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Acura NSX 1997 Service Manual

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1997-2005 NSX Main Menu

General Info

Specifications

Maintenance

Engine

Cooling

Fuel and Emissions

*Transaxle

Steering

Suspension

*Brakes (Including ABS)

*Body

*Heating, Ventilation and

Air Conditioning

*Body Electrical

*Engine Electrical

*SRS

As sections w/ * include SRS components,

special precautions

are required when servicing.

Table of Contents

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Table of Contents

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Summary of Contents for Acura NSX 1997

Page 1 1997-2005 NSX Main Menu General Info Suspension Specifications *Brakes (Including ABS) Maintenance *Body Engine *Heating, Ventilation and Air Conditioning Cooling *Body Electrical Fuel and Emissions *Engine Electrical *Transaxle *SRS Steering As sections w/ * include SRS components, special precautions are required when servicing.
Page 2 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The Acura NSX & NSX-T SRS includes a driver’s airbag in the steering wheel hub, a front passenger’s airbag in the dashboard above the glove box, and seat belt tensioners in the seat belt retractors. Information necessary to safely service the SRS is included in this Service Manual.Items marked with an asterisk (*) on the contents page include, or are located near SRS components.
Page 3: General Information
Main Menu General Information Chassis and Paint Codes ’03 Model ..... . . 1–2f ’00 Model ..... . . 1–5c ’97 Model ’04 Model...
Page 4 Main Menu Table of Contents CANADA Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 5 Main Menu Table of Contents Warning/Caution Label Locations SRS CAUTION LABELS: Refer to page...
Page 6 Main Menu Table of Contents Warning/Caution Label Locations (cont'd)
Page 7 Main Menu Table of Contents...
Page 8 Main Menu Table of Contents Warning/Caution Label Locations (cont'd)
Page 9 Main Menu Table of Contents Under-hood Emissions Control Label Emission Group Identification Engine and Evaporative Families...
Page 10: Lift And Support Points
Main Menu Table of Contents Lift and Support Points Lift and Safety Stands CAUTION: • If ground clearance is inadequate to clear the shop lift, either; — Install rubber spacers on the coil springs to raise the vehicle. Use the floor jack procedures to raise the vehicle (page 1-11).
Page 11: Floor Jack
Main Menu Table of Contents Floor Jack CAUTION: Place a rubber pad between the lift platform and the center support point to avoid damaging the vehicle. The lift platform must contact the support point only; it must not come in contact with any other part of the vehicle. Set the parking brake, and block the wheels that are not being lifted.
Page 12 Main Menu Table of Contents Towing If the vehicle needs to be towed, call a professional tow- ing service. Never tow the vehicle behind another vehi- cle with just a rope or chain. It is very dangerous. There are three widely used methods of towing a vehicle. Flat-bed Equipment —...
Page 13: Service Precautions
"Dacro" type front wheels are 16" in, diameter and the rear wheels nuts and bolts recommended by Acura. are 17" in, so they cannot be rotated front-to-rear. The original-equipment tires on NSX & NSX-T have a...
Page 14: Specifications
Main Menu Specifications Standards and Service Limits ’03 Model ....3–4f ’01 Model Air Conditioning ’04 Model ....3–4g .
Page 15 Main Menu Table of Contents Standards and Service Limits Cylinder Head/Valve Train — Section 6...
Page 16 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8...
Page 17 Main Menu Table of Contents Standards and Service Limits Cooling — Section 10 Fuel and Emission — Section 11 Clutch — Section 12...
Page 18 Main Menu Table of Contents Manual Transmission — Section 13...
Page 19 Main Menu Table of Contents Standards and Service Limits Manual Transmission (cont'd) — Section 13...
Page 20 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 21 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 22 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 23 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 24 Main Menu Table of Contents Standards and Service Limits Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 25 Main Menu Table of Contents Steering — Section 17 Suspension — Section 18 Brakes — Section 19...
Page 26 Main Menu Table of Contents Standards and Service Limits Air Conditioning — Section 22 Electrical — Section 23...
Page 27 Main Menu Table of Contents Design Specifications...
Page 28 Main Menu Table of Contents Design Specifications (cont'd)
Page 29 Main Menu Table of Contents...
Page 30 Main Menu Table of Contents Body Specifications...
Page 31 Main Menu Maintenance Lubrication points ’97 Model ..... . . 4–2 ’98–99 Models ....4–2a ’00 Model .
Page 32 Main Menu Table of Contents 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.
Page 33 Main Menu Table of Contents...
Page 34 Main Menu Table of Contents 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, 10-2 11-149 6-10 23-96 6-14, 10-11 22-88 23-109 11-138 11-129 10-5 13-3 14-105 19-4, 19-6, 19-7,...
Page 35 Main Menu Table of Contents 17-57 16-7 19-4, 19-27 10-2, 13-3, 14-105 19-84 10-2 9-6, 9-7 11-159 11-130 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, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 36 Main Menu Table of Contents Follow the Severe Conditions Maintenance Schedule if the vehicle is driven MAINLY under one or more of the Severe Driving Conditions (page 4-7): 8-4, 10-2 11-149 6-10 23-96 6-14, 10-11 22-88 23-109 11-138 11-129 10-5 13-3 14-105 19-4, 19-6, 19-7,...
Page 37 Main Menu Table of Contents 4-2, 4-3 23-244 17-57 16-7 19-4, 19-27 10-2, 13-3, 14-105 19-84 10-2 9-6, 9-7 11-159 11-130 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, Honda recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 38: Table Of Contents
Main Menu Engine Engine Removal/Installation ......5–1 Cylinder Head/Valve Train ......6–1 Engine Block .
Page 39 Main Menu Engine Removal/Installation Special Tools ..... . 5–2 Engine Removal ......5–3 Installation .
Page 40 Main Menu Table of Contents Special Tools...
Page 41 Main Menu Table of Contents Engine Removal/Installation Removal Remove the strut brace (NSX-T (open top)). • Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct posi- tions on the engine (see section •...
Page 42: Engine Removal/Installation
Main Menu Table of Contents Engine Removal/Installation Removal (cont'd) Disconnect the fan motor connector, then remove Disconnect the spark plug voltage detection module the engine room fan assembly (A/T). connectors, ground cable and engine wire harness clamps. Remove the rear trim panels behind the passenger's seat, then disconnect four connectors from the Disconnect the fuel pump resistor connector.
Page 43 Main Menu Table of Contents 10. Relieve fuel pressure (see section 11). 14. Remove the expansion tank cap. Do not smoke while working on the 15. Raise the hoist to full height. fuel system. Keep open flame away from work 16.
Page 44 Main Menu Table of Contents Engine Removal/Installation Removal (cont'd) 21. Disconnect the engine wire harness connectors. 24. Disconnect the two connectors from the emission control box, then remove the control box. 22. Remove the battery cable from the main fuse box. •...
Page 45 Main Menu Table of Contents 26. Loosen the idler pulley center nut and adjusting nut, 28. Raise the hoist to full height. then remove the air conditioning (A/C) compressor 29. Remove the slave cylinder (M/T see section 12). belt. • Do not disconnect the clutch hose. 30.
Page 46 Main Menu Table of Contents Engine Removal/Installation Removal (cont'd) 33. Remove the left and right parking brake cables (see 36. Remove the A/C compressor (see section 22), then section 19). suspend it from the body. 34. Remove the rear beam rod assembly and parking NOTE: brake cable clamps.
Page 47 Main Menu Table of Contents 40. Remove the right wheel sensor wire clamps and 43. Remove the muffler (M/T). stabilizer link. 44. Position the special tool under the car. Lower the car just above the fixture. With the help of an assistant, 41.
Page 48 Main Menu Table of Contents Engine Removal/Installation Removal (cont'd) 47. Remove the two bolts from the side engine mount 49. Remove the twelve subframe-to-body mounting near the alternator. Pivot the mounting bracket into bolts. the housing of the body. 50. Raise the car a few inches. 51.
Page 49 Main Menu Table of Contents NOTE: Perform steps 53 thru 56 only if the engine assembly is to be removed from the subframe. 53. Remove the adjusting bolt and flange bolt, then separate the lower control arm from the subframe (see section 18).
Page 50 Main Menu Table of Contents Engine Removal/Installation Installation Additional Torque Value Specifications: NOTE: For manifold replacement, refer to section...
Page 51 Main Menu Table of Contents Engine Installation: Install the subframe, then tighten the subframe-to- Install the engine in the reverse order of removal. Reinstall body mounting bolts (see section 20). the mount bolts/nuts in the following sequence. Failure to NOTE: Align the bolt holes of the beam brackets follow these procedures may cause excessive noise and vibration, and reduce bushing life.
Page 52: Cooling
Main Menu Table of Contents Engine Removal/Installation Installation (cont'd) Install the side engine mount, then tighten the bolts Tighten the rear mount mounting bolt. in the numbered sequence as shown • Check that the spring clip on the end of each driveshaft clicks into place.
Page 53: Replacement ('04-05 Models)
Main Menu Cylinder Head/Valve Train Special Tools ....6–2 Timing Belt Rocker Arms and Shafts Valves, Valve Springs and Component Location Removal ....6–31 Valve Seals PCV Collar...
Page 54 Main Menu Table of Contents Special Tools 07HAH - PJ7010B Valve Guide Reamer, 5.5 mm 6-43 07JAA - 001020A Socket, 19 mm 6-12 07JAB - 001020A Holder Handle 6-12 Tappet Adjuster 07MAA - PR70110 6-10 07MAA - PR70120 Tappet Locknut Wrench 6-10 07MAF - PR9010A Valve Spring Compressor Attachment...
Page 55: Vtec Solenoid Valve Inspection
Main Menu Table of Contents VTEC VTEC Solenoid Valve Inspection Disconnect the 2P connector from the VTEC sole- If the filter is not clogged, push the VTEC solenoid noid valve. valve with your finger and check its movement. • If VTEC solenoid valve is normal, check the engine 2.
Page 56 Main Menu Table of Contents Rocker Arms — Manual Inspection Remove the ignition coil covers (see page 6-15). Remove the ignition coils (see page 6-15). Remove the cylinder head covers. NOTE: Refer to pages 6-49, 6-50 when installing the cylinder head cover. Set the No.
Page 57: Inspection Using Special Tools
Main Menu Table of Contents Rocker Arms — Inspection Using Special Tools CAUTION: • Before using the special tool, make sure that the air pressure gauge on the air compressor indicates over 250 kPa (2.5 kgf/cm , 36 psi). • Inspect the valve clearance before rocker arm inspec- tion.
Page 58 Main Menu Table of Contents VTEC Rocker Arms — Inspection Using Special Tools (cont'd) Remove the 10 mm sealing bolt and washer from Make sure that the primary and secondary rocker the inspection hole and connect the tools. arms are mechanically connected by pistons and that the mid rocker arms do not move when pushed manually.
Page 59: Valve Clearance Adjustment
Main Menu Table of Contents Valve Clearance Adjustment NOTE: Rotate the crankshaft to set No. 1 piston at TDC. • Valves should be adjusted cold, when the cylinder • TDC mark (white paint) on the crankshaft pulley head temperature is less than 100°F (38°C). should align with pointer on the timing lower •...
Page 60 Main Menu Table of Contents Valve Clearance Adjustment (cont'd) Tighten the locknut and check the clearance again. Manually inspect the rocker arms for independent operation (see pages 6-7, 6-8). Repeat adjustment if necessary. Adjust valves on No. 1 cylinder. • Adjusting screws are on primary and secondary FEELER rocker arms.
Page 61 Main Menu Table of Contents 7. Rotate the crankshaft 120° clockwise (camshaft pulley 10. Rotate the crankshaft 120° clockwise (camshaft pulley turns 60°). Check that the front intake camshaft pulley turns 60°). Check that the front intake camshaft pulley is positioned as shown. is positioned as shown.
Page 62: Crankshaft Pulley And Pulley Bolt Replacement
Main Menu Table of Contents Crankshaft Pulley and Pulley Bolt Replacement When installing and tightening the pulley, follow the procedure below. Clean, remove any oil and lubricate points shown below. Clean Remove any oil Lubricate CRANKSHAFT PULLEY TIMING BELT CRANKSHAFT DRIVE PULLEY WASHER PULLEY BOLT...
Page 63: Timing Belt
Table of Contents Main Menu Timing Belt Illustrated Index NOTE: • Refer to page 6-18 for positioning crankshaft and pulley before installing the belt. • If it is to be reused, mark the direction of rotation on the belt before removing it. •...
Page 64: Inspection
Main Menu Table of Contents Timing Belt Inspection Tension Adjustment Remove the ignition coil covers and harness clamps. CAUTION: Disconnect the connectors, then remove the ignition • Always adjust timing belt tension with the engine cold. coils. • Do not rotate the crankshaft when the adjusting bolt Remove the cylinder head covers.
Page 65: Removal
Table of Contents Main Menu Removal NOTE: Remove the ignition coil covers, the injector cover • Before removing the belt, turn the crankshaft pulley and the wire harness covers. so the No. 1 piston is at top dead center (TDC) (see page 6-19).
Page 66 Main Menu Table of Contents Timing Belt Removal (cont'd) 7. Remove the breather hose and the air cleaner hous- 12. Remove the transmission mount (see page 5-10). ing (see page 6-26). 13. Install a brace under the engine, then tilt the engine 8.
Page 67 Main Menu Table of Contents 15. Loosen the idler pulley center nut and adjusting nut, 18. Loosen the adjusting bolt 180° turn. Push the ten- then remove the air conditioning (A/C) compressor sioner to remove tension from the timing belt, then belt.
Page 68: Installation
Main Menu Table of Contents Timing Belt Installation Install the timing belt in the reverse order of removal; Set the rear camshaft pulleys so that the No. 1 pis- ton is at TDC. Align the TDC mark on the rear intake Only key points are described here.
Page 69 Main Menu Table of Contents Adjust the timing belt (see page 6-14). 10. If a camshaft is not positioned at TDC, remove the timing belt and adjust the positioning following the Install the lower cover and middle covers. procedure on page 6-18, then reinstall the timing belt.
Page 70: Ckp/Cyp Sensor Replacement
Main Menu Table of Contents CKP/CYP Sensor Replacement Install the CKP/CYP sensor in the reverse order of NOTE: Turn the crankshaft so that the No. 1 piston is at top dead center (see page 6-19). removal. • Refer to page 6-18 and 6-19, when installing the timing belt.
Page 71 Main Menu Table of Contents Cylinder Heads Illustrated Index CAUTION: To avoid damage, wait until the engine coolant temperature drops below 100°F (38°C) before removing the cylin- der head. NOTE: Use new O-rings and gaskets when reassembling. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. CAMSHAFT HOLDER PLATE CAMSHAFT HOLDER...
Page 72 Main Menu Table of Contents Cylinder Heads Illustrated Index (cont'd) CAUTION: To avoid damage, wait until the engine coolant temperature drops below 100°F (38°C) before removing the cylin- der head. NOTE: Use new O-rings and gaskets when reassembling. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. EXHAUST GAS RECIRCULATION (EGR) VALVE REAR VARIABLE VALVE TIMING...
Page 73: Cylinder Head
Main Menu Table of Contents INTAKE VALVE VALVE KEEPERS SPRING OUTER CYLINDER HEAD BOLTS SPRING RETAINER M/T: 11 x 1.5 mm INTAKE VALVE 96 N-m (9.8 kgf-m, 71 Ibf-ft) CYLINDER HEAD BOLT SPRING INNER A/T: 11 x 1.5 mm M/T: 11 x 1.5 mm 76 N-m (7.8 kgf-m, 56 Ibf-ft) VALVE SPRING 96 N-m (9.8 kgf-m, 71 Ibf-ft)
Page 74: Removal
Main Menu Table of Contents Cylinder Heads Removal Engine removal is not required for this procedure. Remove the front exhaust manifold (M/T). Make sure jacks and safety stands are -1. Remove the center rod assembly and under placed properly and hoist brackets are attached to cor- guard (see page 5-7).
Page 75 Main Menu Table of Contents Remove the rear exhaust manifold (M/T). 7. Remove the engine under guard, then remove the front exhaust pipe A (A/T). -1. Remove the muffler (see page 5-9). -2. Remove the rear beam rod B. GASKETS Replace.
Page 76 Main Menu Table of Contents Cylinder Heads Removal (cont'd) 12. Remove the engine cover stay from the strut brace, 17. Remove the hoses, then remove the expansion tank then set the engine cover stay between the engine (see page 5-5). cover and rear hatch latch (NSX-T open top).
Page 77 Main Menu Table of Contents 22. Remove the breather hose, positive Crankcase venti- 24. Remove the water bypass hoses. lation (PCV) hose and vacuum hose. VACUUM HOSE WATER BYPASS BREATHER HOSES PCV HOSE HOSE 25. Remove the harness covers and ground cables from 23.
Page 78 Main Menu Table of Contents Cylinder Heads Removal (cont'd) 26. Remove the engine wire harness connectors and 29. Loosen the adjusting nut and idler pulley center nut, wire harness clamps from the cylinder head and then remove the air conditioning compressor belt intake manifold.
Page 79 Table of Contents Main Menu 32. Remove the water passage. 34. Remove the alternator bracket stiffener (see page 6-16). 35. Remove the alternator bracket. O-RINGS ALTERNATOR Replace. BRACKET CONNECTING PIPE WATER PASSAGE 33. Remove the cylinder head covers. 36. Remove the timing belt (see page 6-15). 37.
Page 80 Table of Contents Main Menu Cylinder Heads Removal (cont'd) 41. Remove the cylinder head bolts, then remove the 38. Remove the front and rear back covers. cylinder head. CAUTION: To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence REAR BACK COVER until all bolts are loosened.
Page 81: Removal
Table of Contents Main Menu Rocker Arms and Shafts Removal Screw a 5 mm bolt into each rocker shaft oil control Bundle the rocker arms with rubber bands to keep them together as sets. orifice, then pull out the rocker shaft oil control ori- fices.
Page 82: Disassembly/Reassembly
Main Menu Table of Contents Rocker Arms and Shafts Disassembly/Reassembly CAUTION: After installing the rocker shaft orifice, try to turn the rocker shaft to make sure that the orifice has been inserted in the hole of the rocker shaft correctly. If the orifice is in place, it should not turn. NOTE: •...
Page 83: Rocker Arms And Lost Motion Assemblies Inspection
Main Menu Table of Contents Rocker Arms and Lost Motion Assemblies Inspection NOTE: When reassembling the primary rocker arm, care- Remove the lost motion assembly from the cylinder fully apply air pressure to the oil passage of the rocker head and inspect it. Pushing it gently with the finger arm.
Page 84 Main Menu Table of Contents Rocker Arms and Shafts Clearance Measure both the intake rocker shafts and exhaust rocker Measure inside diameter of rocker arm, and check for shafts. out-of-round condition. Measure diameter of shaft at first rocker location. Rocker Arm-to-Shaft Clearance (Intake and Exhaust): Standard (New): Primary and Secondary: 0.025-0.052 mm (0.0010-0.0020 in)
Page 85 Main Menu Table of Contents Camshafts Inspection NOTE: Seat the camshaft by pushing it toward the left end of • Do not rotate the camshaft during inspection. cylinder head. • Remove the rocker arms and rocker shafts. Put the camshafts, the camshaft holders and holder Zero the dial indicator against the left end, then push plates on the cylinder head, and then tighten the the camshaft back and forth, and read the end play.
Page 86 Main Menu Table of Contents Camshafts Inspection (cont'd) 9. Remove the camshaft holders and measure widest 11. Check cam lobe height wear. portion of plastigage on each journal. Cam Lobe Height Standard (New): Camshaft-to-Holder Oil Clearance: Standard (New): 0.050 - 0.089 mm (0.002 - 0.004 in) Service Limit: 0.15 mm (0.006 in)
Page 87 Main Menu Table of Contents FRONT BANK CYLINDER ' NUMBER...
Page 88: Valves, Valve Springs And
Main Menu Table of Contents Valves, Valve Springs and Valve Seals Replacement NOTE: Identify valves and valve springs as they are removed so that each item can be reinstalled in its origi- nal position. Using an appropriate-sized socket and plastic mallet, lightly tap the valve retainer to loosen the valve keep- ers before installing the valve spring compressor.
Page 89 Main Menu Table of Contents Valves, Valve Springs and Valve Seals Replacement (cont'd) Install the valve guide seal remover as shown. VALVE GUIDE SEAL REMOVER VALVE SEAL (Commercially available) LISLE P/N 57900 or KD3350 M/T: SEAL Intake Valve Dimensions PULLER A Standard (New): 35.9 - 36.1 mm (1.413 - 1.421 in) B Standard (New): 111.10 - 111.40 mm...
Page 90 Main Menu Table of Contents A/T: Intake Valve Dimensions A Standard (New): 34.9 - 35.1 mm (1.374 - 1.382 in) B Standard (New): 111.10-111.40 mm (4.374 - 4.386 in) C Standard (New): 5.475-5.485 mm (0.2156-0.2159 in) C Service Limit: 5.445 mm (0.2144 in) 1.05—1.35 mm D Standard (New): (0.041-0.053 in)
Page 91 Main Menu Table of Contents Cylinder Heads Warpage NOTE: If camshaft-to-holder oil clearances (see pages 6-35, 6-36) are not within specification, the cylinder head cannot be resurfaced. If camshaft-to-holder oil clearances are within specifica- tions, check the cylinder head for warpage. •...
Page 92: Valve Seats Reconditioning
Main Menu Table of Contents Valve Seats Reconditioning Renew the valve seats in the cylinder head using a After resurfacing the seat, inspect for even valve valve seat grinder. seating: Apply Prussian Blue compound to the valve face, and insert valve in original location in the head, then lift it and snap it closed against the seat sever- NOTE: If guides are worn (see page 6-41), replace them (see page 6-42) before grinding the valve seats.
Page 93: Valve Guides Valve Movement
Main Menu Table of Contents Valve Guides Valve Movement Measure the guide-to-stem clearance with a dial indicator NOTE: An alternate method of checking guide to while rocking the stem in the direction of normal thrust stem clearance is to subtract the O.D. of the valve (wobble method).
Page 94 Main Menu Table of Contents Valve Guides Replacement As illustrated below, use a commercially available Working from the camshaft side, use the driver and air-impact valve guide driver attachment modified to an air hammer to drive the guide about 2 mm (0.1 in) fit the diameter of the valve guides.
Page 95 Main Menu Table of Contents 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 96: Reaming
Main Menu Table of Contents Reaming NOTE: For new valve guides only. Coat both reamer and valve guide with cutting oil. Rotate the reamer clockwise the full length of the valve guide bore. Continue to rotate the reamer clockwise while removing it from the bore.
Page 97 Main Menu Table of Contents Valves, Valve Springs and Valve Seals Installation Sequence NOTE: Exhaust and intake valve seals are NOT interchangeable. VALVE KEEPERS INTAKE VALVE SPRING VALVE SPRING RETAINER VALVE SPRING EXHAUST VALVE SEAL (BLACK SPRING) Replace. NOTE: Place the end of valve spring with closely wound coils toward the cylinder head.
Page 98 Main Menu Table of Contents Valve Installation NOTE: Tap the valve stem only along its axis so you do not bend the stem. • When installing valves in the cylinder head, coat valve stems with oil before inserting into valve guides, and make sure all valves move up and down smoothly.
Page 99: Engine Block
Main Menu Table of Contents Cylinder Heads Installation Install the cylinder heads in the reverse order of removal: • Always use new head gaskets. • Cylinder heads and engine block surface must be clean. • Turn the crankshaft so that No. 1 piston is at TDC (see page 6-19).
Page 100 Main Menu Table of Contents Cylinder Heads Installation (cont'd) REAR PRIMARY Rear: Tighten the cylinder head bolts sequentially in two HEATED OXYGEN SENSOR or three steps. (REAR PRIMARY HO2S) 8 x 1.25 mm • Apply clean engine oil to the bolt threads and 44 N-m (4.5 kgf-m, 22 N-m (2.2 kgf-m, washer contact surfaces.
Page 101: Rocker Arms
Main Menu Table of Contents Rocker Arms Installation Install the rocker arms in the reverse order of removal: • Valve adjusting locknuts should be loosened and adjusting screws backed off before installation. • The component parts must be installed in the original locations.
Page 102 Main Menu Table of Contents Camshafts Installation CAUTION: Valve locknuts should be loosened and ad- justing screws backed off before installation. After wiping down the camshaft and journals in the cylinder head, lubricate both surfaces and install the camshafts and rubber caps. NOTE: Apply liquid gasket around the rubber cap.
Page 103 Main Menu Table of Contents Camshafts Installation (cont'd) Apply liquid gasket to the head mating surfaces of Install the camshaft holder plates. the No. 1 and the No. 4 camshaft holders. Tighten each bolt two turns at a time in the sequence 5.
Page 104 Main Menu Table of Contents 9. Install the CKP/CYP sensor on the front cylinder 11. Insert the dowel pins in the camshaft pulley. head. 12. Install the camshaft pulleys, then tighten the retain- ing bolts to the torque specified. CKP/CYP SENSOR CAMSHAFT PULLEYS RETAINING BOLTS 10 x 1.25 mm...
Page 105 Main Menu Table of Contents Camshafts Installation (cont'd) 17. Apply liquid gasket to the head cover gasket at the 19. Tighten the nuts in two or three steps. In the final step, eight corners of the recesses. tighten all nuts, in sequence, to 12 N-m (1.2 kgf-m, 8.7 Ibf-ft).
Page 106 Main Menu Engine Block Special Tools ..... . 7–2 Piston/Connecting Rod Assemblies and Piston/Connecting Rod Assemblies Crankshaft Inspection ..... . 7–13 Component Location Index .
Page 107: Special Tools
Main Menu Table of Contents Special Tools 7-18 7-18...
Page 108 Main Menu Table of Contents Engine Block Illustrated Index Lubricate all internal parts with engine oil during reassembly. NOTE: • Apply liquid gasket to the mating surfaces of the left • If the bottom of the oil pan is deformed, it should side cover and oil pump case before installing them.
Page 109 Main Menu Table of Contents Engine Block Illustrated Index (cont'd) Lubricate all internal parts with engine oil during reassembly. 11 x 1.5 mm 65 N-m (6.6 kgf-m, 48 Ibf-ft) Apply engine oil to the bolt threads and the washers. NOTE: After torquing each cap, turn crankshaft MAIN BEARING to check for binding.
Page 110 Main Menu Table of Contents CAUTION: NOTE: New rod bearings must be selected by matching • The piston skirt is coated with molybdenum; connecting rod assembly and crankshaft identification handle the piston carefully to prevent any markings (see page 7-8). damage.
Page 111: Flywheel And Drive Plate Replacement
Main Menu Table of Contents Connecting Rods and Crankshaft Flywheel and Drive Plate Replacement End Play Manual Transmission: Connecting Rod End Play: Remove the eight flywheel bolts, then separate the Standard (New): 0.15-0.30 mm flywheel from the crankshaft flange. After installation, (0.006-0.012 in) tighten the bolts in the sequence shown.
Page 112: Main Bearings Clearance
Main Menu Table of Contents Connecting Rod Bearings Main Bearings Clearance Clearance To check main bearing-to-journal oil clearance, Remove the connecting rod cap and bearing half. remove the main caps and bearing halves. Clean each main journal and bearing half with a Clean the crankshaft rod journal and bearing half clean shop towel.
Page 113: Selection
Main Menu Table of Contents Connecting Rod Bearings Main Bearings Selection Selection CAUTION: If the codes are indecipherable because of CAUTION: If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them an accumulation of dirt and dust, do not scrub them with a wire brush or scraper.
Page 114: Piston/Connecting Rod Assemblies And Crankshaft Removal
Main Menu Table of Contents Piston/Connecting Rod Assemblies and Crankshaft Removal Remove the left side cover. If you can feel a ridge of metal or hard carbon around the top of any cylinder, remove it with a ridge reamer. Follow reamer manufacturer's instructions.
Page 115 Main Menu Table of Contents Piston/Connecting Rod Assemblies and Crankshaft Removal (cont'd) • Remove the connecting rod caps after setting 12. Remove the bearing cap bolts and bearing cap side the crank pin at BDC for each cylinder. Remove bolts, then remove the bearing caps. the piston assembly by pushing on the connec- BEARING CAP ting rod.
Page 116: Crankshaft Inspection
Main Menu Table of Contents Crankshaft Inspection • Clean the crankshaft oil passages with pipe Out-of-Round and Taper cleaners or a suitable brush. • Measure out-of-round at the middle of each rod • Check the keyway and threads. and main journal in two places. Alignment •...
Page 117: Cylinder Block Inspection
Main Menu Table of Contents Cylinder Block Inspection Measure wear and taper in directions X and Y at Bore Taper three levels in each cylinder as shown. Limit: (Difference between first and third measure- ment) 0.05 mm (0.002 in) • If measurements in any cylinder are beyond Oversize Bore Service Limit, replace the block.
Page 118: Bore Honing (A/T)
Main Menu Table of Contents Bore Honing (A/T) NOTE: Only scored or scratched cylinder bores must be honed. Measure cylinder bores as shown on page 7-12. If the block is to be reused, hone the cylinders and remeasure the bores. Hone cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree cross-hatch pattern.
Page 119: Piston/Connecting Rod Assemblies Inspection
Main Menu Table of Contents Piston/Connecting Rod Assemblies Inspection Check the piston for distortion or cracks. NOTE: If cylinder is bored, an oversized piston must be used. Measure piston diameter at a point 17 mm (0.67 in) from the bottom of the skirt. NOTE: There are two standard-size pistons (A = no letter and B).
Page 120 Main Menu Table of Contents Piston/Connecting Rod Assemblies Inspection (cont'd) Calculate the difference between cylinder bore diam- eter on page 7-12 and piston diameter.
Page 121: Connecting Rods Selection
Main Menu Table of Contents Connecting Rods Selection Each rod is sorted into one of four tolerance ranges (from O to 0.024 mm, in 0.006 mm increments) depen- ding on the size of its big end bore. It's then stamped with a number (1, 2, 3 or 4) indicating that tolerance.
Page 122: Piston Rings End Gap
Main Menu Table of Contents Piston Rings Replacement End Gap Using a ring expander, remove the old piston rings. Using a piston, push a new ring into the cylinder bore 15-20 mm (0.6 - 0.8 in) from the bottom. Clean all ring grooves thoroughly. NOTE: Measure the piston ring end-gap with a feeler •...
Page 123: Ring-To-Groove Clearance
Main Menu Table of Contents Piston Rings Ring-to-Groove Clearances After installing a new set of rings, measure ring-to-groove clearances: Top Ring Clearance M/T: Standard (New): 0.035 - 0.065 mm (0.0014-0.0026 in) Service Limit: 0.13 mm (0.005 in) A/T: Standard (New): 0.030 - 0.055 mm (0.0012 - 0.0022 in) Service Limit: 0.13 mm (0.005 in)
Page 124: Alignment
Main Menu Table of Contents Piston Rings Alignment Install the rings as shown. NOTE: • The top ring has an R1 or R mark. • The second ring has an R2 or RN mark. NOTE: The manufacturing marks must be facing upward.
Page 125 Main Menu Table of Contents Rotate the rings in their grooves to make sure they do not bind. Position the ring end gaps as shown:...
Page 126 Main Menu Table of Contents Piston/Connecting Rod Assemblies Installation Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores. If the crankshaft is already installed: • Guide the piston carefully to prevent damage. •...
Page 127 Main Menu Table of Contents Piston/Connecting Rod Assemblies Installation (cont'd) If the crankshaft is not installed: • Remove the rod caps and bearings, install the ring compressor, then position the piston in the cylinder and tap it in using the wooden handle of a hammer.
Page 128: Oil Seal Installation
Main Menu Table of Contents 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 seal. Using the special tools, drive in the flywheel-end seal until the driver bottoms against left side cover.
Page 129 Main Menu Table of Contents Crankshaft Installation Before installing the crankshaft, apply a coat of NOTE: engine oil to the main bearings and rod bear- • Guide the piston carefully to prevent damage. ings. • Fit long rubber hoses (about 30 cm long) to con- necting rod bolts to protect the crankshaft.
Page 130 Main Menu Table of Contents Crankshaft Installation (cont'd) Check the rod bearing clearance with plastigage BEARING CAP BOLTS TORQUE SEQUENCE (see page 7-7), then torque the connecting rod cap nuts. NOTE: Reference numbers on connecting rods are for big-end bore tolerance and do NOT indicate the posi- tion of piston in engine.
Page 131 Main Menu Table of Contents OIL PUMP SIDE: BEARING CAP BRIDGE 6 x 1.0 mm CAP BRIDGE BOLT 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) 11 x 1.5 mm 65 N-m (6.6 kgf-m, OIL SCREEN BAFFLE PLATE 48 Ibf-ft) 6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) SIDE BOLT...
Page 132 Main Menu Table of Contents Crankshaft Installation (cont'd) LEFT SIDE COVER Apply liquid gasket along the broken line. OIL PUMP Apply liquid gasket along the broken line. • Do not install the parts if five minutes or more have elapsed since applying liquid gasket. Instead reapply liquid gasket after removing old residue.
Page 133: Engine Lubrication
Main Menu Engine Lubrication Special Tools ......... . . 8–2 Oil Filter Replacement...
Page 134: Special Tools
Main Menu Table of Contents Special Tools...
Page 135 Main Menu Table of Contents Engine Lubrication 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. • If the bottom of the oil pan is deformed, it should be repaired or the oil pan should be replaced to retain proper clearance between the screen and the bottom.
Page 136: Engine Oil
Main Menu Table of Contents Engine Oil Inspection Check engine oil with the engine off and the car parked on level ground. Make certain that the oil level indicated on the dipstick is between the upper and lower marks. If the level has dropped close to the lower mark, add oil until it reaches the upper mark.
Page 137: Replacement
Main Menu Table of Contents Replacement CAUTION: Remove the drain plug carefully while the en- gine is hot, the hot oil may cause scalding. Warm up the engine. Drain the engine oil. Reinstall the drain plug with a new washer, and refill with the recommended oil.
Page 138 Main Menu Table of Contents 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: An oil with a viscosity of 10W-30 is preferred for improved fuel economy and year-round protection in the vehicle.
Page 139: Replacement
Main Menu Table of Contents Oil Filter Replacement CAUTION: Loosen the oil filter carefully while the engine is hot, the hot oil may cause scalding. Remove the oil filter with the special tool as shown. OIL FILTER WRENCH 07912-6110001 Torque: One turn (22 N-m (2.2 kgf-m, 16 Ibf-ft)) Inspect the threads and rubber seal on the new filter.
Page 140: Oil Pressure Testing
Main Menu Table of Contents Oil Pressure Testing If the oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is correct: Remove the engine oil pressure switch, and install an oil pressure gauge. Start the engine.
