Acura NSX 1991 Manual

page of 1640

/ 1640
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

General Info

Specifications

Maintenance

Engine

Cooling

Fuel and Emissions

'91−'92 Models

'93−'94 Models

'95−'96 Models

*Transaxle

Steering

'91−'94 Models

'95−'96 Models

1991-96 NSX Main Menu

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

Need help?

Do you have a question about the NSX 1991 and is the answer not in the manual?

Questions and answers

Summary of Contents for Acura NSX 1991

Page 1 1991-96 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 ’91−’92 Models ’93−’94 Models ’95−’96 Models *SRS *Transaxle Steering As sections w/ * include SRS components, ’91−’94 Models special precautions are required when servicing.
Page 2 Main Menu Table of Contents Chassis and Paint Codes U.S.Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 3 Table of Contents Main Menu CANADA Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 4 Table of Contents Main Menu Identification Number Locations VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER NUMBER ENGINE NUMBER AUTOMATIC TRANSMISSION MANUAL TRANSMISSION NUMBER NUMBER...
Page 5 Table of Contents Main Menu Warning/Caution Label Locations SRS CAUTION LABELS: Refer to page FROZEN BATTERY CAUTION ABS CAUTION BATTERY CAUTION RADIATOR BLEED PLUG CAUTION ABS and BRAKE FLUID CAUTION AIR CONDITIONING R-134a CAUTION (U.S.A. only) RETRACTABLE HEADLIGHT CAUTION EXPANSION TANK CAP CAUTION EMISSION CONTROL...
Page 6 Table of Contents Main Menu Warning/Caution Label Locations A: CABLE REEL CAUTION D: DRIVER'S INFLATOR CAUTION A DANGER [SRS] EXPLOSIVE/FLAMMABLE REFER TO SERVICE MANUAL FOR DETAILED IN- CONTACT WITH ACID, WATER OR HEAVY METALS STRUCTIONS. SUCH AS COPPER, LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.
Page 7 Table of Contents Main Menu G: MONITOR NOTICE E: DRIVER INFORMATION: U.S. MODEL NOTICE CAUTION • NO SERVICEABLE PARTS INSIDE. TO AVOID SERIOUS INJURY: • FOR MAXIMUM SAFETY PROTECTION IN ALL TYPES OF • REFER TO SERVICE MANUAL FOR DETAILED IN- STRUCTIONS.
Page 8 Main Menu Table of Contents Warning/Caution Label Locations L: TENSIONER ELR CAUTION J: PASSENGER'S INFLATOR CAUTION DANGER WARNING EXPLOSIVE MATERIAL INSIDE EXPLOSIVE/FLAMMABLE YOU CAN BE SERIOUSLY HURT OR BURNED. CONTACT WITH ACID, WATER OR HEAVY METALS SUCH • INSTALL RED SHORT CONNECTOR WHEN WIRE HAR AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM- NESS IS DISCONNECTED.
Page 9 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 car. Use the floor jack procedures to raise the car (page 1-10). —...
Page 10 Table of Contents Main Menu Lift and Support Points Floor Jack CAUTION: Place a rubber pad between the lift platform and the center support point to avoid damaging the car. The lift platform must contact the support point only; it must not come in contact with any other part of the car. 1.
Page 11 Main Menu Table of Contents Towing If the car needs to be towed, call a professional towing Front: service. Never tow the car behind another car with just a rope or chain. It is very dangerous. TOWING HOOK There are three widely used methods of towing a car: Flat-bed Equipment —The operator loads the car on the back of a truck.
Page 12 Main Menu Table of Contents Standards and Service Limit Cylinder Head/Valve Train — Section 6...
Page 13 Main Menu Table of Contents Engine Block — Section 7 Engine Lubrication — Section 8 Cooling — Section 10 M/T: Manual Transmission A / T : Automatic Transmission...
Page 14 Table of Contents Main Menu Standards and Service Limits Manual Transmission — Section 13...
Page 15 Table of Contents Main Menu Manual Transmission — Section 13...
Page 16 Table of Contents Main Menu Standards and Service Limits Automatic Transmission — Section 14 " Clutch end plate diameter: 1st: 116 mm (4.57 in) 1st-hold, 2nd, 3rd and 4th: 120 mm (4.72 in)
Page 17 Table of Contents Main Menu Automatic Transmission — Section 14...
Page 18 Table of Contents Table of Contents Main Menu Main Menu Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 19 Table of Contents Table of Contents Main Menu Main Menu Automatic Transmission — Section 14...
Page 20 Main Menu Table of Contents Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 21 Table of Contents Main Menu Standards and Service Limits Steering — Section 17 Suspension — Section 18 Brakes - Section 19 M/T: Manual Transmission A/T: Automatic Transmission...
Page 22 Main Menu Table of Contents Air Conditioning — Section 22 Electrical - Section 23 * 1: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt values. *2: Do not adjust the gap, replace spark plug if it is out of spec.
Page 23 Main Menu Table of Contents Design Specifications...
Page 24 Main Menu Table of Contents...
Page 25 Table of Contents Main Menu Design Specification...
Page 26 Table of Contents Main Menu Body Specifications...
Page 27 Table of Contents Main Menu 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. *1: If Honda MTF is not available, you may use an API service SG or SH-rated motor oil with a viscosity of SAE 10 W-30 or 10 W-40 temporarily.
Page 28 Table of Contents Main Menu...
Page 29 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, 10-5 11-149 23-96 6-15, 10-11 23-109 11-138 11-128 10-6 13-2a 14-105 19-6, 19-9 19-17, 19-19 19-10...
Page 30 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk ( * ) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 31 Main Menu Table of Contents Follow the Severe Conditions Maintenance Schedule if the car is driven MAINLY under one or more of the Severe Driving Conditions (pages 4 - 7 8-4, 8-4, 10-5 11-149 23-96 6-15, 10-11 23-109 11-128 10-6 13-2a 14-105 19-6, 19-9...
Page 32 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk ( * ) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 33 Table of Contents Main Menu Maintenance Transmission Oil NOTE: Check the oil at normal operating temperature (the cooling fan comes on), engine OFF, and the car on level ground. Remove the oil filler plug, then check the level and condition of the oil. WASHER Proper Level Replace.
Page 34 Main Menu Table of Contents Chassis and Paint Codes U.S.Model Vehicle Identification Number Transmission Number Paint Code Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 35 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 36 Main Menu Table of Contents Identification Number Locations VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER NUMBER ENGINE NUMBER AUTOMATIC TRANSMISSION MANUAL TRANSMISSION NUMBER NUMBER...
Page 37 Main Menu Table of Contents Warning/Caution Label Locations SRS CAUTION LABELS: Refer to page TIRE INFORMATION...
Page 38 Main Menu Table of Contents Warning/Caution Label Locations A: CABLE REEL CAUTION D: DRIVER'S INFLATOR CAUTION DANGER EXPLOSIVE/FLAMMABLE REFER TO SERVICE MANUAL FOR DETAILED IN- CONTACT WITH ACID, WATER OR HEAVY METALS STRUCTIONS. SUCH AS COPPER, LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.
Page 39 Main Menu Table of Contents G: MONITOR NOTICE E: DRIVER INFORMATION: U.S. MODEL NOTICE CAUTION NO SERVICEABLE PARTS INSIDE. TO AVOID SERIOUS INJURY: REFER TO SERVICE MANUAL FOR DETAILED IN- FOR MAXIMUM SAFETY PROTECTION IN ALL TYPES OF STRUCTIONS. CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY BELT.
Page 40 Main Menu Table of Contents Warning/Caution Label Locations L: TENSIONER ELR CAUTION J: PASSENGER'S INFLATOR CAUTION DANGER WARNING EXPLOSIVE MATERIAL INSIDE EXPLOSIVE/FLAMMABLE YOU CAN BE SERIOUSLY HURT OR BURNED. CONTACT WITH ACID, WATER OR HEAVY METALS SUCH AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM- •...
Page 41 Main Menu Table of Contents Lift and Support Points Lift CAUTION: If ground clearance is inadequate to clear the shop lift, either: — Install rubber spacers on the coil springs to raise the car. Use the floor jack procedures to raise the car (page 1-10). —...
Page 42 Main Menu Table of Contents Lift and Support Points (cont'd) Floor Jack CAUTION: Place a rubber pad between the lift platform and the center support point to avoid damaging the car. The lift platform must contact the support point only; it must not come in contact with any other part of the car. Set the parking brake, and block the wheels that are CENTER not being lifted.
Page 43 Main Menu Table of Contents Safety Stands CAUTION: Place a rubber pad between the safety stand platforms and the car's front and rear support points to avoid damaging the car. The safety stand platforms must contact the car's support points only; they must not come in contact with any other part of the car.
Page 44 Main Menu Table of Contents Towing If the car needs to be towed, call a professional towing Front: service. Never tow the car behind another car with just a rope or chain. It is very dangerous. TOWING HOOK There are three widely used methods of towing a car: Flat-bed Equipment—The operator loads the car on the back of a truck.
Page 45 16" in, diameter and the rear wheels aluminum alloys, use only the special "Dacro" type are 17" in, so they cannot be rotated front-to-rear. nuts and bolts recommended by Acura. The original-equipment tires on NSX & NSX-T have NOTE: a unidirectional tread pattern, so they cannot be ro- Dacro finish can be identified by gray plating.
Page 46 Main Menu Table of Contents Standards and Service Limit Cylinder Head/Valve Train — Sections 6 * 1 : NIHON HATSUJO made, *2: CHUO HATSUJO made. M/T: Manual Transmission A/T: Automatic Transmission *3: Measured between the rocker arm and camshaft.
Page 47 Main Menu Table of Contents Engine Block — Section 7...
Page 48 Main Menu Table of Contents Standards and Service Limits Engine Lubrication — Section 8 Cooling — Section 10 M/T: Manual Transmission A/T: Automatic Transmission...
Page 49 Main Menu Table of Contents Fuel and Emission — Section 11 Clutch — Section 12...
Page 50 Main Menu Table of Contents Standards and Service Limits Manual Transmission — Section 13...
Page 51 Main Menu Table of Contents Manual Transmission — Section 13...
Page 52 Main Menu Table of Contents Standards and Service Limits Automatic Transmission — Section 14 * Clutch end plate diameter: 1st: 116 mm (4.57 in) 1st-hold, 2nd, 3rd and 4th: 120 mm (4.72 in)
Page 53 Main Menu Table of Contents Automatic Transmission (cont'd) — Section 14...
Page 54 Main Menu Table of Contents Standards and Service Limits Automatic Transmission (cont'd) — Section 14...
Page 55 Main Menu Table of Contents Automatic Transmission — Section 14...
Page 56 Main Menu Table of Contents Differential (Manual Transmission) — Section 15 Differential (Automatic Transmission) — Section 15...
Page 57 Main Menu Table of Contents Standards and Service Limits Steering — Section 17 Suspension — Section 18 Brakes — Section 19 M/T: Manual Transmission A/T: Automatic Transmission...
Page 58 Main Menu Table of Contents Air Conditioning — Section 22 Electrical — Section 23 *1: When using a new belt, adjust deflection or tension to new values. Run the engine for 5 minutes then turn it off. Readjust deflection or tension to used belt values. *2: Do not adjust the gap, replace spark plug if it is out of spec.
Page 59 Main Menu Table of Contents Design Specifications...
Page 60 Main Menu Table of Contents...
Page 61 Main Menu Table of Contents Design Specification...
Page 62 Main Menu Table of Contents Body Specifications...
Page 63 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 64 Main Menu Table of Contents...
Page 65 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. SECTION PAGE 8-4. ('91-92), ('92), or ('94-'96) 8-4, 10-5 ('91-92), ('92), or ('94-'96) 11-149 ('91-'93), or...
Page 66 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 67 Main Menu Table of Contents Follow the Severe Conditions Maintenance Schedule if the car is driven MAINLY under one or more of the Severe Driving Conditions (pages 4-7:) SECTION PAGE 8-4 ('91-'92), ('93), or ('94-'96), 8-4 ('91-92), ('93), or ('94-'96), 10-5 11-149 11-149...
Page 68 According to state and federal regulations, failure to perform maintenance on the items marked with an asterisk (*) will not void customer's emission warranties. However, Acura recommends that all maintenance services be performed at the recommended time or mileage period to ensure long-term reliability.
Page 69 Main Menu Table of Contents Special Tools Description Page Reference Ref. No. Tool Number Engine Removal/Installation Fixture 07MAK – PR7020A 5-9 ('91-'93 Models) ('94-'96 Models) 07MAZ – SL0000A NSX Fender Cover 5-3 ('91-'93 Models) ('94-'96 Models)
Page 70 Main Menu Table of Contents Engine Removal/Installation Removal Remove the strut brace. Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct posi- COUPE: STRUT BRACE tions on the engine (see section 8 x 1.25 mm •...
Page 71 Main Menu Table of Contents Engine Removal/Installation Removal Disconnect the fan motor connector, then remove Disconnect the spark plug voltage detection module the engine room fan assembly. connectors, ground cable and engine wire harness clamps. ENGINE ROOM SPARK PLUG VOLTAGE DETECTION MODULE CONNECTORS GROUND...
Page 72 Main Menu Table of Contents 9. Relieve fuel pressure by loosening the service bolt 13. Remove the expansion tank cap. on the fuel filter about one turn (see section 11). 14. Raise the hoist to full height. Do not smoke while working on the fuel s y s t e m .
Page 73 Main Menu Table of Contents Engine Removal/Installation Removal 20. Disconnect the engine wire harness connectors. 23. Disconnect the two connectors from the emission control box, then remove the control box. 21. Remove the battery cable from the main fuse box. •...
Page 74 Main Menu Table of Contents 25. Loosen the idler pulley center nut and adjusting nut, 27. Raise the hoist to full height. then remove the air conditioning (A/C) compressor belt. 28. Remove the slave cylinder (M/T see section 12). • Do not disconnect the clutch hose. ADJUSTING 29.
Page 75 Main Menu Table of Contents Engine Removal/Installation Removal 32. Remove the left and right parking brake cables (see 35. Remove the A/C compressor (see section 22), then section 19). suspend it from the body. 33. Remove the rear beam rod assembly and parking NOTE: brake cable clamps.
Page 76 Main Menu Table of Contents 39. Remove the right wheel sensor wire clamps and 42. Position the special tool under the car. Lower the car stabilizer link. just above the fixture. With the help of an assistant, attach the fixture to the subframe with two 12 mm nuts and two 10 mm bolts.
Page 77 Main Menu Table of Contents Engine Removal/Installation Removal 46. Remove the transmission mounting bolt. NOTE: Perform steps 51 thru 54 only if the engine assembly is to be removed from the subframe. MOUNTING BOLT 51. Remove the adjusting bolt and flange bolt, then separate the lower control arm from the subframe (see section...
Page 78 Main Menu Table of Contents Engine Removal/Installation Installation Additional Torque Value Specifications: NOTE: For manifold replacement, refer to section...
Page 79 Main Menu Table of Contents Engine Removal/Installation Installation 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 follow these procedures may cause excessive noise and NOTE: Align the bolt holes of the beam brackets vibration, and reduce bushing life.
Page 80 Main Menu Table of Contents Tighten the rear mount mounting bolt. Install the side engine mount, then tighten the bolts in the numbered sequence as shown ( 1.25 mm 95 N·m (9.5 kg-m, 69 Ib-ft) 12 x 1.26 mm 73 N·m (7.3 kg-m, 53 Ib-ft) Replace.
Page 81 Main Menu Table of Contents Special Tools Tool Number Description Ref. No. Page Reference 07HAH—-PJ7010B 6-41 ('91-'93) Valve Guide Reamer, 5.5 mm ('94-'96 Models). 07JAA—001020A Socket, 19 mm 6-12 ('91-'93) ('94-'96 Models). Holder Handle 07JAB—001020A 6-12 ('91-'93) ('94-'96 Models). 07MAA—PR70110 Tappet Adjuster 6-10 ('91-'93) ('94-'96...
Page 82 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 Measure resistance between the BLU/YEL (front/rear) oil pressure.
Page 83 Main Menu Table of Contents Manual Inspection Rocker Arms Rocker Arms Inspection Using Special Tools Remove the ignition coil covers (see page 6-15 ('91-'93) CAUTION: ('94-'96) Before using the special tool, make sure that the air pressure gauge on the air compressor indicates over 2.
Page 84 Main Menu Table of Contents Valve Clearance Adjustment NOTE: 2. 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 Adjustment is the same for both intake and exhaust cover, and TDC grooves on the camshaft pulleys...
Page 85 Main Menu Table of Contents Valve Clearance Adjustment (cont'd) Tighten the locknut and check the clearance again. Manually inspect the rocket arms for independent Repeat adjustment if necessary. operation (see page 6-7, ('94-'96), 6-36, ('91-'93). Adjust valves on No.1 cylinder. INTAKE: •...
Page 86 Table of Contents Main Menu 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 87 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 DRIVE PULLEY CRANKSHAFT WASHER PULLEY BOLT...
Page 88 Main Menu Table of Contents Timing Belt Illustrated Index NOTE: Refer to page 6-18 ('91-'93) ('94-'96) 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. Do not use the middle cover and lower cover for storing removed items.
Page 89 Main Menu Table of Contents Timing Belt Inspection Tension Adjustment CAUTION: Always adjust timing belt tension with the engine cold 1. Remove the ignition coil covers and harness clamps. Do not rotate the crankshaft when the adjusting bolt 2. Disconnect the connectors, then remove the ignition is loose (the timing belt will skid over the teeth of coils.
Page 90 Main Menu Table of Contents 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. 8 piston is at top dead center (TDC) (see Remove the ignition coils and the connectors.
Page 91 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 ('91-'93) ('94-'96) transmission mount ing (see page 6-25 ('91-'93) ('94-'96) 13. Install a brace under the engine, then tilt the engine 8.
Page 92 Table of Contents Main Menu 1 8 . Loosen the adjusting boll 180 turn. Push the ten- 15. Loosen the idler pulley center nut and adjusting nut, then remove the air conditioning (A/C) compressor sioner to remove tension from the timing belt, then re tighten the adjusting bolt.
Page 93 Table of Contents Main Menu Timing Belt Installation Install the timing belt in the reverse order of removal; Set the rear camshaft pulleys so that the No. 1 pis- Only key points are described here. ton is at TDC. Align the TDC mark on the rear intake camshaft pulley to the pointer on the back cover.
Page 94 Main Menu Table of Contents 6. Adjust the timing belt (see page 6-14 ('91-'93) or ('94-'96)) 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 ('91-'93) ('94-'96)
Page 95 Main Menu Table of Contents CKP/CYP Sensor Replacement NOTE: Turn the crankshaft so fhat the No. 1 piston is at Install the CKP/CYP sensor in the reverse order of removal. top dead center (see page 6-19 ('91-'93) or ('94-'96)) Refer to page 6-18 ('91-'93) ('94-'96) when...
Page 96 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 6 x 1.0 mm...
Page 97 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 (39-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 RECIRCULATI0N (EGR) VALVE REAR VARIABLE VALVE TIMING...
Page 98 Table of Contents Main Menu INTAKE VALVE VALVE KEEPERS SPRING OUTER SPRING RETAINER INTAKE VALVE CYLINDER HEAD BOLTS SPRING INNER 11 x 1.5m 78N-m (7.8 kg-m, 56 Ib-ft) VALVE SPRING CYLINDER HEAD BOLT Apply engine oil to SEAT 11 x 1.5 mm VALVE SEAL the bolt threads.
Page 99 Main Menu Table of Contents Cylinder Heads Removal Engine removal is not required for this procedure. Remove the engine under guard, then remove the front exhaust pipe A. Make sure jacks and safety stands are placed properly and hoist brackets ere attached to cor- GASKETS rect positions on the engine.
Page 100 Main Menu Table of Contents 10. Remove the engine cover stay from the strut brace, 15. Remove the Hoses, then remove the expansion tank then set the engine cover stay between the engine (see page 5-5 ('91-'93) or ('94-'96). cover and rear hatch latch (NSX-T open top), 16.
Page 101 Table of Contents Main Menu Cylinder Heads Removal 20. Remove the breather hose and water bypass hoses. 22. Remove the positive Crankcase ventilation (PCV) hose, vacuum hose and harness clamp. BREATHER HOSE 6 x 1.0 mm 10 N-m (1.0 kg-m, 7 Ib-ft) PCV HOSE WATER BYPASS HOSES...
Page 102 Main Menu Table of Contents 24. Remove the engine wire harness connectors and 27. Loosen the adjusting nut and idler pulley center nut, then remove the air conditioning compressor belt wire harness clamps from the cylinder head and (see page 6-17('91-'9 3) or ('94-'96)).
Page 103 Main Menu Table of Contents Cylinder Heads Removal (cont'd) Remove water passage. 32. Remove the alternator bracket stiffener (see page 6-16 ('91-'93) or ('94-'96). 33. Remove the alternator bracket. 8 x 1.25 mm 22 N·m (2.2 kg-m, 16 Ib-ft) 10 x 1,25 mm 45N·m (4.5 kg-m, 33 Ib-ft) 0-RINGS...
Page 104 Table of Contents Main Menu 36. Remove the front and rear back covers. 39. Remove the cylinder head bolts, then remove the cylinder head. CAUTION: To prevent warpage, unscrew the bolts REAR BACK in sequence 1/3 turn at a time; repeat the sequence COVER until all bolts are loosened.
Page 105 Main Menu Table of Contents 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 orifice, then pull out the rocker shaft oil control ori- them together as sets.
Page 106 Main Menu Table of Contents Locations 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: Identify parts as they are removed to ensure reinstallation in priginal locations.
Page 107 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 108 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 109 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. Zero the dial indicator against the left end, then push Put the camshafts, the camshaft holders and holder the camshaft back and forth, and read the end play.
Page 110 Main Menu Table of Contents If camshaft-to-holder oil clearance is out of tolerance: — And camshaft has already been replaced, you must replace the cylinder head. — If camshaft has not been replaced, first check to- tal runout with the camshaft supported on V- blocks.
Page 111 Main Menu Table of Contents Valves, Valve Springs and Valve Seals Replacement Install the special tool as shown. NOTE: Identify valves and valve springs as they are re- moved so that each item can be reinstalled in its original position. VALVE GUIDE SEAL REMOVER VALVE SEAL Using an appropriate-sized socket and plastic mallet,...
Page 112 Main Menu Table of Contents...
Page 113 Main Menu Table of Contents Cylinder Heads Warpage NOTE: If camshaft-to-holder oil clearances (see page 6-34) 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 114 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 seating: Apply Prussian Blue compound to the valve valve seat grinder. 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 6-39), replace al times.
Page 115 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 116 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) towards the combustion chamber.
Page 117 Main Menu Table of Contents Apply a thin film of clean engine oil to the outside of the new valve guides, and install them from the camshaft side of the cylinder head. Drive each guide to the specified height (measured from the top of the valve guide to the cylinder casting as shown).
Page 118 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 119 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 OUTER SPRING VALVE SPRING INNER EXHAUST VALVE SEAL SPRING (BLACK SPRING) (M/T only) Replace.
Page 120 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 121 Main Menu Table of Contents Cylinder Heads Installation Rear: Tighten the cylinder head bolts sequentially in two REAR PRIMARY or three steps. HO2S 8 x 1.25 mm • Apply clean engine oil to the bolt threads and 45 N-m (4.5 kg-m, 22 N-m (2.2 kg-m, washer contact surfaces.
Page 122 Table of Contents Main Menu 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 123 Main Menu Table of Contents Camshafts Installation 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 - Apply liquid gasket to the shaded areas.
Page 124 Main Menu Table of Contents 11. Insert the dowel pins in the camshaft pulley. 9. Install the CKP/CYP sensor on the front cylinder head. 12. Install the camshaft pulleys, then tighten the retain- ing bolts to the torque specified. CKP/CYP SENSOR CAMSHAFT PULLEYS RETAINING BOLTS 1.25 mm...
Page 125 Main Menu Table of Contents Camshafts Installation 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 kg-m, 9 Ib-ft).
Page 126 Main Menu Table of Contents Special Tools 7-18 7-18...
Page 127 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 If the bottom of the oil pan is deformed, it should left side cover and oil pump case before install- be repaired or the oil pan should be replaced re- ing them.
Page 128 Main Menu Table of Contents Engine Block Illustrated Index Lubricate all internal parts with engine oil during reassembly. 11 x 1.5 mm 66 N-m (6.6 kg-m, 48 Ib-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 129 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 130 Main Menu Table of Contents Connecting Rods and Flywheel and Drive Plate Crankshaft 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 131 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 132 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 133 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 134 Main Menu Table of Contents Piston/Connecting Rod Assemblies and Crankshaft Removal • 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 135 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 136 Main Menu Table of Contents Cylinder Block Inspection Check the top of the block for warpage. Measure wear and taper in directions X and Y at three levels in each cylinder as shown. Measure along the edges and across the center as shown.
