0101 T I WHTlYEL BiU REf BLU A C CHECK E l E UMTpcRHESSO RELAY 2 D 20 B PGM FI ECU N o 1 N o 2 N o 3 N o 4 N o 5 N o 6 AIT CONTROL c M R UNIT UNIT lG C ...

Page 1386: ......

Page 1387: ...R LU RiD YE I iT b I GRI HT GRNIWHT YELlWHT BLU 6 a2 WHTlRED GRN PNK YELIRED REDfGRN K WHTlBLK ORNlREO LT GRN WHTIRED 1 TCS CONTROL 1 AIT CONTROL UNIT lB C UNIT C lU 8AIT CONTROL TCS CONTROL UNIT 16C al4 UNIT C 7 A C CONTROL as as a1 UNIT 20 C 3 c S SENSOR gfES E CRUISE CONTROL SHIFT LEVER UNIT lbC POSITION T NATOR d 1 D ASSENBLY TCS CONTROL tToR UNIT lB C To Next Page ...

Page 1388: ......

Page 1389: ...IYEL 1 F r o m Previous Page THROTTLE R p t WHT EPS CONTROL UNIT lS B AIT CONTROL UNIT lG C TCS CON TROL UNIT lS C r i I OCK CONTROL UNIT 17 B GRNIWHT GRNI REI WHT RE EL EL GRNIWHT YELlWHT 9 8 9 WH TCS CONTROL UNIT lB C HT AIT CONTROL UNIT lG D GRNIWHT k TIG PGM FI ECU I I 1 CRANKlCYL SENSOR ...

Page 1390: ......

Page 1391: ...WHl x a REAR VALVE TIMING OIL TIMING 011 PRESSURE PRESSURE SWITCH SWITCH I BLUiBLK A lir I BRNlWHT E L BI I GRNlWHT 1 BLKIYEL No 2 15A YELlBlK No 4 15A YEL No S lOA WHTIYEL No 33 7 5A EL 1 GRNlWHT HT A T CONTROL UNIT lG D 92 BRNlWHT 9 Shielded wire 15 ...

Page 1392: ... ...

Page 1393: ...RN 3 HOOD SWITCH r l K K SWITCH W r Hif i POSITION CONSOLE SWITCH I LIGHTING ER CUT L TI w J RELAY l B l B 7 A ll HT G 9 A 7 B T T B T T BLKlGRN BLKIYEL BLUIRED REDlYEL LT GRNIRED h h A SECURITY CONTROL UNIT BiK B t GRNIBLU GRIND BtljDGR L GRiTGRit GRi 1 R L R L KEY R KEY Mf WITCHES D O O R L O C K M S WITCH E M E R i E R 11 c Ii C I ARiY i SWITCH Securily KlYl I T BLK 77 6301 6401 6402 0501 ...

Page 1394: ......

Page 1395: ...YEL ACCEL A I C COOLANT h A A Ail CONTROL UNIT ILU I OR 88 EE NECTOR A SHIFT LEVER SPEED SHIFT LEVER POSITION SENSOR POSITION lN N K UNIT 5 A GP U I 1 GR LK EL T I I SHIFT POSITION N fLE SWITCH T GRY Bl W H T tYEL H T lK Wl t YEL I LINEAR SOLENOID 7 BRI I 92 d0101 15 c PCEED ED SENSOR SENSOR Shielded wire WH HT 16 ...

Page 1396: ......

Page 1397: ...OCK BRAKE INDICATOR LIGHT in the GAUGE ASSEMBLY 3 c 31v BLUlWHT I I BLU BLK ILEFT REAR SOLENOID 1 115 IN OUT Ii r 7 r 1 l l v w WHTIGRN WHTlGRN WHTlSLK WHTjBtK BLU WHT BLU WHT REDlGRN YELIGRN REOlW I ANTI LOCK BRAKE CONTROL UNIT I Bt GRNlYEL ECTION NECTOR O BLK ORN i j YELIBLK I BLU BLI a3 RN GR SERVICE CHECK C i N CTOR OR HT E L LIRONT RSRONT L REAR R REAR SPEED SENSORS ...

Page 1398: ......