Page 141: Oil Pump Overhaul
Main Menu Table of Contents Oil Pump Overhaul NOTE: • Use new O-rings when reassembling. • Apply oil to O-rings before installation. PUMP COVER 6 x 1.0 mm Inspection, page 8-8, 6 N-m (0.6 kgf-m, 4 Ibf-ft) PUMP HOUSING Inspection, page 8-8, OIL SEAL Installation, page Replace.
Page 142: Removal/Inspection/Installation
Main Menu Table of Contents Oil Pump Removal/lnspection/lnstallation 1. Drain the engine oil. 11. Remove the nine screws from the pump housing, then separate the housing and cover. 2. Remove the timing belt (see page 6-15). 12. Check the inner-to-outer rotor radial clearance. 3.
Page 143 Main Menu Table of Contents 14. Check the housing-to-outer rotor radial clearance. 18. Reassemble the oil pump. Apply liquid thread-lock to the pump housing screws. Housing-to-Rotor Radial Clearance Standard (New): 0.11 - 0.20 mm 19. Check that the oil pump turns freely. (0.004 - 0.008 in) Service Limit: 0.21 mm (0.008 in)
Page 144 Main Menu Table of Contents Oil Pump Removal/lnspection/lnstallation (cont'd) 23. Install the oil pump on the cylinder block. 27. Apply liquid gasket to the oil pump and left side cover mating areas as shown below. 24. Install the oil pass pipe and joint. 25.
Page 145 Main Menu Table of Contents 29. Tighten bolts and nuts finger tight at six points as shown below. 30. Starting with nut torque all bolts and nuts, in a clockwise pattern in three steps. NOTE: Excessive tightening can cause distortion of oil pan gasket and oil leakage.
Page 146: Oil Cooler, Oil Filter Base
Main Menu Table of Contents Oil Cooler, Oil Filter Base Illustrated Index NOTE: • Use new O-rings when reassembling. • Apply oil to O-rings before installation. OIL COOLER CENTER BOLT • Use liquid gasket, Part No. 08718-0001 or 08718-0003. 49 N-m (5.0 kgf-m, 36 Ibf-ft) 2 mm PIN SPRING RELIEF VALVE...
Page 147: Intake Manifold/Exhaust System
Main Menu Intake Manifold/Exhaust System Special Tools ........9–2 Intake Manifold Replacement...
Page 148: Special Tools
Main Menu Table of Contents Special Tools 9-4, 9-5, 9-6,...
Page 149: Intake Manifold Replacement
Main Menu Table of Contents 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. 6 x 1.0 mm INTAKE MANIFOLD 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) PLATE...
Page 150: Exhaust Manifold Replacement
Main Menu Table of Contents Exhaust Manifold Replacement NOTE: Use new gaskets and self-locking nuts. M/T: GASKET Replace. FRONT EXHAUST MANIFOLD COVER 8 x 1.25 mm 8 x 1.25 mm 22 N-m (2.2 kgf-m, 22 N-m (2.2 kgf-m 16 Ibf-ft) 16 Ibf-ft) COVER FRONT PRIMARY HEATED...
Page 151 Main Menu Table of Contents A/T: FRONT PRIMARY HO2S 44 N-m (4.5 kgf-m, 33 Ibf-ft) • Be careful not to damage. • Use the special tool when removing and installing. GASKET Replace. 6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) REAR PRIMARY HO2S...
Page 152: Exhaust Pipe And Muffler Replacement
Main Menu Table of Contents Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. M/T: LONG BOLT REAR SECONDARY HEATED 8 x 1.25 mm OXYGEN SENSOR (REAR 22 N-m (2.2 kgf-m, 16 Ibf-ft) SECONDARY HO2S) Replace.
Page 153 Main Menu Table of Contents A/T: REAR SECONDARY HO2S 44 N-m (4.5 kgf-m, 33 Ibf-ft) GASKETS SELF-LOCKING NUTS • Be careful not to 10 x 1.25 mm Replace. damage. 33 N-m (3.4 kgf-m, 25 Ibf-ft) • Use the special tool Replace.
Page 154 Main Menu Cooling Component Location Index ......10–2 Pressure Testing ........10–8 Radiator Thermostat...
Page 155: Cooling
Main Menu Table of Contents Cooling Illustrated Index NOTE: System is under high pressure when the • Check all cooling system hoses for damage, engine is hot. To avoid danger of releasing scalding leaks or deterioration and replace if necessary. engine coolant, remove the cap only when the engine is •...
Page 156 Main Menu Table of Contents ENGINE OIL COOLER EXPANSION TANK Refilling and bleeding, page 10-5 Leak Test, page 10-8 Test, page 10-8 ENGINE OIL COOLER PIPE AUTOMATIC TRANSMISSION FLUID (ATF) COOLER...
Page 157: Radiator Replacement
Main Menu Table of Contents Radiator Replacement Remove the spare tire. Install the radiator in the reverse order of removal: Drain the radiator (see page 10-5 thru 10-7). NOTE: • Set the upper and lower cushions securely. Disconnect the fan motor connector and the •...
Page 158 Main Menu Table of Contents Engine Coolant Refilling and Bleeding Open the hood, the rear window and the engine CAUTION: When pouring engine coolant, be sure to cover. shut the relay box lid and not let coolant spill on the electrical parts or the paint.
Page 159 Main Menu Table of Contents Radiator Engine Coolant Refilling and Bleeding (cont'd) Install rubber hoses on the drain bolts at the front Open all four bleeders. and rear of the engine under the cylinder banks. 1) Loosen the radiator bleed plug. Loosen the drain bolts to drain the coolant.
Page 160 Main Menu Table of Contents 10. Fill the expansion tank with engine coolant. As 14. Install the expansion tank cap, and turn it 60 degrees (where it engages the first lock tab of filler neck). coolant starts to run out in a steady stream without bubbles, tighten the bleeders in sequence: thermo cover bleed bolt, radiator bleed plug, heater pipe 1 5.
Page 161: Expansion Tank Cap Testing
Main Menu Table of Contents Expansion Tank Cap Testing Remove the expansion tank cap, wet its seal with engine coolant, then install it on the pressure tester. Apply a pressure of 93-123 kPa (0.95 - 1.25 kgf/cm 14-18 psi). PRESSURE TESTER Check for a drop in pressure.
Page 162: Thermostat Replacement
Main Menu Table of Contents Thermostat Replacement NOTE: Use new gaskets and O-rings when reassem- bling. COOLANT TEMPERATURE GAUGE SENDING UNIT 9 N-m (0.9 kgf-m, 7 Ibf-ft) Apply liquid gasket to the threads. WATER PASSAGE 8 x 1.25 mm 22 N-m (2.2 kgf-m, 16 Ibf-ft) BLEED BOLT 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft)
Page 163: Water Pump
Main Menu Table of Contents Water Pump Illustrated Index NOTE: Use new O-rings and new special bolts when reassembling. COOLANT RADIATOR FAN TEMPERATURE GAUGE CONTROL SENSOR SENDING UNIT 27 N-m (2.8 kgf-m, 9 N-m (0.9 kgf-m, 7 Ibf-ft) 20 Ibf-ft) Apply liquid gasket to the threads.
Page 164: Inspection
Main Menu Table of Contents Replacement Inspection Remove the timing belt (see page 6-15). Remove the timing belt (see page 6-15). Turn the water pump pulley counterclockwise. Check Unscrew the bolts, then remove the water pump. that it turns freely. NOTE: Inspect and clean the O-ring groove and Check for signs of seal leakage.
Page 165 Main Menu Fuel and Emissions Special Tools ....11–2 Front Compartment and Under-dash Drive By Wire System Intake Air System Component Location Index ’97–99 Models .
Page 166 Main Menu Table of Contents Special Tools Note: Refer to page 11-2c 11-2g for further page references 11-151,11-155, 11-163, 11-164, 11-172, 11-173, 11-175, 11-178, 11-139 11-173 11-38, 11-60, 11-62, 11-64, 11-81,11-91,11-129,11-160, 11-162, 11-163, 11-38c 11-40 11-133, 11-137...
Page 167 Main Menu Table of Contents Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-52. THROTTLE POSITION (TP) SENSOR EXHAUST GAS RECIRCULATION (EGR) VALVE and LIFT SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR FUEL TANK PRESSURE SENSOR INTAKE AIR TEMPERATURE (IAT) SENSOR EVAPORATIVE EMISSION CRANKSHAFT POSITION/...
Page 168 Main Menu Table of Contents Component Locations Index (cont'd) For Troubleshooting of DTC related components, see chart on page 11-52. CLUTCH SWITCH (M/T only) Troubleshooting, page 11-125 ACCELERATOR POSITION (AP) SENSOR THROTTLE CABLE Inspection/Adjustment, page 11-150 Installation, page 11-150 PGM-FI MAIN RELAY Relay Testing, page 11-143...
Page 169 Main Menu Table of Contents For Troubleshooting of DTC related components, see chart on page 11-52. FUEL TANK EVAPORATIVE EMISSION (EVAP) VALVE FUEL PUMP Testing, page 11-142 Replacement, page 11-142 FUEL FEED PIPE FUEL FILTER Replacement, page 11-138 FUEL PRESSURE REGULATOR Testing, page 11-137 Replacement, page...
Page 170 Main Menu Table of Contents Component Locations Index (cont'd) For Troubleshooting of DTC related components, see chart on page 11-52. THROTTLE BODY (TB) Inspection, page 11-151 Disassembly, page 11-152 AIR CLEANER (ACL) Disassembly, page 11-149 INTAKE AIR DUCT INTAKE AIR BYPASS (IAB) CONTROL DIAPHRAGM Troubleshooting, page 11-155 INTAKE AIR BYPASS (IAB) VALVE BODY ASSEMBLY...
Page 171 Main Menu Table of Contents System Description Vacuum Connections For Troubleshooting of DTC related components, see chart on page 11-52. CONTROL page 11-8 EVAP CONTROL CANISTER VENT SHUT VALVE EVAP PURGE CONTROL SOLENOID EVAP CONTROL VALVE CANISTER To EVAP TWO-WAY VALVE INTAKE BYPASS...
Page 172 Main Menu Table of Contents System Description Vacuum Connections (cont'd) Control Box For Troubleshooting of DTC related components, see chart on page 11-52. EXHAUST GAS RECIRCULATION (EGR) VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INTAKE AIR BYPASS (IAB) CONTROL SOLENOID VALVE...
Page 173 Main Menu Table of Contents INTAKE AIR BYPASS (IAB) CONTROL DIAPHRAGM FRONT PRIMARY HEATED OXYGEN SENSOR (HO2S) FRONT THREE WAY CATALYTIC CONVERTER (TWO (BANK 2, SENSOR 1) REAR THREE WAY CATALYTIC CONVERTER (TWO REAR PRIMARY HEATED OXYGEN SENSOR (HO2S) POSITIVE CRANKCASE VENTILATION (PCV) VALVE (BANK 1, SENSOR 1) EXHAUST GAS RECIRCULATION (EGR) VALVE FRONT SECONDARY HEATED OXYGEN SENSOR (HO2S)
Page 174 Main Menu Table of Contents System Description Electrical Connections FUSES BRAKE LIGHTS HORN (20 A)* THL MOTOR (20 A)** CLOCK (7.5 A)* ACG (120 A)** ACG(S) (20 A)** IG COIL (30 A)** No. 2 FUEL PUMP SRS2 (15 A)*** No. 5 BACK-UP LIGHTS ALTERNATOR In the under-hood fuse/relay box TURN SIGNALS (15 A)**»...
Page 175 Main Menu Table of Contents...
Page 176 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 177 Main Menu Table of Contents...
Page 178 Main Menu Table of Contents System Description Electrical Connections (cont'd) (To page 11-15)
Page 179 Main Menu Table of Contents (From page 11-14)
Page 180 Main Menu Table of Contents System Description Electrical Connections (cont'd) (To page 11-17)
Page 181 Main Menu Table of Contents (From page 11-16)
Page 182 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 183 Main Menu Table of Contents...
Page 184 Main Menu Table of Contents System Description Electrical Connections (cont'd)
Page 185 Main Menu Table of Contents...
Page 186 Main Menu Table of Contents System Description Electrical Connections (cont'd) C489 C145 in engine compartment above fuel filter...
Page 187 Main Menu Table of Contents...
Page 188 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Right Side)]...
Page 189 Main Menu Table of Contents 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). : Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 190 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Left Side)] (cont'd)
Page 191 Main Menu Table of Contents 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). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 192 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 193 Main Menu Table of Contents 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). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 194 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 195 Main Menu Table of Contents 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). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 196 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels] (cont'd)
Page 197 Main Menu Table of Contents 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). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 198 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash] (cont'd) FLOOR WIRE HARNESS UNDER-HOOD FUSE/RELAY UNDER-DASH FUSE FRONT COMPARTMENT WIRE HARNESS SIDE WIRE HARNESS...
Page 199 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEU/BLK and YEL/BLK are not the same). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 200 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash] (cont'd) UNDER-HOOD FLOOR FUSE/RELAY WIRE HARNESS SIDE WIRE HARNESS UNDER-DASH FUSE SUB RELAY BOX A FRONT COMPARTMENT WIRE HARNESS...
Page 201 Main Menu Table of Contents NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, YEU/BLK and YEU/BLK are not the same). Related to Fuel and Emissions System. — Connector with male terminals (double outline): View from terminal side —...
Page 202 Main Menu Table of Contents 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.
Page 203 Main Menu Table of Contents Engine Control Module (ECM) Reset Procedure Either of the following actions, will reset the ECM. Using the OBD II scan tool or Honda PGM Tester to clear the ECM's memory. NOTE: See the OBD II scan tool or Honda PGM Tester user's manuals for specific operating instructions. Turn the ignition switch OFF.
Page 204 Main Menu Table of Contents Troubleshooting Troubleshooting Procedures (cont'd) If the inspection for a particular code requires voltage or resistance checks at the ECM connectors, remove the bulkhead panels. Unbolt the ECM. Check the system according to the procedure described for the appropriate code(s) listed on the following pages.
Page 205 Main Menu Table of Contents CAUTION: Puncturing the insulation on a wire can cause poor or intermittent electrical connections. Bring the tester probe into contact with the terminal from the connector side of wire harness connectors in the engine compartment. For female connectors, just touch lightly with the tester probe and do not insert the probe. TESTER PROBE RUBBER SEAL WIRE HARNESS...
Page 206 Main Menu Table of Contents 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 11-38. Troubleshoot each probable cause in the order listed (from left to right) until the symptom is eliminated.
Page 207 Main Menu Table of Contents Probable Cause List (For the DTC chart, see page 11-52.) Probable Cause Page System Engine Control Module (ECM) 11-61, 11-62 11-132, 11-139 Fuel pressure and fuel pump relay 11-143 PGM-FI main relay Section 23 Ignition system See DTC chart Crankshaft Position/Cylinder Position sensor circuit See DTC chart...
Page 208 Main Menu Table of Contents Troubleshooting Troubleshooting Procedures (cont'd) ECM Data By connecting the OBD II scan tool or the Honda PGM Tester to the 16P data link connector (DLC), various data can be retrieved from the ECM. The items listed in the table below conform to the SAE recommended practice. The Honda PGM Tester also reads data beyond that recommended by SAE.
Page 209 Main Menu Table of Contents Data Description Operating Value Freeze Data HO2S At idle speed: closed Loop status is indicated as "open" or "closed". Feedback Closed: Based on the H02S output, the ECM deter- Loop Status mines the air/fuel ratio and controls the amount of (Bank 1: Rear) injected fuel.
Page 210 Main Menu Main Menu Table of Contents Table of Contents Troubleshooting Engine Control Module Terminal Arrangement ECM CONNECTOR A (26P) Wire side of female terminals ECM CONNECTOR A (26P) NOTE: Standard battery voltage is 12 V. Terminal Wire Description Terminal name Signal number color...
Page 211 Main Menu Main Menu Table of Contents Table of Contents Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR B (16P) *: M/T Terminal Wire Terminal name Description Signal number color With engine at low rpm: 0 V VTP SWF (FRONT VTEC Detects VTEC pressure switch With engine at high rpm:...
Page 212 Main Menu Main Menu Table of Contents Table of Contents Troubleshooting Engine Control Module Terminal Arrangement (cont'd) ECM CONNECTOR C (12P) Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR C (12P) *: M/T Terminal Wire Terminal name Description...
Page 213 Main Menu Main Menu Table of Contents Table of Contents ECM CONNECTOR D (22P) Wire side of female terminals ECM CONNECTOR D (22P) NOTE: Standard battery voltage is 12 V. Terminal Wire Terminal name Decription Signal number color VBU (VOLTAGE BACK UP) Battery voltage at all times Power source for the ECM con- WHT/YEL...
Page 214 Main Menu Table of Contents Troubleshooting Engine Control Module Terminal Arrangement (cont'd) Wire side of female terminals NOTE: Standard battery voltage is 12 V. ECM CONNECTOR F (26P) *: M/T Terminal Wire Terminal name Description Signal number color VCC1 Provides sensor voltage With ignition switch ON (II): about 5 V YEL/WHT With ignition switch OFF: 0 V...
Page 215 Main Menu Table of Contents ECM CONNECTOR G (12P) Wire side of female terminals ECM CONNECTOR G (12P) NOTE: Standard battery voltage is 12 V. Terminal Wire Terminal name Description Signal number color IGM1 (POWER SOURCE) Power source for throttle With ignition switch ON (II): GRN/RED valve control motor...
Page 216 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart Note: Refer to page 11-48c 11-9g for DTCs not listed on this chart. Detection Item Probable Cause Page (MIL indication*) Manifold Absolute • Open or short in MAP sensor circuit •...
Page 217 Main Menu Table of Contents Detection Item Probable Cause Page (MIL indication) • Short in Rear Secondary HO2S (Bank 1, Rear Secondary Heated Oxygen Sensor 2) circuit Sensor P0137 (64) 11-82 • Rear Secondary H02S (Bank 1, Sensor 2) Circuit Low Voltage (Bank 1, Sensor 2) •...
Page 218 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) Detection Item Probable Cause Page (MIL indication) System Too Lean • Fuel supply system [Front Bank (Bank 2)] • Front Primary H02S (Bank 2, Sensor 1) • MAP sensor 11-87 P0174 (45)
Page 219 Main Menu Table of Contents Detection Item Probable Cause Page (MIL indication) P0700 Automatic P0715 Transaxle P0720 P0725 (70)* Section 14 P0730 P0740 P0753 P0758 Barometric • ECM (Baro sensor) Pressure Circuit P1106 (13) 11-103 Range/Performance Problem Barometric • ECM (Baro sensor) P1107 (13) Pressure Circuit...
Page 220 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart (cont'd) Probable Cause Page (MIL indication) Detection Item VTEC System • Open or short in Front VTEC Solenoid Malfunction Valve circuit [Front Bank (Bank 2)] • Front VTEC Solenoid Valve •...
Page 221 Main Menu Table of Contents Detection Item Probable Cause Page (MIL indication) Evaporative Emission Control • Vacuum connection System Leak Detected (Fuel Tank • Fuel tank Area) • Fuel tank pressure sensor • Fuel fill cap P1456 (90)** • EVAP bypass solenoid valve 11-172 ('97-99) •...
Page 222 Main Menu Table of Contents 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 223 Main Menu Table of Contents PGM-FI System System Description INPUTS ENGINE CONTROL MODULE (ECM) OUTPUTS Front Primary H02S Fuel Injectors Rear Primary HO2S PGM-FI M.ain Relay (Fuel Pump) Front Secondary HO2S Malfunction Indicator Lamp Rear Secondary H02S Throttle Valve Control Motor MAP Sensor A/C Compressor Clutch Relay CKP/CYP Sensor...
Page 224 Main Menu Table of Contents PGM-FI System System Description (cont'd) Fuel Cut-off Control During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at speeds over 1,500 rpm. Fuel cut-off action also takes place when engine speed exceeds 8,300 rpm, regardless of the position of the throttle valve, to protect the engine from over-revving.
Page 225 Main Menu Table of Contents Engine Control Module (ECM) The Malfunction Indicator Lamp NOTE: If this symptom is intermittent, check for a loose No. 5 BACK-UP LIGHTS, ALTERNATOR, (MIL) never comes on (even for TURN SIGNALS (15 A) fuse in the under-dash fuse/relay box, a poor connection at ECM terminal two seconds) after ignition is A7, or an intermittent open in the BLU wire between the ECM (A7) and the gauge assembly.
Page 226 Main Menu Table of Contents PGM-FI System Engine Control Module (ECM) (cont'd) The Malfunction Indicator Lamp NOTE: (MIL) stays on or comes on after • When there is no Diagnostic Trouble Code (DTC) stored, the MIL will stay on if the SCS service two seconds.
Page 227 Main Menu Table of Contents (From page 11-62) Check for a short in the wire (MIL line): 1. Turn the ignition switch OFF. 2. Disconnect the ECM connec- tor A (26P). 3. Turn the ignition switch ON (II). Repair short to body ground in Is the MIL ON? the wire between the ECM (A7) and MIL.
Page 228 Main Menu Table of Contents PGM-FI System Engine Control Module (ECM) (cont'd) (From page 11-63) Check for a short in the AP sen- sor: 1. Turn the ignition switch OFF. 2. Connect the SCS service con- nector. 3. Disconnect the AP sensor 3P connector.
Page 229 Main Menu Table of Contents Drive By Wire System System Description The Drive By Wire System is an electronic throttle control system. This system consists of the throttle valve control motor and Throttle Position (TP) sensor assembled in Throttle Body (TB), the accelerator position sensor, and the Engine Control Module (ECM).
Page 230 Main Menu Table of Contents Drive By Wire System System Description (cont'd) Cruise Control Function The ECM controls the throttle valve control motor to maintain the set speed when the cruise control system is operating. The throttle valve control motor takes the place of the cruise control actuator. Traction Control System (TCS) Function If wheel spin occurs during acceleration or cornering, the TCS control unit requests the ECM to reduce the engine power by retarding the ignition timing and closing the throttle valve.
Page 231 Main Menu Table of Contents Idle Control System Air Conditioning Signal This signals the ECM when there is a demand for cooling from the air conditioning system. Inspection of Air Conditioning Signal. Check for a short in the wire (ACS line): 1.
Page 232 Main Menu Table of Contents (From page 11-118) Check for an open in the wire: Momentarily connect the No. 4 ter- Is there a clicking noise from the minal of the 4P connector on the A/C compressor clutch? A/C clutch relay to body ground several times.
Page 233 Main Menu Table of Contents Idle Control System Alternator (ALT) FR Signal This signals the ECM when the Alternator (ALT) is charging. Inspection of ALT FR Signal. Check for a short in the wire (ALTF line): 1. Disconnect the GRN 4P con- nector from the ALT.
Page 234 Main Menu Table of Contents (From page 11-120) Check for an open in the wire (ALTF line): 1. Turn the ignition switch OFF. 2. Disconnect the negative battery cable from the battery. 3. Disconnect the ECM connec- tor D (22P) from the ECM. 4.
Page 235 Main Menu Table of Contents Idle Control System Automatic Transaxle (A/T) Gear Position Signal This signals the ECM when the transmission is in position. Inspection of A/T Gear Position Signal. Check the operation of the A/T gear position switch: 1. Turn the ignition switch ON (II). 2.
Page 236 Main Menu Table of Contents (From page 11-122) Check for an open in the wire (ATF PN line): 1. Turn the ignition switch OFF. 2. Reconnect the 30P (C412) con- nector to the gauge assembly. 3. Reconnect the 26P connector to the TCM.
Page 237 Main Menu Table of Contents Idle Control System Neutral Switch Signal (M/T) This signals the ECM when the transmission is in neutral. Inspection of neutral switch signal. Check for an open in the wire (NTSW line): 1. Turn the ignition switch ON (II). 2.
Page 238 Main Menu Table of Contents Clutch Switch Signal (M/T) This signals the ECM when the clutch is engaged. Inspection of clutch switch signal. Check for an open in the wire (MTCLS line): 1. Turn the ignition switch ON (II). 2. Measure voltage between ECM connector terminals C4 and A26.
Page 239 Main Menu Table of Contents Idle Control System Clutch Switch Signal (M/T) (cont'd) (From page 11-125) Check the clutch switch: 1. Turn the ignition switch OFF: 2. Disconnect the 3P connector from the clutch switch. Is there approx. 5 V? 3.
Page 240 Main Menu Table of Contents Brake Switch Signal This signals the ECM when the brake pedal is depressed. Inspection of Brake Switch Signal. Are the brake lights on without Inspect the brake switch (see depressing the brake pedal? section 19). Depress the brake pedal.
Page 241 Main Menu Table of Contents Idle Control System Starter Switch Signal This signals the ECM when the engine is cranking. Inspection of Starter Switch Sig- NOTE: nal. • M/T: Clutch pedal must be depressed. • A/T: Transmission in position. Check for an open or short in the wire (STS line): Measure voltage between ECM connector terminals C6 and A26...
Page 242 Main Menu Table of Contents Idle Speed Setting Inspection/Adjustment Restart the engine. NOTE: Before setting the idle speed, check the these Check idling in no-load conditions in which the items: headlights, blower fan, rear defogger, cooling fan, The MIL has not been reported on. and air conditioner are not operating.
Page 243 Main Menu Table of Contents Fuel Supply System Fuel Lines Check fuel system lines, hoses, connections and components for damage, leaks or deterioration, and replace if necessary. 27 N-m (2.8 kgf-m, 21 Ibf-ft) 27 N-m (2.8 kgf-m, 21 Ibf-ft) 27 N-m (2.8 kgf-m, 21 Ibf-ft) 22 N-m (2.2 kgf-m, 16 Ibf-ft)
Page 244 Main Menu Table of Contents Check all hose clamps and retighten if necessary.
Page 245 Main Menu Table of Contents Fuel Supply System System Description The fuel supply system consists of a fuel tank, in-tank high-pressure fuel pump, fuel pump relay, fuel pump resistor PGM-FI main relay, fuel filter, fuel pressure regu- lator, fuel injectors, injector resistor (A/T), and fuel deliv- ery and return lines.
Page 246: Fuel Pressure
Main Menu Table of Contents Fuel Pressure Relieving Before disconnecting fuel pipes or hoses, release pres- sure from the system by loosening the 6 mm service bolt on top of the fuel filter. Do not smoke while working on the fuel system. Keep open flames or sparks away from your work area.
Page 247 Main Menu Table of Contents Inspection If the fuel pressure is not as specified, first check the fuel pump (see page 11-142). If the fuel pump is OK, 1. Relieve fuel pressure (see page 11-132) check the following: Remove the service bolt on the fuel filter while If the fuel pressure is higher than specified, inspect for: holding the banjo bolt with another wrench.
Page 248: Fuel Injectors
Main Menu Table of Contents Fuel Supply System Fuel Injectors Replacement Do not smoke during the work. Keep open flames away from your work area. 1. Relieve fuel pressure (see page 11-132). 2. Remove the intake manifold covers. 3. Disconnect the connectors from the fuel injectors and the IAT sensor. 4.
Page 249 Main Menu Table of Contents 13. To prevent damage to the O-rings, install the fuel injectors in the fuel rail first, then install them in the intake mani- fold. FUEL RAILS FUEL RAIL INSULATOR 14. Align the center line on the connector with the mark on the fuel rail. FUEL RAIL 15.
Page 250 Main Menu Table of Contents Fuel Supply System Fuel Injector Resistor (A/T) Description Testing Disconnect the fuel injector resistor connector. The fuel injector resistor lowers the current supplied to the fuel injectors to prevent damage to the fuel injector Check for resistance between each of the fuel injec- coils.
Page 251 Main Menu Table of Contents Fuel Pressure Regulator Description Testing The fuel pressure regulator maintains a constant fuel pressure to the fuel injectors. When the difference Do not smoke during the test. Keep open between the fuel pressure and manifold pressure flames away from your work area.
Page 252 Main Menu Table of Contents Fuel Supply System Fuel Pressure Regulator (cont'd) Replacement Do not smoke while working on fuel sys- tem. Keep open flame away from your work area. Place a shop towel under fuel pressure regulator, then relieve fuel pressure (see page 11-132). Disconnect the vacuum hose and fuel return hose.
Page 253: Fuel Filter
Main Menu Table of Contents Fuel Supply System Fuel Filter Replacement Do not smoke while working on fuel sys- tem. Keep open flame away from your work area. The fuel filter should be replaced every 4 years or 60,000 miles (96,000 km), whichever comes first, or whenever the fuel pressure drops below the specified value [324 - 363 kPa (3.3 - 3.7 kgf/cm , 47 - 53 psi) with the fuel pres-...
Page 254: Fuel Pump
Main Menu Table of Contents Fuel Supply System Fuel Pump Testing Replacement Do not smoke while working on fuel sys- Do not smoke during the test. Keep open flame away from your work area. tem. Keep open flames away from your work area. If you suspect a problem with the fuel pump, check that 1.
Page 255 Main Menu Table of Contents PGM-FI Main Relay Description Relay Testing The PGM-FI main relay actually contains two individual NOTE: If the car starts and continues to run, the PGM-FI relays. main relay is OK. The relay is located behind the passenger's seat back panel.
Page 256 Main Menu Table of Contents Fuel Supply System PGM-FI Main Relay (cont'd) Troubleshooting Engine will not start. Inspection of PGM-FI main relay and relay harness. PGM-FI MAIN RELAY 8P CONNECTOR Check for an open in the wire (PG1 line): 1. Turn the ignition switch OFF. 2.
Page 257 Main Menu Table of Contents (From page 11-144) Check for an open in the wire (IGSW line): Measure voltage between the PGM-FI main relay 4P connector terminal No. 4 and body ground. Replace the IG COIL (30 A) fuse in the engine compart- ment fuse/relay box.
Page 258 Main Menu Table of Contents Fuel Supply System PGM-FI Main Relay (cont'd) (From page 11-145) Check for an open in the wires (IGP lines): 1. Reconnect the ECM connector A (26P). 2. Reconnect the PGM-FI main relay 4P and 8P connectors. 3.
Page 259: Fuel Tank
Main Menu Table of Contents Fuel Tank Replacement Do not smoke while working on fuel system. Keep open flame away from your work area. Make sure lifts are placed properly (see section 1. Raise the vehicle. 2. Remove the drain bolt, and drain the fuel into an approved container. 3.
Page 260 Main Menu Table of Contents Intake Air System System Description The system supplies air for all engine needs. It consists of the intake air pipe. Air Cleaner (ACL), intake air duct, throttle body, and intake manifold. A resonator in the intake air duct provides additional silencing as air is drawn into the system. IAB CONTROL SOLENOID VALVE To No.
Page 261 Main Menu Table of Contents Air Cleaner (ACL) ACL Element Replacement ACL HOUSING COVER ACL ELEMENT Normal conditions: Replace air cleaner element every 30,000 miles (48,000 km) or 24 months whichever comes first. Severe conditions: Clean air cleaner element every ACL HOUSING 15,000 miles (24,000 km) or 12 months and replace every 30,000...
Page 262 Main Menu Table of Contents Intake Air System Throttle Cable ——— Inspection/Adjustment Installation Remove the accelerator position sensor cover. Rotate the throttle linkage counterclockwise, then install the throttle cable in the throttle linkage and Check that the throttle cable operates smoothly with install the cable housing in the cable bracket.
Page 263 Main Menu Table of Contents Throttle Body Description Inspection The throttle body is of the single-barrel side-draft type. The lower portion of the throttle valve is heated by CAUTION: Do not adjust the throttle stop screw. It is engine coolant which is fed from the cylinder head. The preset at the factory.
Page 264 Main Menu Table of Contents Intake Air System Throttle Body (cont'd) Disassembly THROTTLE BODY IDLE ADJUSTING SCREW O-RING Replace. TP SENSOR THROTTLE VALVE CONTROL MOTOR INTAKE AIR DUCT...
Page 265 Main Menu Table of Contents Fuel Injection Air (FIA) Control System Description The Fuel Injection Air (FIA) Control system enables fresh air to be drawn through the throttle body and fuel injector port. AIR FLOW FUEL INJECTOR IDLE ADJUSTING THROTTLE SCREW BODY...
Page 266 Main Menu Table of Contents Intake Air System Intake Air Bypass (IAB) Control System Description Satisfactory power performance is achieved by closing and opening the intake air bypass (IAB) control valves. High torque at low engine speed is achieved when the valves are closed, whereas high power at high engine speed is achieved when the valves are opened.
Page 267 Main Menu Table of Contents Troubleshooting Inspection of IAB Control System. VACUUM PUMP/GAUGE, 0-30 in.Hg A973 - 041 - XXXXX Check for vacuum at idle: 1. Start the engine and allow it to idle. 2. Remove the No. 3 vacuum hose from the IAB control diaphragm and connect a vac- uum gauge to the hose.
Page 268 Main Menu Table of Contents Intake Air System Intake Air Bypass (IAB) Control System (cont'd) (From page 11-155) (From page 11-155) Repair open in the wire between the control box 6P connector and Is there battery voltage? Check for vacuum at 5,000 rpm: No.
Page 269 Main Menu Table of Contents Intake Air Bypass (IAB) Control Valve Testing CAUTION: Do not adjust the IAB control valve full-close screw. It was preset at the factory. Check the IAB control valve shaft for binding or sticking. Check the IAB control valve for smooth movement. Check that of the IAB control valve is in close contact with the stop when the vacuum hose is dis-...
Page 270 Main Menu Table of Contents Emission Control System System Description Tailpipe Emission The emission control system includes two Three Way Inspection Catalytic Converters (TWCs), Exhaust Gas Recirculation (EGR) system, Positive Crankcase Ventilation (PCV) sys- Do not smoke during this procedure. Keep any open flame away from your work area.
Page 271 Main Menu Table of Contents Three Way Catalytic Converter (TWC) Description The Three Way Catalytic Converter (TWC) is used to convert hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas to carbon dioxide (CO2), dinitrogen (N2) and water vapor. SECONDARY HEATED OXYGEN SENSOR (SENSOR 2) THREE WAY CATALYST...
Page 272 Main Menu Table of Contents Exhaust Gas Recirculation (EGR) System 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 vacuum control valve, EGR control solenoid valve, ECM and various sensors.
Page 273 Main Menu Table of Contents Emission Control System Positive Crankcase Ventilation (PCV) System Description Inspection The Positive Crankcase Ventilation (PCV) system is designed to prevent blow-by gas from escaping to the 1. Check the PCV hoses and connections for leaks and atmosphere.
Page 274 Main Menu Table of Contents 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) Control Canister An EVAP control canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the EVAP control canister into the engine and burned.
Page 275 Main Menu Table of Contents EVAP Control Canister Removal/Installation EVAP CONTROL Remove the air cleaner housing. CANISTER Remove the engine compartment fuse/relay box mounting bolts and harness clip. AIR CLEANER HOUSING EVAP CONTROL DUST FILTER CANISTER BRACKET BRACKET HARNESS CLIP DUST FILTER Remove the EVAP control canister bracket mount- ing bolts.
Page 276 Main Menu Table of Contents Emission Control System Evaporative Emission (EVAP) Two Way Valve Testing Remove the fuel fill cap. Remove the vapor line from the EVAP two way valve (located under the engine compartment fuse/relay box), and connect it to a T-fitting from a vacuum gauge and a vacuum pump as shown.
Page 277 Main Menu Transaxle Clutch ..........12–1 Manual Transmission .
Page 278 Main Menu Clutch Special Tools ......... . . 12–2 Pressure Plate, Clutch Disc Removal...
Page 279: Special Tools
Main Menu Table of Contents Special Tools 12-8, 12-12,12-13 12-8, 12-13 12-12 12-12 12-8, 12-13...
Page 280 Main Menu Table of Contents Description Dual Mass Flywheel The dual mass flywheel is designed to reduce the noise and vibrations produced by the engine, clutch, and transmission during acceleration and cruising. The flywheel assembly is actually two flywheels in one, which raises the inertia mass on both the engine and transmis- sion.