Page 137 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 138 Main Menu Table of Contents Piston/Connecting Rod Assemblies Inspection Calculate the difference between cylinder bore diam- eter on page 7-12 and piston diameter. Piston-to-Block Clearance Standard (New): 0.006—0.034 mm (0.0002-0.0014 in) Service Limit: 0.0825 mm (0.0032 in) 0.0825 mm (0.0032 in) Oversize Piston Diameter 0.25: 90.226-90.244 mm (3.5522-3.5530 in) 0.50: 90.476-90.494 mm (3.5620-3.5627 in)
Page 139 Main Menu Table of Contents Connecting Rods Selection Each rod is sorted into one of four tolerance ranges (from 0 to 0.024 mm, in 0.006 mm increments) depen- ding on the size of its big end bore. It's then stamped with a number (1, 2, 3 or 4) indicating that tolerance.
Page 140 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.
Page 141 Main Menu Table of Contents Piston Rings Ring-to-Groove Clearances Alignment After installing a new set of rings, measure ring-to-groove Install the rings as shown on page 7-15. clearances: Identify top and second rings by the chamfer on the Top and Second Ring Clearance edge, and make sure they are in the proper grooves Standard (New): 0.030-0.055 mm in the piston.
Page 142 Main Menu Table of Contents Piston/Connecting Rod Assemblies Installation Before installing the piston, apply a coat of If the crankshaft is not installed: engine oil to the ring grooves and cylinder • Remove the rod caps and bearings, install the bores.
Page 143 Main Menu Table of Contents Crankshaft Installation Before installing the crankshaft, apply a coat of engine oil to the main bearings and bearings. Insert bearing halves in the engine block and con- necting rods. Lower the crankshaft into the block. Install the thrust washers on the No.
Page 144 Main Menu Table of Contents NOTE: Check the rod bearing clearance with plastigage • Guide the piston carefully to prevent damage. (see page 7-7), then torque the connecting rod cap • Fit long rubber hoses (about 30 cm long) to con- nuts.
Page 145 Main Menu Table of Contents Crankshaft Installation BEARING CAP BOLTS TORQUE SEQUENCE BEARING CAP BRIDGE CAP BRIDGE BOLT 11 x 1.5 mm 66 N-m (6.6 kg-m, 48 Ib-ft) SIDE BOLT 10 x 1.25 mm 50 N-m (5.0 kg-m, CAP BOLT 36 Ib-ft) 9 x 1.25 mm 40 N-m (4.0 kg-m,...
Page 146 Main Menu Table of Contents OIL PUMP SIDE: 6 x 1.0 mm 12 N-m (1.2 kg-m, 9 Ib-ft) OIL SCREEN BAFFLE PLATE 6 x 1.0 mm 12 N-m (1.2 kg-m, 9 Ib-ft) LEFT SIDE COVER Apply liquid gasket along the broken line. OIL PASS PIPE SPECIAL BOLTS...
Page 147 Main Menu Table of Contents Special Tools...
Page 148 Main Menu Table of Contents Engine Lubrication Illustrated Index NOTE: • Use new O-rings when reassembling. • Apply oil to O-rings before installation. FRONT CYLINDER ENGINE OIL PRESSURE GAUGE HEAD SENDING UNIT • Use liquid gasket, Part No. 08718-0001. 22 N-m (2.2 kg-m. 16 Ib-ft) •...
Page 149 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 150 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 kg-m, 16 lb-ft)) Inspect the threads and rubber seal on the new filter.
Page 151 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 152 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 kg-m. 4 Ib-ft) PUMP HOUSING Inspection, page 8-8, OIL SEAL Installation, page Replace.
Page 153 Main Menu Table of Contents Oil Pump Removal/lnspection/lnstallation Drain the engine oil. 10. Remove the nine screws from the pump housing, then separate the housing and cover. Remove the timing belt (see page 6-15('91-'93)or('94-'96)). 11. Check the inner-to-outer rotor radial clearance. Remove the dipstick and the pipe.
Page 154 Main Menu Main Menu Table of Contents Table of Contents 13. Check the housing-to-outer rotor radial clearance. 17. 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 18. Check that the oil pump turns freely. (0.004 - 0.008 in) Service Limit: 0.21 mm (0.008 in)
Page 155 Main Menu Main Menu Table of Contents Table of Contents Oil Pump Removal/lnspection/lnstallation 26. Apply liquid gasket to the oil pump and left side 22. Install the oil pump on the cylinder block. cover mating areas as shown below. 23. Install the oil pass pipe and joint. Apply liquid gasket 24.
Page 156 Main Menu Main Menu Table of Contents Table of Contents 28. Tighten bolts and nuts finger tight at six points as shown below. 29. 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 157 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 50 N-m (5.0 kg-m. 36 Ib-ft) • Use liquid gasket, Part No. 08718-0001. 2 mm PIN SPRING RELIEF VALVE...
Page 158 Main Menu Table of Contents Special Tools Description Ref. No. Tool Number Page Reference 07LAA – PT50101 Sensor Socket Wrench 9-4('91-'93) or ('94-'96), ('94-'96),...
Page 159 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. INTAKE MANIFOLD • Replace with a new gasket if damaged. PLATE 6 x 1.0 mm 12 N-m (1.2 kg-m, 9 Ib-ft) 5 x 1.0 mm...
Page 160 Main Menu Table of Contents Exhaust Manifold Replacement NOTE: Use new gaskets and self-locking nuts. FRONT PRIMARY HEATED OXYGEN SENSOR (HO2S) 45 N-m (4.5 kg-m, 33 Ib-ft) • Be careful not to damage. • Use the special tool when removing and installing. GASKET Replace.
Page 161 Main Menu Table of Contents Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. REAR SECONDARY HO2S 45 N-m (4.5 kg-m, 33 Ib-ft) SELF-LOCKING NUTS GASKETS • Be careful not to 10 x 1.25 mm Replace.
Page 162 Main Menu Table of Contents Cooling Illustrated Index NOTE: System is under high pressure when the engine is hot. To avoid danger of releasing scalding • Check all cooling system hoses for damage, leaks or deterioration and replace if necessary. engine coolant, remove the cap only when the engine is cool.
Page 163 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 164 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 165 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 166 Main Menu Table of Contents Radiator Engine Coolant Refilling and Bleeding 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 167 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 coolant starts to run out in a steady stream without (where it engages the first lock tab of filler neck). bubbles, tighten the bleeders in sequence: thermo cover bleed bolt, radiator bleed plug, heater pipe 1 5.
Page 168 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 95-125 kPa (0.95-1.25 kg/cm 14-18 psi). Check for a drop in pressure. PRESSURE TESTER ADAPTOR (for 32 mm neck)
Page 169 Main Menu Table of Contents Thermostat Replacement NOTE: Use new gaskets and O-rings when reassem- bling. ENGINE COOLANT TEMPERATURE (ECT) GAUGE SENDING UNIT 9 N-m (0.9 kg-m, 7 Ib-ft) Apply liquid gasket to the threads. WATER PASSAGE 8 x 1.25 mm 22 N-m (2.2 kg-m, 16 Ib-ft) BLEED BOLT...
Page 170 Main Menu Table of Contents Water Pump Illustrated Index NOTE: Use new O-rings and new special bolts when ENGINE COOLANT reassembling. ECT SWITCH TEMPERATURE (ECT) 18 N-m (1.8 kg-m, GAUGE SENDING UNIT 13 Ib-ft) 9 N-m (0.9 kg-m, 7 Ib-ft) 8 x 1.25 mm Apply liquid gasket 22 N-m (2.2 kg-m...
Page 171 Main Menu Table of Contents Replacement Inspection Remove the timing belt (see page 6-15) ('91-'93) Remove the timing belt (see page 6-15 ('91-'93) ('94-'96). ('94-'96). 2. Check that the water pump pulley turns counterclock- Unscrew the bolts, then remove the water pump. wise.
Page 172 Main Menu Table of Contents Special Tools 11-151,11-155, 11-163, 11-164, 11-168, 11-169, 11-170, 11-171, 11-173 11-173 11-38 11-40 11-133, 11-137...
Page 173 Main Menu Table of Contents Component Locations Index For Troubleshooting of DTC related components. see chart on page 11-52. EXHAUST GAS RECIRCULATION (EGR) VALVE ENGINE COOLANT TEMPERATURE (ECT) SENSOR and LIFT SENSOR INTAKE AIR TEMPERATURE (IAT) SENSOR THROTTLE POSITION (TP) SENSOR CRANKSHAFT POSITION/ CYLINDER POSITION EVAPORATIVE EMISSION (EVAP)
Page 174 Main Menu Table of Contents Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-52. CLUTCH SWITCH (M/T only) Troubleshooting, page 11-124 ACCELERATOR POSITION (AP) SENSOR THROTTLE CABLE Inspection/Adjustment, page 11-150 Installation, page 11-150 PGM-FI MAIN RELAY Relay Testing, page 11-143 SERVICE CHECK CONNECTOR (2P)
Page 175 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 EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE FUEL FILTER Testing, page 11-173 Replacement, page...
Page 176 Main Menu Table of Contents Component Locations Index For Troubleshooting of DTC related components, see chart on page 11-52. THROTTLE BODY (TB) Inspection, page 11-151 Disassembly, page 11-152 POSITIVE CRANKCASE VENTILATION (PCV) VALVE Inspection, page 11-166 AIR CLEANER (ACL) Disassembly, page 11-149 INTAKE AIR DUCT INTAKE AIR BYPASS (IAB) VALVE BODY ASSEMBLY...
Page 177 Main Menu Table of Contents System Description Vacuum Connections CONTROL EVAP PURGE FLOW page 11-8 SWITCH EVAP PURGE CONTROL DIAPHRAGM VALVE EVAP CONTROL CANISTER To EVAP TWO-WAY VALVE INTAKE EGR VALVE BYPASS LIFT SENSOR (IAB) DIAPHRAGM FRONT OF EGR VALVE VEHICLE FUEL PRESSURE REGULATOR...
Page 178 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. EVAPORATIVE EMISSION EXHAUST GAS RECIRCULATION (EGR) (EVAP) PURGE CONTROL SOLENOID VALVE VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION MANIFOLD ABSOLUTE (EGR) CONTROL SOLENOID VALVE PRESSURE (MAP) SENSOR...
Page 179 Main Menu Table of Contents Vacuum hose No. INTAKE AIR BYPASS (IAB) VACUUM TANK FRONT PRIMARY HEATED OXYGEN SENSOR (HO2S) INTAKE AIR BYPASS (IAB) CONTROL SOLENOID VALVE (BANK 2, SENSOR 1) INTAKE AIR BYPASS (IAB) CONTROL DIAPHRAGM REAR PRIMARY HEATED OXYGEN SENSOR (HO2S) FRONT THREE WAY CATALYTIC CONVERTER (TWC) (BANK 1, SENSOR 1) REAR THREE WAY CATALYTIC CONVERTER (TWC)
Page 180 Main Menu Table of Contents System Descriptions Electrical Connections...
Page 181 Main Menu Table of Contents...
Page 182 Main Menu Table of Contents System Descriptions Electrical Connections TERMINAL LOCATIONS...
Page 183 Main Menu Table of Contents...
Page 184 Main Menu Table of Contents System Description Electrical Connections (To page 11-15)
Page 185 Main Menu Table of Contents (From page 11-14)
Page 186 Main Menu Table of Contents (To page 11-17)
Page 187 Main Menu Table of Contents (From page 11-16)
Page 188 Main Menu Table of Contents System Description Electrical Connections...
Page 189 Main Menu Table of Contents...
Page 190 Main Menu Table of Contents System Description Electrical Connections...
Page 191 Main Menu Table of Contents...
Page 192 Main Menu Table of Contents System Description Electrical Connections...
Page 193 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Right Side)]...
Page 194 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK2 are not the same). Related to Fuel and Emissions System. • — Connector with male terminals (double outline): View from terminal side —...
Page 195 Main Menu Table of Contents System Description System Connectors [Engine Compartment (Left Side)]...
Page 196 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK2 are not the same). Related to Fuel and Emissions System. • — Connector with male terminals (double outline): View from terminal side —...
Page 197 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels]...
Page 198 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 199 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels]...
Page 200 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 201 Main Menu Table of Contents System Description System Connectors [Behind the bulkhead panels]...
Page 202 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 203 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash]...
Page 204 Main Menu Table of Contents NOTE: • Different wires with the same color have been given a number suffix to distinguish them (for example, YEL/BLK1 and YEL/BLK2 are not the same). Related to Fuel and Emissions System. • — Connector with male terminals (double outline): View from terminal side —...
Page 205 Main Menu Table of Contents System Description System Connectors [Front Compartment and Under-dash]...
Page 206 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 207 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 208 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. •...
Page 209 Main Menu Table of Contents Troubleshooting Troubleshooting Procedures 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 210 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.
Page 211 Main Menu Table of Contents Troubleshooting Troubleshooting Procedures Symptom Chart Listed below are symptoms and probable causes for problems that DO NOT cause the Malfunction Indicator Lamp (MIL) to come on. If the MIL was reported on, go to page 11-38. Troubleshoot each probable cause in the order listed (from left to right) until the symptom is eliminated.
Page 212 Main Menu Table of Contents Probable Cause List 11-61, 11-62 11-132, 11-139 11-143 Section 23 See DTC chart See DTC chart 11-128 11-151 11-150 See DTC chart See DTC chart See DTC chart 11-121, 11-124 11-126 11-149 11-154 11-159 11-167...
Page 213 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 214 Main Menu Table of Contents...
Page 215 Main Menu Table of Contents Troubleshooting Engine Control Module Terminal Arrangement ECM CONNECTOR A (26P) TERMINAL SIDE OF MALE TERMINALS ECM CONNECTOR A (26P) NOTE: Standard battery voltage is 12 V.
Page 216 Main Menu Table of Contents ECM CONNECTOR B (16P) TERMINAL SIDE OF MALE TERMINALS NOTE: Standard battery voltage is 12 V. ECM CONNECTOR B (16P) *: M/T...
Page 217 Main Menu Table of Contents Troubleshooting Engine Control Module Terminal Arrangement (cont'd) ECM CONNECTOR C (12P) TERMINAL SIDE OF MALE TERMINALS NOTE: Standard battery voltage is 12 V. ECM CONNECTOR C (12P) *: M/T...
Page 218 Main Menu Table of Contents ECM CONNECTOR 0 (22P) TERMINAL SIDE OF MALE TERMINALS ECM CONNECTOR D (22P) NOTE: Standard battery voltage is 12 V.
Page 219 Main Menu Table of Contents Troubleshooting Engine Control Module Terminal Arrangement (cont'd) ECM CONNECTOR F (26P) TERMINAL SIDE OF MALE TERMINALS NOTE: Standard battery voltage is 12 V. ECM CONNECTOR F (26P) *: M/T...
Page 220 Main Menu Table of Contents ECM CONNECTOR G (12P) TERMINAL SIDE OF MALE TERMINALS ECM CONNECTOR G (12P) NOTE: Standard battery voltage is 12 V.
Page 221 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart 11-65 11-67 11-69 11-70 11-71 11-72 11-73 11-74 11-75 11-77 11-78 11-80 11-81 11-85 These DTCs will be indicated by the blinking of the Malfunction Indicator Lamp (MIL) with the SCS service connector connected...
Page 222 Main Menu Table of Contents 11-82 11-83 11-84 11-85 11-78 11-80 11-81 11-85 11-82 11-83 11-84 11-85 11-87 11-87...
Page 223 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart 11-87 11-87 11-89 11-89 11-100 11-100 11-162 11-160 11-160 11-168 11-102 Section 14 indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously.
Page 224 Main Menu Table of Contents 11-103 11-103 11-90 11-109 11-109 11-111 11-111 11-114 11-114 11-114 Section 6 Section 6...
Page 225 Main Menu Table of Contents Troubleshooting Diagnostic Trouble Code (DTC) Chart 11-94 11-90 11-96 11-96 11-98 11-98 11-100 11-100 11-100 11-100 11-100 11-100 11-170...
Page 226 Main Menu Table of Contents 11-163 11-165 11-104 11-104 11-105 11-105 Section 19 Section 19 Section 14 indicator light and the Malfunction Indicator Lamp (MIL) may come on simultaneously.
Page 227 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 228 Main Menu Table of Contents PGM-FI System System Description PGM-FI System The PGM-FI system on this model is a sequential multiport fuel injection system. Fuel Injector Timing and Duration The ECM contains memories for the basic discharge durations at various engine speeds and manifold pressures. The basic discharge duration, after being read out from the memory, is further modified by signals sent from various sensors to obtain the final discharge duration.
Page 229 Main Menu Table of Contents PGM-FI System System Description 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 230 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 231 Main Menu Table of Contents PGM-FI System Engine Control Module (ECM) 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 232 Main Menu Table of Contents (From page 11-62) Check for a short in the wires (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 233 Main Menu Table of Contents PGM-FI System Engine Control Module (ECM) (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 234 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 235 Main Menu Table of Contents Drive By Wire System System Description 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 236 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. ECM CONNECTORS Check for a short in the circuit: 1.
Page 237 Main Menu Table of Contents Idle Control System Air Conditioning Signal (From page 11-117) A/C CLUTCH RELAY 4P CONNECTOR 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 238 Main Menu Table of Contents Alternator (ALT) FR Signal This signals the ECM when the Alternator (ALT) is charging. Inspection of ALT FR Signal. ECM CONNECTORS Check for a short in the circuit: 1. Disconnect the GRN 4P con- nector from the ALT. 2.
Page 239 Main Menu Table of Contents Idle Control System Alternator (ALT) FR Signal (From page 11-119) ALT GRN 4P CONNECTOR Check for an open in the wire: 1. Turn the ignition switch OFF. 2. Disconnect the negative battery cable from the battery. 3.
Page 240 Main Menu Table of Contents 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 241 Main Menu Table of Contents Idle Control System Automatic Transaxle (A/T) Gear Position Signal (From page 11-121) ECM CONNECTORS Check for an open in the wire: 1. Turn the ignition switch OFF. 2. Reconnect the 30P (C412) con- nector to the gauge assembly. 3.
Page 242 Main Menu Table of Contents Neutral Switch Signal (M/T) This signals the ECM when the transmission is in neutral. ECM CONNECTORS Inspection of neutral switch signal. Check for an open in the circuit: 1. Turn the ignition switch ON (II). 2.
Page 243 Main Menu Table of Contents Idle Control System Clutch Switch Signal (M/T) This signals the ECM when the clutch is engaged. ECM CONNECTORS Inspection of clutch switch signal. Check for an open in the circuit: 1. Turn the ignition switch ON (II). 2.
Page 244 Main Menu Table of Contents (From page 11-124) ECM CONNECTORS WIRE SIDE OF FEMALE TERMINALS 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. Turn the ignition switch ON (II). 4.
Page 245 Main Menu Table of Contents Idle Control System 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).
Page 246 Main Menu Table of Contents 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. ECM CONNECTORS Measure voltage between ECM connector terminals C6 and A26 with the ignition switch in the start position.
Page 247 Main Menu Table of Contents Idle Control System Idle Speed Setting Inspection/Adjustment Remove the rubber cap from the tachometer connector and connect a tachometer. NOTE: Before setting the idle speed, check the following items: TACHOMETER — The Check Engine light has not been reported on. RUBBER —...
Page 248 Main Menu Table of Contents Disconnect the SCS service connector. Depress the accelerator pedal and stabilize the engine speed at 1,000 rpm, then slowly release the pedal until the engine idles, then check the idle speed. Idle speed should be:...
Page 249 Main Menu Table of Contents Fuel Supply System Fuel Lines NOTE: Check all fuel system lines and hoses 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 250 Main Menu Table of Contents NOTE: Check all hose clamps and retighten if necessary. Clamp in the middle Clamp in the middle Clamp in the middle...
Page 251 Main Menu Table of Contents Fuel Supply System 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 252 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, Relieve fuel pressure (see page 11-132) check the following: — If the fuel pressure is higher than specified, inspect Remove the service bolt on the fuel filter while holding the banjo bolt with another wrench.
Page 253 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 254 Main Menu Table of Contents 13. Install the fuel injectors and fuel rail assembly in the manifold. CAUTION: To prevent damage to the O-rings, install the fuel injectors in the fuel rail first, then install them in the intake manifold. FUEL RAILS FUEL RAIL...
Page 255 Main Menu Table of Contents Fuel Supply System Fuel Injector Resistor 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 coils. This allows a faster response time of the fuel injec- Check for resistance between each of the fuel injec- tor resistor terminals (2, 3, 4, 6, 7 and 8) and the tors.
Page 256 Main Menu Table of Contents Fuel Pressure Regulator Testing Description 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 257 Main Menu Table of Contents Fuel Supply System Fuel Pressure Regulator (cont'd) 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 258 Main Menu Table of Contents Fuel Supply System Fuel Filter 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 259 Main Menu Table of Contents Fuel Pump Relay Troubleshooting Flowchart Inspection of fuel pump relay. Turn the ignition switch to START (III) position. Inspect the fuel pump resistor Does the engine start? (see page 11-141). ECM CONNECTOR F (26P) Check for an open in the circuit: 1.
Page 260 Main Menu Table of Contents Fuel Supply System Fuel Pump Relay (From page 11-139) FUEL PUMP RELAY 4P CONNECTOR Check for open in the fuel pump CAUTION: * the "A" connector must be relay: disconnected for this test or the ECM 1.
Page 261 Main Menu Table of Contents Fuel Pump Resistor Troubleshooting Flowchart — Engine will not start. — Inspection of fuel pump resis- tor. FUEL PUMP RESISTOR 2P CONNECTOR Check the operation of the PGM- FI main relay: 1. Disconnect the fuel pump resistor 2P connector.
Page 262 Main Menu Table of Contents Fuel Supply System Fuel Pump Testing Replacement Do not smoke during the test. Keep open Do not smoke while working on fuel sys- 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 Remove the fuel tank (see page 11-147).
Page 263 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 Remove the PGM-FI main relay.
Page 264 Main Menu Table of Contents Fuel Supply System PGM-FI Main Relay 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: 1. Turn the ignition switch OFF. 2.
Page 265 Main Menu Table of Contents (From page 11-144) PGM-FI MAIN RELAY 4P CONNECTOR Check for an open in the wire: Measure voltage between the PGM-FI main relay 4P connector terminal No. 4 and body ground. — Replace the IG COIL (30 A) WIRE SIDE OF FEMALE TERMINALS fuse in the engine compart- ment fuse/relay box.
Page 266 Main Menu Table of Contents Fuel Supply System PGM-FI Main Relay (From page 11-145) ECM CONNECTORS Check for an open in the wire: 1. Reconnect the ECM connector A (26P). 2. Reconnect the PGM-FI main relay 4P and 8P connectors. 3.
Page 267 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 car. 2. Remove the drain bolt, and drain the fuel into an approved container. 3.
Page 268 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 269 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 15,000 miles (24,000 km) or 12 months and replace every 30,000 miles (48,000 km) or 24 months...
Page 270 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 271 Main Menu Table of Contents Throttle Body Description Inspection The throttle body is of the single-barrel side-draft type. CAUTION: Do not adjust the throttle stop screw. It is The lower portion of the throttle valve is heated by preset at the factory. engine coolant which is fed from the cylinder head.
Page 272 Main Menu Table of Contents Intake Air System Throttle Body Disassembly THROTTLE BODY IDLE ADJUSTING SCREW O-RING Replace. TP SENSOR THROTTLE VALVE CONTROL MOTOR 22 N-m (2.2 kgf-m, 16 Ibf-ft) INTAKE AIR DUCT...
Page 273 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 IDLE ADJUSTING THROTTLE SCREW FUEL INJECTOR BODY...
Page 274 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 275 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 stopper when the vacuum hose is...
Page 276 Main Menu Table of Contents Emission Control System Tailpipe Emission System Description 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 tem and Evaporative Emission (EVAP) Control system.
Page 277 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 (Nz) and water vapor. SECONDARY HEATED OXYGEN SENSOR (SENSOR 2) THREE WAY CATALYST...
Page 278 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 279 Main Menu Table of Contents Emission Control System Positive Crankcase Ventilation (PCV) System Description Inspection The Positive Crankcase Ventilation (PCV) system is Check the PCV hoses and connections for leaks and clogging. designed to prevent blow-by gas from escaping to the atmosphere.
Page 280 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 281 Main Menu Table of Contents Evaporative Emission (EVAP) Two Way Valve Testing PRESSURE SIDE 1. Remove the fuel fill cap. Remove vapor line from the fuel tank and connect to T-fitting from vacuum gauge and vacuum pump as shown. VACUUM/PRESSURE GAUGE 0-4 in.
Page 282 Table of Contents Main Menu Special Tools Page Reference Ref.No. Tool Number Description 12-10, 17, 07LAB — PV00100 or Ring Gear Holder 07924 — PD20003 12-18, 07MAF—PR80100 Clutch Alignment Shaft 12-17 07746 — 0010200 Attachment, 37 x 40 mm 12-17 07749 —...
Page 283 Table of Contents Main Menu 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 12-6). Inspect the hoses for damage, leaks, interference, and twisting.
Page 284 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 285 Main Menu Table of Contents Clutch Master Cylinder Removal Installation Disconnect the clutch pipe from the clutch master Install the clutch master cylinder in the reverse cylinder. order of removal. Pry out the cotter pin, and pull the clevis pin out of NOTE: Bleed the clutch hydraulic system (see the clevis.
Page 286 Main Menu Table of Contents Slave Cylinder Installation Removal Super High Temp Urea Grease (P/N Disconnect the clutch hose from the slave cylinder. 08798-9002). Brake Assembly Lube or equivalent rubber CAUTION: • Avoid spilling brake fluid on the painted sur- grease.
