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Honda Accord 2008 Manual

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Table of Contents
07/11/02 08:54:14 61TA0000_000_0001
A Few Words About Safety
Service Information
The service and repair information contained in this
manual is intended for use by qualified, professional
technicians. Attempting service or repairs without the
proper training, tools, and equipment could cause
injury to you or others. It could also damage the vehicle
or create an unsafe condition.
This manual describes the proper methods and
procedures for doing service, maintenance, and repairs.
Some procedures require the use of specially designed
tools and dedicated equipment. Any person who
intends to use a replacement part, service procedure, or
a tool that is not recommended by Honda, must
determine the risks to their personal safety and the safe
operation of the vehicle.
If you need to replace any parts, always use the correct
parts supplied by a Honda dealer. Never use inferior
quality parts.
FOR YOUR CUSTOMER'S SAFETY
Proper service and maintenance are essential to the
customer's safety and the reliability of the vehicle. Any
error or oversight while servicing a vehicle can result in
faulty operation, damage to the vehicle, or injury to
others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
FOR YOUR SAFETY
Because this manual is intended for the professional
service technician, we do not provide warnings about
many basic shop safety practices (for example, hot
parts wear gloves). If you have not received shop
safety training or do not feel confident about your
knowledge of safe servicing practices, we recommend
that you do not attempt to do the procedures described
in this manual.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Some of the most important general service safety
precautions follow this text. However, we cannot warn
you of every conceivable hazard that can arise in doing
service and repair procedures. Only you can decide
whether or not you should do a given task.
IMPORTANT SAFETY PRECAUTIONS
• Make sure you have a clear understanding of all basic
shop safety practices, and that you are wearing
appropriate clothing and using safety equipment.
When doing any service task, be especially careful of
the following:
– Read all of the instructions before you begin, and
make sure you have the tools, the replacement or
repair parts, and the skills required to do the tasks
safely and completely.
– Protect your eyes by using proper safety glasses,
goggles, or face shields anytime you hammer, drill,
grind, or work around pressurized air or liquids and
springs, or other stored-energy components. If
there is any doubt, put on eye protection.
– Use other protective wear when necessary, such as
gloves or safety shoes. Handling hot or sharp parts
can cause severe burns or cuts. Before you grab
something that looks like it can hurt you, stop and
put on gloves.
– Protect yourself and others whenever you have the
vehicle up in the air. Anytime you raise the vehicle,
either with a lift or a jack, make sure that it is
always securely supported. Use safety stands if
needed.
– Protect yourself by wearing an approved welding
helmet, gloves, and safety shoes anytime you are
welding. You can receive burns from hot parts;
allow the parts to cool before working in that area.
– Protect yourself from paints and harmful chemicals
by wearing an approved respirator, eye protection,
and gloves whenever you are painting. Spray paint
only in an approved paint booth that is well
ventilated.
• Make sure the engine is off before you begin any
servicing procedures, unless the instruction tells you
to do otherwise. This will help eliminate several
potential hazards:
– Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you
run the engine.
– Burns from hot parts or coolant. Let the engine and
exhaust system cool before working in those areas.
– Injury from moving parts. If the instruction tells you
to run the engine, be sure your hands, fingers, and
clothing are out of the way.
• Gasoline vapors and hydrogen gases from batteries
are explosive. To reduce the possibility of a fire or
explosion, be careful when working around gasoline
or batteries.
– Use only a nonflammable solvent, not gasoline, to
clean parts.
– Never drain or store gasoline in an open container.
– Keep all cigarettes, sparks, and flames away from
the battery and all fuel-related parts.
TA08AE4000000000000ABAT00

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Table of Contents

Troubleshooting

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  Summary of Contents for Honda Accord 2008