Page 281 Main Menu Table of Contents Illustrated Index NOTE: • Whenever the transmission is removed, clean and grease the release bearing sliding surface. • If the parts marked * are removed, the clutch hydraulic system must be bled. • Bleed the clutch hydraulic system (see page 12-7). •...
Page 282: Clutch Pedal Adjustment
Main Menu Table of Contents Clutch Pedal Adjustment NOTE: 4. Thread in the clutch pedal switch A in until it con- • To check the switch, see section tacts the clutch pedal. • The clutch is self-adjusting to compensate for wear. 5.
Page 283: Clutch Master Cylinder Removal
Main Menu Table of Contents Clutch Master Cylinder Installation Removal CAUTION: Install the clutch master cylinder in the reverse • Avoid spilling brake fluid on paint as it may damage order of removal. the finish. • Plug the end of the clutch line and reservoir hose NOTE: Bleed the clutch hydraulic system (see with a shop towel to prevent fluid from flowing out page 12-7).
Page 284: Slave Cylinder Removal
Main Menu Table of Contents Slave Cylinder Removal Installation Disconnect the clutch hose from the slave cylinder. Plug the end of the clutch hose with a shop towel to prevent brake fluid from coming out. CAUTION: Avoid spilling brake fluid on the painted Install the slave cylinder on the clutch housing.
Page 285: Pressure Plate, Clutch Disc Removal
Main Menu Table of Contents Pressure Plate, Clutch Disc Removal 1. Remove the transmission (see section 13). Remove the clutch disc and special tools. Install the special tools. HANDLE HANDLE 07936-3710100 07936-3710100 CLUTCH ALIGNMENT SHAFT CLUTCH ALIGNMENT SHAFT 07MAF-PR80100 07MAF-PR80100 RING GEAR HOLDER 07LAB-PV00100 07924-PD20003...
Page 286: Clutch Disc Inspection
Main Menu Table of Contents Clutch Disc Inspection Inspect the lining of the clutch disc for signs of slip- Measure the depth from the lining surface to the page or oil. Replace it if it is burned black or oil rivets, on both sides.
Page 287: Pressure Plate Inspection
Main Menu Table of Contents Pressure Plate Release Bearing Inspection Inspection Inspect the pressure plate surface for wear, cracks, Check the release bearing for excessive play by and burning. spinning it by hand. Do not wash it in solvent. Inspect the fingers of the diaphragm spring for wear at the release bearing contact area.
Page 288: Flywheel, Flywheel Bearing Inspection
Main Menu Table of Contents Flywheel, Flywheel Bearing Inspection Inspect the ring gear teeth for wear and damage. Turn the inner race of the flywheel bearing with your finger. The flywheel bearing should turn Inspect the clutch disc mating surface on the fly- smoothly and quietly.
Page 289: Replacement
Main Menu Table of Contents Flywheel, Flywheel Bearing Replacement Remove the flywheel mounting bolts in a crisscross Drive the new flywheel bearing into the flywheel pattern in several steps, then remove the flywheel. using the special tools. DRIVER 07749-0010000 ATTACHMENT, 37 x 40 mm 07746-0010200 RING GEAR HOLDER 07LAB-PV00100...
Page 290 Main Menu Table of Contents Pressure Plate, Clutch Disc Installation Install the ring gear holder. Apply grease to the splines of the clutch disc, then install the clutch disc using the special tools as shown. HANDLE 07936-3710100 CLUTCH ALIGNMENT SHAFT 07MAF-PR80100 Torque the mounting bolts in a crisscross pattern as shown.
Page 291: Manual Transmission
Main Menu Manual Transmission Special Tools ....13–2 Reverse Shift Arm, Reverse Shift Fork, Syncro Sleeve Inspection ....13–38 Shift Fork Clearance Inspection...
Page 292: Special Tools
Main Menu Table of Contents Special Tools 13-47 13-47 13-45 13-44 13-45 13-47 13-47 13-44, 13-45...
Page 293: Maintenance Transmission Oil
Main Menu Table of Contents Back-up Light Switch Maintenance Neutral Position Switch Transmission Oil Replacement Check the oil at normal operating temperature (the NOTE: To check the switch, see section cooling fan comes on), engine OFF, and the vehicle on level ground. Disconnect the connector, then remove the switch connector from the connector clamp.
Page 294: Reverse Lockout System
Main Menu Table of Contents Reverse Lockout System Component Location REVERSE LOCKOUT RELAY section 23...
Page 295 Main Menu Table of Contents Description At a vehicle speed of 19 mph (30 km/h) or more, a signal from the vehicle speed sensor (VSS) activates the reverse lockout solenoid, which causes the select lock pin to extend. As a result, the interlock cannot rotate to the reverse shift piece mak- ing it impossible to select reverse gear.
Page 296 Main Menu Table of Contents Troubleshooting Perform the indicated PGM-FI system troubleshooting (see section 11). Remove the reverse lockout relay from the under-hood relay box A, and test the relay (section 23). (To page 13-8)
Page 297 Main Menu Table of Contents Reverse Lockout System Troubleshooting (cont'd) (From page 13-7) Measure the voltage between ECM connector terminal A17 and body ground. (See section 11 how to use the Backprove Sets.) (To page 13-9)
Page 298 Main Menu Table of Contents (From page 13-8) (To page 13-10) Check the reverse lockout sole- noid (see page 13-11). Replace the reverse lockout solenoid (see page 13-11).
Page 299 Main Menu Table of Contents Reverse Lockout System Troubleshooting (cont'd) (From page 13-9) Remove the reverse lockout sole- noid (see page 13-11). Replace the reverse lockout sole- noid (see page 13-11).
Page 300: Test
Main Menu Table of Contents Solenoid Test Solenoid Replacement Disconnect the 3P connector of the reverse lockout Disconnect the 3P connector. solenoid. Measure the resistance between No. 1 and No. 3 terminals. Remove the reverse lockout solenoid from the trans- mission.
Page 301: Transmission Assembly Removal
Main Menu Table of Contents Transmission Assembly Removal Make sure lifts are placed properly, and 6. Remove the connectors from the control box, and hoist brackets are attached to correct positions (see remove the control box. Do not remove the vacuum section tubes from the control box.
Page 302 Main Menu Table of Contents 12. Remove the parking brake cable holders from the rear beam rod. 13. Remove the rear beam rod. 14. Remove the parking brake cable holder from the rear sub frame, and the wheel sensor wire clamp from the lower control arm.
Page 303 Main Menu Table of Contents Transmission Assembly Removal (cont'd) 19. Remove the intermediate shaft heat cover and the intermediate shaft mounting bolts. 20. Pry the intermediate shaft out of the differential. Pull and remove it. Coat all precision finished surfaces with clean engine oil or grease.
Page 304 Main Menu Table of Contents 26. Remove the one of the upper control arm mounting bolt. 27. Remove the lower cover, change wire bracket and upper cover. 28. Remove the shift cable and select cable. 29. Remove the slave cylinder from the transmission. Do not operate the clutch pedal once the slave cylinder has been removed.
Page 305 Main Menu Table of Contents Illustrated Index NOTE: • This transmission uses no gaskets between the major housings; use liquid gasket (P/N 08718-0001). If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings and allow it to cure at least 30 minutes after assembly before filling the transmission with oil.
Page 306 Main Menu Table of Contents BEARING OUTER RACE STRAINER SET SPRING 12 mm SEALING BOLT 75 mm THRUST SHIM OIL PUMP STRAINER 22 N-m (2.2 kgf-m, 16 Ibf-ft) Selection. 14 mm SEALING BOLT STEEL BALL (5/16 in) CLAMP 32 N-m (3.3 kgf-m, 24 Ibf-ft) SHIFT LEVER ASSEMBLY BACK-UP LIGHT SWITCH SPRING (L.
Page 307 Main Menu Table of Contents Transmission Housing Removal Place the clutch housing on two pieces of wood Expand the snap ring on the countershaft ball bear- thick enough to keep the mainshaft from hitting the ing, and remove it from the groove using a pair of workbench.
Page 308 Main Menu Table of Contents Reverse Shift Arm, Reverse Shift Fork Clearance Inspection Measure the clearance between the reverse shift Measure the clearance between the reverse shift arm and reverse shift fork. arm and the reverse shift piece. If the clearance exceeds the service limit, measure If the clearance exceeds the service limit, measure the width of the reverse shift arm.
Page 309: Reverse Shift Arm, Reverse Shift Fork Clearance Inspection
Main Menu Table of Contents Reverse Shift Arm, Reverse Shift Fork Clearance Inspection (cont'd) Measure the clearance between the reverse shift fork and reverse synchro sleeve. If the clearance exceeds the service limit, measure the thickness of the shift fork fingers. If the trickiness is less than the standard, replace the reverse shift fork with a new one.
Page 310: Reverse Idler Gear Shaft Assembly Removal
Main Menu Table of Contents Reverse Idler Gear Shaft Assembly Removal Remove the reverse shift arm from the clutch hous- ing. Shift the reverse shift fork to the driven gear side. Remove the reverse shift fork assembly.
Page 311 Main Menu Table of Contents Remove the reverse idle gear shaft assembly.
Page 312: Disassembly/Reassembly
Main Menu Table of Contents Disassembly/Reassembly NOTE: • The thrust needle bearings are the same size. • The needle bearings are the same size. Prior to reassembling, clean all the parts in sol- vent, dry them, and apply lubricant to any con- tact surface.
Page 313: Reverse Shift Fork Assembly Disassembly/Reassembly
Main Menu Table of Contents Reverse Shift Fork Assembly Disassembly/Reassembly NOTE: The spring pin grooves should be 180° apart. REVERSE SHIFT FORK Inspection, page 13-20 Disassembly: Remove the 3 mm spring pin and 5 mm spring pin. Reassembly: Install the 5 mm spring pin first, then install the 3 mm spring pin.
Page 314: Mainshaft, Countershaft, Differential Assemblies Removal
Main Menu Table of Contents Mainshaft, Countershaft, Differential Assemblies Removal Remove the change holder assembly from the clutch housing. Tape the mainshaft splines to protect them, then remove the mainshaft assembly and countershaft assembly with the shift fork from the clutch housing.
Page 315 Main Menu Table of Contents Remove the differential assembly from the clutch housing.
Page 316: Shift Lever, Select Lever Removal
Main Menu Table of Contents Shift Lever, Select Lever Removal Remove the shift spring set plate and shift detent spring from the transmission housing. Remove the bolt and spring washer. Pull out the shift lever, then remove the shift arm.
Page 317 Main Menu Table of Contents Shift Lever, Select Lever Removal (cont'd) Remove the bolt and spring washer. Pull out the select lever, then remove the select arm.
Page 318: Change Holder Assembly Disassembly/Reassembly
Main Menu Table of Contents Change Holder Assembly Disassembly/Reassembly NOTE: Make sure the return springs are installed properly. Prior to reassembling, clean all parts in solvent, dry them, and apply lubricant to any contact surfaces.
Page 319: Change Holder Assembly, Shift Fork Clearance Inspection
Main Menu Table of Contents Change Holder Assembly, Shift Fork Clearance Inspection Measure the clearance between the shift piece and Measure the clearance between the interlock and select arm. shift arm. Standard: 0.03 - 0.15 mm (0.001 - 0.006 in) If the clearance exceeds the service limit, measure If the clearance exceeds the standard, measure the width of the interlock finger.
Page 320 Main Menu Table of Contents Measure the clearance between the shift fork and shift piece. If the clearance exceeds the service limit, measure the width of the shift piece. If the width of the shift piece is less than the stan- dard, replace the shift piece with a new one.
Page 321: Shift Fork, Syncro Sleeve Clearance Inspection
Main Menu Table of Contents Shift Fork, Synchro Sleeve Clearance Inspection Measure the clearance between each shift fork and its matching synchro sleeve.. If the clearance exceeds the service limit, measure the width of the shift fork fingers. If the width of the shift fork fingers is less than the standard, replace the shift fork with a new one.
Page 322: Shift Fork Assembly Disassembly/Reassembly
Main Menu Table of Contents Shift Fork Assembly Disassembly/Reassembly NOTE: Install the spring pins so their grooves are 180° apart. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. Disassembly: Remove the 3 mm spring pin and 5 mm spring pin. Reassembly: Install the 5 mm spring pin first, then install the 3 mm spring pin.
Page 323: Mainshaft Assembly
Main Menu Table of Contents Mainshaft Assembly Index NOTE: The 3rd/4th and 5th/6th synchro hubs are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th/6th synchro hubs, however, should be installed with a press before lubricating them. OUTER SYNCHRO RING Inspection, page 13-41...
Page 324: Clearance Inspection
Main Menu Table of Contents Mainshaft Assembly Clearance Inspection Measure the clearance between 2nd and 3rd gears. Measure the clearance between 4th gear and the spacer collar. Standard: 0.06 - 0.19 mm Standard: 0.06 - 0.19 mm (0.002 - 0.007 in) Service Limit: 0.3 mm (0.012 in) (0.002 - 0.007 in) Service Limit: 0.3 mm (0.012 in)
Page 325 Main Menu Table of Contents Measure the clearance between the spacer collar 9. Measure the clearance between the distance collar and 5th gear. and 6th gear. 10. If the clearance exceeds the service limit, measure If the clearance exceeds the service limit, measure on the spacer collar.
Page 326: Disassembly
Main Menu Table of Contents Mainshaft Assembly Disassembly Support ball bearing on steel blocks as shown, and Support 5th gear on steel blocks as shown, and press the shaft out of the ball bearing. Use of a jaw- press the shaft out of the 5th/6th synchro hub. type puller can damage the gear teeth.
Page 327: Inspection
Main Menu Table of Contents Mainshaft Assembly Inspection Inspect the gear surface and bearing surface for Support the mainshaft at both ends, and inspect for wear and damage, then measure the mainshaft at runout. points A, B, and C. If the runout exceeds the service limit, replace the mainshaft with a new one.
Page 328: Reassembly
Main Menu Table of Contents Mainshaft Assembly Reassembly Install the 5th/6th synchro hub using a press. CAUTION: • Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. • Press the 3rd/4th and 5th/6th synchro hubs on the mainshaft without lubrication.
Page 329: Countershaft Assembly
Main Menu Table of Contents Countershaft Assembly Index NOTE: The 3rd, 4th, 5th and 6th gears are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd, 4th, 5th and 6th gears should be installed without lubrication using a press. OUTER SYNCHRO RING Inspection, page 13-41...
Page 330: Clearance Inspection
Main Menu Table of Contents Countershaft Assembly Clearance Inspection Measure the clearance between 2nd and 3rd gear. Measure the clearance between 1st and reverse gear. Standard: 0.04 - 0.10 mm (0.002 - 0.004 in) If the clearance exceeds the standard, select the If the clearance exceeds the standard, select the appropriate spacer collar for the correct clearance appropriate thrust washer for the correct clearance...
Page 331: Disassembly
Main Menu Table of Contents Disassembly NOTE: Remove the gears using a press and steel blocks. Support 4th gear on steel blocks, and press the Use of a jaw-type puller can damage the gear teeth. shaft out of 5th and 4th gears. Securely clamp the countershaft assembly in a bench vise with wood blocks.
Page 332: Inspection
Main Menu Table of Contents Countershaft Assembly Inspection Inspect the gear surfaces and bearing surfaces for wear and damage, then measure the countershaft at points A and B inspect oil passages for clogging. If any part of the countershaft is less than the ser- vice limit, replace it with a new one.
Page 333: Reassembly
Main Menu Table of Contents Countershaft Assembly Reassembly CAUTION: • Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. • Press the 3rd, 4th, 5th and 6th gears on the counter- shaft without lubrication.
Page 334 Main Menu Table of Contents Install the ball bearing using a press. Install 5th gear using a press. Install 6th gear using a press. Securely clamp the countershaft assembly in a bench vise with wood blocks. Install the needle bearing using a press then install the bearing outer race.
Page 335: Inspection
Main Menu Table of Contents Synchro Sleeve, Synchro Hub Installation Inspection Inspect gear teeth on all synchro hubs and synchro Each synchro sleeve has three sets of longer teeth (120 sleeves for rounded off corners, which indicates degrees apart) that must be matched with the three wear.
Page 336: Synchro Ring, Gear Inspection
Main Menu Table of Contents Synchro Ring, Gear Inspection Inspection the synchro ring and gear. A : Inspect the inside of the synchro ring for wear. B : Inspect the synchro sleeve teeth and matching teeth on the synchro ring for wear (rounded off). C : Inspect the synchro sleeve teeth and matching teeth on the gear for wear (rounded off).
Page 337: Oil Pump Disassembly/Reassembly
Main Menu Table of Contents Oil Pump Disassembly/Reassembly Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
Page 338: Clearance Inspection
Main Menu Table of Contents Clearance Inspection Check the radial clearance on the pump rotor. Check the clearance between the transmission mat- ing surface of the clutch housing and the oil pump Inner Rotor-to-Outer Rotor Radial clearance gear. Standard: 0.14 mm (0.006 in) max. Service Limit: 0.2 mm (0.008 in) Standard: 0.3 - 0.8 mm (0.012 - 0.031 in)
Page 339: Mainshaft Oil Seal (Clutch Housing) Replacement
Main Menu Table of Contents Mainshaft Oil Seal (Clutch Housing) Replacement Remove the release bearing guide cover, and Drive a new oil seal from the clutch side using the release bearing guide. special tools as shown. ATTACHMENT, Remove the oil seal. DRIVER 52 x 55 mm 07749-0010000...
Page 340: Countershaft Bearing (Clutch Housing) Replacement
Main Menu Table of Contents Countershaft Bearing (Clutch Housing) Replacement Remove the bearing retaining plate. Position the oil guide plate and new needle bearing in the bore of the clutch housing. Position the nee- dle bearing with the oil hole facing up. Drive the needle bearing using the special tools.
Page 341: Mainshaft Thrust Shim Adjustment
Main Menu Table of Contents Mainshaft Thrust Shim Adjustment Select the proper thrust shim on the basis of the Remove the thrust shim and oil guide plate from the transmission housing. following calculations. Do not use more than two thrust shims. Install the mainshaft in the transmission housing.
Page 342 Main Menu Table of Contents NOTE: Clean all the parts thoroughly before installation. • Back-out the mainshaft holder bolt and loosen the two hex bolts. 6. Install the oil guide plate and thrust shim into the • Fit the holder over the mainshaft so its lip is transmission housing.
Page 343 Main Menu Table of Contents Transmission Reassembly Install the oil seal, shift arm, and shift lever in the Install the oil seal, select arm, and select lever in the transmission housing. clutch housing. Install the shift detent spring and spring set plate. Install the differential assembly into the clutch housing.
Page 344 Main Menu Table of Contents Install the spring washer, then insert the mainshaft Install the reverse idle gear shaft assembly. and countershaft into the shift forks and install them as an assembly. Tape the mainshaft splines before installation. Install the change holder assembly in the clutch housing.
Page 345 Main Menu Table of Contents Transmission Reassembly (cont'd) 9. Install the reverse shift arm. 11. Install the dowel pins on the clutch housing. 12. Place the transmission housing over the clutch housing, being careful to line up the shafts. 10. Apply liquid gasket to the surface of the transmis- sion housing mating with the clutch housing as shown, and note those items: Use liquid gasket (P/N 08718 - 0001).
Page 346 Main Menu Table of Contents b. Lower the transmission housing, then place the 13. Lower the transmission housing with snap ring shift arm in the groove of the shift piece by turn- pliers, and set the snap ring in the groove of the ing the shift lever.
Page 347 Main Menu Table of Contents Transmission Reassembly (cont'd) 15. Tighten the transmission housing attaching bolts 18. Apply liquid gasket (P/N 08718-0001) to the in a crisscross pattern in several steps as shown threads, and install the back-up light switch below. and neutral position switch.
Page 348 Main Menu Table of Contents Transmission Assembly Installation MOTE: Use only Super High Temp Urea Grease (P/N 08798 - 9002). 1. Place the transmission on the transmission jack, and raise it to the engine level. Check that the two dowel pins are installed in the clutch housing. 2.
Page 349 Main Menu Table of Contents Transmission Assembly Installation (cont'd) 12. Install a new set ring on the end of the left driveshaft and intermediate shaft. 13. Install the left driveshaft (see section 16). 14. Install the lower control arm to the side beam (see section 18).
Page 350 Main Menu Table of Contents 20. Install the right driveshaft onto the intermediate shaft. 21. Install the lower control arm to the side beam (see section 18). Align the reference marks on the adjusting bolt, adjust- ing cam and lower control arm. 22.
Page 351 Main Menu Table of Contents Transmission Assembly Installation (cont'd) 27. Install the transmission mount and two transmission 31. Install the air cleaner assembly. housing mounting bolts. 32. Install the strut bar. 28. Install the starter motor, and connect the starter 33.
Page 352: Gearshift Mechanism Overhaul
Main Menu Table of Contents Gearshift Mechanism Overhaul NOTE: • Inspect rubber parts for wear and damage when disassembling. • Check that the new cotter pin is seated firmly.
Page 353: Automatic Transmission
Main Menu Automatic Transmission Special Tools ....14–2 Hydraulic System Secondary Valve Body Clutch Description Disassembly/lnspection/ Component Location Symptom–to–component General Operation ..14–3 Reassembly .
Page 354 Main Menu Table of Contents Special Tools 14-149, 14-152 14-121 14-149, 14-152 14-106 14-106 14-51, 14-5a 14-53, 14-102, 14-7a 14-106 14-106 14-157 14-156, 14-157 14-155, 14-156, 14-157 14-155, 14-156, 14-157 14-120, 14-163 14-156...
Page 355 Main Menu Main Menu Table of Contents Table of Contents Description The automatic transmission is a combination of a 3-element torque converter and a triple-shaft electronically controlled automatic transmission which provides 4 speeds forward and 1 speed reverse. The entire unit is positioned in line with the engine.
Page 356 Main Menu Table of Contents Description (cont'd) Gear Selection Rear wheels locked; parking pawl engaged with parking gear on countershaft. All clutches released. Reverse; reverse selector engaged with countershaft reverse gear and 4th clutch locked. All clutches released. General driving; starts off in 1st, shifts automatically to 2nd, 3rd, then 4th, depending on vehicle speed and throttle position.
Page 357 Main Menu Table of Contents TORQUE CONVERTER LOCK-UP CONTROL SOLENOID VALVE ASSEMBLY ATF COOLER 4TH CLUTCH 1ST CLUTCH 3RD CLUTCH 1ST-HOLD CLUTCH DIFFERENTIAL ASSEMBLY [LIMITED SLIP DIFFERENTIAL (LSD)] 2ND CLUTCH...
Page 358 Main Menu Table of Contents Description Clutches The four-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gears. When hydraulic pressure is introduced into the clutch drum, the clutch piston is applied. 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 359 Main Menu Table of Contents COUNTERSHAFT 2ND GEAR COUNTERSHAFT 3RD GEAR MAINSHAFT 3RD GEAR 3RD CLUTCH 4TH CLUTCH DRIVE PLATE MAINSHAFT 4TH GEAR MAINSHAFT REVERSE GEAR MAINSHAFT 1ST GEAR 1ST CLUTCH MAINSHAFT COUNTERSHAFT LOCK-UP 1ST-HOLD CLUTCH CLUTCH SECONDARY SHAFT ONE-WAY CLUTCH COUNTERSHAFT 1ST GEAR PARKING GEAR COUNTERSHAFT REVERSE GEAR...
Page 360 Main Menu Table of Contents Description Power Flow...
Page 361 Main Menu Table of Contents 1st Speed in Position position, hydraulic pressure is applied to the 1st clutch and to the 1st-hold clutch. The power flow when accelerating is as follows; 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 362 Main Menu Table of Contents Description Power Flow (cont'd) 1st Gear in positions position, the optimum gear is automatically selected from the gear ratios of 1st, 2nd, 3rd, and 4th speeds, according to conditions such as the balance between throttle opening (engine load) and vehicle speed. 1.
Page 363 Main Menu Table of Contents 2nd Gear in Positions 1. Power from the mainshaft 3rd gear drives the countershaft 3rd gear. Since there is no hydraulic pressure to the 3rd clutch, the countershaft 3rd gear turns freely and drives the secondary shaft 3rd gear. 2.
Page 364 Main Menu Table of Contents Description Power Flow (cont'd) 3rd Gear in Positions 1. Hydraulic pressure is applied to the 3rd clutch. Power from the mainshaft 3rd is transmitted to the countershaft 3rd gear. 2. Power is transmitted to the final drive gear and drives the final driven gear. NOTE: Hydraulic pressure is also applied to the 1st clutch, but since the rotation speed of the 3rd gear exceeds 1st gear speed, power from 1st gear is cut off at the one-way clutch.
Page 365 Main Menu Table of Contents 4th Gear in Positions 1. Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshaft, and the mainshaft 4th gear. 2. Power is transmitted through countershaft 4th gear to the countershaft. 3.
Page 366 Main Menu Table of Contents Description Electronic Control System The electronic control system consists of the Transmission Control Module (TCM), sensors, a linear solenoid and four solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The TCM is located on the insulator center bulkhead, behind the driver's seat.
Page 367: Shift Control
Main Menu Table of Contents Shift Control Engine torque controls shifting through the linear solenoid. The linear solenoid is controlled by the TCM, and it is used to operate the throttle valve. The TCM instantly determines which gear to select by various signals sent from sensors, and actuates shift control solenoid valves A and B to control shifting.
Page 368 Main Menu Table of Contents Description Electronic Control System (cont'd) • Automatic shifting control in Sport Shifting mode This position also has automatic shifting areas: • 1-2 upshift • 4-3 downshift, 3-1 downshift, 2-1 downshift depending on vehicle speed. To prevent engine over-revving, the transmission has a 1-2 automatic upshift speed, and 4-3, 3-1, 2-1 downshift allowable speeds.
Page 369 Main Menu Table of Contents Description Hydraulic Control The valve bodies include the main valve body, the regulator valve body, the lock-up valve body, the secondary valve body, the servo body, the throttle valve body and the 2nd accumulator body. The ATF pump is driven by splines on the left end of the torque converter which is attached to the engine.
Page 370 Main Menu Table of Contents Throttle Valve Body The throttle valve body is mounted on the servo valve body with the throttle valve built in. Throttle Valve B, Linear Solenoid Throttle valve B converts changes in the throttle opening to changes in transmission hydraulic pressure, to determine transmission shift quality and lock-up operation.
Page 371 Main Menu Table of Contents Description Hydraulic Control (cont'd) Regulator Valve Body The regulator valve body is mounted on the main valve body with the regulator valve, the lock-up control valve and the cooler relief valve built in. The stator shaft arm contacts the regulator valve spring cap. The hydraulic pressure (line pressure) is controlled by the regulator valve.
Page 372 Main Menu Table of Contents Regulator Valve The regulator valve maintains a constant hydraulic pressure from the ATF pump to the hydraulic control system, while also furnishing fluid to the lubricating system and the torque converter. Fluid from the ATF pump flows through B and B'. The regulator valve has a valve orifice. The fluid entering from B flows through the orifice to the A cavity.
Page 373 Main Menu Table of Contents Description Hydraulic Control (cont'd) Main Valve Body The main valve body is located on the torque converter housing. The main valve body houses the ATF pump gears, the torque converter check valve, the manual valve, the 1-2, 2 - 3 , 3 - 4 shift valves, the relief valve and the one-way relief valve.
Page 374 Main Menu Table of Contents ATF Pump The external tooth gear type ATF pump consists of a housing together with the main valve body, a pump drive gear, a pump driven gear, and a pump shaft. The ATF pump is installed on the torque converter housing. The pump's driving force is transmitted by the torque converter pump (directly connected to the engine) to the pump shaft.
Page 375 Main Menu Table of Contents Description Hydraulic Control (cont'd) Secondary Valve Body The secondary valve body is also mounted on the main valve body with the 3-2 kick-down valve, the CPC valve, the 2nd orifice control valve, the 3rd orifice control valve, the modulator valve, the 4th exhaust valve, the 2nd exhaust valve, the servo control valve and the 4-3 kick-down valve built in.
Page 376 Main Menu Table of Contents Modulator Valve The modulator valve uses line pressure from the regulator (to shift control solenoid valves A/B) and the lock-up control solenoid valves A/B, to maintain accurate shift and lock-up characteristics. 2nd Orifice Control Valve For smooth shifting between the 2nd and 3rd gear, the open pressure on the 2nd gear side is relieved through a fixed ori- fice.
Page 377 Main Menu Table of Contents Description Hydraulic Control (cont'd) Servo Body The servo body is mounted on the secondary valve body with the servo valve, the 1st accumulator piston, the 3rd accu- mulator piston, and the 4th accumulator piston built in to it. The primary functions of the servo body are to switch the direction foward and reverse, and to control hydraulic pressure reduction for shifting shock.
Page 378 Main Menu Table of Contents Lock-up Valve Body The lock-up valve body is mounted on the regulator valve body with the lock-up shift valve and the lock-up timing B valve built in. The capacity of the lock-up clutch is controlled by the lock-up shift valve and the lock-up timing B valve.
Page 379 Main Menu Table of Contents Description Hydraulic Flow General Chart of Hydraulic Pressure Distribution of Hydraulic Pressure...
Page 380 Main Menu Table of Contents position As the engine turns, the ATF pump also starts to operate. The ATF is drawn from (99) and discharged into (1). Then, ATF flowing from the ATF pump becomes the line pressure (1). The line pressure (1) is regulated by the regulator valve. The torque converter inlet pressure (92) enters (94) of torque converter through the orifice and discharges into (90).
Page 381 Main Menu Table of Contents Description Hydraulic Flow (cont'd) Position Line pressure (1) becomes line pressure (4), (18), and (25) as it passes through the manual valve. Also, line pressure (1) goes to the modulator valve through the filter and becomes modulator pressure (6). Modulator pressure (6) is supplied to the 1-2 shift valve and 2-3 shift valve.
Page 382 Main Menu Table of Contents Position Line pressure (1) becomes the line pressure (4), (25) as it passes through the manual valve. Line pressure (1) goes to the modulator valve and becomes the modulator pressure (6). The modulator pressure (6) is sup- plied to the 1-2 shift valve and 3-4 shift valve.
Page 383 Main Menu Table of Contents Description Hydraulic Flow (cont'd) Positions 1. 1st Gear The flow of fluid through the torque converter circuit is the same as in position. Line pressure (1) becomes line pressure (4) and 1st clutch pressure (10). The 1st clutch pressure is applied to the 1st clutch and 1st accumulator, and the vehicle will move as engine power is transmitted.
Page 384 Main Menu Table of Contents 2. 2nd Gear The flow of fluid to the 1-2 and 2-3 shift valves is the same as in 1st gear. As the speed of the vehicle reaches the pre- scribed value, solenoid valve A is turned ON by the TCM. As a result, the 1-2 shift valve is moved to the left side and uncovers the port leading to the 2nd clutch, and the 2nd clutch is engaged.
Page 385 Main Menu Table of Contents Description Hydraulic Flow (cont'd) 3. 3rd Gear The flow of fluid to the 1-2, 2-3, and 3-4 shift valves is the same as in 2nd gear. As the speed of the vehicle reaches the prescribed value, shift control solenoid valve B is turned OFF (Shift control solenoid valve A remains ON). The 2-3 shift valve is then moved to the left side, uncovering the fluid port leading to the 3rd clutch.
Page 386 Main Menu Table of Contents 4. 4th Gear The flow of fluid to the 1-2, 2-3, and 3-4 shift valves is the same as in 3rd gear. When the speed of the vehicle reaches the prescribed valve, shift control solenoid valve A is turned OFF (Shift control solenoid valve B remains OFF). As this takes place, the 3-4 shift valve is moved to the left side and uncovers the fluid port leading to the 4th clutch.
Page 387 Main Menu Table of Contents Description Hydraulic Flow (cont'd) Position The flow of fluid through the torque converter circuit is the same as in the position. Fluid (1) from the ATF pump flows through the manual valve and becomes line pressure (3). It then flows through the 1-2 shift valve to the servo valve (3), moving the shift fork shaft to the reverse position.
Page 388 Main Menu Table of Contents Position The flow of fluid through the torque converter circuit is the same as in position. Line pressure (1) becomes line pressure (3) as it passes through the manual valve. Line pressure (3) flows through the 1-2 shift valve, to the servo valve, and to the servo control valve, moving the shift fork to the reverse position as in the position.
Page 389 Main Menu Table of Contents Description Lock-up System Lock-up Clutch 1. Operation (clutch on) With the lock-up clutch on, fluid in the chamber between the converter cover and lock-up piston is discharged, and the converter fluid exerts pressure through the piston against the converter cover. As a result, the converter turbine is locked on the converter cover firmly.
Page 390 Main Menu Table of Contents position and position (2nd, 3rd, and 4th gear), 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 391 Main Menu Table of Contents Description Lock-up System (cont'd) No Lock-up 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 pressure on both ends of the lock-up shift valve are equal, and the shift valve is moved to the right side by valve spring tension.
Page 392 Main Menu Table of Contents Partial Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: OFF The TCM switches solenoid valve A ON to release modulator pressure in the left cavity of the lock-up shift valve. Modulator pressure in the right cavity of the lock-up shift valve overcomes the spring force, and the lock-up shift valve is moved to the left side.
Page 393 Main Menu Table of Contents Description Lock-up System (cont'd) Half Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: ON Modulator pressure is released by solenoid valve B, causing modulator pressure in the left cavity of the lock-up control valve to lower.
Page 394 Main Menu Table of Contents Full Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: ON When the vehicle speed further increases, the throttle B pressure is increased in accordance with the throttle opening. The lock-up timing valve B overcomes the spring force and moves to the left side. Also this valve closes the fluid port leading to the torque converter check valve.