Page 287 Main Menu Table of Contents Clutch Master Cylinder (Canada) Disassembly Reassembly CAUTION: CAUTION: Avoid spilling brake fluid on paint as it may • Before assembling, make sure all parts are complete- damage the finish. ly clean. • Replace parts with new ones whenever specified to Remove the dust seal from the clutch master cylinder.
Page 288 Main Menu Table of Contents Slave Cylinder (Canada) Overhaul/Inspection Super High Temp Urea Grease (P/N 08798-9002). Brake Assembly Lube or equivalent rubber grease. SLAVE CYLINDER BODY Inspect the cylinder wall for scoring and wear. SLAVE CYLINDER SPRING Install with small end facing piston.
Page 289 Main Menu Table of Contents Pressure Plate, Clutch Disc, Mid Plate Removal Install the special tools. Remove the mid plate and the 2nd clutch disc. FLYWHEEL RING GEAR HOLDER 07LAB - PV00100 07924 - PD20003 2ND CLUTCH DISC ADJUSTER ENGINE BLOCK ADJUSTER MID PLATE...
Page 290 Main Menu Table of Contents Pressure Plate Release Bearing Inspection Inspection NOTE: If replacement is required, always replace the Check the release bearing for excessive play by spinning it by hand. pressure plate, mid plate, and flywheel as a set. Inspect the pressure plate surface for wear, cracks, CAUTION: Do not wash the release bearing in and burning.
Page 291 Main Menu Table of Contents 1st and 2nd Clutch Discs Inspection Inspect the lining of the clutch disc for signs of slip- Measure the depth from the lining surface to the rivets, on both sides. ping or oil. Replace it if it is burned black or oil soaked.
Page 292 Main Menu Table of Contents Mid Plate Mid Plate Guide Inspection Inspection NOTE: If replacement is required, always replace the The mid plate guides are the self-adjusting mechanisms pressure plate, mid plate, and flywheel as a set. for the mid plate. 1.
Page 293 Main Menu Table of Contents Mid Plate Guide Initialization NOTE: Screw the 5 mm bolt in 1 50 — 210° further. • If the pressure plate mounting bolts are unscrewed, the mid plate guide must be initialized. • Initialize after tightening the pressure plate mount bolts.
Page 294 Main Menu Table of Contents Replacement NOTE: Make sure all parts are clean before installation. Remove the mid plate guide with the screw installed. Thread and tighten a 4 mm screw into mid plate guide. MID PLATE GUIDE SCREW Thread and tighten a 4 mm screw into the new mid 4 x 0.7 mm SCREW Length of threads plate guide, then remove the mid plate guide from...
Page 295 Main Menu Table of Contents Mid Plate Guide Replacement (cont'd) Install the new mid plate guide with the screw installed. Install the washer, spring and guide collar, then remove the screw. -MID PLATE GUIDE Install as shown. Initialize the mid plate guides after installing the clutch assembly (see page 12-14).
Page 296 Main Menu Table of Contents Mid Plate Guide Flywheel, Flywheel Bearing Replacement (cont'd) Inspection 5. Install the new mid plate guide with the screw NOTE: If replacement is required, always replace the installed. pressure plate, mid plate, and flywheel as a set. Inspect the ring gear teeth for wear and damage.
Page 297 Main Menu Table of Contents Replacement Remove the flywheel mounting bolts in a criss- Drive the new ball bearing into the flywheel using cross pattern in several steps, and remove the the special tools as shown. flywheel. DRIVER 07749 - 0010000 ATTACHMENT, 37 x 40 mm 07746 - 0010200...
Page 298 Main Menu Table of Contents Pressure Plate, Clutch Disc, Mid Plate Installation NOTE: Install the mid plate. • Install the pressure plate, clutch discs, and mid plate as a set. NOTE: Align the mark on the flywheel with the • Do not mix-up the 1st and 2nd clutch discs. The 2nd mark on the mid plate.
Page 299 Main Menu Table of Contents Install the release bearing on the pressure plate. 8. Torque the mounting bolts in a crisscross pattern as shown. Tighten them several steps to prevent 7. Install the pressure plate. warping the diaphragm spring. NOTE: Place the diaphragm spring fingers in the NOTE: groove of the release bearing.
Page 300 Main Menu Table of Contents Special Tools 13-42 13-42 13-39 13-40 13-39 13-42 13-42 13-39, 13-40...
Page 301 Main Menu Table of Contents Back-up Light Switch, Maintenance Neutral Position Switch Transmission Oil Replacement NOTE: To check the switch, see section NOTE: Check the oil at normal operating temperature (the cooling fan comes on), engine OFF, and the car on Disconnect the connector, then remove the switch level ground.
Page 302 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. COTTER PIN 6 x 1.0 mm BOLTS Replace. 10 N-m (1.0 kg-m, 7 Ib-ft) 6 x 1.0 mm SELECT LINK...
Page 303 Main Menu Table of Contents Cable Adjustment Remove the center console panel (see section 20). Measure the distances Move the shift lever into 1st gear. NOTE: • Hold the cable ends up to the select and shift Install the 6 mm bolt to the shift lever. levers as if they were connected to them.
Page 304 Main Menu Table of Contents Transmission Assembly Removal 4. Remove the strut bar. Make sure lifts are placed properly, and hoist brackets are attached to correct positions (see 5. Remove the air cleaner assembly. section 6. Remove the connectors from the control box, and CAUTION: Use fender covers to avoid damaging remove the control box.
Page 305 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 front exhaust pipe A. Corrosion resistant bolt/nut GASKET SELF-LOCKING NUT Replace. Replace. PARKING BRAKE CABLE HOLDERS EXHAUST PIPE A...
Page 306 Main Menu Table of Contents Transmission Assembly Removal 20. Remove the intermediate shaft heat 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 or grease. •...
Page 307 Main Menu Table of Contents 27. Remove the one of the upper control arm mounting bolt. 28. Remove the lower cover, change wire bracket and upper cover. 29. Remove the shift cable and select cable. 30. Remove the slave cylinder from the transmission. NOTE: Do not operate the clutch pedal once the slave cylinder has been removed.
Page 308: Table Of Contents
Main Menu Table of Contents Illustrated Index Clean all parts thoroughly in solvent and dry with compressed air. Lubricate all parts with oil before reassembly. 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 309 Main Menu Table of Contents 36 mm SEALING BOLT SPRING (L. 24.2 mm) BEARING OUTER RACE 35 N-m (3.5 kg-m, 25 Ib-ft) 16 mm SEALING BOLT COMP 75 mm THRUST SHIM STRAINER COVER 42 N-m (4.2 kg-m, 30 Ib-ft) Selection. O-RING CLAMP STEEL BALL (5/16 in)
Page 310 Main Menu Table of Contents Transmission Housing Removal NOTE: 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 311 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 the 5th/reverse shift piece. arm and reverse shift fork. Standard: 0.05-0.30 mm Standard: 0.05-0.35 mm (0.002-0.012 in)
Page 312 Main Menu Table of Contents Reverse Shift Arm, Reverse Shift Fork Clearance Inspection Measure the clearance between the reverse shift fork and reverse synchro sleeve. Standard: 0.45—0.65 mm (0.018-0.026 in) Service Limit: 1.0 mm (0.039 in) REVERSE SHIFT FORK REVERSE SYNCHRO SLEEVE If the clearance exceeds the service limit, measure the thickness of the shift fork fingers.
Page 313 Main Menu Table of Contents Reverse Idler Gear Shaft Assembly Removal Remove the reverse shift arm from the clutch housing. REVERSE SHIFT CLUTCH HOUSING Shift the reverse shift fork to the driven gear side. Lift the mainshaft assembly and reverse idler gear shaft assembly, then remove the reverse shift fork assembly.
Page 314 Main Menu Table of Contents Lift the reverse idler gear shaft, then remove the spring pin from the groove and remove the idler gear shaft assembly. REVERSE IDLE GEAR SHAFT ASSEMBLY SPRING PIN...
Page 315: Disassembly/Reassembly, Page
Main Menu Table of Contents Disassembly/Reassembly NOTE: • The thrust needle bearing are the same size. • The needle bearing are the same size. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surface. 22 x 38 x 3 mm THRUST WASHER THRUST NEEDLE BEARING Inspect for wear and operation.
Page 316 Main Menu Table of Contents Mainshaft, Countershaft, Differential Assemblies Removal Remove the change holder assembly from the clutch housing. CHANGE HOLDER CLUTCH ASSEMBLY HOUSING Remove the mainshaft assembly and countershaft assembly with the shift fork from the clutch housing. NOTE: Tape the mainshaft splines to protect them before removing the mainshaft and countershaft assemblies.
Page 317 Main Menu Table of Contents Remove the differential assembly from the clutch housing. DIFFERENTIAL ASSEMBLY CLUTCH HOUSING...
Page 318 Main Menu Table of Contents Shift Lever, Select Lever Removal Remove the shift spring set plate and shift detent spring from the transmission housing. SHIFT SPRING TRANSMISSION SET PLATE HOUSING SHIFT DETENT SPRING Remove the bolt and spring washer. Pull out the shift lever, then remove the shift arm. SHIFT ARM SPRING WASHER OIL SEAL...
Page 319 Main Menu Table of Contents Shift Lever, Select Lever Removal Remove the bolt and spring washer. Pull out the select lever, then remove the select arm. SELECT ARM SPRING WASHER OIL SEAL Replace. SELECT LEVER...
Page 320: Disassembly/Reassembly, Page
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. SHIFT PIECE SHAFT INTERLOCK SHIFT PIECE CHANGE HOLDER SELECT RETURN SPRING 5TH/REVERSE RETURN SPRING...
Page 321 Main Menu Table of Contents Change Holder Assembly, Shift Fork Clearance Inspection 1. Measure the clearance between the shift piece and Measure the clearance between the interlock and shift arm. select arm. Standard: 0.05—0.25 mm Standard: 0.03-0.15 mm (0.001 - 0.006 in) (0.002-0.010 in) Service Limit: 0.5 mm (0.020 in) SHIFT ARM...
Page 322 Main Menu Table of Contents Measure the clearance between the shift fork, the 5th/reverse shift piece and shift piece. Standard: 0.2-0.5 mm (0.008-0.020 in) Service Limit: 0.6 mm (0.024 in) 1ST/2ND SHIFT FORK 3RD/4TH SHIFT FORK SHIFT PIECE 5TH/REVERSE SHIFT PIECE If the clearance exceeds the service limit, measure the width of the shift piece.
Page 323 Main Menu Table of Contents Shift Fork, Synchro Sleeve Clearance Inspection Measure the clearance between each shift fork and its matching synchro sleeve. Standard: 0.45-0.65 mm (0.018-0.026 in) Service Limit: 1.0 mm (0.039 in) SYNCHRO SLEEVE SHIFT FORK If the clearance exceeds the service limit, measure the width of the shift fork fingers.
Page 324 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 — 0.21 mm (0.002-0.008 in) Standard: 0.06—0.21 mm Service Limit: 0.3 mm (0.012 in) (0.002-0.008 in) Service Limit: 0.3 mm (0.012 in) 2ND GEAR...
Page 325 Main Menu Table of Contents Measure the clearance between the spacer collar and 5th gear. Standard: 0.06—0.21 mm (0.002-0.008 in) Service Limit: 0.3 mm (0.012 in) 4TH GEAR 5TH GEAR If the clearance exceeds the service limit, measure distance on the spacer collar. Standard: 28.53—28.58 mm (1.123-1.125 in)
Page 326 Main Menu Table of Contents Shift Fork Assembly Disassembly/Reassembly NOTE: • Be careful not to lose the 5th shift fork steel ball. • 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.
Page 327 Main Menu Table of Contents Mainshaft Assembly Index NOTE: The 3rd/4th and 5th 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 synchro hubs, however, should be installed with a press before lubricating them. BALL BEARING Inspect for wear and operation.
Page 328 Main Menu Table of Contents Disassembly Remove the ball bearing using a bearing puller as shown. Clutch housing side: BEARING PULLER (Commercially available) BALL BEARING BEARING SEPARATOR, 0-4 1/2 in. (Commercially available) Transmission housing side: BEARING PULLER (Commercially available) BALL BEARING BEARING SEPARATOR, 0-4 1/2 in.
Page 329 Main Menu Table of Contents Mainshaft Assembly Disassembly CAUTION: Remove the synchro hubs using a press and steel blocks as shown. Use of a jaw-type puller can damage the gear teeth. Support 5th gear on steel blocks as shown, and press the shaft out of the 5th synchro hub.
Page 330 Main Menu Table of Contents Mainshaft Assembly Inspection Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B, and C. Standard: A (Ball bearing surface): 32.002—32.018 mm (1.2599-1.2605 in) B (Needle bearing surface): 42.984—43.000 mm (1.6923-1.6929 in) C (Ball bearing surface): 30.984-31.000 mm...
Page 331 Main Menu Table of Contents Inspect for runout. Standard: 0.02 mm (0.001 in) max. Service Limit: 0.05 mm (0.002 in) NOTE: Support the mainshaft at both ends as shown. Rotate two complete revolutions. If the runout exceeds the service limit, replace the mainshaft with a new one.
Page 332 Main Menu Table of Contents Countershaft Assembly Index NOTE: The 3rd, 4th and 5th 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 and 5th gears should be installed without lubrication using a press. LOCKNUT Replace.
Page 333 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) Standard: 0.04-0.10 mm (0.002-0.004 in) 3RD GEAR 1ST GEAR REVERSE 2ND GEAR GEAR If the clearance exceeds the standard, select the...
Page 334 Main Menu Table of Contents Disassembly Securely clamp the countershaft assembly in a Remove the bearing outer race from the needle bench vise with wood blocks. bearing, then remove the needle bearing using a bearing puller as shown. Raise the locknut tab from the groove of the countershaft, and remove the locknut and the spring washer.
Page 335 Main Menu Table of Contents Countershaft Assembly Disassembly Support 2nd gear on steel blocks as shown, and press the shaft out of 3rd and 2nd gears. PRESS ATTACHMENT 3RD GEAR 2ND GEAR...
Page 336 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. Standard: A (Needle bearing surface): 43.974-43.990 mm (1.7313-1.7319 in) B (Ball bearing surface): 33.984—34.000 mm (1.3380-1.3386 in) Service Limit:...
Page 337 Main Menu Table of Contents Reassembly CAUTION: Install 5th gear using a press as shown. • Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. • Press the 3rd, 4th and 5th gears on the countershaft without lubrication.
Page 338 Main Menu Table of Contents Countershaft Assembly Reassembly 5. Install the ball bearing using a press as shown. PRESS BALL BEARING Securely clamp the countershaft assembly in a bench vise with wood blocks. Install the spring washer, tighten the locknut, then stake the locknut tab into the groove.
Page 339 Main Menu Table of Contents Synchro Ring, Gear Inspection SYNCHRO SPRING Inspect 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 SYNCHRO RING off).
Page 340 Main Menu Table of Contents Synchro Sleeve, Synchro Hub Inspection Installation 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 341 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. 6 x 1.0 mm BOLT 12 N-m (1.2 kg-m, 9 Ib-ft) STRAINER COVER O-RING OIL PUMP SHAFT ASSEMBLY Replace.
Page 342 Main Menu Table of Contents Oil Pump Clearance Inspection Check the clearance between the transmission Check the radial clearance on the pump rotor. mating surface of the clutch housing and the oil pump gear. Inner Rotor-to-Outer Rotor Radial clearance Standard: 0.14 mm (0.006 in) max.
Page 343 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. NOTE: Position the needle bearing with the oil hole BEARING RETAINING 6 x 1.0 mm BOLTS facing up.
Page 344 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. RELEASE BEARING GUIDE COVER RELEASE BEARING GUIDE OIL SEAL...
Page 345 Main Menu Table of Contents Mainshaft Thrust Shim Adjustment Remove the thrust shim and oil guide plate from the Select the proper thrust shim on the basis of the transmission housing. following calculations. Install the mainshaft in the transmission housing. NOTE: Do not use more than two thrust shims.
Page 346 Main Menu Table of Contents Mainshaft Thrust Shim Adjustment Install the ball bearing onto the mainshaft using the c. Seat the mainshaft fully by tapping its end special tools, then install the 75 mm spring washer with a plastic hammer. and mainshaft assembly into the clutch housing.
Page 347 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 transmission housing. the clutch housing. 8 x 1.0 mm SPECIAL BOLT 8 x 1.0 mm SPECIAL BOLT 32 N-m (3.2 kg-m, 23 Ib-ft) 32 N-m (3.2 kg-m, 23 Ib-ft) SPRING WASHER...
Page 348 Main Menu Table of Contents Transmission Reassembly Install the spring washer, then insert the mainshaft Lift the mainshaft assembly, then install the and countershaft into the shift forks and install reverse idle gear shaft assembly with the spring pin them as an assembly. matching the groove of the clutch housing.
Page 349 Main Menu Table of Contents 9. Install the reverse shift arm. 11. Install the dowel pins on the clutch housing. 12. Place the transmission housing over the clutch 6 x 1.0 mm SPECIAL BOLTS housing, being careful to line up the shafts. 15 N-m (1.5 kg-m, 11 Ib-ft) NOTE: Make sure the 3rd/4th shift fork shaft col- REVERSE SHIFT ARM...
Page 350 Main Menu Table of Contents Transmission Reassembly 13. Lower the transmission housing with snap ring b. Lower the transmission housing, then place the 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 351 Main Menu Table of Contents 18. Install the back-up light switch and neutral position 1 5. Tighten the transmission housing attaching bolts in a crisscross pattern in several steps as shown below. switch. Torque: 45 N-m (4.5 kg-m, 33 Ib-ft) NOTE: Apply liquid gasket (P/N 08718-0001) to the threads.
Page 352 Main Menu Table of Contents Transmission Assembly Installation (P/N 08798-9002) NOTE: • Check that the two dowel pins are installed in the clutch housing. • 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. 2.
Page 353 Main Menu Table of Contents 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 354 Main Menu Table of Contents Transmission Assembly Installation 20. Install the right driveshaft onto the intermediate shaft. 21. Install the lower control arm to the side beam (see section 18). CAUTION: Align the reference marks on the adjusting bolt, adjusting cam and lower control arm. 22.
Page 355 Main Menu Table of Contents 28. Install the transmission mount and two transmission 31. Install the control box, and connect the control box housing mounting bolts. connectors. 29. Install the starter motor, and connect the starter 32. Install the air cleaner assembly. motor cables.
Page 356 Main Menu Table of Contents Special Tools Ref. No Tool Number Description Page Reference 07GAD—SD40101 Bearing Driver Attachment 15-12 07MAD—PR90100 Attachment, 45 x 55 mm I.D. 15-5 07MAD—PR90200 Pilot, 32 x 50 mm 15-14 07MAJ—PR90100 Differential Inspection Tools 15-4, 6, 9, 11, 07746—0010500 Attachment, 62 x 68 mm 15-12...
Page 357 Main Menu Table of Contents 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 358 Main Menu Table of Contents Preset Torque Inspection On-Car: Assembly: Place one special tool in a vise. Place the left side Block the front wheels. of the differential assembly on the special tool, then preset the differential with 3 - 5 rotations, counter- Shift to low gear.
Page 359 Main Menu Table of Contents Bearing Replacement NOTE: Install the tapered roller bearings using a special tool • The bearing and outer race should be replaced as a and a press as shown. set. • Inspect and adjust the bearing preload whenever the NOTE: Press the tapered roller bearings squarely bearing is replaced.
Page 360 Main Menu Table of Contents Differential Disassembly 1. 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 361 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. NOTE: Turn each bolt two turns at a time to pro- vent cocking the differential housing cover exces- sively.
Page 362 Main Menu Table of Contents Differential Reassembly NOTE: • If the limited slip differential clutch set was replaced, the 65 mm shim (differential housing cover side) and 112 mm shim (differential housing cover side) must be adjusted. • Reassemble the parts in the same order and direction they were before disassembly.
Page 363 Main Menu Table of Contents Differential Reassembly Install the carrier assembly. 4. 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. NOTE: Align the mark on the differential housing cover with the mark on the final driven gear.
Page 364 Main Menu Table of Contents 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. NOTE: 8 x 1.0 mm SPECIAL BOLTS •...
Page 365 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 366 Main Menu Table of Contents 16. Tighten the mounting bolts in a crisscross pattern in several steps. 8 x 1.0 mm SPECIAL BOLTS 40 N-m (4.0 kg-m, 29 Ib-ft) BENCH VISE DIFFERENTIAL INSPECTION TOOLS 07MAJ-PR90100 • 112 mm shim adjustment 17.
Page 367 Main Menu Table of Contents Oil Seal Removal 16. Tighten the mounting bolts in a crisscross pattern Remove the differential assembly. in several steps. Remove the oil seat from the transmission housing. 8 x 1.0 mm SPECIAL BOLTS 40 N·m (4.0 kg-m, 29 Ib ft) OIL SEAL Replace.
Page 368 Main Menu Table of Contents Bearing Preload Adjustment NOTE: 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 90 mm WASHER OIL GUIDE RING Remove the bearing outer race and 75 mm thrust shim from the transmission housing by prying up...
Page 369 Main Menu Table of Contents Lubricate the tapered roller bearing with transmis- Install the standard shim and bearing outer race in- to the transmission housing using the special tools sion oil, then install the differential. as shown. Install the transmission housing. CAUTION: Do not use more than one shim to ad- NOTE: Do not install the mainshaft, countershaft, just the bearing preload.
Page 370 Main Menu Main Menu Table of Contents 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 as shown. special tools as shown. SEAL DRIVER BEARING ATTACHMENT...
Page 371 Main Menu Table of Contents Special Tools Ref. No. Tool Number Description Page Reference 15-26 Bearing Driver Attachment 07GAD — SD40101 Clutch Spring Compressor Bolt Assembly 07GAE — PG40200 07HAE — PL50100 Clutch Spring Compressor Attachment 1 5-2 0 07LAE — PX40100 Clutch Spring Compressor Attachment 15-20, 07MAD —...
Page 372 Main Menu Table of Contents Differential Illustrated Index NOTE: If the parts marked with an asterisk (*) ere replaced, the bearing preload must be adjusted (see page 15-26 parts marked with * 76 mm THRUST SHIM Selection, Adjustment, page 15-27 FINAL DRIVEN GEAR * TAPERED ROLLER BEARING Inspect for wear and damage.
Page 373 Main Menu Table of Contents Preset Torque Inspection On-Car: Assembly: 1. Place one special tool in a vise. Place the left side of 1. 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 374 Main Menu Table of Contents Bearing Replacement NOTE: Install the tapered roller bearings using a special tool • The bearing and outer race should be replaced as a and a press as shown. set. • Inspect and adjust the bearing preload whenever the NOTE: Press the tapered roller bearings squarely bearing is replaced.
Page 375 Main Menu Table of Contents Differential Disassembly 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...
Page 376 Main Menu Table of Contents Screw two 8 x 1.0 mm bolts into the threaded holes Remove the 112 mm thrust shim, clutch discs, clutch plates, and 102 mm washer. in the differential housing cover to push it away from the final driven gear.
Page 377 Main Menu Table of Contents Clutch Disc, Clutch Plate Replacement <Reference> NOTE: The clutch discs and clutch plates should be Measure 41.7– 41.9 mm replaced as a set. (1.642 – 1.650 In) 1. Remove the clutch discs and clutch plates (see page15-20).
Page 378 Main Menu Table of Contents Differential Reassembly Install the clutch disc, clutch plate, central gear, Install the 102 mm washer, clutch discs, clutch and carrier assembly. plates, and 112 mm thrust shim. NOTE: NOTE: Lubricate the clutch disc surface with transmission fluid.
Page 379 Main Menu Table of Contents Differential Reassembly Install the special tools on the stopper plate as Install the differential housing. shown. NOTE: Align the fingers of the clutch plates and clutch discs. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100 DIFFERENTIAL HOUSING STOPPER PLATE CLUTCH SPRING Align the fingers.
Page 380 Main Menu Table of Contents 9. Hold the differential in a bench vise using a special tool, then install the differential housing mounting bolts. NOTE: Tighten the bolts in a crisscross pattern in several steps. 8 x 1.0 mm SPECIAL BOLTS 40 N-m (4.0 kg-m, 29 Ib-ft) BENCH VISE...
Page 381 Main Menu Table of Contents Oil Seal Removal Remove the differential assembly. 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. HOUSING...
Page 382 Main Menu Table of Contents 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 1.
Page 383 Main Menu Table of Contents Install the standard shim and bearing outer race in- 75 mm THRUST SHIM: to the transmission housing using the special tools as shown. CAUTION: Do not use more than one shim to ad- just the bearing preload. NOTE: •...
Page 384 Main Menu Table of Contents Bearing Preload Adjustment Measure the starting torque of the differential assembly with a special tool and a torque wrench as shown. NOTE: Measure the bearing preload at normal room temperature in both directions. Standard: 3.3-4.5 N-m (33-45 kg-cm, 29-39 Ib-in) TORQUE WRENCH DIFFERENTIAL...
Page 385 Main Menu Table of Contents Oil Seal Installation Install the oil seal into the transmission housing using the special tools as shown. 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 as shown.
Page 386 Main Menu Table of Contents Special Tools 16-13, 16-14, 16-16, 16-17 16-16 16-16 16-16 16-17 16-14 16-14, 16-16, 16-17...
Page 387 Main Menu Table of Contents Driveshafts Removal INSPECTION Raise the car, and place safety stands in the proper locations (see section Driveshaft Boot Remove the rear wheels. Check the boots on the driveshaft for cracks, damage, leaking grease and loose boot bands. Drain the transmission oil or fluid (see section 13 If any damage is found, replace the boot.