  • Page 1 – Protect your eyes by using proper safety glasses, a tool that is not recommended by Honda, must goggles, or face shields anytime you hammer, drill, determine the risks to their personal safety and the safe grind, or work around pressurized air or liquids and operation of the vehicle.
  • Page 2 *Restraints First Edition 12/2007 2,960 pages HONDA MOTOR CO., LTD. All Rights Reserved Service Publication Office Specifications apply to USA and Canada As sections with * include SRS components;...
  • Page 3 • To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal or side collision, all SRS service work should be done by an authorized Honda dealer. • Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment of the airbags, side airbags, and/or side curtain airbags.
  • Page 4: Table Of Contents

    07/11/02 08:59:45 61TA0000_010_0001 General Information Chassis and Paint Codes 4-door Model ..........................1-2 2-door Model ..........................1-3 Identification Number Locations ........1-4 Danger/Warning/Caution Label Locations . 1-5 Under-hood Emission Control Label ......1-8 Lift and Support Points ........
  • Page 5: General Information

    000001 K24Z2 1000001 c d e f g h a. Manufacturer, Make, and Type of Vehicle 1HG: Honda of America Mfg. Inc., U.S.A. a. Engine Type Honda passenger vehicle K24Z2: 2.4 L DOHC i-VTEC Sequential Multiport JHM: Honda Motor Co.,Ltd.
  • Page 6: 2-Door Model

    1400001 c d e f g h a. Manufacturer, Make, and Type of Vehicle a. Engine Type 1HG: Honda of America Mfg. Inc., U.S.A. K24A3: 2.4 L DOHC i-VTEC Sequential Multiport Honda passenger vehicle Fuel-injected, 200HP engine b. Line, Body, and Engine Type b.
  • Page 7: Identification Number Locations

    07/11/02 08:59:48 61TA0000_010_0004 General Information Identification Number Locations 4-door: 4-door: *22 *24 Vehicle Identification Vehicle Identification Number (VIN) Number (VIN) Automatic Transmission Number Engine Number Manual Transmission Number 2-door: *25 2-door: *23 Vehicle Identification Vehicle Identification Number (VIN) Number (VIN) Automatic Transmission Number...
  • Page 8: Danger/Warning/Caution Label Locations

    07/11/02 08:59:48 61TA0000_010_0005 Danger/Warning/Caution Label Locations 4-door *26 Front Passenger’s Compartment: SRS WARNING INFORMATION SRS INFORMATION USA models PASSENGER AIRBAG MODULE DANGER SRS WARNING INFORMATION FRONT PASSENGER AIRBAG WARNING TAG (CHILD SEAT) USA models SIDE AIRBAG MODULE DANGER FRONT SEAT BELT STEERING COLUMN NOTICE MONITOR NOTICE TENSIONER CAUTION...
  • Page 9 07/11/02 08:59:48 61TA0000_010_0006 General Information Danger/Warning/Caution Label Locations (cont’d) 2-door *08 Front Passenger’s Compartment: SRS WARNING INFORMATION SRS INFORMATION USA models PASSENGER AIRBAG MODULE DANGER SRS WARNING INFORMATION FRONT PASSENGER AIRBAG WARNING TAG (CHILD SEAT) USA models SIDE AIRBAG MODULE DANGER FRONT SEAT BELT TENSIONER CAUTION...
  • Page 10 07/11/02 08:59:49 61TA0000_010_0007 4-door Model: 2-door Model: *10 *11 EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION and ENGINE COOLANT INFORMATION and ENGINE COOLANT INFORMATION SRS WARNING SRS WARNING AIR CONDITIONING BATTERY INFORMATION AIR CONDITIONING BATTERY RADIATOR CAP DANGER DANGER INFORMATION RADIATOR CAP DANGER DANGER *12...
  • Page 11: Under-Hood Emission Control Label

    S Y S T E M , R E A D T H E O W N E R ’ S M A N U A L R 4 0 - A 0 0 HONDA MOTOR CO. , LTD. O R C H E C K W I T H Y O U R H o n d a D E A L E R .
  • Page 12: Lift And Support Points

