Page 1 1996–04 3.5RL Main Menu General Info Steering Specifications Suspension Maintenance *Brakes (Including ABS, TCS and VSA) *Engine Electrical *Body Engine *Heating, Ventilation and Air Conditioning Cooling *Body Electrical Fuel and Emissions *Restraints *Transaxle As sections w/ * include SRS components, special precautions are required when servicing.
Page 2: Table Of Contents
Main Menu General Information Chassis and Paint Codes Under–hood Emissions Control Label ’96 Models ........1–2 ’97 Models .
Page 3: Chassis And Paint Codes
Main Menu Table of Contents Chassis and Paint Codes 1996 Model Vehicle Identification Number Transmission Number Paint Code Paint Code Color G-79P Juniper Green Pearl G-83P Eucalyptus Green Pearl NH-585P Cayman White Pearl NH-592P Flamenco Black Pearl RP-25P Black Currant Pearl YR-508M Heather Mist Metallic YR-511P...
Page 4: Models
1997 Model Transmission Number Vehicle Identification Number Paint Code Color Paint Code B-75M Crescent Silver Metallic*2 G-79P Juniper Green Pearl Eucalyptus Green Pearl*1 G-83P NH-585P Cayman White Pearl NH-592P Flamenco Black Pearl RP-25P Black Currant Pearl*1 YR-508M Heather Mist Metallic YR-511P Devon Slate Pearl*1 Vehicle Identification Number...
Page 5: Models
Chassis and Paint Codes 1998 Model Vehicle Identification Number Transmission Number Paint Code Color Paint Code B-91M Crystal Silver Metallic G-79P Juniper Green Pearl*1 NH-585P Cayman White Pearl NH-592P Flamenco Black Pearl NH-611M Athlete Gray Metallic*1 R-504P Ruby Red Pearl*1 YR-508M Heather Mist Metallic *1: U.S.
Page 6: Models
1999 Model Vehicle Identification Number Transmission Number Paint Code Color Paint Code B-91M Crystal Silver Metallic B-92P Nighthawk Black Pearl B-93P Monterey Blue Pearl*1 G-97P Vermont Green Pearl NH-624P Premium White Pearl R-504P Ruby Red Pearl*1 YR-524M Naples Gold Metallic *1: U.S.
Page 7: Models
Chassis and Paint Codes 2000 Model Vehicle Identification Number Transmission Number Paint Code Paint Code Color B-92P Nighthawk Black Pearl Monterey Blue Pearl B-93P G-97P Vermont Green Pearl*1 Sebring Silver Metallic NH-552M R-504P Ruby Red Pearl* 1 YR-524M Naples Gold Metallic *1: U.S.
Page 8: Models
Chassis and Paint Codes 2001 Model Vehicle Identification Number Transmission Number Paint Code Paint Code Color B-92P Nighthawk Black Pearl B-502P Indigo Blue Pearl*1 G-97P Vermont Green Pearl* 1 NH-623M Satin Silver Metallic NH-624P Premium White Pearl R-507P Firepepper Pearl YR-524M Naples Gold Metallic *1: U.S.
Page 9: Models
Chassis and Paint Codes 2002 Model Vehicle Identification Number Transmission Number Paint Code Engine Number...
Page 10: Models
Chassis and Paint Codes 2003 Model - Vehicle Identification Number Transmission Number Paint Code...
Page 11: Models
Chassis and Paint Codes 2004 Model...
Page 12 Revised Component Terms Beginning with '01 models, the following component terms have been changed to conform with the standards in SAE docu- ment J1930. If you find a term or abbreviation in a '01 manual that is unfamiliar to you, check this list. If a term is not listed below, it did not change.
Page 13 '00 and Earlier Models '01 and Later Models...
Page 14: Parts Marking ('03-'04 Models)
Parts Marking To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. The original engine or transmission VIN plate is transferred to a replacement engine or transmission and attached with break-off bolts. NOTE: Be careful not to damage the parts marking labels during body repair.
Page 15: Identification Number Locations
Identification Number Locations Vehicle Identification Number Vehicle Identification Number Transmission Number (Automatic) Engine Number...
Page 16: Warning/Caution Label Locations
Caution Label Locations SRS WARNING DRIVER SRS INFORMATION (HOOD) (see page 1-10) PASSENGER SRS INFORMATION U.S. model (on back of sunvisor, see page 1-10) PASSENGER SRS INFORMATION U.S. model (see page 1-10) FRONT SEAT PASSENGER AIRBAG MODULE DANGER/ WARNING (see page 1-10) FRONT SEAT PASSENGER AIRBAG CAUTION...
Page 17 Caution Label Locations (cont'd) DRIVER SRS INFORMATION FRONT SEAT PASSENGER AIRBAG MODULE PASSENGER SRS INFORMATION ('96, '97 models) DANGER/WARNING ('96, '97 models) DANGER CAUTION TO AVOID SERIOUS INJURY: EXPLOSIVE/FLAMMABLE FOR MAXIMUM SAFETY PROTECTION IN ALL TYPES OF CONTACT WITH ACID, WATER OR HEAVY METALS SUCH AS CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY COPPER, LEAD OR MERCURY MAY PRODUCE HARMFUL AND BELT.
Page 18 DRIVER MODULE DANGER ('97 model) STEERING COLUMN NOTICE NOTICE DANGER EXPLOSIVE/FLAMMABLE TO PREVENT SRS DAMAGE, REMOVE STEERING WHEEL CONTACT WITH ACID, WATER OR HEAVY METALS SUCH AS BEFORE REMOVING STEERING SHAFT CONNECTING COPPER, LEAD OR MERCURY MAY PRODUCE HARMFUL AND BOLT.
Page 19 Caution Label Locations (cont'd) SERVICE INFORMATION COOLANT Under-hood Emissions INFORMATION Control Label BATTERY CAUTION HEADLIGHT AIMING INFORMATION RADIATOR CAP AIR CONDITIONING CAUTION INFORMATION '00-01 models '96 - 99 models TIRE INFORMATION SIDE AIRBAG CAUTION TIRE INFORMATION See page 1-11. This caution is also labeled on passenger doorjamb.
Page 20: Under-Hood Emissions Control Label
Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families (1997 model) Engine Family: Example: VACUUM HOSE ROUTING DIAGRAM 50ST (50 State): THIS VEHICLE CONFORMS TO THE U.S. EPA AND THE STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1997 MODEL YEAR NEW MOTOR VEHICLES.
Page 21 Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families (1998 model) Engine Family: Example: VACUUM HOSE ROUTING DIAGRAM Evaporative Family: 50ST (50 States): THIS VEHICLE CONFORMS TO THE U.S. EPA AND THE STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHICLES.
Page 22 Emission Group Identification Engine and Evaporative Families (1999 model) Engine Family: Example: VACUUM HOSE ROUTING DIAGRAM Evaporative Family: 50ST (50 States): THIS VEHICLE CONFORMS TO THE U.S. EPA AND THE STATE OF CALIFORNIA REGULATIONS APPLICABLE TO 1999 MODEL YEAR NEW MOTOR VEHICLES.
Page 23 Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families (2000 model) Engine Family: Example: VACUUM HOSE ROUTING DIAGRAM Evaporative Family: 50ST (50 States): THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULA- TIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2000 MODEL YEAR NEW LEV PASSEN- GER CARS.
Page 24 Emission Group Identification Engine and Evaporative Families (2001 model) Engine Family: Example: VEHICLE EMISSION CONTROL INFORMATION Evaporative Family: 50ST (50 States): THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULA- TIONS APPLICABLE TO 2001 MODEL YEAR NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2001 MODEL YEAR NEW LEV PASSEN- GER CARS.
Page 25 Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families (2003 model)
Page 26 Under-hood Emissions Control Label Emission Group Identification (2004 model)
Page 27: Lift And Safety Stands
Lift and Support Points Lift and Safety Stands 1. Place the lift blocks as shown. 2. Raise the hoist a few inches (centimeters), and rock the vehicle to be sure it is firmly supported. 3. Raise the hoist to full height, and inspect the lift points for solid support. NOTE: Use the same support points to support the vehicle on safety stands.
Page 28: Floor Jack
Floor Jack Block the rear wheels when raising the front of the vehicle; block the front wheels when raising the rear Always use safety stands when working on or under of the vehicle. any vehicle that is supported by only a jack. Place the blocks behind and ahead of the wheels.
Page 29: Towing
Towing If the vehicle needs to be towed, call a professional tow- Front: ing service. Never tow the vehicle behind another vehi- cle with just a rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a vehicle. Flat-bed Equipment —...
Page 30: Service Precautions
Because the front sub frame sections on this vehicle are constructed with aluminum alloys, use only the special type. "Dacro" type nuts and bolts recommended by Acura. Tighten the nuts and bolts with a torque wrench to NOTE: the specifications provided in this manual.
Page 31: Specifications
Specifications Standards and Service Limits Cooling Suspension Engine Electrical ’96–’01 Models ....2–4 ’96–’01 Models ....2–9 ’96–’01 Models .
Page 32 Standards and Service Limits Engine Electrical — Section 4 *1 When using a new belt, adjust deflection to new value. Run the engine for 5 minutes then turn it off. Readjust deflection to used belt value. *2 Do not adjust the gap, replace the spark plug if it is out of service limit. Cylinder Head/Valve Train —...
Page 33 Standards and Service Limits Engine Electrical — Section 4 *1 When using a new belt, adjust deflection or tension to new value. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt value. *2 Do not adjust the gap, replace the spark plug if it is out of service limit.
Page 34 Standards and Service Limits Engine Electrical — Section 4 Cylinder Head/Valve Train — Section 6...
Page 35 Standards and Service Limits Engine Electrical — Section 4 *1 When using a new belt, adjust deflection or tension to new value. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt value. *2 Do not adjust the gap, replace the spark plug if it is out of service limit.
Page 36 Engine Block — Section 7 Engine Lubrication — Section 8...
Page 37 - Engine Block — Section 7 Engine Lubrication — Section 8...
Page 38 Engine Block — Section 7 *1: RIKEN manufactured piston ring. *2: TEIKOKU PISTON RING manufactured piston ring. Engine Lubrication — Section 8...
Page 39 Engine Block — Section 7 Engine Lubrication — Section 8...
Page 40 Standards and Service Limits Cooling — Section 10 Fuel and Emissions — Section 11...
Page 41 Standards and Service Limits Cooling — Section 10 Fuel and Emissions — Section 11...
Page 42 Standards and Service Limits Cooling — Section 10 Fuel and Emissions — Section 11...
Page 43 Standards and Service Limits Cooling — Section 10 Fuel and Emissions — Section 11...
Page 44 Standards and Service Limits Automatic Transmission — Section 14...
Page 45 Automatic Transmission (cont'd) — Section 14...
Page 46 Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 47 Automatic Transmission (cont'd) — Section 14...
Page 48 Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 49 Standards and Service Limits Automatic Transmission — Section 14...
Page 50 Automatic Transmission (cont'd) — Section 14...
Page 51 Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 52 Automatic Transmission (cont'd) — Section 14...
Page 53 Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 54 Standards and Service Limits Differential — Section 15...
Page 55 Standards and Service Limits Differential — Section 15...
Page 56 Standards and Service Limits Differential — Section 15...
Page 57 Standards and Service Limits Differential — Section 15...
Page 58 Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 59 Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 60 Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 61 Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 62 Standards and Service Limits Air Conditioning — Section 22...
Page 63 Standards and Service Limits Air Conditioning — Section 22...
Page 64 Standards and Service Limits Air Conditioning — Section 22 * When using a new belt, adjust deflection or tension to new value. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt value.
Page 65 Standards and Service Limits Air Conditioning — Section 22...
Page 66 Design Specifications...
Page 67 Design Specifications (cont'd)
Page 68 Design Specifications...
Page 69 Design Specifications (cont'd)
Page 70 Design Specifications...
Page 71 Design Specifications...
Page 72 Design Specifications...
Page 73 Design Specifications (cont'd)
Page 74 Body Specifications...
Page 75 Body Specifications...
Page 76 Body Specifications...
Page 77 Body Specifications...
Page 78 Maintenance Lubrication Points ........3–2 Severe Conditions Maintenance Schedule...
Page 79: Lubrication Points
Lubrication Points For the details of lubrication points and types of lubricants to be applied, refer to the Illustrated Index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, etc.) contained in each section. LUBRICANT LUBRICATION POINTS Engine API Service Grade: Use SJ "Energy Conserving" grade oil. The oil container may also display the API Certification seal shown below.
Page 80 NOTE: Lubricate all hinges, latches, and locks once a year. In corrosive areas, more frequent lubrication is necessary. We recommend Honda White Lithium Grease.
Page 81 Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages do not apply. 8-4, 10-5 11-153 4-22 6-13, 10-10 4-33, 17-15, 22-85 11-124 10-5 14-108 15-4 19-10, 19-11, 12, 17, 18, 19-19, 19-23 19-8 19-6...
Page 82 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 83 Follow the Severe Conditions Maintenance Schedule if the vehicle is driven in Canada or MAINLY under one or more of the Severe Driving Conditions (page 3-7): 8-4, 8-5 8-4, 10-5 11-153 4-22 6-13, 10-10 4-33, 17-15, 22-85 11-124 10-5 14-108 15-4 19-10, 19-11, 19-12, 19-17, 19-18,...
Page 84 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 85 Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages 3-10 3-11 do not apply. 8-4, 10-5 11-153 4-22 6-13, 10-10 4-33, 17-15, 22-85 11-124 10-5 14-108 15-4 19-10, 19-11, 12, 17, 18, 19-19, 19-23 19-8...
Page 86 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 87 Follow the Severe Conditions Maintenance Schedule if the vehicle is driven in Canada or MAINLY under one or more of the Severe Driving Conditions (page 3-11): 8-4,8-5 8-4, 10-5 11-153 4-22 6-13, 10-10 4-33, 17-15, 22-85 11-124 10-5 14-108 15-4 19-10, 19-11, 12, 17, 18, 19,23...
Page 88 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 89 Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages 3-14 3-15 do not apply. 8-4, 10-5 11-153 4-22 6-8 to 6-13, 10-10 4-33, 17-15, 22-85 11-124 10-5 14-108 15-4 19-10, 19-11, 12, 17, 18, 19-19, 19-23...
Page 90 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 91 Follow the Severe Conditions Maintenance Schedule if the vehicle is driven MAINLY under one or more of the Severe Driving Conditions (page 3-15): 8-4, 8-5 8-4, 10-5 11-153 4-22 6-13, 10-10 4-33, 17-15, 22-85 11-124 10-5 14-108 15-4 19-10, 19-11, 12, 17, 18, 19-19, 19-23 19-8...
Page 92 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 93 Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages do not apply. 8-4,10-5 11-153 4-22 to 6-13, 10-10 4-33, 17-15, 22-85 11-124 10-5 14-108 15-4 19-10, 19-11, 19-12, 19-17, 19-18, 19-19, 19-23 19-8...
Page 94 * According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 95 Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule on pages do not apply. 8-4, 10-5 11-150 4-22 6-13, 10-10 4-33, 17-15, 22-85 11-121 10-5 14-108 15-4 19-10, 19-11, 19-12, 19-17, 19-18, 19-19, 19-23 19-8 19-7...
Page 96 17-14, 17-23 18-3, 18-21, 18-22 16-3 19-28 8-4, 10-5, 14-108 15-4, 17-16, 19-8 11-123 For Canadian models: Follow the Severe Conditions Maintenance Schedule on page 3-4 and 3-5.
Page 97 Follow the Severe Conditions Maintenance Schedule if the vehicle is driven in Canada or MAINLY under one or more of the Severe Driving Conditions (page 3-5): 8-4,8-5 8-4, 10-5 11-153 4-22 to 6-13, 10-10 4-33, 17-15, 22-85 11-124 10-5 14-108 15-4 19-10, 19-11, 19-12, 19-17,...
Page 98 * According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 99 Follow the Severe Conditions Maintenance Schedule if the vehicle is driven in Canada or MAINLY under one or more of the Severe Driving Conditions (page 3-5): 8-4, 8-5 8-4, 10-5 11-150 4-22 6-13, 10-10 4-33, 17-15, 22-85 11-121 10-5 14-108 15-4 19-10, 19-11, 19-12, 19-17, 19-18,...
Page 100 17-14, 17-23 18-3, 18-21, 18-22 16-3 19-28 8-4, 10-5, 14-108, 15-4, 17-16, 19-8 11-123 23-123 NOTE: If the vehicle is driven OCCASIONALLY under a "severe" condition, you should follow the Normal Conditions Maintenance Schedule on pages 3-3.
Page 101 Engine Electrical Special Tools ....... 4–2 Ignition System Brush Inspection .
Page 102: Special Tools
Special Tools Ref. No. Tool Number Description Page Reference A973X - 041 - XXXXX Vacuum Pump Gauge 4-43 07JGG-001010A Belt Tension Gauge 4-33 07PAZ-0010100 SCS Service Connector 4-18 * Included in Belt Tension Gauge Set, T/N 07TGG - 001000A.
Page 103: Starting System
Starting System Component Location Index STARTER CUT RELAY Wire colors: BLK/WHT, BLK/WHT, BLK/WHT and WHT/RED UNDER-DASH FUSE/RELAY BOX STARTER Test, page Replacement, page Overhaul, page Solenoid Test, page Reassembly, page 4-14...
Page 104: Starter Test
Starter Test NOTE: The air temperature must be between 59 and With the shift lever in , turn the ignition 100°F (15 and 38°C) before testing. switch to START (III). The starter should crank the engine. If the starter Recommended Procedure: does not crank the engine, go to step 3.
Page 105 Starting System Starter Test (cont'd) Check for Wear and Damage The starter should crank the engine smoothly and steadily. If the starter engages, but cranks the engine erratically, remove it, and inspect the starter drive gear and drive plate ring gear for damage. Check the drive gear overrunning clutch for binding or slipping when the armature is rotated with the drive gear held.
Page 106: Starter Replacement
Starting System Starter Replacement Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's pre- set buttons. Disconnect the battery negative terminal first, then the positive terminal. NOTE: The PCM memory setting is needed after reconnecting the battery (see page 11-123).
Page 107 9. Remove the transmission stop collar, then remove 13. Disconnect the starter cable and BLK/WHT wire, then remove the starter. the exhaust pipe A. SELF-LOCKING NUT 8 x 1.25 mm 22 N-m (2.2 kgf-m, 16 Ibf-ft) Replace. 8 x 1.25 mm GASKETS 10 x 1.25 mm 8.8 N-m (0.9 kgf-m,...
Page 108: Starter Overhaul
Starting System Starter Overhaul CAUTION: Disconnect the battery cable before remov- PLANETARY GEAR ARMATURE ing the starter (see page 4-6). NOTE: The PCM memory setting is needed after recon- necting the battery (see page 11-125). BRUSH HOLDER BRUSH SPRING BRUSH HOLDER RING Test, page 4-12...
Page 109: Starter Solenoid Test
Starter Field Winding Test Starter Solenoid Test Remove the starter solenoid from the gear housing. Check for continuity between the brushes. If there's no continuity, replace the armature housing. SOLENOID Check for continuity between each brush and the armature housing (ground). SCREWS If continuity exists, replace the armature housing.
Page 110: Armature Inspection And Test
Starting System Armature Inspection and Test Inspect the armature for wear or damage due to con- If commutator diameter is below the service limit, tact with the permanent magnet. If there is wear or replace the armature. damage, replace the armature. Commutator Diameter Service Limit Inspect for damage...
Page 111 Place the armature on an armature tester. Hold a Check for mica depth. If necessary, undercut the mica with a hacksaw blade to achieve proper depth. If the hacksaw blade on the armature core. If the blade is service limit cannot be maintained, replace the arma- attracted to the core or vibrates while the core is ture.
Page 112: Starter Brush Holder Test
Starting System Starter Brush Holder Test Starter Brush Inspection Check that there is no continuity between the Measure the brush length. If the length not within the brush holders. If there is continuity, replace the service limit, replace the brush holder assembly. brush holder assembly.
Page 113: Planetary Gear Inspection
Planetary Gear Inspection Overrunning Clutch Inspection Check if the planetary gears are worn or damaged. If they Slide the overrunning clutch along the shaft. are, also check the condition of the armature shaft gear Does it move freely? If not, replace it. and ring gear.
Page 114: Overrunning Clutch Removal
Starting System Overrunning Clutch Removal Starter Reassembly Put the end of a pipe (inner diameter 13 mm (0.51 in)) NOTE: Use the illustration on page as reference for against the pinion stop, and strike the pipe to force reassembly. the pinion stop over the spring clip. 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.
Page 115: Performance Test
Performance Test Retracting Test: NOTE: Before starting the following checks, disconnect the wire from terminal M, and make a connection as described below using as heavy a wire as possible (prefer- Disconnect the battery also from the body. If the pinion ably equivalent to the wire used in the vehicle).
Page 116: Ignition System
Ignition System Component Location Index IGNITION COILS Test, page 4-21 SPARK PLUGS Inspection, page 4-22 NOISE CONDENSER Test, page 4-19 IGNITION CONTROL MODULE (ICM) Input Test, page 4-20...
Page 117: Ignition Timing Inspection
Ignition System Ignition Timing Inspection SRS components are located in this area. Review the SRS Inspect ignition timing at idle speed. component locations, precautions, and procedures in the (section 24) before performing repairs or service. Ignition Timing: 15 ± 2° BTDC (RED) at 650 ± 50 rpm with shift lever Start the engine.
Page 118: Idle Speed Check
Idle Speed Check Noise Condenser Capacity Test Start the engine. Hold the engine at 3,000 rpm with Use a commercially available condenser tester. Con- no load (shift lever in ) until the radiator fan nect the condenser tester probes, and measure the comes on, then let it idle.
Page 119: Ignition Control Module Input Test
Ignition System Ignition Control Module (ICM) Input Test NOTE: See section 11 if the malfunction indicator lamp (MIL) blinks. Disconnect the 8P connector from the ignition control module (ICM). Inspect the connector and socket terminals to be sure they are all making good contact. If any terminals are bent, loose or corroded, repair them as necessary, and recheck the system.
Page 120: Ignition Coil Test
Ignition Coil Test Turn the ignition switch OFF. Remove the strut brace, then remove the engine Terminal cover (see section side of male terminals Remove the ignition coil. Using an ohmmeter, measure resistance between the terminals. Replace the coil if the resistance is IGNITION not within specification.
Page 121: Spark Plug Inspection
Ignition System Spark Plug Inspection Do not adjust the gap of platinum tip plugs; replace Inspect the electrodes and ceramic insulator for: the spark plug if the gap is out of specification or if the center electrode is rounded. Improper gap Electrode Gap: Worn or deformed Oil-fouling...
Page 122: Charging System
Charging System Component Location Index ALTERNATOR BELT Inspection and Adjustment, page 4-33 ALTERNATOR Alternator and Regulator Test, page 4-27 Replacement, page 4-29 Overhaul, page 4-30...
Page 123: Troubleshooting
Troubleshooting If the charging system light does not come on or does not go off, or the battery is dead or low, test the following items in the order listed below: Battery (see section Charging System Light (see below) Alternator/Regulator (see page 4-27) Charging System Light Test Check the No.
Page 124 Charging System Troubleshooting (cont'd) (From page 4-25) Check for an open in the IG circuit: Measure the voltage at the No. 1 terminal of the 4P connector. ALTERNATOR Turn the ignition switch OFF, and 4P CONNECTOR Is there battery voltage? repair the open circuit in the BLK/ YEL wire.
Page 125: Alternator Replacement
Alternator Replacement Make sure you have the anti-theft code for the radio, Remove the alternator bracket. then write down the frequencies for the radio's pre- set buttons. ALTERNATOR Disconnect the battery negative terminal first, then BRACKET the positive terminal. NOTE: The PCM memory must be reset after recon- necting the battery (see page 11-125).
Page 126: Alternator Overhaul
Charging System Alternator Overhaul PULLEY NOTE: Do not remove the pulley unless the front bear- ing needs replacement. To loosen the pulley locknut, use the tools as shown. If necessary, use an impact wrench. HARNESS 22 mm BOX CLIP WRENCH BRACKET END COVER BRUSH HOLDER...
Page 127: Rectifier Test
Rectifier Test Alternator Brush Inspection NOTE: The diodes are designed to allow current to pass Remove the end cover, then take out the brush holder in one direction while blocking it in the opposite direc- by removing its two screws. tion.
Page 128: Rotor Slip Ring Test
Charging System Rotor Slip Ring Test Stator Test Check the resistance between the slip rings. Check that there is continuity between each pair of There should be 2.9 ohms. leads. If resistance meets the specification, go to step 2. If resistance does not meet the specification, replace the alternator.
Page 129: Belt Inspection And Adjustment
Alternator Belt Inspection and Adjustment NOTE: When using a new belt, first adjust the deflection Belt tension gauge method: or tension to the values for the new belt, then readjust the deflection or tension to the values for the used belt Attach the belt tension gauge to the belt and measure the after running engine for 5 minutes.
Page 130 Charging System Alternator Belt Inspection and Adjustment (cont'd) If adjustment is necessary: Loosen the mounting bolt and the lock bolt. Move the alternator by turning the adjusting rod to obtain the proper belt tension, then retighten the bolts. Looser Tighter ADJUSTING LOCK BOLT 8 x 1.25 mm...
Page 131: Component Location Index
Cruise Control Component Location Index SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or service. CRUISE CONTROL INDICATOR LIGHT Bulb Locations, page 23-76 SET/RESUME/CANCEL SWITCH MAIN SWITCH Test/Replacement, page 4-39...
Page 132: Control Unit Input Test
Control Unit Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or service. 1. Disconnect the 14P connector from the control unit. 2. Inspect the connector and socket terminals to be sure they are all making good contact. If the terminals are bent, loose, or corroded, repair them as necessary, and recheck the system.
Page 133 Cruise Control Control Unit Input Test (cont'd) Test condition Test: Desired result Possible cause if result is not obtained Cavity Wire Check for continuity to ground: Under all conditions • Poor ground (G401, G402) There should be continuity. • An open in the wire Ignition switch ON (II) and Check for voltage to ground: •...
Page 134: Set/Resume/Cancel Switch Test/Replacement
Set/Resume/Cancel Switch Test/Replacement Front Passenger's Side: SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the Remove the glove box (see section 20). (section 24) before performing repairs or service. Disconnect the front passenger's 2P connector Make sure you have the anti-theft code for the radio, from the SRS main harness.
Page 135 Cruise Control Set/Resume/Cancel Switch Test/Replacement (cont'd) Check for continuity between the terminals of the 8. Remove the two screws, and disconnect the 4P con- combination switch harness connector in each switch nector. Then remove the switch. position according to the table. SET/RESUME/CANCEL SWITCH If there is continuity, and it matches the table, the switch is OK.
Page 136: Main Switch Test
Main Switch Test Brake Pedal Position Switch Test 1. Remove the driver's switch panel (see section 20). Disconnect the 4P connector from the switch. DRIVER'S SWITCH PANEL Terminal side of male terminals TCS SWITCH 4P CONNECTOR CRUISE MAIN SWITCH BULBS (0.84 W x 2) BRAKE PEDAL 2.
Page 137: Actuator Solenoid Test
Cruise Control Actuator Solenoid Test Disconnect the 4P connector from the actuator. VENT VALVE SAFETY VALVE VACUUM VALVE Terminal side of male terminals To VACUUM From VENT TANK HOSE Check for resistance between the terminals accord- ing to the table. NOTE: Resistance will vary slightly with tempera- ture;...
Page 138: Actuator Test
Actuator Test Disconnect the actuator cable from the actuator rod, With voltage and vacuum still applied, try to pull and disconnect the 4P connector. the actuator rod out by hand. You should not be able to pull it out. If you can, it is defective. Connect battery power to the No.
Page 139: Actuator Cable Replacement
Cruise Control Actuator/Cable Replacement Disconnect the 4P connector from the actuator. Loosen the locknut, then disconnect the actuator cable from the throttle linkage. Remove the three mounting bolts and the actuator with the bracket. ACTUATOR ADJUSTING CABLE LOCKNUT VACUUM HOSE MOUNTING BOLT MOUNTING BOLTS CABLE...
Page 140: Actuator Cable Adjustment
Actuator Cable Adjustment Check that the actuator cable moves smoothly with Turn the adjusting nut until it is 5 ± 0.5 mm (0.20 ± no binding or sticking. 0.02 in) away from the bracket. Measure the amount of movement of the output linkage until the engine speed starts to increase.
Page 141 Engine Removal/Installation Special Tools ........5–2 Engine Removal...
Page 142: Special Tools
Special Tools Ref. No. Tool Number Description Page Reference A973X - 041 - XXXXX Vacuum Pump/Gauge, 0-30 in.Hg. 5-21, 5-22...
Page 143: Removal
Engine Removal/Installation Removal Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's pre- Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct positions set buttons.
Page 144 Engine Removal/Installation Removal (cont'd) 10. Raise the coolant reservoir, then remove the battery Remove the intake air duct and air cleaner housing assembly. and battery base. 6 x 1.0 mm 6 x 1.0 mm 12 N-m (1.2 kgf-m, 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) 8.7 Ibf-ft) BATTERY...
Page 145 14. Disconnect the engine wire harness connector on 12. Remove the vacuum hose, then remove the clamp from the under-hood fuse/relay box. the left side of the engine compartment. 15. Remove the connector and engine wire harness clamp. VACUUM CLAMP HOSE CONNECTOR ENGINE WIRE...
Page 146 Engine Removal/Installation Removal (cont'd) 18. Remove the evaporative emission (EVAP) canister 20. Disconnect the connector, then remove the control hose and brake booster vacuum hose. box. 6 x 1.0 mm 12 N-m (1.2 kgf-m, BRAKE BOOSTER 8.7 Ibf-ft) VACUUM HOSE EVAP CONTROL CONTROL CANISTER HOSE...
Page 147 22. Disconnect the spark plug voltage detection module 24. Loosen the mounting bolt, lock bolt and adjusting connector, and remove the engine ground cables. rod, then remove the alternator belt. 6 x 1.0 mm ADJUSTING LOCK BOLT 12 N-m (1.2 kgf-m, GROUND 8 x 1.25 mm 8.7 Ibf-ft)
Page 148 Engine Removal/Installation Removal (cont'd) 29. Remove the radiator cap. 26. Disconnect the power steering pressure (PSP) switch connector. Use care when removing the radiator cap to avoid scalding by hot coolant or steam. LOCKNUT ADJUSTING 8 x 1.25 mm BOLT 22 N-m (2.2 kgf-m, 30.
Page 149 39. Disconnect the compressor clutch connector, then 41. Remove the transmission stop collars. remove the A/C compressor. Do not disconnect the A/C hoses. 42. Remove exhaust pipe A. SELF-LOCKING NUT 8 x 1.25 mm 22 N-m (2.2 kgf-m, 16 Ibf-ft) COMPRESSOR CLUTCH Replace.
Page 150 Engine Removal/Installation Removal (cont'd) 44. Remove the heat shield. 50. Lower the hoist. 51. Remove the upper and lower radiator hoses. Loosen these bolts. HEAT SHIELD UPPER RADIATOR 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) HOSE 45. Remove the ATF cooler hoses. Plug the ATF cooler LOWER RADIATOR hoses and lines.
Page 151 54. Attach the chain hoist to the engine. FUEL PRESSURE REGULATOR 29 N-m (3.0 kgf-m, 22 Ibf-ft) NOTE: Loosen the locknut on the fuel pressure regulator, then turn the fuel pressure regulator 180°.
Page 152 Engine Removal/Installation Removal (cont'd) 55. Raise the hoist. 59. Lower the hoist. 56. Remove the shift cable guide. 60. Separate the left front mount bracket from the left front mount. CAUTION: Take care not to bend the shift cable (see section 14).
Page 153 62. Separate the right engine mount bracket from the 64. Raise the chain hoist to remove all slack from the chain. right engine mount, then remove the vacuum hose. 65. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses and RIGHT ENGINE electrical wiring.
Page 154: Installation
Engine Removal/Installation Installation Bracket Bolts Torque Specifications: REAR ENGINE HANGER 10 x 1.25 mm RIGHT ENGINE MOUNT BRACKET 10 x 1.25 mm 38 N-m (3.9 kgf-m, 44 N-m (4.5 kgf-m, 28 Ibf-ft) 33 Ibf-ft) 12 x 1.25 mm 64 N-m (6.5 kgf-m, 47 Ibf-ft) Apply liquid gasket to the bolt threads.
Page 155 Engine Installation: Tighten the nut on the right engine mount bracket, then install the vacuum hose. Install the engine in the reverse order of removal. Reinstall the mount bolts/nuts in the following sequence. 12 x 1.25 mm Failure to follow these procedures may cause excessive 64 N-m (6.5 kgf-m, noise and vibration, and reduce bushing life.
Page 156 Engine Removal/Installation Installation (cont'd) Install the transmission beam, then tighten the bolts 7. Tighten the right front mount mounting bolt. in the numbered sequence shown ( 12 x 1.25 mm 12 x 1.25 mm 74 N-m (7.5 kgf-m, 54 N-m (5.5 kgf-m, 52 Ibf-ft) 40 Ibf-ft) 10 x 1.25 mm...
Page 157 Mount and Bracket Bolts/Nuts Torque Value Specifications: 10 x 1.25 mm bolts/nuts: 38 N-m (3.9 kgf-m, 28 Ibf-ft) RIGHT ENGINE MOUNT LEFT ENGINE MOUNT RIGHT FRONT MOUNT LEFT FRONT MOUNT...
Page 158: Engine Mount Control System
Engine Mount Control System Component Location Index ENGINE MOUNT CONTROL POWERTRAIN CONTROL SOLENOID VALVE MODULE (PCM) Troubleshooting, page 5-20 Troubleshooting, page 5-20 ENGINE MOUNT DIAPHRAGM ACTUATOR Test, page 5-22...
Page 159 Engine Mount Control System Troubleshooting Flowchart NOTE: Check the vacuum hoses and lines for damage and proper connections. Refer to the Troubleshooting Procedures (see section 11). The engine vibrates excessively when idling. Check Idle Speed: Warm up engine to normal oper- ating temperature (the cooling fan comes on 2 times).
Page 160 IMRC/ENGINE MOUNT CONTROL SOLENOID VALVE ASSEMBLY 6P (From page 5-20) CONNECTOR Test the Engine Mount Control Solenoid Valve Wire: 1. Raise the engine speed above 1,000 rpm. 2. Measure voltage between the No. 3 and No. 6 terminals. Repair short to body ground in Wire side of female LT GRN wire between PCM terminals...
Page 161: Diaphragm Actuator Test
Engine Mount Control System Diaphragm Actuator Test Disconnect the vacuum hoses, then remove the left and right engine mounts (see page 5-17). Remove the actuator cover. 6 x 1.0 mm ACTUATOR COVER 13 N-m (1.3 kgf-m, 9.4 Ibf-ft) Clean and oil the diaphragm actuator rod. With a vacuum pump/gauge, apply vacuum of about 30.7 kPa (230 mm Hg, 9.1 in.Hg), and check that the actuator rod moves smoothly.
Page 162 Cylinder Head/Valve Train Special Tools ..... . . 6–2 CKP/CYP Sensor Valves, Valve Springs and Valve Seals Replacement ..... 6–14 Removal .