Page 388 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 389 Main Menu Table of Contents 15. Pry the driveshaft assembly with a screwdriver as 12. Remove the self-locking nut and flange bolt. shown to force the set ring past the groove. 13. Remove the self-locking nut and adjusting bolt, then disconnect the lower control arm from the sub-frame.
Page 390 Main Menu Table of Contents Driveshafts Disassembly Remove the rollers from the spider. To remove the boot band, pry up the locking tabs with screwdriver, and raise the end of the band. NOTE: Carefully clamp the driveshaft in a vise ROLLER with soft jaws.
Page 391 Main Menu Table of Contents 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 392 Main Menu Main Menu Table of Contents Table of Contents Driveshafts Reassembly 5. Fit the rollers to the spider with their high shoulders Outboard joint side facing outward. NOTE: Wrap the splines with vinyl tape to prevent CAUTION: damage to the boot. •...
Page 393 Main Menu Main Menu Table of Contents Table of Contents Install the spring and cap, then fit the outboard Inboard joint side joint onto the driveshaft. NOTE: Wrap the splines with vinyl tape to prevent damage to the boot. 9. Install the inboard boot to the driveshaft, then remove the vinyl tape.
Page 394 Main Menu Table of Contents Driveshafts Reassembly 1 5. Fit the inboard joint onto the driveshaft. 13. Fit the rollers to the spider with their high shoulders facing outward. CAUTION: • Reinstall the rollers in their original positions on the spider. INBOARD JOINT •...
Page 395 Main Menu Table of Contents 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. 18. Lightly tap on the doubled-over portions to reduce 20.
Page 396 Main Menu Table of Contents Intermediate Shaft Replacement NOTE: Mark the support base and bearing support Drain the oil from the transmission (see section 13 M/T or section 14 A/T). during disassembly to ensure proper positioning during reassembly. Remove the right driveshaft assembly (see page CAUTION: The bearing support and support base 16-3).
Page 397 Main Menu Table of Contents Disassembly CAUTION: The bearing support and support base are Press the intermediate shaft out of the shaft bear- made of aluminum. Be careful not to damage them ing using the special tool. when servicing. Remove the intermediate shaft outer seal from the bearing support.
Page 398 Main Menu Table of Contents Intermediate Shaft Disassembly Press the intermediate shaft bearing out of the bearing support using the special tools. Press DRIVER 07749 - 0010000 ATTACHMENT, BEARING 52 x 55 mm 07746 - 0010400 HUB DIS/ASSEMBLY BASE 07GAF - SD40700...
Page 399 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 fitted and must be replaced as an assembly. Corrosion resistant bolt/nut SUPPORT BASE Check for damage.
Page 400 Main Menu Table of Contents Intermediate Shaft Reassembly Press the intermediate shaft bearing into the bear- Press the intermediate shaft inner seal into the bearing support using the special tools. ing support using the special tools. Press DRIVER 07749-0010000 Press SEAL DRIVER DRIVER ATTACHMENT...
Page 401 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. Press DRIVER 07749-0010000...
Page 402 Main Menu Table of Contents Special Tools 17-55 17-63 17-23 17-61, 17-44 17-60...
Page 403: Index, Page
Main Menu Table of Contents Component Locations Index NOTE: • If an intact airbag assembly has been removed from a scrapped car or has been found defective or damaged during transit, storage or service, it should be deployed (see section 24).
Page 404 Main Menu Table of Contents System Description Steering Column The NSX/NSX-T has a till/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 405 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 stopper shim at the tip of the lever pivot, allowing the shaft to telescope.
Page 406 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 407 Main Menu Main Menu Table of Contents 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 408 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 409 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 410 Main Menu Table of Contents System Description Function and Operation Steering Sensor The steering sensor consists of a torque sensor, an TORSION BAR interface, and the rotation sensor. INPUT SHAFT Torque Sensor The torque sensor converts steering torque input and its direction to voltage signals, in conjunction with the interface.
Page 411 Main Menu Table of Contents Rotation Sensor The rotation sensor is housed inside the steering gearbox near the pinion. It converts the rotation speed and direction of steering into voltage signals. The rotation of the steering wheel is transmitted to the pinion, which drives the sensor by accelerating its speed through the three pieces of transmission the gears.
Page 412 Main Menu Table of Contents System Description Function and Operation EPS Control Unit The control unit receives input signals from the car's speed sensors, torque sensor and rotation sensor. It performs a mul- titude of control functions, including a circuit which can detect troubles in each functional part of the system and the con- trol unit itself.
Page 413 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 414 Main Menu Table of Contents System Description Function and Operation The 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. The driving circuit controls the rotational direction and speed of the motor by driving the FET bridge circuit with a pulse width modu- lation (PWM) method on receipt of an input of driving signals from the EPS control unit.
Page 415 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 416 Main Menu Table of Contents Component Locations TRANSMISSION CONTROL GAUGE ASSEMBLY MODULE (TCM) 22P CONNECTOR EPS CONTROL UNIT ALTERNATOR UNDER-HOOD FUSE/ 4P CONNECTOR RELAY BOX VEHICLE SPEED SENSOR (VSS) (M/T) PULSE UNIT 7P CONNECTOR TORQUE SENSOR 6P CONNECTOR/ ROTATION SENSOR 4P CONNECTOR STEERING GEARBOX (TORQUE SENSOR/...
Page 417 Main Menu Table of Contents GAUGE ASSEMBLY EPS INDICATOR LIGHT UNDER-HOOD FUSE/RELAY BOX IG SW (50 A) CLOCK (7.5 A) E-PS (50 A) UNDER-DASH FUSE BOX No. 5 (15 A) No. 2 (15 A)
Page 418 Table of Contents Main Menu EPS Control Unit Terminal Arrangement...
Page 419 Main Menu Table of Contents 3P CONNECTOR (LEFT SIDE) VB: Battery voltage IG SW: Ignition switch WIRE SIDE OF FEMALE TERMINALS 3P CONNECTOR (RIGHT SIDE) VB: Battery voltage IG SW: Ignition switch WIRE SIDE OF FEMALE TERMINALS 6P CONNECTOR PULSE UNIT 7P CONNECTOR (MT) WIRE SIDE OF FEMALE TERMINALS WIRE SIDE OF FEMALE TERMINALS 4P CONNECTOR...
Page 420 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 421 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 422 Main Menu Table of Contents Diagnostic Trouble Code (DTC) Indication DTC Indication Pattern: Example: 1.3 seconds DTC: 11 DTC: 12 0.28 seconds EPS Indicator light ON Repeat EPS Indicator light OFF Connect the SCS Turn the ignition service connector switch ON (II) 0.36 seconds 1.3 seconds •...
Page 423 Main Menu Table of Contents Diagnostic Trouble Code (DTC) Symptom-to-System Chart 17-27 17-29 17-31 17-36 17-38 17-40 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 424 Main Menu Table of Contents Troubleshooting Hard Steering Steering is heavy. Start the engine and check the EPS indicator light. Does the EPS indicator light Refer to the symptom-to-system come on? Chart (see page 17-25). Check the tire pressure and front wheel alignment.
Page 425 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 426 Main Menu Table of Contents Steering Wheel Removal Remove the Torx bolts using a Torx T30 bit, then Airbag Removal remove the 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 427 Main Menu Table of Contents Steering Wheel Removal Disconnect the connectors from the horn and cruise Remove the steering wheel nut. control set/resume switches, then remove the cable reel connector from its clips. Remove the steering wheel by rocking it slightly from side-to-side as you pull steadily with both hands.
Page 428 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 airbag assembly before install- down, accidental deployment could propel the unit with ing.
Page 429 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 STEERING WHEEL not pinched or interfering with other car parts.
Page 430 Main Menu Table of Contents Steering Wheel Installation 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 TORX BOLT system operation: 10 N-m (1.0 kg-m, 7 Ib-ft) •...
Page 431 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 432 Main Menu Table of Contents Steering Column Removal Remove the combination switch assembly from the 10. Remove the steering joint bolts and toothed lock column shaft. washers from the steering joint. STEERING JOINT NOTE: The combination switch can be removed by disconnecting only the TCS sensor connector.
Page 433 Main Menu Table of Contents Inspection 6 mm SOCKET BOLT RETAINING SHIM 10 N-m COLLARS (1.0 kg-m, 7 lb-ft) Check for damage. STEERING COLUMN ASSEMBLY TCS SENSOR TOOTHED STEERING JOINT LOCK WASHER BOLTS 22 N-m (2.2 kg-m, 16 Ib-ft) COLUMN HOLDER 8 mm FLANGE NUTS CLIP 16 N-m...
Page 434 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 435 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. COMBINATION SWITCH UPPER COLUMN COVER ASSEMBLY LOWER COLUMN COVER 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 436 Main Menu Table of Contents Steering Column Installation 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. DASHBOARD BRACE DASHBOARD LOWER DASHBOARD LOWER PANEL...
Page 437 Main Menu Table of Contents Steering Gearbox Removal/Installation 7. Install the 10 mm hex nut on the balt joint. Be sure NOTE: Before removing the steering gearbox, make that the 10 mm hex nut is flush with the ball joint sure the front wheels are straight ahead.
Page 438 Main Menu Main Menu Table of Contents Table of Contents Steering Gearbox Removal/Installation 16. Remove the radiator pipe bracket at the front com- 12. Disconnect the connectors from the EPS wire har- ness. partment bulkhead. 13. Remove the ground cable by removing the EPS wire harness stay.
Page 439 Main Menu Main Menu Table of Contents Table of Contents NOTE: Before removing the gearbox, place a stand jack Lower the gearbox and front crossbeam with care under the gearbox and front crossbeam to lightly sup- so as not to interfere with the radiator pipe. port them.
Page 440 Main Menu Main Menu Table of Contents Table of Contents Steering Gearbox Removal/Installation 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.
Page 441 Table of Contents Main Menu Illustrated Index CAUTION: Do not try to disassemble the power steering gearbox. If the gearbox is faulty, replace it as an assembly. Corrosion resistant bolt/nut 10 x 97 mm FLANGE BOLT 10 x 84 mm FLANGE BOLT STEERING 60 N-m...
Page 442 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 443 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 444 Main Menu Table of Contents Steering Gearbox Inspection 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 (0.4 in) in length.
Page 445 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 446 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 447 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 448 Main Menu Table of Contents 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 Disposal ..18-44 Removal, page 18-21...
Page 449 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 450 Main Menu Table of Contents (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 451 Main Menu Table of Contents 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 452 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 453 Main Menu Table of Contents Wheel Alignment Front Wheel Alignment Adjustment Procedure NOTE: Camber: • NSX/NSX-T four wheel alignment requires the use of — Loosen the self-locking nut on the front lower control arm adjusting point, and adjust the equipment designed specifically for four wheel in- camber by turning the adjusting cam.
Page 454 Main Menu Table of Contents 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 455 Main Menu Table of Contents Wheel Alignment Front Turning Angle Inspection NOTE: • Place a car on a level surface before inspection. • Release the parking brake and be sure that the car is empty. • Check that the suspensions are at the standard height (see page 18-6).
Page 456 Main Menu Table of Contents Rear Wheel Alignment Adjusting Procedure Rear wheel alignment adjusting procedure 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. TOP VIEW...
Page 457 Main Menu Table of Contents Wheel Alignment Rear Wheel Alignment Adjusting Procedure NOTE: Camber • NSX/NSX-T four wheel alignment requires the use of — 1. Loosen the self-locking nut on the rear lower equipment designed specifically for four wheel control arm adjusting point, then adjust the cam independent suspensions and capable of immediate position so that the right and left graduations feedback.
Page 458 Main Menu Table of Contents Runout Bearing End Play Raise the car off the ground, and support it with safe- Front Wheel End Play: ty 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 rim, and turn the wheel slowly by hand.
Page 459 Main Menu Table of Contents 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 kg-m, 0.7 Ib-ft) of torque to turn the test nut on the bolt). •...
Page 460 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 461 Main Menu Table of Contents Front Suspension Hub Replacement Loosen the wheel nuts slightly. Remove the wheel sensor from the knuckle and front lower control arm. Raise the front of car, and support it on safety stands in proper locations (see section NOTE: •...
Page 462 Main Menu Table of Contents Remove the flat head screws. Front Wheel Bearing Replacement: Screw two 8 x 12 mm bolts into the disc to push it Raise the locking tab on the spindle nut, then remove the nut. away from the hub. NOTE: Turn each bolt two turns at a time to pre- SPINDLE NUT Unstake...
Page 463 Main Menu Table of Contents 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 464 Main Menu Table of Contents 7. Tighten the new spindle nut to specified torque, then stake the spindle nut shoulder against the spindle. 335 N-m (33.5 kg-m, 242 Ib-ft) Stake After tightening, use a drift to stake spindle nut shoulder against the spindle.
Page 465 Main Menu Table of Contents 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 466 Main Menu Table of Contents Knuckle/Control Arms/Compliance Pivot 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 467 Main Menu Table of Contents 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 468 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 19. Separate the lower control arm and damper by HEX WRENCH removing the damper mounting bolt.
Page 469 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. 23. Install the 12 mm hex nut on the ball joint. Be sure 27.
Page 470 Main Menu Table of Contents NOTE: 31. Remove the compliance pivot assembly by remov- • Install the upper control arm on the frame before ing the bolts and nuts shown. installing the compliance pivot assembly. 32. Remove the upper control arm assembly by remov- •...
Page 471 Main Menu Table of Contents Knuckle/Control Arms/Compliance Pivot Ball Joint Boot Replacement NOTE: The upper control arm ball joint, lower control Wipe the grease off the sliding surface of the ball arm ball joint and knuckle upper ball joint are attached pin, and pack with fresh grease.
Page 472 Main Menu Table of Contents Front Damper Removal Disassembly/Inspection 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. Separate the damper and lower arm by removing CAUTION: Do not compress the spring more than necessary to remove the nut.
Page 473 Main Menu Table of Contents Front Damper Inspection SELF-LOCKING NUT 10 x 1.25 mm Replace. 30 N-m (3.0 kg-m. 22 Ib-ft) DAMPER MOUNTING RUBBER SELF-LOCKING DAMPER MOUNTING WASHER 10 x 1.25 mm Check for weakness. Replace. 44 N-m DAMPER MOUNTING (4.4 kg-m, 32 Ib-ft) COLLAR DUST COVER PLATE...
Page 474 Main Menu Table of Contents Installation Reassembly Install the damper unit on a spring compressor. Reposition the damper on the frame with the weld- ed nut of the hose bracket facing outside as Assemble the damper in reverse order of removal shown.
Page 475 Main Menu Table of Contents 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 kg-m, 0.7 Ib-ft) of torque to turn the test nut on the bolt). •...
Page 476 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 477 Main Menu Table of Contents Rear Suspension Hub Replacement Remove the banjo bolt and disconnect the brake Remove the center cap, then pry the spindle nut lock tab away from the spindle and loosen the nut. hose, then remove the brake hose clamp from the knuckle.
Page 478 Main Menu Table of Contents Remove the flat head screws. Rear Wheel Bearing Replacement: Screw 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 479 Main Menu Table of Contents 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 480 Main Menu Table of Contents 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 481 Main Menu Table of Contents 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. Remove the splash guard from the knuckle. Hold the ball pin of the stabilizer link with a hex wrench, then loosen the self-locking nut.
Page 482 Main Menu Table of Contents 15. Separate the knuckle from the upper control arm 9. Remove the cotter pin from the castle nut of the lower control arm ball joint, and remove the nut. and driveshaft outboard joint. NOTE: Do not remove the driveshafts from the dif- 10.
Page 483 Main Menu Table of Contents Knuckle/Control Arms Removal 19. Remove the toe control arm. 17. 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 1.5 mm 95 N-m Replace.
Page 484 Main Menu Table of Contents Ball Joint Boot Replacement Wipe the grease off the sliding surface of the ball NOTE: The upper control arm ball joint is attached with the boot retainer to improve the sealing efficiency of the pin, and pack with fresh grease (upper ball joint boot.
Page 485 Main Menu Table of Contents Rear Damper Removal Remove the rear wheels. Remove the three self-locking nuts. Remove the lower rear hatch glass trim. Remove the rear strut brace. SELF-LOCKING NUT 10 x 1.25 mm REAR HATCH GLASS STRUT BRACE Replace.
Page 486 Main Menu Table of Contents 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. KNUCKLE STABILIZER STABILIZER LINK Corrosion resistant bolt/nut...
Page 487 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 as shown. tions, then remove the self-locking nut. 3.
Page 488 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 kg-m, 39 Ib-ft) BUMP STOP DAMPER PLATE MOUNTING BASE DUST COVER DAMPER SLEEVE MOUNTING...
Page 489 Main Menu Table of Contents Rear Damper Installation Reposition the damper assembly between the frame and knuckle. 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 490 Main Menu Table of Contents 6. Install the new self-locking nuts on the top of the damper assembly. 7. Tighten the damper mounting nut to the specified torque. 8. Secure the damper assembly to the frame with the self-locking nuts. 9.
Page 491 Main Menu Table of Contents Special Tools Ref. No. Tool Number Description Page Reference Bleeder T-Wrench 19-62('91-'92)('93-'96),64 07HAA – SG00100 or ('91-'92)('93-'96),65('91-'92) 07HAA – SG00101 ('93-'96),69('91-'92)('93-'96) 07HAE – SG00100 Brake Spring Compressor 19-21, 07HAJ – SG00100or ALB Checker (US) 19-41, 43, 64('91-'92)('93-'96), 69('91-'92)('93-'96) 07HAJ –...
Page 492 Main Menu Table of Contents Illustrated Index The accumulator contains high-pressure nitrogen gas; do not puncture, expose to flame or attempt to disassemble the accumulator or it may explode; severe personal injury may result. HYDRAULIC SYSTEM Relieving Accumulator/line pressure, page 19-62 ('91-'92) ('93-'96) MASTER CYLINDER Index/Torque, page...
Page 493 Main Menu Table of Contents Parking Brake Pedal Height Adjustment Adjustment Loosen the brake switch locknut, and back off the Remove the console mat, the four screws and the brake switch until it is no longer touching the brake console box. pedal.
Page 494 Main Menu Table of Contents Front Brakes Index/Inspection CAUTION: • Do not spill brake fluid on the car; it may damage • Never use an air hose or dry brush to clean brake the paint; if brake fluid does contact the paint, assemblies.
Page 495 Main Menu Table of Contents Front Brake Pads Inspection/Replacement Remove the two brake hose mounting bolts. Remove the two caliper mounting bolts, and move the caliper • Never use an air hose or dry brush to clean brake out of the way. assemblies.
Page 496 Main Menu Table of Contents 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. 7. Install the pad retainers. 12. Set the caliper down into position, then install the brake hose mounting bolts and the caliper moun- ting bolts.
Page 497 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 498 Main Menu Table of Contents Front Caliper Front Brake Disc Run-Out Inspection Reassembly Raise each side of the car, and support it on safety CAUTION: • Before reassembling, check that all parts are free of stand (see page through 1-11). Remove the front dust and other foreign particles.
Page 499 Main Menu Table of Contents Front Brake Disc Thickness and Parallelism Inspection Raise each side of the car, and support it on safety stands (see page through 1-11). Remove the front wheels. Remove the brake disc pads (see page 19-6). Using a micrometer, measure disc thickness at eight points, approximately 45°...
Page 500 Main Menu Table of Contents Master Cylinder and Brake Booster Index/Torque BRAKE BOOSTER Do not disassemble. Tests, page 19-14 Pushrod Clearance Adjustment, page 19-15 MASTER CYLINDER Inspection, page 19-13...
Page 501 Main Menu Table of Contents Master Cylinder Inspection CAUTION: • Be careful not to bend or damage the brake pipes when removing the master cylinder. • Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediate- ly with water.
Page 502 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 1 5 seconds.
Page 503 Main Menu Table of Contents Pushrod Clearance Adjustment NOTE: If the clearance between the gauge body NOTE: Master cylinder pushrod-to-piston clearance must be checked and adjustments made, if necessary, and adjusting nut is 0.4 mm (0.02 in), the pushrod- before installing master cylinder. to-piston clearance is 0 mm.
Page 504 Main Menu Table of Contents Rear Brakes Torque/Inspection CAUTION: • Do not spill brake fluid on the car; it may damage • Never use an air hose or dry brush to clean brake the paint; if brake fluid does contact the paint, assemblies.
Page 505 Main Menu Table of Contents Rear Brake Pads Inspection/Replacement Remove the two caliper mounting bolts and the caliper from the bracket. • Never use an air hose or dry brush to clean brake assemblies, Use an OSHA-approved vacuum cleaner to avoid CAUTION: •...
Page 506 Main Menu Table of Contents Rear Brake Pads Inspection/Replacement (cont'd) 9. Install the new brake pads and pad shims on caliper Remove the pad shims, pads and pad retainers. bracket. Using vernier calipers, measure the thickness of each brake pad lining. •...
Page 507 Main Menu Table of Contents 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. Install the new cable clip securely. 13.
Page 508 Main Menu Table of Contents Rear Brake Disc Run-Out Inspection Raise each side of the car, and support it on safety stands (see page through 1-8). Remove the rear wheels. 2. Remove the brake pads (see page 19-17). Inspect the disc surface for grooves, cracks, and rust.
Page 509 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 car; it may damage the paint;...
Page 510 Main Menu Table of Contents 9. Adjust the special tool as shown. Remove the circlip, washer, adjusting spring A, and the adjusting nut from the piston. 07HAE-SG00100 Remove the piston seal. 10. Install the special tool between the caliper body and spring guide as shown.
Page 511 Main Menu Table of Contents Rear Caliper Disassembly (cont'd) 12. Remove the adjusting bolt. 1 5. Remove the return spring. 13. Remove the spring cover, adjusting spring B, 16. Remove the parking lever and cam as an assembly spacer, bearing A and cup from the adjusting bolt. from the caliper body.
Page 512 Main Menu Table of Contents Reassembly CAUTION: 5. Install the pin in the cam. • Make sure all parts are clean before reassembly. • Use only new replacement parts. Install a new O-ring on the sleeve piston. • Use only clean DOT3 or 4 brake fluid. •...
Page 513 Main Menu Table of Contents Rear Caliper Reassembly (cont'd) 11. Install the special tool as shown. 8. Install a new cup with its groove facing the bearing A side on the adjusting bolt. 12. Compress the spring until it bottoms out. 9.
Page 514 Main Menu Table of Contents 16. Coat the new piston seal and piston boot with 18. Install the brake pad retainers and brake pads. silicone grease, and install them in the caliper. 19. Install the pad spring on the caliper. 20.
Page 515 Main Menu Table of Contents Brake Hoses/Pipes Inspection Inspect the brake hoses for damage, deterioration, leaks, interference or twisting. Check the brake lines for damage, rusting and leakage. Also check for bent brake lines. Check for leaks at hose and line joints or connections, and retighten if necessary. CAUTION: Replace the brake hose clip whenever the brake hose is serviced.
Page 516 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 permature cable failure.
Page 517 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 maneuverabily of the vehicle is reduced if the front wheels are locked, creating an extremely unstable condition.
Page 518 Main Menu Table of Contents Master Cylinder Construction A tandem master cylinder with center valves are 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 separately on each system (front right wheel &...