    07/11/02 08:59:50 61TA0000_010_0009 Lift and Support Points Floor Jack NOTE: If you are going to remove heavy components such as suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall 1.
  • Page 13: Towing

    07/11/02 08:59:51 61TA0000_010_0010 General Information Towing If the vehicle needs to be towed, call a professional Rear: towing service. Never tow the vehicle behind another *21 vehicle with just a rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a vehicle. Flat-bed Equipment −...
  • Page 14 07/11/02 08:59:55 61TA0000_010_0011 Wheel Lift Equipment − The tow truck uses two pivoting arms that go under the tires (front or rear) and • Improper towing preparation will damage the lifts them off the ground. The other two wheels remain transmission.
  • Page 15: Parts Marking

    07/11/02 08:59:55 61TA0000_010_0012 General Information Parts Marking To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. These labels should not be removed. The original engine or transmission VIN plates are not transferable to the replacement engine or transmission.
  • Page 16 07/11/02 09:02:39 61TA0000_020_0001 Specifications Standards and Service Limits Engine Electrical ........................2-2 Engine Assembly ........................2-2 Cylinder Head ..........................2-3 Engine Block ..........................2-4 Engine Lubrication ......................2-5 Cooling System ............
  • Page 17: Standards And Service Limits

    07/11/02 09:02:39 61TA0000_020_0002 Standards and Service Limits Engine Electrical Item Measurement Qualification Standard or New Service Limit Ignition coil Rated voltage 12 V Firing order 1 3 4 2 − − − Spark plug Type All models NGK: ILZKR78B-11S except PZEV DENSO: SXU22HCR11S PZEV model NGK: DILZKR7A11GS...
  • Page 18: Cylinder Head

    07/11/02 09:02:39 61TA0000_020_0003 Cylinder Head Item Measurement Qualification Standard or New Service Limit ――― Head Warpage 0.05 mm (0.002 in.) Height 103.95 104.05 mm (4.093 4.096 in.) − − ――― Camshaft End play 0.05 0.20 mm (0.002 0.008 in.) − −...
  • Page 19: Engine Block

    07/11/02 09:02:39 61TA0000_020_0004 Standards and Service Limits Engine Block Item Measurement Qualification Standard or New Service Limit Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.) Bore diameter A or I 87.010 87.020 mm (3.4256 3.4260 in.) 87.070 mm (3.4279 in.) −...
  • Page 20: Engine Lubrication

    TRAD 8.1 L (2.14 US gal) reservoir) M/T model: coolant DENSO 6.1 L (1.61 US gal) Use Honda Long Life Antifreeze/ change TRAD 6.0 L (1.59 US gal) Coolant Type 2 A/T model: engine DENSO 8.1 L (2.14 US gal)
  • Page 21: Fuel And Emissions

    07/11/02 09:02:39 61TA0000_020_0006 Standards and Service Limits Fuel and Emissions Item Measurement Qualification Standard or New − − − Fuel pressure Pressure with regulator vacuum hose 333 382 kPa (3.4 3.9 kgf/cm , 48 55 psi) regulator disconnected Fuel tank Capacity 64.7 L (17.1 US gal) Engine idle...
  • Page 22: Manual Transmission And M/T Differential

    Item Measurement Qualification Standard or New Service Limit Manual Capacity Fluid change 1.9 L (2.0 US qt) transmission Use Honda MTF Overhaul 2.0 L (2.1 US qt) fluid Mainshaft End play 0.11 0.17 mm (0.004 0.007 in.) − − Adjust Diameter of bushing contact area 20.80 20.85 mm (0.8189 0.8209 in.)
  • Page 23 07/11/02 09:02:40 61TA0000_020_0008 Standards and Service Limits Manual Transmission and M/T Differential (cont’d) Item Measurement Qualification Standard or New Service Limit − − Reverse idler I.D. 20.016 20.043 mm (0.7880 0.7891 in.) 20.90 mm (0.832 in.) gear Gear-to-reverse gear shaft clearance 0.036 0.084 mm (0.0014 0.0033 in.) −...
  • Page 24: Automatic Transmission And A/T Differential