Page 163: Special Tools
Special Tools Ref. No. Tool Number Description Page Reference 07HAH-PJ7010B Valve Guide Reamer, 5.5 mm 6-34 07JAA-001020A Socket, 19 mm 07JAB-001020A Holder Handle 07MAB - PY3010A Holder Attachment, 50 mm, Offset 07742-0010100 Valve Guide Driver, 5.5 mm 6-33, 6-34 07757-PJ1010A Valve Spring Compressor Attachment 6-29, 6-35...
Page 164: Crankshaft Pulley And Pulley Bolt Replacement
Crankshaft Pulley and Pulley Bolt Replacement When installing and tightening the pulley, follow the procedure below. Clean, remove any oil, and lubricate the points shown below. Clean Remove any oil CRANKSHAFT Lubricate PULLEY TIMING BELT DRIVE PULLEY CRANKSHAFT WASHER TIMING BELT PULLEY BOLT GUIDE PLATE BALANCER...
Page 165 Timing Belt and Balancer Belt Illustrated Index NOTE: Refer to page 6-10 for how to position the crankshaft and pulley before installing the belt. Mark the direction of rotation on the belt before removing it. Do not use the upper covers and lower cover to store removed items. Clean the upper covers and lower cover before installing them.
Page 166: Removal
Timing Belt and Balancer Belt Removal NOTE: Loosen the adjusting bolt, locknut and mounting Replace the timing belt and timing balance belt at bolt, then remove the power steering (P/S) pump 105,000 miles (168,000 km) according to the mainte- belt (see page 6-6). nance schedule (normal conditions, severe condi- Disconnect the TCS throttle sensor connector, the tions).
Page 167 9. Remove the breather hose and vacuum hoses. 11. Remove the idler pulley bracket, dipstick and tube. 6 x 1.0 mm DIPSTICK/TUBE 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) BREATHER HOSE O-RING Replace. IDLER PULLEY BRACKET VACUUM HOSES 8 x 1.25 mm 22 N-m (2.2 kgf-m, 16 Ibf-ft) 12.
Page 168 Timing Belt and Balancer Belt Removal (cont'd) 14. Loosen the balancer belt adjusting bolt 180°. Push the tensioner to remove tension from the balancer belt, then retighten the adjusting bolt. BALANCER BELT ADJUSTING BOLT 10 x 1.25 mm 44 N-m (4.5 kgf-m, 33 Ibf-ft) 15.
Page 169: Installation
Timing Belt and Balancer Belt Installation Install the timing belt and balancer belt in the reverse order of removal; only key points are described here. CAUTION: Do not rotate the crankshaft pulley or cam- shaft pulleys with the timing belt removed. The pistons may hit the valves and cause damage.
Page 170 5. Install the timing belt in the sequence shown. 4. Set the camshaft pulleys so that the No. 1 piston is at TDC. Align the TDC marks on the camshaft pulleys to Timing belt drive pulley (crankshaft) Adjusting the pointers on the back covers. pulley Left camshaft pulley Water pump...
Page 171 Timing Belt and Balancer Belt Installation (cont'd) 12. Align the maintenance hole and the balancer shaft 14. Set the timing belt drive pulley so that the No. 1 pis- hole. Insert a 6 mm bolt that is at least 45 mm (1.8 ton is at TDC (see page 6-10).
Page 172: Inspection
22. Check that the crankshaft pulley and camshaft pul- 23. If the camshaft and crankshaft pulleys are not posi- leys are at TDC. tioned at TDC, remove the timing belt and adjust the positioning following the procedure on page 6-10, CRANKSHAFT PULLEY: then reinstall the timing belt.
Page 173 Timing Belt Inspection Tension Adjustment Remove the left upper cover. CAUTION: Always adjust the timing belt tension with the engine Inspect the timing belt for cracks and oil or coolant cold. soaking. Do not rotate the crankshaft when the adjusting bolt is loose.
Page 174: Balancer Belt Inspection
Balancer Belt Inspection 1. Remove the engine cover (see page 5-3). 11. Remove the crankshaft pulley (see page 6-3). 2. Remove the intake air duct and air cleaner housing 12. Remove the idler pulley, the dipstick, and the dip- assembly (see page 5-4). stick tube (see page 6-9).
Page 175: Tension Adjustment
Tension Adjustment CAUTION: 13. Set the No. 1 piston at TDC (see page 6-13). Always adjust the balancer belt tension with the 14. Rotate the crankshaft clockwise one turn. engine cold. Do not rotate the crankshaft when the adjusting bolt 15.
Page 176: Ckp/Cyp Sensor Replacement
CKP/CYP Sensor Replacement Turn the crankshaft so that the No. 1 piston is at top Remove the left back cover. dead center (see page 6-13). Remove the CKP/CYP sensor from the left cylinder Remove the breather hose and vacuum hoses (see head.
Page 177 Cylinder Heads Illustrated Index NOTE: Use new O-rings and gaskets when reassembling. CYLINDER HEAD COVER HEAD COVER GASKET Refer to page 6-38 when Replace when leaking, damaged installing. or deteriorated. 6 x 1.0 mm Apply liquid gasket at the four corners 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) of the recesses, page 6-38...
Page 178: Cylinder Head
Cylinder Heads Illustrated Index (cont'd) CAUTION: To avoid damage, wait until the engine coolant temperature drops below 100°F (38°C) before removing a cylinder head. When handling a metal gasket, take care not to fold it or damage the contact surface. NOTE: Clean the oil control orifice when installing.
Page 179 NOTE: Use new O-rings and gaskets when reassembling. Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. 8 x 1.25 mm 6 x 1.0 mm 22 N-m (2.2 kgf-m, 12 N-m (1.2 kgf-m, 8.7 Ibf-ft)
Page 180: Removal
Cylinder Heads Removal Make sure jacks and safety stands are 8. Remove the throttle cover (see page 5-4). placed properly and hoist brackets are attached to the correct positions on the engine. 9. Remove the throttle cable and cruise control cable by loosening the locknuts, then slip the cable ends CAUTION: out of the accelerator linkage (see page 5-4).
Page 181 12. Remove the vacuum hoses, then remove the clamp 16. Remove the evaporative emission (EVAP) canister from the under-hood fuse/relay box (see page 5-5). hose and brake booster vacuum hose. 13. Remove the battery cables from the under-hood fuse/relay box, then remove the under-hood fuse/ relay box.
Page 182 Cylinder Heads Removal (cont'd) 18. Loosen the mounting bolt, lock bolt and adjusting 20. Loosen the adjusting bolt, locknut and mounting bolt, rod, then remove the alternator belt. then remove the power steering (P/S) pump belt (see page 6-6). LOCK BOLT 21.
Page 183 24. Remove the six ignition coils from the left and right 26. Remove the EGR pipe. cylinder head covers. GASKET Replace. 6 x 1.0 mm 12 N-m (1.2 kgf-m, EGR PIPE 8.7 Ibf-ft) IGNITION COIL GASKET Replace. 6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) 27.
Page 184 Cylinder Heads Removal (cont'd) 31. Remove the vacuum line mounting bolts, wire har- 28. Remove the wire harness holder mounting bolts. ness holder and positive crankcase ventilation (PCV) hose. WIRE HARNESS 6 x 1.0 mm HOLDER 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) PCV HOSE VACUUM LINE...
Page 185 33. Remove the TCS control valve upper and lower 38. Remove the three bolts securing the alternator brackets (see page 6-8). bracket. 6 x 1.0 mm 34 Disconnect the TCS throttle position sensor connec- 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) tor and TCS throttle actuator connector, then remove ALTERNATOR the TCS control valve assembly (see page 6-8).
Page 186 Cylinder Heads Removal (cont'd) 40. Remove the left and right camshaft pulleys, then 41. Remove the left and right cylinder head covers. remove the back covers. 6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) RIGHT CAMSHAFT PULLEY CYLINDER HEAD COVER BACK COVER 8 x 1.25 mm...
Page 187: Warpage
Cylinder Heads Warpage NOTE: If camshaft-to-holder oil clearance (see page 6-27) is not within specifications, the cylinder head can- not be resurfaced. If camshaft-to-holder oil clearance is within specifica- tions, check the cylinder head for warpage. If warpage is less than 0.05 mm (0.002 in), cylinder head resurfacing is not required.
Page 188: Installation
Cylinder Heads Installation Install the cylinder heads in the reverse order of removal. NOTE: Always use new cylinder head gaskets. Cylinder heads and cylinder block surface must be clean. Turn the camshafts so the pulley locating pin holes are at the top. Turn the crankshaft so the No.
Page 189 Cylinder Heads Installation (cont'd) Install the cylinder heads on the cylinder block. Install the head cover gasket in the groove of the cylinder head cover. Seat the recesses for the cam- Tighten the cylinder head bolts sequentially in 2 or shaft first, then work it into the groove around the outside edges.
Page 190 When installing the cylinder head cover, hold the 10. Install the left and right back covers, then install the head cover gasket in the groove by placing your fin- left and right camshaft pulleys. gers on the camshaft holder contacting surfaces (top of the semicircles).
Page 191 Cylinder Heads Installation (cont'd) 12. Install the intake manifold and water passage, then tighten the intake manifold mounting bolts and nuts in a crisscross pattern in 2 or 3 steps, beginning with the inner bolts. NOTE: Always use new intake manifold gaskets. 13.
Page 192: Rocker Arm Assembly Disassembly/Reassembly
Rocker Arm Assembly Disassembly/Reassembly NOTE: Refer to page 6-26 for rocker arm assembly removal. Identify parts as they are removed to ensure reinstallation in original locations. Inspect rocker shafts and rocker arms (see page 6-28). Rocker arms must be installed in the same position if reused. When removing or installing the rocker arm assembly, do not remove the camshaft holder bolts.
Page 193: Removal
Rocker Arm Assembly Removal NOTE: • To prevent damage to the valves or rocker arm assem- bly, unscrew the camshaft holder bolts two turns at a time in a crisscross pattern. • When removing the rocker arm assembly, do not remove the camshaft holder bolts.
Page 194: Camshaft
Camshaft Inspection NOTE: • Do not rotate the camshaft during inspection. • Remove the rocker arms and rocker shafts. Put the camshaft and the camshaft holders on the cylinder head, then tighten the bolts to the specified torque. Specified torque: 8 mm bolts: 22 N-m (2.2 kgf-m, 16 Ibf-ft) 6 mm bolts: 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) 8 mm bolts:...
Page 195 If camshaft-to-holder oil clearance is out of toler- Remove the bolts, then remove the camshaft hold- ers from the cylinder head. ance: And the camshaft has already been replaced, you must replace the cylinder head. Lift the camshaft out of the cylinder head, wipe it If the camshaft has not been replaced, first check clean, then inspect the lift ramps.
Page 196: Rocker Arms And Shafts Clearance Inspection
Rocker Arms and Shafts Clearance Inspection Measure the intake rocker shafts and exhaust rocker Measure the inside diameter of each rocker arm, shaft. and check for an out-of-round condition. Rocker Arm-to-Shaft Clearance: Measure the diameter of the shaft at the first rocker location.
Page 197: Valves, Valve Springs And Valve Seals Removal
Valves, Valve Springs and Valve Seals Removal NOTE: Identify valves and valve springs as they are Install the valve guide seal remover. removed so that each item can be reinstalled in its origi- nal position. VALVE GUIDE SEAL REMOVER LISLE P/N 57900 or KD3350 Using an appropriate-sized socket and plastic mal- or EQUIVALENT VALVE SEAL...
Page 198 Valves, Valve Springs and Valve Seals Removal (cont'd) Inspect the valves for wear. Intake Valve Dimensions 32.90-33.10 mm A Standard (New): (1.295-1.303 in) 113.58-113.88 mm B Standard (New): (4.472 - 4.483 in) 5.48 - 5.49 mm C Standard (New): (0.2157-0.2161 in) 5.45 mm (0.215 in) C Service Limit: D Standard (New):...
Page 199: Installation
Valves, Valve Springs and Valve Seals Installation Coat the valve stems with engine oil. Install the Install the valve spring and valve retainer, then valves in the valve guides. install the valve spring compressor. Compress the spring and install the valve keepers. NOTE: Make sure the valves move up and down smoothly.
Page 200: Valve Guides Valve Movement
Valve Guides Valve Movement Wobble Method Alternate Method Measure the guide-to-stem clearance with a dial indica- An alternate method of checking guide to stem clear- tor while rocking the stem in the direction of normal ance is to subtract the O.D. of the valve stem, measured thrust.
Page 201: Replacement
Valve Guides Replacement As illustrated below, use a commercially available Working from the camshaft side, use the driver and an air hammer to drive the guide about 2 mm (0.1 in) air-impact valve guide driver attachment modified to fit the diameter of the valve guides. In most cases, towards the combustion chamber.
Page 202 Valve Guides Replacement (cont'd) Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the camshaft side of the head; use the special tool to drive the guide in to the specified installed height. If you have all 12 guides to do, you may have to reheat the head.
Page 203: Reaming
Valve Guides Reaming NOTE: For new valve guides only. Coat both the reamer and valve guide with cutting oil. Rotate the reamer clockwise the full length of the valve guide bore. REAMER HANDLE VALVE GUIDE REAMER, 5.5 mm 07HAH-PJ7010B Turn reamer in clockwise direction only.
Page 204: Valve Seats Reconditioning
Valve Seats Reconditioning Renew the valve seats in the cylinder head using a After resurfacing the seat, inspect for even valve valve seat cutter. seating: Apply Prussian Blue compound to the valve face, insert the valve in its original location in the NOTE: If the guides are worn (see page 6-31), head, then lift it and snap it closed against the seat replace them (see page 6-33) before cutting the...
Page 205: Hydraulic Tappets
Hydraulic Tappets Bleeding Fill a container with 5W - 30 or 10W - 30 engine oil, and place the hydraulic tappet in it. Press down on the check ball with a thin wire. Bleed the tappet of air by pumping the plunger slowly until no bubbles come out of the hydraulic tappet.
Page 206: Camshafts/Rocker Arms And Camshaft Seals
Camshafts/Rocker Arms and Camshaft Seals CAUTION: • Make sure that all rockers are in alignment with their valves when torquing the rocker assembly bolts. • To prevent the rocker arm assembly from coming apart, leave the camshaft holder bolts in the holes. •...
Page 207 Apply liquid gasket to the head mating surfaces of the No. 1 and the No. 5 camshaft holders. Apply liquid gasket to the shaded areas. No. 5 No. 1 Tighten each bolt 2 turns at a time in the sequence shown below to ensure that the rockers do not bind on the valves.
Page 208 Engine Block Special Tools ..... . . 7–2 Pistons and Crankshaft Piston Pins Removal ......7–10 Removal .
Page 209 Special Tools 07GAD - PH70201 7-30 07LAB - PV00100 07749 - 0010000 7-22, 7-30 07948 - SB00101 7-22, 7-30 07965 - SD90200 7-30...
Page 210 Illustrated Index Lubricate all internal parts with engine oil during reassembly. NOTE: Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003. BALANCER SHAFT HOLDER BALANCER BALANCER SHAFT Apply liquid gasket around SHAFT REAR COVER the oil hole to the block mating surface.
Page 211 Illustrated Index (cont'd) Lubricate all internal parts with engine oil during reassembly. NOTE: • Apply liquid gasket to the mating surfaces of the rear cover and oil pump case before installing them. • Use liquid gasket. Part No. 08718 - 0001 or 08718 - 0003. OIL PAN Apply liquid gasket OIL FILTER...
Page 212 9 x 1.25 mm 39 N-m (4.0 kgf-m, 29 Ibf-ft) Apply engine oil to the bolt threads and the washer. 11 x 1.5 mm 76 N-m (7.8 kgf-m, 56 Ibf-ft) Apply engine oil to the bolt threads and the washers. NOTE: After torquing each cap, turn crankshaft to check for binding.
Page 213 Illustrated Index (cont'd) FRONT (timing belt side) NOTE: New rod bearings must be selected by matching RIGHT BANK connecting rod assembly and crankshaft identification LEFT BANK markings (see page 7-9). No. 1 Lubricate all internal parts with engine oil during No.
Page 214: Engine Block
Connecting Rod and Drive Plate Crankshaft Replacement End Play Remove the eight drive plate bolts, then separate the Connecting Rod End Play: drive plate from the crankshaft flange. After installation, Standard (New): 0.15 - 0.30 mm tighten the bolts in a crisscross pattern. (0.006 - 0.012 in) Service Limit: 0.40 mm (0.016 in)
Page 215: Main Bearings
Main Bearings Selection Clearance To check main bearing-to-journal oil clearance, CAUTION: If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them with a remove the main caps and bearing halves. wire brush or scraper. Clean them only with solvent or Clean each main journal and bearing half with a detergent.
Page 216: Connecting Rod Bearings
Connecting Rod Bearings Clearance Selection Remove the connecting rod cap and bearing half. CAUTION: If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them Clean the crankshaft rod journal and bearing half with a wire brush or scraper. Clean them only with sol- with a clean shop towel.
Page 217: Pistons And Crankshaft
Pistons and Crankshaft Removal Remove the balancer gear case. Hold the balancer shaft as shown below, then remove the rear balancer weight. O-RING Replace. DOWEL REAR BALANCER BALANCER GEAR WEIGHT CASE Remove the balancer shaft rear cover. Pull out the balancer shaft. NOTE: Take care not to damage the journals when removing the balancer shaft.
Page 218 Remove the balancer shaft holder (see page 7-3). 9. If you can feel a ridge of metal or hard carbon around the top of any cylinder, remove it with a ridge reamer. Remove the oil pan assembly. Follow the reamer manufacturer's instructions. Remove the rear cover.
Page 219 Pistons and Crankshaft Removal (cont'd) 11. Remove the bearing from the cap. Keep all caps/bear- To help with removal of the caps, install the cap bolts in ings in order. the outside bolt holes. 12. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.
Page 220: Crankshaft
Crankshaft Inspection • Clean the crankshaft oil passages with pipe cleaners Out-of-Round and Taper or a suitable brush. • Measure out-of-round at the middle of each rod and • Check the keyway and threads. main journal in two places. • The difference between measurements on each journal Alignment must not be more than the service limit.
Page 221: Installation
Crankshaft Installation Before installing the crankshaft, apply a coat of Install the bearings and caps. Tighten the cap bolts engine oil to the main bearings and rod bearings. only enough to seat the bearing caps. Insert the bearing halves in the cylinder block and BEARING CAPS connecting rods.
Page 222 Install the piston/connecting rod assemblies (see Tighten the 9 x 1.25 mm cap bolts to the specified torque. page 7-23). Check the connecting rod bearing clearance with Torque: 39 N-m (4.0 kgf-m, 29 Ibf-ft) plastigage (see page 7-9), then torque the connect- Apply engine oil to the bolt threads.
Page 223 Crankshaft Installation (cont'd) NOTE: 10. Apply liquid gasket to the cylinder block mating sur- • Apply a light coat of oil to the crankshaft and to the face of the rear cover, then install the cover on the cylinder block. lip of the oil seal.
Page 224 12. Install the oil pump with new O-rings. 13. Apply liquid gasket to the cylinder block, then install the oil pan. NOTE: • Apply a light coat of oil to the crankshaft and to CYLINDER the lip of the seal. BLOCK •...
Page 225 Crankshaft Installation (cont'd) 14. Tighten the oil pan bolts as shown. 16. Install the balancer shaft holder (see page 7-3). NOTE: Apply liquid gasket around the oil hole to the block mating surface. OIL PAN BOLT TIGHTENING SEQUENCE 17. Install the rear balancer weight. 8 x 1.25 mm: 22 N-m (2.2 kgf-m, 16 Ibf-ft) 18.
Page 226 20. Align the maintenance hole and the balancer shaft 22. Install the balancer gear case. hole. Insert a 6 mm bolt that is at least 45 mm (1.8 in) long into the balancer shaft. 6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) 45 mm (1.8 in) or longer 6 mm BOLT...
Page 227: Pistons Inspection
Pistons Inspection Check the piston for distortion or cracks. Calculate the difference between cylinder bore diame- ter (see page 7-15) and piston diameter. Measure the piston diameter at a point 14.0 mm (0.55 in) from the bottom of the skirt. Piston-to-Block Clearance Standard (New): 0.02 - 0.04 mm NOTE: There are two standard-size pistons (No let-...
Page 228 Pistons Installation Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores. Install the ring compressor, check that the bearing is securely in place; then position the piston in the The arrow must face cylinder and tap it in using the wooden handle of a the timing belt side hammer.
Page 229: Cylinder Block
Cylinder Block Inspection Oversize Measure wear and taper in directions X and Y at three levels in each cylinder as shown. 0.25: 90.250 - 90.270 mm (3.5531 - 3.5539 in) 0.50: 90.500 - 90.520 mm (3.5630 - 3.5638 in) Bore Taper Limit: (Difference between first and third measure- ment) 0.05 mm (0.002 in) Reboring Limit: 0.5 mm (0.02 in)
Page 230: Bore Honing
Cylinder Block Bore Honing Measure the cylinder bores as shown on page 7-15. If the cylinder block is to be reused, hone the cylin- ders and remeasure the bores. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree crosshatch pattern. NOTE: •...
Page 231: Piston Pins
Piston Pins Removal Apply engine oil to the piston pin snap rings, and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores. NOTE: Take care not to damage the ring grooves. SNAP RING Cutout in the piston pin bore...
Page 232 Heat the piston and connecting rod assembly to approximately 158°F (70°C), then remove the piston pin. Work carefully to prevent getting burned. NOTE: Inspect the piston, piston pin and connecting rod when they are at the room temperature.
Page 233: Inspection
Piston Pins Inspection NOTE: Inspect the piston, piston pin and connecting rod Check the difference between the piston pin diame- when they are at room temperature. ter and piston pin hole diameter on the piston. Measure the diameter of the piston pin. NOTE: Check the piston for distortion or cracks.
Page 234: Installation
Installation Install a piston pin snap ring. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with engine oil. Install the piston pin. SNAP RING NOTE: Install the piston with its offset mark and the oil hole in the connecting rod on the same side.
Page 235: Connecting Rods
Connecting Rods Selection Each rod falls into one of four tolerance ranges (from 0 to 0.024 mm (0.0009 in), in 0.006 mm (0.0002 in) increments) depending on the size of its big end bore. It's then stamped with a number (1, 2, 3 or 4/I, l or l) indicating the range.
Page 236: Piston Rings
Piston Rings End Gap Replacement Using a piston, push a new ring into the cylinder Using a ring expander, remove the old piston rings. bore 15-20 mm (0.6 - 0.8 in) from the bottom. Clean all the ring grooves thoroughly. Measure the piston ring end-gap with a feeler gauge: NOTE:...
Page 237: Ring-To-Groove Clearance
Ring-to-Groove Clearance After installing a new set of rings, measure the ring-to- groove clearance: Top Ring Clearance Standard (New): 0.055 - 0.080 mm (0.0022 - 0.0031 in) Service Limit: 0.13 mm (0.005 in) Second Ring Clearance Standard (New): 0.030 - 0.055 mm (0.0012 - 0.0022 in) Service Limit: 0.13 mm (0.005 in)
Page 238: Alignment
Alignment Install the rings as shown. TOP RING (Chrome) SECOND RING (Dark) Piston Ring Dimensions: Top Ring (Standard) A: 3.3 mm (0.13 in) B: 1.5 mm (0.06 in) Second Ring (Standard) A: 3.5 mm (0.14 in) B: 1.2 mm (0.05 in) NOTE: The manufacturing marks must be facing upward.
Page 239 Piston Rings Alignment (cont'd) Rotate the rings in their grooves to make sure they do not bind. Position the ring end gaps as shown: DO NOT position any ring gap SECOND RING GAP at piston thrust surfaces. Approx. 90° OIL RING TOP RING GAP SPACER GAP DO NOT position any ring gap...
Page 240: Crankshaft Oil Seal
Crankshaft Oil Seal Installation The seal surface on the block should be dry. Apply a light coat of oil to the crankshaft and to the lip of the oil seal. Using the special tool, drive the crankshaft oil seal into the rear cover. REAR COVER DRIVER 07749-0010000...
Page 241 Crankshaft Oil Seals Installation (engine removal not required) NOTE: The seal surface on the block should be dry. Measure the crankshaft oil seal thickness and the oil Apply a light coat of grease to the crankshaft and to the seal housing depth. Using the special tool, drive the lips of the seals.
Page 242 Engine Lubrication Special Tools ......... . . 8–2 Oil Pressure Testing...
Page 243: Special Tools
Special Tools Tool Number 07LAC-PW50101 8-11 07MAF-PY40101 8-15 07746-0010500 07749-0010000 8-15 07912-6110001...
Page 244 Illustrated Index NOTE: • Use new O-rings when reassembling. • Apply oil to O-rings before installation. • Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003. • Clean the oil control orifice before installing. OIL CONTROL ORIFICE •...
Page 245: Engine Oil Inspection
Engine Oil Inspection Park the vehicle on level ground, and turn off the engine. Allow the oil a few minutes to drain back into the oil pan so the dipstick will show the actual level. Make certain that the oil level indicated on the dip- stick is between the upper and lower marks.
Page 246: Replacement
Engine Oil Replacement CAUTION: Remove the drain bolt carefully while the engine is hot; the hot oil may cause scalding. Warm up the engine. Drain the engine oil. WASHER Replace. DRAIN BOLT 44 N-m (4.5 kgf-m, 33 Ibf-ft) Do not overtighten. 3.
Page 247 The numbers in the middle of the API Service label tell you the oil's SAE viscosity or weight. Select the oil for your vehicle according to this chart: Ambient Temperature An oil with a viscosity of 5W - 30 is preferred for improved fuel economy and year-round protection in the vehicle.
Page 248: Oil Filter Replacement
Oil Filter Replacement CAUTION: Loosen the engine oil filter carefully while the engine is hot, the hot oil may cause scalding. Remove the oil filter with the special oil filter wrench. Inspect the threads and rubber seal on the new fil- ter.
Page 249 Oil Filter Replacement (cont'd) Install the oil filter by hand. Use this procedure to tighten the filter if eight numbers (1 to 8) are printed on the surface of the filter. After the rubber seal seats, tighten the oil filter clockwise with the tool.
Page 250: Oil Pressure Switch Testing
Oil Pressure Switch Oil Pressure Testing Testing If the oil pressure indicator light stays on with the Remove the YEL/RED wire from the engine oil pres- engine running, check the engine oil level. If the oil level sure switch. is correct: Check for continuity between the positive terminal and the engine (ground).
Page 251: Oil Pan Removal
Oil Pan Removal Engine removal is not required in this procedure. 12. Remove the lower plate from the rear beam. • Make sure jacks and safety stands are placed properly (see section • Apply the parking brake and block the rear wheels so the vehicle will not roll off stands while you are working under it.
Page 252 17. Disconnect the vacuum hose, then remove the right 21. Remove the differential mounting bolts and 26 mm engine mount. shim, then remove the differential assembly. 10 x 1.25 mm 12 x 1.25 mm 38 N-m (3.9 kgf-m, RIGHT ENGINE 64 N-m (6.5 kgf-m, 47 Ibf-ft) MOUNT 28 Ibf-ft)
Page 253: Installation
Oil Pan Installation Install the oil pan in the reverse order of removal: NOTE: Use new O-rings. Apply oil to the O-rings before installation. • Always use new O-rings. • Oil pan and cylinder block mating surface must be clean. O-RINGS Apply liquid gasket to the cylinder block, then install Replace.
Page 254 Install the differential assembly. Select the appropriate 26 mm shim whenever the EXTENSION SHAFT oil pan or the cylinder block is replaced. SET RING INSTALLER Replace. Refer to section 15 for selection of the correct 07MAF-PY40101 26 mm shim. Apply grease to the spline of the extension shaft, then install the new set ring with the open side fac- ing up.
Page 255: Oil Pump
Oil Pump Overhaul NOTE: Use new O-rings when reassembling. Apply oil to the O-rings before installation. Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003. The rotors must be installed in the same direction. After reassembly, check that the rotors move without binding. PUMP HOUSING Inspection, page 8-14...
Page 256: Removal/Inspection/Installation
Removal/lnspection/lnstallation NOTE: To remove the oil pump, the engine must be Hold the balancer shaft as shown below, then remove removed from the vehicle and separated from the trans- the rear balancer weight. mission. Remove the balancer gear case. O-RING Replace.
Page 257 Oil Pump Removal/lnspection/lnstallation (cont'd) 8. Remove the screws from the pump housing, then Remove the balancer shaft holder (see page 7-3). separate the housing and cover. Remove the oil pan assembly. 9. Check the inner-to-outer rotor radial clearance on Remove the oil pump. the pump rotor.
Page 258 11. Check the housing-to-outer rotor radial clearance. If 15. Reassemble the oil pump, applying liquid thread the housing-to-outer rotor radial clearance exceeds lock to the pump housing screws. the service limit, replace the set of inner and outer rotors and/or the pump housing. 16.
Page 259 Oil Pump Removal/lnspection/lnstallation (cont'd) 23. Install the balancer shaft holder (see page 7-3). 20. Install the oil pump to the cylinder block. NOTE: Apply liquid gasket around the oil hole to the block mating surface. DOWEL PIN OIL PUMP O-RINGS 24.
Page 260 27. Align the maintenance hole and the balancer shaft 29. Install the balancer gear case. hole. Insert a 6 mm bolt that is at least 45 mm (1.8 in) long into the balancer shaft. 6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) 45 mm (1.8 in) or longer 6 mm BOLT...
Page 261 Intake Manifold/Exhaust System Special Tools ........9–2 Intake Manifold Replacement...
Page 262: Special Tools
Special Tools Description Page Reference Tool Number Ref. No. 07LAA-PT50101 02 Sensor Socket Wrench...
Page 263: Intake Manifold
Intake Manifold Replacement NOTE: Use new O-rings and gaskets when reassembling. CAUTION: Check for folds or scratches on the surface of the gasket. Replace with a new gasket if damaged. INTAKE MANIFOLD Replace if cracked or if mating surfaces are 8 x 1.25 mm WATER damaged.
Page 264: Exhaust Manifold Replacement
Exhaust Manifold Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. CAUTION: Check for folds or scratches on the surface of the gasket. Replace with a new gasket if damaged. 10 x 1.25 mm LEFT: HEAT 25 N-m (2.5 kgf-m, SHIELD 18 Ibf-ft) LEFT PRIMARY...
Page 265: Exhaust Pipe And Muffler
Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. 6 x 1.0 mm GASKET 9.8 N-m (1.0 kgf-m, HEAT Replace. 7.2 Ibf-ft) SHIELD MUFFLER TWC TORQUE SEQUENCE SELF-LOCKING NUT 8 x 1.25 mm 23 N-m (2.3 kgf-m, 17 Ibf-ft) Replace.
Page 266 Inspection Using a flashlight, make a visual check for plugging, melting or cracking of the catalyst. FLASHLIGHT...
Page 267 HO2S Replacement Primary HO2S: Disconnect the left and/or right primary HO2S con- nector, then remove the left and/or right primary H02S. LEFT: LEFT PRIMARY SENSOR SOCKET HO2S CONNECTOR WRENCH 07LAA-PT50101 44 N-m (4.5 kgf-m, 33 Ibf-ft) RIGHT: SENSOR SOCKET WRENCH 07LAA-PT50101 44 N-m (4.5 kgf-m, 33 Ibf-ft) RIGHT PRIMARY...
Page 268 Secondary HO2S: Remove the secondary HO2S. Move the front passenger's seat forward. Pull the carpet back to expose the secondary HO2S connector. SECONDARY HO2S 44 N-m (4.5 kgf-m, 33 Ibf-ft) Disconnect the secondary HO2S connector. SECONDARY HO2S CONNECTOR SENSOR WRENCH (Commercially available) Remove the wire harness cover, then remove the Install the secondary HO2S in reverse order of...
Page 269 Cooling Radiator Water Pump Component Location Index ......10–2 Component Location Index ......10–10 Replacement .
Page 270 Radiator Illustrated Index System is under high pressure when the CAUTION: When pouring engine coolant, be sure to engine is hot. To avoid danger of releasing scalding shut the relay box lid and not to spill coolant on the elec- coolant, remove the cap only when the engine is cool.
Page 271 Engine Hose Connections: HEATER HOSES HEATER FAST IDLE THERMO VALVE VALVE WATER BYPASS HOSES IDLE AIR CONTROL VALVE REAR WATER OUTLET THERMOSTAT HOUSING ATF COOLER HOSES Refer to section 14 when installing. ATF COOLER LINES COOLANT RESERVOIR...
Page 272: Replacement
Radiator Replacement Drain the engine coolant. Remove the fan shroud assemblies and other parts from the radiator. Remove the upper and lower radiator hoses and ATF cooler hoses. Install the radiator in the reverse order of removal. Disconnect the fan motor connectors and radiator fan NOTE: control sensor connector.
Page 273: Engine Coolant Refilling And Bleeding
Engine Coolant Refilling and Bleeding 6. Mix the recommended antifreeze with an equal '96 -00 models: amount of water in a clean container. CAUTION: When pouring engine coolant, be sure to NOTE: shut the relay box lid and not to let coolant spill on the electrical parts or the paint.
Page 274 Radiator Engine Coolant Refilling and Bleeding '01 model: 7. Loosen the air bleed bolt in the thermostat housing, then pour Honda All Season Antifreeze/Coolant CAUTION: When pouring engine coolant, be sure to Type 2 into the radiator to the bottom of the filler shut the relay box lid and not to let coolant spill on the neck.
Page 275: Cap Testing
Testing Cap Testing Remove the radiator cap, wet its seal with engine Wait until the engine is cool, then carefully remove coolant, then install it on the pressure tester. the radiator cap and fill the radiator with engine coolant to the top of the filler neck. RADIATOR PRESSURE TESTER (Commercially available) Attach the pressure tester to the radiator and apply...
Page 276: Thermostat
Thermostat Replacement NOTE: Use new O-rings when reassembling. ENGINE COOLANT BLEED BOLT TEMPERATURE 9.8 N-m (1.0 kgf-m, (ECT) SENSOR 7.2 Ibf-ft) 18 N-m (1.8 kgf-m, 13 Ibf-ft) ENGINE COOLANT TEMPERATURE (ECT) GAUGE SENDING UNIT 9 N-m (0.9 kgf-m, 7 Ibf-ft) O-RING Replace.
Page 277: Testing
Testing Replace the thermostat if it is open at room temperature. To test a closed thermostat: Suspend the thermostat in a container of water as shown. THERMOMETER THERMOSTAT Heat the water, and check the temperature with a thermometer. Check the temperature at which the thermostat first opens, and at which it is fully open.
Page 278: Water Pump
Water Pump Illustrated Index NOTE: Use new O-rings when reassembling. Use liquid gasket, Part No. 08718 - 0001 or 08718 - 0003. ENGINE COOLANT BLEED BOLT TEMPERATURE 9.8 N-m (1.0 kgf-m, (ECT) SENSOR 7.2 Ibf-ft) 18 N-m (1.8 kgf-m, 13 Ibf-ft) 8 x 1.25 mm ENGINE COOLANT 22 N-m (2.2 kgf-m, 16 Ibf-ft)
Page 279: Inspection
Inspection Replacement Remove the timing belt (see page 6-8). 1. Remove the timing belt (see page 6-8). Turn the water pump pulley counterclockwise. Remove the left camshaft pulley and back cover Check that it turns freely. (see page 6-24). 3. Remove the water pump. NOTE: Inspect and clean the O-ring groove and mating surface with the cylinder block.