Page 1399: ...YELfGRN Y ELIRED IED OR J UNIT h I WHTlBLU LK 1 VOLTAGE 9 PARKING BRAKEI REGULATOR BRAKE FLUID in ALTERNATOR l D Ek EL BWITCHEB DAiTlME RUNNING LIGHT CONTROL UNIT CANADA 7 D 7BLK 1 0302 T 6202 1 LIB i ILlAl LK I ED WH M TSLK Q D BAT No lZOA BLKlYEL 101 BlKlYEL Na Z l5A Y E L I B L K No 4 15A YEL No S iOA WHTlYEL No 33 7 5A No 30 40A 1 M OCK MOTOR 0302 ...

Page 1400: ......

Page 1401: ...lYEL Gl ANTI LOCK BRAKE C TiO L UNIT E No 16 l15A ED HT YELlRED LT GRNlRED BR 0 IT GRNlWHT BRNlWHT STEERING ANGLE SENSOR BRNIWHT I IIN f ILK TCS FAIL SAFE RELAY T r loi 5 15A 5 B 25 Y REDIBLK IN T RED I If 28 DASHLIGHT YE1 y T SS UNIT B TCS fiATOR r I 3 c 15 B YELIBLK BLU TCS CONTROL UNIT STEP MOTOR ...

Page 1402: ......

Page 1403: ...M ECU TCS OFF ACTIVATION E F EfTE cc H fD IC 9TOR ATOR No53E2 20A 7 y 7 y 7 T B p j I RED REDlYEL BLU WHTlBtK WHTIRED ORNIRED GRN GRNlWHT GRYIBLK REDfGRN WHTlBLK h A I h BLK a I G405 fE PARKING BRAKEI AIT SHIFT BRAKE FLUID N CTOR E3 EAt SWlTCH KiTRot P yM ECU POSITION INDICATOR 16 D DAYTIME RUNNING A T LIGHT CONTROL 5 B UNIT 7 D Shielded wire 18 ...

Page 1404: ......

Page 1405: ... BLKIYEL No 2 15A BLKIYEL No 4 15A YELIBLK No S lOA YEL No 33 7 5A WHTlYEL L G401 0402 0403 it b WH EL LK 01 iI TORQUE SENSOR 81 EL I I I STEERING WHEEL SPEED SENSOR EPS CONTROL UNIT IN YELlRED OLU P STEERING GEARBOX 64 ...

Page 1406: ......

Page 1407: ... 1 1 1 1 L L 9 9 13 II II II I VOLTAGE HT djlN I RN II OR BLU ORljlBLU TROL REGULATOR I WHi BLU 1 BR I r c in ALTERNATOR l D 1 1 1 I 1 1 4 BLK 1 I f I I I H II u POWER UNll a TYEL BLK BAT No 9 120A BLKIYEL IGl BLKlYEL No 2 15A YELIBLK No l l5A W H T I Y E L No 33 7 5A BATTERY NEGATIVE Y m w shielded wie 19 ...

Page 1408: ......

Page 1409: ...A WHTlYEL B AIR BAG INFLATOR G R N O R N BRN GRNIRED REdrBlU A h A I LDASH SENSOR R DABH SENSOR SRS CONTROL UNIT E l 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 CHECK CONNCTOR i No 1 lOA 4BLK 1 BLK SRS M ATOR 3 D IKIO RED No 21 lOA RN YE RE P Sf ECU AIT CONTRA UNIT 16D f PR R SSOR ...

Page 1410: ... ...

Page 1411: ...FAN ld UNIT PGM FI ECU NEPI 14 c 22 eGRN GRYlBLK K R E D BLOWER DASHLIGHT HI RELAY BRIGHTNESS N R Ol UNIT BLK BLK 0401 6401 0402 G402 W H LK A SUNLIGHT SENSOR B COOLANT TEMPERATURE SENSOR C EVAPORATOR TEMPERATURE SENSOR D AMBIENT TEMPERATURE SENSOR E IN CAR TEMPERATURE SENSOR GRNIRED f Q BLKlGRN LT BLU 0 LT GRN B L K 2 RN 20 ...

Page 1412: ......

Page 1413: ... I 8 t 0 0 L Inm ...

Page 1414: ...4B ...

Page 1415: ... I f ...

Page 1416: ......

Page 1417: ...cted System Connectors ...

Page 1418: ......

Page 1419: ...NOTE Several different wires have the same color They have been given a number suffix to distinguish them for example YEL BLK and YEL BLK2 are not the same 0 Related to PGM FI SYSTEM CANADA ...

Page 1420: ......

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