Page 519 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation (cont'd) 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 520 Main Menu Table of Contents 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 voltages with frequency in proportion to wheel rotating speed.
Page 521 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation (cont'd) 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." 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...
Page 522 Main Menu Table of Contents 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 523 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation (cont'd) 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 524 Main Menu Table of Contents Operation 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 525 Main Menu Table of Contents Anti-lock Brake System (ABS) Description Features/Construction/Operation (cont'd) If brake inputs (force excerted 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 526 Main Menu Table of Contents Wiring/Connector Location...
Page 527 Main Menu Table of Contents ALB Checker Function Test NOTE: NOTE: Place the vehicle on level ground with the • The ALB checker is designed to confirm proper wheels blocked, put the transmission in neutral for operation of the anti-lock brake system (ABS) by manual transmission models, and in simulating each system function and operating con- automatic transmission models.
Page 528 Main Menu Table of Contents ALB Checker Function Test (cont'd) Turn the Mode Selector switch further to "2". Mode 5: Sends the driving signal of each wheel, then sends 5. Depress the brake pedal firmly and push the Start the lock signal of the front right wheel to the ABS Test switch control unit.
Page 529 Main Menu Table of Contents Wheel Sensor Signal Confirmation NOTE: Use the ALB checker (mode 0) to confirm pro- per wheel sensor operation. Disconnect the 6-P inspection connector from the connector cover located under the glove box, and connect the 6-P inspection connector to the ALB checker.
Page 530 Main Menu Table of Contents Troubleshooting Anti-lock Brake System (ABS) Indicator Light Temporary Driving Conditions: ABS Indicator Light Circuit: 1. The ABS indicator light will come on and the ABS CAUTION: Use only the digital multimeter to control unit memorizes the diagnostic trouble code check the system.
Page 531 Main Menu Table of Contents Diagnostic Trouble Code (DTC): Stop the engine. Disconnect the service check connector from the connector cover located under the glove box. Connect the two terminals of the service check connector with a jumper wire. Turn the ignition switch on, but do not start the engine. Record the blinking frequency of the ABS indicator light.
Page 532 Main Menu Table of Contents Troubleshooting Symptom-to-System Chart 19-71 19-47 19-50 19-71 19-51 19-52 19-71 19-53 19-55 19-57 19-59...
Page 533 Main Menu Table of Contents Hydraulic System Hydraulic Connections CAUTION: Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
Page 534 Main Menu Table of Contents Hydraulic System Relieving Accumulator/Line Pressure Drain the brake fluid from the master cylinder and modulator reservoir thoroughly. Remove the red cap from the bleeder on the top of the power unit. 3. Install the special tool on the bleeder screw, and turn it out slowly 90° to collect high-pressure fluid into reservoir. Turn the special tool out one complete turn to drain the brake fluid thoroughly.
Page 535 Main Menu Table of Contents Modulator/Solenoid Unit Index/Torque CAUTION: • Do not damage the brake pipes when removing the spare tire and modulator/solenoid unit. • Do not spill brake fluid on the car; it may damage the paint; if brake fluid does contact the paint, wash it off immediate- ly with water.
Page 536 Main Menu Table of Contents Modulator/Solenoid Unit Solenoid Leak Test Start the engine and release the parking brake. Disconnect the 6-P inspection connector (PNK) from the connector cover located under the glove Turn the Mode Selector to 1, and press the Start box, and connect the 6-P inspection connector to Test button.
Page 537 Main Menu Table of Contents Solenoid Flushing 5. Connect the RED terminal from one solenoid con- Remove the motor relay from the under-hood nector to the battery positive (+) terminal with a fuse/relay box. (Location: see page 19-40) remote starter switch. Connect the BLK terminal from the same solenoid to the battery negative (-) Install the special tool into the two motor relay cavi- terminal with a jumper lead as shown.
Page 538 Main Menu Table of Contents Power Unit Torque/Inspection CAUTION: • Do not attempt to disassemble the power unit ex- Before reassembling, check that all parts are free of cept for those components shown in this illustration. dust and other foreign particles. •...
Page 539 Main Menu Table of Contents Accumulator/Pressure Switch Index/Torque CAUTION: Do not spill brake fluid on the car; it may damage the Make sure no dirt or other foreign matter is allowed paint; if brake fluid does contact the paint, wash it to contaminate the brake fluid.
Page 540 Main Menu Table of Contents Accumulator/Pressure Switch Accumulator/Pressure Accumulator Disposal Switch Removal 1. Drain the high pressure brake fluid from the power The accumulator contains high-pressure unit (see page 19-62). nitrogen gas, do not puncture, expose to flame, or at- tempt to disassemble the accumulator or it may ex- Remove three 6 mm flange bolts, then remove the plode;...
Page 541 Main Menu Table of Contents Bleeding Air Bleeding with ALB Checker 1. Disconnect the 6-P inspection connector (PNK) Start the engine and release the parking brake. from the connector cover located under the glove box, and connect the 6-P inspection connector to NOTE: Depress the brake pedal firmly while test in the special tool.
Page 542 Main Menu Table of Contents ABS Control Unit Replacement Disconnect the connectors from the ABS control unit SRS components are located in this area. Review the SRS by removing the wire harness band. component locations, precautions, and procedures in the section 24 before performing repairs or service.
Page 543 Main Menu Table of Contents ABS Control Unit Pulsers/Sensors Fail-Safe Relays/Motor Relay Inspection Inspection Check for continuity between terminals Check the pulser for chipped or damaged teeth. There should be no continuity. 2. Measure air gap between the sensor and pulser all 2.
Page 544 Main Menu Table of Contents Pulsers/Sensors Front Sensor Replacement NOTE: • Be careful when installing the sensors to avoid twisting the wires. • After sensor replacement confirm proper opera- tion (see page 19-43). CORROSION RESISTANT BOLT 6 x 1.0 mm 10 N-m (1.0 kg-m.
Page 545 Table of Contents Main Menu Special Tools Ref. No. Tool Number Description Page Reference 07PAZ-0010100 SCS Service Connector 19-84('91-'93)('94-'96)
Page 546 Main Menu Table of Contents Component Locations RIGHT-REAR WHEEL SENSOR ENGINE CONTROL MODULE (ECM) TRANSMISSION CONTROL MODULE (TCM) ABS CONTROL UNIT THROTTLE BODY UNDER-HOOD STEERING ANGLE SENSOR FUSE/RELAY BOX RIGHT-FRONT WHEEL SENSOR THROTTLE ACTUATOR LEFT-REAR WHEEL SENSOR TCS CONTROL UNIT TCS SWITCH LEFT-FRONT LATERAL ACCELERATION (Lg) SENSOR...
Page 547 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 548 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 549 Main Menu Table of Contents System Description Construction and Function 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 TCS INDICATOR LIGHT...
Page 550 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 Lg SENSOR TCS control unit as a lateral acceleration signal.
Page 551 Main Menu Table of Contents TCS Control Unit Terminal Arrangement...
Page 552 Main Menu Table of Contents...
Page 553 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 554 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 555 Main Menu Table of Contents Troubleshooting Troubleshooting Guide Refer page 19-87(' 9 1-' 9 3)(' ' 9 4-' 9 6) 19-89(' 9 1-' 9 3)(' ' 9 4-' 9 6) 19-90(' 9 1-' 9 3)(' ' 9 4-' 9 6) 19-91(' 9 1-' 9 3)(' ' 9 4-' 9 6) 19-94(' 9 1-' 9 3)(' ' 9 4-' 9 6) 19-97(' 9 1-' 9 3)(' ' 9 4-' 9 6)
Page 556 Main Menu Table of Contents Electronic Components TCS Switch Inspection Lateral Acceleration (Lg) Sensor Inspection Between terminal No. 4 and No. 5 CAUTION: Be careful not to drop or bump the Lg sensor, (Illumination light circuit) and don't remove or install it with an impact wrench; the Lg sensor may be damaged.
Page 557 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 558 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: 2. 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 559 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). 2. Remove the wire harness bracket. Disconnect the TCS control unit connectors. Remove the TCS control unit. TCS CONTROL UNIT CONNECTORS WIRE HARNESS BRACKET...
Page 560 Main Menu Table of Contents Special Tools Ref. No. Tool Number Description Page Reference 07MAZ-SP00200 SRS Service Connector 20-55('91-'93)('94-'96), 56('91-'93)('94-'96),...
Page 561 Main Menu Table of Contents 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 562 Main Menu Table of Contents 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 563 Main Menu Table of Contents 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< Part Name Material Replacement section 23 Headlight lid PA6/PPE-M Polyamide/Polyphenylene ether...
Page 564 Main Menu Table of Contents Doors Index REAR SASH GLASS Adjustment, see page 20-14('93-'96), Adjustment, see page 20-17('93-'96),16('91-'92) 13('91-'92) REAR GLASS FRONT SASH GUIDE Adjustment, see page 20-17('93-'96), 16('91-'92) FRONT GLASS GUIDE STOPPER PLATES REGULATOR POWER MIRROR ASSEMBLY INNER MOLDING INSIDE STABILIZERS OUTER MOLDING DOOR...
Page 565 Main Menu Table of Contents Disassembly NOTE: Lower the glass fully. Disconnect the connector and handle cable, then 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 566 Main Menu Table of Contents Doors Disassembly 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 567 Main Menu Table of Contents 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: Before removing the adjusting bolt, measure and...
Page 568 Main Menu Table of Contents Doors Disassembly 17. 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 569 Main Menu Table of Contents 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 570 Main Menu Table of Contents Doors Moldings Removal Door Removal Lower the glass fully. NOTE: Lower the glass fully. Remove: (see pages 20-7('93-'96),6('91-'92), 2. Remove the seat (see page 20-39('93-'96),38('91-'92) 8('93-'96),7('91-'92) Trim plate Sash covers Disconnect the connectors. Inside door handle Door panel Inner molding: Remove the door by removing the door mounting...
Page 571 Main Menu Table of Contents Assembly Assemble the door in the reverse order of disassembly, 2. Roll the glass up and down to see if it moves freely and also: without binding. Also make sure that there is no clearance between the glass and upper weather- Grease all the sliding surfaces of the regulator strip when the glass is closed.
Page 572 Main Menu Table of Contents Doors Glass Adjustment Adjusting bolt locations. NOTE: Take care not to damage location on the front and rear sashes. GLASS GLASS STOPPERS STOPPER PLATE STOPPER PLATE FRONT SASH INSIDE STABILIZERS REAR SASH FRONT GLASS GUIDE REGULATOR ASSEMBLY REAR GLASS GUIDE...
Page 573 Main Menu Table of Contents NOTE: Measuring Points: 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 ('93-'96), 18('91-'92) Lower the glass fully. 1.
Page 574 Main Menu Table of Contents Doors Glass Adjustment (cont'd) Adjust the Clearance "H" as follows: "H" (See page 20-15 ('93-'96),14('91-'92) GLASS c. Loosen the nuts securing the rear glass guide, and adjust the glass fore and aft by moving the rear glass guide.
Page 575 Main Menu Table of Contents 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 GLASS that the ends of the adjusting bolts still project out of the locknuts.
Page 576 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 577 Main Menu Table of Contents Position Adjustment Striker Adjustment After installing the door, check for a flush fit with the Make sure the door latches securely without slamming. body, then check for equal gap between the front, rear, If it needs adjustment: and bottom door edges and the body.
Page 578 Main Menu Table of Contents 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('93-'96),6('91-'92), 8('93-'96),7('91-'92).
Page 579 Front and Center Pillar Retainer/Upper Weatherstrip/ Main Menu Table of Contents Center Pillar Panel Replacement Disassemble in numbered sequence. CAUTION: Wear gloves to remove and install the retainer. SPECIAL BOLT (2) NOTE: Check the upper weatherstrip for damage and deterioration, and replace it if necessary. Take care not to bend the front and center pillar retainer.
Page 580: Installation, Page
Main Menu Table of Contents Windshield, Rear Window, Rear Hatch Glass Index ( ): Quantity of parts used. MOLDING Replacement, see page 20-36('93-'96), 35('91-'92) REAR HATCH GLASS Removal. see page 20-33 ('93-'96),32('91-'92) Installation, see page 20-33 ('93-'96),32('91-'92) UPPER RUBBER INNER RUBBER OUTER RUBBER UPPER MOLDING LOWER MOLDING...
Page 581 Main Menu Table of Contents Windshield Removal CAUTION: 4. Using an awl, make a hole through the adhesive 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. Use covers to avoid damaging any surfaces.
Page 582 Main Menu Table of Contents 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 583 Main Menu Table of Contents 8. Thoroughly mix all the adhesive and hardener Glue the rubber dam to the inside face of the wind- together on a glass or metal plate with a putty shield, as shown, to contain the adhesive during installation.
Page 584 Main Menu Table of Contents Windshield Installation 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 585 Main Menu Table of Contents 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 586 Main Menu Table of Contents Rear Window Removal 15. Let the adhesive dry for at least one hour, then CAUTION: spray water over the windshield and check for Wear gloves to remove and install the rear window. leaks. Mark leaking areas and let the windshield Since the rear window is double glazed glass with the dry, then seal with urethane windshield adhesive.
Page 587 Main Menu Table of Contents Rear Window Removal Apply protective tape along the edge of the body. 4. 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 588 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 589 Main Menu Table of Contents Rear Window Installation 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 590 Main Menu Table of Contents 15. Thoroughly adhesive hardener 13. 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 591 Main Menu Table of Contents Rear Window Installation 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 592 Main Menu Table of Contents 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 593 Main Menu Table of Contents 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 594 Main Menu Table of Contents 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 595 Main Menu Table of Contents Headliner/lnterior Trim Replacement To remove the headliner, first remove the: Sunvisors Center pillar trim panels Front pillar trim panels HEADLINER Seats (see page 20-39('93-'96) Ceiling light (see section NOTE: When installing the headliner, be careful not to fold or bend it.
Page 596 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 597 Seats Main Menu Table of Contents Seat Cover Replacement CAUTION: Wear gloves to remove and install the seat Detach the clips from under the seat, then remove the seat cushion. cover. Clip locations NOTE: Take care not to tear the seams or damage the cover.
Page 598 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 599 Main Menu Table of Contents Seats Seat Cover Replacement 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 600 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 COVER...
Page 601 Main Menu Table of Contents 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('93-'96)
Page 602 Main Menu Table of Contents 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 603 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 604 Main Menu Table of Contents 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('93-'96), 38('91-'92) Side sill pad (see page 20-38('93-'96), 37('91-'92) Footrest Rear side trim panel (see page 20-38('93-'96),...
Page 605 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 606 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 607 Main Menu Table of Contents 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 608 Main Menu Table of Contents After insertting 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 609 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. Center console panel removal: NOTE: Take cere not to scratch the dashboard, center console panel and related parts. Do not drop the screws inside the dashboard.
Page 610 Main Menu Table of Contents Climate control unit, stereo cassete/radio and glove box removal: Disassemble in numbered sequence. NOTE: Remove the center console panel. CLIMATE CONTROL UNIT Disconnect the connectors. SRS UNIT STEREO CASSETE RADIO Disconnect the connectors. GROUND CABLE Passenger's: Disconnect the connectors.
Page 611 Main Menu Table of Contents Dashboard Component 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. NOTE: Take care not to scratch the dashboard, steering column and related parts.
Page 612 Main Menu Table of Contents Replacement NOTE: SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the Remove the access panel, then remove the section (24) before performing repairs or service. short connector (RED). Disconnect the connec- 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 613 Main Menu Table of Contents Dashboard Replacement 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 kg-m.
Page 614 Main Menu Table of Contents 5. Remove the mounting screws, then remove the side air vents from each side of the dashboard. 6. Remove the dashboard end plate, and fold the console carpet down (see page 20-47('94-'96) ('91-'93)). Remove the dashboard mounting bolts and screw, then lift and remove the dashboard. NOTE: Take care not to scratch the dashboard.
Page 615 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 616 Main Menu Table of Contents Front Bumper Disassembly BUMPER WASHER TANK BRACKET BUMPER BEAM ABSORBER GUARD UPPER SEAL BUMPER UPPER PLATE HEADLIGHT LID UPPER PLATE UPPER FRAME FOG LAMP SIDE PLATE BRACKET TOWING HOOK COVER SIDE FRAME BUMPER LOWER EXTENSION Front spoiler installation: SKIRT FRONT...
Page 617 Main Menu Table of Contents Rear Bumper Replacement Fold the trunk floor trim panel forward, and remove the bumper mounting nuts. Remove the bumper mounting nuts on each side from under the trunk floor. Lower the inner fender. Remove the skirt mounting bolts and under covers from inside the rear fender on each side. Remove the bumper mounting nuts on each side.
Page 618 Main Menu Table of Contents Rear Bumper Disassembly UPPER FRAME BUMPER BEAM LEFT ABSORBER BUMPER BRACKET UPPER PLATE RIGHT ABSORBER BUMPER CENTER LOWER STAY SIDE FRAME BUMPER SKIRT LICENSE PLATE SUPPORT...
Page 619 Main Menu Table of Contents Hood Replacement/Adjustment Disconnect the washer hose at the Y-joint, then pull it out of the hood. 2. 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 620 Main Menu Table of Contents 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 621 Main Menu Table of Contents 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 622 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 623 Main Menu Table of Contents 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. HIGH-MOUNT BRAKE LIGHT Carefully pry out the caps with a flat tip CAUTION: When prying with a flat tip screwdriver, screwdriver, and remove the mounting screws.
Page 624 Main Menu Table of Contents Opener Cables Replacement 1. Remove the openers and latches, then disconnect the opener cables. 2. Remove the fuel lid latch. 3. 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. Take care not to bend the opener cables, 4.
Page 625 Main Menu Table of Contents Opener/Latch Replacement NOTE: Take care not to bend the cables. Rear Hatch Opener/Latch: LATCH SWITCH Be careful not to damage REAR HATCH the latch switch. Discon- OPENER CABLE nect the latch switch Disconnect the rear connector.
Page 626 Main Menu Table of Contents Trunk Lid Opener/Latch: NOTE: Take care not to bend the cable and rod. TRUNK LID OPENER MOUNTING BOLTS ACTUATOR 6 x 1.0 mm 10 N-m (1.0 kg-m, 7.2 Ib-ft) TRUNK KEY SWITCH Be careful not to damage the trunk key switch.
Page 627 Main Menu Table of Contents 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 628 Main Menu Table of Contents 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 SIDE CLIP NOTE: Loosen the screw, SIDE CLIP (9) I NOTE: When removing the side sill...
Page 629 Main Menu Table of Contents Front Sub-frame/Battery, Spare Tire Holder Sub-frame torque value specifications: 10 x 1.25 mm 60 N-m (6.0 kg-m, 43 Ib-ft) 10 x 1.25 mm 60 N-m (6.0 kg-m, 43 Ib-ft) CROSS BEAM RIGHT BEAM BRACKET 10 x 1.25 mm 39 N-m (3.9 kg-m, LEFT BEAM 28 Ib-ft)
Page 630 Main Menu Table of Contents Rear Sub-frame Sub-frame torque value specifications: LEFT REAR BRACKET 10 x 1.25 mm RIGHT REAR BRACKET 60 N-m (6.0 kg-m. 10 x 1.25 mm 43 Ib-ft) 60 N-m (6.0 kg-m. 43 Ib-ft) 12 x 1.25 mm 95 N-m (9.5 kg-m, 69 Ib-ft)
Page 631 Main Menu Table of Contents Frame Repair Chart Unit: mm (in)
Page 632 Main Menu Table of Contents...
Page 633 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 634 Main Menu Table of Contents 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 635 Main Menu Table of Contents Roof Rail Trim, Front and Rear Replacement 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 636 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 REAR LOCK RECEIVER Replacement, RELEASE KNOB Replacement, page 20-92 page 20-83 Adjustment, page 20-92 ROOF LOCK GUIDE Replacement, page...
Page 637 Main Menu Table of Contents Roof Roof Trim/Panel Replacement CAUTION: Remove the roof side trim from each side. • To prevent damage, place the roof on an appropriate pad. • When prying with a flat tip screwdriver, wrap it with protective tape to prevent damage.
Page 638 Main Menu Table of Contents 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 1.5 N-m (0.15 kg-m, 1.1 Ib-ft) ROOF SIDE SEAL BONDED PORTION...
Page 639 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 640 Main Menu Table of Contents 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 641 Main Menu Table of Contents Roof 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 642 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 643 Main Menu Table of Contents Roof Roof Side Seal/Retainer Replacement 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 644 Main Menu Table of Contents 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 645 Main Menu Table of Contents Roof Roof Side Seal/Retainer Replacement 16. Install the side portion of the roof side seal into the 15. Install the screws on each end of the roof side seal. roof side retainer as shown. NOTE: Do not press on the seal yet to make the adhesive stick.
Page 646 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 647 Main Menu Table of Contents Roof 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) •...
Page 648 Main Menu Table of Contents Roof Roof Side Lock Unit Replacement (cont'd) If necessary, remove the roof side hook. ROOF SIDE LOCK UNIT ROOF SIDE HOOK SCREW 5 x 0.8 mm 5 N-m (0.5 kg-m, 3.6 Ib-ft) Apply liquid thread lock. Installation is the reverse of the removal procedure.
Page 649 Main Menu Table of Contents 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 650 Main Menu Table of Contents 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 651 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 652 Main Menu Table of Contents 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. Install the roof on the body.
Page 653 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 654 Main Menu Table of Contents Roof Lock Receivers Adjustment 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 655 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 656 Main Menu Table of Contents 5. 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 657 Main Menu Table of Contents Front Pillar Seal/Retainer Replacement 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 where sealant will be applied.
Page 658 Main Menu Table of Contents 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 659 Main Menu Table of Contents Front Pillar Seal/Retainer Replacement 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 6 x 1.0 mm 11 N-m (1.1 kg-m, 8 Ib-ft) FRONT PILLAR...
Page 660 Main Menu Table of Contents 19. Press on the roof portion of the butyl tape to make BUTYL TAPE the adhesive stick. FRONT PILLAR SEPARATOR SEAL NOTE: Do not press on the front pillar seal portion BUTYL TAPE of the seal yet. SEPARATOR BUTYL TAPE PLASTIC...
Page 661 Main Menu Table of Contents Front Pillar Seal/Retainer Replacement 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 662 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 663 Main Menu Table of Contents Remove the screws, then remove the rear pillar 9. Install the rear pillar retainer. retainer. NOTE: • Be careful not to touch the rear pillar retainer Screw locations, 2 where sealant will be applied. • First tighten the screw at top of the rear pillar retainer.
Page 664 Main Menu Table of Contents Rear Pillar Seal/Retainer Replacement 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 665 Main Menu Table of Contents 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 666 Main Menu Table of Contents Rear Pillar Seal/Retainer Replacement 14. Install the roof portion of the rear pillar seal to the 15. Carefully pull the separator away from the butyl tape retainer on the roof rail. at the roof portion of the rear pillar seal. NOTE: •...