Page 280: Fan Control
Fan Controls Component Location Index FAN CONTROL RADIATOR FAN RELAY MODULE Wire colors: BLK/YEL, YEL, LT GRN/BLK and BLU CONDENSER FAN RELAY Wire colors: BLK/YEL, WHT, BLU and BLU/ORN RADIATOR FAN MAIN RELAY Wire colors: BLK/YEL, RED, LT GRN/BLK, BLK and BLU RADIATOR FAN RADIATOR FAN CONTROL SENSOR...
Page 281: Troubleshooting
Fan Controls Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence. G301 G302 G301 G302 G402 G402 Fan Control Module Terminals Terminal Wire Connects to FAN CONTROL MODULE GRN/RED A/C pressure switch Not used Ground RED/WHT A/C pressure switch Radiator fan relay (Coil LT GRN/BLK Radiator fan control sensor...
Page 282: Fan Motor Testing
Fan Motor Testing Radiator Fan Control Sensor Testing Disconnect the 2P connector. Removing the radiator fan control sensor while the engine is hot can cause the coolant to spray RADIATOR FAN MOTOR out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator fan control sensor.
Page 283: Gauge Testing
Engine Coolant Temperature (ECT) Gauge Gauge Testing ECT Sending Unit Testing 1. Check the No. 20 (20 A) fuse in the under-dash fuse/ 1. Remove the engine cover (see page 5-3). relay box before testing. 2. Disconnect the YEL/GRN wire from the ECT sending Remove the engine cover (see page 5-3).
Page 284 Fuel and Emissions Special Tools ....11–2 PGM–FI System Fuel Pump Relay ....11–139 Intake Air Bypass (IAB) Control Component Locations Index...
Page 285: Special Tools
Special Tools For additional 2004 information, refer to page 11-2c. Ref. No. Tool Number Description Page Reference A973X-041 -XXXXX Vacuum Pump/Gauge, 0-30 in.Hg 11-137, 11-139, 11-155, 11-158, 11-159, 11-162, 11-163, 11-168, 11-169, 11-182, 11-184, 11-185, 11-187, 11-189, 11-190, 11-193, 11-194, 11-195, 11-197, 11-198, 11-199, 11-200, 11-203, 11-204, 11-205...
Page 286 Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-53. '96 - 99 models: INTAKE INTAKE BYPASS (IAB) HIGH MANIFOLD ABSOLUTE BYPASS (IAB) CONTROL PRESSURE (MAP) SOLENOID SENSOR CONTROL VALVE SOLENOID ENGINE Troubleshooting, VALVE MOUNT EXHAUST GAS RECIRCULATION (EGR) page 11-156 Troubleshooting,...
Page 287 Component Locations Index (cont'd) For Troubleshooting of DTC related components, see chart on page 11-53 ('00-'03 models) 11-41 ('04 model). '00 - 04 models: INTAKE MANIFOLD INTAKE MANIFOLD MANIFOLD ABSOLUTE RUNNER CONTROL RUNNER CONTROL PRESSURE (MAP) (IMRC) (IMRC) SENSOR SOLENOID SOLENOID VALVE 1 VALVE 2...
Page 288 For Troubleshooting of DTC related components, see chart on page 11-53 ('00-'03 models) 11-41 ('04 model). SECONDARY HEATED OXYGEN SENSOR (SECONDARY HO2S) (SENSOR 2) THREE WAY CATALYTIC CONVERTER (TWO PGM-FI MAIN RELAY Relay Testing, page 11-146 Troubleshooting, page 11-147 SERVICE CHECK CONNECTOR Troubleshooting procedures, page 11-40 DATA LINK CONNECTOR (DLC)
Page 289 Component Locations Index (cont'd) For Troubleshooting of DTC related components, see chart on page 11-53 ('00-'03 models) 11-41 ('04 model). INTAKE MANIFOLD INTAKE MANIFOLD RUNNDER CONTROL (IMRC) RUNNER CONTROL (IMRC) POSITIVE CRANKCASE VENTILATION (PCV) VALVE DIAPHRAGM 2 DIAPHRAGM 1 Inspection, page 11-174 Testing, page 11-162...
Page 290 For Troubleshooting of DTC related components, see chart on page 11-53. '96-99 models: FUEL TANK Replacement, page 11-150 FUEL TANK EVAPORATIVE EMISSION (EVAP) VALVE FUEL FILTER FUEL GAUGE SENDING UNIT Replacement, page 11-142 Testing, page 11-144 FUEL PRESSURE REGULATOR FUEL PUMP Testing, page 11-135 Testing, page...
Page 291 Component Locations Index (cont'd) For Troubleshooting of DTC related components, see chart on page 11-53 ('00-'03 models) 11-41 ('04 model). '00 - 04 models: FUEL TANK VAPOR CONTROL VALVE FUEL TANK Testing, page 11-201 Replacement, page 11-151 FUEL FILTER FUEL GAUGE SENDING UNIT Testing, page 11-144 Replacement, page...
Page 292 System Description Vacuum Connections '96 - 99 models: CONTROL BOX INTAKE AIR page 11-11 BYPASS (IAB) INTAKE AIR HIGH CONTROL EXHAUST GAS RECIRCULATION BYPASS (IAB) LOW SOLENOID VALVE (EGR) VALVE and LIFT SENSOR CONTROL SOLENOID VALVE ENGINE MOUNT CONTROL SOLENOID MANIFOLD VALVE ABSOLUTE...
Page 293 System Description Vacuum Connections (cont'd) '00 - 04 models: INTAKE MANIFOLD CONTROL BOX RUNNER CONTROL (IMRC) INTAKE MANIFOLD page 11-11 SOLENOID VALVE 1 RUNNER CONTROL (IMRC) SOLENOID VALVE 2 EXHAUST GAS RECIRCULATION (EGR) VALVE and POSITION SENSOR ENGINE MOUNT CONTROL SOLENOID VALVE MANIFOLD ABSOLUTE...
Page 294 Control Box: For Troubleshooting of DTC related components, see chart on page 11-53. EXHAUST GAS RECIRCULATION (EGR) VALVE VACUUM CONTROL SOLENOID VALVE EXHAUST GAS RECIRCULATION (EGR) VALVE VACUUM CONTROL VALVE PRESSURE REGULATOR VACUUM CONTROL SOLENOID VALVE Vacuum hose No.
Page 295: System Description Vacuum Connections
System Description Vacuum Connections (cont'd) '96 - 99 models: Vacuum hose No. LEFT PRIMARY HEATED OXYGEN SENSOR (LEFT PRIMARY INTAKE AIR BYPASS (IAB) LOW CONTROL DIAPHRAGM HO2S) (BANK 2, SENSOR 1) VALVE RIGHT PRIMARY HEATED OXYGEN SENSOR (RIGHT PRIMA- INTAKE AIR BYPASS (IAB) HIGH CONTROL SOLENOID VALVE RY HO2S) (BANK 1, SENSOR 1) SECONDARY HEATED OXYGEN SENSOR (SECONDARY...
Page 296 '00 - 01 models: Vacuum hose No. LEFT PRIMARY HEATED OXYGEN SENSOR (LEFT PRIMARY INTAKE MANIFOLD RUNNER CONTROL (IMRC) VACUUM HO2S) (BANK 2, SENSOR 1) RESERVOIR INTAKE MANIFOLD RUNNER CONTROL (IMRC) SOLENOID RIGHT PRIMARY HEATED OXYGEN SENSOR (RIGHT P Y HO2S) (BANK 1 , SENSOR 1 ) VALVE 1 SECONDARY HEATED OXYGEN SENSOR (SECONDARY INTAKE MANIFOLD RUNNER CONTROL (IMRC)
Page 297: Electrical Connections
System Description Electrical Connections To IMMOBILIZER UNIT FUSES No. 6 ECU(PCM) (20A) BACK UP (RADIO) (7.5A)* No. 25 IG COIL (30A) STOP HORN (15A)* No. 22 FUEL PUMP (20A) BATTERY (120 A)* *2: '00-01 models No. 20 ECU(PCM) (20A) FUSE BOX (50A)* No.14 STARTER SIGNAL (7.5A) IG.
Page 298 IGNCOIL1 A11 IGNCOIL2 A24 IGNCOI IGNCCHL4 B11 IGNCOIL5 B10 IGNCOIL6 B2 PHRSTL F7 PHRSTR F3 MFPLSL F8 MFPLSR F4 ILU E22 *1: '96-99 models *2: '00-01 models...
Page 299 System Description Electrical Connections (cont'd) TERMINAL LOCATIONS...
Page 300 LEFT PRIMARY HO2S (BANK 2. SENSOR 1) RIGHT PRIMARY HO2S (BANK 1. SENSOR 1)
Page 301 System Description Electrical Connections (cont'd) JUNCTION CONNECTOR JUNCTION CONNECTOR JUNCTION CONNECTOR (To page 11-19)
Page 302 (From page 11-18) C254 C101 G101 JUNCTION CONNECTOR ENGINE MOUNT CONTROL SOLENOID VALVE JUNCTION CONNECTOR To MFCS UNIT TACHOMETER CONNECTOR To IMMOBILIZER UNIT...
Page 303 System Description Electrical Connections (cont'd)
Page 304 JUNCTION CONNECTOR...
Page 305 System Description Electrical Connections (cont'd) •1: '96 - 99 models...
Page 306 •2: '00 - 01 models...
Page 307 System Description Electrical Connections (cont'd) To A/C PRESSURE SWITCH *1: '96 - 99 models...
Page 308 (To page 11-26)
Page 309 System Description Electrical Connections (cont'd) (From page 11-25) (To page 11-27)
Page 310 (From page 11-26) •2: '00 - 01 models...
Page 311 System Description Electrical Connections...
Page 313 System Description Electrical Connections (cont'd)
Page 314 System Description Electrical Connections...
Page 315 (cont'd)
Page 316 System Description Electrical Connections (cont'd)
Page 317 (cont'd)
Page 318 System Description Electrical Connections (cont'd)
Page 319 (cont'd)
Page 320 System Description Electrical Connections (cont'd)
Page 321 (cont'd)
Page 322 System Description Electrical Connections (cont'd)
Page 323 (cont'd)
Page 324 System Description Electrical Connections (cont'd)
Page 325 (cont'd)
Page 326 System Description Electrical Connections (cont'd)
Page 327 (cont'd)
Page 328: System Connectors
System Description System Connectors [Engine Compartment] A/T SUB-HARNESS C162 C110 C161 C108 C106 C323 C109 C320* C319* C139 C171 C138 C145 C144 C143 C163 C137 G101 C129 C127 ENGINE WIRE HARNESS C128 C126 C130 C308 C301 C124 C303 LEFT ENGINE COMPARTMENT WIRE HARNESS C344...
Page 329 NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side Related to Fuel and Emissions System.
Page 330 System Description System Connectors [Engine Compartment] (cont'd) A/T SUB-HARNESS C257 C253 C136 C102 C255 C135 C254 C105 C101 C134 C107 C142 C141 C140 C251 C103 C113 C114 C256 C116 C123 C151 C115 C252 C104 C152 VEHICLE SPEED SENSOR SUB-HARNESS C119 C120 C172 ENGINE...
Page 331 Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK NOTE: and YEL/BLK are not the same). Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side Related to Fuel and Emissions System.
Page 332 System Description System Connectors [Dash and Floor] DASHBOARD WIRE HARNESS MAIN WIRE HARNESS C430 C503 C428 LEFT C413 ENGINE C654 COMPARTMENT WIRE C414* HARNESS C656* C405 C404 C406 C329 C651 C417 C327 C416 C421 C432 C433 C418 C324 C325 C419 C420 C326 C328...
Page 333 *1: '00 - 01 models NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side Related to Fuel and Emissions System.
Page 334 System Description System Connectors [Dash and Floor] (cont'd) DASHBOARD C509 WIRE HARNESS C508 MAIN WIRE HARNESS LEFT ENGINE COMPARTMENT WIRE HARNESS C501 C502 LEFT SIDE WIRE HARNESS...
Page 335 *: Canada "1: with VSA NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side Related to Fuel and Emissions System.
Page 336 System Description System Connectors [Dash and Floor] (cont'd) C476 RIGHT C462 (PCM-F) C517 ENGINE C464 COMPARTMENT DASHBOARD C454 C458 WIRE WIRE (PCM-E) C456 HARNESS HARNESS C451 C201 CONVERTER UNIT* C448 C450* C463 (PCM-D) C460 (PCM-C) C469 C470 C442 C601 C461 (PCM-B) C459 MAIN...
Page 337 •: with TCS *1: with VSA ": with TCS "1: with VSA *: '00 - 01 models *: with TCS NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same).
Page 338 System Description System Connectors [Dash and Floor] (cont'd) REAR TCS CONTROL UNIT* WIRE HARNESS C623* C624* C667 C704 C670 C701 RIGHT SIDE WIRE HARNESS C675* C669 C721 C722 C674* FUEL UNIT C673* WIRE HARNESS LEFT SIDE WIRE HARNESS *1: '96 - 99 models *2: '00 - 01 models...
Page 339 *1: '96 - 99 models *2: '00 - 01 models Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK NOTE: and YEL/BLK are not the same). Connector with male terminals (double outline): View from terminal side Connector with female terminals (single outline): View from wire side Related to Fuel and Emissions System.
Page 340 System Description System Connectors [Engine Compartment]...
Page 341 NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). • — Connector with male terminals (double outline): View from terminal side — Connector with female terminals (single outline): View from wire side •...
Page 342 System Description System Connectors [Engine Compartment] (cont'd)
Page 343 NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). • — Connector with male terminals (double outline): View from terminal side — Connector with female terminals (single outline): View from wire side •...
Page 344 System Description System Connectors [Dash and Floor]...
Page 345 NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). • — Connector with male terminals (double outline): View from terminal side — Connector with female terminals (single outline): View from wire side (cont'd) •...
Page 346 System Description System Connectors [Dash and Floor] (cont'd)
Page 347 NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). • — Connector with male terminals (double outline): View from terminal side — Connector with female terminals (single outline): View from wire side •...
Page 348 System Description System Connectors [Dash and Floor] (cont'd)
Page 349 NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). • — Connector with male terminals (double outline): View from terminal side (cont d) —...
Page 350 System Description System Connectors [Dash and Floor] (cont'd)
Page 351 NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK and YEL/BLK are not the same). • — Connector with male terminals (double outline): View from terminal side — Connector with female terminals (single outline): View from wire side •...
Page 352: Procedures
Troubleshooting Troubleshooting Procedures How To Begin Troubleshooting When the Malfunction Indicator Lamp (MIL) has been reported on, or there is a driveability problem, use the appropri- ate procedure below to diagnose and repair the problem. A. When the MIL has come on: 1.
Page 353 Powertrain Control Module (PCM) Reset Procedure NOTE: The PCM memory setting is needed after resetting the PCM (see page 11-125). Either of the following actions will reset the PCM. • Use the OBD II scan tool or Honda PGM Tester to clear the PCM's memory. NOTE: See the OBD II scan tool or Honda PGM Tester user's manuals for specific operating instructions.
Page 354 Troubleshooting Troubleshooting Procedures (cont'd) IV. Known-Good PCM Substitution Use the following procedure if you need a known-good PCM to test a vehicle. It allows you to swap an PCM from a "donor" vehicle without having to program it to the test vehicle's ignition key. 1.
Page 355 How to Use the Backprobe Sets Connect the backprobe adapters to the stacking patch cords, and connect the cords to a multimeter. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it comes in contact with terminal end of the wire.
Page 356: Symptom Chart
Troubleshooting Troubleshooting Procedures (cont'd) Symptom Chart Listed below are symptoms and probable causes for problems that DO NOT cause the Malfunction Indicator Lamp (MIL) to come on. If the MIL was reported on, go to page 11-40. Troubleshoot each probable cause in the order listed (from left to right) until the symptom is eliminated. The probable cause and troubleshooting page reference can be found below.
Page 357 PCM Data You can retrieve data from the PCM by connecting the OBD II scan tool or the Honda PGM Tester to the Data Link Connector (DLC). The items listed in the table below conform to SAE recommended practice. The Honda PGM Tester also reads data beyond that recommended by SAE so that this data may help you find the causes of intermittent problems.
Page 358 Troubleshooting Troubleshooting Procedures (cont'd) Data Description Operating Value Freeze Data Fuel System Loop status is indicated as "open" or "closed". At idle speed: closed Loop Status Closed: Based on the HO2S output, the PCM deter- (Bank 1: Right) mines the air/fuel ratio and controls the amount of (Bank 2: Left) injected fuel.
Page 359 Troubleshooting Troubleshooting Procedures Symptom Chart Listed below are symptoms and probable causes for problems that DO NOT cause the Malfunction Indicator Lamp (MIL) to come on. If the MIL was reported on, check the DTC. Troubleshoot each probable cause in the order listed (from left to right) until the symptom is eliminated. The probable cause and troubleshooting page reference can be found below.
Page 360 Powertrain Control Module Terminal Arrangement PCM CONNECTOR A (26P) Wire side of female terminals PCM CONNECTOR A (26P) NOTE: Standard battery voltage is 12 V. *: '96 - 99 models *1: '00 - 01 models...
Page 361 Troubleshooting Powertrain Control Module Terminal Arrangement (cont'd) PCM CONNECTOR B (16P) Wire side of female terminals PCM CONNECTOR B (16P) NOTE: Standard battery voltage is 12 V.
Page 362 PCM CONNECTOR C (12P) Wire side of female terminals PCM CONNECTOR C (12P) NOTE: Standard battery voltage is 12 V. *: with TCS *1:with VSA (cont'd) 11-49...
Page 363 Troubleshooting Powertrain Control Module Terminal Arrangement (cont'd) PCM CONNECTOR D (22P) Wire side of female terminals PCM CONNECTOR D (22P) NOTE: Standard battery voltage is 12 V. *: with TCS *1: with VSA...
Page 364 PCM CONNECTOR E (26P) Wire side of female terminals PCM CONNECTOR E (26P) NOTE: Standard battery voltage is 12 V. *: with TCS *1: with VSA...
Page 365 Troubleshooting Powertrain Control Module Terminal Arrangement (cont'd) PCM CONNECTOR F (8P) Wire side of female terminals PCM CONNECTOR F (8P) NOTE: Standard battery voltage is 12 V.
Page 366 Troubleshooting Powertrain Control Module Terminal Arrangement PCM CONNECTOR A (26P)
Page 367 Troubleshooting Powertrain Control Module Terminal Arrangement (cont'd) PCM CONNECTOR B (16P)
Page 368 PCM CONNECTOR C (12P)
Page 369 Troubleshooting Powertrain Control Module Terminal Arrangement (cont'd) PCM CONNECTOR D (22P)
Page 370 PCM CONNECTOR E (26P)
Page 371 Troubleshooting Powertrain Control Module Terminal Arrangement (cont'd) PCM CONNECTOR F (8P)
Page 372 Diagnostic Trouble Code (DTC) Chart 11-69 11-71 11-72 11-74 11-75 11-76 11-77 11-78 11-79 11-80 11-82 11-84 11-86 11-87 11-91 *1: These DTCs will be indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the SCS service connector connected.
Page 373 Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) 11-88 11-89 11-90 11-91 11-84 11-86 11-87 11-91 11-93 11-93 11-93 11-93 *2: These DTCs require two "trips" or two driving cycles unless the SCS service connector is connected.
Page 374 11-100 11-95 11-95 11-106 11-106 11-167 11-165 11-177 11-178 11-180 11-113 11-101 Section 14 11-108 11-109 11-109 *2: These DTCs require two "trips" or two driving cycles unless the SCS service connector is connected. *5: The indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously. *7: '97 - 01 models *9: '98 - 01 models *10: '00 - 01 models...
Page 375 Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) 11-83 11-83 11-73 11-73 11-96 11-100 11-96 11-102 11-102 11-104 11-104 11-106 11-106 *7: '97 - 01 models *8: '96 - 97 models *9: '98 - 01 models...
Page 376 11-106 11-106 11-106 11-106 11-182 ('96-99) 11-187 ('00-03) 11-192 ('96-99) 11-196 ('00-03) 11-110 11-168 11-173 11-115 11-111 Section 19 Section 19 Section 19 Section 14 *2: These DTCs require two "trips" or two driving cycles unless the SCS service connector is connected. *5: The indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously.
Page 377 Diagnostic Trouble Code (DTC) Chart Detection Item Probable Cause Page (MIL indication* Manifold Absolute Pressure (MAP) • Open or short in MAP sensor circuit P0107 Sensor Circuit Low Voltage • MAP sensor 11-71 • PCM Manifold Absolute Pressure (MAP) • Open in MAP sensor circuit P0108 Sensor Circuit High Voltage •...
Page 378 Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) Detection Item Probable Cause Page (MIL indication) • Secondary H02S (Sensor 2) Secondary Heated Oxygen Sensor (Secondary H02S) Slow Response P0139 (63)* 11-90 (Sensor 2) • Open or short in Secondary H02S Secondary Heated Oxygen (Sensor 2) heater circuit Sensor (Secondary HO2S) Heater 11-91...
Page 379 Detection Item Probable Cause Page (MIL indication) Crankshaft Position (CKP) 1 • CKP 1 Sensor P0345 Sensor Circuit No Signal • CKP 1 Sensor circuit 11-64 • PCM Crankshaft Position (CKP) 1 • CKP 1 Sensor P0349 Sensor Intermittent Interruption •...
Page 380 Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) Detection Item Probable Cause Page (MIL indication) Idle Air Control (IAC) Valve • IAC valve P0511 (14) Circuit Failure • IAC valve circuit 11-80 • PCM PCM Back-up Circuit Low Voltage • PCM Back-up Circuit •...
Page 381 Probable Cause Detection Item Page (MIL indication) • CMP (CYP) 2 Sensor Camshaft Position (CMP) (Cylinder Position (CYP)) 2 Sensor P1386 (59) 11-64 Intermittent Interruption Camshaft Position (CMP) (Cylinder • CMP (CYP) 2 Sensor P1387 (59) Position (CYP)) 2 Sensor •...
Page 382 Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) Detection Item Probable Cause Page (MIL indication) • Right Primary H02S (Bank 2, Sensor 1) Right Primary Heated Oxygen • Short in Right Primary H02S (Bank 2, Sensor (Right Primary H02S) P2297 Sensor 1) circuit 11-56 Circuit High Voltage •...
Page 383: How To Read Flowcharts
Troubleshooting How to Read Flowcharts A flowchart is designed to be used from start to final repair. It's like a map showing you the shortest distance. But beware: if you go off the "map" anywhere but a "stop" symbol, you can easily get lost. Describes the conditions or situation to start a troubleshooting flowchart.
Page 384: Pgm-Fi System
PGM-FI System System Description INPUTS POWERTRAIN CONTROL MODULE (PCM) OUTPUTS CKP/CYP Sensor Cruise Control Injectors MAP Sensor Signal ('04) PGM-FI Main Relay (Fuel Pump) ECT Sensor Fuel Pump Relay IAT Sensor TP Sensor D4 Indicator Light EGR Valve Position Sensor IAC Valve Left Primary HO2S A/C Compressor Clutch Relay...
Page 385 PGM-FI System System Description (cont'd) 3. Fuel Cut-off Control • During deceleration with the throttle valve closed, current to the injectors is cut off to improve fuel economy at speeds over 1,000 rpm. • Fuel cut-off action also takes place when engine speed exceeds 5,900 rpm, regardless of the position of the throttle valve, to protect the engine from over-revving.
Page 386: How To Set Readiness Codes
How to Set Readiness Codes EVAP Leak Monitor Catalytic Converter NOTE: NOTE: • Do not turn the ignition switch OFF. • When the battery negative cable is disconnected, all • When the battery negative cable is disconnected, all readiness codes are cleared. readiness codes are cleared.
Page 387 PGM-FI System How to Set Readiness Codes (cont'd) HO2S Monitor NOTE: • Do not turn the ignition switch OFF. • When the battery negative cable is disconnected, all readiness codes are cleared. Required condition ('96 - 97 models): • Ambient temperature between 32 - 95°F (0 - 35°C). •...
Page 388: Mil Circuit Troubleshooting
MIL Circuit Troubleshooting Turn the ignition switch ON (II) NOTE: and watch the Malfunction If this symptom is intermittent, check for the following problems. Indicator Lamp (MIL). • The MIL never comes on after the ignition switch is turned ON (II). —...
Page 389 PGM-FI System MIL Circuit Troubleshooting (cont'd) (From page 11-63) — Repair short in the wire between No. 6 ECU (PCM) (20 A) fuse and PGM-FI main relay. — Repair short in the wire between PGM-FI main relay Is the fuse OK? and the PCM, fuel injectors, or IAC valve.
Page 390 (From page 11-64) PCM CONNECTOR A (26P) Check for an open in the wires (PG, LG lines): 1. Reconnect the fuel injector and IAC valve connectors. 2. Measure voltage between body ground and the PCM connector terminals A12, A25, A26, and B9 individually. Wire side of female terminals Repair open in the wire(s) Is there less than 1.0V?
Page 391 PGM-FI System MIL Circuit Troubleshooting (cont'd) (From page 11-63) Check the Diagnostic Trouble Code (DTC): 1. Turn the ignition switch OFF. 2. Honda PGM Tester. 3. Turn the ignition switch ON (II). 4. Read the DTC with the Honda PGM Tester. Go to the DTC Troubleshooting Are any DTC(s) indicated? Index (see page 11-53).
Page 392 (From page 11-66) DATA LINK CONNECTOR (DLC) (16P) Wire side of female terminals Check for an open in the wire (K-line): Check for continuity between the DLC 16P connector terminal No. PCM CONNECTOR D (22P) 15 and PCM connector terminal Wire side of female terminals Repair open in the wire between Is there continuity?
Page 393 PGM-FI System MIL Circuit Troubleshooting (cont'd) (From page 11-63) PCM CONNECTOR A (26P) Check for an open in the wire or JUMPER WIRE bulb (MIL line): 1. Turn the ignition switch OFF. MIL (LT GRN/RED) 2. Connect PCM connector ter- minal A7 and body ground with a jumper wire.
Page 394 PGM-FI System MIL Circuit Troubleshooting Turn the ignition switch ON (II) NOTE: and watch the Malfunction If this symptom is intermittent, check for the following problems. Indicator Lamp (MIL). • The MIL never comes on after the ignition switch is turned ON (II). —...
Page 395 (From page 11-70) Inspect No. 6 ECU (PCM) (20 A) fuse in the under-dash fuse/relay box. Repair short in the wire between No. 6 ECU (PCM) (20 A) fuse and PGM-FI main relay. Repair short in the wire between PGM-FI main relay Is the fuse OK? and the PCM, fuel injectors, or IAC valve.
Page 396 PGM-FI System MIL Circuit Troubleshooting (cont'd) PCM CONNECTOR A (26P) (From page 11-71) (BRN/BLK) Check for an open in the wires (PG, LG lines): 1. Reconnect the fuel injector and IAC valve connectors. 2. Measure voltage between body ground and the PCM connector terminals A12, A25, A26, and 69 individually.
Page 397 (From page 11-70) Check the Diagnostic Trouble Code (DTC): 1. Turn the ignition switch OFF. 2. Connect the scan tool or the HDS. 3. Turn the ignition switch ON (II). 4. Read the DTC with the scan tool or the HDS. Go to the DTC Troubleshooting Are any DTC(s) indicated? Index (see page 11-41).
Page 398 MIL Circuit Troubleshooting (cont'd) (From page 11-73) Check for an open in the wire (K-line): Check for continuity between the DLC 16P connector terminal No.7 and PCM connector terminal D4. Repair open in the wire between Is there continuity? the DLC and PCM (D4). Check for a short in the wire (MIL line): Turn the ignition switch ON (II).
Page 399 (From page 11-70) Check for an open in the wire or bulb (MIL line): 1. Turn the ignition switch OFF. 2. Connect PCM connector ter- minal A7 and body ground with a jumper wire. 3. Turn the ignition switch ON (II). Repair open in the wires between the PCM (A7) and Does the MIL come on?
Page 400: Idle Control System
Idle Control System System Description The idle speed of the engine is controlled by the Idle Air Control (IAC) Valve. The valve changes the amount of air bypassing into the intake manifold in response to electric current controlled by the PCM.
Page 401: Air Conditioning Signal
Idle Control System Air Conditioning Signal This signals the PCM when there is a demand for cooling from the air conditioning system. Inspection of Air Conditioning PCM CONNECTORS Signal. Check for a short in the wire (ACS line): 1. Turn the ignition switch OFF. Wire side of female terminals 2.
Page 402 (From page 11-116) A/C CLUTCH RELAY CONNECTOR (C344) Check for an open in the wire (ACC line): Is there a clicking noise from Momentarily connect the A/C the A/C compressor clutch? clutch relay connector terminal No. 4 to body ground with a jumper wire several times.
Page 403: Alternator Fr Signal
Idle Control System Alternator (ALT) FR Signal This signals the PCM when the Alternator (ALT) is charging. PCM CONNECTORS Inspection of ALT FR Signal. Check for a short in the wire (ALT F line): 1. Disconnect the GRN 4P con- nector from the ALT.
Page 404: Starter Switch Signal
Starter Switch Signal This signals the PCM when the engine is cranking. Inspection of Starter Switch Sig- NOTE: Transmission in position. nal. PCM CONNECTORS Check for an open or short in the wire (STS line): Measure voltage between PCM connector terminals C6 and A26 with the ignition switch in the start position (III).
Page 405 Idle Control System Power Steering Pressure (PSP) Switch Signal This signals the PCM when the power steering load is high. PCM CONNECTORS Inspection of PSP switch signal. Check for an open in the wire (PSP SW line): 1. Turn the ignition switch ON (II). Wire side of female terminals 2.
Page 406 (From page 11-120) Check for a short in the PSP PCM CONNECTORS switch: 1. Turn the ignition switch OFF. 2. Disconnect the 2P connector from the PSP switch. 3. Turn the ignition switch ON (II). 4. Measure voltage between PCM connector terminals B3 and A26.
Page 407: Brake Pedal Position Switch Signal
Idle Control System Brake Pedal Position Switch Signal This signals the PCM when the brake pedal is depressed. Inspection of Brake Pedal Position Switch Signal. Are the brake lights on without Inspect the brake pedal position depressing the brake pedal? switch (see section 19).
Page 408: Idle Air Control Thermal Valve
Idle Air Control Thermal Valve Inspection Description To prevent erratic running when the engine is warming NOTE: The idle air control thermal valve is factory up, it is necessary to raise the idle speed. The idle air control thermal valve is controlled by a thermowax adjusted;...
Page 409: Idle Speed Setting
Idle Control System Idle Speed Setting Inspection/Adjustment Disconnect the IAC valve connector. NOTE: • Before setting the idle speed, check the following items: — The MIL has not been reported on. — Ignition timing — Spark plugs — Air cleaner —...
Page 410 6. Turn the ignition switch OFF. Reconnect the 2P connector on the IAC valve, then do the PCM reset procedure. NOTE: The PCM memory setting is needed after resetting the PCM. Restart and idle the engine with no-load conditions for one minute, then check the idle speed. NOTE: (Canada) Pull the parking brake lever up.
Page 411: Pcm Memory Setting
PCM Memory Setting NOTE: The PCM reset procedure and disconnecting the battery or the BACK UP RADIO (7.5 A) fuse cancels the PCM memory for idle control. The following procedure is needed after the PCM reset procedure and reconnect- ing the battery or the BACK UP RADIO (7.5 A) fuse. Start the engine.
Page 412: Fuel Supply System
Fuel Supply System Fuel Lines Check fuel system lines, hoses, fuel filter, and other components for damage, leaks or deterioration, and replace if neces- sary. '96 - 99 models: 22 N-m (2.2 kgf-m, 22 N-m 16 Ibf-ft) (2.2 kgf-m, 16 Ibf-ft) 37 N-m (3.8 kgf-m, 27 Ibf-ft) '00 - 01 models:...
Page 413 '96 - 99 models: Check all hose clamps and retighten if necessary. FUEL GAUGE SENDING FUEL PUMP UNIT ASSEMBLY FUEL TANK EVAPORATIVE ASSEMBLY EMISSION (EVAP) VALVE BASE GASKET Replace. BASE FUEL GASKET PRESSURE Replace. REGULATOR FUEL FILTER FUEL TANK EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE EVAPORATIVE EMISSION (EVAP) CONTROL...
Page 414 Fuel Supply System Fuel Lines (cont'd) '00 - 01 models: Check all hose clamps and retighten if necessary. A: Do not disconnect. FUEL GAUGE SENDING UNIT ASSEMBLY FUEL PUMP ASSEMBLY FUEL TANK VAPOR CONTROL VALVE To FUEL FILTER FUEL TANK Clamp in the middle Clamp in the middle...
Page 415: Fuel Tube/Quick-Connect Fittings
Fuel Tube/Quick-Connect Fittings Precautions Disconnection Do not smoke while working on the fuel Do not smoke while working on the fuel system. Keep open flames away from your work area. system. Keep open flames away from your work area. The fuel tube/quick-connect fittings assembly connects 1.
Page 416 Fuel Supply System Fuel Tube/Quick-Connect Fittings (cont'd) To prevent damage and keep out foreign matter, Connection cover the disconnected connector and pipe end with plastic bags. Do not smoke while working on the fuel system. Keep open flames away from your work area. Check the pipe contact area for dirt and damage, and clean if necessary.
Page 417 Before connecting a new fuel tube/quick-connect fitting Make sure the connection is secure and the pawls assembly, remove the old retainer from the mating pipe. are firmly locked into place; check visually and by pulling the connector. Pull apart. CONNECTOR With the tabs pulled apart, pull...
Page 418: System Description
Fuel Supply System System Description The fuel supply system consists of a fuel tank, in-tank Inspection high-pressure fuel pump, PGM-FI main relay, fuel filter, fuel pressure regulator, fuel pressure regulator control Relieve fuel pressure. solenoid valve, injectors, and fuel delivery and return Remove the service bolt on the fuel filter while hold- lines.
Page 419 Injectors Replacement Do not smoke when working on the fuel system. Keep open flames away from your work area. 1. Remove the strut bar. 2. Remove the engine cover. 3. Relieve fuel pressure (see page 11-132). 4. Disconnect the connectors from the injectors. 5.
Page 420 Fuel Supply System Injectors (cont'd) 13. Slide new cushion rings onto the injectors. 14. Coat new O-rings with clean engine oil, and put them on the injectors. 15. Insert the injectors into the fuel rail first. 16. Coat new seal rings with clean engine oil and press them into the intake manifold. 17.
Page 421: Fuel Pressure Regulator
Fuel Pressure Regulator Description Testing The fuel pressure regulator maintains a constant fuel pressure to the injectors. When the difference between Do not smoke during the test. Keep open the fuel pressure and manifold pressure exceeds 294 flames away from your work area. kPa (3.0 kgf/cm , 43 psi), the diaphragm is pushed upward, and the excess fuel is fed back into the fuel tank...