    Measurement Qualification Standard or New Service Limit Automatic Capacity Fluid change 2.5 L (2.6 US qt) transmission Use Honda ATF-Z1 Overhaul 6.5 L (6.9 US qt) fluid ATF pressure Line pressure At 2,000 rpm in 927 986 kPa − 878 kPa N or P (9.45 10.05 kgf/cm , 134 143 psi)
  • Page 25 07/11/02 09:02:40 61TA0000_020_0010 Standards and Service Limits Automatic Transmission and A/T Differential (cont’d) Item Measurement Qualification Standard or New Service Limit Clutch (cont’d) 1st clutch end-plate thickness Mark 1 2.6 mm (0.102 in.) When discolored Mark 2 2.7 mm (0.106 in.) When discolored Mark 3 2.8 mm (0.110 in.)
  • Page 26 07/11/02 09:02:40 61TA0000_020_0011 Item Measurement Qualification Standard or New Service Limit − − Mainshaft Diameter of needle bearing contact At stator shaft 22.984 23.000 mm (0.905 0.906 in.) When worn or damaged area At 5th gear 51.975 51.991 mm (2.046 2.047 in.) −...
  • Page 27 07/11/02 09:02:41 61TA0000_020_0012 Standards and Service Limits Automatic Transmission and A/T Differential (cont’d) Item Measurement Qualification Standard or New Service Limit − − Secondary shaft Diameter of needle bearing contact At 1st gear 39.986 39.999 mm (1.5742 1.5748 in.) When worn or damaged area At 2nd gear 39.986 39.999 mm (1.5742 1.5748 in.)
  • Page 28 07/11/02 09:02:41 61TA0000_020_0013 Item Measurement Qualification Standard or New Service Limit − − Idler gear shaft Diameter of needle bearing contact End cover side 32.003 32.013 mm (1.2600 1.2604 in.) When worn or damaged area Thickness of cotters 1.39 1.42 mm (0.055 0.056 in.) −...
  • Page 29 07/11/02 09:02:41 61TA0000_020_0014 Standards and Service Limits Automatic Transmission and A/T Differential (cont’d) Item Measurement Qualification Standard or New Wire Diameter O.D. Free Length No. of Coils Regulator valve Stator reaction spring 4.5 mm 35.4 mm 30.3 mm 1.92 body spring (0.177 in.) (1.394 in.) (1.193 in.)
  • Page 30: Steering

    Output pressure with shut-off valve 8,140 8,820 kPa (83 90 kgf/cm , 1,180 1,280 psi) closed Power steering Capacity Reservoir 0.32 L (0.33 US qt) fluid Use Honda Power Steering Fluid capacity System capacity 1.05 L (1.11 US qt) Suspension Item Measurement Qualification...
  • Page 31: Brakes

    07/11/02 09:02:41 61TA0000_020_0016 Standards and Service Limits Brakes Item Measurement Qualification Standard or New Service Limit Parking brake Distance traveled when lever pulled 7 to 9 clicks with 196 N (20 kgf, 44 lbf) of force Brake pedal Pedal height (carpet moved aside) 156 mm (6 1/8 in.) 160 mm (6 5/16 in.) Free play...
  • Page 32: Design Specifications

    07/11/02 09:02:41 61TA0000_020_0017 Design Specifications Item Measurement Qualification Specification DIMENSIONS Overall length 4,930 mm (194.1 in.) (4-door) Overall width 1,847 mm (72.7 in.) Overall height 1,475 mm (58.1 in.) Wheelbase 2,800 mm (110.2 in.) Track Front Equipped with P215/60R16 94H tires: 1,580 mm (62.2 in.) Equipped with P225/50R17 93V tires: 1,590 mm (62.6 in.) Rear Equipped with P215/60R16 94H tires: 1,580 mm (62.2 in.)
  • Page 33: Clutch