Page 395 Main Menu Table of Contents Description Lock-up System (cont'd) Deceleration Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: Duty Operation The TCM switches the solenoid valve B to ON and OFF alternately at high speeds under certain conditions. The slight lock-up and half lock-up regions are maintained so as to lock the torque converter properly.
Page 396 Main Menu Table of Contents ATF Cooler The radiator is mounted at the front of the vehicle. The ATF cooler is installed directly on the transmission housing. The ATF is cooled by the engine coolant.
Page 397 Main Menu Table of Contents Component Locations...
Page 398 Main Menu Table of Contents <Engine Compartment> LOCK-UP CONTROL SOLENOID ENGINE COOLANT TEMPERATURE (ECT) VALVE ASSEMBLY SENSOR MAINSHAFT SPEED SENSOR LINEAR SOLENOID SHIFT CONTROL SOLENOID VALVE ASSEMBLY THROTTLE POSITION (TP) SENSOR COUNTERSHAFT SPEED VEHICLE SPEED SENSOR (VSS) SENSOR TRANSMISSION CONTROL MODULE (TCM) TCS CONTROL UNIT ENGINE CONTROL MODULE...
Page 399 Main Menu Table of Contents Troubleshooting Procedures Checking the Diagnostic Trouble Code (DTC) with an OBDII Scan Tool or the Honda PGM Tester When the TCM senses an abnormality in the input or output systems, the indicator light in the gauge assembly will blink.
Page 400 Main Menu Table of Contents Checking the Diagnostic Trouble Code (DTC) with the Service Check Connector and Special Toot When the TCM senses an abnormality in the input or output systems, the indicator light in the gauge assembly will blink. When the Service Check Connector (2P) (located to the lower right of the glove compartment) 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 401 Main Menu Table of Contents Troubleshooting Procedures 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 seat back panels (see section 20). Remove the connector holder from the TCS control unit, and disconnect the antenna lead.
Page 402 Main Menu Table of Contents Inspect the circuit on the TCM according to the troubleshooting flowchart with the special tools and a digital multime- ter as shown. How to use the Backprobe Set Connect the backprobe adapters to the stacking patch cords, and connect the cords to a multimeter. Using the wire insulation as a guide for the contoured tip of the backprobe adapter, gently slide the tip into the connector from the wire side until it comes in contact with the terminal end of the wire.
Page 403 Main Menu Table of Contents Linear Solenoid Test Remove the linear solenoid connector. Measure the resistance between the A and B terminal. STANDARD: 5.0-5.5 Ω (at 70°F, 20°C) LINEAR SOLENOID TERMINAL SIDE OF MALE TERMINALS Replace the linear solenoid if resistance is out of specification.
Page 404 Main Menu Table of Contents Linear Solenoid Replacement NOTE: Select the appropriate shim when the linear sole- noid is replaced. Remove the linear solenoid and shim from the trans- mission housing. Clean the mounting surface. Measure the distance between the mounting surface of the linear solenoid and the throttle valve body.
Page 405 Main Menu Table of Contents Select a new shim from the chart below. Apply liquid gasket to both sides of the linear solenoid shim as shown. Use liquid gasket Part No. NOTE: Identification color is painted on the side of 08718-0001.
Page 406 Main Menu Table of Contents Mainshaft/Countershaft Speed Sensors Replacement Remove the 6 mm bolt from the transmission hous- ing, then remove the mainshaft and countershaft speed sensors. Replace the O-ring with a new one before reassem- bling the mainshaft and countershaft speed sensors. Install the washer only on the countershaft speed sensor.
Page 407 Main Menu Table of Contents Transmission Control Module (TCM) Replacement SRS components are located in this area. Review the Disconnect the A (26P) and B (22P) connectors from SRS component locations, precautions, and procedures the TCM, then remove the TCM. in the SRS (section 24) before performing repairs or ser-...
Page 408 Main Menu Table of Contents Symptom-to-Component Chart Hydraulic System...
Page 409 Main Menu Table of Contents PROBABLE CAUSE...
Page 410 Main Menu Table of Contents Symptom-to-Component Chart Hydraulic System (cont'd)
Page 411 Main Menu Table of Contents...
Page 412: Road Test
Table of Contents Main Menu Road Test position 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. Apply parking brake and block the wheels. Start the engine, and warm up the engine to normal operating temperature (the cooling fan comes on).
Page 413 Main Menu Table of Contents Upshift Downshift 3. 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 76 mph (123 km/h) or from position to...
Page 414 Main Menu Table of Contents Stall Speed Test CAUTION: • To prevent transmission damage, do not test stall speed for more than 10 seconds at a time. • Do not move the shift lever while raising the engine speed. • Be sure to remove the pressure gauge before testing stall speed. Engage the parking brake and block all four wheels.
Page 415: Fluid Level
Main Menu Table of Contents Fluid Level Checking/Changing Checking Changing NOTE: Check the fluid level with the engine at nor- Bring the transmission up to operating temperature mal operating temperature (the cooling fan comes by driving the vehicle. Park the vehicle on level on).
Page 416 Main Menu Table of Contents Pressure Testing • Line Pressure/Clutch Pressure Measurement • While testing, be careful of the rotating rear wheels. • Make sure lifts are placed properly (see section 1. Allow the rear wheels to rotate freely. CAUTION: 2.
Page 417 Main Menu Table of Contents 1ST-HOLD CLUTCH PRESSURE INSPECTION HOLE 2ND CLUTCH PRESSURE INSPECTION HOLE 4TH CLUTCH PRESSURE INSPECTION HOLE LINE PRESSURE/1ST CLUTCH PRESSURE INSPECTION HOLE 3RD CLUTCH PRESSURE INSPECTION HOLE...
Page 418 Main Menu Table of Contents Pressure Testing (cont'd) • Clutch Low/High Pressure Measurement With the engine idling, press down the accelerator pedal approximately 1/2 of its possible travel and While testing, be careful of the rotating increase the engine rpm until pressure is indicated rear wheels.
Page 419 Main Menu Table of Contents • Throttle B Pressure Measurement While testing, be careful of the rotat- ing rear wheels. 1. Allow the rear wheels to rotate freely. 2. Disconnect the linear solenoid connector. 3. Shift to position. 4. Run the engine at 2,000 rpm. 5.
Page 420 Main Menu Table of Contents Transmission Removal Make sure lifts are placed properly, and 4. Remove the strut bar. hoist brackets are attached to correct position (see section 5. Remove the air cleaner housing. CAUTION: Use fender covers to avoid damaging painted 6.
Page 421 Main Menu Table of Contents 11. Remove the parking brake cable holders from the rear beam rod. 12. Remove the rear beam rod. 13. Remove the front exhaust pipe A. 14. Remove the parking brake cable holder and the wheel sensor wire clamp. 1 5.
Page 422 Main Menu Table of Contents Transmission Removal (cont'd) 20. Remove the intermediate shaft heat shield cover and the intermediate shaft mounting bolts. 21. Pry the intermediate shaft out of the differential. Pull and remove it. NOTE: • Coat all precision finished surfaces with clean engine oil. •...
Page 423 Main Menu Table of Contents 28. Remove the one upper arm mounting bolt shown. 29. Remove the shift cable cover and shift cable holder. 30. Remove the shift cable from the control lever. 31. Remove the torque converter cover, then remove the drive plate bolts. 32.
Page 424 Main Menu Table of Contents Illustrated Index Left Side Cover/Transmission...
Page 425 Main Menu Table of Contents TORQUE SPECIFICATION...
Page 426 Main Menu Table of Contents Illustrated Index Transmission Housing...
Page 427 Main Menu Table of Contents TORQUE SPECIFICATION...
Page 428 Main Menu Table of Contents Illustrated Index Torque Converter Housing/Valve Body...
Page 429 Main Menu Table of Contents TORQUE SPECIFICATION...
Page 430 Main Menu Table of Contents Left Side Cover Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Cut the lock tabs of each shaft locknut using a chisel, then remove the locknuts and conical spring washers from each shaft.
Page 431 Main Menu Table of Contents Transmission Housing Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • The (7/32) #7 steel ball in the reverse idler gear shaft is under spring pressure. Take care not to let it pop out. 1.
Page 432 Main Menu Table of Contents Valve Body Removal NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. • Accumulator covers are spring loaded; to prevent stripping the threads in the torque converter housing, press down on the accumulator covers while unscrewing the bolts in a crisscross pattern.
Page 433 Main Menu Table of Contents Repair NOTE: This repair is only necessary if one or more Remove the #600 paper and thoroughly wash the of the valves in a valve body do not slide smoothly entire valve body in solvent, then dry with com- in their bores.
Page 434 Table of Contents Main Menu Valve Assembly • Set the spring in the valve, and install it in the valve NOTE: Coat all parts with ATF before assembly. body. Push the spring in with a screwdriver, then install the spring seat. •...
Page 435 Main Menu Table of Contents • Set the spring in the valve, and install it in the valve • Install the valve, spring and cap in the valve body. body. Install the spring with a screwdriver, then Push on the cap, then install the stopper seat. install the valve cap with the cutout aligned with the screwdriver.
Page 436 Main Menu Table of Contents Valve Caps Description • Caps with one projected tip and one flat end are in- • Caps with hollow ends are installed with the hollow stalled with the flat end toward the spring. end away from the spring. •...
Page 437 Table of Contents Main Menu ATF Pump Inspection Remove the shaft, then measure the thrust clear- Install the pump gears and shaft in the main valve ance of the driven gear-to-valve body. body. Drive/Driven Gear thrust (Axial) Clearance: Standard (New): 0.03-0.05 mm (0.001-0.002 in.) Service Limit: 0.07 mm (0.0028 in.)
Page 438 Main Menu Table of Contents Main Valve Body Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. Replace valve body as an assembly if any parts are worn or damaged. Check all valves for free movement.
Page 439 Main Menu Table of Contents NOTE: All check balls are the same size (7/32) #7.
Page 440 Main Menu Table of Contents Secondary Valve Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace valve body as an assembly if any parts are worn or damaged. •...
Page 441 Main Menu Table of Contents NOTE: All check balls are the same size (7/32) #7.
Page 442 Main Menu Table of Contents Servo Body/Throttle Valve Body Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. Replace valve body as an assembly if any parts are worn or damaged. Check all valves for free movement.
Page 443 Main Menu Table of Contents NOTE: • After disassembly of the ATF strainer, check that it is in good condition, and the inlet opening is not clogged. Replace the strainer with a new one if it is clogged or damaged. •...
Page 444 Main Menu Table of Contents Regulator Valve Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace valve body as an assembly if any parts are worn or damaged. •...
Page 445 Main Menu Table of Contents Lock-up Valve Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace valve body as an assembly if any parts are worn or damaged. •...
Page 446 Main Menu Table of Contents 2nd Accumulator Body Disassembly/Inspection/Reassembly NOTE: • Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. • Blow out all passages. • Replace valve body as an assembly if any parts are worn or damaged. •...
Page 447 Table of Contents Main Menu Mainshaft Disassembly/Inspection/Reassembly NOTE: • Lubricate all parts with ATF during reassembly. • Install thrust needle bearings with unrolled edge of bearing retainer facing washer. • Inspect thrust needle and needle bearings for galling and rough movement. •...
Page 448 Main Menu Table of Contents Countershaft Disassembly/Inspection/Reassembly NOTE: • Lubricate all parts with ATF during reassembly. • Install thrust needle bearings with unrolled edge of bearing retainer facing washer. • Inspect thrust needle and needle bearings for galling and rough movement. •...
Page 449 Main Menu Table of Contents Inspection/Installation NOTE: Lubricate all parts with ATF during assembly. Hold the 2nd gear against the 3rd gear. Measure the clearance between the 3rd gear and thrust needle Assemble the parts below on the countershaft. bearing with a feeler gauge. NOTE: Do not install the O-rings during inspection.
Page 450 Main Menu Table of Contents Countershaft Inspection/Installation (cont'd) If the clearance is out of tolerance; If the clearance is out of tolerance, select and install a new cotters. Select and install a new 3rd gear collar, and recheck the clearance. If the clearance is still out of tolerance, replace the two thrust needle bearings, and recheck the clearance.
Page 451 Main Menu Table of Contents 10. Measure the clearance between 4th gear and reverse selector hub with a feeler gauge. NOTE: Take measurements in at least three places, and take the average as the actual clearance. STANDARD: 0.05 - 0.11 mm (0.002 - 0.004 in) 12.
Page 452 Table of Contents Main Menu One-way Clutch/Parking Gear Disassembly/lnspection/Reassembly Separate countershaft 1 st gear from the parking Inspect the parts as follows: gear by turning the parking gear in the direction shown. Remove the one-way clutch by prying it up with the end of a screwdriver.
Page 453 Main Menu Table of Contents Secondary Shaft Disassembly/Inspection/Reassembly NOTE: • Lubricate all parts with ATF during reassembly. • Install thrust needle bearings with unrolled edge of bearing retainer facing washer. • Inspect thrust needle and needle bearings for galling and rough movement. •...
Page 454 Main Menu Table of Contents Secondary Shaft Inspection/Installation NOTE: Hold the 2nd clutch assembly against the 3rd gear. • Lubricate all parts with ATF during assembly. Measure the clearance between the 2nd gear and • Before installing the O-rings, wrap the shaft splines thrust needle bearing using a feeler gauge.
Page 455 Main Menu Table of Contents If the clearance is out of tolerance, select and in- stall a new thrust washer. After replacing the thrust washer, make sure that the clearance is within tolerance.
Page 456 Main Menu Table of Contents Clutch Illustrated Index...
Page 457 Main Menu Table of Contents 1ST-HOLD CLUTCH 3RD CLUTCH...
Page 458 Table of Contents Main Menu Clutch Illustrated Index (cont'd) 2ND CLUTCH...
Page 459 Table of Contents Table of Contents Main Menu Main Menu Disassembly Remove the snap rings, then remove the clutch end Install the special tools as shown. plate, clutch discs and plates. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100 07HAE - PL50100 Remove the disc spring.
Page 460 Table of Contents Table of Contents Main Menu Main Menu Clutch Disassembly (cont'd) Compress the clutch return spring. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the pis- ton. Place a finger tip on the other end while apply- ing air pressure.
Page 461 Main Menu Table of Contents Reassembly NOTE: Install the piston in the clutch drum. Apply pressure • Clean all parts thoroughly in solvent or carburetor and rotate to ensure proper seating. cleaner, and dry with compressed air. • Blow out all passages. NOTE: Lubricate the piston O-ring with ATF before •...
Page 462 Main Menu Table of Contents Clutch Reassembly (cont'd) Install the special tools as shown. Compress the clutch return spring. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE - PX40100 07HAE-PL50100 CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY 07GAE - PG40200 07GAE - PG4020A CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsup-...
Page 463 Main Menu Table of Contents 10. Install the disc spring. 13. Install the snap ring. NOTE: • For 1st-hold and 2nd clutches. • Install the disc spring in the direction shown. 11. Soak the clutch discs thoroughly in ATF for a mini- mum of 30 minutes.
Page 464 Main Menu Table of Contents Clutch Reassembly (cont'd) 14. Measure the clearance between the clutch end plate 15. If the clearance is not within the service limits, select and top disc with a dial indicator. Zero the dial indi- a new clutch end plate from the following table. cator with the clutch end plate lowered, and lift it up to the snap ring.
Page 465 Table of Contents Main Menu 1st-hold Clutch Bearing Replacement Remove the 1st-hold clutch bearing using a bearing puller. Install a new bearing using the special tools as shown. NOTE: Drive in the bearing until it is fully seated. DRIVER 07749-0010000 ATTACHMENT, 72 x 75 mm 07746-0010600...
Page 466 Main Menu Table of Contents Torque Converter Housing Bearings Mainshaft Bearing/Oil Seal Replacement Install the new oil seal flush with the housing using Drive out the mainshaft bearing and oil seal using the special tools as shown. the special tools as shown. DRIVER DRIVER 07749-0010000...
Page 467 Main Menu Table of Contents Secondary Shaft Bearing Countershaft Bearing Replacement Replacement Remove the countershaft bearing using the special 1. Remove the secondary shaft bearing using the spe- tools as shown. cial tools as shown. ADJUSTABLE BEARING PULLER, 25 - 40 mm 07736-A01000B 07736-A01000A ADJUSTABLE...
Page 468 Table of Contents Main Menu Transmission Housing Bearings Replacement To remove the mainshaft, countershaft and secondary Expand each snap ring with the snap ring pliers, insert shaft bearings from the transmission housing, expand the new bearing part-way into it, then release the pli- each snap ring with the snap ring pliers, then push the ers.
Page 469: Reverse Idler Gear
Main Menu Table of Contents Reverse Idler Gear Installation Install the reverse idler gear. Install the reverse idler shaft holder into the transmis- sion housing, then tighten the bolts. Set the spring in the reverse idler shaft. Push the spring in with the steel ball, then install the needle bearing.
Page 470 Main Menu Table of Contents Parking Brake Stopper Manual Valve Detent Spring Inspection/Adjustment Replacement/Adjustment Set the parking brake lever in the position. NOTE: Select the appropriate manual valve detent spring when these parts are replaced: Measure the distance between the face of the park- •...
Page 471 Main Menu Table of Contents Transmission Reassembly NOTE: Coat all parts with ATF. Reassemble the valve bodies in the following numbered sequence. CAUTION: To prevent stripping the threads, press down on the accumulator cover while installing the bolts. NOTE: Install the ATF pump driven gear with its chamfered side facing down.
Page 472 Main Menu Table of Contents Transmission Reassembly (cont'd) Assemble the transmission housing in the following numbered sequence. NOTE: See page 14-159 when installing the reverse idler gear. NOTE: Install the three shafts together. NOTE: Align the control shaft spring pin with the groove in the transmission housing.
Page 473 Main Menu Table of Contents Assemble transmission following Set the parking brake lever in the position, then numbered sequence. verify that the parking brake pawl engages the parking gear. NOTE: Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O- If the pawl does not engage fully, check the parking rings.
Page 474 Main Menu Table of Contents Transmission Reassembly (cont'd) Install a new conical spring washer and a new lock- 10. Stake each locknut into its shaft using a 3.5 mm nut on each shaft. punch. CAUTION: Install the conical spring washers in the direction shown.
Page 475 Main Menu Table of Contents 13. Install the left side cover. 15. Install the control lever, new lock washers, change shaft, and change shaft cap on the other end of the TORQUE: 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) control shaft. Tighten the bolts, then bend the tab against the bolt head.
Page 476 Main Menu Table of Contents Torque Converter/Drive Plate...
Page 477 Main Menu Table of Contents Transmission Installation 1. Place the transmission on a transmission jack, and raise it to engine level. 2. Check that the 14 mm and 10 mm dowel pins are installed in the torque converter housing. 3. Install the three transmission housing mounting bolts. 4.
Page 478 Main Menu Table of Contents Transmission Installation (cont'd) 11. Install a new set ring on the end of the left driveshaft and intermediate shaft. Apply a light film of grease around the set ring grooves, then center the new set ring on the shafts. The grease keeps the set ring centered, making shaft installation easier.
Page 479 Main Menu Table of Contents 19. Install the right driveshaft on the intermediate shaft. 20. Install the lower control arm to the side beam. CAUTION: Line up the reference marks on the adjusting bolt, adjusting cam, and lower control arm. 21.
Page 480 Main Menu Table of Contents Transmission Installation (cont'd) 27. Install the three transmission mounting bolts and 34. Refill the transmission with ATF. the two transmission housing mounting bolts. 35. Connect the positive (+) and negative (-) cables to 28. Install the starter motor, and tighten the starter the battery.
Page 481 Main Menu Table of Contents Shift Cable Adjustment Raise the vehicle (see section 6. Check that the hole in the control lever is perfectly aligned with the hole in the shift cable. Shift to the position. Remove the shift cable cover. Remove the control lever pin and lock pin from the control lever.
Page 482 Main Menu Table of Contents Shift Cable Removal/Installation 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. Make sure lifts are placed properly (see section Remove the center console panel (see section...
Page 483 Table of Contents Main Menu Shift Lever 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.
Page 484 Main Menu Main Menu Table of Contents Table of Contents Shift Indicator Panel Adjustment SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or ser- vice. Check that the index mark of the indicator aligns with the N mark of the shift indicator panel with the transmission in NEUTRAL.
Page 485 Main Menu Differential Manual Transmission Automatic Transmission Special Tools ......... . . 15–2 Special Tools .
Page 486: Special Tools
Table of Contents Main Menu Special Tools 15-12 15-5 15-14 15-4, 15-6, 15-9, 15-11, 15-13 15-12 15-13 15-12, 15-13, 15-14 15-14 15-14...
Page 487 Table of Contents Main Menu Differential Illustrated Index NOTE: • If the parts marked with an asterisk ( * ) are replaced, the bearing preload must be adjusted (see page 15-12). • If replacement is required, always replace the limited slip differential clutch set. *75 mm THRUST SHIM Selection, Adjustment, page 15-13...
Page 488: Preset Torque Inspection
Main Menu Table of Contents Preset Torque Inspection On-Vehicle: Assembly: Block the front wheels. Place one special tool in a vise. Place the left side of the differential assembly on the special tool, then Shift to low gear. preset the differential with 3 - 5 r o t a t i o n s , counter clockwise.
Page 489: Bearing Replacement
Main Menu Table of Contents Bearing Replacement NOTE: Install the tapered roller bearings using a special • The bearing and outer race should be replaced as a tool and a press. Press the tapered roller bearings set. squarely until they bottom against the case. •...
Page 490: Differential
Table of Contents Main Menu Differential Disassembly Hold the differential in a bench vise using a special Remove the 112 mm shim, clutch discs, clutch tool, then remove the differential housing mounting plates, and 102 mm washer. bolts in a crisscross pattern in several steps. 112 mm SHIM CLUTCH DISCS...
Page 491 Main Menu Table of Contents Screw two 8 x 1.0 mm bolts into the threaded holes in the differential housing cover to push it away from the final driven gear. Turn eacr bolt two turns at a time to prevent cocking the differential housing cover excessively.
Page 492: Reassembly
Table of Contents Main Menu Reassembly NOTE: • If the limited slip differential clutch set was replaced, the 65 mm shim (differential housing cover side) and 1 1 2 mm shim (differential housing cover side) must be adjusted. • Reassemble the parts in the same order and direction they were before disassembly.
Page 493 Table of Contents Main Menu Differential Reassembly Install the carrier assembly. Install the washers, thrust needle bearing, and cen- tral gear. CARRIER CENTRAL GEAR ASSEMBLY THRUST NEEDLE DIFFERENTIAL BEARING WASHERS HOUSING Install the final driven gear. Align the mark on the differential housing cover with the mark on the final driven gear.
Page 494 Table of Contents Main Menu Install the washer, thrust needle bearing, 65 mm Tighten the mounting bolts in a crisscross pattern shim, 112 mm shim, clutch disc, and spring plate. in several steps. Be careful not to move the plastigauge when installing the washer.
Page 495 Main Menu Table of Contents Differential Reassembly 11. Measure the widest part of the plastigauge. • After installing a thinner shim: If the measured value is less than 0.18 mm, select Standard: 0.18-0.229 mm the next thinner shim, and recheck. If the new value is more than 0.229 mm, the selected shim is OK.
Page 496 Main Menu Table of Contents 16. Tighten the mounting bolts in a crisscross pattern in several steps. 8 x 1.0 mm SPECIAL BOLTS 39 N-m (4.0 kgf-m, 29 Ibf-ft) BENCH VISE DIFFERENTIAL INSPECTION TOOLS 07MAJ-PR90100 17. Measure the preset torque (see page 15-4). Standard: 59-137 N-m (6-14 kgf-m, 43-101 Ibf-ft) 112 mm SHIM...
Page 497: Oil Seal Removal
Main Menu Table of Contents Oil Seal Removal Remove the differential assembly. Remove the oil seal from the transmission housing. OIL SEAL Replace. TRANSMISSION HOUSING Remove the oil seal from the clutch housing. OIL SEAL CLUTCH HOUSING Replace.
Page 498: Bearing Outer Race Replacement (Clutch Housing Side)
Main Menu Table of Contents Bearing Outer Race Replacement (Clutch Housing Side) NOTE: • The outer race and bearing should be replaced as a set. • Inspect and adjust the bearing preload whenever the bearing is replaced. Remove the bearing outer race, 90 mm washer, and oil guide ring using the special tools.
Page 499: Bearing Preload Adjustment
Table of Contents Main Menu Bearing Preload Adjustment If any of the items listed below are replaced, the bearing preload must be adjusted. • TRANSMISSION HOUSING • CLUTCH HOUSING • DIFFERENTIAL • TAPERED ROLLER BEARING and OUTER RACE • 75 mm THRUST SHIM •...
Page 500 Main Menu Table of Contents Install the standard shim and bearing outer race Lubricate the tapered roller bearing with transmis- into the transmission housing using the special sion oil, then install the differential. tools. Install the bearing outer race squarely, and check that there is no clearance between the bear- Install the transmission housing.
Page 501: Oil Seal Installation
Main Menu Table of Contents Oil Seal Installation Install the oil seal into the transmission housing Install the oil seal into the clutch housing using the using the special tools. special tools. SEAL DRIVER BEARING ATTACHMENT DRIVER DRIVER ATTACHMENT 07947 - SD90100 07749 - 0010000 07965 - SA00600 DRIVER...
Page 502 Main Menu Table of Contents 15-26 15-20, 15-24 15-20, 15-24 15-20, 15-24 15-19 15-28 15-18, 20, 25, 28 15-26 15-27 15-26, 15-27, 28 15-28 15-28...
Page 503: Differential
Table of Contents Main Menu Differential Illustrated Index NOTE: If the parts marked with an asterisk ( * ) are replaced, the bearing preload must be adjusted (see page 15-26). 75 mm THRUST SHIM Selection, Adjustment, page 15-27 FINAL DRIVEN GEAR TAPERED ROLLER BEARING Inspect for wear and damage.
Page 504 Table of Contents Main Menu Preset Torque Inspection Assembly: On-Vehicle: Place one special tool in a vise. Place the left side of Lift up right rear wheel, and place the safety stand. the differential assembly on the special tool, then (Lift and Support Points, see section preset the differential with 3 —...
Page 505 Main Menu Table of Contents Bearing Replacement Install the tapered roller bearings using a special NOTE: • The bearing and outer race should be replaced as a tool and a press as shown. Press the tapered roller set. bearings squarely until they bottom against the •...
Page 506 Table of Contents Main Menu Compress the spring plate. Hold the differential in a bench vise using a special tool, then remove the differential housing mounting bolts in a crisscross pattern in several steps. DIFFERENTIAL HOUSING BENCH VISE DIFFERENTIAL INSPECTION TOOLS 07MAJ - PR90100 Remove the differential housing, then install the Remove the stop clip.
Page 507 Main Menu Table of Contents Remove the 112 mm thrust shim, clutch discs, Screw two 8 x 1.0 mm bolts into the threaded holes clutch plates, and 102 mm washer. in the differential housing cover to push it away from the final driven gear. Turn each bolt two turns at a time to prevent cocking the differential housing cover excessively.
Page 508: Clutch Disc, Clutch Plate
Table of Contents Main Menu Clutch Disc, Clutch Plate Replacement NOTE: The clutch discs and clutch plates should be replaced as a set. Remove the clutch discs and clutch plates (see page 15-20). Soak the clutch discs for five minutes in transmis- 112 mm THRUST SHIM sion oil.
Page 509 Main Menu Table of Contents Differential Reassembly Install the 102 mm washer, clutch discs, clutch Install the clutch disc, clutch plate, central gear, and plates, and 112 mm thrust shim. Lubricate the carrier assembly. Lubricate the clutch disc surface with transmission fluid. clutch discs with transmission fluid.
Page 510 Table of Contents Main Menu Differential Reassembly Install the special tools on the stop plate. Install the differential housing. Align the fingers of the clutch plates and clutch discs. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE - PX40100 DIFFERENTIAL HOUSING STOP PLATE CLUTCH SPRING Align the fingers.
Page 511 Table of Contents Main Menu Hold the differential in a bench vise using a special tool, then install the differential housing mounting bolts. Tighten the bolts in a crisscross pattern in several steps. 8 x 1.0 mm SPECIAL BOLTS 39 Nm (4.0 kgf-m, 29 Ibf-ft) BENCH VISE DIFFERENTIAL...
Page 512: Oil Seal Removal
Table of Contents Main Menu Oil Seal Removal 1. Remove the differential assembly. 2. Remove the oil seal from the transmission housing. OIL SEAL TRANSMISSION Replace. HOUSING Remove the oil seal from the torque converter housing. OIL SEAL TORQUE CONVERTER Replace.
Page 513: Bearing Outer Race Replacement (Torque Converter Housing Side)
Main Menu Table of Contents Bearing Outer Race Replacement (Torque Converter Housing Side) NOTE: • The outer race and bearing should be replaced as a set. • Inspect and adjust the bearing preload whenever the bearing is replaced. Remove the bearing outer race, 90 mm washer, and oil guide ring using the special tools.
Page 514: Bearing Preload Adjustment
Table of Contents Main Menu Bearing Preload Adjustment NOTE: If any of the items listed below are replaced, the bearing preload must be adjusted. TRANSMISSION HOUSING TORQUE CONVERTER HOUSING DIFFERENTIAL TAPERED ROLLER BEARING and OUTER RACE 75 mm THRUST SHIM 90 mm WASHER OIL GUIDE RING Remove the bearing outer race and 75 mm thrust...
Page 515 Table of Contents Main Menu Install the standard shim and bearing outer race 75 mm THRUST SHIM: into the transmission housing using the special tools as shown. Install the bearing outer race squarely. Check that there is no clearance between the bear- ing outer race, shim, and transmission housing.
Page 516 Main Menu Table of Contents Bearing Preload Adjustment (cont'd) Measure the starting torque of the differential assembly with a special tool and a torque wrench. Measure the bearing preload at normal room tem- perature in both directions. Standard: 3.3 - 4.5 N-m (33 - 45 kgf-cm, 29 - 39 Ibf-in) TORQUE WRENCH DIFFERENTIAL...
Page 517: Oil Seal Installation
Main Menu Table of Contents Oil Seal Installation Install the oil seal into the transmission housing using the special tools. DRIVER 07749 - 0010000 OIL SEAL Replace. BEARING DRIVER ATTACHMENT 07965 - SA00600 PILOT, 32 x 50 mm 07MAD - PR90200 Install the oil seal into the torque converter housing using the special tools.
Page 518 Main Menu Driveshafts Special Tools ......... . . 16–2 Intermediate Shaft Driveshafts...
Page 519: Special Tools
Main Menu Table of Contents Special Tools 16-13, 16-14, 16, 17 16-16 16-16 16-16 16-17 16-14 16-14, 16-16, 16-17...
Page 520: Driveshafts Removal
Table of Contents Main Menu Driveshafts Removal Inspection Raise the vehicle, and place safety stands in the proper locations (see section Driveshaft Boot Check the boots on the driveshaft for cracks, damage, Remove the rear wheels. leaking grease or loose boot bands. If any damage is found, replace the boot Drain the transmission fluid (see section 13...
Page 521 Main Menu Table of Contents Driveshafts Removal Remove the wheel sensor from the knuckle and the 9. Hold the damper lower mount of stabilizer link with rear of the lower arm, then secure the wheel sensor a wrench, and remove the damper mounting nut. wire to the suspension arm.
Page 522 Table of Contents Main Menu 12. Remove the self-locking nut and flange bolt. 15. Pry the driveshaft assembly with a screwdriver as shown to force the set ring past the groove. Corrosion resistant bolt/nut SELF-LOCKING NUT 14 x 1.5 mm SCREWDRIVER Replace.
Page 523: Disassembly
Table of Contents Main Menu Driveshafts Disassembly To remove the boot band, pry up the locking tabs Remove both joints. with screwdriver, and raise the end of the band. Outboard joint side only: Remove the circlip from NOTE: Carefully clamp the driveshaft in a vise with the outboard joint groove, then remove the out- soft jaws.
Page 524: Inspection
Table of Contents Main Menu Inspection Grease Quantity: : Thoroughly pack the inboard joint and outboard joint with joint grease included in the new joint boot set. NOTE: Mark the rollers and roller grooves during disassembly to ensure proper positioning during reassembly.
Page 525: Reassembly
Table of Contents Main Menu Driveshafts Reassembly Outboard joint side Fit the rollers to the spider with their high shoulders facing outward. NOTE: Wrap the splines with vinyl tape to prevent CAUTION: damage to the boot. • Reinstall the rollers in their original positions on the spider.
Page 526 Main Menu Table of Contents Install the spring and cap, then fit the outboard joint Inboard joint side onto the driveshaft. NOTE: Wrap the splines with vinyl tape to prevent damage to the boot. CAUTION: Reinstall the outboard joint in the origi- nal position on the rollers.
Page 527 Main Menu Table of Contents Driveshafts Reassembly 1 3. Fit the rollers to the spider with their high shoulders 15. Fit the inboard joint onto the driveshaft. facing outward. CAUTION: Reinstall the inboard joint in the original CAUTION. position on the rollers. •...
Page 528 Table of Contents Main Menu 17. Install new boot bands on the boots, then bend both 19. Install the new set rings in the driveshaft groove and intermediate shaft groove. sets of locking tabs. 20. Apply a light film of grease around the set ring groove 1 8.
Page 529: Intermediate Shaft Replacement