Page 422 Fuel Supply System Fuel Pressure Regulator (cont'd) Reassembly Removal Do not smoke while working on fuel sys- Install the fuel pressure regulator in the fuel rail. Turn tem. Keep open flame away from your work area. it by hand until it stops. Remove the strut bar.
Page 423 No. 1 VACUUM HOSE Troubleshooting Flowchart VACUUM PUMP/GAUGE, 0 - 30 in.Hg Inspection of Fuel Pressure Regu- A973X - 041 - XXXXX lator Control Solenoid Valve. Check for vacuum at idle: 1. Start the engine. Hold the engine at 3,000 rpm with no load (in Park or neutral) until the radiator fan comes on.
Page 424 Fuel Supply System Fuel Pressure Regulator (cont'd) (From page 11-137) CONTROL BOX 4P CONNECTOR (C257) Check for an open in the wire (IG1 line): Measure voltage between the (BLK/YEL) control box 4P connector termi- nal No. 4 and body ground. Repair open in wire between Wire side of female terminals No.
Page 425: Fuel Pump Relay
Fuel Pump Relay Troubleshooting Flowchart Inspection of fuel pump relay. Turn the ignition switch to the START (III) position. Inspect the fuel pump resistor Does the engine start? (see page 11-141). PCM CONNECTOR C (12P) Check for an open in the circuit: 1.
Page 426 Fuel Supply System Fuel Pump Relay (cont'd) (From page 11-139) FUEL PUMP RELAY 4P CONNECTOR (C667) JUMPER Check for open in the fuel pump CAUTION: * the PCM connector C (12P) WIRE must be disconnected for this test or relay: 1.
Page 427: Fuel Pump Resistor
Fuel Pump Resistor Troubleshooting Flowchart — Engine will not start. — Inspection of fuel pump resis- tor. FUEL PUMP RESISTOR 2P CONNECTOR (C704) Check the operation of the PGM- FI main relay: 1. Disconnect the fuel pump resistor 2P connector. 2.
Page 428: Fuel Filter
Fuel Supply System Fuel Filter Replacement Do not smoke while working on fuel system. Keep open flame away from your work area. • While replacing the fuel filter, be careful to keep a safe distance between battery terminals and any tools. The fuel filter should be replaced whenever the fuel pres- sure drops below the specified value [299 - 348 kPa (3.05 - 3.55 kgf/cm...
Page 429: Fuel Pump
Fuel Supply System Fuel Pump Testing Do not smoke during the test. Keep open flame away from your work area. If you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is ON, you will hear some noise if you hold your ear to the fuel fill port with the fuel fill cap removed.
Page 430 Replacement Do not smoke while working on fuel sys- tem. Keep open flames away from your work area. section 20). 2. Remove the access panel from the floor. Disconnect the 2P connector from the fuel pump. Remove the fuel pump mounting nuts. 5.9 N-m (0.6 kgf-m, 4.3 Ibf-ft)
Page 431: Fuel Gauge
Fuel Gauge Testing NOTE: Refer to section 23 for the fuel gauge system cir- cuit. Check the No. 13 METER (7.5 A) fuse in the under- dash fuse/relay box, METER (15 A) fuse in the under- hood fuse/relay box and gauge relay before testing. Remove the rear seat cushion (see section 20).
Page 432 Fuel Supply System Fuel Gauge (cont'd) Turn the ignition switch OFF. Attach a jumper wire between the No. 1 and No. 2 terminals, then turn the ignition switch ON (II). Check that the pointer of the fuel gauge starts mov- ing toward the "F"...
Page 433: Fuel Gauge Sending Unit
Fuel Supply System Fuel Gauge Sending Unit Testing Do not smoke while working on the fuel system. Keep open flame away from your work area. Remove the seat cushion (see section 20). Remove the access panel. 3. With the ignition switch OFF, disconnect the 3P con- nector from the fuel gauge sending unit.
Page 434 5. Measure the resistance between the No. 1 and No. 2 terminals at E (EMPTY), 1/2 (HALF FULL) and F (FULL) by moving the float. Terminal side of male terminals Top of the workbench (Bottom of the fuel tank) If you do not get the above readings, replace the fuel gauge sending unit.
Page 435: Low Fuel Indicator System
Low Fuel Indicator System Indicator Light Testing Check the No. 13 METER (7.5 A) fuse in the under- Do not smoke while working on the fuel system. Keep open flame away from the work area. Drain fuel only into an approved container. Drain the fuel into an approved container.
Page 436: Pgm-Fi Main Relay
Fuel Supply System PGM-FI Main Relay Description Relay Testing This PGM-FI main relay is located behind the dashboard NOTE: If the engine starts and continues to run, the PGM- lower cover. The PGM-FI main relay actually contains FI main relay is OK. two individual relays.
Page 437 Troubleshooting Flowchart Engine will not start. Inspection of PGM-FI main relay and relay harness. Check for an open in the wire (PG1 PGM-FI MAIN RELAY 8P CONNECTOR (C433) line): 1. Turn the ignition switch OFF. 2. Disconnect the PGM-FI main relay 4P connector and 8P connector.
Page 438 Fuel Supply System PGM-FI Main Relay (cont'd) (From page 11-147) PGM-FI MAIN RELAY 4P CONNECTOR (C432) Check for an open in the wire (IGSW line): Measure voltage between the PGM-FI main relay 4P connector IGSW terminal No. 4 and body ground. (BLK/YEL) Repair open or short in the wire between the PGM-FI...
Page 439 (From page 11-148) Check for an open in the wires PCM CONNECTORS (IGP1, IGP2 lines): 1. Reconnect the PCM connector A (26P). 2. Reconnect the PGM-FI main relay 4P and 8P connectors. 3. Turn the ignition switch ON (II). 4. Measure voltage between PCM connector terminals A13, B1, and A12.
Page 440: Fuel Tank
Fuel Supply System Fuel Tank '96 - 99 models: Replacement Do not smoke while working on fuel system. Keep open flame away from your work area. 1. Relieve the fuel pressure (see page 11-132). 2. Remove the seat cushion (see section 20).
Page 441 '00 - 01 models: Replacement Do not smoke while working on fuel system. Keep open flame away from your work area. 1. Relieve the fuel pressure (see page 11-132). 2. Remove the seat cushion (see section 20). 3. Disconnect the 10P connector from the fuel unit wire harness. 4.
Page 442: Intake Air System
Intake Air System System Description The system supplies air for all engine needs. It consists of the intake air pipe. Air Cleaner, intake air duct. Throttle Body, Idle Air Control (IAC) Valve, idle air control thermal valve, and intake manifold. A resonator in the intake air pipe provides additional silencing as air is drawn into the system.
Page 443: Air Cleaner
Air Cleaner Air Cleaner Element Replacement AIR CLEANER ELEMENT Normal conditions: Replace air cleaner element every 30,000 miles (48,000 km) or 24 AIR CLEANER HOUSING months whichever comes first. COVER Severe conditions: Clean air cleaner element every 15,000 miles (24,000 km) or 12 months and replace every 30,000 miles (48,000 km) or 24 months whichever comes first.
Page 444: Throttle Cable
Intake Air System Throttle Cable Inspection/Adjustment Installation Check that the throttle cable operates smoothly with Open the throttle valve fully, then install the throttle no binding or sticking. Repair as necessary. cable in the throttle linkage and install the cable housing in the cable bracket.
Page 445: Throttle Body
Throttle Body Allow the engine to idle, and check that the gauge Description The throttle body is a single-barrel side-draft type. The indicates no vacuum. lower portion of the throttle valve is heated by engine If there is vacuum, check the throttle cable (see coolant from the cylinder head.
Page 446 Intake Air System Throttle Body (cont'd) Disassembly With TCS/VSA*: Remove the TCS/VSA* control valve (see section 19). GASKET Replace. TP SENSOR THROTTLE CABLE 22 N-m (2.2 kgf-m, 16 Ibf-ft) CRUISE CONTROL CABLE *: '00 - 01 models NOTE: • Do not adjust the throttle stop screw. •...
Page 447: Intake Manifold Runner Control (Imrc)
Intake Manifold Runner Control (IMRC) System Description Satisfactory power performance is achieved by closing and opening the intake manifold runner control (IMRC) valves. High torque at low RPM is achieved when the valves are closed, whereas high power at high RPM is achieved when the valves are opened.
Page 448 Intake Air System Intake Manifold Runner Control (IMRC) System (cont'd) No. 2 VACUUM Troubleshooting Flowchart HOSE Inspection of IMRC System. Check for vacuum at idle: 1. Start engine and allow it to idle. 2. Remove No. 2 vacuum hose VACUUM PUMP/ from the IMRC diaphragm, and GAUGE, 0 - 30 in.Hg connect vacuum gauge to the...
Page 449 (From page 11-158) (From page 11-158) Repair open in wire between the 6P connector and No. 20 ECU Is there battery voltage? (PCM) (20 A) fuse in the under- dash fuse/relay box. PCM CONNECTOR A (26P) Check for an open in the wire (IABCS1 line): 1.
Page 450 Intake Air System Intake Manifold Runner Control (IMRC) System (cont'd) (From page 11-159) (From page 11-159) Replace the IMRC solenoid valve Check for vacuum at 3,400 rpm: Is there battery voltage? 1. Raise engine speed to 3,400 rpm. IMRC/ENGINE MOUNT CONTROL SOLENOID 2.
Page 451 (From page 11-160) (From page 11-160) PCM CONNECTOR A (26P) Check for vacuum at 4,000 rpm: Check for a short in the wire 1. Raise engine speed to 4,000 (IABSC1 line): rpm. 1. Turn the ignition switch OFF. 2. Check for vacuum at No. 8 2.
Page 452 Intake Air System Intake Manifold Runner Control (IMRC) System (cont'd) Intake Manifold Runner Control (IMRC) Valve 1 Testing Intake Manifold Runner Control (IMRC) Valve 2 Testing Disconnect the No. 2 hose from the vacuum hose Disconnect the No. 8 hose from the vacuum hose manifold, and attach a vacuum pump to the vacuum manifold, and attach a vacuum pump to the vacu- hose manifold.
Page 453: Intake Air Bypass (Iab) Control System
Intake Air Bypass Control System Testing Description Start the engine. Hold the engine at 3,000 rpm with The Intake Air Bypass Control system enables fresh air to be drawn through the throttle body and fuel injector no load in Park or neutral until the radiator fan comes on.
Page 454: Emission Control System
Emission Control System System Description Three Way Catalytic Converter (TWC) The emission control system includes a Three Way Cata- Description lytic Converter (TWC), Exhaust Gas Recirculation (EGR) system, Positive Crankcase Ventilation (PCV) system and The Three Way Catalytic Converter (TWC) is used to Evaporative Emission (EVAP) system.
Page 455 Emission Control System Exhaust Gas Recirculation (EGR) System Description The EGR system is designed to reduce oxides of nitrogen emissions (NOx) by recirculating exhaust gas through the EGR valve and the intake manifold into the combustion chambers. It is composed of the EGR valve, EGR valve vacuum control valve, EGR valve vacuum control solenoid valve, PCM and various sensors.
Page 456 Emission Control System Positive Crankcase Ventilation (PCV) System Description Inspection The Positive Crankcase Ventilation (PCV) system is 1. Remove the engine cover. Check the PCV hoses and designed to prevent blow-by gas from escaping to the connections for leaks and clogging. atmosphere.
Page 457: Evaporative Emission Controls Description
Evaporative Emission (EVAP) Controls Description The evaporative emission controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. The system consists of the following components: A. Evaporative Emission (EVAP) Canister An EVAP canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the EVAP canister into the engine and burned.
Page 458 Emission Control System Evaporative Emission (EVAP) Controls (cont'd) '00 - 01 models: INTAKE MANIFOLD From No. 20 ECU (PCM) (20 A) FUSE (in the under-dash fuse/relay box) FUEL TANK VARIOUS FUEL VAPOR SENSORS TANK FUEL TANK SIGNAL PRESSURE VAPOR CONTROL TUBE SENSOR VALVE...
Page 459 Evaporative Emission (EVAP) Control Canister and EVAP '00 - 04 models: Control Canister Vent Shut Valve Replacement Disconnect the connector and hoses. '96 - 99 models Remove the EVAP canister mounting bolt and the Remove the front bumper (see section 20).
Page 460 Emission Control System Evaporative Emission (EVAP) Controls (cont'd) Evaporative Emission (EVAP) Two Way Valve and EVAP Bypass Solenoid Valve Replacement '96 - 99 models: O-RING Replace. '00 - 04 models: O-RING Replace.
Page 461 Fuel Tank Vapor Control Valve Test ('00-'04 model) Valve Test Make sure the fuel tank is less than half full. Float Test Make sure the fuel tank is less than half full. 2. Remove the fuel fill cap. Remove the fuel fill cap to relieve the fuel tank pres- Remove the fuel hose joint pretector.
Page 462 Emission Control System Evaporative Emission (EVAP) Controls (cont'd) Connect a second vacuum pump to the fuel tank vapor signal tube. FUEL TANK VAPOR SIGNAL TUBE VACUUM PUMP/GAUGE, A973X - 041 - XXXXX Apply vacuum (1 pump) to the fuel tank vapor sig- nal tube, then check the vacuum on the pump in step 6.
Page 463 Emission Control System Evaporative Emission (EVAP) Controls (cont'd) Fuel Tank Vapor Control Valve Replacement Remove the fuel tank (see page 11-151). Remove the Fuel Tank Vapor Control valve from the fuel tank. Install parts in the reverse order of removal. (0.4 kgf-m, 3 Ibf-ft) FUEL TANK VAPOR CONTROL VALVE...
Page 464 Evaporative Emission (EVAP) Two Way Valve Testing Move the vacuum pump hose from the vacuum fit- Remove the fuel fill cap. ting to the pressure fitting, and move the vacuum Remove the vapor line from the EVAP two way gauge hose from the vacuum side to the pressure valve (located above the EVAP canister), and con- side as shown.
Page 465: Automatic Transmission
Automatic Transmission Special Tools ....14–2 Road Test ....14–104 Regulator Valve Body Clutch...
Page 466 Special Tools Bearing Driver Attachment 07GAD - SD40101 14-158, 14-173 07GAE - PG40200 or Clutch Spring Compressor Bolt Assembly 14-164, 14-167 07GAE - PG4020A 07HAC - PK4010A Housing Puller 14-133 07LAC - PW50101 Extension Shaft Puller 14-118 07LAD - SM40100 Seal Driver Attachment 14-176 07LAE - PX40100...
Page 467 Description The automatic transmission is a combination of a 3-element torque converter and a dual-shaft electronically controlled automatic transmission which provides 4 speeds forward and 1 reverse. The entire unit is positioned in line with the engine. Torque Converter, Gears and Clutches The torque converter consists of a pump, turbine and stator, assembled in a single unit.
Page 468 Description (cont'd) Gear Selection The shift lever has seven positions: PARK, REVERSE, NEUTRAL, 1st through 4th gear ranges, 1st through 3rd gear ranges, 2nd gear and 1st gear. Position Description PARK Front wheels locked; park pawl engaged with park gear on countershaft. All clutches released. REVERSE Reverse;...
Page 469 ATF DIPSTICK RING GEAR/DRIVE PLATE TORQUE CONVERTER 4TH CLUTCH 1ST CLUTCH 2ND CLUTCH MAINSHAFT DIFFERENTIAL ASSEMBLY EXTENSION SHAFT SECONDARY DRIVEN GEAR COUNTERSHAFT 1ST-HOLD 3RD CLUTCH REVERSE CLUTCH CLUTCH...
Page 470 Description Clutches The four-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gears. When the hydraulic pressure is introduced into the clutch drum, the clutch piston moves. This presses the friction discs and steel plates together, locking them so they don't slip. Power is then transmitted through the engaged clutch pack to its hub-mounted gear.
Page 471 DIFFERENTIAL EXTENSION SHAFT SECONDARY DRIVE GEAR 3RD CLUTCH SECONDARY DRIVEN GEAR MAINSHAFT 3RD GEAR COUNTERSHAFT 3RD GEAR MAINSHAFT 4TH COUNTERSHAFT 4TH GEAR GEAR 4TH CLUTCH 1ST-HOLD CLUTCH 1ST CLUTCH 1ST-GEAR ONE-WAY CLUTCH COUNTERSHAFT 1ST GEAR MAINSHAFT 1ST GEAR ONE-WAY CLUTCH HUB MAINSHAFT 2ND COUNTERSHAFT 2ND GEAR GEAR...
Page 472: Power Flow
Description Power Flow Operates, Doesn't operate. *1: Although the 1st clutch engages, driving power is not transmitted as the 1st gear one-way clutch slips. *2: Although the 1st and 2nd clutches engage, driving power is not transmitted as the one-way clutches slip. *3: The one-way clutch engages when accelerating, and slips when decelerating.
Page 473 Position Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. Position Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft is locked by the park pawl interlocking the park gear. 2ND CLUTCH 1ST CLUTCH 4TH CLUTCH...
Page 474 Description Power Flow (cont'd) Position position, hydraulic pressure is applied to the 1st clutch and the 1st-hold clutch. The power flow when accelerating is as follows: 1. The hydraulic pressure is applied to the 1st clutch on the mainshaft, and power is transmitted via the 1st clutch to the mainshaft 1st gear.
Page 475 Position The power flow when decelerating is as follows: 1. Rolling resistance from the road surface goes through the front wheels to the secondary drive gear, then to the counter- shaft 1st gear via the 1st-hold clutch which is applied during deceleration. 2.
Page 476 Description Power Flow (cont'd) Position Position is provided to drive only in 2nd gear. position, hydraulic pressure is applied to the 2nd clutch and to the 1st-hold clutch. The power flow when accelerating is as follows: 1. The hydraulic pressure is applied to the 2nd clutch on the mainshaft, and power is transmitted via the 2nd clutch to the mainshaft 2nd gear.
Page 477 Position The power flow when decelerating is as follows: 1. Rolling resistance from the road surface goes through the front wheels to the secondary drive gear, then to the counter- shaft 1st gear via the Ist-hold clutch which is applied during deceleration. 2.
Page 478 Description Power Flow (cont'd) position, the optimum gear is automatically selected from 1st, 2nd, 3rd, and 4th gears, according to conditions such as the balance between throttle opening (engine load) and vehicle speed. Position, 1st gear 1. The hydraulic pressure is applied to the 1st clutch, which rotates together with the mainshaft, causing the mainshaft 1st gear to rotate.
Page 479 Position, 2nd gear 1. The hydraulic pressure is applied to the 2nd clutch, which rotates together with the mainshaft, causing the mainshaft 2nd gear to rotate. 2. Power is transmitted to the countershaft 2nd gear, which drives the countershaft via the 2nd gear one-way clutch. 3.
Page 480 Description Power Flow (cont'd) Position, 3rd gear 1. The hydraulic pressure is applied to the 3rd clutch. Power from mainshaft 3rd gear is transmitted to the countershaft 3rd gear. 2. Power is transmitted to the secondary drive gear, which drives the secondary driven gear. NOTE: In position, 3rd gear, hydraulic pressure is also applied to the 1st clutch and to the 2nd clutch, but since the rotation speed of 3rd gear exceeds that of 2nd gear, power from 2nd gear is cut off at the 2nd gear one-way...
Page 481 Position, 4th gear 1. The hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshaft, causing the mainshaft 4th gear to rotate. 2. Power is transmitted to the countershaft 4th gear, which drives the countershaft. 3. Power is transmitted to the secondary drive gear, which drives the secondary driven gear. NOTE: In position, 4th gear, hydraulic pressure is also applied to the 1st clutch and to the 2nd clutch, but since the rotation speed of 4th gear exceeds that of 2nd gear, power from 2nd gear is cut off at the 2nd gear one-way clutch.
Page 482 Description Power Flow (cont'd) Position 1. The hydraulic pressure is applied to the reverse clutch. Power is transmitted from the mainshaft reverse gear via the reverse idler gear to the countershaft reverse gear. 2. The rotation direction of the countershaft reverse gear is changed via the reverse idler gear in the rear cover. 3.
Page 483 Electronic Control System The electronic control system consists of a Powertrain Control Module (PCM), sensors, a A/T clutch pressure control solenoid and four solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all con- ditions. The PCM is located below the dashboard, under the front lower panel on the passenger's side. Vehicle Speed Sensor Throttle Position Sensor Signal...
Page 484 Description Electronic Control System (cont'd) Shift Control The PCM instantly determines which gear should be selected by various signals sent from sensors, and it actuates the shift solenoid valves A and B to control shifting. Also, a Grade Logic Control System controls shifting in position while the vehicle is ascending or descending a slope, or reducing speed.
Page 485 Grade Logic Control System How it works: The PCM compares actual driving conditions with driving conditions memorized in the PCM, based on the input from the vehicle speed sensor, throttle position sensor, engine coolant temperature sensor, barometric pressure sensor, brake pedal position switch signal and shift lever position signal, to control shifting while a vehicle is ascending or descending a slope.
Page 486 Description Electronic Control System (cont'd) Ascending Control When the PCM determines that the vehicle is climbing a hill in position, the system extends the engagement area of 3rd gear to prevent the transmission from frequently shifting between 3rd and 4th gears, so the vehicle can run smooth and have more power when needed.
Page 487 Circuit Diagram and Terminal Locations...
Page 488 Description Hydraulic Control The hydraulic control system is controlled by the ATF pump, valves and accumulators in the valve bodies. The ATF pump is driven by splines on the end of the torque converter which is attached to the engine. Fluid from the ATF pump flows through the regulator valve to maintain specified pressure through the main valve body to the manual valve, directing pressure to each of the clutches.
Page 489 Lower Valve Body Assembly The lower valve body assembly is located on the bottom of the transmission housing. The lower valve body assembly consists of the main valve body, the secondary valve body and the ATF passage. Main Valve Body The main valve body houses the manual valve, the 1-2 shift valve, the 2-3 shift valve, the 3-4 shift valve, the 4-3 kick-down valve and the main orifice control valve.
Page 490 Description Hydraulic Control (cont'd) ATF Pump Body The ATF pump body is located on the torque converter housing. The ATF pump body consists of the ATF pump gears, the relief valve, the lock-up control valve, the lock-up timing valve and the torque converter check valve. The torque converter check valve is located between the ATF pump body and the torque converter housing.
Page 491 Regulator Valve The regulator valve regulates the line pressure, and also supplies the fluid to the lubricating system and torque converter. To regulate the line pressure, the regulator valve passes the fluid from the ATF pump through the lubricating system and the torque converter, and the regulator valve receives line pressure control pressure.
Page 492 Description Hydraulic Flow General Chart of Hydraulic Pressure ATF Pump Regulator Valve Line Pressure Modulator Pressure Throttle B Pressure Clutch Pressure Line Pressure Control Pressure Torque Converter Pressure Lubrication Pressure Distribution of Hydraulic Pressure Regulator Valve Torque Converter Pressure • Lubrication Pressure To Regulate Line Pressure Manual Valve - To Select Line Pressure...
Page 493 Position As the engine turns, the ATF pump also starts to operate. Automatic transmission fluid (ATF) is drawn from (99) and dis- charged into (1). Then, ATF flowing from the ATF pump becomes the line pressure (1). The line pressure (1) is regulated by the regulator valve.
Page 494 Description Hydraulic Flow (cont'd) Position The line pressure (1) flows to the manual valve, the modulator valve, the line pressure control valve and the throttle valve. The line pressure (1) becomes the modulator pressure (6) at the modulator valve, and the line pressure (4) and (7), and the 1st-hold clutch pressure (70) at the manual valve.
Page 495 Position The line pressure (1) flows to the manual valve, the modulator valve, the line pressure control valve and the throttle valve. The line pressure (1) becomes the modulator pressure (6) at the modulator valve, the line pressure (4) and the 1st-hold clutch pressure (70) at the manual valve.
Page 496 Description Hydraulic Flow (cont'd) Position 1. 1st Gear The flow of fluid through the torque converter circuit is the same as in position. The line pressure (1) flows through the manual valve, the modulator valve, the line pressure control valve and the throttle valve. The line pressure (1) becomes the modulator pressure (6) at the modulator valve, and the line pressure (4) at the manual valve.
Page 497 2. 2nd Gear As the speed of the vehicle reaches the prescribed value, shift solenoid valve A is turned ON by means of the PCM. Shift solenoid valve B remains ON. The modulator pressure (6A) in the left end of the 1-2 shift valve is released by turn- ing shift solenoid valve A ON.
Page 498 Description Hydraulic Flow (cont'd) Position 3. 3rd Gear As the speed of the vehicle reaches the prescribed value, shift solenoid valve B is turned OFF by means of the PCM. Shift solenoid valve A remains ON. The modulator pressure (6B) flows to the right ends of the 1-2 shift valve and the 2- 3 shift valve.
Page 499 Position 4. 4th Gear As the speed of the vehicle reaches the prescribed value, shift solenoid valve A is turned OFF by means of the PCM. Shift solenoid valve B remains OFF. The modulator pressure (6A) flows to the right end of the 3-4 shift valve and the left end of the 1-2 shift valve.
Page 500 Description Hydraulic Flow (cont'd) Position The flow of fluid through the torque converter circuit is the same as in position. The line pressure (1) becomes the modulator pressure (6) at the modulator valve, and the line pressure (3) at the manual valve.
Page 501 Position The flow of fluid through the torque converter circuit is the same as in position. The line pressure (1) is intercepted by the manual valve. Hydraulic pressure is not supplied to the clutches, and power is not transmitted. NOTE: •...
Page 502 Description Lock-up System Lock-up Clutch 1. Operation (clutch on) With the lock-up clutch on, the fluid in the chamber between the torque converter cover and the lock-up piston is drained off, and the converter fluid exerts pressure through the piston against the torque converter cover. As a result, the converter turbine is locked to the converter cover.
Page 503 position in 2nd, 3rd and 4th, and position in 3rd, pressurized fluid is drained from the back of the torque converter through a passage, causing the lock-up piston to be held against the torque converter cover. As this takes place, the main- shaft rotates at the same speed as the engine crankshaft.
Page 504 Description Lock-up System (cont'd) No Lock-up The pressurized fluid regulated by the modulator works on both ends of the lock-up shift valve and on the left side of the lock-up control valve. Under this condition, the pressures working on both ends of the lock-up shift valve are equal, and the shift valve is moved to the right side by the tension of the valve spring alone.
Page 505 Partial Lock-up Torque Converter Clutch (Lock-up Control) Solenoid Valve A: ON Torque Converter Clutch (Lock-up Control) Solenoid Valve B: OFF The PCM switches the solenoid valve A on to release the modulator pressure in the left cavity of the lock-up shift valve. The modulator pressure in the right cavity of the lock-up shift valve overcomes the spring force;...
Page 506 Description Lock-up System (cont'd) Half Lock-up Torque Converter Clutch (Lock-up Control) Solenoid Valve A: ON Torque Converter Clutch (Lock-up Control) Solenoid Valve B: ON The modulator pressure is released by the solenoid valve B, causing the modulator pressure in the left side of the lock-up control valve to lower.
Page 507 Full Lock-up Torque Converter Clutch (Lock-up Control) Solenoid Valve A: ON Torque Converter Clutch (Lock-up Control) Solenoid Valve B: ON When the vehicle speed further increases, throttle B pressure is increased in accordance with the throttle opening. Throttle B pressure (55) flows to the right side of the lock-up timing valve and the lock-up control valve, and they are moved to the left side.
Page 508 Description Lock-up System (cont'd) Deceleration Lock-up Torque Converter Clutch (Lock-up Control) Solenoid Valve A: ON Torque Converter Clutch (Lock-up Control) Solenoid Valve B: Duty Operation The PCM switches solenoid valve B on and off rapidly under certain conditions. The slight lock-up and half lock-up regions are maintained so as to lock the torque converter properly.
Page 509 Park Mechanism The park mechanism locks the transmission by engaging the park pawl with the park gear which is splined to the counter- shaft. Shifting to [3 position causes the park cone (installed at the end of the park rod) to press the park pawl onto the park gear. Even if the end of the park pawl rides on top of the park gear teeth, slight movement of the countershaft will cause the park pawl and the park gear to mesh with each other completely because the park cone receives tension from the park rod spring.
Page 510 PCM Terminal Voltage/Measuring Conditions A/T Control System The PCM terminal voltage and measuring conditions are shown for the connector terminals the A/T control system. The other PCM terminal voltage and measuring conditions are described in section PCM Terminal Locations PCM CONNECTOR B (16P) PCM CONNECTOR C (12P)
Page 511 PCM CONNECTOR D (22P) PCM CONNECTOR E (26P)
Page 512 PCM Terminal Voltage/Measuring Conditions A/T Control System (cont'd) PCM CONNECTOR E (26P) (cont'd)
Page 513 Component Locations POWERTRAIN CONTROL MODULE (PCM) SHIFT LOCK SOLENOID PARK PIN SWITCH COUNTERSHAFT SPEED SENSOR MAINSHAFT SPEED SENSOR TORQUE CONVERTER CLUTCH (LOCK-UP CONTROL) SHIFT SOLENOID SOLENOID VALVES A AND B VALVES A AND B (Located in transmission.) VEHICLE SPEED SENSOR (VSS) TRANSMISSION A/T CLUTCH PRESSURE RANGE SWITCH...
Page 514 Troubleshooting Procedures Checking the Diagnostic Trouble Code (DTC) with an OBD II Scan Tool or Honda PGM Tester When the PCM senses an abnormality in the input or output systems, the indicator light in the gauge assembly will blink. When the 16P Data Link Connector (DLC) (located behind the ashtray) is connected to the OBD II Scan Tool or Honda PGM Tester as shown, the scan tool or tester will indicate the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II).
Page 515 Checking the Diagnostic Trouble Code (DTC) with the Service Check Connector and Special Tool When the PCM senses an abnormality in the input or output systems, the indicator light in the gauge assembly will blink. When the Service Check Connector (located under the dash on the passenger side) is connected with the special tool as shown, the indicator light will blink the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II).
Page 516 Troubleshooting Procedures (cont'd) SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or service. 1. Remove the right door sill molding (see section 20). 2. Pull the carpet back to expose the PCM. 3.
Page 517 PCM Reset Procedure 1. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Turn the ignition switch OFF. 3. Remove the No. 56 BACK UP, RADIO fuse (7.5 A) from the under-hood fuse/relay box for 10 seconds to reset the PCM. NOTE: •...
Page 518 Symptom-to-Component Chart Electrical System 14-74 14-72 14-78 14-77 14-68 14-70 14-63 14-66 14-58 14-60 14-76 14-62 DTC*: The DTC in parentheses is the code the indicator light indicates when the service check connector is connected to the special tool (SCS service connector).
Page 519 If the self-diagnostic indicator light does not blink, perform an inspection according to the table below. 14-79 14-81 14-82 14-84...
Page 520 Symptom-to-Component Chart Electrical System Indicator DTC* Detection Item Page Light ('96 - 97 models) P0715 (15) Mainshaft speed sensor 14-74 Blinks ('98 - 04 models) P0720 (9) Blinks Countershaft speed sensor 14-72 P0730 (41) Shift control system 14-78 14-68 P0740 (40) Lock-up control system 14-77 P0753 (7)
Page 521 If the self-diagnostic indicator light does not blink, perform an inspection according to the table below. Symptom Inspection Ref. page indicator light does not come on for two seconds after ignition 14-79 switch is first turned on (II). indicator light is on constantly (not blinking) whenever the ignition 14-81 switch is on (II).
Page 522 Torque Converter Clutch (Lock-up Control) Solenoid Valves A and B Test If the resistance is out of specification, disconnect Disconnect the transmission sub-harness connector the 2P connector from the torque converter clutch (14P). solenoid valves A and B. TRANSMISSION SUB-HARNESS CONNECTOR (14P) Terminal side of male terminals...
Page 523: Replacement
Replacement NOTE: Torque converter clutch (lock-up control) solenoid valves A and B must be replaced as an assem- bly. Remove the mounting bolts and torque converter clutch solenoid valves A and B. TORQUE CONVERTER CLUTCH SOLENOID VALVES 6 x 1.0 mm A AND B 12 N-m (1.2 kgf-m, 8.7 Ibf-ft)
Page 524 Shift Solenoid Valves A and B Test Disconnect the transmission sub-harness connector Measure the resistance between the No. 1 terminal (14P). of the shift solenoid valve/A/T clutch pressure con- TRANSMISSION SUB-HARNESS trol solenoid valve harness connector and body CONNECTOR (14P) ground, and between the No.
Page 525: Solenoid Valve
A/T Clutch Pressure Control Solenoid Valve Test Disconnect the transmission sub-harness connector Measure the resistance between the No. 3 and No. 4 terminals of the shift solenoid valve/A/T clutch pres- (HP). sure control solenoid valve harness connector. TRANSMISSION SUB-HARNESS CONNECTOR (14P) STANDARD: 4.0 - 6.0 (at 70°F, 20°C) SHIFT SOLENOID VALVE/...
Page 526: Replacement
Mainshaft/Countershaft Speed Sensors Replacement Make sure lifts, jacks, and safety stands Remove the heat shields. are placed properly (see section 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) Pull the carpet back to expose the secondary heated oxygen sensor (secondary HO2S) connector. Discon- nect the connector, then push it out under the vehi- cle.
Page 527 10. Raise the transmission with a jack. 6. Lower the transmission. 7. Remove the 6 mm bolt from the transmission hous- 11. Install the transmission beam on the rear transmis- ing, and remove the mainshaft and countershaft sion mount bracket/mount, then tighten the four bolts loosely.
Page 528: Test
Transmission Range Switch (A/T Gear Position Switch) Test Make sure lifts, jacks, and safety stands are placed properly (see section 1. Raise the front of the vehicle, and support it with safety stands (see section 2. Set the parking brake, and block both rear wheels securely. 3.
Page 529: Replacement
Replacement Make sure lifts, jacks and safety stands are placed properly (see section 1. Raise the front of the vehicle, and support it with safety stands (see section 2. Set the parking brake, and block both rear wheels securely. 3. Shift the transmission to the position.
Page 530 Transmission Range Switch (A/T Gear Position Switch) Replacement (cont'd) 12. Set a new transmission range switch to the posi- 14. Install the transmission range switch on the control tion as shown. shaft, and loosely install the bolts. 6 x 1.0 mm BOLTS NOTE: The transmission range switch clicks in the Loosely install.
Page 531 18. Install the control lever. 21. Connect the transmission range switch harness connector, then clamp the harness clamp on the CAUTION: Take care not to bend the shift cable. brackets. 22. Turn the ignition switch ON (II). Move the shift lever 8 x 1.25 mm 16 N-m (1.6 kgf-m, 12 Ibf-ft) through all gears, and check the transmission range...
Page 532 A/T Gear Position Indicator Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or service. Remove the gauge assembly from the dashboard (see section 20), and disconnect the 30P and 22P connectors from the gauge assembly (see...
Page 533: Interlock System
Interlock System Key Interlock Solenoid Test Shift Lock Solenoid Test Remove the dashboard lower cover and knee bol- 1. Remove the center console (see section 20). ster (see section 20). Disconnect the shift lock solenoid 2P connector. Disconnect the 8P connector from the main wire harness.