Page 667 Main Menu Table of Contents 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 668 Main Menu Table of Contents Seals/Retainers Alignment Adjustment NOTE: When the following parts have been replaced or Remove the front and rear roof rail trim (see page removed, this adjustment should be done. 20-79). Loosen the lock receiver mounting bolts at each of the •...
Page 669 Main Menu Table of Contents 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 670 Main Menu Table of Contents Seals/Retainers Alignment Adjustment 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 671 Main Menu Table of Contents 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 672 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 If there are leaks, recheck the work performed, and door have been adjusted, this water leak test should be done.
Page 673 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 674 Main Menu 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 675 Main Menu 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 676 Main Menu Table of Contents Engine Cover/Roof Cover Replacement Nut locations, 4 Remove the roof stop brackets and hook stops from the engine cover. 6 x 1.0 mm 10 N-m (1.0 kg-m, RIGHT HOOK STOP 7.2 Ib-ft) LEFT ROOF STOP BRACKET/ ROOF STOP ROOF HOLDER SWITCH BRACKET...
Page 677 Main Menu Table of Contents Special Tools Tool Number Ref. No. Description Page Reference 07JGG — 001010A Belt Tension Gauge 22-88 Backprobe Set 07SAZ — 001000A 22-49 ('94-'96) ('91-'93) 22-50 ('94-'96) ('91-'93)
Page 678 Main Menu Table of Contents EVAPORATOR SUNLIGHT SENSOR TEMPERATURE MODE CONTROL MOTOR Removal, page 22-63 ('93-'96), 87 ('91-'92 Models) SENSOR Replacement, page 22-57 Test, page 22-63 ('93-'96), 87 ('91-'92 Models) ('93-'96), 69 ('91-'92 Models) Removal, page 22-65 ('93-'96), 88 ('91-'92 Models) Test, page 22-58 Test, page...
Page 679 Main Menu Table of Contents Heater-Evaporator Door Position...
Page 680 Main Menu Table of Contents...
Page 681 Main Menu Table of Contents Description Outline The air conditioning removes the heat from the passenger compartment via the route shown below. Using the refrigerant (R134a) High temperature/ High temperature/ High temperature/ high pressure gas high pressure liquid Traps debris and acts high pressure liquid as an accumulator.
Page 682 Main Menu Table of Contents 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 683 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. RADIATOR FAN (Low) RADIATOR FAN CONTROL...
Page 684 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 A (CONDENSER FAN RELAY, COMPRESSOR CLUTCH RELAY, BLOWER MOTOR HIGH RELAY, BLOWER MOTOR RELAY) UNDER-HOOD FUSE/RELAY...
Page 685 Main Menu Table of Contents 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 686 Main Menu Table of Contents 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 687 Troubleshooting Main Menu Table of Contents 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 in, starting with .
Page 688 Main Menu Table of Contents Climate Control Unit Input/Output Signals CLIMATE CONTROL UNIT...
Page 689 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 690 Main Menu Table of Contents Remove the three screws and center console panel, then disconnect the 3P connector and 4P connector from the floor wire harness. Remove the four screws, then disconnect the 14P and 30P connectors from the floor wire harness. Take out the automatic climate control unit.
Page 691 Main Menu Table of Contents 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 692 Main Menu Table of Contents Air Mix Control Motor Replacement 4. If necessary, to adjust the heater valve cable: 1. 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 HEATER VALVE at the valve.
Page 693 Main Menu Table of Contents Mode Control Motor Replacement Test 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. 2 terminal; the air mix control motor should run, and stop at HOT, If it doesn't, reverse the connections;...
Page 694 Main Menu Table of Contents Mode Control Motor Test 3. 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 695 Main Menu Table of Contents Recirculation Control Motor Replacement Test 1. 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 2. Remove the three screws and the recirculation con- the No.
Page 696 Main Menu Table of Contents 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 697 Main Menu Table of Contents In-car Temperature Sensor Test Removal Compare the resistance reading between the No, 1 and The in-car temperature sensor assembly includes a small fan (aspirator fan) to draw air past the sensor (see No. 2 terminals of the in-car temperature sensor with page 22-66('93-'96), 91('91-'92)).
Page 698 Main Menu Table of Contents 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 699 Main Menu Table of Contents Sunlight Sensor Removal Test With a small screwdriver, carefully pry the sunlight sen- Measure the voltage between the terminals with the sen- sor out of the dashboard and disconnect its connector. sor out of direct sunlight. •...
Page 700 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 701 Main Menu Table of Contents Evaporator Temperature Sensor Removal Test 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 702 Main Menu Table of Contents 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 703 Main Menu Table of Contents Blower Unit Replacement 1. Remove the spare tire (refer to Owner's manual). 4. Remove the under-hood relay box A and the water drain duct. Disconnect the connectors from the blower motor, power transistor and recirculation 2.
Page 704 Main Menu Table of Contents Blower Unit Overhaul BLOWER MOTOR RECIRCULATION CONTROL MOTOR POWER TRANSISTOR...
Page 705 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 (ND-OIL 8: P/N 38899-PR7-A01), which are not compatible with CFC-12 (R-12) refrigerant and mineral oil. Do not use R-12 refriger- ant or mineral oil in this system, and do not attempt to use R-12 servicing equipment;...
Page 706 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 707 Main Menu Table of Contents To complete the charts: USA: • Mark the delivery temperature along the vertical line. • Mark the intake temperature (air temperature) along the bottom line. DELIVERY • Draw a line straight up from the air temperature PRESSURE to the humidity.
Page 708 Main Menu Table of Contents 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 709 Main Menu Table of Contents 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 System. (see page 22-73). section (24) before performing repairs or service.
Page 710 Main Menu Table of Contents 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 and sensors attached to the heater- (see page 22-57) . evaporator unit.
Page 711 Main Menu Table of Contents 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 712 Main Menu Table of Contents "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 on gear 1 Loosen this screw in gear 2.
Page 713 Main Menu Table of Contents 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 New parts (R-134a) RECEIVER/DRYER...
Page 714 Main Menu Table of Contents 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 from bumper (see section 20). remove the condenser. 3. Recover the refrigerant using a R-134a refrigerant *: CORROSION RESISTANT BOLT Recover/Recycling/Charging System (see page (Right Condenser)
Page 715 Main Menu Table of Contents 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 New parts (R-134a) CONDENSER...
Page 716 Main Menu Table of Contents Compressor Description This compressor is a Nippondenso piston type for R-134a. A revolving inclined disc drives the surrounding 10 reciprocating pistons. As the inclined disc revolved, it pushes the pistons, protected by a ceramic shoe, thus compress- ing the refrigerant.
Page 717 Main Menu Table of Contents Compressor Illustrated Index CENTER BOLT PRESSURE PLATE SHIM(S) CLUTCH SET Inspection, page 22-85 SNAP RING B Replace. PULLEY SNAP RING A Replace. FIELD COIL Inspection, page 22-85 COMPRESSOR (Do not disassembly) RELIEF VALVE Replacement, page 22-87 O-RING Replace.
Page 718 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 719 Compressor Main Menu Table of Contents Replacement (cont'd) 9, If necessary, remove the one bolt from the idler 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 ex- bolts and the compressor bracket.
Page 720 Main Menu Table of Contents 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) ,•...
Page 721 Main Menu Table of Contents Compressor Clutch Overhaul Use snap ring pliers to remove snap ring B, then Remove the center bolt while holding the pressure remove the pulley. plate. CENTER BOLT NOTE: 12 N-m (1.2 kg-m, 9 Ib-ft) • Be careful not to damage the pulley and com- pressor during removal/installation.
Page 722 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. Install parts in the reverse order of removal, and: •...
Page 723 Main Menu Table of Contents Relief Valve Replacement 1. 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. Clean off the mating surface. Replace O-ring with new one at the relief valve, and apply refrigerant oil (ND-OIL 8) to it.
Page 724 Main Menu Table of Contents Belt Adjustment Deflection Method Tension Gauge Method Apply a force of 100 N (10 kg, 22 Ib) 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 725 Main Menu Table of Contents 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 726 Main Menu Table of Contents 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 727 Main Menu Table of Contents 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 728 Main Menu Table of Contents Special Tools Ref. No. Tool Number Description Page Reference 07JAA — 001000C Antenna Nut Wrench 23-242, 244 07JGG — 001010A Bait Tension Gauge 23-109 07LAJ — PT3020A Test Harness 23-132 ('94-'96) ('91-'93) 07LAZ— SL40300 Test Harness C 23-250 , 307 ('93-'96) ('91-'92) 07PAZ —...
Page 729 Main Menu Table of Contents 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 •...
Page 730 Main Menu Table of Contents Troubleshooting Tips and Precautions • Insert the connector all the way, and make sure it is Seat grommets in their grooves properly. securely locked. • Position wires so that the open end of the cover faces down.
Page 731 Main Menu Table of Contents Five-step Troubleshooting Verify The Complaint 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. Be sure to use proper tools and safe toms.
Page 732 Main Menu Table of Contents Relay and Control Unit Locations Front Compartment HORN RELAY A/C COMPRESSOR CLUTCH LEFT HEADLIGHT RETRACTOR WINDSHIELD WIPER RELAY CUT RELAY LOW RELAY RIGHT HEADLIGHT RETRACTOR WINDSHIELD WIPER CUT RELAY INTERMITTENT RELAY RADIATOR FAN LOW RELAY REAR FAIL-SAFE RELAY BLOWER RELAY RADIATOR FAN...
Page 733 Main Menu Table of Contents Relay and Control Unit Locations Dashboard TURN SIGNAL/HAZARD CLIMATE CONTROL UNIT RELAY SRS UNIT FOOT WELL LIGHT DASHBOARD LOWER COVER INTEGRATED CONTROL UNIT UNDER-DASH FUSE BOX...
Page 734 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 735 Main Menu Table of Contents Relay and Control Unit Locations Rear Bulkhead THROTTLE VALVE CONTROL TRANSMISSION CONTROL MOTOR RELAY MODULE (TCM) (A/T) Wire colors: BLK, PGM-FI MAIN RELAY PULSE UNIT (M/T) YEL/BLK, GRN/RED, TCS CONTROL UNIT and WHT/BLU FAN CONTROL UNIT DASH LIGHTS BRIGHTNESS...
Page 736 Main Menu Table of Contents RETRACTABLE HEADLIGHT INTERLOCK CONTROL CONTROL UNIT UNIT (A/T) FUEL PUMP RELAY Wire colors: YEL, RED, BLK/YEL, and BLK/RED...
Page 737 Main Menu Table of Contents Relay and Control Unit Locations Engine Compartment REAR WINDOW DEFOGGER ENGINE COMPARTMENT RELAY FAN RELAY (A/T) 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 738 Main Menu Table of Contents 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 739 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 740 Main Menu Table of Contents 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 741 Main Menu Table of Contents 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 742 Main Menu Table of Contents 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 743 Main Menu Table of Contents Ignition Switch Test Electrical Switch Replacement 1. Remove the dashboard lower cover and disconnect 1. Remove the dashboard lower cover (see next column). the floor wire harness connectors. Disconnect the 7-P connector from the floor wire harness.
Page 744 Main Menu Table of Contents Steering Lock Removal/Installation Remove the steering column lower and upper cov- SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the ers. section 24 before performing repairs or service. NOTE: Be careful not to damage the steering column Remove the dashboard lower cover, and disconnect covers.
Page 745 Main Menu Table of Contents Ignition Switch Steering Lock Removal/Installation Disconnect the ignition switch 7-P and 8-P connec- 10. Insert the key, and turn it to "I". tors. 11. Push the lock pin, and pull out the steering lock Remove the column holder mounting bolts and the assembly.
Page 746 Main Menu Table of Contents 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 ('93-'96) ('91-'92) Replacement, page 23-161 ('93-'96) ('91-'92) CLUTCH INTERLOCK SWITCH (M/T) Test, page...
Page 747: Clutch Interlock Switch (M/T)
Main Menu Table of Contents 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: 1 5 — 20 mm (0.59 — 0.79 in) from fully depressed position.
Page 748 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. •...
Page 749: A/T Gear Position Switch
Main Menu Table of Contents - 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 problems. rpm. - 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 750 Main Menu Table of Contents Starting System Starter Cut Relay Test Clutch Interlock Switch Test (M/T) 1. Remove the dashboard lower cover and knee bolster, 1. Remove the glove box (see section 20). then disconnect the 2-P connector from the switch. Disconnect the 4-P connector from the starter cut Check for continuity between the terminals accord- relay.
Page 751 Main Menu Table of Contents Starter Replacement Starter Solenoid Test 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. 2. Remove the engine wire harness from the harness clip on the starter motor.
Page 752 Main Menu Table of Contents 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 ARMATURE PINION GEAR END COVER O-RING...
Page 753 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 the armature housing and brush holder If continuity exists, replace the brush holder assembly.
Page 754 Main Menu Table of Contents Starting System Armature Inspection and Test Commutator Runout Inspect the armature for wear or damage due to 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 755 Main Menu Table of Contents 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 756 Main Menu Table of Contents Starting System Solenoid Plunger Inspection Starter Field Winding Test Check the contact points and face of the starter Check for continuity between the brushes. there's continuity, replace armature solenoid plunger for burning, pitting or any other defects.
Page 757 Main Menu Table of Contents Overrunning Clutch Inspection Starter Reassembly Check if the overrunning clutch moves along the Reassemble the starter in the reverse order of shaft freely. If not, replace the overrunning clutch disassembly. assembly. Pry back each brush spring with a screwdriver, Check if the overrunning clutch locks in one direc- then position the brush about halfway out of its tion and rotates smoothly in reverse.
Page 758 Main Menu Table of Contents Ignition System Component Local IGNITION TIMING CONTROL SYSTEM Description, page 23-89 Inspection, page 23-91 ('94-'96) ('91-'93). Troubleshooting, section 11 SERVICE CHECK CONNECTOR (2-P) (Connector color: BLU) SPARK PLUG (6) Inspection, page 23-96 TEST TACHOMETER CONNECTOR NOISE CONDENSER Test, page 23-97...
Page 759 Main Menu Table of Contents 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 760 Main Menu Table of Contents Ignition Timing Inspection SRS components are located in this area. Review the SRS 3. 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;...
Page 761 Main Menu Table of Contents Ignition System Idle Speed Inspection Ignition Control Module (ICM) Replacement 1. Start the engine. Hold the engine at 3,000 rpm with Disconnect the 8-P and 6-P connectors from the ig- no load (A/T in position, M/T in neutral) until nition control module (ICM).
Page 762 Main Menu Table of Contents Ignition Control Module (ICM) Input Test Disconnect the 8-P connector from the ignition control NOTE: module (ICM). • The tachometer should operate normally. Inspect the connector and socket terminals to be sure • See section 11 when the malfunction indicator they are all making good contact.
Page 763 Main Menu Table of Contents Ignition Coil Test With the ignition switch OFF, remove the ignition A TERMINAL coil. 2. Using an ohmmeter, measure resistance between the terminals. Replace the coil if the resistance is not within specifications. IGNITION NOTE: Resistance will vary with the coil B TERMINAL COIL temperature;...
Page 764 Main Menu Table of Contents Ignition System Spark Plug Inspection Inspect the electrodes and ceramic insulator for: Replace the plug if it is fouled or worn. NOTE: Do not use spark plugs other than those Worn or deformed listed below. electrodes Spark Plug: PFR6N-11 (NGK)
Page 765 Main Menu Table of Contents Noise Condenser Capacity Test Use a commercially available condenser tester. Con- nect the tester probes and measure the condenser capacity. Condenser capacity: 0.47 ± 0.09 microfarads POSITIVE TERMINAL BODY GROUND (Negative) NOTE: The noise condenser is intended to reduce ignition noise.
Page 766 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 767 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 768 Main Menu Table of Contents (From page 23-100) Turn the ignition switch off. Check fuse No. 2 (15 A). Is the fuse OK? Replace the fuse. L (WHT/BLU) IG (YEL) Disconnect the 4-P connector from the alternator. Turn the ignition switch on. View from terminal side Check for voltage in the YEL wire...
Page 769 Main Menu Main Menu Table of Contents Table of Contents Charging System Troubleshooting 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...
Page 770 Main Menu Table of Contents 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 (star- ting). Start the engine and let it idle un- til it reaches normal operating temperature.
Page 771 Main Menu Table of Contents Charging System Troubleshooting (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 772 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. Disconnect the 4-P connector from the alternator. ADJUSTMENT-LOCK Remove the nut and the BLK wire from the B terminal.
Page 773 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 774 Main Menu Table of Contents Rectifier Test Alternator Brush Inspection NOTE: The diodes are designed to allow current to Remove the end cover, then take out the brush pass in one direction while blocking it in the opposite holder by removing its two screws. direction.
Page 775 Main Menu Table of Contents Charging System Stator Test Rotor Slip Ring Test 1. 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 776 Main Menu Table of Contents Alternator Belt Adjustment Deflection Method: Tension Gauge Method: 1. Apply a force of 100 N (10kg, 22 Ibs) between the 1. Attach the belt tension gauge to the belt and alternator and crankshaft pulley, and measure its measure belt tension.
Page 777 Main Menu Table of Contents Radiator and Condenser Fan Controls Component Location Index RADIATOR FAN LOW RELAY Wire colors: WHT/BLU, YEL/BLK, RED and GRN/BLK RADIATOR FAN HIGH RELAY Wire colors: WHT/BLU BLK, YEL/BLK and BLU/RED CONDENSER FAN RELAY Wire colors: WHT/GRN, BLK YEL/BLK and ORN/BLU CLIMATE CONTROL UNIT Troubleshooting, see...
Page 778 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 23-118 Test, page 23-120 Replacement, page...
Page 779 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 780 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 781 Main Menu Table of Contents Radiator and Condenser Fan Controls Radiator Fan Resistor Test Control Unit Terminals THROTTLE VALVE CONTROL Disconnect the 3-P connector from the resistor. MOTOR RELAY RADIATOR 3-P CONNECTOR RESISTOR NOT USED FAN CONTROL UNIT Using an ohmmeter, measure resistance between the A and B terminals.
Page 782 Main Menu Table of Contents Radiator Fan Motor Test Condenser Fan Motor Test Disconnect the 2-P connector from the condenser Disconnect the 2-P 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 783 Main Menu Table of Contents Radiator and Condenser Fan Controls Engine Compartment Fan Motor Engine Compartment Fan Motor Test (A/T) Removal (A/T) Disconnect the 2-P connector from the engine Disconnect the 2-P 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 784 Main Menu Table of Contents 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 785 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 786: (Neutral Position Switch) Test Page
Main Menu Table of Contents 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 787 Main Menu Table of Contents 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 788 Main Menu Table of Contents 6. Remove the eight screws, then remove the steering 8. 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.
Page 789 Main Menu Table of Contents Gauge Assembly Bulb Locations GAUGE LIGHTS (1.4W x 2) SRS INDICATOR LIGHT (1.4 W) HIGH BEAM INDICATOR LIGHT (1.4 W) RIGHT TURN SIGNAL INDICATOR LIGHT (1.4 W) LEFT TURN SIGNAL INDICATOR LIGHT (1.4 W) EPS INDICATOR LIGHT (1.4 W) INDICATOR LIGHT (1.4 W) BRAKE SYSTEM LIGHT (1.4 W) CHARGING SYSTEM LIGHT (1.4 W)
Page 790 Main Menu Table of Contents 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 791 Main Menu Table of Contents Speedometer/Trip Meter/Odometer Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence. View from the back of the gauge assembly...
Page 792 Main Menu Table of Contents NOTE: A short to ground in the ORN wire can be caused by a short in any component connected to it. Vehicle Speed Sensor (VSS) Test Speedometer does not work. View from terminal side Inspect No. 5 (15 A) fuse in the under-dash fuse box before , BLK 3-P CONNECTOR...
Page 793 Main Menu Table of Contents Speedometer/Trip Meter/Odometer Troubleshooting (From page 23-131) WHT TEST HARNESS Connect the Test Harness (07LAJ — CLIP PT3020A) between the VSS and the engine wire harness. TEST HARNESS 07LAJ - PT3020A Raise the rear of the car, and sup- RED TEST HARNESS port it with stands.
Page 794 Main Menu Table of Contents Vehicle Speed Sensor (VSS) Replacement Disconnect the 3-P connector from the vehicle speed sensor (VSS). 3-P CONNECTOR MOUNTING BOLTS COVER DRIVE LINK 2. 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 795 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 796 Main Menu Table of Contents Sending Unit Test Do not smoke while working on the fuel Measure the resistance between the A and B termi- system. Keep open flame away from work area. nals by moving the float to the heights listed for E (EMPTY), 1/2 (HALF FULL) and F (FULL).
Page 797 Main Menu Table of Contents Engine Coolant Temperature (ECT) Gauge ECT Gauge Test ECT Sending Unit Test Disconnect the YEL/GRN wire from the sending unit, and with the engine cold, use an ohmmeter to meas- ure resistance between the positive terminal and the Before testing, check the No.
Page 798 Main Menu Table of Contents Engine Oil Pressure Warning System Engine Oil Pressure Gauge Gauge Test Engine Oil Pressure Switch Test 1. Raise the car, and place safety stands in the proper locations (see section Before testing, check the No. 5 (1 5 A) fuse in the Remove the right rear tire.
Page 799 Main Menu Table of Contents Brake Warning System Parking Brake Switch Test Brake Fluid Level Switch Test Remove the center console, and disconnect the con- Remove the reservoir cap. Check that the float nector from the switch. moves up and down freely; if it doesn't, replace the reservoir cap assembly.
Page 800 Main Menu Table of Contents 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 2-P connector from the seat belt switch. Check continuity between the A and B terminals with 1.
Page 801 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. TCS CONTROL UNIT INTERLOCK CONTROL UNIT Input Test, page 23-142 A / T GEAR POSITION SWITCH...
Page 802 Main Menu Table of Contents Interlock System Control Unit Input Test Disconnect the 8-P connector from the control unit. INTERLOCK 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 803 Main Menu Table of Contents Key Interlock Solenoid Test Check for continuity between the terminals in each 1. Remove the dashboard lower cover, and disconnect the floor wire harness connectors. switch position according to the table. Check that the key cannot be removed with power and ground connected to the C and B terminals.
Page 804 Main Menu Table of Contents Interlock System Shift Lock Solenoid Test/Replacement Test: When the shift lock solenoid is OFF, make sure that the lock pin is blocked by the top of the shift lock lever. Remove the console, then disconnect the 3-P con- nector of the shift lock solenoid from the floor wire harness.
Page 805 Main Menu Table of Contents 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) Removal, page 23-129 ('93-'96) ('91-'92) Troubleshooting, page...
Page 806 Main Menu Table of Contents 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 807 Main Menu Table of Contents *1: Terminal is in floor wire harness side of connector. *2: NSX-T (open top) only...
Page 808 Main Menu Table of Contents Safety Indicator Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence. *1: NSX-T (open top) only...
Page 809 Main Menu Table of Contents Brake Light Failure Sensor Test First make sure the brake lights come on when the Remove the rear trim panel that covers the left tail- brake pedal is pressed. light. Watch the light as you turn the ignition switch from OFF to ON (II), with the A (GRN) wire of the 6-P connector grounded and the brake •...