Main Menu Table of Contents Intermediate Shaft Replacement Drain the fluid from the transmission The bearing support assembly is a light press fit in (see section 13 M/T or section 14 A/T). the support base. To remove the bearing support assembly, remove the 8 x 1.25 mm flange bolts with 2.
Page 530: Disassembly
Table of Contents Main Menu Disassembly CAUTION: The bearing support and support base are Press the intermediate shaft out of the shaft bearing made of aluminum. Be careful not to damage them using the special tool and a press. when servicing. Remove the intermediate shaft outer seal from the bearing support.
Page 531: Intermediate Shaft
Table of Contents Main Menu Intermediate Shaft Disassembly (cont'd) Press the intermediate shaft bearing out of the bear- ing support using the special tools and & press. Press DRIVER 07749 - 0010000 ATTACHMENT, BEARING 52 x 55 mm 07746 - 0010400 HUB DIS/ASSEMBLY BASE 07GAF - SD40700...
Page 532: Index/Inspection
Main Menu Table of Contents Index/Inspection CAUTION: • The bearing support and support base are made of aluminum. Be careful not to damage them when servicing. • The bearing support and support base are a matched set and must be replaced as an assembly. Corrosion resistant bolt/nut SUPPORT BASE Check for damage.
Page 533: Reassembly
Main Menu Table of Contents Intermediate Shaft Reassembly Press the intermediate shaft bearing into the bear- Press the intermediate shaft inner seal into the ing support using the special tools and a press. bearing support using the special tools and a press. Press DRIVER 07749 - 0010000...
Page 534 Main Menu Table of Contents Seat the external circlip in the groove of the in- termediate shaft. CAUTION: Install the circlip with the radiused side facing out. EXTERNAL CIRCLIP Press the outer seal into the bearing support using the special tools and a press. Press DRIVER 07749-0010000...
Page 535 Main Menu Steering *: Read SRS precautions before working in this area Special Tools ....17–2 EPS Control Unit Terminal Inspection Steering Gearbox Component Location Index Arrangement .
Page 536: Special Tools
Main Menu Table of Contents Special Tools 17-53 17-61 17-23 17-59, 17-42 17-58...
Page 537 Main Menu Table of Contents Component Locations Index NOTE: • If an intact airbag assembly has been removed from a scrapped vehicle or has been found defective or damaged during transit, storage or service, it should be deployed (see section 24).
Page 538: System Description Steering Column
Main Menu Table of Contents System Description Steering Column The NSX/NSX-T has a tilt/telescopic steering column. The tilt/telescopic mechanism makes it possible to adjust the steer- ing wheel in fore and aft, and up and down directions. Tilt Mechanism In the upper portion of the steering column is a joint on the steering shaft. This joint allows the steering wheel to be adjusted up or down.
Page 539 Main Menu Table of Contents Telescopic Mechanism The upper steering shaft is divided into two shafts, connected by splines, making it possible for the shaft to telescope while transmitting the rotation of the steering wheel. When the telescopic lever is lowered, the lever pivot turns in a direc- tion to loosen the stop shim at the tip of the lever pivot, allowing the shaft to telescope.
Page 540: Energy-Absorbing Steering Column/Wheel
Main Menu Table of Contents System Description Energy-absorbing Steering Column/Wheel Both the steering column and steering wheel are designed to absorb impact energy during a collision. Steering Wheel The steering wheel absorbs the energy of a collision through the deformation of the spoke portion. Should the impact absorbing capacity of the column side decrease due to the deformation of the vehicle body during a collision, the steering wheel will help absorb the impact.
Page 541: Electrical Power Steering (Eps)
Main Menu Table of Contents Electrical Power Steering (EPS) Outline The NSX/NSX-T uses an electric motor-driven power steering, which possesses the characteristics best suited for a mid- engine automobile. This system is a power-assisted steering device, with a motor inside the steering gearbox driven by the EPS control unit.
Page 542: Major Components
Main Menu Table of Contents System Description Major Components The Electrical Power Steering system is composed of the following major components: • A steering gearbox that converts rotary operation of the steering wheel into transverse operation via a rack and pinion mechanism.
Page 543: System Operation
Main Menu Table of Contents System Operation Manual Steering Operation Steering wheel input rotates the pinion of the gearbox through a universal joint. Due to the rack and pinion mechanism, the rotation of pinion is converted into a transverse motion at the rack, which steers the front wheels throught the tie-rods and knuckles the same as an ordinary rack and pinion system.
Page 544: Function And Operation
Main Menu Table of Contents System Description Function and Operation Steering Sensor The steering sensor consists of a torque sensor, an interface. Torque Sensor The torque sensor converts steering torque input and its direction to voltage signals, in conjunction with the interface.
Page 545 Main Menu Table of Contents Interface Circuit The interface circuit is housed inside the steering gearbox near the pinion. It rectifies and amplifies the signals from the torque sensor, and transmits the steering signals to the EPS control unit.
Page 546 Main Menu Table of Contents System Description Function and Operation (cont'd) EPS Control Unit The control unit receives input signals from the vehicle speed sensors, torque sensor. It performs a multitude of control functions, including a circuit which can detect troubles in each functional part of the system and the control unit itself. The control unit operates the system while the engine is in the process of starting, on receipt of voltage generated by the alter- nator.
Page 547 Main Menu Table of Contents Self-Diagnosis Function The EPS control unit monitors the system inputs and outputs, and the driving current of the motor. If there is a problem in the system, the control unit turns the system off by actuating the relay. Power assist stops and normal manual steering operation resumes.
Page 548 Main Menu Table of Contents System Description Function and Operation (cont'd) The power module in the EPS control unit consists of a driving circuit, current sensor, field effect transistor (FET) bridge circuit, and two relays. It receives control signals from the central processing unit (CPU) and controls the driving current of the motor.
Page 549 Main Menu Table of Contents Steering Gearbox Motor and Power Assist Mechanism A motor is housed inside the gearbox housing. It consists of a yoke with a permanent magnet fixed in it, a rotor with a field coil, and brushes which pass electricity to rotor commutators. The motor is on the rack shaft of the steering gearbox. The drive current from the control unit flows through the power relay and fail-safe relay to the brushes of the motor.
Page 550: Component Locations
Main Menu Table of Contents Component Locations...
Page 551 Main Menu Table of Contents...
Page 552: Eps Control Unit Terminal Arrangement
Main Menu Table of Contents EPS Control Unit Terminal Arrangement 18P CONNECTOR WIRE SIDE OF FEMALE TERMINALS...
Page 553 Main Menu Table of Contents 3P CONNECTOR (LEFT SIDE) VB: Battery voltage IG SW: Ignition switch 3P CONNECTOR (RIGHT SIDE) VB: Battery voltage IG SW: Ignition switch PULSE UNIT 7P CONNECTOR (MT) 6P CONNECTOR...
Page 554: Troubleshooting Precautions
Main Menu Table of Contents Troubleshooting Precautions EPS Indicator Light Under normal conditions, the EPS indicator light in the gauge assembly comes on when the ignition switch is turned to the ON (II) position, then goes off after the engine is started. This indicates that the bulb and its circuits are operating cor- rectly.
Page 555 Main Menu Table of Contents Diagnostic Trouble Code (DTC) Indication Connect the SCS service connector to the service check connector under the glove box. SERVICE CHECK SCS SERVICE CONNECTOR CONNECTOR (2P) 07PAZ-0010100 Turn the ignition switch ON (II), but do not start the engine. Record the blinking frequency of the EPS indicator light.
Page 556: Diagnostic Trouble Code (Dtc)
Main Menu Table of Contents Diagnostic Trouble Code (DTC) Symptom-to-System Chart 17-27 17-29 17-36 17-31 17-36 17-38 • Initial diagnosis: Performed right after the engine starts until the EPS indicator light goes off. • Regular diagnosis: Continuously performed (under some conditions) after the EPS indicator light goes off until the engine stops.
Page 557: Hard Steering
Main Menu Table of Contents Troubleshooting Hard Steering Refer to the Symptom-to-System Chart (see page 17-25). Power Assist Check with Car Parked: Connect a spring scale to the steering wheel and turn the wheel. Read the measurement when the front wheels start to move.
Page 558: Inspection
Main Menu Table of Contents Inspection Steering Wheel Rotational Play Steering Gearbox Adjustment Place the front wheels in a straight ahead position, Serious burns may result if you touch any and measure the distance the steering wheel can be cooling components when the cooling system is hot. turned without moving the front wheels.
Page 559: Steering Wheel Removal
Main Menu Table of Contents Steering Wheel Removal Remove the Torx bolts using a Torx T30 bit, then Airbag Removal remove the driver's airbag assembly. Store a removed airbag assembly with the pad surface up. If the airbag is improperly stored face down, accidental deployment could propel the unit with enough force to cause serious injury.
Page 560 Main Menu Table of Contents Steering Wheel Removal (cont'd) Remove the steering wheel nut. Disconnect the connectors from the horn and cruise control set/resume switches, then remove the cable reel 3P connector from its clips. Remove the steering wheel by rocking it slightly from side-to-side as you pull steadily with both hands.
Page 561: Disassembly/Reassembly
Main Menu Table of Contents Steering Wheel Disassembly/Reassembly Store a removed airbag assembly with the CAUTION: pad surface up. If the airbag is improperly stored face * Carefully inspect the driver's airbag assembly before down, accidental deployment could propel the unit with installing.
Page 562: Installation
Main Menu Table of Contents Installation NOTE: Before installing the steering wheel, make sure Install the steering wheel. the front wheels are straight ahead. NOTE: Be sure the steering wheel shaft engages CAUTION: the cable reel. • Be sure to install the harness wires so that they are not pinched or interfering with other car parts.
Page 563 Main Menu Table of Contents Steering Wheel Installation (cont'd) Install the airbag assembly with new Torx bolts. 9. Connect the battery positive terminal, and then con- nect the negative terminal. 10. After installing the airbag assembly, confirm proper system operation: •...
Page 564: Steering Column Removal
Main Menu Table of Contents Steering Column Removal SRS components are located in this area. Review the Remove the column covers. SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or ser- NOTE: Be careful not to damage the column covers. vice.
Page 565 Main Menu Table of Contents Steering Column Removal (cont'd) Remove the combination switch assembly from the 10. Remove the steering joint bolts and toothed lock column shaft. washers from the steering joint. NOTE: The combination switch can be removed by disconnecting only the TCS sensor connector.
Page 566: Inspection
Main Menu Table of Contents Inspection NOTE: • Check the telescopic mechanism, tilt mechanism, and steering joint bearings or steering shaft for movement and damage. Replace as an assembly if damaged or faulty. • If either the steering column assembly or TCS sensor is removed, select the appropriate shim and adjust the distance between the steering shaft and TCS sensor.
Page 567: Installation
Main Menu Table of Contents Steering Column Installation SRS components are located in this area. Review the Install the column holder with the 8 mm bolts. SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or ser- vice.
Page 568 Main Menu Table of Contents Install the combination switch assembly over the 9. Install the column covers. column shaft. NOTE: Be careful not to damage the column covers. 10. Insert the cable reel 3P connector through the col- umn lower panel, and attach it to the column lower panel with the connector holder.
Page 569 Main Menu Table of Contents Steering Column Installation (cont'd) 12. Install the dashboard brace and dashboard lower pad. 13. Connect the foot well light harness and light-on warning chime to the dashboard lower panel, then install the dashboard lower panel. 14.
Page 570: Steering Gearbox
Main Menu Table of Contents Steering Gearbox Removal/Installation NOTE: Before removing the steering gearbox, make 7. Install the 10 mm hex nut on the ball joint. Be sure sure the front wheels are straight ahead. that the 10 mm hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin Remove the steering joint cover.
Page 571 Main Menu Table of Contents Steering Gearbox Removal/Installation (cont'd) 12. Disconnect the connectors from the EPS wire har- 16. Remove the radiator pipe bracket at the front com- ness. partment bulkhead. 13. Remove the ground cable by removing the EPS wire harness bracket.
Page 572 Main Menu Table of Contents NOTE: Before removing the gearbox, place a stand jack 19. Lower the gearbox and front crossbeam with care under the gearbox and front crossbeam to lightly sup- so as not to hit or damage the radiator pipe. port them.
Page 573 Main Menu Table of Contents Steering Gearbox Removal/Installation (cont'd) 21. Install the gearbox in the reverse order of removal. NOTE: When connecting the steering joint, make sure that the cable reel of airbag system is centered. 22. Set the steering rack in the center of its stroke. 23.
Page 574 Main Menu Table of Contents Steering Gearbox Illustrated Index CAUTION: Do not try to disassemble the power steering gearbox. If the gearbox is faulty, replace it as an assembly.
Page 575 Main Menu Table of Contents Steering Gearbox Inspection Carefully clamp the gearbox in a vise with soft jaws. • Preload inspection: Remove the boot bands. Slide the steering rack in the cylinder until the end of the rack projects 60 mm (2.4 in) from the cylinder end.
Page 576 Main Menu Table of Contents Retighten the locknut while holding the rack Tie-rod installation: guide screw with a wrench. Screw each rack end into the rack while holding the lock washer so its tabs are in the slots in the rack end.
Page 577 Main Menu Table of Contents Steering Gearbox Inspection (cont'd) Install the boots on the rack end with the tube clamps. 9. If the tie-rod ends were removed, install the tie-rods on the right and left rack ends and screw them in until the threaded section is 11 mm (7/16 in) in NOTE: •...
Page 578: Replacement
Main Menu Table of Contents Ball Joint Boot Replacement Remove the set ring and the boot. Insert the special tool into the threads in the ball pin, and align the end of the tool with the groove in the CAUTION: Do not contaminate the boot installa- boot.
Page 579 Main Menu Table of Contents EPS Control Unit Replacement SRS components are located in this area. Review the Disconnect the connectors from the EPS control SRS component locations, precautions, and procedures unit, then remove it. in the SRS (section 24) before performing repairs or ser- vice.
Page 580 Main Menu Suspension Special Tools ..... . 18–2 Front Suspension Rear Suspension Component Location Index ..18–3 Torque Specifications .
Page 581: Special Tools
Main Menu Table of Contents Special Tools 18-33, 18-34 18-18,18-34 18-18, 18-33 18-26, 18-39 18-21, 18-22, 18-24, 18-37 18-21, 18-36 18-26 18-18, 18-34 18-39...
Page 582: Component Location
Table of Contents Main Menu Component Locations Index Front Suspension: FRONT DAMPER Removal, page 18-27 Disassembly/Inspection, page 18-27 Reassembly, page 18-29 FRONT SUSPENSION ASSEMBLY Installation, page 18-29 • Knuckle/Control Arms/ Compliance Pivot Removal, page 18-21 • Illustrated Index, page 18-20 •...
Page 583: System Description
Main Menu Table of Contents System Description Suspension Composition Outline Double wishbone independent suspension has been selected for each of the four wheels. This eliminates damper friction along the steering axis, and permits suspension geometry that takes full advantage of the performance potential of the wide, low aspect ratio tires.
Page 584 Table of Contents Main Menu (Front Compliance Mechanism) To avoid the usual compromise between ride quality and handling characteristics, a pivot-type "compliance mechanism" has been designed as an integral part of the front suspension. When one of the front wheels is subjected to a rearward movement by an uneven road surface or by heavy braking, the load produced has two separate effects.
Page 585: Wheel Alignment
Table of Contents Main Menu Wheel Alignment Height NSX/NSX-T four wheel alignment requires the use of equipment designed specifically for four wheel independent suspensions and capable of immediate feedback. NOTE: For proper inspection/adjustment of the wheel alignment, check and adjust the following before checking the alignment.
Page 586: Front Wheel Alignment Adjusting Procedure
Main Menu Table of Contents Front Wheel Alignment Adjusting Procedure Adjustment NOTE: NSX/NSX-T four wheel alignment requires the use of equipment designed specifically for four wheel independent suspensions and capable of immediate feedback. The NSX/NSX-T suspension can be adjusted for camber, caster (front only), and toe. However, because each of them relates to the other, the camber changes when the toe is adjusted for example.
Page 587 Table of Contents Main Menu Wheel Alignment Front Wheel Alignment Adjustment Procedure NOTE: Camber: — Loosen the self-locking nut on the front lower • NSX/NSX-T four wheel alignment requires the use of control arm adjusting point, and adjust the equipment designed specifically for four wheel in- camber by turning the adjusting cam.
Page 588 Table of Contents Main Menu Measure the caster on the both sides, and adjust the caster to specifications. Caster: Loosen the pivot adjuster mounting nuts (self- locking nuts) under the compliance pivot, and adjust the caster by turning the adjusting cam. ADJUSTING CAM SELF-LOCKING Replace.
Page 589: Front Turning Angle Inspection
Table of Contents Main Menu Wheel Alignment Front Turning Angle Inspection NOTE: • Place a vehicle on a level surface before inspection. • Release the parking brake and be sure that the vehicle is empty. • Check that the suspensions are at the standard height (see page 18-6).
Page 590: Rear Wheel Alignment Adjusting Procedure
Table of Contents Main Menu Rear Wheel Alignment Adjusting Procedure Rear wheel alignment adjusting procedure TOP VIEW: Check tire pressure on both sides. Check the ride height on both sides. Adjust both camber and toe of the left side. CAMBER Adjust both camber and toe of the right side.
Page 591 Table of Contents Main Menu Wheel Alignment Rear Wheel Alignment Adjusting Procedure NOTE: NSX/NSX-T four wheel alignment requires the Camber use of equipment designed specifically for four wheel -1. Loosen the self-locking nut on the rear lower independent suspensions and capable of immediate control arm adjusting point, then adjust the feedback.
Page 592: Runout
Table of Contents Main Menu Runout Bearing End Play Raise the vehicle off the ground, and support it with Front Wheel End Play: safety stands in the proper locations (see section Standard: 0 mm (0 in) Service limit: 0.05 mm (0.002 in) max. Place the dial gauge on each front and rear wheel Rear Wheel End Play: rim, and turn the wheel slowly by hand.
Page 593: Front Suspension Torque Specifications
Table of Contents Main Menu Front Suspension Torque Specifications CAUTION: • Replace the self-locking nuts after removal. • Replace the self-locking bolts if you can easily thread a non-self-locking nut past their nylon locking inserts. (It should require 1 N-m (0.1 kgf-m, 0.7 Ibf-ft) of torque to turn the test nut on the bolt). •...
Page 594: Hub Replacement
Main Menu Table of Contents Hub Replacement NOTE: • Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damage the aluminum wheels. • On the aluminum wheels, remove the center cap from inside of the wheel after removing the wheel. •...
Page 595 Table of Contents Main Menu Front Suspension Hub Replacement Remove the wheel sensor from the knuckle and Loosen the wheel nuts slightly. front lower control arm. Raise the front of vehicle, and support it on safety NOTE: stands in proper locations (see section •...
Page 596 Main Menu Table of Contents Remove the flat head screws. Install two 8 x 12 mm Front Wheel Bearing Replacement: bolts into the disc to push it away from the hub. Raise the locking tab on the spindle nut, then remove the nut.
Page 597 Table of Contents Main Menu Front Suspension Hub Replacement Separate the wheel bearing from the hub using the NOTE: Replace the bearing with a new one after special tools and a press. removal. CAUTION: Hold onto the hub to keep it from fall- Press a new wheel bearing into the hub using the ing when pressed clear.
Page 598 Main Menu Table of Contents 7. Tighten the new spindle nut to specified torque, then stake the spindle nut shoulder against the spindle. 329 N-m (33.5 kgf-m, 242 Ibf-ft) Stake After tightening, use a drift to stake spindle shoulder against the spindle.
Page 599: Knuckle/Control Arms/Compliance Pivot
Table of Contents Main Menu Knuckle/Control Arms/Compliance Pivot Illustrated Index Overall Suspension NOTE: Align the white line on the stabilizer bar with the bushing end, and install the stabilizer bar. NOTE: • Wipe off the grease before tightening the nut at the ball joint. •...
Page 600: Removal
Table of Contents Main Menu Removal Remove the front wheel and bearing unit assembly NOTE: Use the ball joint removers to separate the ball (see page 18-15). joints from the suspension or steering arm. Remove the splash guard from the knuckle. CAUTION: •...
Page 601 Table of Contents Main Menu Knuckle/Control Arms/Compliance Pivot Removal 9. Once the tool is in place, turn the adjusting bolt as 12. Remove the cotter pin and lower control arm ball necessary to make the jaws parallel. Then hand- joint nut. tighten the pressure bolt, and recheck the jaws to make sure they are still parallel.
Page 602 Main Menu Table of Contents 18. Remove the knuckle. 20. Hold the ball pin of the stabilizer link with a hex wrench, and loosen the self-locking nut. STABILIZER LINK LOWER CONTROL KNUCKLE HEX WRENCH 19. Separate the lower control arm and damper by removing the damper mounting bolt.
Page 603 Main Menu Table of Contents Knuckle/Control Arms/Compliance Pivot Removal 22. Remove the cotter pin and lower arm ball joint nut. 26. Remove the cotter pin and upper arm ball joint nut. CASTLE NUT CASTLE NUT 12 x 1.25 mm 12 x 1.25 mm 54 - 64 N-m 54 - 64 N-m (5.5 - 6.5 kgf-m, 40 - 47 Ibf-ft)
Page 604 Main Menu Table of Contents 31. Remove the compliance pivot assembly by remov- NOTE: ing the bolts and nuts shown. • Install the upper control arm on the frame before installing the compliance pivot assembly. SELF-LOCKING • Install the compliance pivot bolts and nuts. NUTS Torque them to the specified torque in the order.
Page 605: Ball Joint Boot Replacement
Table of Contents Main Menu Knuckle/Control Arms/Compliance Pivot Ball Joint Boot Replacement Wipe the grease off the sliding surface of the ball NOTE: The upper control arm ball joint, lower control arm ball joint and knuckle upper ball joint are attached pin, and pack with fresh grease.
Page 606: Front Damper Removal
Table of Contents Main Menu Front Damper Disassembly/Inspection Removal Remove the front wheel. Disassembly: Compress the damper spring with the spring com- Remove the brake hose mounting bolt from the pressor according to the manufacturer's instruc- damper. tions, then remove the self-locking nut. CAUTION: Do not compress the spring more than BRAKE HOSE MOUNTING BOLT necessary to remove the nut.
Page 607: Inspection
Table of Contents Main Menu Front Damper Inspection SELF-LOCKING NUT 10 x 1.25 mm Replace. 29 N-m (3.0 kgf-m, 22 Ibf-ft) DAMPER MOUNTING RUBBER SELF-LOCKING DAMPER MOUNTING WASHER 10 x 1.25 mm Check for weakness. Replace. 43 N-m DAMPER MOUNTING (4.4 kgf-m, 32 Ibf-ft) COLLAR DUST COVER PLATE...
Page 608: Reassembly
Main Menu Table of Contents Reassembly Installation Install the damper unit on a spring compressor. Reposition the damper on the frame with the welded nut of the hose bracket facing outside. Assemble the damper in reverse order of removal BRAKE HOSE MOUNTING BOLT except the damper mounting washer and self-locking DAMPER 22 N-m (2.2 kgf-m, 16 Ibf-ft)
Page 609: Rear Suspension Torque Specifications
Table of Contents Main Menu Rear Suspension Torque Specifications CAUTION: • Replace the self-locking nuts after removal. • Replace the self-locking bolts if you can easily thread a non-self-locking nut past their nylon locking inserts. (It should require 1 N-m (0.1 kgf-m, 0.7 Ibf-ft) of torque to turn the test nut on the bolt). •...
Page 610: Hub Replacement
Main Menu Table of Contents Hub Replacement NOTE: • Use only genuine Honda wheel weights for aluminum wheels. Non-genuine wheel weights may corrode and damage the aluminum wheels. • On the aluminum wheels, remove the center cap from inside of the wheel after removing the wheel. •...
Page 611 Table of Contents Main Menu Rear Suspension Hub Replacement Remove the center cap, then pry the spindle nut Remove the banjo bolt and disconnect the brake lock tab away from the spindle and loosen the nut. hose, then remove the brake hose clamp from the knuckle.
Page 612 Table of Contents Main Menu Rear Wheel Bearing Replacement: Remove the flat head screws. Install two 8 x 12 mm bolts into the disc to push it away from the hub. Separate the wheel bearing from the hub using the special tools and a press.
Page 613 Table of Contents Main Menu Rear Suspension Hub Replacement NOTE: Replace the bearing with a new one after removal. Press a new wheel bearing onto the hub using the special tools and a press. Press HUB ASSEMBLY DRIVER ATTACHMENT 07GAF - SD40200 WHEEL BEARING SUPPORT BASE HUB DIS/ASSEMBLY PIN...
Page 614: Knuckle/Control Arms
Table of Contents Main Menu Knuckle/Control Arms Illustrated Index Overall Suspension NOTE: • Wipe off the grease before tightening the nut at the ball joint. • Torque specifications, see page 18-30. • Align the white line on the stabilizer bar with the bushing end, and install the stabilizer bar. Corrosion resistant bolt/nut REAR DAMPER STABILIZER BAR...
Page 615: Removal
Table of Contents Main Menu Knuckle/Control Arms Removal Remove the rear wheel and bearing unit assembly Hold the damper lower mount of stabilizer link with (see page 18-31). a wrench, then remove the damper mounting nut. DAMPER MOUNTING NUT Remove the splash guard from the knuckle. 12 x 1.25 mm Replace.
Page 616 Main Menu Table of Contents 9. Remove the cotter pin from the castle nut of the 15. Separate the knuckle from the upper control arm lower control arm ball joint, and remove the nut. and driveshaft outboard joint. BALL JOINT NOTE: Do not remove the driveshafts from the dif- REMOVER, 32 mm ferential case or intermediate shaft.
Page 617 Main Menu Table of Contents Knuckle/Control Arms Removal 19. Remove the toe control arm. 1 7. Remove the lower control arm by removing the ad- justing bolt and flange bolt. FLANGE BOLT SELF-LOCKING NUT 12 x 1.25 mm Corrosion resistant bolt/nut 14 x 15 mm 93 N-m Replace.
Page 618: Ball Joint Boot Replacement
Table of Contents Main Menu Ball Joint Boot Replacement NOTE: The upper control arm ball joint is attached with Wipe the grease off the sliding surface of the ball the boot retainer to improve the sealing efficiency of the pin, and pack with fresh grease (upper ball joint boot.
Page 619: Rear Damper Removal
Table of Contents Main Menu Rear Damper Removal Remove the three self-locking nuts. Remove the rear wheels. Remove the lower rear hatch glass trim. SELF-LOCKING NUT 10 x 1.25 mm STRUT BRACE Replace. REAR HATCH GLASS TRIM Corrosion resistant bolt/nut Remove the rear strut brace (NSX-T model only).
Page 620 Table of Contents Main Menu Remove the self-locking nut, then remove the stabilizer link from the stabilizer bar and knuckle. REAR DAMPER SELF-LOCKING NUT 12 x 1.25 mm Replace. STABILIZER STABILIZER LINK Corrosion resistant bolt/nut...
Page 621: Disassembly/Inspection
Main Menu Table of Contents Rear Damper Disassembly/Inspection Inspection: Disassembly: Reassemble all parts, except the spring. Compress the damper spring with the spring com- pressor according to the manufacturer's instruc- Push on the damper assembly and check for smooth tions, then remove the self-locking nut. operation through a full stroke, both compression and extension.
Page 622: Inspection
Main Menu Table of Contents Inspection SELF-LOCKING NUT 10 x 1.25 Replace. DAMPER DAMPER MOUNTING MOUNTING RUBBER WASHER SELF-LOCKING DAMPER 10 x 1.25 mm MOUNTING Replace. COLLAR 54 N-m (5.4 kgf-m, 39 Ibf-ft) BUMP STOP DAMPER PLATE MOUNTING BASE DUST COVER DAMPER SLEEVE MOUNTING...
Page 623: Reassembly
Table of Contents Main Menu Rear Damper Reassembly Install the damper unit on a spring compressor. Assemble the damper in reverse order of removal except the damper mounting washer and self-lock- ing nut. NOTE: Align the bottom of damper spring and spring lower seat.
Page 624: Installation
Table of Contents Main Menu Installation Reposition the damper assembly between the frame and knuckle. SELF-LOCKING NUT 12 x 1.25 mm Replace. STABILIZER BAR STABILIZER LINK Corrosion resistant bolt/nut Install the stabilizer link and connect the stabilizer bar. Loosely install a new self-locking nut. Hold the ball pin of the stabilizer link with a hex wrench, then tighten the self-locking nut.
Page 625 Table of Contents Main Menu 6. Install the new self-locking nuts on the top of the damper assembly. STRUT BRACE SELF-LOCKING NUT 10 x 1.25 mm Replace. 53 N-m (5.4 kgf-m, 39 Ibf-ft) Corrosion resistant bolt/nut 7. Tighten the damper mounting nut to the specified torque.
Page 626 Main Menu Brakes Conventional Brake Special Tools ....19-2 Front Brake Pads Master Cylinder and Brake Booster Rear Brake Disc Component Location Index ..19-3 Inspection/Replacement .
Page 627 Main Menu Table of Contents Special Tools 19-77, 19-79, 19-80, 19-84 19-22, 19-25 19-42, 19-44, 19-79, 19-84 19-16 19-80 19-48, 19-10c 19-22, 19-25...
Page 628 Main Menu Main Menu Table of Contents Table of Contents Illustrated Index The accumulator contains high-pressure nitrogen gas; do not puncture, expose to flame or attempt to dis- assemble the accumulator or it may explode; severe personal injury may result. HYDRAULIC SYSTEM Relieving Accumulator/line pressure, page 19-77...
Page 629: Inspection And Adjustment
Main Menu Table of Contents Inspection and Adjustment Brake System Rubber Parts and Brake Booster Brake Booster Brake Hoses Check brake operation by applying the brakes. Visually check for damage or signs of fluid leakage. If the brakes do not work properly, check the brake Replace the brake hose with a new one if it is dam- booster.
Page 630 Main Menu Table of Contents Parking Brake Pedal Height Adjustment Adjustment NOTE: After rear brake caliper servicing, loosen the 1. Loosen the brake switch locknut, and back off the brake switch until it is no longer touching the brake parking brake adjusting nut, start the engine, and pedal.
Page 631: Front Brakes
Main Menu Table of Contents Front Brakes Index/Inspection CAUTION: • Never use an air hose or dry brush to clean brake • Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash assemblies.
Page 632: Front Brake Pads
Main Menu Table of Contents Front Brake Pads Inspection/Replacement Remove the two brake hose mounting bolts. Remove • Never use an air hose or dry brush to clean brake the two caliper mounting bolts, and move the caliper assemblies. out of the way. Support the caliper with a piece of •...
Page 633 Main Menu Table of Contents Front Brake Pads Inspection/Replacement (cont'd) 6. Clean the caliper thoroughly; remove any rust, and 11. Push in the pistons so that the caliper will fit over check for grooves and cracks. the brake pads. 12. Set the caliper down into position, then install the 7.
Page 634: Front Caliper
Main Menu Table of Contents Front Caliper Disassembly If necessary, apply compressed air to the caliper • Never use an air hose or dry brush to clean brake fluid inlet to get the pistons out. Place a shop rag or assemblies.
Page 635 Main Menu Table of Contents Front Caliper Front Brake Disc Reassembly Run-Out Inspection CAUTION: Raise each side of the vehicle, and support it on • Before reassembling, check that all parts are free of safety stand (see page 1-10 through 1-12). Remove the dust and other foreign particles.
Page 636 Main Menu Table of Contents Thickness and Parallelism Inspection Raise each side of the vehicle, and support it on safety stands (see page 1-10 through 1-12). Remove the front wheels. Remove the brake disc pads (see page 19-7). Using a micrometer, measure disc thickness at eight points, approximately 45°...
Page 637 Main Menu Table of Contents Bleeding CAUTION: • Always use Genuine Honda DOT 3 Brake Fluid. Using 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 638 Main Menu Table of Contents Bleeding (cont'd) FRONT: REAR:...
Page 639 Main Menu Table of Contents Master Cylinder and Brake Booster Index/Torque BRAKE BOOSTER Do not disassemble. Tests, page 19-15 Pushrod Clearance Adjustment, page 19-16 MASTER CYLINDER Inspection, page 19-14...
Page 640: Master Cylinder
Main Menu Table of Contents Master Cylinder Inspection CAUTION: • Be careful not to bend or damage the brake lines when removing the master cylinder. • 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.
Page 641: Brake Booster
Main Menu Table of Contents Brake Booster Tests Functional Test Booster Check Valve Test With the engine stopped, depress the brake pedal Disconnect the brake booster vacuum hose at the several times to deplete the vacuum reservoir, then booster or at the booster side of the valve. depress the pedal hard and hold it for 15 seconds.
Page 642 Main Menu Table of Contents Brake Booster Pushrod Clearance Adjustment NOTE: Master cylinder pushrod-to-piston clearance NOTE: If the clearance between the gauge body and adjusting nut is 0.4 mm (0.02 in), the pushrod- must be checked and adjustments made, if necessary, to-piston clearance is 0 mm.
Page 643: Rear Brakes
Main Menu Table of Contents Rear Brakes Torque/Inspection CAUTION: • Never use an air hose or dry brush to clean brake • Do not spill brake fluid on the vehicle; it may damage assemblies. the paint; if brake fluid does contact the paint, wash •...
Page 644 Main Menu Table of Contents Rear Brake Pads Inspection/Replacement Remove the two brake hose mounting bolts. • Never use an air hose or dry brush to clean brake Remove the two caliper mounting bolts, and the assemblies. caliper from the bracket. •...
Page 645 Main Menu Table of Contents Remove the pad shims, pads and pad retainers. 9. Install the new brake pads and pad shims on caliper bracket. Using vernier calipers, measure the thickness of each brake pad lining. • When reusing the pads, always reinstall the Brake Pad Thickness: brake pads in their original positions to prevent Standard:...