Page 534 Interlock System Shift Lock Solenoid Replacement Remove the center console and shift lever knob (see Remove the two mounting bolts, then remove the section 20). shift lock solenoid. Disconnect the connectors from the shift lock sole- noid and park pin switch. 6 x 1.0 mm 8 N-m (0.8 kgf-m Remove the two locknuts and through bolts, then...
Page 535 Park Pin Switch Test/Replacement 1. Remove the center console (see section 20). Remove the screw, then remove the park pin switch from the base bracket. Disconnect the park pin switch 2P connector. SHIFT LEVER Push the shift lever to the right in the direction shown.
Page 536: Hydraulic System
Symptom-to-Component Chart Hydraulic System Before troubleshooting a problem in the hydraulic system, check the self-diagnosis indicator light indication. If the light indicates a trouble code, perform the electrical troubleshooting according to the Electrical System Symptom-to- Component Chart. If the indicator light does not indicate a trouble code and a failure is not found during electrical trou- bleshooting, perform hydraulic troubleshooting using the chart.
Page 538 Symptom-to-Component Chart Hydraulic System (cont'd)
Page 539 NOTES Flush the ATP cooler and cooler line (see page 14-195 and 14-196). Set idle rpm in gear to specified idle speed. If still no good, adjust motor mounts as outlined in engine section of service manual. If the large clutch piston O-ring is broken, inspect the piston groove for rough machining. If the clutch pack is seized or is excessively worn, inspect the other clutches for wear and check the orifice control valves and throttle valve for free movement.
Page 540 Road Test NOTE: Warm up the engine to normal operating temperature (the radiator fan comes on). 1. Apply parking brake and block the wheels. Start the engine, then shift to position while pressing the brake pedal. Press the accelerator pedal and release it suddenly. The engine should not stall. 2.
Page 541 Positions Upshift Downshift Lock-up NOTE: • Lock-up ON: Torque Converter Clutch (Lock-up control) solenoid valve B turns on. • Lock-up OFF: Torque Converter Clutch (Lock-up control) solenoid valve B turns off.
Page 542 Road Test (cont'd) 4. Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift from position to position. The vehi- cle should immediately begin slowing down from engine braking. CAUTION: Do not shift from position to position at speeds over 63 mph (100 km/h);...
Page 543 Stall Speed Test CAUTION: • To prevent transmission damage, do not test stall speed for more than 10 seconds at a time. • Do not shift the lever while raising the engine speed. • Be sure to remove the pressure gauge before testing stall speed. 1.
Page 544: Fluid Level
Fluid Level Checking/Changing Changing Checking Bring the transmission up to normal operating tem- NOTE: Check the fluid level with the engine at normal operating temperature (the radiator fan comes on). perature (the radiator fan comes on) by driving the vehicle. Park the vehicle on level ground, turn the Park the vehicle on level ground.
Page 545 Pressure Testing • While testing, be careful of the rotating front wheels. • Make sure lifts, jacks and safety stands are placed properly (see section CAUTION: • Before testing, be sure the transmission fluid is filled to the proper level. •...
Page 546 Pressure Testing (cont'd) 6. Disconnect the transmission sub-harness connector (14P). 7. Start the engine, and run it at 2,000 rpm. TRANSMISSION SUB-HARNESS CONNECTOR (14P) Terminal side of female terminals 8. Shift to the position, and measure line pressure at the fully opened throttle condition. 9.
Page 547 14. Shift to the respective shift lever position, and measure each clutch pressure. LINE PRESSURE 1ST CLUTCH PRESSURE INSPECTION HOLE INSPECTION HOLE REVERSE CLUTCH PRESSURE 4TH CLUTCH INSPECTION HOLE PRESSURE INSPECTION HOLE 3RD CLUTCH 1ST-HOLD CLUTCH PRESSURE PRESSURE INSPECTION HOLE INSPECTION HOLE THROTTLE B 2ND CLUTCH PRESSURE...
Page 548 Lower Valve Body Assembly Removal/Installation Make sure lifts, jacks and safety stands are 8. Remove the shift solenoid/A/T clutch pressure con- placed properly (see section trol solenoid valve harness connector stop. Raise the front of the vehicle, and support it with 6 x 1.0 mm CONNECTOR STOP safety stands (see...
Page 549 Disassembly/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Do not let the check balls fall out of the main valve body when removing the main valve body. •...
Page 550 Throttle Valve Body/A/T Clutch Pressure Control Solenoid Valve Test Replacement Connect the No. 4 (RED: +) terminal of the shift NOTE: Throttle valve body/A/T clutch pressure control solenoid valve/A/T clutch pressure control solenoid solenoid valve must be replaced as an assembly. valve harness connector to the battery positive ter- minal and the No.
Page 551 Shift Solenoid Valves A and B Test Replacement Measure the resistance between the No. 2 terminal NOTE: Shift solenoid valves A and B must be replaced of the shift solenoid valve/A/T clutch pressure con- as an assembly. trol solenoid valve harness connector and body ground, and between the No.
Page 552 Transmission Removal Make sure lifts are placed properly and 9. Pull the carpet back to expose the secondary heated hoist brackets are attached to the correct position on oxygen sensor (secondary HO2S) connector, then the engine (see section disconnect the connector, and push it out from inside of the vehicle.
Page 553 11. Remove the transmission stop collars, then remove 14. Remove the ATP cooler hoses at the ATP cooler the exhaust pipe A. lines. Turn the ends of the cooler hoses up to pre- vent ATP from flowing out, then plug the ATP cooler lines and hoses.
Page 554 Transmission Removal (cont'd) 22. Remove the shift cable guide bracket from the 20. Disconnect the transmission range switch connector, transmission beam. then remove the clamp from the harness bracket. CAUTION: Take care not to bend the shift cable. CLAMP SHIFT CABLE GUIDE TRANSMISSION REAR MOUNT...
Page 555 26. Remove the transmission housing mounting bolts. 31. Pull the transmission away from the engine until it clears the dowel pins, then lower it on the transmis- sion jack. TRANSMISSION HOUSING MOUNTING BOLT TRANSMISSION HOUSING MOUNTING BOLTS 27. Remove the engine stiffener. TRANSMISSION HOUSING DRIVE PLATE MOUNTING BOLT...
Page 556 Transmission Reassembly NOTE: • Coat all parts with ATF. • Replace the following parts: O-rings Lock washers - Gaskets Mainshaft and countershaft locknuts and conical disc springs Sealing washers...
Page 557 Install the torque converter housing separator plate 4. Install the accumulator body (seven bolts and eight special bolts). and three dowel pins on the torque converter hous- ing. 5. Install the two dowel pins on the accumulator body, Install the ATF pump drive gear, ATF pump driven then install the accumulator cover while pressing it gear, ATF driven gear shaft, torque converter check down (four bolts).
Page 558 Transmission Reassembly (cont'd) 20. Install the transmission housing mounting bolts with 17. Install the mainshaft sub-assembly and the counter- the transmission hanger, harness clamp bracket, shaft sub-assembly together in the torque converter housing. and speed sensor connector bracket, then tighten them in two or more steps in the sequence shown.
Page 559 4. Combine the mainshaft 2nd gear with the park gear, 28. Install the reverse clutch distance collar and a new countershaft conical spring washer on the counter- then install them on their respective shafts. shaft. COUNTERSHAFT MAINSHAFT NOTE: Install the conical spring washers in the MAINSHAFT PARK GEAR direction shown.
Page 560 Transmission Reassembly (cont'd) 33. Install the special tool onto the mainshaft as shown. 38. Install two dowel pins, four ATF feed pipes with new O-rings, and a new rear cover gasket on the trans- mission housing. 39. Install the rear cover, and engage the reverse gears MAINSHAFT HOLDER while rotating the mainshaft.
Page 561 47. Install the ATF pan with two dowel pins and a new 43. Assemble the lower valve body assembly (see page gasket (14 bolts). 14-113). 48. Install the ATF cooler lines with new sealing wash- 44. Pass the shift solenoid valve/A/T clutch pressure con- trol solenoid valve harness through the transmission ers, then tighten the line bolts.
Page 562 Transmission Installation Flush the ATF cooler (see pages 14-195 and 14-196). Attach the transmission to the engine, then install the transmission housing mounting bolt with the 26 mm shim. 2. Install the torque converter securely with a new O-ring on the mainshaft, and install two 14 x 20 mm dowel pins in the torque converter housing.
Page 563 Transmission Installation (cont'd) 12. Tighten the transmission beam outer bolts (four 10. Install the transmission housing mounting bolts from the transmission side. bolts). TRANSMISSION BEAM CENTER BOLTS 10 x 1.25 mm 38 N-m (3.9 kgf-m, 28 Ibf-ft) TRANSMISSION HOUSING MOUNTING BOLTS 12 x 1.25 mm 64 N-m (6.5 kgf-m, 47 Ibf-ft) TRANSMISSION...
Page 564 17. Connect the transmission range switch connector, 19. Install the extension shaft using the special tool as shown. then install the clamp to the harness bracket. NOTE: Push the extension shaft in the secondary driven gear shaft until the extension shaft stops. CLAMP EXTENSION SHAFT HARNESS...
Page 565 Transmission Installation (cont'd) 22. Shift the transmission to the position by rotating 24. Remove the steering gearbox mounting bolts, then install the lower plate. the control shaft. 23. Install the 36 mm sealing bolt. '96 - '99 models: STEERING GEARBOX Apply liquid gasket (P/N 08718 - 0001) to the 36 mm sealing bolt threads, then install and tighten the sealing bolt.
Page 566 26. Install the shift cable holder on the shift cable holder 31. Install the exhaust pipe A and the three way catalytic base. converter, then install the transmission stop collars. 27. Install the shift cable cover, and install the shift 10 x 1.25 mm solenoid valve/A/T clutch pressure control solenoid 33 N-m (3.4 kgf-m,...
Page 567 Transmission Installation (cont'd) 35. Install the transmission housing mounting bolts. TRANSMISSION 6 x 1.0 mm SUB-HARNESS 12 N-m (1.2 kgf-m, 6 x 1.0 mm CONNECTOR 8.7 Ibf-ft) 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) TRANSMISSION HOUSING MOUNTING BOLTS 12 x 1.25 mm 64 N-m (6.5 kgf-m, 47 Ibf-ft) 36.
Page 568 Cooler Flushing To prevent injury to face and eyes, always 7. With the water and air valves off, attach the water and wear safety glasses or a face shield when using the air supplies to the flusher. (Use hot water if available.) transmission flusher.
Page 569 Transmission Cooler Flushing (cont'd) 17. Make sure the transmission is in the position. Then fill the transmission with ATF, and run the engine for 30 seconds or until approximately 0.95 (1.0 US qt., 0.8 Imp qt.) is discharged. 18. Remove the drain hose, and reconnect the cooler return hose to the transmission (see next column).
Page 570 Illustrated Index Transmission Housing/Lower Valve Body...
Page 571 SHIFT SOLENOID VALVE A O-RING Replace. HARNESS CLAMP A/T CLUTCH PRESSURE CONTROL SOLENOID VALVE/THROTTLE VALVE BODY ASSEMBLY 1ST ACCUMULATOR COVER 2ND ACCUMULATOR COVER O-RING Replace. DOWEL PINS THROTTLE SEPARATOR PLATE SECONDARY VALVE BODY DOWEL PINS CHECK BALLS MAIN SEPARATOR PLATE MAIN VALVE BODY DOWEL PINS FILTER Replace.
Page 572 Illustrated Index Rear Cover...
Page 573 O-RINGS Replace. TRANSMISSION RANGE SWITCH HARNESS BRACKET O-RING Replace. THRUST WASHER, 29 mm REVERSE ACCUMULATOR PISTON THRUST NEEDLE BEARING O-RING Replace. MAINSHAFT 2ND GEAR REVERSE ACCUMULATOR SPRING NEEDLE BEARING THRUST NEEDLE BEARING O-RINGS Replace. REVERSE ACCUMULATOR SLEEVE MAINSHAFT 2ND GEAR COLLAR COUNTERSHAFT LOCKNUT, 24 x 1.25 mm SNAP RING THRUST WASHER, 14 x 30 mm...
Page 574 Illustrated Index Transmission Housing...
Page 575 SEALING RINGS, 42 mm SNAP RING THRUST WASHER SET RING Replace. TAPERED ROLLER BEARING THRUST NEEDLE BEARING SECONDARY DRIVEN GEAR SHAFT MAINSHAFT 1ST GEAR TAPERED ROLLER BEARING NEEDLE BEARINGS THRUST NEEDLE BEARING SECONDARY DRIVEN GEAR SHAFT OIL SEAL MAINSHAFT 1ST GEAR DISTANCE COLLAR Replace.
Page 576 Illustrated Index Torque Converter Housing/Valve Body...
Page 577 REGULATOR VALVE BODY O-RING Replace. STATOR SHAFT STOP SHAFT DOWEL PINS REGULATOR SEPARATOR PLATE FILTER Replace. ATP PUMP BODY ATF PUMP DRIVEN GEAR SHAFT ATF PUMP DRIVEN GEAR ATF PUMP DRIVE GEAR TORQUE CONVERTER CHECK VALVE TORQUE CONVERTER CHECK VALVE SPRING ATF FEED PIPE, 10 x 60 mm ATF FEED PIPES, 8 x 57.5 mm ATF FEED PIPES, 8 x 40 mm...
Page 578 Transmission Housing/Lower Valve Body Assembly Removal CONNECTOR STOP DOWEL PIN DOWEL PIN ATP PAN GASKET Replace. DOWEL O-RING Replace. HARNESS CONNECTOR DOWEL PIN ATP PAN LOWER VALVE BODY ASSEMBLY 6 x 1.0 mm 6 Bolts O-RING Replace. ATP STRAINER 6 x 1.0 mm 3 Bolts 6 x 1.0 mm 14 Bolts...
Page 579 NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • When removing the lower valve body assembly, replace the following: — O-rings — ATP pan gasket CAUTION: Do not turn over the transmission before removing the ATP pan.
Page 580 Rear Cover Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • When removing the rear cover, replace the following: — O-rings — Mainshaft and countershaft locknuts —...
Page 581 Remove the one bolt securing the ATP cooler lines 6. Engage the park pawl with the park gear. to the transmission housing and the line bolts, then remove the ATP cooler lines. 7. Cut the lock tabs of each shaft locknut using a chisel as shown, then remove the locknuts from each shaft.
Page 582 Transmission Housing Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • When removing the transmission housing, replace the following: — O-rings — Transmission housing gasket...
Page 583 Remove the mainshaft and countershaft speed sen- Remove the mainshaft sub-assembly and counter- sors from the transmission housing. shaft sub-assembly together. Remove the 16 bolts securing the transmission NOTE: Remove the shafts carefully to avoid dam- aging the regulator valve body. housing with the transmission hanger, harness clamp bracket, and speed sensor connector bracket.
Page 584 Torque Converter Housing/Valve Body Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • When removing the valve body from the torque converter housing, replace the O-ring.
Page 585 Remove the eight 6 mm bolts and one 8 mm bolt securing the regulator valve body, then remove the regulator valve body. Remove the Stator shaft, stop shaft, and regulator separator plate. Remove the three 6 mm bolts and two 8 mm bolts securing the ATP pump body, then remove the ATP pump body.
Page 586 Valve Body Repair Remove the #600 paper. Thoroughly wash the entire NOTE: This repair is only necessary if one or more of valve body in solvent, then dry it with compressed the valves in a valve body do not slide smoothly in their air.
Page 587 Valve Assembly NOTE: Coat all parts with ATP before assembly. • Set the spring in the valve, then install them in the valve body. Push the spring in with a screwdriver, then install the spring seat. • Install the valve, valve spring and cap in the valve body, and secure with the roller.
Page 588 Valve Caps Description • Caps with one projected tip and one flat end are • Caps with hollow ends are installed with the hollow installed with the flat end toward the inside of the end away from the inside of the valve body. valve body.
Page 589 Secondary Valve Body Disassembly/lnspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. • Blow out all passages. • Check all valves for free movement. If any fail to slide freely, see Valve Body Repair on page 14-136. •...
Page 590 Main Valve Body Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blow out all passages. Replace the valve body as an assembly if any parts are worn or damaged. Check all valves for free movement. If any fail to slide freely, see Valve Body Repair on page 14-136. Coat all parts with ATP during assembly.
Page 591 NOTE: Do not position the check ball in this hollow. CHECK BALLS CHECK BALLS CHECK BALLS CHOKE FILTERS SPRING SPECIFICATIONS Unit: mm (in)
Page 592 Regulator Valve Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. • Blow out all passages. • Replace the valve body as an assembly if any parts are worn or damaged. •...
Page 593 Accumulator Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. • Blow out all passages. • Check all pistons for free movement. If any fail to slide freely, see Valve Body Repair on page 14-136. •...
Page 594 ATP Pump Body Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blow out all passages. Replace the valve body as an assembly if any parts are worn or damaged. Check all valves for free movement. If any fail to slide freely, see Valve Body Repair on page 14-136. Coat all parts with ATP during assembly.
Page 595 ATP Pump Inspection Install the ATP pump gears and ATP pump driven Measure the side clearance of the ATF pump drive gear shaft in the ATP pump body. and driven gears. ATF Pump Gears Side (Radial) Clearance: NOTE: • Lubricate all parts with ATP during the inspec- Standard (New): ATF Pump Drive Gear tion.
Page 596 Reverse Accumulator/1st-hold Accumulator Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. • Blow out all passages. • Replace the O-rings. • Check all pistons for free movement. If any fail to slide freely, see Valve Body Repair on page 14-136. •...
Page 597 Accumulator Piston Removal Remove the snap ring. Remove the accumulator sleeve and spring. Wrap a shop towel around the accumulator piston, and apply air pressure to the fluid passage to remove the piston. • Do not place your fingers in front of piston. •...
Page 598 Rear Cover/Clutch Feed Pipes Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace the O-rings. • Coat all parts with ATF during assembly. SNAP RING SNAP RING FEED PIPE GUIDE O-RINGS...
Page 599 Rear Cover/Reverse Idler Gear Disassembly/lnspection/Reassembly NOTE: • Inspect the needle bearings for galling and rough movement. • Coat all parts with ATF before reassembly. 8 x 1.25 mm 26 N-m (2.7 kgf-m, 20 Ibf-ft) REVERSE IDLER GEAR SHAFT HOLDER DOWEL PIN REVERSE IDLER GEAR SHAFT REVERSE IDLER GEAR...
Page 600 Mainshaft Disassembly/Inspection/Reassembly NOTE: • Lubricate all parts with ATF during reassembly. • Inspect the thrust needle bearings and the needle bearings for galling and rough movement. • Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. Install the sealing ring with the mating faces as shown.
Page 601 Mainshaft 3rd Gear Removal Remove the mainshaft 3rd gear, 4th gear, and thrust washer, 43 x 74 mm from the mainshaft using the special tool and a press as shown. PRESS COLLAR MAINSHAFT 4TH GEAR ATTACHMENT, 45 x 55 mm I.D. 07MAD - PR90100 THRUST WASHER, 43 x 74 mm...
Page 602 Inspection NOTE: • Inspect and adjust the 43 x 74 mm thrust washer when disassembling the mainshaft assembly or replacing mainshaft 3rd gear and/or 1st/4th clutch assembly. • Lubricate all parts with ATF during assembly. Install mainshaft 3rd gear on the mainshaft using the special tool and a press as shown.
Page 603 Mainshaft Inspection (cont'd) Assemble the thrust needle bearing, needle bear- Remove the mainshaft bearing from the transmis- ing, and 4th gear, then install the 43 x 74 mm thrust sion housing (see page 14-178). washer using the special tool and a press as shown. Assemble the parts below on the mainshaft.
Page 604 Measure the clearance between the 1st/4th clutch 9. If the clearance is out of tolerance, remove the guide and 1st gear collar with a feeler gauge. 43 x 74 mm thrust washer, and measure its thick- ness. STANDARD: 0 - 0.08 mm (0 - 0.003 in) NOTE: If the 0.08 mm (0.003 in) feeler gauge can be NOTE: Take measurements in at least three places, inserted, perform this step.
Page 605 Mainshaft Sub-assembly NOTE: • Lubricate all parts with ATF during assembly. • Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. • Assemble the mainshaft sub-assembly when assem- bling the transmission. • Refer to page 14-151 and 14-152, when installing the 3rd gear, 4th gear, and 43 x 74 mm thrust washer.
Page 606 Countershaft Disassembly/lnspection/Reassembly NOTE: • Lubricate all parts with ATF during reassembly. • Inspect the thrust needle bearings and the needle bearings for galling and rough movement. • Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. •...
Page 607 Countershaft Inspection Clearance Measurements Torque the countershaft locknut to 29 N-m (3.0 kgf-m, 22 Ibf-ft). NOTE: Lubricate all parts with ATF during assembly. NOTE: Countershaft locknut has left-hand threads. Assemble the parts below on the countershaft. NOTE: Do not install the O-rings during inspection. Hold the 1st-hold clutch assembly against the park gear.
Page 608 If the clearance is out of tolerance, remove the 1st- 8. Measure 2nd gear axial clearance while pushing the hold clutch distance collar and measure its length. 1st gear towards the reverse clutch assembly. Select and install a new 1st-hold clutch distance col- NOTE: Take measurements in at least three places, lar, then recheck the clearance.
Page 609 Countershaft 2nd Gear Assembly Countershaft Ball Bearing Replacement Sub-assembly NOTE: Lubricate all parts with ATF during assembly. NOTE: • Lubricate all parts with ATF during assembly. Remove the one-way clutch hub and ball bearing • Before installing the O-rings, wrap the shaft splines from the countershaft 2nd gear using the special with tape to prevent damage to the O-rings.
Page 610 2nd Gear One-way Clutch Disassembly/lnspection/Reassembly Inspect the parts as follows: Separate the countershaft 2nd gear from the park gear by turning the park gear in the direction shown. PARK GEAR Inspect for wear and scoring. ONE-WAY CLUTCH Inspect for damage and faulty movement.
Page 611 1st Gear One-way Clutch Disassembly/lnspection/Reassembly Inspect the parts as follows: Remove the set plate from the countershaft 1st gear. COUNTERSHAFT Remove the one-way clutch by prying it up with the 2ND GEAR ASSEMBLY end of a screwdriver. ONE-WAY CLUTCH HUB COUNTERSHAFT 1ST GEAR Inspect for wear and scoring.
Page 612 Clutch Illustrated Index 1ST/4TH CLUTCH ASSEMBLY SNAP RING CLUTCH END PLATE CLUTCH DISCS Standard thickness: CLUTCH PLATES 1.94 mm (0.076 in) Standard thickness: 2.0 mm (0.079 in) O-RINGS Replace. CHECK VALVE 4TH CLUTCH PISTON RETURN SPRING SPRING RETAINER CLUTCH DISCS SNAP RING Standard thickness: 2.34 mm (0.092 in)
Page 613 Clutch Illustrated Index (cont'd) 2ND CLUTCH ASSEMBLY 3RD CLUTCH ASSEMBLY CLUTCH DRUM SNAP RING CLUTCH DISCS Standard thickness: 2.34 mm (0.092 in) O-RINGS CLUTCH END PLATE Replace. CLUTCH PLATES Standard thickness: 2.0 mm (0.079 in) CLUTCH PISTON CHECK VALVE DISC SPRING RETURN SPRING SPRING RETAINER SNAP RING...
Page 614 1ST-HOLD CLUTCH ASSEMBLY REVERSE CLUTCH ASSEMBLY SNAP RING SNAP RING CLUTCH END CLUTCH END PLATE PLATE CLUTCH DISCS Standard thickness: CLUTCH PLATES 1.94 mm (0.076 in) Standard thickness: 2.0 mm (0.079 in) CLUTCH PLATES Standard thickness: 2.0 mm (0.079 in) CLUTCH DISCS Standard thickness: SNAP RING...
Page 615 Clutch Disassembly Install the special tools as shown. Remove the snap ring, then remove the clutch end plate, clutch discs, and plates. 2nd, 3rd, 1st-hold, and reverse clutches: SCREWDRIVER CLUTCH SPRING COMPRESSOR SNAP RING ATTACHMENT 07LAE - PX40100 CLUTCH SPRING COMPRESSOR Remove the disc spring.
Page 616 CAUTION: If either end of the special tool is set over an Remove the snap ring. Then remove the special tools, area of the spring retainer which is unsupported by the spring retainer and return spring. return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.
Page 617 Clutch Reassembly Install the piston in the clutch drum by applying NOTE: pressure to the piston and rotate it to ensure proper • Clean all parts thoroughly in solvent or carburetor seating. cleaner, and dry them with compressed air. • Blow out all passages. NOTE: Lubricate the piston O-ring with ATF before •...
Page 618 Install the special tools as shown. CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsup- 2nd, 3rd, 1st-hold and reverse clutches: ported by the return spring, the retainer may be damaged.
Page 619 Clutch Reassembly (cont'd) 10. Soak the clutch discs thoroughly in ATF for a mini- Install the snap ring. mum of 30 minutes. 11. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with the flat side toward the disc.
Page 620 13. Measure the clearance between the clutch end plate PLATE NUMBER Thickness and top disc with a dial indicator. Zero the dial indi- cator with the clutch end plate lowered, and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.
Page 621 Secondary Driven Gear Shaft Oil Seal Replacement Components Remove the oil seal from the secondary driven gear SET RING shaft. Replace. OIL SEAL TAPERED ROLLER Replace. BEARING SECONDARY DRIVEN GEAR SHAFT SCREWDRIVER TAPERED ROLLER BEARING SECONDARY DRIVEN GEAR Install the oil seal into the secondary driven gear SHAFT OIL SEAL shaft using the special tools as shown.
Page 622 Tapered Roller Bearing Replacement NOTE: Install the bearings using the special tool and a press • The bearing and outer race should be replaced as a set. as shown. • If the bearing is replaced, inspect and adjust the bear- ing preload (see page 14-174).
Page 623 Secondary Driven Gear Shaft Tapered Roller Bearing Outer Race Replacement Install the thrust shim and outer race in the trans- NOTE: • Replace the bearing with a new one whenever the mission housing using the special tools as shown. outer race is to be replaced. •...
Page 624 Install the outer race in the torque converter hous- ing using the special tools as shown. NOTE: • Install the outer race squarely in the torque con- verter housing. • Check that there is no clearance between the outer race and torque converter housing. DRIVER 07749-0010000 BEARING DRIVER...
Page 625 Secondary Driven Gear Shaft Tapered Roller Bearing Preload Adjustment NOTE: If the transmission housing, torque converter Select the 1.98 mm (0.078 in) thrust shim from the middle of the table below. housing, secondary driven gear shaft, tapered roller bearing, outer race, thrust shim, or thrust washer were replaced, the bearing preload must be adjusted.
Page 626 Install the sealing bolt to the secondary driven gear Rotate the secondary driven gear shaft in both direc- tions to seat the bearing. shaft, and torque it to 20 N-m (2.0 kgf-m, 14 Ibf-ft). Measure the starting torque of the secondary driven 8 x 1.25 mm 33 N-m (3.4 kgf-m, 25 Ibf-ft) gear shaft with a torque wrench.
Page 627 Oil Seals Installation Removal Install the oil seal into the transmission housing Remove the oil seal from the transmission housing. using the special tool as shown. DRIVER 07749-0010000 SEAL DRIVER ATTACHMENT 07LAD-SM40100 10.5-11.5 mm (0.41 - 0.45 in) OIL SEAL TRANSMISSION Replace.
Page 628 Torque Converter Housing Bearings Mainshaft Bearing/Oil Seal Replacement Drive in the new mainshaft bearing until it bottoms Drive out or pull up the mainshaft bearing and oil seal in the housing using the special tools as shown. using the special tools as shown. DRIVER DRIVER 07749-0010000...
Page 629 Torque Converter Housing Transmission Housing Bearings Mainshaft Bearing Countershaft Bearing Replacement Replacement Remove the countershaft roller bearing using the To remove the mainshaft bearing from the trans- special tool as shown. mission housing, expand the snap ring with the snap ring pliers, then push the bearing out. NOTE: Do not remove the snap ring unless it's nec- essary to clean the groove in the housing.
Page 630 Park Mechanism Disassembly/lnspection/Reassembly 1. Remove the park pawl shaft sleeve, park pawl and park pawl spring. 2. Remove the transmission range switch (see page 14-180). 3. Remove the bolt securing the detent lever to the control shaft, then remove the control shaft. 4.
Page 631 Transmission Range Switch (A/T Gear Position Switch) Removal Shift the detent lever to the position. TRANSMISSION RANGE SWITCH DETENT LEVER LOCK WASHER Replace. LOCKNUT CONTROL SHAFT Pry the locktabs on the lock washer, then remove the locknut and lock washer. Remove the bolts securing the transmission range switch, then remove the transmission range switch.
Page 632 Transmission Range Switch (A/T Gear Position Switch) Installation Set the transmission range switch to the position as shown. NOTE: The transmission range switch clicks in the position. POSITION MARK TRANSMISSION RANGE SWITCH CONTROL SHAFT HOLE Shift the detent lever to the position.
Page 633 Install the transmission range switch on the control shaft, then install the bolts loosely. TRANSMISSION RANGE SWITCH CONTROL SHAFT 6 x 1.0 mm Tighten loosely. Install a new lock washer on the transmission range switch by aligning its projected tip with the posi- tion mark on the transmission range switch as shown.
Page 634 Torque Converter/Drive Plate/Ring Gear 8 x 1.25 mm 22 N-m (2.2 kgf-m, 16 Ibf-ft) DRIVE PLATE/RING GEAR WASHER TORQUE CONVERTER ASSEMBLY 12 x 1.0 mm 74 N-m (7.5 kgf-m, 54 Ibf-ft) Torque in a crisscross pattern O-RING Replace.
Page 635 ATF Cooler Hoses Connection Connect the ATF cooler hoses to the ATF cooler lines, then secure them with the clips as shown. 2-4 mm (0.1 - 0.2 in) RADIATOR TRANSMISSION 6 - 8 mm (0.2 - 0.3 in) ATF COOLER LINE ATF COOLER HOSE CLIP...
Page 636 Shift Lever Removal/Installation Shift the transmission into the [HI position. 2. Remove the center console (see section 20). Disconnect the shift lock solenoid and park pin switch connectors. Shift the transmission into the Q] position. Remove the self-locking nut and shift cable end collar, then remove the shift cable from the shift lever link. CAUTION: Take care not to bend the shift cable.
Page 637 Shift Lever Disassembly SHIFT LEVER KNOB A/T GEAR POSITION SHIFT LOCK PANEL RELEASE LEVER COLLAR RUBBER LEVER COVER LOCK PIN SHIFT LOCK STOP 6 x 1.0 mm LINK ADJUSTER 8 N-m (0.8 kgf-m, 6 Ibf-ft) LOCKNUT 7 N-m (0.7 kgf-m, 5 Ibf-ft ) BRACKET BASE SHIFT LOCK SOLENOID CONTROL SEAL...
Page 638 Link Adjustment Verify that the shift position is in the position on • Make sure lifts, jacks and safety stands are placed the transmission. properly (see section • Apply parking brake, and block rear wheels so vehi- SHIFT CABLE cle will not roll off stands and fall on you while work- ing under it.
Page 639 Shift Lever Link Adjustment (cont'd) 7. Check that the hole in the link adjuster is perfectly aligned with the hole in the link rod. LINK ADJUSTER LINK ROD Link adjuster Link adjuster Exact Too Short Alignment Too Long NOTE: There are two holes in the link adjuster. They are positioned 90°...
Page 640 Shift Cable Replacement • Make sure lifts, jacks, and safety stands are placed properly (see section THREE WAY • Apply the parking brake, and block the rear wheels so CATALYTIC 8 x 1.25mm CONVERTER the vehicle will not roll off the stands and fall on you 22 N-m (2.2 kgf-m, 10 x 1.25 mm while working under it.
Page 641 Shift Cable Replacement (cont'd) 13. Remove the shift cable cover mounting bolts. 11. Remove the shift cable bracket. CAUTION: Take care not to bend the shift cable. SHIFT CABLE LOCKNUT 6 x 1.0mm 29 N-m (3.0 kgf-m , 6 x 1.0mm 12 N-m (1.2 kgf-m , 22 Ibf-ft) 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft)
Page 642 Main Menu Differential Special Tools ..... . 15–2 Inspection ..... . 15–10 Backlash Inspection .
Page 643: Special Tools
Special Tools Ref. No. Tool Number Description Page Reference 07GAD-SD40101 Bearing Driver Attachment 15-17, 15-18 07HAA-SF10100 Locknut Socket, 36 x 41 mm 15-10, 11, 15-19, 15-21, 22 07LAC-PW50100 or Extension Shaft Puller 15-5 07LAC-PW50101 07LAD - PW50500 Pinion Cover Driver Attachment 15-21 07MAD-PR90100 Attachment, 45 x 55 mm I.D.
Page 644: Troubleshooting
Differential Troubleshooting NOTE: Most problems in the unit are to be diagnosed by identifying noises from the gears or bearings. Care should be taken during diagnosis not to confuse differential noises with those from other drivetrain components. [Noise symptoms will be most prominent] Symptom Probable Cause Remedy...
Page 645: Differential Oil
Maintenance Differential Oil NOTE: Check the differential oil with engine OFF, and Reinstall the oil filler plug with a new washer. the vehicle on level ground. Oil Capacity Remove the oil filler plug, then check the level and 1.05 (1.11 US qt, 0.92 Imp qt) at oil change condition of the oil.
Page 646: Differential Assembly
Differential Assembly Removal Remove the 36 mm sealing bolt and O-ring, then Make sure jacks and safety stands are placed properly, disconnect the extension shaft from the differential and hoist brackets are attached to correct positions on using the special tool. the engine.
Page 647 Differential Assembly Removal (cont'd) 10. Remove the lower plate, then reinstall the steering 12. Remove the air cleaner housing assembly. gearbox mounting bolts. AIR CLEANER HOUSING ASSEMBLY STEERING GEARBOX MOUNTING BOLTS 59 N-m (6.0 kgf-m, 4.3 Ibf-ft) LOWER PLATE 11. Disconnect the vehicle speed sensor (VSS) connec- 13.
Page 648 14. Disconnect the breather tube from the clamp, then 16. Attach the chain hoist to the engine (see section remove the right exhaust manifold cover. 17. Remove the right and left engine mount bracket nuts, then remove the right engine mount bracket. ENGINE MOUNT BRACKET NUT CLAMP...
Page 649 Differential Assembly Removal (cont'd) 19. Remove the mounting bolts and 26 mm shim, then remove the differential assembly. O-RING Replace. DIFFERENTIAL ASSEMBLY 26 mm SHIM...
Page 650 Illustrated Index OIL GUIDE PIPE 43 mm THRUST SHIM Selection, page 15-24 DIFFERENTIAL CASE DOWEL PINS 6 x 1.0 mm THRUST 12 N-m (1.2 kgf-m, WASHER 8.7 Ibf-ft) DRIVE PINION OIL SEAL Replace. TAPERED ROLLER BEARING THRUST THRUST WASHER WASHER PINION SPACER Replace.