    07/11/02 09:02:41 61TA0000_020_0018 Design Specifications Item Measurement Qualification Specification CLUTCH Clutch type Single plate dry, diaphragm spring Clutch friction material 210 cm (32.55 sq in.) surface area MANUAL Type Synchronized, five-speed forward, one reverse TRANSMISSION Primary reduction Direct 1:1 Gear ratio 3.267 1.778 1.154...
  • Page 34: Brakes

    07/11/02 09:02:41 61TA0000_020_0019 Item Measurement Qualification Specification BRAKES Type of service brake Front Power-assisted self-adjusting ventilated disc Rear Power-assisted self-adjusting solid disc Type of parking brake Mechanical actuating, rear wheels Pad friction surface area Front: (NISSIN type) 50.6 cm (7.84 sq in.) x 2 Front: (AKEBONO type) 45.7 cm (7.08 sq in.) x 2 Rear...
  • Page 35: Electrical Ratings

    07/11/02 09:02:42 61TA0000_020_0020 Design Specifications Item Measurement Qualification Specification − − ELECTRICAL Battery All models except PZEV 12 V 47 Ah/20 HR (12 V 38 Ah/5 HR) RATINGS PZEV 12 V 65 Ah/20 HR (12 V 52 Ah/5 HR) − −...
  • Page 36: Body Specifications

    07/11/02 09:02:46 61TA0000_020_0021 Body Specifications 4-door: *01 1,580 mm (62.2 in.) 1,590 mm (62.6 in.) 1,847 mm (72.7 in.) 1,580 mm (62.2 in.) 2,800 mm (110.2 in.) 1,590 mm (62.6 in.) 4,930 mm (194.1 in.) *1: Equipped with P215/60R16 94H tires *2: Equipped with P225/50R16 93V tires (cont’d) 2-21...
  • Page 37 07/11/02 09:02:46 61TA0000_020_0022 Design Specifications Body Specifications (cont’d) 2-door: *01 1,580 mm (62.2 in.) 1,848 mm (72.7 in.) 2,740 mm (107.9 in.) 1,580 mm (62.2 in.) 4,849 mm (190.9 in.) 2-22 TA08ABA000000000000NCAT00...
  • Page 38 07/11/02 09:03:48 61TA0000_030_0001 Maintenance Lubricants and Fluids ................3-2 Maintenance Minder General Information ......................3-4 Maintenance Main Items ..................3-7 Maintenance Sub Items .................... . 3-8 TA08AE40000000J0301ZCAT00...
  • Page 39 Brake system (including VSA lines) Honda DOT 3 Brake fluid: P/N 08798-9008 Clutch system (manual transmission) Always use Honda DOT 3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. Shift lever (manual transmission)
  • Page 40 07/11/02 09:03:49 61TA0000_030_0003 NOTE: • Lubricate the following areas using the recommended lubricants and fluids. • In corrosive areas, more frequent lubrication is necessary. *31...
  • Page 41 07/11/02 09:03:49 61TA0000_030_0004 Maintenance Minder General Information Maintenance Display The maintenance minder is an important feature of the information display. Based on engine and transmission operating conditions, the Accord’s onboard computer (ECM/PCM) calculates the remaining engine oil and the transmission fluid life. The system also displays the remaining engine oil life along with the codes for other scheduled maintenance items needing service.
  • Page 42 07/11/02 09:03:50 61TA0000_030_0005 Service Information 3. When the remaining engine oil life is 1 % to 5 %, the maintenance message ‘‘SERVICE’’ (A) appears 1. The remaining engine oil life on the engine oil life along with the same maintenance item code(s), indicator (A) is displayed as a percentage on the when the ignition switch is ON (II).
  • Page 43 07/11/02 09:03:50 61TA0000_030_0006 Maintenance Minder General Information (cont’d) Resetting the Maintenance Information 5. If the indicated maintenance is not done, the engine Display oil life indicator shows a negative mileage, for − example ‘‘ 10’’ blinking on the display. A negative mileage will display after the vehicle is driven 10 NOTE: miles (for USA models) or 10 km (for Canada...
  • Page 44 NOTE: According to state and federal regulations, failure to do the maintenance items marked with an asterisk ( ) will not void the customer’s emissions warranties. However, Honda recommends that all maintenance services be done at the recommended interval, to ensure long-term reliability.
  • Page 45 Capacity (including reservoir): M/T 6.1 L (1.61 US gal) (DENSO) or 6.0 L (1.59 US gal) (TRAD), A/T 6.0 L (1.59 US gal) (DENSO) or 5.9 L (1.56 US gal) (TRAD); use Honda Long Life Antifreeze/ Coolant Type 2, and add Honda Coolant Concenrate in severe cold temperatures.
  • Page 46 07/11/02 09:03:50 61TA0000_030_0009 TA08AE40000000J0301ZAAT00...
  • Page 47 • To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal or side collision, all SRS service work should be done by an authorized Honda dealer. • Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment of the airbags, side airbags, and/or side curtain airbags.
  • Page 48 07/11/02 09:04:46 61TA0000_040_0002 Engine Electrical Engine Electrical Special Tools ............4-2 Alternator Control Circuit Troubleshooting .... . 4-29 Starting System Drive Belt Inspection ......4-31 Component Location Index . 4-3 Drive Belt Removal/ Symptom Troubleshooting Installation ......
  • Page 49: Special Tools