Page 646 Main Menu Table of Contents Rear Brake Pads Inspection/Replacement (cont'd) 11. Install and tighten the two caliper mounting bolts. 12. Insert the cable through the arm, and connect the cable to the lever with the clevis pin and new lock pin.
Page 647 Main Menu Table of Contents Rear Brake Disc Run-Out Inspection Raise each side of the vehicle, and support it on safety stands (see page 1-10 through 1-12). Remove the rear wheels. Remove the brake pads (see page 19-18). Inspect the disc surface for grooves, cracks, and rust.
Page 648 Main Menu Table of Contents Thickness and Parallelism Inspection Raise both sides of the vehicle, and support it on safety stands (see page 1-10 through 1-12). Remove the rear wheels. Move the caliper and pads out of the way as described on the preceding page.
Page 649 Main Menu Table of Contents Rear Caliper Disassembly • Never use an air hose or dry brush to clean brake assemblies. • Use an OSHA-approved vacuum cleaner to avoid breathing brake dust. CAUTION: • Do not spill brake fluid on the vehicle; it may damage the paint;...
Page 650 Main Menu Table of Contents Rear Caliper Disassembly (cont'd) 9. Adjust the special tool as shown. Remove the circlip, washer, adjusting spring A, and the adjusting nut from the piston. BRAKE SPRING COMPRESSOR 07HAE - SG00100 Remove the piston seal. 10.
Page 651 Main Menu Table of Contents 12. Remove the adjusting bolt. 15. Remove the return spring. 13. Remove the spring cover, adjusting spring B, spacer, 16. Remove the parking lever and cam as an assembly bearing A and cup from the adjusting bolt. from the caliper body.
Page 652 Main Menu Table of Contents Rear Caliper Reassembly CAUTION: Install the pin in the cam. • Make sure all parts are clean before reassembly. Install a new O-ring on the sleeve piston. • Use only new replacement parts. • Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and Install the sleeve piston so the hole in the bottom of the piston is aligned with the pin in the cam, and...
Page 653 Main Menu Table of Contents 8. Install a new cup with its groove facing the bearing 11. Install the special tool as shown. A side on the adjusting bolt. 12. Compress the spring until it bottoms out. 9. Fit the bearing A, spacer, adjusting spring B and spring cover on the adjusting bolt, and install in the 13.
Page 654 Main Menu Table of Contents Rear Caliper Reassembly (cont'd) 16. Coat the new piston seal and piston boot with sili- 18. Install the brake pad retainers and brake pads. cons grease, and install them in the caliper. 19. Install the pad spring on the caliper. 20.
Page 655 Main Menu Table of Contents Brake Hoses/Lines Inspection 1. Inspect the brake hoses for damage, deterioration, leaks, interference or twisting. 2. Check the brake lines for damage, rusting and leakage. Also check for bent brake lines. 3. Check for leaks at hose and line joints or connections, and retighten if necessary. 4.
Page 656: Parking Brake
Main Menu Table of Contents Parking Brake Disassembly and Reassembly CAUTION: The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature cable failure.
Page 657 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation General In a conventional brake system, if the brake pedal is depressed excessively, the wheels can lock before the vehicle comes to a stop. In such a case, the stability of the vehicle is reduced if the rear wheels are locked, and maneuverability of the vehicle is reduced if the front wheels are locked, creating an extremely unstable condition.
Page 658 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation (cont'd) Master Cylinder 1. Construction A tandem master cylinder with center valves is used to improve braking system safety. The master cylinder has one reservoir tank which is connected to the cylinder sections by two small holes. It has two pistons - primary and secondary, which are crisscross connected with the calipers so that the fluid pressure works sep- arately on each system (front right wheel &...
Page 659 Main Menu Table of Contents 3. Responses when fluid is leaking (1) In case of leaking from the primary system Since the fluid pressure on the primary side does not rise, the primary piston is pushed by the fluid pressure of the secondary piston and the tension of the piston spring until the end hits on the cylinder;...
Page 660 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation (cont'd) Wheel Sensor The wheel sensor is a contactless type, and it detects the rotating speeds of a wheel. It is composed of a permanent magnet and coil. When the gear pulsers attached to the rotating parts of each wheel (rear wheel: outboard joint of the driveshaft, front: hub bearing unit) turn, the magnetic flux around the coil in the wheel sensor alternates, generating volt- ages with frequency in proportion to wheel rotating speed.
Page 661 Main Menu Table of Contents ABS Control Unit The ABS control unit consists of a main function section, which controls the operation of anti-lock brake system, and sub- function, which controls the pump motor and "self-diagnosis." 1. Main Function The main function section of the ABS control unit performs calculations on the basis of the signals from each wheel sensor and controls the operation of the anti-lock brake system by putting into action the solenoid valves in the modu- lator unit for each front and rear brake.
Page 662 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation (cont'd) Modulator Unit Modulators and solenoid valves for each wheel are integrated in the modulator unit. The modulators for front and rear brakes are of independent construction. The solenoid valve features quick response (5 ms or less). The inlet and outlet valves are integrated in the solenoid valve unit.
Page 663 Main Menu Table of Contents Pressure Switch The pressure switch monitors the pressure accumulation (pressure from the pump) in the accumulator and is turned off when the pressure becomes lower than a prescribed level. When the pressure switch is turned off, the switching signal is sent to the ABS control unit.
Page 664 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation (cont'd) Operation 1. Ordinary Braking Function In ordinary brake operations, the cut-off out valve in the modulator is open to transmit the hydraulic pressure from the master cylinder to the brake calipers via the chamber A and the chamber B. The chamber C is connected to the reservoir through the outlet valve which is normally open.
Page 665 Main Menu Table of Contents If brake inputs (force exerted on brake pedal) are excessively large and a possibility of wheel locking occurs, the control unit operates the solenoid valve, closing the outlet valve and opening the inlet valve. As a result, the high pressure is directed into chamber C, the piston is pushed upward, causing the slide piston to move upward and the cut-off valve to close.
Page 666 Main Menu Table of Contents Component Locations...
Page 667 Main Menu Table of Contents...
Page 668 Main Menu Table of Contents ABS Control Unit Terminal Arrangement...
Page 669 Main Menu Table of Contents...
Page 670 Main Menu Table of Contents ABS Control Unit Terminal Arrangement...
Page 671 Main Menu Table of Contents...
Page 672 Main Menu Table of Contents Troubleshooting Precautions ABS Indicator Light: The ABS indicator light comes on for three seconds and then goes off when the control unit detects no problem during the initial diagnosis right after the engine starts. The ABS indicator light comes on, and the ABS control unit memorizes the diagnostic trouble code (DTC) under certain conditions.
Page 673 Main Menu Table of Contents Troubleshooting: • When two or three DTCs are stored in the control unit, perform troubleshooting for the DTC that appears first. • When a customer's reported problem cannot be verified on the vehicle, ask the customer about the conditions when the ABS indicator light came ON, and test-drive the vehicle under those conditions, if possible.
Page 674 Main Menu Table of Contents Diagnostic Trouble Code (DTC) Diagnostic Trouble Code (DTC) Indication NOTE: This operation can also be done with the Honda PGM Tester. Connect the SCS service connector to the service check connector (2P) under the glove box. Turn the ignition switch ON (II), but do not start the engine.
Page 675 Main Menu Table of Contents Troubleshooting Index 19-50 19-52 19-54 19-58 19-59 19-61 19-62 19-63 19-64 19-65 19-67 19-69 19-71 19-73 19-73...
Page 676 Main Menu Table of Contents 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. Raise the vehicle off the ground, and support it with safety stands.
Page 677 Main Menu Table of Contents 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 of each wheel to the ABS control unit to check the system under the normal driving.
Page 678: Hydraulic System
Main Menu Table of Contents Hydraulic System Hydraulic Connections 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.
Page 679 Main Menu Table of Contents Relieving Accumulator/Line Pressure Use the Bleeder T-wrench before disassembling the parts shaded in the illustration. 1. Drain the brake fluid from the master cylinder and modulator reservoir thoroughly. 2. Remove the red cap from the bleeder on the top of the power unit. 3.
Page 680 Main Menu Table of Contents Modulator/Solenoid Unit Index/Torque CAUTION: • Do not damage the brake lines when removing the spare tire and modulator/solenoid unit. • 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.
Page 681 Main Menu Table of Contents Solenoid Leak Test Disconnect the 6P inspection connector (PNK) from Start the engine and release the parking brake. the connector cover located under the glove box, and connect the 6P inspection connector to the ALB Turn the Mode Selector to 1, and press the Start checker.
Page 682 Main Menu Table of Contents Modulator/Solenoid Unit Solenoid Flushing 5. Connect the RED terminal from one solenoid con- Remove the motor relay from the under-hood fuse/relay box. (Location: see page 19-38) nector to the battery positive (+) terminal with a remote starter switch.
Page 683 Main Menu Table of Contents Power Unit Torque/Inspection CAUTION: • Do not attempt to disassemble the power unit except • Before reassembling, check that all parts are free of for those components shown in this illustration. dust and other foreign particles. •...
Page 684 Main Menu Table of Contents Accumulator/Pressure Switch Index/Torque CAUTION: • Do not spill brake fluid on the vehicle; it may damage • Make sure no dirt or other foreign matter is allowed the paint; if brake fluid does contact the paint, wash to contaminate the brake fluid, it off immediately with water.
Page 685 Main Menu Table of Contents Accumulator/Pressure Accumulator Disposal Switch Removal Drain the high pressure brake fluid from the power The accumulator contains high-pressure unit (see page 19-77). nitrogen gas; do not puncture, expose to flame, or attempt to disassemble the accumulator or it may Remove three 6 mm flange bolts, then remove the explode;...
Page 686 Main Menu Table of Contents Bleeding Air Bleeding with ALB Checker CAUTION: 4. Start the engine and allow it to idle for a few min- • Do not spill brake fluid on the vehicle; it may damage utes, then stop it. Check the fluid level in the modu- the paint;...
Page 687 Main Menu Table of Contents Electronic Components ABS Control Unit Replacement SRS components are located in this area. Review the SRS Disconnect the connectors from the ABS control unit component locations, precautions, and procedures in the by removing the wire harness band. section 24 before performing repairs or service.
Page 688 Main Menu Table of Contents Electronic Components Pulsers/Sensors Relay Inspection Inspection Check the pulser for chipped or damaged teeth. Check for continuity between terminals There should be no continuity. Measure air gap between the sensor and pulser all Connect a 12 V battery across terminals the way around while rotating the driveshaft by There should be continuity between terminals hand.
Page 689 Main Menu Table of Contents Front Sensor Replacement NOTE: • Be careful when installing the sensors to avoid twist- ing the wires. • After sensor replacement confirm proper operation (see page 19-62). Rear Sensor Replacement NOTE: • Be careful when installing the sensors to avoid twisting the wires.
Page 690 Main Menu Table of Contents Special Tools 19-100...
Page 691 Main Menu Table of Contents Component Locations...
Page 692 Main Menu Table of Contents System Description Outline Role of System The NSX/NSX-T 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 693 Main Menu Table of Contents Construction and Function TCS Control unit Acceleration 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. Deceleration Control When the drive wheel speed drops below 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 control engine braking properly.
Page 694 Main Menu Table of Contents System Description Construction and Function (cont'd) 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 695 Main Menu Table of Contents Lateral Acceleration Detection Lateral acceleration is detected by the lateral accelera- tion (Lg) sensor located under the rear center trim panel. The Lg sensor varies the output voltage in accordance with the left or right side acceleration and sends it to the TCS control unit as a lateral acceleration signal.
Page 696 Main Menu Table of Contents TCS Control Unit Terminal Arrangement...
Page 697 Main Menu Table of Contents 20P CONNECTOR...
Page 698 Main Menu Table of Contents Troubleshooting TCS Indicator Light Temporary Driving Conditions: The TCS indicator light will come on and the control unit memorizes the Diagnostic Trouble Code (DTC) under certain temporary conditions: • The spare tire is installed, or a tire of the improper size is installed. •...
Page 699 Main Menu Table of Contents NOTE: • The TCS control unit has three memory registers. When a problem occurs, the control unit stores the Diagnostic Trouble Code (DTC) in the first memory register. If another problem occurs, or the same problem occurs again, the con- trol unit moves the first code to the next memory register and stores the second code in the first register.
Page 700 Main Menu Table of Contents Troubleshooting Troubleshooting Guide 19-103 19-105 19-106 19-107 19-110 19-113 19-116 19-118 19-119 19-121 19-122...
Page 701 Main Menu Table of Contents Electronic Components TCS Switch Inspection Lateral Acceleration (Lg) Sensor Inspection CAUTION: Be careful not to drop or bump the Lg sensor, Between terminal No. 4 and No. 5 (Illumination light circuit) and don't remove or install it with an impact wrench; the Lg sensor may be damaged.
Page 702 Main Menu Table of Contents Electronic Components Steering Angle Sensor Replacement Removal Installation Remove the steering column covers. Install the steering angle sensor by tightening two bolts, and make sure the adjusting shims are installed properly. CAUTION: Do not apply any grease or oil to the adjusting shim.
Page 703 Main Menu Table of Contents Steering angle sensor system check Selection of the adjusting shims for the steering angle sensor air gap adjustment Start the engine. NOTE: Push the TCS switch three times within three seconds. • The adjustment of the air gap between the steering shaft and the steering angle sensor should be carried NOTE: Always maintain the same number of rota- out in order to obtain adequate sensor output.
Page 704 Main Menu Table of Contents Electronic Components TCS Control Unit Replacement Remove the left rear trim panel and rear upper trim panel (see section 20). Remove the wire harness bracket. Disconnect the TCS control unit connectors. Remove the TCS control unit. Install the TCS control unit in the reverse order of removal.
Page 705 Main Menu Body *: Read SRS precautions before working in this area Coupe and Common Components Special Tools ....20–2 Windshield, Rear Window, Seat Cover Replacement .
Page 706: Special Tools
Main Menu Table of Contents Special Tools 20-55, 20-56...
Page 707: Features
Table of Contents Main Menu Construction Features • Mid-engine car with ground-hugging, full-forward canopy design. • The lower body is AH-PO for greater resistance to corrosion and collision damage. • Outer panels, (except the roof) are constructed of individual panels to allow more convenient and economical repairs. •...
Page 708: Composition
Table of Contents Main Menu Construction Composition REAR HATCH FRAME TRUNK LID (#6000) HOOD (#6000) ROOF PANEL (#6000) SIDE SILL (#6000) REAR FENDER (#6000) DOOR (#6000) Body Composites (#5000) FRONT FENDER (#6000) Types of aluminum alloys for pressings:...
Page 709: Replacement
Table of Contents Main Menu Types and Materials of Exterior Resin Parts NOTE: A standard symbol is stamped on the underside of each resin part to show the type of material used. Example: HONDA >PP< Replacement Part Name Material Headlight lid PA6/PPE-M Polyamide/Polyphenylene ether section 23 Front bumper...
Page 710 Table of Contents Main Menu Doors Index REAR SASH GLASS Adjustment, see page 20-17 Adjustment, see page 20-14 FRONT SASH Adjustment, see page 20-17 DOOR Disassembly, see page 20-7 Assembly, see page 20-13 Adjustment, see page 20-19. STRIKER Adjustment, see page 20-19...
Page 711: Disassembly
Table of Contents Main Menu Disassembly Disconnect the connector and handle cable, then NOTE: Lower the glass fully. remove the inner handle by pulling it forward. Carefully pry out the trim plate with a flat tip NOTE: Take care not to bend the handle cable. screwdriver as shown.
Page 712 Main Menu Table of Contents Doors Disassembly (cont'd) Remove the mounting screws and disconnect the Remove the mounting screws. Lift the door panel connectors, then remove the power window con- straight up off the sill. trol unit and speaker unit. Disconnect the connectors: •...
Page 713 Table of Contents Main Menu 9. Remove the mounting screws, then remove the 12. Remove the mounting bolt, locknut and adjusting front sash panel from the front sash. bolt. Remove the rear sash, then disconnect the handle rod. FRONT SASH PANEL FRONT SASH NOTE: •...
Page 714 Main Menu Table of Contents Doors Disassembly (cont'd) 1 7. Disconnect the lock rod and remove the lock crank. 14. Remove the locknuts, then remove the rear glass Remove the handle cable and clips. guide. Remove the mounting screws, then remove the latch assembly through the hole in the door.
Page 715 Table of Contents Main Menu 21. Remove the mounting bolts and loosen the motor 19. Carefully lower the glass until you can see its mounting bolts, then take out the regulator mounting bolts, then remove them. Pull the glass assembly through the window slot. out through the window slot.
Page 716: Molding Removal
Table of Contents Main Menu Doors Door Removal Moldings Removal Lower the glass fully. NOTE: Lower the glass fully. Remove: (see pages 20-7, 20-8) Remove the seat (see page 20-39). • Trim plate • Sash covers • Inside door handle •...
Page 717: Assembly
Main Menu Table of Contents Assembly Roll the glass up and down to see if it moves freely Assemble the door in the reverse order of disassembly, without binding. Also make sure that there is no and also: clearance between the glass and upper weather- Grease all the sliding surfaces of the regulator strip when the glass is closed.
Page 718: Glass Adjustment
Main Menu Table of Contents Doors Glass Adjustment * : Adjusting bolt locations. NOTE: Take care not to damage location on the front and rear sashes.
Page 719 Table of Contents Main Menu NOTE: • Place the vehicle on a firm, level surface when ad- justing the glass. • Make sure the door position is adjusted properly before adjusting the glass (see page 20-19). • Lower the glass fully. Remove: •...
Page 720 Main Menu Table of Contents Doors Glass Adjustment (cont'd) Adjust the Clearance "H" as follows: "H" (See page 20-15) c. Loosen the nuts securing the rear glass guide, and adjust the glass fore and aft by moving the rear glass guide. a.
Page 721 Table of Contents Main Menu Adjust the clearance "B" as follows: NOTE: Turn the front and rear adjusting bolts the same amount so as to keep the glass guide brack- et parallel with the seating surface of the door. After tightening the adjusting bolts, make sure that the ends of the adjusting bolts still project out of the locknuts.
Page 722 Main Menu Table of Contents Doors Glass Adjustment (cont'd) 13. Check for water leaks. 10. After the clearances have been adjusted properly, reinstall the retainers and upper weatherstrip. NOTE: Do not use high-pressure water. 11. Reinstall the door trim. 12. With the door and glass closed fully, check that the glass contacts with the upper weatherstrip evenly.
Page 723: Position Adjustment
Table of Contents Main Menu Position Adjustment Striker Adjustment Make sure the door latches securely without slamming. After installing the door, check for a flush fit with the If it needs adjustment: body, then check for equal gap between the front, rear, and bottom door edges and the body.
Page 724: Mirrors Removal
Table of Contents Main Menu Mirror Mirror Holder Replacement Removal NOTE: Raise the glass fully. Insert a Phillips screwdriver in the door mirror through the service hole, then loosen the actuator Remove the door panel, and carefully remove the retaining screw. plastic cover (see pages 20-7, 20-8).
Page 725: Replacement
Main Menu Table of Contents Front and Center Pillar Retainer/Upper Weatherstrip/ Center Pillar Panel Replacement Disassemble in numbered sequence. CAUTION: Wear gloves to remove and install the retainer. NOTE: • Check the upper weatherstrip for damage and deterioration, and replace it if necessary. •...
Page 726 Main Menu Table of Contents Windshield, Rear Window, Rear Hatch Glass Index Quantity of parts used. MOLDING Replacement, see page 20-36 REAR HATCH GLASS Removal, see page 20-33 Installation, see page 20-33 UPPER RUBBER INNER RUBBER OUTER RUBBER UPPER MOLDING LOWER MOLDING LOWER RUBBER REAR WINDOW...
Page 727 Table of Contents Main Menu Windshield Removal Using an awl, make a hole through the adhesive CAUTION: from inside the car. Push piano wire through the • Wear gloves to remove and install the windshield. hole, and wrap each end around a piece of wood. •...
Page 728 Table of Contents Main Menu Windshield Installation Scrape the old adhesive smooth with a knife to a Glue the lower spacers and defrost panel seals in thickness of about 2 mm (0.08 in) on the bonding place as shown. surface around the entire windshield flange. LOWER SPACER NOTE: •...
Page 729 Table of Contents Main Menu 8. Thoroughly mix all the adhesive and hardener Glue the rubber dam to the inside face of the wind- shield, as shown, to contain the adhesive during together on a glass or metal plate with a putty knife.
Page 730 Main Menu Table of Contents Windshield Installation (cont'd) 11. With a sponge, apply a light coat of body primer to 13. Use suction cups to hold the windshield over the the original adhesive remaining around the wind- opening, align it with the alignment marks made in shield flange.
Page 731 Table of Contents Main Menu 15. Let the adhesive dry for at least one hour, then spray water over the windshield and check for leaks. Mark leaking areas and let the windshield dry, then seal with urethane windshield adhesive. NOTE: •...
Page 732: Removal
Table of Contents Main Menu Rear Window Removal CAUTION: • Wear gloves to remove and install the rear window. • Since the rear window is double glazed glass with the inner glass (interior-side) larger than the outer glass, care should be taken not to damage the edge of the inner glass when removing the outer glass.
Page 733 Table of Contents Main Menu Rear Window Removal (cont'd) Apply protective tape along the edge of the body. Remove the rear defogger sub-harness and ground cable/antenna lead from the upper molding. Using an awl, make a hole through the adhesive UPPER MOLDING from inside the car.
Page 734: Installation
Main Menu Table of Contents Installation Scrape old adhesive smooth with a knife to a Clean the rear window surface with alcohol where thickness of about 2 mm (0.08 in) on the bonding the new moldings are to be installed. surface around the entire rear window flange.
Page 735: Installation
Table of Contents Main Menu Rear Window Installation (cont'd) 8. Press the upper and lower moldings into position 11. Set the rear window upright on the body, then around the entire edge of the rear window. center it in the opening. Make alignment marks by marking lines across the rear window and body with NOTE: Check that the upper and lower moldings a grease pencil at the four points shown.
Page 736 Main Menu Table of Contents 15. Thoroughly adhesive hardener 1 3. With a sponge, apply a light coat of glass primer together on a glass or metal plate with a putty around the edge of the rear window as shown, then knife.
Page 737 Main Menu Table of Contents Rear Window Installation (cont'd) 18. Use suction cups to hold the rear window over the opening, align it with the alignment marks made in step 11 and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around.
Page 738: Rear Hatch Glass Removal
Table of Contents Main Menu Rear Hatch Glass Removal CAUTION: • Use covers to avoid damaging the body. • Wear gloves to remove and install the glass. • Do not damage the defroster grid lines. • Take care not scratch or score the molding. Remove the rear hatch assembly from the body (see page 20-64).
Page 739: Installation
Main Menu Table of Contents Rear Hatch Glass Installation NOTE: • Do not scrape down to the painted surface of the hatch frame; damaged paint will interfere with pro- per bonding. • Mask off surrounding surfaces before painting. Use a putty knife to scrape off all traces of old adhesive and outer/inner rubber dams, then clean the rear hatch frame and glass (new) surface with alcohol where new adhesive is to be applied.
Page 740 Main Menu Table of Contents Rear Hatch Glass Installation (cont'd) Install the rear hatch frame, and adjust it fit to the Place the glass gently on the rear hatch frame, then weatherstrip and engine cover seal. center it in the opening. Make alignment marks by marking lines across the glass and body with a NOTE: Do not install the support struts.
Page 741 Main Menu Table of Contents 9. Pack adhesive into the cartridge without air With a brush, apply a light coat of body primer to pockets to ensure continuous delivery. Put the car- the original adhesive remaining around the rear tridge in a calking gun, and run a bead of adhesive hatch frame.
Page 742 Table of Contents Main Menu Rear Hatch Glass Installation (cont'd) 11. Scrape or wipe the excess adhesive off with a put- ty knife or towel. NOTE: Use a soft shop towel dampened with alcohol to remove adhesive from a painted surface or glass.
Page 743: Rear Hatch Glass Molding Replacement
Table of Contents Main Menu Rear Hatch Glass Molding Replacement CAUTION: • Wear gloves to replace the molding. • Do not damage the glass and defroster grid lines. Remove the rear hatch assembly (see page 20-64). Place the rear hatch assembly on its surface as shown.
Page 744 Table of Contents Main Menu Scrape all traces of the old molding from the cham- 10. Press the molding into position around the entire fered edges of the glass. edge of the glass. NOTE: Be sure to scrape all traces of the old mold- NOTE: Check that the molding is not wrinkled or ing throughly.
Page 745: Replacement
Main Menu Table of Contents Headliner/Interior Trim Replacement To remove the headliner, first remove the: • Sunvisors • Center pillar trim panels • Front pillar trim panels • Seats (see page 20-39) • Ceiling light (see section NOTE: • When installing the headliner, be careful not to fold or bend it.
Page 746 Main Menu Table of Contents Seats Replacement NOTE: SEAT MOUNT SEAT • Before removing the seat, move the seat until you COVER CAP can see its mounting bolts and seat mount cover caps. • Take care not to scratch the seat cover, interior trim, dashboard and center armrest.
Page 747 Table of Contents Main Menu Seats Seat Cover Replacement Detach the clips from under the seat, then remove CAUTION: Wear gloves to remove and install the seat the seat cushion. cover. Clip locations NOTE: • Take care not to tear the seams or damage the cover.
Page 748 Main Menu Table of Contents Detach the clips from the seat-back, then pull the Detach the clips, then pull the seat cover back. seat-back cushion up as shown. Remove the retain- Remove the fasteners by pulling the seat-back ers, then remove the headrest by pulling it up. Re- cushion.
Page 749 Table of Contents Main Menu Seats Seat Cover Replacement (cont'd) Installation is the reverse of the removal procedure. Detach the hooks, then remove the seat-back cushion. HOOKS NOTE: • To prevent wrinkles when installing the seat cover, make sure the material is stretched even- ly over the frame before securing all the hooks and clips.
Page 750 Main Menu Table of Contents Seat Belts Replacement SRS wire harnesses are routed near the retractor. RETRACTOR All SRS wire harnesses and connec- SEAT BELT tors are colored yellow. Do not use electrical test TENSIONER TENSIONER equipment on these circuits. CONNECTOR PROTECTIVE CAUTION:...
Page 751 Table of Contents Main Menu Seat Belts Replacement (cont'd) Anchor bolt construction: TOOTHED SPRING WASHER LOCK WASHER PLAIN WASHER * UPPER ANCHOR BOLT TOOTHED LOCK WASHER BEARING * LOWER ANCHOR BOLT RETRACTOR BOLT TOOTHED LOCK WASHER SPRING WASHER * CENTER ANCHOR BOLT SPRING WASHER Check that the retractor locking mechanism functions as described on page 20-45.
Page 752 Table of Contents Main Menu Inspection SRS wire harnesses are routed near the retractor. Replace the seat belt with a new one if there is any abnormality. All SRS wire harnesses and connec- tors are colored yellow. Do not use electrical test On-the-Car Seat Belt Inspection equipment on these circuits.
Page 753: Rearview Mirror
The tether bracket and bolt are available at your Acura dealer. The tether at- Loosen the lock bolt, then slide the mirror stay from tachment point is located on the panel behind the the lug.
Page 754: Carpet Replacement
Table of Contents Main Menu Carpet Replacement 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: • Seats (see page 20-39) • Side sill pad (see page 20-38) •...
Page 755 Main Menu Table of Contents Carpet Replacement (cont'd) Pull up the retainers, then remove the floor carpets. Remove the console carpets. RETAINERS FOOTREST SRS UNIT CONSOLE CARPETS FOOTREST MOUNTING BOLTS FLOOR CARPETS RETAINERS SEAT HARNESSES Installation is the reverse of the removal procedure. NOTE: •...
Page 756: Center Armrest Replacement
Main Menu Table of Contents Center Armrest Replacement CAUTION: When removing the center armrest inner panel, wrap the flat tip screwdriver with protective tape or a shop towel to prevent damage. NOTE: Take care not to scratch the center armrest, dashboard and rear center trim panel. Disassemble in numbered sequence.
Page 757: Component Removal/Installation
Table of Contents Main Menu Dashboard Component Removal/Installation Clock and center air vent removal: To make a gap between the center air vent and dashboard, pull the top of the center air vent while lowering it as shown. NOTE: Take care not to scratch the dashboard and related parts.
Page 758 Table of Contents Main Menu After inserting the screwdriver, turn it 90°. 8. Pull the center air vent backward while prying the hook. CAUTION: Use a shop towel on the dashboard to prevent damage. HOOK DASHBOARD CENTER AIR HOOK VENT CENTER AIR VENT 30 mm...
Page 759 Table of Contents Main Menu Dashboard Component Removal/Installation (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. Center console panel removal: NOTE: • Take care not to scratch the dashboard, center console panel and related parts. •...
Page 760 Main Menu Table of Contents Climate control unit, stereo cassette/radio and glove box removal: Disassemble in numbered sequence. NOTE: Remove the center console panel. CLIMATE CONTROL UNIT Disconnect the connectors. SRS UNIT STEREO CASSETTE RADIO Disconnect the connectors. GROUND CABLE Passenger's: Disconnect the connectors.
Page 761 Main Menu Table of Contents Dashboard Component Removal/Installation (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. NOTE: Take care not to scratch the dashboard, steering column and related parts.
Page 762 Table of Contents Main Menu Replacement SRS components are located in this area. Review the SRS NOTE: component locations, precautions, and procedures in the • Remove the access panel, then remove the short connector (RED). Disconnect the connec- (section 24) before performing repairs or service. tor between the airbag and cable reel, then con- nect the short connector (RED) to the airbag To remove the dashboard, first remove the:...
Page 763 Main Menu Table of Contents Dashboard Replacement (cont'd) NOTE: To prevent damage to the steering column, • Connect the special tool to the SRS main wire harness connector. wrap it with a shop towel. STEERING COLUMN PASSENGER'S AIRBAG CONNECTOR/ SHORT CONNECTOR (RED) 8 x 1.25 mm 16 N-m (1.6 kgf-m, SRS MAIN WIRE...
Page 764 Main Menu Table of Contents Remove the mounting screws, then remove the side air vents from each side of the dashboard. Remove the dashboard end plate, and fold the console carpet down (see page 20-47). 7. Remove the dashboard mounting bolts and screw, then lift and remove the dashboard. NOTE: •...
Page 765: Front Bumper
Main Menu Table of Contents Front Bumper Replacement Loosen the mounting screw, then pull the right and left front turn signal lights out and disconnect the connectors. Remove the skirt covers, then remove the bumper mounting bolts on each side, and lower skirt mounting bolt. Lower the inner fender, then remove the bumper mounting nuts and the skirt mounting bolts from inside the front fender on each side.
Page 766: Disassembly
Table of Contents Main Menu Disassembly...
Page 767 Main Menu Table of Contents Hood Replacement/Adjustment Disconnect the washer hose at the Y-joint, then pull it out of the hood. Remove the hood by removing the hood mounting bolts on each side. To remove the hood hinges, remove the front windshield lower molding. ALIGNMENT: •...
Page 768 Table of Contents Main Menu Opener/Latch/Opener Cable Replacement Remove the mounting bolts, then remove the hood release handle and disconnect the opener cable. Remove the mounting bolts and cover, then remove the hood latch and disconnect the opener cable and hood switch connector.
Page 769: Rear Hatch/Engine Cover Replacement/Adjustment
Table of Contents Main Menu Rear Hatch/Engine Cover Replacement/Adjustment CAUTION: Use fender covers to avoid damaging painted surfaces. Remove the engine cover. Remove the connector cover, and disconnect the rear defogger, antenna lead and ground cable connectors. Remove the rear hatch assembly by removing the support strut mounting bolts and rear hatch mounting bolts. NOTE: •...
Page 770: Trunk Lid
Main Menu Table of Contents Trunk Lid Replacement/Adjustment Remove the mounting screws, then remove the rear hatch air scoop. Disconnect the high-mount brake light harness connector, and remove the harness clamp from the support strut. Remove the trunk lid by removing the trunk lid mounting bolts. Installation is the reverse of the removal procedure.
Page 771: Replacement