Page 651: Inspection
Differential Assembly Inspection To establish a starting point before disassembly, inspect Measure the backlash of the ring gear on the differ- the following: ential carrier using the special tools as shown. After measuring, remove the dial gauge and turn the dif- Ring gear backlash ferential carrier one full turn, then remeasure the Total bearing preload...
Page 652 Use a dial-type torque wrench on the drive pinion to Gear tooth contact measure the drive pinion bearing preload (Tp). 8. Remove the differential case cover and differential carrier. Clean and paint the ring gear teeth lightly and Standard: 1.42 - 1.91 N-m evenly with Prussian Blue (on both sides of each (14.5 - 19.5 kgf-cm, 12.6 - 16.9 Ibf-in) tooth).
Page 653: Disassembly
Differential Assembly Disassembly Remove the bolts in a crisscross pattern, in several Remove the bearing outer race and the 79.5 mm steps, then remove the differential case cover. thrust shim(s) from the differential case cover by heat- ing the differential case cover to about 212°F (100°C). DIFFERENTIAL NOTE: CASE COVER...
Page 654 Remove the differential carrier from the differential Hold the drive pinion with a 1 1/4" (32 mm) hex bit and socket as shown. case. DIFFERENTIAL CARRIER DRIVE PINION 1 1/4" (32 mm) HEX BIT and SOCKET (Commercially available) Raise the locknut tab from the groove of the drive pinion, and remove the locknut, thrust washer and DIFFERENTIAL CASE pinion hub.
Page 655 Differential Assembly Disassembly (cont'd) 9. Remove the oil seal, then remove the thrust washer. 11. Remove the bearing outer races, thrust washers and Use a plastic hammer to carefully tap the drive pin- 79.5 mm thrust shims from the differential case by ion out of the tapered roller bearing, then remove heating the differential case to about 212°F (100°C).
Page 656 Differential Carrier Tapered Roller Bearing Replacement Backlash Inspection Remove the tapered roller bearings using the bear- Remove the tapered roller bearings (see tapered ing separator and a press as shown. roller bearing replacement). NOTE: Support the differential carrier with your Install the left driveshaft and the intermediate shaft hand so it does not fall and hit the ground when in the side gears.
Page 657 Differential Carrier Ring Gear Replacement Remove the bolts in a crisscross pattern, in several steps, and remove the ring gear. 11 x 1.0 mm 118 N-m (12.0 kgf-m, 87 Ibf-ft) DIFFERENTIAL CARRIER RING GEAR Install the ring gear by tightening the bolts in a crisscross pattern, in several steps.
Page 658: Reassembly
Differential Assembly Reassembly NOTE: If replacement is required, always replace the drive pinion and ring gear as a set. If the drive pinion and ring gear are replaced, check the height adjustment (see page 15-24). If replacement of one of the tapered roller bearings in the drive pinion and in the differential carrier is required, use the same make bearings and replace both bearings at the same time.
Page 659 Next install the inboard bearing outer race. Check the differential case bearing surface areas for burrs, and remove as needed. Position the inboard thrust washer into the differential case. Using the TAPERED BEARING RACE sides of the special tools stamped "A", install the INSTALLER A outboard bearing outer race as shown.
Page 660 Differential Assembly Reassembly (cont'd) Install the 79.5 mm thrust shim(s) and bearing outer Apply lubricant to the tapered roller bearing, then race using the special tools as shown. install it using the special tool while holding the drive pinion as shown. NOTE: Install the 79.5 mm thrust shim(s) that was removed.
Page 661 8. Hold the drive pinion with a 1 1/4" (32 mm) hex bit 12. Install the special tool as shown, then rotate the and socket as shown, then carefully tighten the pin- drive pinion in both directions so that the ring gear rotate one full turn in both directions.
Page 662 Differential Assembly Reassembly (cont'd) 15. Apply lubricant to the tapered roller bearing, then 17. Hold the drive pinion with a 1 1/4" (32 mm) hex bit install it using the special tool while holding the and socket as shown. drive pinion as shown. 1 1/4"...
Page 663: Drive Pinion
19. Clean the ring gear teeth, then paint them lightly and Standard: evenly with Prussian Blue (on both sides of each tooth). New differential carrier tapered roller bearing: Total bearing preload (from step 23) 20. Install the differential carrier into the differential -Tp (from step 18) case, and reinstall the differential case cover.
Page 664 Differential Assembly Reassembly (cont'd) 25. Hold the differential assembly using a bench vise 28. If the backlash is less than the standard, adjust the with soft jaws as shown. ring gear backlash (see page 15-25). Inspection 29. Remove the differential case cover, and check the hole tooth contact pattern (face and flank).
Page 665 34. Install the oil seal using the special tools as shown. 32. Install the differential carrier in the differential case. DIFFERENTIAL DRIVER ATTACHMENT DRIVER CARRIER 07965-SA00600 07749-0010000 OIL SEAL Replace. DIFFERENTIAL CASE PILOT, 32 x 50 mm 07MAD-PR90200 33. Install the differential case cover, and tighten the bolts in a crisscross pattern in several steps.
Page 666: Height Adjustment
Drive Pinion Height Adjustment NOTE: If the drive pinion and ring gear are replaced 43 mm THRUST SHIM (always as a set), the height has to be adjusted. Part Number Thickness Select the proper shim as follows: 1.64 mm (0.0646 in) 41410 -PSD -000 First, calculate the difference in size between the old 41411-P5D-000...
Page 667 Ring Gear Tooth Contact Ring Gear Backlash Adjustment Adjustment Correct Tooth Contact If the backlash exceeds the standard, correct by decreasing the shim thickness on one side and increasing the thickness of the other shim the same amount. NOTE: • The total thickness of both shims must still equal Toe Contact the total thickness of the original shims.
Page 668 Differential Assembly Installation NOTE: If the differential case is replaced, the 26 mm Install the two dowel pins on the differential assem- shim must be adjusted (see step 1). If the differential bly. case was not replaced, go to step 4. DOWEL PINS Install the differential assembly.
Page 669 9. Remove the chain hoist. Install the right engine mount. 10. Install the engine stop mount bracket bolts. RIGHT ENGINE 10 x 1.25 mm MOUNT 38 N-m (3.9 kgf-m, 28 Ibf-ft) ENGINE STOP MOUNTS 12 x 1.25 mm 10 x 1.25 mm 74 N-m (7.5 kgf-m, 38 N-m (3.9 kgf-m, 54 Ibf-ft)
Page 670 Differential Assembly Installation (cont'd) 12. Install the extension shaft using the special tool as 15. Install the right exhaust manifold cover, then install shown. the breather tube to the clamp. NOTE: Push the extension shaft in the secondary driven gear shaft until the extension shaft stops. SET RING CLAMP 8 x 1.25 mm...
Page 671 17. Install the air cleaner housing assembly. 19. Remove the steering gearbox mounting bolts, then install the lower plate and the steering gearbox 6 x 1.0 mm mounting bolts. 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) AIR CLEANER STEERING GEARBOX HOUSING ASSEMBLY MOUNTING BOLTS 59 N-m (6.0 kgf-m, 43 Ibf-ft)
Page 672 Differential Assembly Installation (cont'd) 22. Install the splash shield. SPLASH SHIELD 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) 23. Refill the differential with the recommended oil (see page 15-4).
Page 673 Driveshafts Special Tools ........16–2 Intermediate Shaft Driveshafts...
Page 674 Special Tools 07GAD - PH70201 or 16-20 07GAD - PH70200 07MAC - SL00100 16-4 07MAD - SP00100 16-21 07746 - 0010300 16-18 07746 - 0010400 16-20 16-20 07746 - 0030100 07749 - 0010000 16-18, 16-20, 16-21 07XAC - 001020A 16-7...
Page 675: Inspection
Driveshafts Inspection Boot Damage Check the boots on the driveshaft for cracks, damage, leaking grease, and loose boot bands. If any damage is found, replace the boot and boot bands. Loose Splines Turn the driveshaft by hand, and make sure the splines and joint are not excessively loose.
Page 676 Driveshafts Removal Loosen the wheel nuts slightly. Raise the front of the vehicle, and support it with safety stands in the proper locations (see section Remove the wheel nuts and front wheels. WHEEL NUT 12 x 1.5 mm SPINDLE NUT 24 x 1.5 mm FRONT WHEEL Replace.
Page 677 Driveshafts Removal (cont'd) 8. Remove the cotter pin from the lower arm ball joint 12. Pull the inboard joint, and remove the driveshaft castle nut, and remove the nut. from the differential case as an assembly. CAUTION: • Do not pull on the driveshaft; the inboard joint may come apart.
Page 678 Disassembly Inboard Joint Side: Crimping Type Carefully clamp the driveshaft in a vise with soft jaws, then remove the set ring from the inboard BOOT BAND joint. Replace. Remove the boot bands. Take care not to damage the boot. • If the boot band is a locking tab type, pry up the locking tabs with a screwdriver, and raise the end of the band.
Page 679 Disassembly (cont'd) Outboard Joint Side: 4. Mark the rollers and spider to identify the locations of the rollers on the spider, then remove the rollers. Lift up the three tabs with a screwdriver, then remove the boot bands. Take care not to damage BEARING REMOVER (Commercially available) the boot.
Page 680 Wipe off the grease to expose the driveshaft and 7. Remove the driveshaft from the vise. the outboard joint inner race. 8. Remove the stop ring from the driveshaft. Mark the driveshaft at the same position of the out- board joint end with paint. DRIVESHAFT DRIVESHAFT PAINT MARK...
Page 681 Driveshafts Reassembly Note these items during reassembly: • Clean the disassembled parts with solvent, and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent. • The '98 Canada model and all '99 - 01 models use a TPE (Thermoplastic Polyester Elastomer) outboard joint boot. Use the ear clamp type boot band in the outboard joint boot set.
Page 682 Inboard Joint Side: Fit the rollers onto the spider. Wrap the splines with vinyl tape to prevent damage NOTE: to the inboard boot and dynamic damper. • Reinstall the rollers in their original positions on the spider by aligning the marks. •...
Page 683 Driveshafts Reassembly (cont'd) 9. Set the double loop band onto the boot with the Fit the inboard joint onto the driveshaft. band end toward the front of the vehicle. NOTE: • Reinstall the inboard joint onto the driveshaft by aligning the marks on the inboard joint with the marks on the rollers.
Page 684 12. Thread the free end of the band through the nose 15. Unwind the boot band tool, and cut off the excess section of the commercially available boot band free end of the band to leave a 5 - 10 mm (0.2 - 0.4 tool KD-3191 or equivalent, and into the slot on the in) tail protruding from the clip.
Page 685 Driveshafts Reassembly (cont'd) Outboard Joint Side: Insert the driveshaft into the outboard joint until the stop ring is close on the joint. Wrap the splines with vinyl tape to prevent damage to the boot. DRIVESHAFT OUTBOARD JOINT TPE TYPE: OUTBOARD BOOT STOP RING VINYL TAPE BOOT BAND...
Page 686 Check the alignment of the paint mark with the out- 8. Fit the boot ends onto the driveshaft and outboard board joint end. joint. OUTBOARD BOOT (TPE) DRIVESHAFT PAINT MARK OUTBOARD JOINT END OUTBOARD BOOT DRIVESHAFT OUTBOARD BOOT OUTBOARD JOINT Pack the outboard joint with the joint grease included 9.
Page 687 Driveshafts Reassembly (cont'd) 11. Close the ear portion of the band with a commercially 13. Fit the boot ends onto the driveshaft and the available boot band pincers Kent-Moore J-35910 or outboard joint. equivalent. BOOT BAND PINCERS Kent-Moore J-35910 or equivalent 14.
Page 688 17. Thread the free end of the band through the nose 20. Unwind the boot band tool, and cut off the excess section of the commercially available boot band free end of the band to leave a 5 - 10 mm (0.2 - 0.4 tool KD-3191 or equivalent, and into the slot on the in) tail protruding from the clip.
Page 689 Driveshafts Installation Install the outboard joint into the knuckle. Insert the inboard end of the driveshaft into the dif- ferential or intermediate shaft until the set ring locks in the groove. NOTE: Clean the areas where the driveshaft con- KNUCKLE tacts the differential thoroughly with solvent or car- buretor cleaner, and dry with compressed air.
Page 690 6. Install the damper fork over the driveshaft and onto the lower arm. Install the damper in the damper fork so the aligning tab is aligned with the slot in the damper fork. ALIGNING TAB DAMPER FORK FLANGE BOLT 10 x 1.25 mm 43 N-m (4.4 kgf-m, 32 Ibf-ft) SELF-LOCKING NUT 12 x 1.25 mm...
Page 691: Intermediate Shaft
Intermediate Shaft Removal 1. Drain the differential oil (see section 15). Remove the left driveshaft (see page 16-3). Remove the three flange bolts. FLANGE BOLT 8 x 1.25 mm Remove the intermediate shaft from the differential. INTERMEDIATE SHAFT...
Page 692: Disassembly
Intermediate Shaft Disassembly NOTE: The bearing support is made of aluminum. Be Press the intermediate shaft out of the shaft bearing careful not to damage it when servicing. using a press as shown. Remove the set ring. Press SET RING Replace.
Page 693 Remove the intermediate shaft inner seal from the bearing support. INNER SEAL Replace. BEARING SUPPORT Check for damage. O-RING Replace. Remove the O-ring.
Page 694: Reassembly
Reassembly CAUTION: • The bearing support is made of aluminum. Be careful not to damage it when servicing. • Do not damage the lip on the inner and outer seals during installation. NOTE: Clean the disassembled parts with solvent, and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent.
Page 695 Intermediate Shaft Reassembly (cont'd) Press the intermediate shaft inner seal into the Seat the internal snap ring into the groove of the bearing support using the special tools and a press bearing support. as shown. Press BEARING SUPPORT HANDLE DRIVER 07749-0010000 INTERNAL SNAP RING BEARING...
Page 696 Seat the external snap ring into the groove of the intermediate shaft. INTERMEDIATE SHAFT EXTERNAL SNAP RING Press the outer seal into the bearing support using the special tools and a press as shown. NOTE: Drive in the outer seal until it is 7.0 mm (0.28 in) from the end of the bearing support.
Page 697: Installation
Installation Insert the intermediate shaft into the differential with "LOWER" mark facing down. NOTE: Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent or carburetor cleaner, and dry with compressed air. INTERMEDIATE SHAFT MARK Install the three flange bolts, then tighten them. FLANGE BOLT 8 x 1.25 mm 22 N-m (2.2 kgf-m, 16lbf-ft)
Page 698 Main Menu Steering *: Read SRS precautions before working in this area Special Tools ..... . 17–2 Linkage and Gearbox .
Page 699: Special Tools
Special Tools 17-38 17-43 17-17 17-17 17-15 17-44 17-45 17-30 17-34, 17-46 17-42 17-43 17-35 17-17 17-13 17-26, 17-30 17-41,17-42, 17-44 17-28 17-41, 17-42, 17-44 17-53...
Page 700 Component Locations Index NOTE: • If an intact airbag assembly has been removed from a scrapped vehicle or has been found defective or damaged dur- ing transit, storage or service, it should be deployed (see section 24). • Before removing the gearbox, remove the driver's airbag assembly and steering wheel. •...
Page 701: General Troubleshooting
Troubleshooting General Troubleshooting Check the following before you begin: Has the suspension been modified in a way that would affect steering? Are tire sizes, tire variety and air pressure correct? Is the steering wheel original equipment or equivalent? Is the power steering pump belt properly adjusted? Is steering fluid reservoir filled to proper level? Is the engine idle speed correct and steady? Hard Steering (Check the power assist (see page 17-12).
Page 702 From page 17-4 Check force required to turn the wheel (see page 17-12). Start the engine and measure force required to turn the wheel to the right and left. Difference of the force required to turn the wheel to the right and to the left should be 2.9 N (0.3 kgf, 0.7 Ibf) or less.
Page 703 Troubleshooting General Troubleshooting (cont'd) If the problem is not corrected by Assist (excessively light steering) at Check the rack guide for proper adjusting the rack guide, adjust high speed. adjustment (see page 17-16). the front wheel alignment (see section 18). Shock or vibration when wheel is Check the rack guide for proper Rack guide was backed off exces-...
Page 704 Adjust rack guide (see page 17-16). If the problem is not corrected by adjusting the rack guide, replace the gearbox. Adjust belt tension. Replace the belt, if necessary (see page 17-15). If the engine stalls when the wheel is turned while the vehicle is stopped or moving at low speed, adjust idle speed (see section...
Page 705: Noise And Vibration
Troubleshooting Noise and Vibration NOTE: Pump noise in first 2 - 3 minutes after starting in cold weather is normal. Check the rack guide for proper adjustment (see page 17-16). CAUTION: When inspecting, do not hold the steering wheel all the way to the right or the left.
Page 706 If pump noise is abnormally loud, remove and inspect the pump for wear and damage (see page 17-25).
Page 707: Fluid Leaks
Troubleshooting Fluid Leaks Check the gearbox assembly for oil leaks carefully. Oil can leak out of various points, depending on location of the faulty oil seals/seal rings. Check the following before removing the gearbox from the frame.
Page 708 Replace front seal (see page 17-25). Replace the leaking or seal (see page 17-25). If the housing still leaks, replace the pump.
Page 709: Inspection And Adjustment
Inspection and Adjustment Power Assist Check with Vehicle Steering Operation Parked Place the front wheels in the straight ahead position, and measure the distance the steering wheel can be 1. Check the power steering fluid level (see page 17-16) turned without moving the front wheels. and pump belt tension (see page 17-15).
Page 710: Power Steering Speed Sensor Replacement
Assist Check at Road Speed Power Steering Speed Sensor Replacement Assist (excessively light steering) at high speed: Disconnect the VSS connector from the power steer- Check the power steering fluid level (see page 17-16), ing speed sensor. and pump belt tension (see page 17-15). Remove the sensor mounting bolt, then remove the Start the engine, allow it to idle, and turn the steering power steering speed sensor from the differential...
Page 711 Inspection and Adjustment Steering Linkage and Gearbox...
Page 712: Pump Belt
Pump Belt Adjustment NOTE: When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the deflection or tension to the values for the used belt Remove the air cleaner (ACL). after running engine for 5 minutes.
Page 713: Rack Guide Adjustment
Inspection and Adjustment Rack Guide Adjustment Fluid Replacement NOTE: Perform rack guide adjustment with the wheels Check the reservoir at regular intervals, and add the rec- in the straight ahead position. ommended fluid as necessary. Loosen the rack guide screw locknut with the spe- CAUTION: Always use Genuine Honda Power Steering Fluid-V or S.
Page 714: Pump Pressure Check
Pump Pressure Check Check the fluid pressure as follows to determine 7. Start the engine and let it idle. whether the trouble is in the pump or gearbox. 8. Turn the steering wheel from lock-to-lock several NOTE: First check the power steering fluid level and times to warm the fluid to operating temperature.
Page 715: Steering Wheel
Steering Wheel Removal Installation SRS components are located in this area. Review the CAUTION: Do not tap on the steering wheel or steering SRS component locations, precautions, and procedures column shaft when installing the steering wheel. in the SRS (section 24) before performing repairs or ser- vice.
Page 716: Disassembly/Reassembly
Disassembly/Reassembly '96 - 98 models: HORN SWITCH Test, see section 23 RADIO REMOTE SWITCH Test, see section 23 CRUISE CONTROL SET/RESUME/CANCEL SWITCH Test, see section 23 RADIO REMOTE SWITCH Test, see section 23 CRUISE CONTROL SET/RESUME/CANCEL SWITCH Test, see section 23...
Page 717: Steering Column
Steering Column Removal/Installation SRS components are located in this area. Review the 3. Remove the column covers. SRS component locations, precautions, and procedures Remove the combination switch assembly from the in the SRS (section 24) before performing repairs or ser- steering column shaft by disconnecting the connec- tors and removing the screws.
Page 718 NOTE: STEERING JOINT BOLTS • Make sure the steering joint is connected as follows: 22 N-m (2.2 kgf-m, 16 Ibf-ft) STEERING JOINT a. Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole with the flat on the shaft), and loosely install the upper joint bolt, b.
Page 719: Inspection
Inspection • For tilt/extend-retract motors and sensors inspection, refer to the Driving Position Memory System (DPMS) in the section • Check the steering column bail bearing and the steering joint bearings for play and proper movement. If there is noisy or if there is excessive play, replace the steering column as an assembly.
Page 720: Steering Lock Replacement
Steering Column Steering Lock Replacement 1. Remove the steering column (see page 17-20). 7. Insert the ignition key into the new steering lock body, and turn it to "ACC (I)" position. File a notch into the shear bolt head. 8. Push the lock pin down, and insert the steering lock body into the steering column until it clicks into place.
Page 721: Power Steering Hoses, Lines Fluid Leakage Inspection
Power Steering Hoses, Lines Fluid Leakage Inspection HOSES and LINES • Inspect hoses for damage, leaks, interference and twisting. • Inspect fluid lines for damage, rusting and leakage. • Inspect for leaks at hose and line joints and connec- tions. Replacement NOTE: CAUTION: Check all clamps for deterioration or defor-...
Page 722: Power Steering Pump
Power Steering Pump Removal/Installation NOTE: Before disconnecting the hoses from the pump, 5. Connect the inlet and outlet hoses. Tighten the pump fittings securely. place a suitable container under the vehicle. 1. Remove the air cleaner (ACL) and intake air duct. 6.
Page 723: Disassembly
Disassembly CAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly. NOTE: • Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol- vent.
Page 724 Power Steering Pump Disassembly (cont'd) Drain the fluid from the pump. Hold the steering pump in a vise with soft jaws, hold the pulley with the special tool, and remove the pulley nut and pulley. CAUTION: Be careful not to damage the pump hous- ing with the jaws of the vise.
Page 725: Inspection
Power Steering Pump Inspection Flow Control Valve: Check the flow control valve for wear, burrs, and other damage to the edges of the grooves in the valve. Inspect the bore and the flow control valve for scratches and wear. Slip the valve back in the pump, and check that it moves in and out smoothly.
Page 726 Submerge the valve in a container of power steering Ball Bearing Inspection/Replacement: fluid or solvent, and blow in the hose. If air bubbles leak through the valve at less than 98 kPa Inspect the ball bearing by rotating the outer race (1.0 kgf/cm ,14.2 psi), repair it as follows.
Page 727: Reassembly
Power Steering Pump Reassembly Install the new pump seal in the pump housing by Set the pump cam ring over the two rollers with the hand, then install the pump seal spacer. " ° " mark on the cam ring downward. NOTE: Insert the pump seal with its grooved side facing in.
Page 728 9. Coat the O-ring with power steering fluid, and 13. Coat the flow control valve with power steering fluid. install it into the grooves in the side plate. 14. Install the flow control valve and spring on the pump housing. 15.
Page 729 Power Steering Pump Reassembly (cont'd) 19. Install the pulley as shown below, then loosely install the pulley nut. Hold the steering pump in a vise with soft jaws. CAUTION: Be careful not to damage the pump hous- ing with the jaws of the vise. 20.
Page 730: Power Steering Gearbox
Power Steering Gearbox Removal NOTE: Using solvent and a brush, wash any oil and dirt off the valve body unit its lines, and the end if the gear- box. Blow dry with compressed air. Drain the power steering fluid as described on page 17-16.
Page 731 10. Disconnect the feed line from the valve body unit Remove the steering joint bolts, then disconnect the upper side. steering joint by moving the joint toward the column. CAUTION: After disconnecting the feed line, plug or seal the line fitting with a piece of tape or equivalent to prevent foreign materials from entering the valve body unit.
Page 732 Power Steering Gearbox Removal (cont'd) 12. Disconnect the three lines (sensor inlet line, 10 mm return line and 6 mm return line) from the hoses. CAUTION: After disconnecting the line, plug or seal the line with a piece of tape or equivalent. 13.
Page 733: Disassembly
Power Steering Gearbox Disassembly Steering Rack Disassembly NOTE: • Before disassembling the gearbox, wash it off with solvent and a brush. • Do not dip seals and 0-rings in solvent. Remove the steering gearbox (see page 17-30). Remove the both tie-rod ends. Remove the three lines (sensor inlet line, 10 mm return line and 6 mm return line) from the valve body unit.
Page 734 Remove the boot bands and tie-rod clips. Pull the 7. Loosen the locknut, then remove the rack guide boots away from the ends of the gearbox. screw and O-ring ('96 - 98 models only). 8. Remove the spring and rack guide from the gearbox housing.
Page 735 Power Steering Gearbox Disassembly (cont'd) 11. Remove the two flange bolts, then remove the valve 13. Install the special tool on the gearbox housing. body unit from the gearbox (see page 17-36 for valve body unit disassembly). CAUTION: Do not clamp the cylinder housing. 14.
Page 736 18. Remove the cylinder end seal from the steering 20. Insert a 24" long 3/8" drive extension into the cylin- rack. der and the special tool from the gearbox side. CAUTION: Be careful not to damage the inside sur- face of the cylinder wall with the tools. 21.
Page 737 Power Steering Gearbox Disassembly (cont'd) Valve Body Unit Disassembly 22. Check the rubber stop for damage or deterioration; if OK, go on step 23; if not, replace the rubber stop as shown below: Valve body unit: Remove the rubber stop by prying it out of the gear- box housing with a flat tip screwdriver.
Page 738 27. Check the inner wall of the valve housing where the 29. Remove the snap ring and pinion shaft sleeve from seal ring slides with your finger. If there is a step in the pinion shaft. the wall, the valve housing is worn. Replace the valve housing.
Page 739 Power Steering Gearbox Disassembly (cont'd) 31. Using a cutter or an equivalent tool, cut the valve 33. Press the valve oil seal and roller bearing out of the seal ring and O-ring at the groove the pinion shaft. valve housing using a hydraulic press and the spe- Remove the valve seal ring and O-ring.
Page 740 36. Remove the pressure control valve, assist control Pressure Control Valve: valve and springs from the valve body. • Inspect its surface for scoring and scratches. • Slip it back into the valve body unit, and make sure it slides smoothly without drag or side play. 37.
Page 741: Reassembly
Power Steering Gearbox Reassembly NOTE: • Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol- vent. • Always replace the O-rings and rubber seals with new ones before assembly. •...
Page 742 Valve Body Unit Reassembly Coat the cap seal with power steering fluid, and install the it in the groove of the cap. Assist control valve unit: Install the cap on the valve body. Coat the housing seal with power steering fluid, and install it in the groove of the valve housing.
Page 743 Power Steering Gearbox Reassembly (cont'd) 12. Apply vinyl tape to the splines and stepped portion 7. Press the new roller bearing into the valve housing using a hydraulic press and the special tools as shown. of the shaft, and coat the surface of the vinyl tape with the power steering fluid.
Page 744 23. Apply power steering fluid to the seal rings on the 20. Apply power steering fluid to the surface of the pin- ion shaft. Assemble the sleeve over the pinion shaft sleeve, and to the entire inside surface of the spe- by aligning the locating pin on the inside of the cial tool.
Page 745 Power Steering Gearbox Reassembly (cont'd) Steering Rack Installation 29. Press the pinion shaft/sleeve into the valve housing using a hydraulic press as shown. 31. If the rubber stop was removed, position the new rubber stop in the gearbox housing, then press it in using a hydraulic press and the special tools as shown.
Page 746 35. Coat the piston seal ring and the inside of the special 39. Coat the inside surface of the new cylinder end seal tool with power steering fluid. with power steering fluid. PISTON SEAL RING SIZING TOOL 07LAG-SM40200 07LAG-SM4020A 36. Carefully slide the tool onto the rack and over the piston seal ring.
Page 747 Power Steering Gearbox Reassembly (cont'd) 43. Grease the steering rack teeth, then insert the steer- 46. Wrap vinyl tape around the rack end edges, and ing rack into the gearbox housing. coat the surface of the tape with the power steering fluid.
Page 748 51. Coat the inside surface of the cylinder end with 54. Select the 44 mm shim(s) ('96 - 98 models only). power steering fluid, then install the cylinder end by screwing it into the gearbox housing. NOTE: Only reinstall the original 44 mm shim(s) when the steering gearbox is reassembled without replacing 52.
Page 749 Power Steering Gearbox Reassembly (cont'd) Determine the required thickness of the 44 mm 60. Install cylinder lines A and B. shims by subtracting the clearance obtained in the step - "C" from the total thickness of the four shims. NOTE: (Total thickness of the four shims) - (Clearance) = •...
Page 750 65. Install the new lock washer in the groove in the 69. Apply steering grease to the circumference of the rack end housing. steering rack. 66. Install the steering rack ends into the rack. 67. Hold the steering rack with a wrench ('99 - 01 mod- els: left end only), and tighten the rack ends with another wrench.
Page 751 Power Steering Gearbox Reassembly (cont'd) 72. Install the new boot bands on the boots as shown. 76. Install the three lines (6 mm return line, 10 mm return line and sensor inlet line) to the valve body unit as shown. 77.
Page 752: Installation
Installation CAUTION: Be careful not to bend or damage cylinder Position the line mounting cushions by aligning the lines A and B or the four fluid lines when installing the marks on the 10 mm return line (large diameter gearbox. line).
Page 753 Power Steering Gearbox Installation (cont'd) Reconnect the three lines (sensor inlet line, 10 mm 9. Install the steering joint, and reconnect the steering return line and 6 mm return line) to the hoses. shaft and pinion shaft. NOTE: NOTE: Make sure the steering joint is connected as •...
Page 754 11. Reconnect the tie-rod ends to the steering knuckles, tighten the castle nut ('96 - 98 models) or hex nut ('99 - 01 models) to the specified torque, and install new cotter pins. NOTE: Before connecting the tie-rod ends, wipe off any grease contamination from the ball joint tapered section and threads.
Page 755: Ball Joint Boot Replacement
Ball Joint Boot Replacement CAUTION: Do not contaminate the boot installation sec- tion with grease. Remove the boot from the tie-rod end, and wipe the old grease off the ball pin. 2. Pack the lower area of the ball pin with fresh grease. Pack the interior of the new boot and lip with fresh grease.
Page 756 Suspension Special Tools ..... . . 18–2 Front Suspension Rear Suspension Component Location Index ..18–3 Knuckle/Hub Replacement .
Page 757: Special Tools
Special Tools Ref. No. Tool Number Description Page Reference 07GAD-SD40101 Driver Attachment, 78 x 90 mm 18-13 07GAF-SE00100 Hub Dis/AssemblyTool 18-12 07GAF - SD40700 Hub Dis/Assembly Base 18-12 07GAG - SD40700 Ball Joint Boot Clip Guide 18-14, 18-23 07 MAC-S LO0100 Ball Joint Remover, 32 mm 18-11 07MAC - SL00200...
Page 758 Component Locations Index Front Suspension Wheel Alignment, page 18-4 FRONT DAMPER • Removal, page 18-17 • Disassembly/Inspection, page 18-17 • Reassembly, page 18-18 • Installation, page 18-18 UPPER ARM • Removal/Inspection, page 18-15 • Installation, page 18-16 KNUCKLE/HUB • Replacement, page 18-8 •Wheel Bearing Replacement, page 18-11...
Page 759: Wheel Alignment
Wheel Alignment Caster Camber Inspection NOTE: For proper inspection/adjustment of the wheel alignment, check and adjust the following before check- ing the alignment: NOTE: Use commercially-available computerized four wheel alignment equipment to measure wheel align- Check that the suspension is not modified. ment (caster, camber, toe, and/or turning angle).
Page 760: Front Toe Inspection/Adjustment
Rear Toe Inspection/Adjustment Front Toe Inspection/Adjustment NOTE: Use commercially-available computerized four NOTE: Use commercially-available computerized four wheel alignment equipment to measure wheel align- wheel alignment equipment to measure wheel align- ment (caster, camber, toe, and/or turning angle). ment (caster, camber, toe and/or turning angle). Follow Follow the equipment manufacturer's instructions.
Page 761: Turning Angle Inspection
Wheel/Hub Inspection Wheel Alignment Turning Angle Inspection Bearing End Play NOTE: Use commercially-available computerized four Raise the vehicle off the ground, and support it with safety stands in the proper locations (see section wheel alignment equipment to measure wheel align- ment (caster, camber, toe, and/or turning angle).
Page 762: Wheel Runout
Wheel Runout Raise the vehicle off the ground, and support it with safety stands in the proper locations (see section Check for bent or deformed wheels. Attach the dial gauge as shown. Axial Runout Standard: Aluminum Wheel: 0 - 0.7 mm (0 - 0.03 in) Service Limit: 2.0 mm (0.08 in) Radial Runout...
Page 763: Front Suspension
Front Suspension Knuckle/Hub Replacement NOTE: • Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damage aluminum wheels. • Before installing the wheel, clean the mating surface of the brake disc and inside of the wheel. KNUCKLE CASTLE NUT 10 x 1.25 mm...
Page 764 Remove the wheel sensor from the knuckle. Loosen the wheel nuts slightly. NOTE: Do not disconnect the wheel sensor connec- Raise the front of the vehicle, and support it with tor. safety stands in the proper locations (see section 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) Remove the wheel nuts and front wheel.
Page 765 Front Suspension Knuckle/Hub Replacement (cont'd) 8. Remove the 6 mm brake disc retaining screws. 14. Install the special tool as shown. Insert the jaws carefully, making sure you do not damage the ball 9.8 N-m joint boot. Adjust the jaw spacing by turning the (1.0 kgf-m, 7.2 Ibf-ft) pressure bolt.
Page 766 18. Remove the cotter pin and lower arm ball joint nut. 24. Pull the knuckle outward, and remove the driveshaft outboard joint from the knuckle by tapping the driveshaft end with a plastic hammer, then remove the knuckle. CASTLE NUT 69 - 78 N-m (7.0 - 8.0 kgf-m, KNUCKLE...
Page 767 Front Suspension Knuckle/Hub Replacement (cont'd) 27. Remove the splash guard. 29. Press the wheel bearing out of the knuckle using the special tools and a press. ATTACHMENT, DRIVER 72 x 75 mm Press 07749-0010000 07746-0010600 SPLASH GUARD 6 mm SCREW WHEEL BEARING HUB DIS/ASSEMBLY BASE...
Page 768 NOTE: Wash the knuckle and hub thoroughly in 33. Install the splash guard, and tighten the screws. high flash point solvent before reassembly. 6 mm SCREW 4.9 N-m (0.5 kgf-m, 4 Ibf-ft) 31. Press a new wheel bearing into the knuckle using the old bearing, plate and a press.
Page 769: Ball Joint Boot Replacement
Front Suspension Ball Joint Boot Replacement Install the upper and lower ball joint boot set rings 1. Remove the set ring and the boot using the special tools as follows: CAUTION: Do not contaminate the boot installation section with grease. Adjust the special tool with the adjusting bolt until the end of the tool aligns with the groove on the Pack the interior of the boot and lip with grease.
Page 770: Suspension Arms Removal/Inspection
Suspension Arms Removal/Inspection CAUTION: • Replace the self-locking nuts after removal. • Be careful not to damage the ball joint boot. STABILIZER END UPPER ARM ASSEMBLY RUBBER BUSHING Check for damage. Check for deterioration and damage. BALL JOINT Inspect for faulty movement and wear.
Page 771 Front Suspension Suspension Arms Installation NOTE: • Wipe off the grease before tightening the nut at the ball joint. • The right and left damper forks are not symmetrical. The left damper fork is marked with "Z5L" while the right damper fork is marked with "Z5R".