    07/11/02 09:04:46 61TA0000_040_0003 Engine Electrical Special Tools Ref. No. Tool Number Description 07746-0010300 Attachment, 42 x 47 mm 07749-0010000 Handle Driver 01 01 TA08AE40000000J0401PAAT00...
  • Page 50: Component Location Index

    07/11/02 09:04:49 61TA0000_040_0004 Starting System Component Location Index *01 STARTER CUT RELAY Test, page 22-91 DRIVER’S UNDER-DASH FUSE/RELAY BOX CLUTCH INTERLOCK SWITCH (M/T model) Test, page 4-9 *09 BATTERY Test, page 22-88 STARTER TRANSMISSION RANGE SWITCH Starter System Circuit Troubleshooting, page 4-7 (A/T model) Performance Test, page 4-10 Test, page 14-289...
  • Page 51: Symptom Troubleshooting Index

    PZEV model (see page 6-56) Check for a damaged or broken cam chain. Do the engine control module (ECM)/powertrain control module (PCM) reset function with the Honda Diagnostic System (HDS) to cancel the ALL INJECTORS STOP function. Engine is hard to start Check for PGM-FI DTCs (see page 11-3).
  • Page 52: Circuit Diagram

    07/11/02 09:04:49 61TA0000_040_0006 Circuit Diagram M/T model *01 UNDER-HOOD FUSE/RELAY BOX IGNITION SWITCH BATTERY No. 1 (100 A) No. 3 (50 A) ST HOT in START (III) DRIVER’S STARTER UNDER-DASH FUSE/RELAY RELAY BLK/WHT BLK/YEL CLUTCH INTERLOCK SWITCH ON: Pedal pressed STARTER G302 TA08AEAA46500000000EAAT00...
  • Page 53 07/11/02 09:04:49 61TA0000_040_0007 Starting System Circuit Diagram (cont’d) A/T model *01 UNDER-HOOD FUSE/RELAY BOX IGNITION SWITCH BATTERY No. 1 (100 A) No. 3 (50 A) ST HOT in START (III) DRIVER’S STARTER UNDER-DASH FUSE/RELAY RELAY LT GRN BLK/WHT BLK/YEL C101 BLU/WHT TRANSMISSION RANGE...
  • Page 54: Starter System Circuit Troubleshooting