Table of Contents Main Menu Trunk Lid Spoiler/Trunk Trim Panel Replacement NOTE: • Take care not to scratch the trunk lid. • Take care not to bend or scratch the trim panels. CAUTION: When prying with a flat tip screwdriver, wrap it with protective tape or a shop towel to prevent damage.
Page 772: Replacement
Main Menu Table of Contents Opener Cables Replacement Remove the openers and latches, then disconnect the opener cables. Remove the fuel lid latch. Remove the opener cables by removing the clips as shown. NOTE: • Before pulling out the opener cables, tie a string to the opener cable so you can pull it back in later. •...
Page 773: Opener/Latch Replacement
Main Menu Table of Contents Opener/Latch Replacement NOTE: Take care not to bend the cables. Rear Hatch Opener/Latch: REAR HATCH OPENER CABLE Disconnect the rear hatch opener cable. Replacement, see page 20-67 REAR SIDE TRIM PANEL Removal, see page 20-38 FUEL LID OPENER CABLE Replacement, see page...
Page 774 Table of Contents Main Menu Trunk Lid Opener/Latch: NOTE: Take care not to bend the cable and rod. TRUNK LID OPENER CABLE Replacement, see page 20-67 Installation is the reverse of the removal procedure. NOTE: Make sure the opener cable is routed and connected properly.
Page 775: Side Air Scoop/Side Sill Panel/Side Step Panel Replacement
Table of Contents Main Menu Side Air Scoop/Side Sill Panel/Side Step Panel Replacement CAUTION: When prying with a flat tip screwdriver, wrap it with protective tape or a shop towel to prevent damage. NOTE: • Take care not to scratch the body and related parts. •...
Page 776 Table of Contents Main Menu NOTE: • Take care not to twist the side sill panel. • Take care not to scratch the body and related parts. Disassemble in numbered sequence. SIDE SILL Clip locations Clip locations PANEL CLIP Forward SIDE CLIP NOTE: Loosen the screw, SIDE CLIP (9)
Page 777: Front Sub-Frame/Battery, Spare Tire Holder
Main Menu Table of Contents Front Sub-frame/Battery, Spare Tire Holder Sub-frame torque value specifications: 10 x 1.25 mm 59 N-m (6.0 kgf-m, 43 Ibf-ft) 10 x 1.25 mm 59 N-m (6.0 kgf-m, 43 Ibf-ft) CROSS BEAM RlGHT BEAM BRACKET 10 x 1.25 mm 38 N-m (3.9 kgf-m, LEFT BEAM 28 Ibf-ft)
Page 778: Rear Sub-Frame
Table of Contents Main Menu Rear Sub-frame Sub-frame torque value specifications: LEFT REAR BRACKET RIGHT REAR BRACKET REAR BEAM FRONT BEAM CENTER ROD CORROSION RESISTANT BOLT/NUT...
Page 779: Frame Repair Chart
Main Menu Table of Contents Frame Repair Chart Unit: mm (in) BASE LINE...
Page 780 Main Menu Table of Contents...
Page 781: Construction Features
Main Menu Table of Contents Construction Features The reinforced parts are located as shown. : Reinforced parts. ROOF PANEL TRUNK FRONT CROSS MEMBER DASHBOARD UPPER CROSS MEMBER FLOOR CROSS MEMBER BULKHEAD CENTER PILLAR UPPER REINFORCEMENT CENTER PILLAR UPPER LOWER REINFORCEMENT STIFFENER SIDE SILL STIFFENER...
Page 782 Table of Contents Main Menu Roof Rail Trim, Front and Rear Replacement CAUTION: Pull away the door trim, then lower the front pillar • Wear gloves to remove and install the trim. trim by detaching the clips from each side. Then •...
Page 783 Table of Contents Main Menu Roof Rail Trim, Front and Rear Replacement (cont'd) Rear roof rail trim: Remove the rear roof rail trim by sliding it forward. Remove the ceiling light (see section 23). Hook locations, 4 Pull away the door trim, then lower the rear pillar trim by detaching the clips from each side.
Page 784 Main Menu Table of Contents Roof Index ROOF REAR RECEIVER REAR RECEIVER SWITCH DAMPER SHIM HOOK STOP (see page 20-94) ROOF SIDE HOOK ROOF SIDE LOCK SIDE LOCK Replacement, REAR LOCK RECEIVER Replacement, page 20-92 RELEASE KNOB page 20-83 Adjustment, page 20-92 ROOF LOCK GUIDE Replacement, page...
Page 785 Table of Contents Main Menu Roof Roof Trim/Panel Replacement Remove the roof side trim from each side. CAUTION: • To prevent damage, place the roof on an appropriate Clip, hook locations pad. Clip, 6 Hook, 6 • When prying with a flat tip screwdriver, wrap it with protective tape to prevent damage.
Page 786 Table of Contents Main Menu Move the rear roof stop guide on each side as shown. NOTE: Do not disturb the bonded portion of the roof side seal. SCREWS 4 x 0.7 mm 1.47 N-m (0.15 kgf-m, 1.08 Ibf-ft) Loosen. ROOF SIDE SEAL BONDED...
Page 787: Roof Side Lock Replacement
Main Menu Table of Contents Roof Side Lock Replacement CAUTION: To prevent damage, place the roof on an appropriate pad. Remove the roof. Remove the roof front trim and roof side trim (see page 20-82). Install the roof side lock handle. Turn the roof side lock handle, then remove the screws.
Page 788 Table of Contents Main Menu Roof Roof Side Lock Replacement (cont'd) Move the roof side lock, then pull the lock pins out and remove the lock. NOTE: Take care not to bend the rods and lock pins. LOCK ROOF SIDE LOCK LOCK Installation is the reverse of the removal procedure.
Page 789: Roof Side Seal/Retainer Replacement
Table of Contents Main Menu Roof Side Seal/Retainer Replacement CAUTION: To prevent damage, place the roof on an appropriate pad. Remove the roof. Remove the roof front trim and roof side trim (see page 20-82). Remove the screws from each end of the roof side seal.
Page 790 Main Menu Table of Contents Remove the bonded portion of the roof side seal Remove the screws, then remove the roof side from one end, then pull the seal away from the roof retainer. side retainer, and remove the bonded portion from the other end.
Page 791 Main Menu Table of Contents Roof Roof Side Seal/Retainer Replacement (cont'd) 9. If the old roof side retainer is to be reinstalled, glue 11. Install the roof side retainer. the new EPT sealer to it as shown. NOTE: NOTE: Be careful not to touch the roof side retainer •...
Page 792 Table of Contents Main Menu 13. Apply new sealant to the roof and roof side retainer 14. Engage the lip of the roof side seal with the groove as shown. of the roof side retainer as shown, then gently set each end of the roof side seal down on the sealant.
Page 793 Main Menu Table of Contents Roof Roof Side Seal/Retainer Replacement (cont'd) 15. Install the screws on each end of the roof side seal. 16. Install the side portion of the roof side seal into the roof side retainer as shown. NOTE: Do not press on the seal yet to make the adhesive stick.
Page 794 Main Menu Table of Contents 17. Scrape or wipe the excess sealant off with a putty knife or towel. NOTE: To remove sealant from a painted surface or the roof side seal, wipe with a soft shop towel dampened with alcohol. 18.
Page 795: Roof Side Lock Unit Replacement
Main Menu Table of Contents Roof Side Lock Unit Replacement CAUTION: To prevent damage, place the roof on an appropriate pad. Remove the roof. Remove: • Roof front trim (see page 20-82) • Roof side trim (see page 20-82) • Roof side seal (see page 20-84) •...
Page 796 Table of Contents Main Menu Roof Roof Side Lock Unit Replacement (cont'd) If necessary, remove the roof side hook. ROOF SIDE LOCK UNIT ROOF SIDE HOOK Installation is the reverse of the removal procedure. NOTE: • Grease the location indicated by the arrow and the lock pins.
Page 797: Roof Lock Guides Replacement
Main Menu Table of Contents Roof Roof Lock Guides Replacement CAUTION: To prevent damage, place the roof on an appropriate pad. Remove the roof. Remove: • Roof front trim (see page 20-82) • Roof side trim (see page 20-82) • Roof side lock (see page 20-83) Remove the roof lock guides.
Page 798 Table of Contents Main Menu 4. Clean the roof lock guide installing portion of the roof side lock unit and rear roof stop guide with a sponge dampened in alcohol. NOTE: After cleaning, keep oil, grease and water from getting on the surface. 5.
Page 799 Main Menu Table of Contents Rear Roof Stop Guide Replacement CAUTION: To prevent damage, place the roof on an appropriate pad. Remove the roof. Remove: • Roof front trim (see page 20-82) • Roof side trim (see page 20-82) • Roof side lock (see page 20-83) •...
Page 800 Main Menu Table of Contents Roof Lock Receivers Replacement Remove the roof. Remove the front and rear roof rail trim (see page 20-79). Disconnect the connector, and detach the harness clip (rear lock receiver). Remove the bolts, then remove the front and rear lock receivers. Installation is the reverse of the removal procedure.
Page 801 Table of Contents Main Menu Roof - Lock Receivers Adjustment NOTE: This adjustment should be done in the following order after removing or replacing the lock receiver. Loosen the lock receiver mounting bolts at each of the four corners, then tighten them lightly. Front: FRONT LOCK RECEIVER...
Page 802 Main Menu Table of Contents Secure the roof by turning both roof side lock han- ROOF dles. Make sure they are locked securely. NOTE: Turn each roof side lock handle until a faint click is heard. ROOF SIDE LOCK HANDLE FRONT LOCK REAR LOCK RECEIVER...
Page 803 Main Menu Table of Contents Roof Lock Receivers Adjustment (cont'd) Rear: REAR LOCK RECEIVER 7. Tighten the lock receiver mounting bolts. 8. Check that each roof side lock handle works smoothly. 9. Remove the roof. 10. Reinstall all remaining removed parts.
Page 804 Main Menu Table of Contents Front Pillar Seal/Retainer Replacement NOTE: • When the front pillar seal has been removed, and or it is damaged, replace it with new one. • Have an assistant help replace the front pillar seal. Remove the roof. Remove the front roof rail trim (see page 20-79).
Page 805 Table of Contents Main Menu Remove the front pillar seal. 7. Scrape the old sealant from the body bonding sur- face with a putty knife. NOTE: Do not scrape down to the painted surfaces of the body. 8. Clean the body bonding surface with a sponge dampened in alcohol.
Page 806 Table of Contents Main Menu Front Pillar Seal/Retainer Replacement (cont'd) 11. Install the front pillar retainer. 13. Peel the separator off from the butyl tapes on the new front pillar seal. NOTE: • Be careful not to touch the front pillar retainer NOTE: Fold the separator of the butyl tape at the roof portion of the front pillar seal.
Page 807 Table of Contents Main Menu 14. Align the holes on the front pillar seal with the NOTE: Install the pillar and roof portions of the front holes on the body, and engage the lips of the front pillar seal into the retainers about 50 mm (2 in). pillar seal with the groove of the retainers, then gently set each corner of the front pillar seal down FRONT PILLAR...
Page 808 Main Menu Table of Contents Front Pillar Seal/Retainer Replacement (cont'd) 15. Install the hook stop on each side. Clip locations, 6 NOTE: Do not press on the seal yet to make the adhe- sive stick. Nut locations, 4 FRONT PILLAR HOOK STOP SEAL 16.
Page 809 Main Menu Table of Contents 19. Press on the roof portion of the butyl tape to make BUTYL TAPE the adhesive stick. SEPARATOR FRONT PILLAR SEAL NOTE: Do not press on the front pillar seal portion BUTYL TAPE of the seal yet. SEPARATOR BUTYL TAPE PLASTIC...
Page 810 Main Menu Table of Contents Front Pillar Seal/Retainer Replacement (cont'd) 22. Let the sealant dry for at least three hours after installing the front pillar seal. 23. Install the roof on the body, then check that the seals fit flush (see page 20-107). NOTE: If necessary, align the roof side seal by adjusting the roof side lock unit (see page 20-106).
Page 811 Main Menu Table of Contents Rear Pillar Seal/Retainer Replacement NOTE: • When the rear pillar seal has been removed, and/or it is damaged, replace it with new one. • Have an assistant help replace the rear pillar seal. Remove the roof. Remove the rear roof rail trim (see page 20-80).
Page 812 Table of Contents Main Menu 9. Install the rear pillar retainer. Remove the screws, then remove the rear pillar retainer. NOTE: Screw locations, 2 • Be careful not to touch the rear pillar retainer where sealant will be applied. • First tighten the screw at top of the rear pillar retainer.
Page 813 Main Menu Table of Contents Rear Pillar Seal/Retainer Replacement (cont'd) 11. Peel the separator off from the butyl tape on the new 12. Align the hole and clip on the rear pillar seal with the rear pillar seal. grommet and hole on the body, and engage the lips of the rear pillar seal with the groove of the retainers, NOTE: Fold the separator of butyl tape at the roof then gently set each corner of the rear pillar seal...
Page 814 Table of Contents Main Menu NOTE: Install the screw, attach the clip on each side, 13. Install each pillar portion of the rear pillar seal into and install the pillar and roof portions of the rear pillar the rear pillar retainer as shown, then attach the clips. seal into the retainers about 50 mm (2 in).
Page 815 Table of Contents Main Menu Rear Pillar Seal/Retainer Replacement (cont'd) 15. Carefully pull the separator away from the butyl tape 14. Install the roof portion of the rear pillar seal to the at the roof portion of the rear pillar seal. retainer on the roof rail.
Page 816 Table of Contents Main Menu 17. Scrap or wipe the excess sealant off with a putty knife or towel. NOTE: To remove sealant from a painted surface or the rear pillar seal, wipe with a soft shop towel damp- ened with alcohol. 18.
Page 817: Seals/Retainers Alignment Adjustment
Table of Contents Main Menu Seals/Retainers Alignment Adjustment Remove the front and rear roof rail trim (see page NOTE: When the following parts have been replaced or removed, this adjustment should be done. 20-79). • Roof side seals Loosen the lock receiver mounting bolts at each of the four corners, then tighten them lightly.
Page 818 Table of Contents Main Menu 11. Adjust the seal and retainer alignment by moving both roof side lock units in or out. ROOF NOTE: Align the roof side retainer with the front pillar retainer and rear pillar panel evenly on each side, and make the seals fit flush.
Page 819 Table of Contents Main Menu Seals/Retainers Alignment Adjustment (cont'd) Rear: 14. Check the height of the roof with the body. If necessary, loosen the lock receiver mounting bolts, ROOF REAR PILLAR then adjust the height of the roof to make the roof fit PANEL ROOF SIDE flush with the body by using shims.
Page 820 Table of Contents Main Menu 16. Check that each roof side lock handle works b. Mark a line on the door glass using a thin plastic smoothly. plate as shown, c. Open the door, then check that there is 1 - 3 mm 17.
Page 821: Water Leak Test
Main Menu Table of Contents Water Leak Test NOTE: When the following parts have been replaced or Check for water leaks. removed, and or the roof side lock unit, door glass and door have been adjusted, this water leak test should be If there are leaks, recheck the work performed, and done.
Page 822: Engine Cover/Roof Cover Removal
Main Menu Table of Contents Engine Cover/Roof Cover Removal NOTE: Remove the support rod from the engine cover. • Take care not to scratch the body. Remove the bolts, than remove the engine cover. • Open the rear hatch. Open the engine cover, and support it with the sup- port rod.
Page 823: Replacement
Main Menu Main Menu Table of Contents Table of Contents Engine Cover/Roof Cover Replacement NOTE: • : Nut locations, 4 • Take care not to scratch the body. • Open the rear hatch. ENGINE COVER Roof cover (Engine cover) removal: Open the roof cover, remove the nuts, then remove the roof cover.
Page 824 Main Menu Main Menu Table of Contents Table of Contents Opener/Latch/Opener cable/Hook stop/Roof stop Remove the roof cover latch, roof cover opener and bracket removal: roof cover opener cable from the engine cover. Open the engine cover. Remove the screws, then NOTE: Take care not to bend the roof cover opener remove the support rod bracket.
Page 825 Table of Contents Table of Contents Main Menu Main Menu Engine Cover/Roof Cover Replacement (cont'd) Nut locations, 4 Remove the roof stop brackets and hook stops from the engine cover. RIGHT HOOK STOP LEFT ROOF STOP BRACKET/ ROOF STOP ROOF HOLDER SWITCH BRACKET Installation is the reverse of the removal procedure.
Page 826 Main Menu HVAC (Heating, Ventilation and Air Conditioning) *: Read SRS precautions before working in this area Special Tools ....22–2 Climate Control Unit Sunlight Sensor Leak Test .
Page 827: Special Tools
Table of Contents Main Menu Special Tools 22-88 22-49...
Page 828 Main Menu Table of Contents EVAPORATOR SUNLIGHT SENSOR TEMPERATURE Removal, page 22-63 SENSOR Test, page 22-63 MODE CONTROL MOTOR Removal, page 22-65 Replacement, page 22-57 CLIMATE CONTROL UNIT Test, page 22-65 Test, page 22-58 Replacement, page 22-54 HEATER VALVE CABLE Adjustment, page 22-55 COMPRESSOR (NIPPONDENSO)
Page 829 Table of Contents Main Menu Heater-Evaporator Door Position (MAX COOL) U.S.A model VENT DOOR DEFROSTER DOOR HEAT DOOR AIR MIX DOOR A/C EVAPORATOR HEATER CORE CORE...
Page 830 Main Menu Table of Contents...
Page 831: Description Outline
Table of Contents Main Menu Description Outline The air conditioning removes the heat from the passenger compartment via the route shown below. Using the refrigerant (R-134a) High temperature/ High temperature/ High temperature/ high pressure gas high pressure liquid Traps debris and acts high pressure liquid as an accumulator.
Page 832: A/C Triple Pressure Switch
Table of Contents Main Menu A/C Triple Pressure Switch Construction The A/C triple pressure switch consists of a High-Low pressure switch (A/C pressure switch A) and a Middle pressure switch (A/C pressure switch B). High-Low pressure switch If the refrigerant pressure becomes too high (due to blockage), or too low (due to leakage), the A/C triple pressure switch sends a signal to the fan control unit to prevent the compressor from operating.
Page 833: Fan Control Unit
Main Menu Table of Contents Description Fan Control Unit The fan control unit performs calculations based on signals from the radiator fan control sensor. It them controls the operation of radiator fan speed (High-Low), engine compartment fan, condenser fan and A/C compressor. When engine coolant temperature is above 183°F (84°C), the fan control unit turns Tr1 ON and radiator fan runs at low speed.
Page 834 Main Menu Table of Contents 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. UNDER-HOOD RELAY BOX B BLOWER MOTOR RELAY BLOWER MOTOR HIGH RELAY UNDER-HOOD RELAY BOX A COMPRESSOR CLUTCH RELAY (CONDENSER FAN RELAY)
Page 835: Troubleshooting Self-Diagnosis Circuit Check
Table of Contents Main Menu Troubleshooting Self-diagnosis Circuit Check The Automatic Climate Control System has a built-in self diagnosis feature. To run it, turn the ignition switch ON (II), then turn the fan speed dial to the AUTO position. Set the temperature control dial to 60°F (18°C), then gradually move the dial up the temperature range to 90°F (32°C).
Page 836: Function Selection And Operation Check
Table of Contents Main Menu Function Selection and Operation Check This check will quickly and automatically select and operate all functions of the climate control system, in the combina- tions and sequence shown below. It may help clarify a problem, or identify one that didn't show up when you perform the self-diagnosis circuit check.
Page 837 Table of Contents Main Menu Troubleshooting Symptom-to-Components Chart Use this chart if the self-diagnosis checks don't identify any cause for the symptom. Across each row in the chart, the potential sources of a symptom are ranked in the order they should be inspected, start- ing with Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column.
Page 838: Climate Control Unit Input/Output Signals
Table of Contents Main Menu Climate Control Unit Input/Output Signals CLIMATE CONTROL UNIT View from wire side...
Page 839: Climate Control Unit Replacement
Main Menu Table of Contents Climate Control Unit Replacement SRS components are located in this area. Review the SRS Take out the ashtray and remove the two screws component locations, precautions, and procedures in the from under the ashtray. section 24 before performing repairs or service.
Page 840 Table of Contents Main Menu Remove the three screws and center console panel, then disconnect the 3P connector and 4P connector from the floor wire harness. CENTER CONSOLE PANEL Remove the four screws, then disconnect the 14P and 30P connectors from the automatic climate control unit and remove it.
Page 841: Adjustment
Table of Contents Main Menu Adjustment The calibration switch can raise or lower the set temper- ature by ± 3°F (1.5°C) in relation to the digitally- displayed temperature.
Page 842: Air Mix Control Motor Replacement
Table of Contents Main Menu Air Mix Control Motor Replacement If necessary, to adjust the heater valve cable: Disconnect the heater valve cable from the air mix control motor. • Set the air mix control motor at COOL position (see page 22-57) with the cable disconnected at HEATER VALVE the valve.
Page 843: Test
Table of Contents Main Menu Mode Control Motor Air Mix Control Motor Test Replacement Connect battery power to the No. 1 terminal of the Remove the three screws and mode control motor. air mix control motor, then connect ground to the No.
Page 844: Test
Main Menu Table of Contents Mode Control Motor Test Plug the connector back into the motor. Operate Disconnect the mode control motor connector, turn the mode switch on the climate control unit to each the ignition switch ON (II), and move the blower mode.
Page 845: Recirculation Control Motor
Table of Contents Main Menu Recirculation Control Motor Replacement Test Remove the blower unit (see page 22-67) Connect battery power to the No. 1 terminal of the recirculation control motor, then connect ground to Remove the three screws and the recirculation con- the No.
Page 846: Vent Door Control Motor
Table of Contents Main Menu Vent Door Control Motor Replacement ————————— Test 1. Connect battery power to the No. 1 terminal of the 1. Remove the three screws and vent door control vent door control motor, then connect ground to the motor.
Page 847: In-Car Temperature Sensor
Table of Contents Main Menu In-car Temperature Sensor Removal Test The in-car temperature sensor assembly includes a Compare the resistance reading between the No. 1 and small fan (aspirator fan) to draw air past the sensor (see No. 2 terminals of the in-car temperature sensor with page 22-66).
Page 848: Outside Air Temperature Sensor
Table of Contents Main Menu Outside Air Temperature Sensor Test Removal Compare the resistance reading between the terminals Remove the screw, disconnect the connector, and of the outside air temperature sensor with specifica- remove the outside air temperature sensor. Be careful tions shown in the following graph: It should be within not to damage the front grille and front bumper.
Page 849: Sunlight Sensor Removal
Table of Contents Main Menu Sunlight Sensor Removal Test Protect the dashboard with a shop towel, then with a Measure the voltage between the terminals with the sen- small screwdriver, carefully pry the sunlight sensor out sor out of direct sunlight. of the dashboard and disconnect its connector.
Page 850: Heater Core Temperature Sensor Removal
Main Menu Table of Contents Heater Core Temperature Sensor Removal Test Disconnect the connector, remove the clamp and the Compare the resistance reading between the terminals heater core temperature sensor. of the heater core temperature sensor with specifica- tions shown in the following graph: It should be within specification.
Page 851: Evaporator Temperature Sensor Removal
Table of Contents Main Menu Evaporator Temperature Sensor Test Removal Give the evaporator temperature sensor a quarter turn, Compare the resistance reading between the terminals then pull out to remove it. of the evaporator temperature sensor with specification shown in the following graph: It should be within specification.
Page 852: Aspirator Fan Test
Table of Contents Main Menu Aspirator Fan Relay Test Test Connect battery power to the No. 3 terminal of the There should be continuity between the C and D aspirator fan, and connect ground to the No. 4 terminal. terminals. The aspirator fan should run.
Page 853: Blower Unit Replacement
Main Menu Table of Contents Blower Unit Replacement Remove the spare tire (refer to Owner's manual). Remove the under-hood relay box A and the water drain duct. Disconnect the connectors from the blower motor, power transistor and recirculation Remove the spare tire holder. control motor.
Page 854: Overhaul
Table of Contents Main Menu Blower Unit Overhaul BLOWER MOTOR RECIRCULATION CONTROL MOTOR POWER TRANSISTOR...
Page 855: A/C Service Tips And Precautions
Main Menu Table of Contents A/C Service Tips and Precautions The air conditioning system uses HFC-134a (R-134a) refrigerant and polyalkyleneglycol (PAG) refrigerant oil*, which are not compatible with CFC-12 (R-12) refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system, and do not attempt to use R-12 servicing equipment;...
Page 856: A/C System Service Performance Test
Main Menu Table of Contents A/C System Service Performance Test The performance test will help determine if the air con- Recovery/Recycling/Charging System ditioning system is operating within specifications. Only use service equipment that is U.L.-listed and is cer- tified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system.
Page 857 Table of Contents Main Menu To complete the charts: • Mark the delivery temperature along the vertical line. • Mark the intake temperature (air temperature) along the bottom line. • Draw a line straight up from the air temperature to the humidity. •...
Page 858: Pressure Test Chart
Table of Contents Main Menu A/C System Service Pressure Test Chart NOTE: Performance Test on page 22-70. see page 22-89 see page 22-91...
Page 859: Charging
Table of Contents Main Menu Recovery Only use service equipment that is U.L.-listed and is cer- tified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. CAUTION: Exposure to air conditioner refrigerant Recovery/Recycling/Charging System. and lubricant vapor or mist can irritate eyes, nose and throat.
Page 860: Heater-Evaporator Unit
Table of Contents Main Menu Heater-Evaporator Unit Replacement 5. Recover the refrigerant from the A/C system with a SRS components are located in this area. Review the SRS R-134a refrigerant Recovery/Recycling/Charging component locations, precautions, and procedures in the section 24 before performing repairs or service.
Page 861 Table of Contents Main Menu 15. If necessary, adjust the heater valve cable: 11. Disconnect the connectors from all the control • Set the air mix control motor at COOL position motors sensors attached to the heater- (see page 22-57). evaporator unit.
Page 862: Overhaul
Table of Contents Main Menu Heater-Evaporator Unit Overhaul Remove the heater core cover, remove the pipe clamp, then pull out the heater core. Remove the lower half of the housing, then remove the evaporator. Remove the expansion valve if necessary. HEATER CORE PIPE CLAMP HEATER CORE...
Page 863: Def" Door Adjustment
Table of Contents Main Menu "HEAT" Door Adjustment "DEF" Door Adjustment Turn this lever all the way Connect the control rod to clockwise and hold it there. the clip. Reposition gear 2 so this mark lines up with the mark Loosen this screw in gear 2.
Page 864: Condenser Description
Table of Contents Main Menu Condenser Description Dual condensers are mounted behind the right and left side of the front bumper as shown. The cooling efficiency of parallel- dual condensers is as good as or better than a single condenser mounted in front of radiator. LEFT CONDENSER RECEIVER/DRYER RIGHT CONDENSOR...
Page 865: Replacement
Table of Contents Main Menu Replacement Disconnect the negative cable from the battery. Disconnect the connector from the condenser fan, remove the two mounting bolts and nut, then Remove the front bumper (see section 20). remove the condenser. Recover the refrigerant using a R-134a refrigerant CORROSION RESISTANT BOLT Recover/Recycling/Charging System (see page (Right Condenser)
Page 866: Overhaul
Table of Contents Main Menu Condenser Overhaul Remove the four bolts and nuts. Then separate the condenser duct from the condenser shroud, and remove the condenser. Remove the three mounting screws, then remove the condenser fan from the condenser shroud. CONDENSER CONDENSER DUCT...
Page 867: Compressor Description
Main Menu Table of Contents Compressor Description This compressor is a DENSO piston type for R-134a. A revolving inclined disc drives the surrounding 10 reciprocating pis- tons. As the inclined disc revolved, it pushes the pistons, protected by a ceramic shoe, thus compressing the refrigerant. RELIEF VALVE PISTONS FIELD COIL...
Page 868 Table of Contents Main Menu Compressor Illustrated Index CENTER BOLT PRESSURE PLATE Inspection, page 22-85 SHIM(S) SNAP RING B Replace. PULLEY Inspection, page 22-85 SNAP RING A Replace. FIELD COIL Inspection, page 22-85 COMPRESSOR (Do not disassembly) RELIEF VALVE Replacement, page 22-87 O-RING Replace.
Page 869: Replacement
Main Menu Table of Contents Replacement Loosen the idler pulley center nut and adjusting bolt, If the compressor still works, run the engine at idle then remove the belt from compressor. for a few minutes with the A/C on, then shut the engine off and disconnect the negative cable from the battery.
Page 870 Table of Contents Main Menu Compressor Replacement 9. If necessary, remove the one bolt from the idler 11. Check the idler pulley bearing for play and drag. pulley bracket, then remove the four mounting Replace it with a new one if it's noisy or has exces- bolts and the compressor bracket.
Page 871: Clutch Inspection
Table of Contents Main Menu Clutch Inspection Check the plated parts of the pressure plate for color Check resistance of the field coil. changes, peeling or other damage. If there is dam- age, replace the clutch set. Field Coil Resistance: 3.6 ± 0.2 ohms at 68°F (20°C) Check the pulley bearing play and drag by rotating If resistance is not within specifications, replace the the pulley by hand.
Page 872: Clutch Overhaul
Table of Contents Main Menu Compressor Clutch Overhaul Remove the center bolt while holding the pressure Use snap ring pliers to remove snap ring B, then remove the pulley. plate. NOTE: CENTER BOLT • Be careful not to damage the pulley and com- 14 N-m (1.4 kgf-m, 10 Ibf-ft) pressor during removal/installation.
Page 873 Main Menu Table of Contents Remove the snap ring A and the field coil. NOTE: • Be careful not to damage the field coil and com- pressor during removal/installation. • Once the snap ring A was removed, replace it with a new one. SNAP RING A Replace.
Page 874: Relief Valve Replacement
Table of Contents Main Menu Relief Valve Replacement Remove the relief valve and O-ring. Don't let any refrigerant oil run out. NOTE: Be sure to use the right O-rings for R-134a. O-RING Replace. RELIEF VALVE 13.2 N-m (1.35 kgf-m, 9.76 Ibf-ft) Clean off the mating surface.
Page 875: Belt Adjustment
Main Menu Table of Contents Belt Adjustment Deflection Method Tension Gauge Method Apply a force of 98 N (10 kgf, 22 Ibf) and measure Attach the belt tension gauge to the A/C compres- the deflection between the A/C compressor and the sor belt as shown below, and measure the tension crankshaft pulley.
Page 876 Table of Contents Main Menu A/C System Service Evacuation Only use service equipment that is U.L.-listed and is cer- Recovery/Recycling/Charging System tified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irritate eyes, nose and throat.
Page 877 Table of Contents Main Menu A/C System Service Leak Test Only use service equipment that is U.L.-listed and is cer- Recovery/Recycling/Charging System tified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system. CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irritate eyes, nose and throat.
Page 878 Table of Contents Table of Contents Main Menu Main Menu Charging Only use service equipment that is U.L.-listed and is Recovery/Recycling/Charging System certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioner system. CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irritate eyes, nose and throat.
Page 879 Main Menu Body Electrical *: Read SRS precautions before working in this area Special Tools ....23-2 Coolant Temperature Gauge Key-in Reminder System HID Inverter Unit Replacement Troubleshooting Gauge Test (’02-05 Models)
Page 880 Main Menu Body Electrical (Cont’d) Side Marker/Turn Signal/Hazard Antenna Tube Keyless Buzzer Wiper/Washers Replacement ... . . 23-246 Test/Replacement Flasher System Component Location Front/Rear Speaker (’04-05 Models) ..23-20g Index .
Page 881 Main Menu Engine Electrical Starting System Ignition System Alternator Engine Compartment Fan Motor (A/T) Component Location Index ..23–75 Component Location Index ..23–88 Replacement ....23–105 Test .
Page 882: Special Tools
Main Menu Table of Contents Special Tools 23-244, 23-246 23-109 23-132 23-252, 23-309 23-91...
Page 883: Troubleshooting Tips And Precautions
Table of Contents Main Menu Troubleshooting Tips and Precautions Before Troubleshooting Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. Check applicable fuses in the appropriate fuse box. Check the battery for damage, state of charge, and Always reinstall plastic covers.
Page 884 Table of Contents Main Menu Troubleshooting Tips and Precautions (cont'd) Seat grommets in their grooves properly. Insert the connector all the way, and make sure it is securely locked. Position wires so that the open end of the cover faces down. Face NOT GOOD open end...
Page 885: Five-Step Troubleshooting
Main Menu Table of Contents Five-step Troubleshooting ————— Verify The Complaint 4. Fix The Problem Turn on all the components in the problem circuit to Once the specific problem is identified, make the verify the customer complaint. Note the symp- repair.
Page 886: Under-Hood Fuse/Relay Box
Main Menu Table of Contents Relay and Control Unit Locations Front Compartment ABS REAR FAIL-SAFE RADIATOR FAN LOW RELAY RELAY RADIATOR FAN HIGH RELAY WINDSHIELD WIPER UNDER-HOOD HORN RELAY INTERMITTENT RELAY RELAY BOX A/C COMPRESSOR ABS FRONT FAIL-SAFE CLUTCH RELAY WINDSHIELD WIPER RELAY HIGH RELAY...
Page 887: Dashboard
Main Menu Table of Contents Relay and Control Unit Locations Dashboard IMMOBILIZER CONTROL UNIT CLIMATE CONTROL UNIT TURN SIGNAL/HAZARD RELAY DASHBOARD LOWER COVER INTEGRATED CONTROL UNIT UNDER-DASH FUSE BOX...
Page 888: Abs Control Unit
Main Menu Table of Contents Dashboard, Door and Floor DRIVER'S DOOR PANEL ABS CONTROL UNIT DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada) POWER DOOR LOCK CONTROL UNIT POWER WINDOW CONTROL UNIT STARTER CUT RELAY Wire colors: BLK/WHT, BLK/WHT, BLK/GRN, and BLK/BLU SECURITY CONTROL UNIT EPS CONTROL UNIT (Behind foot well...
Page 889: Rear Bulkhead
Main Menu Table of Contents Relay and Control Unit Locations Rear Bulkhead THROTTLE VALVE CONTROL MOTOR RELAY Wire colors: BLK, YEL/BLK, GRN/RED, and WHT/BLU PGM-FI MAIN RELAY TRANSMISSION CONTROL MODULE (TCM) (A/T) PULSE UNIT (M/T) TCS CONTROL UNIT FAN CONTROL UNIT DASH LIGHTS BRIGHTNESS...
Page 890 Main Menu Table of Contents INTERLOCK CONTROL UNIT (A/T) FUEL PUMP RELAY RETRACTABLE HEADLIGHT Wire colors: YEL, RED, CONTROL UNIT BLK/YEL, and BLK/RED...
Page 891: Engine Compartment
Table of Contents Main Menu Relay and Control Unit Locations Engine Compartment ENGINE COMPARTMENT REAR WINDOW DEFOGGER FAN RELAY (A/T) RELAY Wire colors: YEL/BLK, BLU/RED, WHT/GRN, and WHT/BLU ENGINE COMPARTMENT FUSE/RELAY BOX IGNITION CONTROL MODULE (ICM) SPARK PLUG VOLTAGE DETECTION MODULE...
Page 892: Component Location Index