Page 810 Main Menu Table of Contents 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 3-P connector from the roof lock off).
Page 811 Main Menu Table of Contents Roof Holder Switch Test Open the rear hatch and engine cover. Disconnect the 1- P 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 812 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 sec- tion 14.
Page 813 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 814 Main Menu Table of Contents...
Page 815 Main Menu Table of Contents 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. 1.
Page 816 Main Menu Table of Contents 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 817 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 818 Main Menu Table of Contents View from wire side Entry Light Timer System: Terminal Test condition Test: Desired result Possible cause if result is not obtained Key-in Reminder System: Terminal Test condition Test: Desired result Possible cause if result is not obtained...
Page 819 Main Menu Table of Contents Integrated Control Unit Input Test View from wire side Lights-on Reminder System: Terminal Test condition Test: Desired result Possible cause if result is not obtained Seat Belt Reminder System: Terminal Test condition Test: Desired result Possible cause if result is not obtained...
Page 820 Main Menu Table of Contents Rear Window Defogger Timer System: Terminal Test condition Test: Desired result Possible cause if result is not obtained Oil Pressure Indicator System: Terminal Test condition Test: Desired result Possible cause if result is not obtained...
Page 821 Main Menu Table of Contents Integrated Control Unit Input Test View from wire side Side Marker Light Flasher System: Test condition Terminal Test: Desired result Possible cause if result is not obtained Power Window Key-off Timer System: Terminal Test condition Test: Desired result Possible cause if result is not obtained...
Page 822 Main Menu Table of Contents Combined Operation Wiper/Washer System: Terminal Test condition Test: Desired result Possible cause if result is not obtained...
Page 823 Main Menu Table of Contents Lights-on Reminder Systen. Chime Test NOTE: Refer to page 23-158 ('93-'96) ('91-'92) for a dia- gram of the lights-on reminder circuit, and page 23-166 CHIME for the input test of the 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 824 Main Menu Table of Contents Key-in Reminder System Ignition Key Switch Test NOTE: Refer to page 23-165 for the input test of key-in Disconnect the 8-P connector from the floor wire reminder, beeper circuit. harness. 4. There should be continuity between the No. 8 and When the ignition key is not removed, the key-in No.
Page 825 Main Menu Table of Contents Lighting System Component Location Index RETRACTABLE HEADLIGHT CONTROL UNIT Input Test, page 23-178 ('94-'96) ('91-'93) HIGH BEAM INDICATOR LIGHT (In the gauge assembly) Gauge Assembly, page 23-121 COMBINATION LIGHT SWITCH Test, page 23-181 Replacement, page 23-162 DAYTIME RUNNING LIGHTS CONTROL UNIT (Canada)
Page 826: Adjustment, Page
Main Menu Table of Contents LEFT HEADLIGHT UNDER-HOOD FUSE/RELAY BOX UNDER-HOOD RELAY BOX A RETRACTOR CUT RELAY Test page 23-190 ('94-'96) ('91-'93) DIMMER RELAY RIGHT HEADLIGHT Test, page 23-189 RETRACTOR CUT RELAY Test, page 23-190 ('94-'96) ('91-'93) TAILLIGHT RELAY Test, page 23-190 ('94-'96) ('91-'93) HEADLIGHT RELAY...
Page 827 Main Menu Table of Contents 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 828 Main Menu Table of Contents Lighting System Retractable Headlight Control Unit Input Test REAR BULKHEAD Remove the rear bulkhead panels, and disconnect the 18-P connector from the control unit. Inspect the connector and socket terminals to be sure they are all making good contact. RETRACTABLE HEADLIGHT CONTROL UNIT •...
Page 829 Main Menu Table of Contents Wire Test condition Test: Desired result Possible cause if result is not obtained...
Page 830 Main Menu Table of Contents Lighting System Daytime Running Lights Control Unit Input Test (Canada) Remove the glove box lower panel and glove box. Disconnect the 4-P and 8-P 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 831 Main Menu Table of Contents Combination Light/Turn Signal Switch Test 1. Remove the dashboard lower cover (see page 23-182). Disconnect the 18-P connector from the floor wire harness. Check for continuity between the terminals, in each switch position, according to the table. 18-P CONNECTOR View from wire side Headlight/Dimmer/Passing Switch...
Page 832 Main Menu Table of Contents Lighting System Headlight/Turn Signal Switch Replacement SRS components are located in this area. Review the 3. Remove the tilt cover. SRS component locations, precautions, and procedures in the SRS section 24 before performing repairs or ser- vice.
Page 833 Main Menu Table of Contents 5. Disconnect the 18-P and 10-P 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 10-P CONNECTOR...
Page 834 Main Menu Table of Contents 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 835 Main Menu Table of Contents Retractor Switch Test Retractor Switch Light Bulb Replacement Remove the retractor switch (see previous page). Remove the retractor switch (see previous page). Check for continuity between the terminals in each Turn the bulb 45° counterclockwise to remove it. switch position according to the table.
Page 836 Main Menu Table of Contents 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. •...
Page 837 Main Menu Table of Contents 7. Disconnect the 6-P connector. MOUNTING BOLT/NUT 10 N-m (1.0kg-m. 7.2 Ib-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 838 Main Menu Table of Contents Headlight Housing Adjustment 1. Remove the stop bolt caps. 2. Adjust stop bolts A and B. STOP BOLT CAPS STOP STOP BOLT B BOLT A STOP BOLTC 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 839 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 840 Main Menu Table of Contents Lighting System Retractor Motor Test 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 841 Main Menu Table of Contents 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. •...
Page 842 Main Menu Table of Contents Lighting System Retractor Relay Test Retractor Cut/Taillight Relay Test Remove the retractor cut relay and taillight relay. 1. Remove the retractor relay (located at the right side of the front compartment area). Check continuity at the relay terminals. Check continuity at the relay terminals.
Page 843 Main Menu Table of Contents Headlights Description The light first forms basic pattern A after being interrupt- ed by the interrupter plate and passed through the con- vex lens. The interrupter plate determines the form. The outer lens distributes the light into pattern B. CONVEX LENS INTERRUPTER PLATE BULB...
Page 844 Main Menu Table of Contents 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 845 Main Menu Table of Contents 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. •...
Page 846 Main Menu Table of Contents Daytime Running Lights Headlights (Canada) Bulb Replacement Replacement 1. Remove the bolt, and pull out the daytime running CAUTION: light, then disconnect the 2-P connector. • Halogen headlights can become very hot in use; do not touch them or the attaching hardware immediately after they have been turned off.
Page 847 Main Menu Table of Contents Front Side Marker Front Turn Signal/Front Lights Parking Lights Replacement Replacement Carefully pry the front side marker light out of the Remove the screw and pull the light assembly out front fender. Be careful not to damage the front side of the front bumper.
Page 848 Main Menu Table of Contents Taillights Bulb Replacement Replacement Open the trunk lid, and remove the rear trim panel. Open the trunk lid, and remove the rear trim panel. Disconnect the 8-P connector and 2-P connector Turn each socket 45° counterclockwise to remove from the taillight assembly.
Page 849 Main Menu Table of Contents Rear Side Marker Lights License Plate Lights Replacement Replacement Carefully pry the rear side marker light out of the rear Remove the eight screws, and disconnect the 4-P fender. Be careful not to damage the rear parking connector.
Page 850 Main Menu Table of Contents Glove Box Light Replacement/Test Remove the two screws from the glove box light. 1. Remove the glove box lower panel. GLOVE BULB (3.4 W) GLOVE BOX LIGHT GLOVE GLOVE BOX LOWER PANEL 2. Remove the eight screws, then pull out the glove 5.
Page 851: Replacement, Page
Main Menu Table of Contents Ceiling/Courtesy/Trunk Lights Component Location Index CEILING LIGHT (*') Test, page 23-202 Replacement, page 23-203 CEILING LIGHT (Coupe) Test, page 23-201 PASSENGER'S DOOR Replacement, page 23-203 COURTESY LIGHT Test/Replacement, page 23-204 PASSENGER'S DOOR SWITCH Test, page 23-204 DRIVER'S DOOR COURTESY LIGHT...
Page 852 Main Menu Table of Contents Ceiling Light Test Coupe: Check for continuity between the terminals in each switch position according to the table. View from terminal side...
Page 853 Main Menu Table of Contents Ceiling/Courtesy/Trunk Lights Ceiling Light Test NSX-T (open top): Check for continuity between the terminals in each switch position according to the table.
Page 854 Main Menu Table of Contents Ceiling Light Replacement Coupe: NSX-T (open top): 1. Turn the light switch OFF. Turn the light switch OFF. Pry off the lens. Pry off the lens. Remove the two bolts and the housing. Remove the two screws and the housing. Disconnect the 4-P connector from the housing.
Page 855 Main Menu Table of Contents Ceiling/Courtesy/Trunk Lights Courtesy Light Test/Replacement Door Switch Test NOTE: The bulb or lens alone can be replaced without 1. Remove the door panel (see section 20). having to remove the door panel. Disconnect the 2-P connector from the door switch. Remove the door panel (see section 20).
Page 856 Main Menu Table of Contents Trunk Light Test/Replacement Latch Switch Test/Replacement Open the trunk lid, and remove the trunk rear panel. NOTE: The bulb or lens alone can be replaced without having to remove the trunk side panel. Disconnect the trunk latch 3-P connector. 1.
Page 857 Main Menu Table of Contents Back-up Lights Component Location Index A/T GEAR POSITION SWITCH (Back-up light switch) Test, page 23-160 ('93-'96) ('91-'92). UNDER-DASH FUSE BOX BACK-UP LIGHT SWITCH (M/T) Test, page 23-208 ('93-'96) ('91-'92). BACK-UP LIGHTS Bulb replacement, page 23-206...
Page 858 Main Menu Table of Contents Back-up Lights Test Automatic Transmission: Manual Transmission: 1. If only one back-up light does not go on, check that 1. If only one back-up right does not go on, check that bulb in the taillight. bulb in the taillight.
Page 859 Main Menu Table of Contents Brake Lights Component Location Index BRAKE SWITCH HIGH MOUNT BRAKE LIGHT (LED) Test, page 23-211 LED Replacement, page 23-212 ('94-'96) ('91-'93) Replacement, page 23-212 ('94-'96) ('91-'93) Test, page 23-211 RIGHT TAILLIGHT Bulb Replacement, page 23-196 Failure Sensor Test, page 23-153 LEFT TAILLIGHT...
Page 860 Main Menu Table of Contents Brake Switch Test High Mount Brake Light Test Open the trunk lid and engine compartment lid. 1. If one of the brake lights does not go on, check that brake light bulb in the taillight or the high mount light 2.
Page 861 Main Menu Table of Contents Brake Lights Rear Spoiler Replacement High Mount Brake Light Replacement CAUTION: Be careful not to damage the high mount CAUTION: Be careful not to damage the high mount brake light, rear spoiler, and trunk lid. brake light, rear spoiler, and trunk lid.
Page 862 Main Menu Table of Contents Side Marker/Turn Signal/Hazard Flasher 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. HAZARD WARNING SWITCH TURN SIGNAL INDICATOR LIGHTS Removal, page 23-220...
Page 863 Main Menu Table of Contents Side Marker/Turn Signal/Hazard Flasher System Description To cope with dimensional requirements for the airbag components and to offer better operational feel, the turn signal lever and the cancel mechanism are separated mechanically, and connected electrically instead. The system cancels the turn signals electrically, by means of a solenoid, after a turn is made.
Page 864 Main Menu Table of Contents A cam plate is installed around the steering shaft. A pair of switches (A and B) are installed beside it. When the steering is turned in direction of the arrow, switch A turns on first. Then switch B turns on.
Page 865 Main Menu Table of Contents Side Marker/Turn Signal/Hazard Flasher System Turn Signal/Hazard Relay Input Test Remove the dashboard lower cover. Remove the turn signal/hazard relay from the left kick panel, TURN/SIGNAL then disconnect the 6-P connector. HAZARD RELAY Inspect the connector and socket terminals to be sure they are all making good contact.
Page 866 Main Menu Table of Contents Cancel Unit Input Test TURN SIGNAL Remove the steering column covers. Disconnect the CANCEL UNIT 10-P connector from the turn signal cancel unit. Inspect the connector terminals to be sure they are 10-P CONNECTOR all making good contact. •...
Page 867 Main Menu Table of Contents Side Marker/Turn Signal/Hazard Flasher System Hazard Warning Switch Replacement SRS components are located in this area. Review the Remove the steering 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 steering column vice.
Page 868 Main Menu Table of Contents 7. Remove the screws, then separate the hazard warn- ing switch from the other switches. HAZARD WARNING SWITCH If necessary, remove the hazard warning switch bulb. HAZARD WARNING SWITCH BULB (0.91...
Page 869 Main Menu Table of Contents Hazard Warning Switch Test Remove the dashboard lower cover (see page 23-220). Disconnect the 20-P connector from the floor wire harness. Check for continuity between the terminals, in each switch position, according to the table. HAZARD WARNING SWITCH Terminal N is View from wire side...
Page 870: Replacement, Page
Main Menu Table of Contents Dash Lights Brightness Control Component Location Index TRANSMISSION CONTROL MODULE (TCM) DASH LIGHTS BRIGHTNESS CONTROL UNIT Input Test, page 23-224 COMBINATION LIGHT SWITCH Test, page 23-181 Replacement, page 23-182 DASH LIGHTS BRIGHTNESS CONTROLLER Test, page 23-226 HEADLIGHT RETRACTOR SWITCH...
Page 871 Main Menu Table of Contents Dash Lights Brightness Control Control Unit Input Test Disconnect the 7-P 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 872: Srs Components Are Located In This Area. Review The Srs Component Locations, Precautions, And Procedures In The Srs Section
Main Menu Table of Contents Controller Removal SRS components are located in this area. Review the SRS 4. Remove the steering column covers. component locations, precautions, and procedures in the section 24 before performing repairs or service. UPPER COVER Remove the dashboard lower cover, and disconnect the connectors.
Page 873 Main Menu Table of Contents Dash Lights Brightness Control Controller Test Controller Light Bulb Replacement Remove the dash lights brightness controller from Remove the dash lights brightness controller. the instrument panel (see previous page). Turn the socket 45° counterclockwise to remove it. Measure resistance between A and B terminals while rotating the adjusting dial.
Page 874: Input Test, Page
Main Menu Table of Contents Entry Light Timer System 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. Description: It the driver's door has been opened by the outer handle, the foot well light and a light at the Ignition switch go on and stay on for about eight seconds after the driver's door has been dosed.
Page 875 Main Menu Table of Contents Foot Well Light Replacement Ignition Key Light Replacement Remove the dashboard lower cover. Remove the dashboard lower cover. Disconnect the 2-P connector from the foot well Remove the dashboard lower pad. light. Remove the bulb/socket from the key light housing by turning the socket 45°.
Page 876 Main Menu Table of Contents Removal Terminals CAUTION: Be careful not to damage the center air vent or clock. Pull the clock out with your fingers (if necessary, use a screwdriver). Disconnect the 4-P connector from the clock. 4-P CONNECTOR CENTER AIR VENT CLOCK Terminal...
Page 877 Main Menu Table of Contents Replacement Disconnect the thermo fuse case from the end of SRS components are located in this area. Review the SRS component locations, precautions, and procedures the cigarette lighter socket. in the SRS section 24 before performing repairs or ser- vice.
Page 878 Main Menu Table of Contents Cigarette Lighter Relay Test Remove the glove box (see section 20). Disconnect the 4-P connector from the cigarette lighter relay (wire colors of 4-P connector: BLU/ GRN, YEL/RED, BRN/YEL, BLK). Check continuity at the relay terminals. •...
Page 879 Main Menu Table of Contents Stereo Sound 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 ser- vice. POWER AMPLIFIER RELAY Test, page 23-240 STEREO RADIO/CASSETTE PLAYER...
Page 880 Main Menu Table of Contents Stereo Sound System Unit Removal SRS components are located in this area. Review the Remove the four screws, then remove the center SRS component locations, precautions, and procedures armrest. in the SRS section 24 before performing repairs or ser- vice.
Page 881 Main Menu Table of Contents Remove the four screws, then disconnect the 16-P Remove the five screws and center console panel, then disconnect the 3-P connector and 4-P connec- connector, mast antenna lead, and window anten- tor from the floor wire harness. na lead and take out the stereo radio/cassette player.
Page 882 Main Menu Table of Contents Stereo Sound System Power Amplifier Relay Test Unit Terminals Remove the power amplifier relay from under-hood relay box 8. Check continuity at the relay terminals. • There should be continuity between the C and D terminals.
Page 883 Main Menu Table of Contents Power Antenna Motor Test Open the trunk lid and remove the side trim panel. If the motor fails to operate properly, replace it. Disconnect the 4-P connector from the motor and check power to the motor at the connector terminals: •...
Page 884 Main Menu Table of Contents Stereo Sound System Antenna Mast Replacement Removal: NOTE: The antenna mast alone can be replaced without removing the power antenna motor. Remove the antenna nut, O-ring, spacer, and bush- ing. Carefully withdraw the antenna mast while extend- ing it by turning the radio switch ON.
Page 885 Main Menu Table of Contents Installation: Install the parts shown below. Hold the antenna mast drive cable so its teeth point CAUTION: Do not overtighten the antenna nut; the in the direction shown, and carefully insert the drive rear fender will be deformed. cable into the antenna housing.
Page 886 Main Menu Table of Contents Stereo Sound System Antenna Tube Replacement Remove the antenna mast (see page 23-242). Insert the new antenna tube. 2. Remove the power antenna motor (see page With an alignment mark: 23-242). — Insert the new antenna tube in its socket, and align the mark on the tube with the screw used Remove the retaining screw, and pull the antenna to retain it.
Page 887 Main Menu Table of Contents Front/Rear Speaker Replacement Foot Well Bass Speaker Replacement Front speaker: Pull back the carpet on the passenger's side. Remove the door panel (see section 20). Remove the foot well bass speaker cover. Remove the door speaker assembly from the door panel by removing the five screws.
Page 888 Main Menu Table of Contents Horns 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. HORN RELAY Test, page 23-249 UNDER-HOOD RELAY BOX A CABLE REEL...
Page 889 Main Menu Table of Contents Horns Horn Test Disconnect the 2-P connector from the horn. Test the horn by connecting power to the A or B terminals and ground to the other. The horn should Remove the right and left horns. sound.
Page 890 Main Menu Table of Contents 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. Disconnect the battery negative cable, then discon- nect the positive cable.
Page 891 Main Menu Table of Contents Horns Switch Test (cont'd) Disconnect the cable reel harness 6-P connector Remove the Torx bolts using a Torx T30 bit, then from the SRS main harness, then connect test remove the airbag assembly. harness C only to the cable reel harness. Store a removed airbag assembly with the pad surface up.
Page 892 Main Menu Table of Contents 8. Check for continuity between the horn positive ter- minal and the steering column shaft with the horn switch pressed. There should be no continuity. STEERING COLUMN SHAFT POSITIVE TERMINAL • If there is continuity, replace the cable reel (see section 24).
Page 893 Main Menu Table of Contents Trunk Opener Component Location Index TRUNK OPENER MAIN SWITCH Test, page 23-253 ('94-'96) ('93) ('91-'92) TRUNK OPENER SWITCH Test, page 23-254 TRUNK LATCH TRUNK OPENER SOLENOID Test/Replacement, page 23-254...
Page 894 Main Menu Table of Contents Main Switch Test 1. Remove the glove box, and disconnect the 2-P con- nector from the switch. Check for continuity between the terminals. • There should be continuity between the No. 1 terminal and No. 2 terminal with the main switch ON.
Page 895 Main Menu Table of Contents Trunk Opener Opener Switch Test Solenoid Test/Replacement Open the trunk lid, and remove the trunk side trim 1. Remove the driver's door panel, then push the switch out of the door panel as shown. panel. Disconnect the 2-P connector from the solenoid assembly, and test solenoid operation by connec- ting battery power and ground to the A and B ter-...
Page 896 Main Menu Table of Contents Power Mirrors Component Location Index LEFT MIRROR RIGHT MIRROR Test, page 23-259 Test, page 23-259 Replacement, page 23-259 Replacement, page 23-259 POWER MIRROR SWITCH Function Test, page 23-257 Removal, page 23-258 Test, page 23-258 UNDER-DASH FUSE BOX...
Page 897 Main Menu Table of Contents Function Test NOTE: Before testing, remove the left door panel, then Check for continuity between the BLK terminal and disconnect all connectors from the door panel. body ground. There should be continuity. If there is no continui- ty, check for: 10-P CONNECTOR •...
Page 898 Main Menu Table of Contents Power Mirrors Switch Removal Switch Test Remove the power mirror switch from the armrest. Remove the left door panel, then disconnect all connectors from the door panel (see section 20). Check for continuity between the terminals in each Remove the three screws, then remove the mirror switch position according to the table.
Page 899 Main Menu Table of Contents Door Mirror Test Door Mirror Replacement Remove the door panel, and carefully remove the Remove the door panel, and carefully remove the plastic cover (see section 20). plastic cover (see section 20). Disconnect the 3-P connector. Disconnect the power mirror 3-P connector.
Page 900 Main Menu Table of Contents Power Mirrors Door Mirror Actuator Replacement Remove the mirror and actuator assembly from the Set the new actuator on the back of the mirror with housing (see section 20). the lug protruding through the middle. Pull up on the lug, and install the roll pin removed in step 3.
Page 901 Main Menu Table of Contents Power Door Locks Component Location Index UNDER-HOOD FUSE/RELAY BOX Located at right side of front compartment POWER DOOR LOCK IGNITION KEY SWITCH CONTROL UNIT Test, page 23-171 Input Test, page 23-264 PASSENGER'S DOOR LOCK SWITCH Test, page 23-268 PASSENGER'S DOOR SWITCH...
Page 902 Main Menu Table of Contents Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence.
Page 903 Main Menu Table of Contents Power Door Locks Control Unit Input Test Remove the glove box, then disconnect the 18-P con- nector from the control unit. Inspect the connector 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 904 Main Menu Table of Contents Test condition Test: Desired result Possible cause if result is not obtained Wire CAUTION: To prevent damage to the motor, connect power and ground only momentarily.
Page 905 Main Menu Table of Contents Power Door Locks Driver's Door Actuator Test Check for continuity between the terminals in each 1. Remove the door panel (see section 20). switch position according to the table. Disconnect the 8-P connector from the actuator. Key Cylinder Switch: View from wide side ACTUATOR...
Page 906 Main Menu Table of Contents Passenger's Door Actuator Test - 5. Check for continuity between the terminals in each 1. Remove the door panel (see section 20). switch position according to the table. Disconnect the 8-P connector from the actuator. Key Cylinder Switch: View from wide side ACTUATOR...
Page 907 Main Menu Table of Contents Power Door Locks Door Lock Switch Test 1. Remove the door grip assembly. Disconnect the 3-P connector from the switch. Check for continuity between the terminals, in each switch position, according to the table. View from wire side DOOR LOCK SWITCH DOOR GRIP ASSEMBLY...
Page 908 Main Menu Table of Contents Power Windows Component Location Index POWER WINDOW RELAY DRIVER'S DOOR SWITCH PASSENGER'S DOOR SWITCH Test, page 23-277 Test, page 23-204 ('94-'96) ('91-'93) Test, page 23-204 PASSENGER'S MOTOR Test, page 23-276('94-'96) ('91-'93) PASSENGER'S SWITCH Replacement, section 20 Test, page 23-274('94-'96) Replacement, page...
Page 909 Main Menu Table of Contents Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence.
Page 910 Main Menu Table of Contents Power Windows Control Unit Input Test NOTE: The control unit only controls the driver's door POWER WINDOW window. POWER WINDOW CONTROL UNIT MASTER SWITCH Remove the driver's door panel and disconnect the 4-P and 6-P connectors from the control unit. Inspect the connector and socket terminals to be sure they are all making good contact.
Page 911 Main Menu Table of Contents Master Switch Test Driver's Switch Remove the door panel (see section 20). Disconnect the 12-P connector. Check for continuity between the terminals in each switch position according to the tables. Passenger's Switch MASTER SWITCH Switch Light View from wire side...