    07/11/02 09:04:50 61TA0000_040_0008 Starter System Circuit Troubleshooting Special Tools Required 3. Connect the Honda Diagnostic System (HDS) to the Alternator, Regulator, Battery & Starter tester OTC3131 data link connector (DLC) (see step 2 on page 11-3). Available through the Honda Tool and Equipment Program 1-888-424-6857 4.
  • Page 55 07/11/02 09:04:50 61TA0000_040_0009 Starting System Starter System Circuit Troubleshooting (cont’d) 10. Make sure the shift lever is in N or P (A/T model) or 12. Connect the alternator, the regulator, the battery & neutral (M/T model), then disconnect the starter starter tester (OTC 3131) to the battery.
  • Page 56: Clutch Interlock Switch Test

    07/11/02 09:04:50 61TA0000_040_0010 Clutch Interlock Switch Test M/T model 1. Disconnect the clutch interlock switch 2P connector (A). *01 Terminal side of male terminals 2. Remove the clutch interlock switch (B). 3. Check for continuity between the terminals according to the table. •...
  • Page 57: Starter Performance Test

    07/11/02 09:04:51 61TA0000_040_0011 Starting System Starter Performance Test 1. Remove the starter (see page 4-11). 5. Clamp the starter firmly in a vise. 2. Connect a fully charged battery to the starter for 6. Connect the starter to the battery as shown, and this test using the thickest (gauge) wire possible confirm that the motor starts and keeps rotating.
  • Page 58: Starter Removal And Installation

    07/11/02 09:04:51 61TA0000_040_0012 Starter Removal and Installation Removal Installation 1. Do the battery removal procedure (see page 22-90). 1. Install the starter, then tighten the two bolts. *03 2. Remove the intake manifold (see page 9-3). 3. Disconnect the starter cable (A) from the B terminal, and disconnect the BLK/WHT wire (B) from the solenoid S terminal.
  • Page 59 07/11/02 09:04:51 61TA0000_040_0013 Starting System Starter Removal and Installation (cont’d) 4. Install the intake manifold (see page 9-5). 5. Do the battery installation procedure (see page 22-90). 6. Start the engine to make sure the starter works properly. 4-12...
  • Page 60: Starter Overhaul

    07/11/02 09:04:52 61TA0000_040_0014 Starter Overhaul Disassembly/Reassembly *01 RING GEAR HOLDER SWITCH PLUNGER GEAR PLUNGER GEAR COVER ASSEMBLY PUSH NUT CONTACT SPRING SWITCH SHAFT MOVING CONTACT BRUSH HOLDER ASSEMBLY BRUSH SPRING END COVER DRIVE PLATE PLANETARY GEARS Apply molybdenum disulfide. ARMATURE HOUSING ARMATURE Apply molybdenum disulfide.
  • Page 61 07/11/02 09:04:52 61TA0000_040_0015 Starting System Starter Overhaul (cont’d) Armature Inspection and Test 5. Check the commutator diameter. If the diameter is below the service limit, replace the armature. 1. Remove the starter (see page 4-11). Commutator Diameter 2. Disassemble the starter as shown at the beginning Standard (New): 28.0 28.1 mm (1.102 1.106 in.) −...
  • Page 62 07/11/02 09:04:53 61TA0000_040_0016 7. Check the mica depth (A). If the mica is too high (B), 9. Place the armature (A) on an armature tester (B). undercut the mica with a hacksaw blade to the Hold a hacksaw blade (C) on the armature core. If proper depth.
  • Page 63 07/11/02 09:04:53 61TA0000_040_0017 Starting System Starter Overhaul (cont’d) Starter Brush Inspection Planetary Gear Inspection 11. Measure the brush length. If it is shorter than the 13. Check the planetary gears (A) and internal ring gear service limit, replace the brush holder assembly. (B).
  • Page 64 07/11/02 09:04:54 61TA0000_040_0018 Overrunning Clutch Inspection Starter Reassembly 14. While holding the drive gear (A), turn the gear 17. Install the brush into the brush holder, and set the shaft (B) counterclockwise. Check that the drive armature (A) in the brush holder (B). gear comes out to the other end.
  • Page 65: Ignition System