Table of Contents Main Menu Battery Component Location Index BATTERY Type: 80D26L (A/T) 70D23L (M/T) CHECK INDICATOR BATTERY HOLDER HEAT SHIELD Replacement Remove the spare tire and the spare tire holder. Disconnect both the negative cable and positive cable from the battery. Remove the battery holder, then take out the battery.
Page 893 Main Menu Table of Contents Battery Test Battery fluid (electrolyte) contains sulfuric acid. It may cause severe burns if it gets on your skin or in your eyes. Wear protective clothing and a face shield. — If electrolyte gets on your skin or clothes, rinse it off with water immediately. —...
Page 894 Table of Contents Main Menu Charge on High Setting (40 amps) Charge until EYE shows charge is OK; plus an additional 30 minutes to assure full charge. NOTE: If the battery charge is very low, it may be necessary to bypass the charger's polarity protection circuitry.
Page 895: Removal/Installation
Table of Contents Main Menu Under-dash Fuse Box Removal/Installation SRS components are located in this area. Review the SRS Disconnect the under-dash fuse box connectors. component locations, precautions, and procedures in the (section 24) before performing repairs or service. NOTE: The SRS main harness connector is double locked.
Page 896 Table of Contents Main Menu Installation: Connect the connectors to the under-dash fuse box. NOTE: To reinstall the SRS main harness connec- tor, push it into position until it clicks, then close the connector lid. Install the under-dash fuse box. Install the side sill trim, fuse box door and door sill pad.
Page 897: Ignition Switch Test
Table of Contents Main Menu Ignition Switch Electrical Switch Replacement Test Remove the dashboard lower cover, and disconnect Remove the dashboard lower cover (see next the floor wire harness connectors. column). Disconnect the 7P connector from the floor wire harness. Check for continuity between the terminals in each switch position according to the table.
Page 898: Steering Lock Removal/Installation
Table of Contents Main Menu Steering Lock Removal/Installation Remove the steering column lower and upper cov- SRS components are located in this area. Review the SRS ers. Be careful not to damage the steering column component locations, precautions, and procedures in the covers.
Page 899 Table of Contents Main Menu Ignition Switch Steering Lock Removal/Installation (cont'd) 8. Center-punch the shear bolt, and drill its head off Installation: with a 5 mm (3/16 in) drill bit. Do not damage the Turn the key to "I", push the pin, and insert the switch body.
Page 900: Replacement, Page
Table of Contents Main Menu Starting System Component Location Index STARTER CUT RELAY Wire colors: BLK/WHT, BLK/BLU, BLK/WHT and BLK/GRN Test, page 23-80 A/T GEAR POSITION SWITCH (Neutral position switch) •Test, page 23-160 • Replacement, page 23-163 IMMOBILIZER CONTROL UNIT Input Test, page 23-334 CLUTCH INTERLOCK...
Page 901 Table of Contents Main Menu Starting System Description Starter Interlock System (M/T): The starter interlock system prevents the engine from starting unless the clutch pedal is fully depressed. The clutch interlock switch turns on at the position where the clutch disengages: 15 - 20 mm (0.59 - 0.79 in) from fully depressed position.
Page 902 Main Menu Table of Contents Starting System Starter Test Disconnect the No. 13 (30 A) fuse from the engine NOTE: The air temperature must be between 59 and compartment fuse/relay box. 100°F (15 and 38°C) before testing. Recommended Procedure: Use a starter system tester. Connect and operate the equipment in accor- dance with manufacturer's instructions.
Page 903 Table of Contents Main Menu — If the starter still does not crank the engine, Check cranking rpm: remove the starter and diagnose its internal Engine speed during cranking should be above 100 rpm. problems. — If the starter cranks the engine, check for an If speed is too low, check for: open in the BLK/WHT wire and connectors be- tween the starter and ignition switch.
Page 904 Table of Contents Main Menu Starting System Clutch Interlock Switch Test (M/T) - Starter Cut Relay Test Remove the dashboard lower cover, then disconnect Remove the glove box (see section 20). the 2P connector from the switch. Disconnect the 4P connector from the starter cut Check for continuity between the terminals accord- relay.
Page 905: Starter Solenoid Test
Main Menu Table of Contents Starter Solenoid Test Starter Replacement Check the hold-in coil for continuity between the S Disconnect the battery negative cable. terminal and the armature housing (ground). The coil is OK if there is continuity. Remove the engine wire harness from the harness clip on the starter motor.
Page 906: Inspection, Page
Table of Contents Main Menu Starting System Starter Overhaul CAUTION: Disconnect the ground cable from the bat- SOLENOID STARTER tery before removing the starter. PLUNGER SOLENOID Inspection, page 23-86 Test, page 23-81 OVERRUNNING CLUTCH ASSEMBLY BRUSH HOLDER IDLER GEAR PINION GEAR ARMATURE END COVER O-RING...
Page 907 Main Menu Table of Contents Starter Brush Holder Test Starter Brush Inspection Check that there is no continuity between the Measure the brush length. If not within the service limit, brush holders. replace armature housing brush holder If continuity exists, replace the brush holder...
Page 908 Table of Contents Main Menu Starting System Armature Inspection and Test Inspect the armature for wear or damage due to Commutator Runout contact with the field coil magnets. Standard (New): 0-0.02 mm (0-0.0008 in) Service Limit: 0.05 mm (0.002 in) Inspect for damage.
Page 909 Table of Contents Main Menu With an ohmmeter, check that no continuity exists Check for continuity between the segments of the between the commutator and armature coil core, commutator. If an open circuit exists between any and between the commutator and armature shaft. segments, replace the armature.
Page 910 Table of Contents Main Menu Starting System Solenoid Plunger Inspection Starter Field Winding Test Check for continuity between the brushes. If Check the contact points and face of the starter there's continuity, replace armature solenoid plunger for burning, pitting or any other housing.
Page 911: Starter Reassembly
Main Menu Table of Contents Overrunning Clutch Inspection Starter Reassembly Reassemble the starter in the reverse order of Check if the overrunning clutch moves along the shaft freely. If not, replace the overrunning clutch disassembly. assembly. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its Check if the overrunning clutch locks in one direc- holder, and release the spring to hold it there.
Page 912: Inspection, Page
Table of Contents Main Menu Ignition System Component Location Index IGNITION TIMING CONTROL SYSTEM Description, page 23-89 Inspection, page 23-91 Troubleshooting, section 11 SERVICE CHECK CONNECTOR (2P) (Connector color: BLU) SPARK PLUG (6) Inspection, page 23-96 NOISE CONDENSER Test, page 23-97 TEST TACHOMETER CONNECTOR SERVICE LOOP...
Page 913 Table of Contents Main Menu Description ——————————————————————————————————————— Ignition Timing Control: The programmed ignition used in this engine provides optimum control of ignition timing. A microcomputer determines the timing in response to engine speed and manifold vacuum pressure. The input signals are transmitted by the crank- shaft position/cylinder position (CKP/CYP) sensor, throttle position (TP) sensor, ECT sensor, and MAP sensor.
Page 914: Ignition Timing Inspection
Table of Contents Main Menu Ignition Timing Inspection SRS components are located in this area. Review the SRS Check the idle speed (see page 23-92). component locations, precautions, and procedures in the (section 24) before performing repairs or service. Connect a timing light to the service loop; while the engine idles, point the light toward the pointer on Pull out the service check connector located under the timing belt cover.
Page 915: Idle Speed Inspection
Table of Contents Main Menu Ignition System Ignition Control Module (ICM) Idle Speed Inspection Replacement Start the engine. Hold the engine at 3,000 rpm with Disconnect the 8P and 6P connectors from the igni- no load (A/T in position, M/T in neutral) tion control module (ICM).
Page 916 Table of Contents Main Menu Ignition Control Module (ICM) Input Test Disconnect the 8P connector from the ignition control NOTE: module (ICM). The tachometer should operate normally. Inspect the connector and socket terminals to be sure section 11 when the malfunction indicator they are all making good contact.
Page 917 Main Menu Table of Contents Ignition System Ignition Coils/Spark Plugs Removal CAUTION: NOTE: Different ignition coils and ignition coil Ignition coils and spark plugs can become very hot in covers are used for the front and rear cylinders. Be sure to use the correct ones when mounting them. use;...
Page 918: Ignition Coil Test
Main Menu Table of Contents Ignition Coil Test 1. With the ignition switch OFF, remove the ignition A TERMINAL coil. Using an ohmmeter, measure resistance between the terminals. Replace the coil if the resistance is not within specifications. IGNITION NOTE: Resistance will vary with...
Page 919: Spark Plug Inspection
Table of Contents Main Menu Ignition System Spark Plug Inspection Replace the plug if it is fouled or worn. Do not use Inspect the electrodes and ceramic insulator for: spark plugs other than those listed below. Worn or deformed Spark Plug: electrodes PFR6L-11 (NGK) PK20PR-L11 (DENSO)
Page 920: Noise Condenser Capacity Test
Table of Contents Main Menu Noise Condenser Capacity Test Use a commercially available condenser tester. Connect the tester probes, and measure the con- denser capacity. Condenser capacity: 0.47 ±0.09 microfarads POSITIVE TERMINAL BODY GROUND (Negative) NOTE: The noise condenser is intended to reduce ignition noise.
Page 921: Charging System Component Location Index
Main Menu Table of Contents Charging System Component Location Index CHARGING SYSTEM LIGHT (Built into the gauge assembly) Test, page 23-100 BATTERY Test, page 23-68 ALTERNATOR BELT Adjustment, page 23-109 ALTERNATOR • Alternator and Regulator Test, page 23-102 • Replacement, page 23-105 •...
Page 922 Main Menu Table of Contents Charging System Troubleshooting If the charging system light is on, or the battery is dead or low, test the following items in the order listed: Battery (see page 23-68) Charging System Light Alternator/Regulator Charging System Light Test Turn the ignition switch ON (II).
Page 923 Table of Contents Table of Contents Main Menu Main Menu (From page 23-100) Turn the ignition switch off. Check fuse No. 2 (15 A). Is the fuse OK? Replace the fuse. Disconnect the 4P connector from the alternator. Turn the ignition switch ON (II). Check for voltage in the YEL wire at the IG terminal of the 4P con- nector.
Page 924: Alternator/Regulator Test
Table of Contents Main Menu Charging System Troubleshooting (cont'd) Attach the negative tester cable and the voltmeter Alternator/Regulator Test negative lead to the top of the intake manifold. Use the SUN VAT-40 (or equivalent) tester. NEGATIVE CABLE VOLTMETER FULL FIELD NEGATIVE LEAD LEAD (BLU) LOAD ADJUSTER...
Page 925 Table of Contents Main Menu NOTE: Be sure the battery is sufficiently charged (see page 23-68). Connect the Sun VAT-40 (see page 23-102) and turn the selec- tor switch to position 1 (starting). Start the engine, and let it idle until it reaches normal operating temperature.
Page 926 Table of Contents Main Menu Charging System Troubleshooting (cont'd) (From page 23-103) Apply a load with the VAT-40 until the battery voltage drops to between 12-13.5 V. Charging system is OK. Is the amperage 85 A or more? NOTE: Attach a probe to the VAT-40 full-field test lead, and insert the probe into the full-field access With the engine speed still at hole at the back of the alternator.
Page 927: Alternator Replacement
Main Menu Table of Contents Alternator Replacement Remove the nut from the adjustment-lock bolt, Disconnect the negative cable from the battery. loosen the mounting bolt and the adjusting bolt, then remove the belt from the pulley. 2. Disconnect the 4P connector from the alternator. Remove the nut and the BLK wire from the B ADJUSTMENT-LOCK terminal.
Page 928: Tests, Page
Main Menu Table of Contents Charging System Alternator Overhaul NOTE: It is only necessary to separate the pulley, drive end housing and rotor when the front bearing needs PULLEY replacement. Loosen the locknut with 10 mm and 22 mm wrenches to remove the pulley from the rotor.
Page 929: Rectifier Test
Main Menu Table of Contents Alternator Brush Inspection Rectifier Test Remove the end cover, then take out the brush NOTE: The diodes are designed to allow current to pass in one direction while blocking it in the opposite holder by removing its two screws. direction.
Page 930: Rotor Slip Ring Test
Main Menu Table of Contents Charging System Stator Test Rotor Slip Ring Test Check that there is continuity between each pair of Check that there is continuity between the slip rings. leads. Check that there is no continuity between the slip rings and the rotor or rotor shaft.
Page 931: Alternator Belt Adjustment
Table of Contents Main Menu Alternator Belt Adjustment Deflection Method: Tension Gauge Method: Apply a force of 98 N (10 kgf, 22 Ibf) between the Attach the belt tension gauge to the belt, and mea- alternator and crankshaft pulley, and measure its sure belt tension.
Page 932: Radiator And Condenser Fan Controls Component Location Index
Table of Contents Main Menu Radiator and Condenser Fan Controls Component Location Index CONDENSER FAN RELAY Wire colors: BLK, WHT/GRN, YEL/BLK, RADIATOR FAN LOW RELAY ORN/BLU Wire colors: WHT/BLU, Test, page 23-119 RED, YEL/BLK, GRN/BLK Test, page 23-119 UNDER-HOOD RELAY BOX B UNDER-HOOD RADIATOR FAN HIGH RELAY RELAY BOX A...
Page 933: Replacement, Page
Main Menu Table of Contents THROTTLE VALVE CONTROL MOTOR RELAY FAN CONTROL UNIT ENGINE COMPARTMENT FAN RELAY (A/T) Wire colors: YEL/BLK, BLU/RED, WHT/GRN, and WHT/BLU Test, page 23-119 ENGINE COMPARTMENT FAN MOTOR (A/T) RADIATOR FAN CONTROL SENSOR Test, page 23-120 Test, page 23-118 Replacement, page...
Page 934 Main Menu Table of Contents Radiator and Condenser Fan Controls Description Fan control system: The cooling fan system is comprised of the radiator fan, condenser fan (left and right), engine compartment fan, radiator fan low relay, radiator fan high relay, condenser fan relay, engine compartment fan relay, radiator fan resistor, radiator fan control sensor, A/C pressure switch, fan control unit, climate control unit, and ECM.
Page 935: Troubleshooting
Main Menu Table of Contents Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence. *: Refer to section 22 for A/C pressure inspection of the A/C system.
Page 936: Control Unit Terminals
Table of Contents Main Menu Radiator and Condenser Fan Controls Radiator Fan Resistor Test Control Unit Terminals THROTTLE VALVE CONTROL Disconnect the 3P connector from the resistor. MOTOR RELAY RADIATOR 3P CONNECTOR RESISTOR NOT USED Using an ohmmeter, measure resistance between the A and B terminals.
Page 937: Radiator Fan Motor Test
Main Menu Table of Contents Radiator Fan Motor Test Condenser Fan Motor Test 1. Disconnect the 2P connector from the condenser Disconnect the 2P connector from the radiator fan fan motor. motor. NOTE: The illustration shows the right condenser. Test the motor by connecting battery power to the A terminal, and ground to the B terminal.
Page 938: Engine Compartment Fan Motor (A/T) Test
Table of Contents Main Menu Radiator and Condenser Fan Controls Engine Compartment Fan Motor Engine Compartment Fan Motor Removal (A/T) Test (A/T) Disconnect the 2P connector from the engine Disconnect the 2P connector from the engine compartment fan motor. compartment fan motor. Remove the engine compartment fan relay, the test tachometer connector, and the engine wire harness from the engine compartment fan shroud.
Page 939: Fan Relay Tests
Table of Contents Main Menu Fan Relay Tests Check continuity at the relay terminals. Engine compartment fan relay (A/T) There should be continuity between the C and D ter- minals. There should be continuity between the A and B ter- minals when power and ground are connected to the C and D terminals.
Page 940: Radiator Fan Control Sensor Test
Main Menu Table of Contents Radiator and Condenser Fan Controls Radiator Fan Control Sensor Test Heat the coolant, and check coolant temperature NOTE: Bleed air from the cooling system after install- with a thermometer (see table below). ing the radiator fan control sensor (see section 10).
Page 941: Gauge Assembly
Table of Contents Main Menu Gauge Assembly Gauge/Terminal 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. SPEEDOMETER: Indicates 60 mph [60km/h] at 1.026 [637] rpm of the vehicle speed sensor (VSS).
Page 942: Removal
Table of Contents Main Menu Gauge Assembly Removal SRS components are located in this area. Review the SRS 3. Remove the three screws, then remove the tilt cover component locations, precautions, and procedures in the from the steering column. (section 24) before performing repairs or service.
Page 943 Table of Contents Main Menu Remove the eight screws, then remove the steering Lay a protective cloth on the combination switches column covers. to prevent scratching the gauge assembly. Remove the four screws, then take out the gauge assembly as shown. UPPER COVER GAUGE ASSEMBLY...
Page 944: Bulb Locations
Main Menu Table of Contents Gauge Assembly Bulb Locations GAUGE LIGHTS (1.4 W x 2) SRS INDICATOR LIGHT (1.4 W) TCS INDICATOR LIGHT (1.96 W) RIGHT TURN SIGNAL INDICATOR LIGHT 11.4 W) LEFT TURN SIGNAL INDICATOR LIGHT (1.4 W) INDICATOR LIGHT (1.4 W) EPS INDICATOR LIGHT (1.4 W) BRAKE SYSTEM LIGHT (1.4 W) CHARGING SYSTEM LIGHT (1.4 W)
Page 945: Disassembly
Table of Contents Main Menu Disassembly NOTE: Handle the terminals and printed circuit boards carefully to avoid damaging them. Replace the speedometer, trip meter, and printed circuit board A as a unit if any of them is faulty. Replace the tachometer, odometer, and printed circuit board B as a unit if any of them is faulty. SPEEDOMETER MOUNTING SCREWS (x3) TACHOMETER MOUNTING SCREWS (x3) HOUSING...
Page 946: Speedometer/Trip Meter/Odometer Troubleshooting
Main Menu Table of Contents Speedometer/Trip Meter/Odometer Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence.
Page 947: Vss Replacement
Table of Contents Main Menu Vehicle Speed Sensor (VSS) Replacement Disconnect the 3P connector from the vehicle speed sensor (VSS). 3P CONNECTOR MOUNTING BOLTS COVER DRIVE LINK Remove the mounting bolts and the VSS, then take out the VSS assembly. NOTE: The VSS drive link is a very small part, be careful not to lose it.
Page 948: Fuel Gauge
Main Menu Table of Contents Fuel Gauge Gauge Test Connect the voltmeter positive probe to the B (YEL/WHT) terminal and the negative probe to the C (BLK) terminal, then turn the ignition switch ON Before testing, check the No. 5 (15 A) fuse in the (II).
Page 949: Sending Unit Test
Table of Contents Main Menu Sending Unit Test Measure the resistance between the A and B termi- Do not smoke while working on the fuel nals by moving the float to the heights listed for E system. Keep open flame away from work area. (EMPTY), 1/2 (HALF FULL) and F (FULL).
Page 950: Coolant Temperature Gauge
Main Menu Table of Contents Coolant Temperature Gauge Coolant Temperature Gauge ——— Coolant Temperature Gauge Test Sending Unit Test Disconnect the YEL/GRN wire from the sending unit, and with the engine cold, use an ohmmeter to measure resistance between the positive terminal Before testing, check the No.
Page 951: Gauge Test
Table of Contents Main Menu Engine Oil Pressure Warning System Engine Oil Pressure Gauge Gauge Test Engine Oil Pressure Switch Test Raise the car, and place safety stands in the proper locations (see section Before testing, check the No. 5 (15 A) fuse in the Remove the right rear tire.
Page 952: Brake Warning System Parking Brake Switch Test
Table of Contents Main Menu Brake Warning System Parking Brake Switch Test Brake Fluid Level Switch Test Remove the reservoir cap. Check that the float Remove the center console, and disconnect the con- nector from the switch. moves up and down freely; if it doesn't, replace the reservoir cap assembly.
Page 953: Seat Belt Reminder System Seat Belt Switch Test
Table of Contents Main Menu Low Fuel Indicator Seat Belt Reminder System Indicator Light Test Seat Belt Switch Test Slide the driver's seat all the way forward, then dis- connect the 2P connector from the seat belt switch. Check continuity between the A and B terminals with Park the car on level ground.
Page 954: Interlock System Component Location Index
Main Menu Table of Contents Interlock System 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. INTERLOCK CONTROL UNIT Input Test, page 23-143...
Page 955 Table of Contents Main Menu PARKING PIN SWITCH Test, page 23-146 Replacement, page 23-146 A/T GEAR POSITION SWITCH Test, page 23-162 Replacement, page 23-163 KEY INTERLOCK SOLENOID SHIFT LOCK SOLENOID Test, page 23-145 and KEY INTERLOCK SWITCH Replacement, page 23-145 (In the steering lock assembly) Test, page 23-144...
Page 956: Control Unit Input Test
Table of Contents Main Menu Control Unit Input Test INTERLOCK CONTROL UNIT Disconnect the 8P connector from the control unit. 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 957: Key Interlock Solenoid Test
Main Menu Table of Contents Interlock System Key Interlock Solenoid Test Check for continuity between the terminals in each Remove the dashboard lower cover, and disconnect switch position according to the table. the floor wire harness connectors. Check that the key cannot be removed with power and ground connected to the C and B terminals.
Page 958: Shift Lock Solenoid
Table of Contents Main Menu Shift Lock Solenoid Test/Replacement Test: When the shift lock solenoid is OFF, make sure that Remove the center console panel and dashboard the lock pin is blocked by the top of the shift lock lever. (see section 20).
Page 959: Parking Pin Switch
Table of Contents Main Menu Interlock System Parking Pin Switch Test/Replacement Remove the center console panel and dashboard Remove the self-locking nut and parking pin switch. (see section 20). Disconnect the 2P connector of the parking pin switch from the floor wire harness. Check for continuity between the terminals in each switch lever position according to the table.
Page 960: Safety Indicator Component Location Index
Table of Contents Main Menu Safety Indicator Component Location Index SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the section 24 before performing repairs or service. SAFETY INDICATOR (In the gauge assembly) •...
Page 961: Indicator Input Test
Table of Contents Main Menu Safety Indicator Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the (section 24) before performing repairs or service. Remove the dashboard lower cover, dashboard lower pad and instrument panel.
Page 962 Table of Contents Main Menu Wire Test condition Test: Desired result Possible cause if result is not obtained Under all conditions Check for continuity to ground: • Poor ground (G401, G402, G403) • An open in the wire There should be continuity. Ignition switch ON (II) Check for voltage to ground: •...
Page 963: Troubleshooting
Table of Contents Main Menu Safety Indicator Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence.
Page 964: Brake Light Failure Sensor Test
Table of Contents Main Menu Brake Light Failure Sensor Test Remove the rear trim panel that covers the left tail- First make sure the brake lights come on when the light. Watch the light as you turn the brake pedal is pressed. ignition switch from OFF to ON (II) with the A (GRN) wire of the 6P connector grounded and the brake If all the brake lights come on, go to step 2.
Page 965: Roof Lock Switch Test
Table of Contents Main Menu Safety Indicator (NSX-T "open top") Roof Lock Switch Test Remove the headliner (see section 20). There should be continuity between the A and B ter- minals with the switch released (roof unlatched or Disconnect the 3P connector from the roof lock off).
Page 966: Roof Holder Switch Test
Main Menu Table of Contents Roof Holder Switch Test Open the rear hatch and engine cover. Disconnect the 1P connector from the roof holder switch. There should be continuity between the A and B ter- minals with the switch released (roof not stored). There should be no continuity with the switch pushed (roof stored).
Page 967: A/T Gear Position Indicator Component Location Index
Main Menu Table of Contents A/T Gear Position Indicator Component Location Index SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS (section 24) before performing repairs or ser- vice. NOTE: For indicator troubleshooting, refer to section A/T GEAR POSITION...
Page 968: Indicator Input Test
Main Menu Table of Contents 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 ser- vice. Remove the dashboard lower cover, dashboard lower pad and instrument panel.
Page 969 Table of Contents Main Menu Test condition Test: Desired result Wire Possible cause if result is not obtained Under all conditions Check for continuity to ground: • Poor ground (G401, G402, G403) There should be continuity. • An open in the wire Ignition switch ON (II) Check for voltage to ground: •...
Page 970: A/T Gear Position Switch Test
Table of Contents Main Menu A/T Gear Position Indicator A/T Gear Position Switch 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 ser- vice. Remove the center console panel and dushboard (see section...
Page 971: Replacement
Table of Contents Main Menu A/T Gear Position Switch Bulb Replacement Replacement SRS components are located in this area. Review the SRS components are located in this area. Review the SRS component locations, precautions, and procedures SRS component locations, precautions, and procedures in the SRS section 24 before performing repairs or ser-...
Page 972: Integrated Control Unit Input Test
Main Menu Table of Contents Integrated 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 ser- vice. Remove the left kick panel cover, and the relay holder from its bracket, then disconnect the 16-P connector from the integrated control unit.
Page 973 Table of Contents Main Menu Entry Light Timer System: Terminal Test condition Test: Desired result Possible cause if result is not obtained Under all conditions Check for continuity to ground: • Poor ground (G401, G402, G403) There should be continuity. •...
Page 974 Table of Contents Main Menu Integrated Control Unit Input Test (cont'd) Lights-on Reminder System: Terminal Test condition Test: Desired result Possible cause if result is not obtained Under all conditions Check for continuity to ground: • Poor ground (G401, G402, G403) There should be continuity.
Page 975 Table of Contents Main Menu Rear Window Defogger Timer System: Terminal Test condition Test: Desired result Possible cause if result is not obtained Under all conditions Check for continuity to ground: • Poor ground (G401, G402, G403) There should be continuity. •...
Page 976 Table of Contents Main Menu Integrated Control Unit Input Test (cont'd) Side Marker Light Flasher System: Terminal Test condition Test: Desired result Possible cause if result is not obtained Under all conditions Check for continuity to ground: • Poor ground (G401, G402, G403) There should be continuity.
Page 977 Table of Contents Main Menu Combined Operation Wiper/Washer System: Test condition Test: Desired result Terminal Possible cause if result is not obtained Under all conditions Check for continuity to ground: • Poor ground (G401, G402, G403) There should be continuity. •...
Page 978: Lights-On Reminder System Chime Test
Main Menu Table of Contents Lights-on Reminder System Chime Test NOTE: Refer to page 23-168 for the input test of the CHIME lights-on reminder circuit. When the ignition key is turned off and removed with the lights on, voltage is applied to the reminder circuit in the integrated control unit.
Page 979: Key-In Reminder System Ignition Key Switch Test
Table of Contents Main Menu Key-in Reminder System Ignition Key Switch Test Disconnect the 8P connector from the floor wire NOTE: Refer to page 23-167 for the input test of the key -in reminder beeper circuit. harness. When the ignition key is not removed, the key-in There should be continuity between the No.
Page 980: Lighting System
Table of Contents Main Menu Lighting System Component Location Index RETRACTABLE HEADLIGHT CONTROL UNIT Input Test, page 23-180 HIGH BEAM INDICATOR LIGHT (In the gauge assembly) Gauge Assembly, page 23-121 COMBINATION LIGHT SWITCH Test, page 23-183 Replacement, page 23-184 DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada) Test, page 23-182...
Page 981 Table of Contents Main Menu UNDER-HOOD FUSE/RELAY BOX DIMMER RELAY Test, page 23-191 TAILLIGHT RELAY Test, page 23-192 HEADLIGHT RELAY Test, page 23-191 LEFT HEADLIGHT RETRACTOR RELAY Test, page 23-192 RIGHT HEADLIGHT RETRACTOR RELAY Test, page 23-192 RIGHT HEADLIGHT RETRACTOR MOTOR Test, page 23-190 Replacement, page...
Page 982: Switches
Table of Contents Main Menu Switches The lighting system is controlled by five switches and the turn signal cancel unit. HAZARD WARNING SWITCH HEADLIGHT SWITCH TURN SIGNAL CANCEL UNIT TURN SIGNAL and DIMMER SWITCH TURN SIGNAL CANCEL SWITCH...
Page 983: Retractable Headlight Control Unit Input Test
Table of Contents Main Menu Lighting System Retractable Headlight Control Unit Input Test Remove the rear bulkhead panels, and disconnect the 18P connector from the control unit. 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 984 Table of Contents Main Menu Test condition Wire Test: Desired result Possible cause if result is not obtained Check for voltage to ground: • Faulty headlight relay or passing Passing switch ON LT GRN/ switch There should be battery voltage. •...
Page 985 Table of Contents Main Menu Lighting System Daytime Running Lights Control Unit Input Test (Canada) Remove the glove box lower panel and glove box. Disconnect the 4P and 8P connectors from the daytime running lights control unit. DAYTIME RUNNING LIGHTS Inspect the connector and socket terminals to be sure CONTROL UNIT (Canada) they are all making good contact.
Page 986: Combination Light/Turn Signal Switch Test
Table of Contents Main Menu Combination Light/Turn Signal Switch Test Remove the dashboard lower cover (see page 23-184). Disconnect the 18P connector from the floor wire harness. Check for continuity between the terminals, in each switch position, according to the table. Headlight/Dimmer/Passing Switch Terminal Position...
Page 987: Headlight/Turn Signal Switch Replacement
Table of Contents Main Menu Lighting System Headlight/Turn Signal Switch Replacement SRS components are located in this area. Review the Remove the tilt cover. SRS component locations, precautions, and procedures in the SRS section 24 before performing repairs or ser- vice.
Page 988 Table of Contents Main Menu Disconnect the 18P and 10P connectors. If necessary, remove the headlight switch bulb. CAUTION: Be careful not to damage the SRS wire harness. Remove the six screws, then remove the headlight- turn signal switch assembly. HEADLIGHT SWITCH HEADLIGHT SWITCH 10P CONNECTOR...
Page 989: Retractor Switch Removal
Table of Contents Main Menu Lighting System Retractor Switch Removal SRS components are located in this area. Review the SRS Remove the steering column covers. component locations, precautions, and procedures in the UPPER COVER section 24 before performing repairs or service. Remove the dashboard lower cover, and disconnect the connectors.
Page 990: Bulb Replacement
Table of Contents Main Menu Retractor Switch Test Retractor Switch Light Bulb Replacement Remove the retractor switch (see page 23-186). Remove the retractor switch (see page 23-186). Check for continuity between the terminals in each Turn the bulb 45° counterclockwise to remove it. switch position according to the table.
Page 991: Retractor Motor Replacement
Table of Contents Main Menu Lighting System Retractor Motor Replacement CAUTION: Remove the two caps, four screws, and cowl clips. Halogen headlights can become very hot in use; do not touch them or the attaching hardware immediately after they have been turned off. Do not try to replace or clean headlights with the lights COWL CLIP Remove the No.
Page 992 Main Menu Table of Contents 7. Disconnect the 6P connector. MOUNTING BOLT/NUT 9.8 N-m (1.0 kgf-m, 7 Ibf-ft) '/• RETRACTOR MOTOR BRACKET 6-P CONNECTOR MOTOR ARM JOINT 8. Remove the two mounting bolts and the mounting nut. 9. Pry the retractor linkage off the motor arm. 10.
Page 993: Headlight Housing Adjustment
Main Menu Table of Contents Headlight Housing Adjustment Remove the stop bolt caps. Adjust stop bolts A and B. STOP BOLT CAPS STOP STOP BOLT B BOLT A STOP BOLT C STOP BOLT LOCKNUT Adjust stop bolt C in or out until the headlight hous- ing fits flush with the front fender when the head- light is down.
Page 994 Main Menu Table of Contents Lighting System Headlight Housing Adjustment (cont'd) Adjust the retractor motor toward front or rear until the headlight housing fits flush with the front fender when the headlight is down. NOTE: Be careful not to damage the headlight housing.
Page 995: Retractor Motor Test
Main Menu Table of Contents Lighting System Retractor Motor Test Remove the retractor motor. Test the motor by connecting battery power to the A terminal and ground to the D terminal. The motor should run continuously. If the motor does not run or fails to run smoothly, replace it.
Page 996: Headlight Relay Test
Table of Contents Main Menu Headlight Relay Test Dimmer Relay Test Remove the dimmer relay from the under-hood Remove the headlight relay from the under-hood fuse/relay box. fuse/relay box. Check continuity at the relay terminals. Check continuity at the relay terminals. There should be continuity between the C and D There should be continuity between the F and E terminals.
Page 997: Retractor Relay Test
Table of Contents Main Menu Lighting System Retractor Cut/Taillight Relay Test Retractor Relay Test Remove the retractor cut relay and taillight relay. Remove the retractor relay (located at the right side of the front compartment). Check continuity at the relay terminals. Check continuity at the relay terminals.
Page 998: Headlights Description
Main Menu Table of Contents Headlights Description The light first forms basic pattern A after being inter- rupted by the interrupter plate and passing through the convex lens. The interrupter plate determines the form. The outer lens distributes the light into pattern B. CONVEX LENS INTERRUPTER PLATE BULB...
Page 999 Table of Contents Main Menu Headlights Adjustment Adjust the headlights to local requirements by turning the adjusters as shown. NOTE: Be careful not to damage the front fender or the headlight housing when adjusting. HEADLIGHT HORIZONTAL AIM ADJUSTER PROTECTIVE TAPE HEADLIGHT VERTICAL AIM ADJUSTER...
Page 1000: Headlight Replacement
Table of Contents Main Menu Headlight Replacement CAUTION: Remove the two caps, four screws, and cowl clips. Halogen headlights can become very hot in use; do not touch them or the attaching hardware immediately after they have been turned off. Do not try to replace or clean the headlights with the COWL CLIP lights on.

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