Page 912 Main Menu Table of Contents Power Windows Master Switch Replacement Passenger's Switch Test 1. Remove the door panel (see section 20). 1. Remove the door panel (see section 20). Disconnect the 8-P connector. Remove the four screws, then remove the power window master switch from the door panel.
Page 913 Main Menu Table of Contents Switch Light Bulb Replacement Passenger's Switch Replacement Remove the door panel (see section 20). Remove the door panel (see section 20). Remove the four screws, then remove the power Remove screws, then remove window switch from the door panel. passenger's switch from the door panel.
Page 914 Main Menu Table of Contents Power Windows Driver's Motor Test Passenger's Motor Test 1. Remove the door panel (see section 20). Motor Test: 1. Remove the door panel (see section 20). Disconnect the 2-P connector from the motor. Disconnect the 4-P connector from the driver's motor.
Page 915 Main Menu Table of Contents Relay Test Remove the power window relay in the under-hood fuse/relay box. Check continuity at the relay terminals. • There should be continuity between the C and D terminals. • There should be continuity between the A and B terminals when power and ground are connect- ed to the C and D terminals.
Page 916 Main Menu Table of Contents Power Seats Component Location Index DRIVER'S SEAT PASSENGER'S SEAT ENGINE COMPARTMENT FUSE/RELAY BOX RECLINE MOTOR Test, page 23-273 ('93-'96) ('91-'92) POWER SEAT SWITCH Test, page 23-280 SLIDE MOTOR Test, page 23-281...
Page 917 Main Menu Table of Contents Power Seats Seat Switch Test CAUTION: Be careful not to damage the seats, the interior trim or the body. Remove the two screws, then remove the power seat switch from the power seat. Disconnect the 5-P connectors from each power seat switch.
Page 918 Main Menu Table of Contents Motor Test Test motor operation. CAUTION: Be careful not to damage the seats, the interior trim or the body. CAUTION: When the motor stops running, discon- 1. Remove the power seat, then disconnect the 2-P nect power immediately.
Page 919 Main Menu Table of Contents Rear Window Defogger 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. REAR WINDOW DEFOGGER TIMER CIRCUIT (In the integrated control unit) REAR WINDOW...
Page 920 Main Menu Table of Contents Rear Window Defogger Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence.
Page 921 Main Menu Table of Contents Switch Replacement SRS components are located in this area. Review the 3. Remove the tilt cover. SRS component locations, precautions, and procedures in the SRS section 24 before performing repairs or ser- vice. Remove the dashboard lower cover, and disconnect the connectors.
Page 922 Main Menu Table of Contents Rear Window Defogger Switch Replacement (cont'd) Disconnect the 18-P and 10-P connectors. CAUTION: Be careful not to damage the SRS wire harness. Remove the six screws, then remove the rear win- dow defogger-light switch assembly. 10-P CONNECTOR REAR WINDOW DEFOGGER- LIGHT SWITCH ASSEMBLY...
Page 923 Main Menu Table of Contents Rear Window Defogger Relay Test Remove the defogger relay in the engine compart- ment fuse/relay box. Check continuity at the relay terminals. There should be continuity between the C and D terminals. There should be continuity between the A and B terminals when power and ground are connected to the C and D terminals.
Page 924 Main Menu Table of Contents Switch Test Remove the dashboard lower cover (see page 23-285). If necessary, remove the dashboard lower pad. Disconnect the 18-P connector from the floor wire harness. Check for continuity between the terminals in each switch position according to the table. REAR WINDOW DEFOGGER...
Page 925 Main Menu Table of Contents Rear Window Defogger Function Test Defogger Wires Repair CAUTION: Be careful not to scratch or damage the To make an effective repair, the broken section must be defogger wires with the tester probe. no longer than one inch. Check for voltage between the positive terminal Lightly scrub the area around the break with fine and body ground with the ignition switch and the...
Page 926 Main Menu Table of Contents Wipers/Washers 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. UNDER-HOOD RELAY BOX B WINDSHIELD WIPER WIPER INTERMITTENT ARMS/BLADES RELAY...
Page 927 Main Menu Table of Contents Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence. Intermittent Wiper Relay Test Remove the wiper intermittent relay from the under-hood relay box B. There should be continuity between the A and C terminals when power and ground are connected to the E and F terminals.
Page 928 Main Menu Table of Contents Wipers/Washers High Relay/Washer Relay Test Low Relay Test Remove the wiper high relay or the washer relay Remove the wiper low relay from under-hood relay from under-hood relay box B. box B. Check continuity at the relay terminals. Check continuity at the relay terminals.
Page 929 Main Menu Table of Contents Windshield Wiper Motor Test Open the hood, and remove the cap nuts and the Test motor operation: wiper arms. Don't let the wiper arms hit the hood. LOW SPEED: Connect battery power to the B (GRN/BLK) terminal and ground to the Lo (BLU) terminal.
Page 930 Main Menu Table of Contents Wipers/Washers Windshield Wiper Motor Windshield Wiper/Washer Switch Replacement Replacement 1. Open the hood, and remove the cap nuts and the SRS components are located in this area. Review the wiper arms. Don't let the wiper arms hit the hood. SRS component locations, precautions, and procedures in the SRS section (24)
Page 931 Main Menu Table of Contents Wipers/Washers Windshield Wiper/Washer Switch Test Remove the dashboard lower cover (see page 23-294). Disconnect the 20-P connector from the floor wire harness. Check for continuity between the terminals in each switch position according to the table. WINDSHIELD WIPER/WASHER SWITCH 20-P CONNECTOR...
Page 932 Main Menu Table of Contents Windshield Washer Motor Test Washer Replacement Disconnect the hose and the 2-P connectors from Disconnect the 2-P connector from the washer motor and remove the front bumper. the washer motor. Test the washer motor operation by connecting Remove the bumper, then remove the washer reservoir by removing the three mounting bolts.
Page 933 Main Menu Table of Contents Cruise Control Component Location Index SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section (24) before performing repairs or ser- vice. MAIN SWITCH Test, page 23-306 Replacement, page 23-305...
Page 934 Main Menu Table of Contents section 11 VEHICLE SPEED SENSOR (VSS) Test, page 23-131 ('94-'96) ('91-'93)
Page 935 Main Menu Table of Contents Cruise Control Description The cruise control system uses mechanically and electri- Operation: cally operated devices to maintain vehicle speed at a The cruise control system will set and automatically setting selected by the driver. maintain any speed above 25 mph (45 km/h). To set, make sure that the main switch is in the "ON"...
Page 936 Main Menu Table of Contents Cruise Control Troubleshooting NOTE: • The numbers in the table show the troubleshooting sequence. • Before troubleshooting: — Check the No. 5 (15 A) fuse in the under-dash fuse box, and the No. 29 (50 A) and No. 45 (20 A) fuses in the under- hood fuse/relay box.
Page 937 Main Menu Table of Contents 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 bulkhead panel, then disconnect the con- nectors from the ECM and make the following tests.
Page 938 Main Menu Table of Contents Cruise Control Control Unit Input Test View from View from wire side View from wire side wire side Possible cause if result is not obtained Wire Test condition Test: Desired result...
Page 939 Main Menu Table of Contents Main Switch Replacement Remove the tilt cover. 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, and disconnect the connectors.
Page 940 Main Menu Table of Contents Cruise Control Main Switch Replacement (cont'd) Disconnect the 20-P, 4-P and 5-P connectors from the floor wire harness. CAUTION: Be careful not to damage the SRS wire harness. Remove the six screws, then remove the windshield wiper-cruise control switch assembly.
Page 941 Main Menu Table of Contents Cruise Control Main Switch Test Remove the dashboard lower cover (see page 23-305). If necessary, remove the dashboard lower pad. Disconnect the 20-P connector, and check for conti- nuity between the terminals, in each switch posi- tion, according to the table.
Page 942 Main Menu Table of Contents SET/RESUME Switch Test Remove the switch cover from the SET/RESUME CAUTION: Before disconnecting any part of an SRS wire harness, connect the short connectors (see section 24). switch, then remove the SET/RESUME switch by removing the two screws. Disconnect the cable reel harness and main harness 6-P connector.
Page 943 Main Menu Table of Contents Cruise Control Clutch Switch Test Brake Switch Test Disconnect the 4-P connector from the switch. Disconnect the 3-P connector from the switch. BRAKE SWITCH CLUTCH SWITCH 3-P CONNECTOR 4-P CONNECTOR BRAKE PEDAL CLUTCH BRAKE PEDAL PEDAL Check for continuity between the terminals accor- Check for continuity between the terminals accor-...
Page 944: A/T Gear Position Switch
Main Menu Table of Contents A/T Gear Position Switch Test 1. Remove the front console, then disconnect the 12-P connector from the A/T gear position switch. 2. Check for continuity between the terminals in each switch position according to the table. •...
Page 945: Replacement, Page
Main Menu Table of Contents Security Alarm 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 ser- vice. RIGHT REAR SIDE IGNITION MARKER LIGHT KEY SWITCH...
Page 946 Main Menu Table of Contents *1:NSX-T (open top) RETRACTABLE HEADLIGHT CONTROL UNIT Input Test, page 23-178 ('94-'96) ('91-'93) LEFT FRONT ROOF LOCK SWITCH* SIDE MARKER LIGHT Test, page 23-154 ('94-'96) ('91-'93) Replacement, page 23-195 ENGINE COMPARTMENT LID SWITCH Test, page 23-325 ('93-'96) ('91-'92) TRUNK LATCH SWITCH STARTER CUT...
Page 947 Main Menu Table of Contents Security Alarm System Description This system is activated automatically 15 seconds after everything has been closed and locked. The security alarm system indicator light located on the driver's door panel will flash after the doors are properly locked. If any of the following conditions occur, the horns will sound, the headlights will pop up and flash, and the side marker lights, parking lights and taillights will flash for about two minutes, or until the system is disarmed by unlocking either door from the outside with the key.
Page 948 Main Menu Table of Contents From page 23-312 Indicator flashes. 0.2 sec ON / 2.4 sec OFF (ARMED) Want the system disarmed? Trunk opened by key? Trunk lid switch ON Trunk key cylinder switch Illegal activity 1. Door is opened forcibly. 2.
Page 949 Main Menu Table of Contents Security Alarm System Wiring Connections NSX-T (open top) TRUNK KEY DRIVER'S CYLINDER SWITCH DOOR KEY CYLINDER SWITCH TRUNK LATCH REAR SWITCH LEFT DRIVER'S DOOR LOCK WIRE ROOF ACTUATOR ASSEMBLY HARNESS LOCK UNDER-HOOD RELAY BOX A ENGINE SWITCH (HORN RELAY)
Page 950 Main Menu Table of Contents Troubleshooting NOTE: The numbers in the table show the troubleshooting sequence. NSX-T (open top)
Page 951 Main Menu Table of Contents Security Alarm System Control Unit Input Test SECURITY Remove the glove box, and disconnect the 22-P connec- CONTROL UNIT tor and 16-P connector from the control unit. Inspect the connector and socket terminals to be sure they are all making good contact.
Page 952 Main Menu Table of Contents Test condition Possible cause if result is not obtained Wire Test: Desired result...
Page 953 Main Menu Table of Contents Security Alarm System Control Unit Input Test View from wire side Wire Test condition Test: Desired result Possible cause if result is not obtained NSX-T (open top)
Page 954 Main Menu Table of Contents Trunk Latch Switch Test Door Switch Test Open the trunk lid and remove the trunk rear trim Remove the door panel (see section 20). panel. Disconnect the 2-P connector from the door lock Disconnect the 3-P connector from the trunk latch. actuator assembly.
Page 955 Main Menu Table of Contents Security Alarm System Indicator Replacement Trunk Key Cylinder Switch Test 1. Remove the door panel (see section 20). Open the trunk lid and remove the trunk rear panel. Disconnect the 2-P connector from the trunk key Remove the two screws from the indicator.
Page 956 Main Menu Table of Contents Engine Compartment Lid Switch Hood Switch Test Test Open the engine compartment lid. Open the hood. Disconnect the 2-P connector from the engine Disconnect the 2-P connector from the hood compartment lid switch. switch. Check continuity at the switch connector terminals. Check continuity at switch connector terminals.
Page 957 Main Menu Table of Contents Security Alarm System Ignition Key Switch Test SRS components are located in this area. Review the Disconnect the 8-P connector from the floor wire SRS component locations, precautions, and procedures harness. in the SRS section 24 before performing repairs or ser- vice.
Page 958 Main Menu Table of Contents Chassis and Paint Codes U.S.Model Vehicle Identification Number Transmission Number Paint Code Paint Code Color G-70P Chariot Green Pearl NH-547 Berlina Black NH-565 Grand Prix White R-77 Formula Red Vehicle Identification Number and Federal Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 959 Main Menu Table of Contents CANADA Model Vehicle Identification Number Transmission Number Paint Code Paint Code Color NH-547 Berlina Black G-70P Chariot Green Pearl NH-565 Grand Prix White R-77 Formula Red Vehicle Identification Number and Canadian Motor Vehicle Safety Standard Certification Engine Number Paint Code...
Page 960 Main Menu Table of Contents Warning/Caution Label Locations SRS CAUTION LABELS: Refer to page 1-8. FROZEN BATTERY CAUTION ABS CAUTION BATTERY CAUTION RADIATOR BLEED PLUG CAUTION ABS and BRAKE FLUID CAUTION AIR CONDITIONING R-134a CAUTION (U.S.A only) RETRACTABLE HEADLIGHT CAUTION EXPANSION TANK CAP CAUTION...
Page 961 Main Menu Table of Contents Warning/Caution Label Locations (cont'd) A: CABLE REEL CAUTION A D: DRIVER'S INFLATOR CAUTION DANGER EXPLOSIVE/FLAMMABLE REFER TO SERVICE MANUAL FOR DETAILED IN- CONTACT WITH ACID, WATER OR HEAVY METALS STRUCTIONS. SUCH AS COPPER, LEAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS.
Page 962 Main Menu Table of Contents (SUNVISOR) F: DRIVER INFORMATION L: CONSOLE BOX INFORMATION ALWAYS WEAR YOUR SEAT BELT AIRBAG INFORMATION THIS CAR IS EQUIPPED WITH A DRIVER AIR- SUPPLEMENTAL RESTRAINT SYSTEM (SRS) BAG AS A SUPPLEMENTAL RESTRAINT SYS- THE SRS MUST BE INSPECTED TEN YEARS AF- TEM (SRS) TER IT IS INSTALLED.
Page 963 Main Menu Table of Contents Warning/Caution Label Locations (cont'd) L: PRETENSIONER ELR CAUTION J: PASSENGER'S INFLATOR CAUTION DANGER CAUTION EXPLOSIVE/FLAMMABLE FOLLOW INSTRUCTIONS BELOW CONTACT WITH ACID, WATER OR HEAVY MET- REMOVAL OF THE PRETENSIONER. SHORT COUPLER (RED) IS TO BE INSTALLED ALS SUCH AS COPPER, LEAD OF MERCURY HARMFUL AND IRRITATING GASES OR EXPLO- IMMEDIATELY WHENEVER COUPLER IS DIS-...
Page 964 Table of Contents Main Menu R—Replace I—Inspect After inspection, clean, adjust, repair or replace if necessary. NOTE PAGE 11-129 ('94-'96) 11-102 ('94-'96) 11-151 ('94-'96) 11-114 ('94-'96) 11-4 ('94-'96) 23-96 8-4 ('94-'96) 8-5 ('94-'96) 23-109 10-2 10-5 6-21 ('94-'96) 10-10 11-144 ('94-'96) 9-4 ('94-'96) 9-4 ('94-'96) 13-3...
Page 965 Main Menu Table of Contents R-Replace I — Inspect After inspection, clean, adjust, repair or replace if necessary. PAGE 19-6 19-8 19-18 19-26 19-4 19-10 19-69 19-41 19-43 19-44 19-62 18-7 17-21 ('93-'96) ('94-'96) 17-60(' 9 4-' 9 6) ('94-'96) 17-6 18-14 18-30...
Page 966 Table of Contents Main Menu Engine Oil 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. WASHER Replace. API CERTIFICATION MARK The numbers in the middle of the API Service label tell DRAIN PLUG you the oil's SAE viscosity or weight.
Page 967 Main Menu Table of Contents Chassis and Paint Codes U.S. Model Vehicle Identification Number Transmission Number Manufacturer, Make and Transmission Type Type of Vehicle JH4: HONDA MOTOR CO., LTD. Serial Number J4A4: 2000001 ~ Body Type MR9A: 2000001~ Door and Transmission Type Paint Code Vehicle Grade Paint Code...
Page 968 Main Menu Table of Contents CANADA Model Transmission Number Vehicle Identification Number JH4NA115*PT800001 J4A4-2000001 Transmission Type J4A4: 5-speed Manual Transmission MR9A: 4-speed Automatic Transmission Serial Number J4A4: 2000001 MR9A: 2000001 Paint Code Paint Code Color NH-547 Berlina Black NH-552M Sebring Silver Metallic NH-565 Grand Prix White R-77...
Page 969 Table of Contents Main Menu Warning/Caution Label Locations SRS CAUTION LABELS: Refer to page 1-8. FROZEN BATTERY CAUTION ABS CAUTION BATTERY CAUTION RADIATOR BLEED PLUG CAUTION ABS and BRAKE FLUID CAUTION AIR CONDITIONING R-134a CAUTION (U.S.A only) RETRACTABLE HEADLIGHT CAUTION EXPANSION TANK CAP CAUTION...
Page 970 MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS. STORAGE TEMPERATURES MUST NOT EXCEED 200°F. FOR PROPER HANDLING. STORAGE, AND DISPOSAL PROCEDURES REFER TO THE ACURA SERVICE MANUAL, SRS SUPPLEMENT. POISON A: CABLE REEL CAUTION A CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM NITRATE.
Page 971 LIGHTS WHILE DRIVING OR FLASHES; FAILS TO LIGHT OR STAYS ON AFTER THE STORE IN A CLEAN, DRY AREA. IGNITION IS FIRST TURNED ON: SEE YOUR AUTHORIZED ACURA DEALER. I: STEERING COLUMN CAUTION CAUTION TO AVOID DAMAGING THE SRS CABLE OR REEL,...
Page 972 Main Menu Table of Contents Warning/Caution Label Locations (cont'd) M: PRETENSIONER ELR CAUTION K. PASSENGER'S INFLATOR CAUTION DANGER CAUTION FOLLOW THE INSTRUCTIONS BELOW FOR EXPLOSIVE/FLAMMABLE CONTACT WITH ACID, WATER OR HEAVY MET- REMOVAL OF THE PRETENSIONER. SHORT COUPLER (RED) IS TO BE IN- ALS SUCH AS COPPER, LEAD OF MERCURY STALLED IMMEDIATELY WHENEVER COU- HARMFUL AND IRRITATING GASES OR EXPLO-...
Page 973 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. LUBRICATION POINTS LUBRICANT Engine...
Page 974 Table of Contents Main Menu...
Page 975 Main Menu Table of Contents R-Replace I—Inspect After inspection, clean, adjust, repair or replace if necessary. PAGE 11-129 11-102 11-151 6-54 11-114 11-4 23-96 23-109 10-2 10-5 6-21 10-10 11-144 13-3 14-90 Check oil and coolant level at each fuel stop. For cars sold in California, this service is recommended only: other areas, it is required.
Page 976 Main Menu Table of Contents R—Replace I —Inspect After inspection, clean, adjust, repair or replace if necessary. Service at the interval listed x 1,000 miles (or km) or after that number of months, whichever comes first. NOTE PAGE 19-6 19-8 19-18 19-26 19-4...
Page 977 Main Menu Table of Contents Outline Description This engine is a 2,977 cm (181.6 cu-in) DOHC mid-ship unit having 6 cylinders of 90° —V configuration; it is water cool- ed and equipped with a center plug type pent roof combustion chamber. It is specified for unleaded fuel and uses a PGM-FI system.
Page 978 Table of Contents Main Menu This engine has the following new features. VTEC; High output and a broad power band is achieved through control of low-speed and high-speed valve operation by the Engine Control Module (ECM). (Two knock sensors are used to detect octane level of the fuel.) Titanium connecting rods ;...
Page 979 Main Menu Table of Contents Variable Valve Timing and Valve Lift Electronic Control System (VTEC) Outline The engine is equipped with multiple cam lobes per cylinder, providing one valve timing and lift profile at low speed and a different profile at high speed. Switch-over from one profile to the other is controlled electronially, and is selected by monitoring current engine speed and load.
Page 980 Table of Contents Main Menu In general, it would be ideal if the high rpm performance of a racing engine and the low rpm performance of a standard passenger car engine could be combined in a single engine. This would result in a maximum performance engine with a wide power band.
Page 981 Table of Contents Main Menu Cylinder Head Camshaft The camshaft is a cast piece. By improving dimensional accuracy, it became possible to achieve minimum space be- tween cams, thus allowing a more compact cylinder head. Each camshaft is supported on four bearing journals with forc- ed lubrication.
Page 982 Main Menu Table of Contents Lubrication System Lubrication Flow VTEC SOLENOID VALVE ROCKER SHAFT ORIFICES Front CYLINDER HEAD ORIFICE OIL SCREEN OIL PUMP No. 6 No. 5 No. 4 RELIEF VALVE OIL FILTER CRANKSHAFT MAIN JOURNAL ENGINE COOLANT MAIN BEARING CAP BRIDGE ENGINE OIL COOLER...
Page 983 Table of Contents Main Menu Exhaust System Dual Exhaust System Features A compact dual exhaust system is used to provide low back pressure. Sound tuning has been optimized to give a sporty exhaust sound note suitable to this type of car. This is done by a col- lection chamber in muffler.
Page 984 Main Menu Table of Contents Cooling Cooling System Two cooling systems are employed: An antifreeze/water system with the radiator mounted in the front of the vehicle. An air-cooling system driven by a fan mounted in the engine compartment. BLEEDER RADIATOR DRAIN BLEEDER WATER VALVE...
Page 985 Main Menu Table of Contents Special Tools Ref. No. Tool Number Description Page Reference 5-27 07MAK-PR7020A Engine Removal/Installation Fixture...
Page 986 Table of Contents Main Menu Engine Removal/Installation Remove the expansion tank cap to speed draining. Make sure jacks and safety stands are placed proper- ly and hoist brackets are attached to the correct Use care when removing the expan- positions on the engine (see section sion tank cap to avoid scalding by hot engine Make sure the car will not roll off stands and fall...
Page 987 Main Menu Table of Contents Engine Removal/Installation (cont'd) 10. Disconnect the resistor connector and fan motor 11. Remove the rear trim panels behind the connector, then remove the engine room fan passenger's seat, then disconnect four connectors assembly. from Engine Control Module (ECM) and five con- nectors from floor wire harness.
Page 988 Main Menu Table of Contents 1 5. Remove the fuel feed pipe. 12. Remove the intake manifold plate and the top cover. 16. Remove the fuel return hose from the pressure con- 13. Remove the throttle cable by loosening the locknut, trol valve.
Page 989 Main Menu Table of Contents Engine Removal/Installation (cont'd) 21. Disconnect the two engine wire harness connec- 18. Remove the breather pipe, then remove the air in- tors from the side wire harness at left side of take duct and the air cleaner case. engine compartment, and remove the engine wire 6 x 1.0 mm harness terminal and the starter cable terminal...
Page 990 Main Menu Table of Contents 24. Disconnect the three connectors from the emission 27. Raise hoist to full height. control box. Do not disconnect the vacuum hoses. 28. Remove the clutch slave cylinder from the transmission case (M/T see section 12).
Page 991 Main Menu Table of Contents Engine Removal/Installation (cont'd ) 32. Remove the rear beam rod assembly. 33. Remove the front beam. Lower and suspend the air conditioning (A/C) compressor. Reinstall the front beam. NOTE: Do not remove the compressor hoses. Do not let the compressor hang from hoses.
Page 992 Main Menu Table of Contents 36. Remove the rear brake hoses. Plug the brake pipes 38. Remove the adjust bolt and flange bolt, then with rubber caps. separate the lower control arm from the subframe. 37. Remove the wheel sensor wire clamps. 39.
Page 993 Main Menu Table of Contents Engine Removal/Installation (cont'd) 43. Remove the half shaft heat cover. 40. Remove the heated oxygen sensor (HO2S) connectors. 44. Remove the driveshafts. 41. Remove the self-locking nuts, then remove front NOTE: exhaust pipe and the front three way catalytic Coat all precision finished surfaces with clean converter.
Page 994 Main Menu Table of Contents 45. Install the front engine mounting bolt, torque the 47. Adjust the pads on the fixture to support the oil nut temporarily. pan and transmission housing. 46. Position the Engine Removal/Installation Fixture 48. Lower the car so the fixture is resting on its casters (07MAK –PR7020A) under the car.
Page 995 Main Menu Table of Contents Engine Removal/Installation (cont'd) 49. Remove the two bolts from the side engine mount 52. Raise the car a few inches. near the alternator. Pivot the mounting bracket into 53. Check that all wires and hoses are disconnected the housing of the body.
Page 996 Table of Contents Main Menu 55. Attach a chain hoist to the engine. Remove the front and rear mounting bolts, then separate the engine from the suspension and the beam assembly. CAUTION: Do not hit the engine oil cooler on the rear right beam bracket.
Page 997 Table of Contents Main Menu 55. Attach a chain hoist to the engine. Remove the front and rear mounting bolts, then separate the engine from the suspension and the beam assembly. CAUTION: Do not hit the engine oil cooler on the rear right beam bracket.
Page 998 Main Menu Table of Contents Engine Removal/Installation (cont'd) After the engine is in place: Check that the transmission shifts into gear Torque the engine mounting bolts in sequence smoothly (M/T see section 13, A/T see section 14). shown below. Adjust the alternator belt (see section 23).
Page 999 Main Menu Table of Contents Additional Torque Value Specifications: 8x 1.25 mm 10 x 1.25 mm 22 N m (2.2 kg-m, 45 N m (4.5 kg-m, 16 Ib-ft) 33 Ib-ft) NOTE: For manifold replacement, refer to section ALTERNATOR 8 x 1.25 mm BRACKET ENGINE HANGER 30 N...
Page 1000 Main Menu Table of Contents Engine Removal/Installation (cont'd) Sub-frame Torque Value Specifications: LEFT REAR BRACKET RIGHT REAR 10 x 1.25 mm BRACKET 60 N m (6.0 kg-m. 10 x 1.25 mm 43 Ib-ft) 60 N m (6.0 kg-m 43 Ib-ft) ROD B 12 x 1.25 mm 95 N...

This manual is also suitable for:

Nsx 1992 Nsx 1993 Nsx 1994 Nsx 1995 Nsx 1996

Acura NSX 1991 Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Acura NSX 1991

Summary of Contents for Acura NSX 1991

This manual is also suitable for:

Table of Contents