Page 772: Front Damper
Front Damper Removal Disassembly/Inspection Disassembly Remove the brake hose clamps from the damper. BRAKE HOSE Compress the damper spring with the spring com- CLAMPS pressor according to the manufacturer's instructions, then remove the self-locking nut. CAUTION: Do not compress the spring more than necessary to remove the nut.
Page 773: Reassembly
Front Damper Installation Reassembly Install the damper unit on a spring compressor. Loosely install the damper on the frame with the aligning tab facing inside, then loosely install the NOTE: Follow the manufacturer's instructions. five flange nuts. DAMPER STRUT SPRING COMPRESSOR: (Commercially available) BRANICK®...
Page 774: Rear Suspension
Rear Suspension Hub Bearing Unit Replacement NOTE: • Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheels weights may corrode and damage aluminum wheels. • Before installing the wheel, clean the mating surfaces of the brake disc and inside of the wheel. FLANGE NUT 16 x 1.5 mm 140 N-m (14.3 kgf-m, 103 Ibf-ft)
Page 775 Rear Suspension Hub Bearing Unit Replacement (cont'd) Raise the rear of the vehicle, and support it with Remove the 6 mm brake disc retaining screws. safety stands in proper locations (see section Remove the rear wheel. BRAKE DISC 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) Remove the hub cap, then pry the spindle nut lock tab away from the spindle, and loosen the nut.
Page 776: Suspension Arms Removal/Inspection
Suspension Arms Removal/Inspection CAUTION: • Replace the self-locking nuts after removal. • Be careful not to damage the ball joint boot. NOTE: • The ball joint remover will interfere with the lower arm when removing the lower arm. To prevent interference, remove the beam's pivot bolts before installing the ball joint remover.
Page 777 Rear Suspension Suspension Arms Installation CAUTION: • Any bolts or nuts connected to rubber mounts or bushings should be tightened with the vehicle on the ground. • Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole.
Page 778: Ball Joint Boot Replacement
Rear Suspension Rear Damper Ball Joint Boot Replacement Removal Remove the set ring and the boot. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see section Remove the retainer (upper ball joint only). Remove the rear speaker and damper cap.
Page 779: Disassembly/Inspection
Rear Damper Disassembly/Inspection Reassembly Disassembly Install the damper unit on a spring compressor. Compress the damper spring with the spring com- NOTE: Follow the manufacturer's instructions. pressor according to the manufacturer's instruc- STRUT SPRING COMPRESSOR: tions, then remove the self-locking nut. (Commercially available) BRANICK®...
Page 780 Installation Lower the rear suspension, and set the damper assembly in its original position. Loosely install the damper mounting bolt. Raise the rear suspension with a floor jack until the weight of the vehicle is on the damper. NOTE: • The damper mounting bolts should be tightened with the damper under vehicle load.
Page 781 Brakes Conventional Brake Special Tools ....19–2 Front Brake Disc Rear Brake Pads Lining Surface Break-in Component Location Index ..19–3 Disc Runout Inspection .
Page 782: Special Tools
Special Tools Ref. No. Page Reference Tool Number Description 19-15 07JAG-SD40100 Pushrod Adjustment Gauge...
Page 783 Inspection Brake System Rubber Parts and Brake Booster '96-99 models: Caliper Piston Seal and Piston Boots Check brake operation by applying the brake. Visually check for damage or signs of fluid leakage. If the pedal does not operate properly, the brakes drag, or there is damage or signs of Brake Hoses fluid leakage, disassemble and inspect the Visually check for damage or signs...
Page 784: Inspection And Adjustment
Inspection and Adjustment Brake Pedal Pedal Height Screw in the brake pedal position switch until its plunger is fully pressed (threaded end touching the Disconnect the brake pedal position switch connec- pad on the pedal arm). Then back off the switch 1/4 tor, loosen the brake pedal position switch locknut, turn to make 0.3 mm (0.01 in) of clearance between and back off the brake pedal position switch...
Page 785: Parking Brake Pedal
Inspection and Adjustment Parking Brake Pedal Inspection Minor adjustment: Press the parking brake pedal with 294 N (30 kgf, 66 Raise the rear wheels off the ground, and support Ibf) of pressure to fully apply the parking brake. the vehicle on safety stands. The parking brake pedal should be locked within the specified number of clicks.
Page 786 Turn the brake shoe adjuster up with a flat blade Major adjustment: screwdriver until the shoes lock, then back off 8 Adjust the parking brake shoe lining-to-drum clearance stops. with the adjuster in the drum of each rear wheel. NOTE: Make sure the parking brake linings are not worn beyond the service limit (see page 19-23).
Page 787: Bleeding
Inspection and Adjustment Bleeding CAUTION: • Always use Genuine Honda DOT 3 Brake Fluid. Using FRONT: a non-Honda brake fluid can cause corrosion and decrease the life of the system. • Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
Page 788: Brake System Indicator
Brake System Indicator Parking Brake Switch Test Brake Fluid Level Switch Test Remove the dashboard lower cover and knee bol- Remove the reservoir cap. Check that the float ster (see section 20). moves up and down freely; if it doesn't, replace the Disconnect the connector from the parking brake reservoir cap assembly.
Page 789: Front Brake Pads
Front Brake Pads Inspection and Replacement Using vernier calipers, measure the thickness of • Never use an air hose or dry brush to clean brake each brake pad lining. assemblies. • Use an OSHA-approved vacuum cleaner to avoid Brake Pad Thickness: breathing brake dust.
Page 790 12. Push in the piston so the caliper will fit over the 10. Apply grease to the points indicated by the arrows pads. Make sure the piston boot is in position to in the following illustration: prevent damaging it when pivoting the caliper down.
Page 791: Front Brake Disc
Front Brake Disc Disc Runout Inspection Disc Thickness and Parallelism Inspection Loosen the front wheel nuts slightly, then raise the vehicle, and make sure it is securely supported. Loosen the front wheel nuts slightly, then raise the Remove the front wheels. vehicle, and make sure it is securely supported.
Page 792: Front Brake Caliper
Front Brake Caliper Disassembly/Reassembly Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner to avoid breathing brake dust. Contaminated brake discs or pads reduce stopping ability. When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency. CAUTION: Do not spill brake fluid on the vehicle;...
Page 793 Master Cylinder/Brake Booster Removal/Installation 9. Remove the four brake booster mounting nuts. CAUTION: Be careful not to bend or damage the brake lines when removing the master cylinder. 10. Pull the brake booster forward until the clevis is clear of the bulkhead. Do not spill brake fluid on the vehicle;...
Page 794: Master Cylinder Inspection
Master Cylinder Inspection CAUTION: • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. • Before reassembling, check that all parts are free of dust and other foreign particles.
Page 795 Pushrod Clearance Adjustment NOTE: Master cylinder pushrod-to-piston clearance must be checked and adjustments made, if necessary, before installing the master cylinder. Set the special tool on the master cylinder body; push in the center shaft until the top of it contacts the end of the secondary piston by turning the adjusting nut.
Page 796 Master Cylinder/Brake Booster Pushrod Clearance Adjustment (cont'd) NOTE: If the clearance between the gauge body and adjusting nut is 0.2 mm (0.008 in), the pushrod-to-piston clearance is 0 mm. However, if the clearance between the gauge body and adjusting nut is 0 mm, the pushrod- to-piston clearance is 0.2 mm (0.008 in) or more.
Page 797 Master Cylinder/Brake Booster Brake Booster Inspection Functional Test With the engine stopped, press the brake pedal sev- eral times to deplete the vacuum reservoir, then press the pedal hard and hold it for 15 seconds. If the pedal sinks, either the master cylinder is bypassing internally, or the brake system (master cylinder, lines, modulator, or caliper) is leaking.
Page 798: Rear Brake Pads
Rear Brake Pads Inspection and Replacement Using vernier calipers, measure the thickness of Never use an air hose or dry brush to clean brake each brake pad lining. assemblies. Use an OSHA-approved vacuum cleaner to avoid Brake Pad Thickness: Standard: 8.5-9.5 mm (0.33-0.37 in) breathing brake dust.
Page 799 Rear Brake Pads Inspection and Replacement (cont'd) 10. Apply grease to the points indicated by the arrows 12. Push in the piston so that the caliper will fit over the in the following illustration: pads. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper Piston end and inner shim B contact surface down.
Page 800 Rear Brake Disc Disc Runout Inspection Disc Thickness and Parallelism Inspection Loosen the rear wheel nuts slightly, then raise the vehicle and make sure it is securely supported. Loosen the rear wheel nuts slightly, then raise the Remove the rear wheels. vehicle, and make sure it is securely supported.
Page 801: Rear Brake Caliper
Rear Brake Caliper Disassembly/Reassembly Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner to avoid breathing brake dust. Contaminated brake discs or pads reduce stopping ability. When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency. CAUTION: Do not spill brake fluid on the vehicle;...
Page 802 Brake cylinder grease or equivalent rubber grease. Silicone grease (Use recommended grease in the caliper set). BLEED SCREW 9 N-m (0.9 kgf-m, BANJO BOLT 6.5 Ibf-ft) 34 N-m (3.5 kgf-m, CALIPER BODY 25 Ibf-ft) Check for scoring on cylinder wall. PISTON SEALING WASHERS Replace.
Page 803 Parking Brake Inspection Block the front wheels, loosen the rear wheel nuts Never use an air hose or dry brush to clean brake slightly, support the rear of the vehicle on safety assemblies. stands (see section 1), then remove the rear wheels. Use an OSHA-approved vacuum cleaner to avoid breathing brake dust.
Page 804 Measure the inside diameter of the disc/drum using Check the brake linings for cracking, glazing, wear, and contamination. inside vernier calipers. Drum Inside Diameter: Measure the brake lining thickness. Standard: 169.9 - 170.0 mm (6.689 - 6.693 in) Service Limit: 171.0 mm (6.732 in) NOTE: Measurement does not include brake shoe thickness.
Page 805 Parking Brake Parking Brake Shoes Replacement Do the lining surface brake-in when Disconnect the rod spring, and remove the connect- replacing the shoes with new linings and/or new brake ing rod. discs (drums). Remove the rear brake caliper and rear brake disc/ drum (see section 18).
Page 806 Remove the brake shoe by disconnecting the park- 9. Apply Molykote 44 MA grease to the sliding surface ing brake cable from the parking brake lever. of the pivot pin, and insert the pin into the parking brake shoe. 10. Install the parking brake lever and wave washer on the pivot pin, and secure them with a new U-clip.
Page 807 Parking Brake Parking Brake Shoes Replacement (cont'd) 12. Apply Molykote 44 MA grease on each sliding sur- 15. Connect the rod spring to the connecting rod and face. parking brake shoe as shown. NOTE: Hook the rod spring to the connecting rod CAUTION: Contaminated brake linings or drums with the spring end pointing downward.
Page 808 17. Install the upper return springs. 18. Install the brake disc/drum and rear brake caliper (see section 18). 19. Adjust the parking brake (see page 19-6).
Page 809 Lining Surface Break-in CAUTION: • Perform the lining surface break-in when replacing the shoes with new linings and/or new discs (drums). • Check the number of parking brake pedal clicks. Adjust the pedal before breaking-in the lining surface (see page 19-6). Do this operation in a safe area.
Page 810 31 mph (50 km/h) for 400 m (1/4 mile). Park the vehicle for 5-10 minutes to allow the drums to cool. Repeat step 3. Check the parking brake pedal adjustment refer to the '96-01 3.5 RL Service Manual (see page 19-6).
Page 811 Brake Hoses/Lines Inspection/Torque Specifications Inspect the brake hoses for damage, deterioration, leaks, interference, and twisting. Check the brake lines for damage, rusting, and leakage. Also check for bent brake lines. Check for leaks at hose and line joints and connections, and retighten if necessary. Check the master cylinder and ABS modulator unit ('00 - 01 models, VSA modulator unit and pump) for damage and leakage.
Page 812: Hose Replacement
Hose Replacement CAUTION: Install the brake hose on the knuckle and damper first, then connect the brake hose to the caliper with Before reassembling, check that all parts are free of dust and other foreign particles. the banjo bolt and new sealing washers. Replace parts with new ones whenever specified to do so.
Page 813: Parking Brake Cable
Parking Brake Cable Inspection and Replacement CAUTION: The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature cable failure. Disconnect the parking brake switch connector. Remove the parking brake shoes (see page 19-24). Release the parking brake pedal, and disconnect the Remove the parking brake cable from the backing parking brake cable from the pedal.
Page 814: Special Tools
Special Tools Ref. No. Tool Number Description Page Reference 07HAJ-SG0010Aor ALB Checker 19-95 07HAJ - SG0010B 07PAZ-0010100 SCS Service Connector 19-40...
Page 815 Component Locations SERVICE CHECK CONNECTOR (2P) ABS INSPECTION CONNECTOR (6P) RIGHT-REAR WHEEL SENSOR ABS CONTROL UNIT LEFT-REAR WHEEL MODULATOR UNIT SENSOR CONNECTOR RIGHT-FRONT WHEEL SENSOR CONNECTOR LEFT-REAR WHEEL SENSOR RIGHT-FRONT RIGHT-REAR WHEEL WHEEL SENSOR SENSOR CONNECTOR UNDER-HOOD UNDER-DASH FUSE/RELAY BOX RELAY BOX B UNDER-HOOD FUSE/RELAY BOX...
Page 816: Abs Control Unit Terminal Arrangement
ABS Control Unit Terminal Arrangement 26P CONNECTOR Terminal side of male terminals 26P CONNECTOR NOTE: Standard voltage is 12 V.
Page 817 22P CONNECTOR Terminal side of male terminals 22P CONNECTOR NOTE: Standard voltage is 12 V.
Page 818: Troubleshooting Precautions
Troubleshooting Precautions ABS Indicator Light: The ABS indicator light comes on for 3 seconds and then goes off when the control unit detects no problem during the ini- tial diagnosis right after the engine starts. However, the ABS indicator light can stay on for up to 40 seconds when the control unit starts to check for pump overrun, etc.
Page 819 Kickback and Pump Operation: When the engine is started, the ABS control unit begins the initial diagnosis and operates the solenoid valve one time. The kickback may be felt when the brake pedal is pressed. When the ABS control unit detects the pressure switch OFF signal during the initial diagnosis, it operates the pump motor, and performs the pump motor over-run diagnosis and pump motor diagnosis.
Page 820 Diagnostic Trouble Code (DTC) Indication Connect the SCS service connector to the service check connector under the glove box. SERVICE CHECK CONNECTOR (2P) SCS SERVICE CONNECTOR 07PAZ-0010100 2. Turn the ignition switch ON (II), but do not start the engine. Record the blinking frequency of the ABS indicator light.
Page 821: Dtc Indication
DTC Indication Pattern (When the ABS control unit detected a problem three times.): Turn the ignition switch ON (II). The ABS indicator light comes on for 2 seconds to check the bulb. The ABS control unit indicates the DTC 3 times. If you miscount the blinking frequency or if you recheck the blinking frequency, turn the ignition switch OFF then turn it ON (II) to cycle the ABS indicator light again.
Page 822: Symptom-To-System Chart
Diagnostic Trouble Code (DTC) Symptom-to-System Chart DIAGNOSTIC PERIOD REFER PROBLEM DIAGNOSIS/ LOCATION SYMPTOM PAGE MAIN ABS indicator light does not come on when ignition switch is 19-43 turned ON (II) No DTC ABS indicator light does not go off after engine is 19-45 started (No DTC) Pump motor over-run...
Page 823 ABS Function Test NOTE: The ABS system can be checked with the ALB 7. Turn the Mode Selector switch to "1". checker or with the Honda PGM Tester. Monitor Lights Raise the vehicle off the ground, and support it with safety stands.
Page 824 ABS Function Test (cont'd) Operation Sequence Simulated by Modes of ALB Checker NOTE: The wheel sensors and sensor wire harnesses are not checked by the ALB checker. Mode 1: Sends the simulated driving signal 0 mph (0 km/h) 113 mph (180 km/h) 0 mph (0 km/h) of each wheel to the ABS control unit to check the system under the normal driving.
Page 825 Modulator Unit Relieving System Pressure CAUTION: Be sure to relieve system pressure completely before performing the modulator function check, disposing the modulator unit, or replacing the accumulator and ABS pump motor replacement. Do not spill brake fluid on the vehicle; it may damage the paint;...
Page 826 Modulator Unit High-Pressure Brake Fluid Replacement/Bleeding Replacement Bleeding 1. Relieve system pressure (see page 19-97). Leave the When the brake fluid is completely drained from the tube and wrench on the maintenance bleeder, and reservoir (air enters the modulator unit), bleed the air leave the tube in the container.
Page 827 Modulator Function Check Removal NOTE: This inspection determines whether the basic Disconnect the 14P and 2P connectors. brake system continues to operate normally when the modulator unit high-pressure side is low. Disconnect the six brake lines, then remove the modulator unit. 1.
Page 828 Modulator Unit Installation Wire Harness Replacement NOTE: This procedure is for modulator unit replacement. Remove the modulator unit (see page 19-99). Fill the modulator reservoir to the MAX line. Remove the cover, then remove the wire harness. Bleed air from the suction port in the modulator unit by leaning the modulator unit to one side slow- MODULATOR UNIT ly (about 45 degrees) as shown.
Page 829 Pump Motor Replacement Reservoir Replacement The modulator unit contains high-pressure Remove the modulator unit (see page 19-99). brake fluid. Be sure to relieve system pressure unit before removing the pump motor. Replace the reservoir. Relieve system pressure (see page 19-97). O-RING Remove the modulator unit (see page 19-99).
Page 830: Removal/Installation
Modulator Unit ABS Control Unit Accumulator Replacement and Removal/Installation Disposal 1. Remove the glove box. • The modulator unit contains high-pressure brake fluid. 2. Remove the glove box back cover. Be sure to relieve system pressure before removing 3. Remove the right front door trim. the accumulator.
Page 831: Wheel Sensor Replacement
Pulsers/Wheel Sensor Inspection Wheel Sensor Replacement Inspection points: NOTE: Resistance Be careful when installing the sensors to avoid twist- Front: 700-1,100 ing the wires. Rear: 1,400-2,000 The torque value of the bolts is at 9.8 N-m (1.0 kgf-m, Open in the wires 7 Ibf-ft).
Page 832: Special Tools
Special Tools Tool Number Description Ref. No. Page Reference 07PAZ-0010100 SCS Service Connector 19-119...
Page 833 Component Locations SERVICE CHECK CONNECTOR (2P) RIGHT-REAR WHEEL SENSOR ABS CONTROL UNIT MODULATOR UNIT LEFT-REAR WHEEL SENSOR UNDER-DASH FUSE/RELAY BOX RIGHT-FRONT WHEEL SENSOR UNDER-HOOD FUSE/RELAY BOX LEFT-FRONT WHEEL SENSOR UNDER-HOOD RELAY BOX C UNDER-HOOD FUSE/RELAY BOX GAUGE ASSEMBLY STOP/HORN ABS PUMP (15 A) FUSE MOTOR RELAY BATTERY...
Page 834: Anti-Lock Brake System
Anti-lock Brake System (ABS) Features/Construction When the brake pedal is pressed during driving, the wheels can lock before the vehicle comes to a stop. In such an event, the maneuverability of the vehicle is reduced if the front wheels are locked, and the stability of the vehicle is reduced if the rear wheels are locked, creating an extremely unstable condition.
Page 835 Anti-lock Brake System (ABS) Features/Construction (cont'd) ABS Control The ABS control unit detects the wheel speed based on the wheel sensor signal it received, then it calculates the vehicle speed based on the detected wheel speed. The control unit detects the vehicle speed during deceleration based on the rate of deceleration.
Page 836 Self-diagnosis 1. The ABS control unit is equipped with a main CPU and a sub CPU, that check each other for problems. 2. The CPUs check the circuit of the system. 3. Self-diagnosis can be classified into 2 categories. Initial diagnosis: Performed right after the engine starts and until the ABS indicator goes off. Regular diagnosis: Performed right after the initial diagnosis until the ignition switch is turned OFF.
Page 837 Anti-lock Brake System (ABS) Features/Construction (cont'd) ABS Modulator The ABS modulator consists of the inlet solenoid valve, outlet solenoid valve, reservoir, pump, pump motor and the damping chamber. The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, reservoir and the master cylinder.
Page 838 Wheel Speed and Modulator Control VEHICLE SPEED SPEED REFERENCE VEHICLE SPEED WHEEL SPEED TIME PRESSURE OUTLET VALVE INLET VALVE MOTOR When the wheel speed drops sharply below the vehicle speed, the inlet valve closes to retain the caliper fluid pressure. When the wheel speed drops further, the outlet valve opens momentarily to reduce the caliper fluid pressure.
Page 839: Abs Control Unit Terminal Arrangement
ABS Control Unit Terminal Arrangement ABS CONTROL UNIT 22P CONNECTOR Wire side of female terminals Measurement Terminal sign Terminal Wire (Terminal Description Conditions number color Terminal Voltage name) (Ignition switch ON (ID) GND3 Ground Below 0.3 V 1-GND (Ground 3) Outputs left-front wheel WHT/RED* (Front-left...
Page 840 Measurement Terminal Wire Terminal sign Description Conditions number color (Terminal name) Terminal Voltage (Ignition switch ON (ID) GND4 Ground 12-GND Below 0.3 V (Ground 4) Outputs left-rear wheel GRY/WHT* (Rear-left 13-GND Spin wheel slowly sensor signal pulse) Detects service check con- Below 0.3 V SCS service Connected (Service check...
Page 841 ABS Control Unit Terminal Arrangement ABS CONTROL UNIT 12P CONNECTOR Wire side of female terminals Measurement Terminal Terminal sign Wire Description Conditions number color (Terminal name) Terminal Voltage (Ignition switch ON (ID) Drives ABS indicator 4 - 6 V WALP (Turns the indicator drive BLU/WHT ABS indicator...
Page 842 Troubleshooting Precautions ABS Indicator 1. If the system is OK, the ABS indicator goes off 2 seconds after turning the ignition switch ON (II) without starting the engine, and then comes on again and goes off after 2 seconds. This occurs because the ABS control unit is turned on by the IG2 power source.
Page 843 Troubleshooting Precautions Kickback The motor operates when the ABS is functioning, and the fluid in the reservoir is forced out to the master cylinder, causing kickback at the brake pedal. Pump Motor 1. The pump motor operates when the ABS is functioning. The ABS control unit checks the pump motor operation during initial diagnosis when the vehicle is started.
Page 844 Diagnostic Trouble Code (DTC) Diagnostic Trouble Code (DTC) Indication NOTE: This operation can also be done with the Honda PGM Tester. 1. Connect the SCS service connector to the service check connector (2P) under the glove box. 2. Turn the ignition switch ON (II) without the brake pedal pressed. NOTE: If the brake pedal is pressed when turning the ignition switch ON (II), the system shifts to the DTC Erasure mode.
Page 845: Dtc Erasure
Diagnostic Trouble Code (DTC) DTC Erasure NOTE: This operation can also be done with the Honda PGM Tester. 1. Connect the SCS service connector to the service check connector (2P) under the glove box. 2. Press the brake pedal. 3. Turn the ignition switch ON (II) while keeping the brake pedal pressed. 4.
Page 846: Troubleshooting Index
Troubleshooting Index DETECTION TIMING FAIL- REFER PROBLEM SAFE DIAGNOSIS/SYMPTOM LOCATION MODE PAGE ABS indicator does not come on 19-122 ABS indicator does not go off (No DTC) 19-124 Wheel sensor (open/short to body ground/short to 19-126 power) Wheel sensor (electrical noise/intermittent interrup- 19-127 tion) Pulser...
Page 847 Modulator Unit Removal/Installation NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does not contact the paint, wash it off immediately with water. Take care not to damage or deform the brake lines during removal and installation. To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent mate- rial.
Page 848 Pulsers/Wheel Sensors ABS Control Unit Removal/Installation Inspection 1. Remove the glove box. Check the front and rear pulser for chipped or dam- aged teeth. 2. Remove the glove box back cover. Measure the air gap between the wheel sensor and 3.
Page 849: Wheel Sensor Replacement
Wheel Sensor Replacement Install the sensors carefully to avoid twisting wires. Front 6 mm BOLT 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) WHEEL SENSOR Rear 6 mm BOLT 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) WHEEL SENSOR...
Page 850: Special Tools
Special Tools Ref. No. Tool Number Description Page Reference 07PAZ-0010100 SCS Service Connector 19-159...
Page 851: Component Locations
Component Locations SERVICE CHECK CONNECTOR (2P) STEERING ANGLE SENSOR RIGHT-REAR WHEEL SENSOR POWERTRAIN CONTROL MODULE (PCM) ABS CONTROL UNIT TCS CONTROL UNIT ECT SENSOR TCS CONTROL VALVE SENSOR RIGHT-FRONT WHEEL SENSOR LEFT-REAR WHEEL SENSOR TCS CONTROL VALVE ACTUATOR TCS/CRUISE SWITCH UNDER-HOOD RELAY BOX C UNDER-DASH FUSE/RELAY BOX LEFT-FRONT WHEEL SENSOR...
Page 852: System Description
System Description Outline Role of System The traction control is a variable system designed to enhance traction during acceleration and cornering. It does so by determining the optimum amount of wheel spin for any given driving situation, then suppressing surplus engine power accordingly.
Page 853: Construction And Function
Construction and Function TCS Control unit Driving Control When the drive wheel speed exceeds the vehicle speed by a given amount, the TCS control unit judges that the drive wheels are slipping, and it outputs the traction control signal to reduce engine power. Handling Control Based on signals about right and left driven wheel rotational speeds, the control unit calculates the vehicle's "yaw"...
Page 854 System Description Fail-Safe Function If the control unit detects an abnormality, it shuts the traction control system off and causes the TCS indicator light to come on. However if the abnormality is detected while the TCS is activated, the control unit first estab- lishes the appropriate wheel spin velocity, then shuts the system down, thus preventing excessive wheel spin.
Page 855 Engine Output Control When the TCS is activated, the TCS control unit signals the TCS control valve actuator and PCM. The actuator is linked to the TCS control valve which is normally returned to the fully open position by the two return springs. Although the throttle valve is still within the driver's control, the engine output is relaxed by the TCS control valve and PCM to achieve optimum traction.
Page 856 TCS Control Unit Terminal Arrangement TCS CONTROL UNIT 14P CONNECTOR Wire side of female terminals VB: Battery Voltage Voltage Wire Terminal Terminal sign Description Measurement Conditions Output number color (Terminal name) terminals (Ignition Switch ON (ID) voltage Detects right-front Rotate the right-front WHT/GRN About 2.5 V 1-GND...
Page 857 TCS CONTROL UNIT 20P CONNECTOR Wire side of female terminals VB: Battery Voltage Voltage Terminal Wire Terminal sign Description Conditions Output Measurement number color (Terminal name) terminals (Ignition Switch ON (II)) voltage Detects ignition switch BLK/YEL 1-GND (Ignition 1) IG1 signal Depress the parking Below 0.6 V brake pedal.
Page 858 Troubleshooting Precautions 1. In any of these cases, the TCS indicator light may come on or stay on even the TCS system is normal. The coolant temperature is 32°F (0°C) or below. The parking brake is applied for more than 30 seconds while the vehicle is being driven. The tires are not inflated to the specified pressure.
Page 859 Diagnostic Trouble Code (DTC) Diagnostic Trouble Code (DTC) Indication 1. Connect the SCS service connector to the service check connector under the glove box. 2. Turn the ignition switch ON (II), but do not start the engine. 3. Record the blinking frequency of the TCS indicator light. The blinking frequency indicates the diagnostic trouble code (DTC).
Page 860 Diagnostic Trouble Code (DTC) DTC Erasure 1. Press the parking brake pedal. 2. Push and hold the TCS switch, then turn the ignition switch ON (II). 3. Hold the TCS switch pushed for 4 to 6 seconds, then release the TCS switch. 4.
Page 861 Troubleshooting Guide Related components Refer System Indicated page TCS indicator light does not come on when ignition 19-162 switch is turned ON (II) 19-164 — TCS indicator light does not go off after engine is started 19-165 Parking brake 19-168 Steering angle sensor TC-INH signal 19-171...
Page 862: Steering Angle Sensor
Steering Angle Sensor Replacement CAUTION: Do not damage or drop the steering angle sensor as it is sensitive. 1. Remove the combination switch (see section 17). 2. Remove the circlip and screw, then remove the steering angle sensor from the combination switch. 3.
Page 863 TCS Control Valve Assembly Replacement CAUTION: Be careful not to damage the TCS control valve when handling the TCS control valve assembly. 1. Disconnect the vacuum tube, breather pipe and air hose from the intake air duct. 2. Loosen the intake air duct band screws, then remove the intake air duct. NOTE: When installing the duct, BREATHER PIPE align the cutout with mark.
Page 864: Tcs Control Unit
TCS Switch TCS Control Unit Replacement Test Remove the rear seat-back (see section 20). 1. Remove the TCS/CRUISE switch from the switch panel. 2. Disconnect the connectors from TCS control unit. TCS/CRUISE SWITCH TCS CONTROL UNIT Check for continuity between terminal No. 1 and No.
Page 865 Special Tools Ref. No. Tool Number Description Page Reference 07PAZ-0010100 SCS Service Connector 19-206...
Page 866 Special Tools 19-7...
Page 867 Component Locations SERVICE CHECK CONNECTOR (2P) RIGHT-REAR WHEEL SENSOR STEERING VSA CONVERTER UNIT ANGLE SENSOR PRECHARGE YAW RATE/LATERAL PUMP MOTOR ACCELERATION SENSOR VSA MODULATOR CONTROL UNIT TCS CONTROL VALVE SENSOR RIGHT-FRONT WHEEL SENSOR LEFT-REAR WHEEL SENSOR VSA OFF SWITCH TCS CONTROL VALVE ACTUATOR UNDER-DASH FUSE/RELAY BOX UNDER-HOOD...
Page 868 Terminal Arrangement VSA CONTROL UNIT 42P CONNECTOR Wire side of female terminals...
Page 869 Measurement (With the VSA control unit 42P Terminal Wire Terminal connector disconnected) Description number color sign Terminals Conditions Voltage Ignition switch ON Battery Power source for activating the YEL/BLK 23-GND system Voltage (II) CAN (+) Communication signal Ground for the pressure sensor Detects pressure sensor signal Press the VSA off Battery...
Page 870 Terminal Arrangement VSA CONVERTER UNIT 26P CONNECTOR Wire side of female terminals...
Page 871 Measurement (With the VSA converter unit 26P Terminal Wire Terminal connector connected) Description number color sign Terminals Conditions Voltage...
Page 872 Troubleshooting Precautions System Indicators If the system is OK, the ABS indicator goes off once after turning the ignition switch ON (II) without starting the engine, and then come on again and go off several seconds later after starting the engine. This occurs because the VSA control unit is turned on by the IG2 power source.
Page 873 Troubleshooting The troubleshooting flowchart procedures assume that the cause of the problem is still present and the ABS indicator and/or VSA system indicator is still on. Following the flowchart when the ABS indicator and/or VSA system indicator does not come on can result in incorrect diagnosis. The connector illustrations show the female terminal connectors with a single outline and the male terminal connectors with a double outline.
Page 874 Diagnostic Trouble Code (DTC) DTC Indication NOTE: This operation can also be done with the Honda PGM Tester. 1. Connect the SCS service connector to the service check connector (2P) under the glove box. 2. Turn the ignition switch ON (II). 3.
Page 875 DTC Clearing 1. Press the parking brake pedal. 2. Push the VSA off switch, and hold it, then turn the ignition switch ON (II). 3. Hold the VSA off switch for 3 to 5 seconds, then release the VSA off switch. 4.
Page 876 Diagnostic Trouble Code (DTC) Troubleshooting Index REFER PAGE 19-210 19-211 19-213 19-215 19-217 19-219 19-220 19-221 19-222 19-223 19-226 19-228 19-230 19-231 19-232 19-233 19-234 * See page 19-236 ('00-01) 19-3a ('02-04).
Page 877 REFER PAGE 19-237 19-238 19-239 19-240 19-241 19-243 19-244 19-245 19-246 19-251 19-252 19-254 19-255 19-257 19-258 19-260 19-262 * See page 19-247 ('00-01) 19-5a ('02-04). ** See page 19-265 ('00-01) 19-6a ('02-04).
Page 878 Steering Angle Sensor Replacement CAUTION: Do not damage or drop the steering angle sensor as it is sensitive. 1. Remove the combination switch (see section 17). 2. Remove the circlip and screw, then remove the steering angle sensor from the combination switch. 3.
Page 879 Steering Angle Sensor Neutral Position Check and Memorizing Check 1. Connect the SCS service connector to the service check connector (2P) under the glove box. 2. Turn the ignition switch ON (II). The VSA activation indicator comes on then goes off. 3.
Page 880 Steering Angle Sensor Neutral Position Check and Memorizing Check 1. Connect the SCS service connector to the service check connector (2P) located under the glove box. 2. Turn the ignition switch ON (II). The VSA activation indicator comes on then goes off. 3.
Page 881 Steering Angle Sensor Neutral Position Check and Memorizing (cont'd) Memorizing NOTE: Beacause timing is impotant, familiarize yourself with the whole procedure before you begin. 1. Connect the SCS service connector to the service check connector (2P) located under the glove box. 2.
Page 882: Vsa Modulator-Control Unit
VSA Modulator-Control Unit Removal/Installation NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme- diately with water. Take care not to damage or deform the brake lines during removal and installation. To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material.
Page 883 VSA Modulator-Control Unit Removal/Installation NOTE: • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme- diately with water. • Take care not to damage or deform the brake lines during removal and installation. •...
Page 884: Precharge Pump Motor
Precharge Pump Motor Removal/Installation NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off imme- diately with water. Take care not to damage or deform the brake lines during removal and installation. To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material.
Page 885 Precharge Brake Line Bleeding 1. Connect the SCS service connector to the service check connector (2P) under the glove box. 2. Press the parking brake pedal. 3. Press the VSA off switch, and hold it. 4. Turn the ignition switch ON (II). 5.
Page 886 Precharge Brake Line Bleeding 1. Connect the SCS service connector to the service check connector (2P) located under the glove box. 2. Press the parking brake pedal. 3. Press the VSA off switch, and hold it. 4. Turn the ignition switch ON (II). 5.
Page 887: Tcs Control Valve Assembly
TCS Control Valve Assembly Replacement CAUTION: Be careful not to damage the TCS control valve when handling the TCS control valve assembly. 1. Disconnect the vacuum tube, breather pipe, and air hose from the intake air duct. 2. Loosen the intake air duct band screws, then remove the intake air duct. NOTE: When installing the duct, align the cutout with the mark.
Page 888: Removal/Installation
VSA Off Switch VSA Converter Unit Test Removal/Installation Remove the VSA off switch from the switch panel. 1. Remove the glove box. 2. Remove the glove box back cover. 3. Remove the right front door trim. 4. Remove the right kick panel. 5.
Page 889: Yaw Rate/Lateral Acceleration Sensor Removal/Installation
Pulsers/ Yaw Rate/Lateral Wheel Sensors Acceleration Sensor Inspection Removal/Installation Check the front and rear pulser for chipped or dam- CAUTION: Do not damage or drop the yaw rate/lateral acceleration sensor as it is sensitive. aged teeth. Measure the air gap between the wheel sensor and Remove the trunk front trim and the spare tire lid pulser all the way around while rotating the pulser.
Page 890: Wheel Sensor Replacement
Wheel Sensor Replacement Install the sensors carefully to avoid twisting wires. Front 6 mm BOLT 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) WHEEL SENSOR Rear 6 mm BOLT 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) WHEEL SENSOR...
Page 891 Body *: Read SRS precautions before working in this area Doors (Front) Windshield/Rear Window Console Panel/Rear Console Rear Bumper Removal ..20–74 Hood Adjustment ... . . 20–75 Component Location Index .
Page 892: Doors (Front)
Doors Front Door Index SASH TRIM Removal, page OUTER MIRROR 20-8 WEATHERSTRIP Removal, page 20-18 INNER SASH DOOR TRIM Adjustment, Removal, page page 20-17 20-8 INNER WEATHERSTRIP OUTER MOLDING FRONT CORNER INNER TRIM MOLDING HINGE SECURITY DYNAMIC PLASTIC INDICATOR DAMPER COVER DETENT (driver's)
Page 893 GLASS RUN CHANNEL GLASS Removal, page 20-7 Adjustment, page 20-16 REAR LOWER FRONT CHANNEL CHANNEL OUTER HANDLE COVER REGULATOR SEAT B Removal, page 20-7 OUTER HANDLE BASE STRIKER Adjustment, page CYLINDER 20-18 SWITCH SEAT A LOCK CYLINDER OUTER HANDLE Removal, page 20-5 INNER HANDLE CABLE...
Page 894: Door Panel Removal
Doors Door Panel Removal NOTE: Take care not to scratch the door panel and other DOOR PANEL parts. Remove the trim plate, then remove the screws. NOTE: Do not remove the inner handle from the door panel. Screw locations, 2 Pry here.
Page 895: Outer Handle/Latch Removal
Outer Handle/Latch Removal NOTE: Raise the glass fully. Remove the outer handle cover, then remove the lock cylinder. Remove: NOTE: Door panel Plastic cover (see page 20-2) Take care not to drop the bolt inside the door. Remove in numbered sequence. Remove the glass run channel as needed, then Bolt locations remove the rear lower channel.
Page 896 Doors Outer Handle/Latch Removal (cont'd) Remove the outer handle as shown. Slide the outer handle base, and remove it from the door. Disconnect the connector, detach the clips, OUTER HANDLE then remove the latch with the outer handle base BASE LEVER through the hole in the door.
Page 897: Glass/Regulator Removal
Glass/Regulator Removal Remove: Disconnect the connector, then remove the regula- Door panel (see page 20-4) tor through the hole in the door. Plastic cover (see page 20-2) Inner molding (see page 20-2) Bolt locations, 7 Carefully move the glass until you can see the bolts, then remove them.
Page 898: Sash Trim Removal
Doors Sash Trim Removal Inner Sash Trim Removal NOTE: Lower the glass fully. NOTE: Lower the glass fully. Remove: Take care not to scratch the inner sash trim. Door panel (see page 20-4) Remove the door panel (see page 20-4). Inner sash trim Remove the glass run channel and outer weather- Clip locations...
Page 899: Glass Adjustment
Doors Glass Adjustment NOTE: Tighten the glass mounting bolts and regulator Place the vehicle on a firm, level surface when adjust- mounting bolts. ing the glass. Check the weatherstrips and glass run channel for dam- Loosen the front channel mounting bolts or rear age or deterioration, and replace them if necessary.
Page 900 9. Check that the glass moves smoothly. 10. Raise the glass fully and check for gaps. 11. Check the glass operation. NOTE: Check that the glass contacts the glass run channel evenly. OUTER WEATHERSTRIP GLASS RUN CHANNEL GLASS 12. Check for water leaks. Spray water over the roof and on the sealing area as shown.
Page 901: Position Adjustment
Position Adjustment NOTE: Place the vehicle on a firm, level surface when adjusting the doors. After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and bottom door edges and the body. The door and body edges should also be parallel.
Page 902: Striker Adjustment
Doors Mirrors Striker Adjustment Power Mirror Removal NOTE: Take care not to scratch the mirror and door. Make sure the door latches securely without slamming it. If necessary, adjust the striker: The striker nuts are fixed. The striker can be adjusted slightly up or down, and in or Raise the glass fully.
Page 903 Rear Door Index SASH TRIM OUTER Removal, page 20-15 WEATHERSTRIP INNER WEATHERSTRIP INNER SASH TRIM Removal, page 20-15 OUTER INNER HINGE MOLDING MOLDINGS DOOR Adjustment, page DETENT 20-17 ADAPTER LOCK KNOB PLASTIC SPACER COVER DOOR COVER PROTECTOR SPEAKER STOP ARMREST SWITCH PANEL COURTESY...
Page 904 Doors Rear Door Index (cont'd) GLASS Removal, page 20-13 Adjustment, page 20-16 GLASS RUN CHANNEL QUARTER GLASS Removal, page 20-13 FRONT LOWER CHANNEL REAR CHANNEL OUTER HANDLE COVER SEAT B REGULATOR Removal, page 20-13 OUTER HANDLE OUTER HANDLE BASE Removal, page 20-12 OUTER HANDLE HOLDER...
Page 905: Door Panel Removal
Door Panel Removal NOTE: Take care not to scratch the door panel and other INNER parts. HANDLE POWER WINDOW CABLE SWITCH Remove the trim plate, then remove the screws. CONNECTOR NOTE: Do not remove the inner handle from the door panel. Screw locations, 2 Pry here.
Page 906: Outer Handle/Latch Removal
Doors Outer Handle/Latch Removal Remove: Remove the outer handle as shown. Door panel (see page 20-11) OUTER HANDLE Plastic cover (see page 20-9) BASE Inner molding (see page 20-9) LEVER Inner sash trim (see page 20-15) Sash trim (see page 20-15) Glass Rear channel (see page 20-14) Remove the rod protector.
Page 907 Slide the outer handle base, and remove it from the door. Disconnect the connector, detach the clips, and remove the lock crank, then remove the latch with the outer handle base through the hole in the door. Pry the outer handle rod out from the outer handle base using diagonal cutters.
Page 908: Glass/Regulator Removal
Glass/Quarter Glass/Regulator Removal Remove: • Door panel (see page 20-11) • Plastic cover (see page 20-9) • Inner molding (see page 20-9) • Inner sash trim (see page 20-15) • Sash trim (see page 20-15) Carefully move the glass until you can see the bolts, then remove them.
Page 909 Doors Glass/Quarter Glass/Regulator Removal (cont'd) Disconnect the connector, then remove the regula- Remove the glass run channel as needed, remove the bolts and screw, then move the rear channel tor through the hole in the door. forward. Bolt locations, 7 Bolt, screw locations 6 x 1.0 mm 8 N-m (0.8 kgf-m,...
Page 910: Sash Trim Removal
Inner Sash Trim Removal Sash Trim Removal NOTE: NOTE: Lower the glass fully. Lower the glass fully. Remove: Take care not to scratch the inner sash trim. Door panel (see page 20-11) Remove the door panel (see page 20-11). Inner sash trim Remove the glass run channel and outer weather- Clip locations strip as needed.
Page 911: Glass Adjustment
Doors Glass Adjustment NOTE: Tighten the glass mounting bolts and regulator Place the vehicle on a firm, level surface when adjust- mounting bolts. ing the glass. Check the weatherstrips and glass run channel for dam- Loosen the front channel mounting bolts or rear age or deterioration, and replace them if necessary.
Page 912 9. Check that the glass moves smoothly. 10. Raise the glass fully and check for gaps. 11. Check the glass operation. NOTE: Check that the glass contacts the glass run channel evenly. OUTER WEATHERSTRIP GLASS RUN CHANNEL GLASS 12. Check for water leaks. Spray water over the roof and on the sealing area as shown.
Page 913: Position Adjustment
Position Adjustment NOTE: Place the vehicle on a firm, level surface when adjusting the doors. After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and bottom door edges and the body. The door and body edges should also be parallel.
Page 914: Striker Adjustment
Doors Mirrors Striker Adjustment Power Mirror Removal NOTE: Take care not to scratch the mirror and door. Make sure the door latches securely without slamming it. If necessary, adjust the striker: The striker nuts are fixed. The striker can be adjusted slightly up or down, and in or Raise the glass fully.
Page 915: Mirror Holder Removal
Mirror Holder Removal NOTE: Take care not to scratch the mirror housing. Pry the mirror holder out from the bottom until you can see the actuator, then detach the hooks using a flat tip screwdriver. CAUTION: When prying with a flat-tip screwdriver, wrap it with a shop towel to prevent damage.
Page 916: Rearview Mirror Removal
Rearview Mirror Removal '96 - 98 models: Carefully remove the cover with a flat tip screwdriver. CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Loosen the lock bolt, then slide the mirror stay from the lug.
Page 917 Mirrors Rearview Mirror Removal (cont'd) '99 - 01 models (With automatic dimming): Remove the wire cover from the mirror bracket by releasing the hooks in the sequence shown. CAUTION: When prying with a flat-tip screwdriver, MIRROR wrap it with protective tape to prevent damage. HOOK BRACKET Remove the front ceiling light (see...
Page 918 Mirrors Rearview Mirror Removal - with OnStar System Carefully remove the rearview mirror base lower Disconnect the connector, and loosen the screw cover with a flat-tip screwdriver. with a Torx T20 bit, then slide the rearview mirror rearward and off the lug. CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage.
Page 919 Windshield/Rear Window Index NOTE: The numbers after the part names show the quantities of the parts used. Windshield: FASTENER, 2 (Self-adhesive-type, glass side) (Required for replacement or reinstallation) RUBBER DAM A WINDSHIELD FASTENER, 2 Removal, page 20-22 (Clip-type, body side) Installation, page 20-23 (Required for replacement or reinstallation)
Page 920 Windshield Removal CAUTION: Apply protective tape along the edge of the dash- Put on gloves to protect your hands. board and body as shown. Using an awl, make a Wear eye protection when removing the glass with hole through the rubber dam and adhesive from piano wire.
Page 921 Installation Using a knife, scrape the old adhesive smooth to a Glue the rubber dams, defogger seal and fasteners thickness of about 2 mm (0.08 in.) on the bonding to the inside face of the windshield as shown. surface around the entire windshield opening flange. NOTE: Be careful not to touch the windshield where NOTE: adhesive will be applied.
Page 922 Windshield Installation (cont'd) Glue the molding corner seal to the molding on Install the fasteners to the body as shown. each side. Fastener locations, 2 MOLDING ALIGNMENT MARK MOLDING 2.5 mm CORNER (0.98 in.) SEAL Align and glue the molding to the edge of the wind- shield.
Page 923 10. With a sponge, apply a light coat of glass primer 11. With a sponge, apply a light coat of body primer to around the edge of the windshield as shown, then the original adhesive remaining around the wind- lightly wipe it off with gauze or cheesecloth. shield opening flange.
Page 924 Windshield Installation (cont'd) 13. Pack adhesive into the cartridge without air pockets 14. Use suction cups to hold the windshield over the to ensure continuous delivery. Put the cartridge in a opening, align it with the alignment marks made in caulking gun, and run a bead of adhesive around step 8, and set it down on the adhesive.
Page 925 Rear Window Removal CAUTION: Remove the lower molding, then remove the remain- ing molding. Put on gloves to protect your hands. Wear eye protection when removing the glass with piano wire. NOTE: If necessary, replace any damaged molding Use seat covers to avoid damaging any surfaces. holders and clips.
Page 926 Rear Window Removal (cont'd) Apply protective tape along the edge of the body as shown. Using an awl, make a hole through the adhesive from inside the vehicle. Push the piano wire through the hole, and wrap each end around a piece of wood.
Page 927 Rear Window Installation Using a knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire rear window opening flange. NOTE: • Do not scrape down to the painted surface of the body;...
Page 928 Glue the rubber dam, fasteners, and spacers to the Align and glue the molding to the edge of the rear inside face of the rear window as shown. If neces- window. sary, glue the terminal base cover to the rear win- dow.
Page 929 Rear Window Installation (cont'd) Set the rear window, then center it in the opening. 10. With a sponge, apply a light coat of body primer to Make alignment marks across the rear window and the original adhesive remaining around the rear window opening flange.
Page 930 12. Pack adhesive into the cartridge without air pockets 14. Scrape or wipe the excess adhesive off with a putty knife or towel. to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of adhesive around the edge of the rear window as shown.
Page 931 Moonroof Index GLASS Removal, page 20-34 Adjustment, page 20-33 BRACKET COVER CABLE ASSEMBLY Replacement, page 20-37 MOONROOF SWITCH PLATE A CONTROL Adjustment, UNIT page 20-39 DRAIN CHANNEL SWITCH PLATE B Adjustment, page 20-40 SUNSHADE Removal, page 20-34 SHIMS GLASS BRACKET Removal, page 20-34...
Page 932: Glass Height Adjustment
Troubleshooting Symptom Probable Cause Water leaks Clogged drain tube. Gap between glass weatherstrip and roof panel. Defective or improperly installed glass weatherstrip. Gap between drain seal and roof panel. Wind noise Excessive clearance between glass weatherstrip and roof panel. Motor noise Loose motor.
Page 933: Glass, Glass Bracket, And Sunshade Removal
Moonroof Glass, Glass Bracket, and Sunshade Removal Close the glass fully. Remove the drain channel. SCREW Slide the sunshade all the way back. DRAIN CHANNEL Remove both bracket covers. SCREW BRACKET COVER SCREW PLUG Forward Remove the nuts from both glass brackets. Remove the holder cover, then remove the rail holder B.
Page 934 9. Remove the rail holder A. 12. Slide the sunshade forward, then remove it. 6 x 1.0 mm 9 N-m (0.9 kgf-m, 7 Ibf-ft RAIL HOLDER A SUNSHADE GLASS BRACKET 13. Installation is the reverse of the removal procedure. NOTE: Check the glass height (see page 20-33). 14.
Page 935: Motor, Drain Tube And Frame Removal
Moonroof Motor, Drain Tube and Frame Removal CAUTION: • Put on gloves to protect your hands. • Be careful not to damage the seats, dashboard, and other interior trim. 1. Remove the headliner (see page 20-45). Disconnect the connectors, detach the harness clip, and remove the ground wire. NOTE: When removing the motor, disconnect the motor connector, detach the connector from the frame, remove the bolts and nuts, then remove the motor.
Page 936 Pull the drain tubes out the front and rear pillars. NOTE: Before pulling out the drain tube, tie a string to the end of it so it can be reinstalled. Installation is the reverse of the removal procedure. NOTE: • Before installing the frame, clear the drain tubes and drain valves by using compressed air.
Page 937: Guide Rails/Cable Assembly
Guide Rails/Cable Assembly Replacement CAUTION: Put on gloves to protect your hands. Remove the frame (see page 20-36). Disconnect the connectors, detach the harness clips, and remove the adhesive tapes from the frame. Remove the motor, glass bracket, and sunshade (see page 20-34).
Page 938 Moonroof Guide Rails/Cable Assembly Replacement (cont'd) Remove the nuts, lift off each guide rail, then remove the cable assembly with the sliders attached. NOTE: Take care not to bend the cable tubes and guide rails. Bolt, screw locations Nut locations 6 x 1.0 mm 6 x 1.0 mm 6 x 1.0 mm...
Page 939: Position
Switch Plate Adjustment (Fully Closed Position/Auto Stop Position) Remove the headliner (see page 20-45). Using the moonroof wrench, close the glass fully. NOTE: Check the glass fit to the roof panel. Using an open-end wrench, loosen the switch plate A mounting bolts. Adjust position of switch plate A (switch cam) as shown.
Page 940 Moonroof Switch Plate Adjustment (Fully Closed Position/Auto Stop Position) (cont'd) Using the moonroof wrench, open the glass to the auto stop position as shown. Using an open-end wrench, loosen the switch plate B mounting bolts. 7. Adjust position of switch plate B (switch cam) as shown. NOTE: Move switch plate B a little at a time, then secure switch plate B at the position where the switch cam contacts the auto stop position switch (a faint click is heard).
Page 941: (Motor Removed)
Opening Drag Check Closing Force Check (Motor Removed) (Motor Installed) Before installing the motor, measure the effort required After installing all removed parts, have a helper to open the glass using a spring scale as shown. hold the switch to close the glass while you mea- sure the force required to stop it.
Page 942 Interior Component Location Index SRS components are located in the areas marked with an asterisk (*). Review the SRS component locations, precautions, and procedures in the Restraints (section 24) before performing repairs or service. KICK PANEL CENTER PILLAR (see page 20-43) TRIM (see page 20-43) HEADLINER...
Page 943: Interior Trim
Interior Trim Removal CAUTION: Put on gloves to protect your hands. When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. NOTE: Take care not to bend or scratch the trim and panels. : Clip, hook locations ROOF SIDE TRIM HOOKS FRONT DOOR...
Page 944: Trunk Trim
Trunk Trim Removal CAUTION: Put on gloves to protect your hands. When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. NOTE: Take care not to bend or scratch the trim and panels. Screw locations, 2 Clip locations NOTE: Do not push the inner clip in too far.
Page 945 Headliner Removal CAUTION: When prying with a flat-tip screwdriver, Remove the sunvisor and holder from each side. Disconnect both positive terminals or 2P connector wrap it with protective tape to prevent damage. (with Homelink, remove the control panel). NOTE: Screw locations Take care not to bend and scratch the headliner.
Page 946 Headliner Removal (cont'd) Remove the clips and roof trim, detach the rear clips, then remove the headliner. Clip locations FASTENER HEADLINER JOINT ROOF TRIM Remove the headliner through the passenger's door opening. Installation is the reverse of the removal procedure. NOTE: When inserting the headliner through the door opening, be careful not to fold or bend it.
Page 947 NAVIGATION MIC HOMELINK CONNECTOR ACCESS SWITCH COVER CONNECTOR Remove these items. Refer to the '96 - 01 Acura 3.5 RL Service Manual, P/N 61SZ305 (see section 20): Rear seat cushion and rear seat-back TELEMATICS SWITCH Front and rear side trim...
Page 948 Remove the clips and roof trim, detach the rear clips, then remove the headliner. FASTENER HEADLINER JOINT ROOF TRIM Remove the headliner through the passenger's door opening. Installation is the reverse of the removal procedure, and note these items: • When inserting the headliner through the door opening, be careful not to fold or bend it.
Page 949 Carpet Removal SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the Restraints (section 24) before performing repairs or service. Remove: Front seat (see page 20-57) Rear seat cushion (see page 20-67) Front and rear side trim (see page 20-43) Kick panel (see page 20-43) Front and rear door trim (see page 20-43) Front seat belt lower anchor (see...
Page 950 Remove the console lower carpet from each side. Installation is the reverse of the removal procedure. Cut area in the carpet, then pull it back as shown. NOTE: Clip locations Take care not to damage, wrinkle, or twist the carpet. Make sure the seat harness is routed correctly.
Page 951: Console Panel/Rear Console
Console Panel/Rear Console Removal — '96 - 98 Models CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. NOTE: Take care not to scratch the console panel, rear console, front seat, and related parts. Disassemble in numbered sequence.
Page 952 Removal — '99 - 01 Models CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. NOTE: Take care not to scratch the console panel, rear console, front seat, and related parts. Disassemble in numbered sequence. Bolt, screw locations Clip locations 6 x 1.0 mm...
Page 953: Component Removal/Installation
Dashboard Component Removal/Installation CAUTION: When prying with a flat-tip screwdriver, wrap Dashboard lower cover: it with protective tape, and apply protective tape around the related parts, to prevent damage. Detach the clips, then remove the dashboard lower cover. NOTE: Take care not to scratch the dashboard and related parts.
Page 954 Climate control unit and audio unit ('96 - 98 models): Remove the bolts, then pull out the climate control unit and audio unit as an assembly. Disconnect the connectors and antenna leads, then remove it. SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the Restraints (section...
Page 955 Dashboard Component Removal/Installation (cont'd) Installation is the reverse of the removal procedure. Climate control unit, audio unit and center air vent ('99 - 01 models): NOTE: SRS components are located in this area. Review the Make sure the connectors and antenna lead are SRS component locations, precautions, and procedures connected properly.
Page 956 Glove box: Remove the glove box back cover. Remove the dashboard lower cover. Screw locations, 3 Clip locations, 4 Clip locations, 3 HOOKS GLOVE BOX BACK COVER Detach the connector. DASHBOARD LOWER COVER Remove the glove box stop from each side. Installation is the reverse of the removal procedure.
Page 957 Dashboard Component Removal/Installation (cont'd) Side air vent (passenger's): Insert a flat metal plate under the clips, then detach the clips by prying up. Pull the side air vent backward while prying the clips. Side defogger trim: Carefully pry the side defogger trim at the rear edge, then remove it.
Page 958 Dashboard Removal SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the Restraints (section 24) before preforming repairs or ser- vice. NOTE: • An assistant is helpful when removing and installing the dashboard. •...
Page 959 Disconnect the dashboard wire harness connectors, the clip and the air hose. Remove the bolts and the self-tapping screw, then lift and remove the dashboard. CAUTION: Use protective plates on the bottom of the front pillar trim. Bolt locations 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 1.2 Ibf-ft) DASHBOARD...
Page 960 Seats Component Location Index SRS components are located in this areas marked with an asterisk (*). Review the SRS component locations, precautions, and procedures in the Restraints (section 24) before performing repairs or service. REAR SEAT Removal, page 20-67 *FRONT SEATS Trunk pass-through cover Removal, page 20-57...
Page 961: Front Seat
Front Seat Removal SRS components are located in this area. Review the Lift the front seat, then disconnect the connectors. SRS component locations, precautions, and procedures Clip location in the Restraints (section 24) before performing repairs Driver's seat: or service. SIDE AIRBAG POWER CONNECTOR...
Page 962 Front Seat Disassembly CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. NOTE: Take care not to scratch the seat covers and body. HEADREST 8-way power adjustable (with seat heater): BACK COVER HOOKS NOTE: Refer to page 20-65 for the seat wire harness installation.
Page 963 Disassembly 4-way power adjustable (with seat heater): HEADREST NOTE: Refer to page 20-66 for the seat wire harness installation. BACK COVER HOOKS SEAT-BACK HOOK SEAT-BACK HEATER CONNECTOR SEAT CUSHION CLIPS CLIP To seat cushion cover. RECLINE 10 x 1.25 mm COVER 47 N-m (4.8 kgf-m, 35 Ibf-ft)
Page 964 Disassembly SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service. Refer to the '99 - 01 Acura 3.5 RL Service Manual, P/N 61SZ305. CAUTION: • Put on gloves to protect your hands.
Page 965 Disassembly 4-way power adjustable (with seat heater): HEADREST NOTE: Refer to page 20-66 for the seat wire harness installation. BACK COVER HOOKS SEAT-BACK HOOK SEAT-BACK HEATER CONNECTOR SEAT CUSHION CLIPS CLIP To seat cushion cover. RECLINE 10 x 1.25 mm COVER 47 N-m (4.8 kgf-m, 35 Ibf-ft)
Page 966 Front Seat Seat Cover Replacement SRS components are located in this area. Review the Loosen the seat-back cover by releasing all the SRS component locations, precautions, and procedures hooks. in the Restraints (section 24) before performing repairs or service. '96 - 98 models CAUTION: Put on gloves to protect your hands.
Page 967 To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the hooks and clips. Replace the released clips with new ones. Use only original Acura replacement seat-back covers ('99 - 01 models).
Page 968 Front Seat Seat Cover Replacement (cont'd) Seat cushion cover removal: Installation is the reverse of the removal procedure. 1. Remove the seat cushion (see pages 20-58, 20-59). NOTE: To prevent wrinkles when installing a seat cush- Remove the clips and hooks from under the seat ion cover, make sure the material is stretched cushion, then remove the seat cushion cover with evenly over the pad before securing the clips and...
Page 969: Seat Cover Replacement '96-03 Models
SRS components are located in this area. Review the SRS component locations and precautions and proce- dures in the SRS section before performing repair or service. Refer to the '99 - 01 Acura 3.5 RL Service Manual, P/N 61SZ305. CAUTION: Put on gloves to protect your hands.
Page 970 Release the hooks of the reinforceing cloth from the Pull back the edge of the seat-back cover all the way seat-back frame. around, and release the clips, then remove the seat- back cover. CLIP HOOK REINFORCEING CLOTH SEAT-BACK SEAT-BACK WIRE COVER FRAME (Pad side)
Page 971 • Reinstall the hooks of the reinforceing cloth securely. • Use only original Honda or Acura replacement seat-back covers. • Passenger's seat: Reinitialize the OPDS control unit. Refer to the '99 - 01 Acura 3.5 RL Service Manual, P/N 61SZ305 (see section 24). CLIP...
Page 972: Seat Linkage Disassembly
Seat Linkage Disassembly CAUTION: Put on gloves to protect your hands. Apply liquid RECLINE 8-way power adjustable: thread lock. ADJUSTER 5 x 0.8 mm RECLINE NOTE: 3 N-m (0.3 kgf-m, MOTOR Before removing the front seat, raise the seat cushion 2 Ibf-ft) to its maximum height.
Page 973 Front Seat Seat Linkage Disassembly (cont'd) 4-way power adjustable: NOTE: To remove the slide motor and slide gearbox, slide the front seat backward fully. 5 x 0.8 mm 3 N-m (0.3 kgf-m, 21 Ibf-ft) RECLINE RECLINE ADJUSTER MOTOR 8 x 1.25 mm 14 N-m (1.4 kgf-m, 8 x 1.25 mm 10 Ibf-ft)
Page 974 Seat Wire Harness Installation NOTE: When assembling the front seat, install the seat Power seat wire harness location: Clip locations Screw location wire harness and connectors correctly. 8-way power adjustable (with seat heater and side airbag): : Clip locations SEAT-BACK View from under SIDE AIRBAG ('99-01 models)
Page 975 Front Seat Seat Wire Harness Installation (cont'd) 4-way power adjustable (with seat heater and side airbag): : Screw location : Clip locations SEAT-BACK SIDE AIRBAG ('99 - 00 models) WIRE TIES WIRE TIES SEAT-BACK WIRE HEATER TIES HARNESS OPDS UNIT <A>...
Page 976 Seat Harness Wiring Locations NOTE: When assembling the front seat, make sure the seat harness and connectors are fastened correctly. 8-way power adjustable (with power lumbar support and seat heater): SEAT-BACK POWER LUMBAR SUPPORT MOTOR WIRE TIES SEAT-BACK HEATER HARNESS SIDE AIRBAG HARNESS [C] [A] [B]...
Page 977: Power Lumbar Support ('04 Model) Replacement
SRS section before performing repair or motor. service. Refer to the '99 - 01 Acura 3.5 RL Service Manual, P/N 61SZ305. CAUTION: • Put on gloves to protect your hands.
Page 978 Front Seat Power Lumbar Support Replacement (cont'd) Install the lumbar support in the reverse order of removal, and note these items: • Replace the wire ties as news ones. • To prevent wrinkles when installing a seat-back cover, make sure the material is stretched evenly over the pad before securing the hook strip.
Page 979: Rear Seat
Rear Seat Removal NOTE: Take care not to scratch the seat covers and body. Disassemble in numbered sequence. CENTER SEAT : Bolt locations BELT GUIDE ('98 - 01 models) HEADREST HEADREST 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) SEAT-BACK 6 x 1.0 mm 9.8 N-m (1.0 kgf-m,...
Page 980: Trunk Pass-Through Cover Key Cylinder Replacement
Rear Seat Trunk Pass-through Cover Key Cylinder Replacement NOTE: Remove the trunk handle and rear seat handle together at the same time. When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. REAR SEAT Take care not to scratch the cover. HANDLE TRUNK TRUNK HANDLE...
Page 981: Seat Cover Replacement
Seat Cover Replacement CAUTION: Put on gloves to protect your hands. Loosen the seat-back cover by releasing all the clips, hooks, and inside springs. NOTE: Take care not to tear the seams or damage the SEAT-BACK seat covers. CLIPS HOOKS COVER Seat-back cover: Remove the seat-back (see page 20-67).
Page 982 Rear Seat Seat Cover Replacement (cont'd) Seat cushion cover: Installation is the reverse of the removal procedure. NOTE: Remove the seat cushion (see page 20-67). To prevent wrinkles when installing a seat cush- Loosen the seat cushion cover by releasing all the ion cover, make sure the material is stretched clips.
Page 983 Exterior Component Location Index NOTE: Refer to the 1996 Acura 3.5RL Body Repair Manual (P/N 61SZ330) for the hood and trunk lid removal. TRUNK LID SIDE WINDOW WEATHERSTRIP MOLDINGS Installation, TRUNK LID Removal, page 20-78 Adjustment, page 20-76 Page 20-79...
Page 984: Front Bumper
Front Bumper Removal — '96 - 98 Models : Bolt, screw locations CAUTION: Put on gloves to protect your hands. NOTE: An assistant is helpful when removing and installing 6 x 1.0 mm 8 x 1.25 mm 9.8 N-m (1.0 kgf-m, 22 N-m (2.2 kgf-m, the front bumper.
Page 985 Removal — '99 - 01 Models CAUTION: Put on gloves to protect your hands. NOTE: An assistant is helpful when removing and installing the front bumper. Take care not to scratch the front bumper and body. : Clip locations, 7 Bolt, screw locations 6 x 1.0 mm 8 x 1.25 mm...
Page 986: Rear Bumper
Rear Bumper Removal CAUTION: Put on gloves to protect your hands. NOTE: Bolt, screw locations An assistant is helpful when removing and installing '96 - 99 models the rear bumper. Take care not to scratch the rear bumper and body. 10 x 1.25 mm To remove the rear bumper beam, remove the rear 38 N-m (3.9 kgf-m,...
Page 987 Hood Adjustment NOTE: Before adjusting the hood, remove the support strut from each side of the hood, and loosen each hood mounting bolt slightly. Adjust the hood right and left, as well as fore and aft, by using the elongated holes on the hood hinge. 2.
Page 988: Trunk Lid
Trunk Lid Adjustment NOTE: Before adjusting the trunk lid, loosen each bolt slightly. Adjust the trunk lid hinges right and left, as well as fore and aft, by using the elongated holes. Turn the trunk lid edge cushions, as necessary, to make the trunk lid fit flush with the body at the rear and side edges. Adjust the fit between the trunk lid and the trunk lid opening by moving the striker.
Page 989: Trunk Lid Torsion Bars
Trunk Lid Torsion Bars Front Grille Removal Removal NOTE: Take care not to scratch the hood. CAUTION: Put on gloves to protect your hands. Open the hood, then remove the nuts. NOTE: Take care not to damage the body. Detach the clips, then remove the front grille. Remove the torsion bars with the torsion bar assembly tool while holding the trunk lid as shown.
Page 990: Trunk Lid Weatherstrip Installation
Trunk Lid Weatherstrip Installation When installing the trunk lid weatherstrip, align it with the alignment mark on the trunk lid opening. NOTE: • Make sure there are no wrinkles in the weatherstrip, • Check for water leaks.
Page 991: Removal ('04 Model)
Trunk Lid Hinge Cover Removal Pull out on the top of the trunk lid hinge cover to NOTE: Take care not to bend or scratch the trim and detach the clip, and pull the cover away from the covers. trunk lid hinge. 1.
Page 992 Roof Molding Removal CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage, and use pro- tective tape on the body. NOTE: Take care not to scratch the body. BRACKET ROOF MOLDING (Body side) WINDSHIELD MOLDING PROTECTIVE TAPE...
Page 993 Door and Side Moldings Removal — '96 - 98 Models CAUTION: When prying with a flat- tip screwdriver, wrap it with protective tape to prevent damage. NOTE: To remove the front side molding, remove the inner fender (see page 20-85). To remove the door molding, remove the door panel (see pages 20-4, 20-11) and plastic cover (see pages 20-2, 20-9).
Page 994 Door and Side Moldings Removal — '99 - 01 Models CAUTION: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. NOTE: To remove the front side molding, remove the inner fender (see page 20-85). To remove the door molding, remove the door panel (see pages 20-4, 20-11) and plastic cover (see pages 20-2, 20-9). To remove the rear side molding, insert a flat-tip screwdriver between the body and molding, then detach the clip.
Page 995 If the old molding is to be reinstalled: 7. Glue the new adhesive tape to the moldings as shown. The following materials and tools are required to repair the molding. : Adhesive tape locations Width: 5 mm (0.2 in.) NOTE: Follow the manufacturer's instructions. Thickness: 1.2 mm (0.05 in.) Materials: (Reference) Forward...
Page 996 Side Sill Panel Removal NOTE: Take care not to scratch the body. SIDE CLIP : Clip locations : Screw locations, 4 LOWER CLIP SIDE SILL PANEL NOTE: Loosen the screw, SIDE CLIP then remove the lower clip Remove the side clips from the body using a clip remover.
Page 997: Inner Fender, Fenderwell Trim
Inner Fender, Fenderwell Trim, Rear Fender Cover, and Rear Air Outlet Removal NOTE: If necessary, replace any damaged clips Inner fender: : Bolt, screw locations 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) : Clip locations, 11 INNER FENDER Fenderwell trim/Rear fender cover/Rear air outlet: STEEL NOTE:...
Page 998 Opener Cable/Opener and Latch/Wiper and Washer Component Location Index LOCK CYLINDER (see page 20-90) HOOD RELEASE HANDLE (see page 20-88) WINDSHIELD WIPER ARMS and LINKAGE Removal, page 20-91 TRUNK LID LATCH Adjustment, page 20-94 (see page 20-90) WINDSHIELD WASHER NOZZLES Adjustment, page 20-93 FUEL FILL DOOR LATCH...
Page 999 Opener Cables Removal NOTE: When removing the clips, use a clip remover. HOOD RELEASE Take care not to bend the opener cables. HANDLE (see page 20-88) Hood opener cable: NOTE: Remove the inner fender (see page 20-85) and kick panel (see page 20-43) from the left side of the vehicle. HOOD OPENER CABLE : Clip locations...
Page 1000 Opener and Latch Removal Hood latch: NOTE: Take care not to bend the opener cables. Hood release handle: : Bolt locations, 3 6 x 1.0 mm NOTE: Remove the dashboard lower cover (see page 9.8 N-m 20-49). (1.0 kgf-m, 7.2 Ibf-ft) Bolt locations, 2 HOOD LATCH 6 x 1.0 mm...
Page 1001 Fuel fill door opener: Fuel fill door latch: Bolt, screw locations NOTE: Remove the following parts. Rear trim panel (see page 20-44) Rear edge of the trunk side trim (left side, see page 6 x 1.0 mm 20-44) 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) : Bolt locations, 2...
Page 1002 Opener and Latch Removal (cont'd) Trunk lid latch/Lock cylinder: NOTE: Remove the trunk lid trim (see page 20-78). Bolt locations 6 x 1.0 mm 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft) 7.2 Ibf-ft) LOCK CYLINDER SWITCH CONNECTOR CYLINDER...

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