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Honda CR-V 2002 Shop Manual
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Honda CR-V 2002 Shop Manual

Honda CR-V 2002 Shop Manual

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Summary of Contents for Honda CR-V 2002

  • Page 1 +RQGD &59 6KRS 0DQXDO D‡…‚qˆp‡v‚ " UhiyrÃPsÃ8‚‡r‡†  % Dqr‘  "...
  • Page 2 Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk (*) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items will require special precautions and tools, and should be done only by an authorized Honda dealer. :$51,1* ‡...
  • Page 3 ,QWURGXFWLRQ *HQHUDO ,QIR +RZ WR 8VH 7KLV 0DQXDO 6SHFLILFDWLRQV The 2002 CR-V Shop Manual is divided into 23 sections. The first page of each section is marked with a black tab that lines up with its corresponding thumb index tab on this page. You can quickly find the first page of each section without looking through a full table of contents.
  • Page 4 If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 5 $ )HZ :RUGV $ERXW 6DIHW\ ,03257$17 6$)(7< 35(&$87,216 ‡ Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: ±...
  • Page 6 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV 7DEOH 2I &RQWHQWV +RQGD &59 6KRS 0DQXDO  6833/(0(17$/ 5(675$,17 6<67(0 656   ,QWURGXFWLRQ   How to Use This Manual........................ 00-3 Safety Messages ........................... 00-3 $ )HZ :RUGV $ERXW 6DIHW\   Service Information ........................
  • Page 7 7DEOH 2I &RQWHQWV Cylinder Head ..........................02-3 Engine Block ..........................02-4 Engine Lubrication ......................... 02-5 Cooling............................02-6 Fuel and Emissions ........................02-6 Clutch............................. 02-6 Manual Transmission and M/T Differential ..................02-7 Automatic Transmission and A/T Differential................. 02-9 Rear Differential ........................... 02-15 Steering ............................
  • Page 8 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV Spark Plug Inspection ........................04-37 &KDUJLQJ 6\VWHP   Component Location Index ......................04-38 Circuit Diagram ..........................04-39 Charging Circuit Troubleshooting ....................04-40 Drive Belt Inspection ........................04-43 Drive Belt Replacement ....................... 04-44 Drive Belt Auto-tensioner Inspection....................
  • Page 9 7DEOH 2I &RQWHQWV Rocker Arm Assembly Removal ....................06-27 Rocker Arms and Shafts Disassembly/Reassembly..............06-28 Rocker Arms and Shafts Inspection .................... 06-29 Camshaft Inspection ........................06-30 Valves, Springs and Valve Seals Removal.................. 06-32 Valve Inspection .......................... 06-33 Valve Stem-to-Guide Clearance Inspection................. 06-33 Valve Guide Replacement ......................
  • Page 10 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV Exhaust Manifold Removal and Installation ................... 09-8 Exhaust Pipe and Muffler Replacement..................09-9 (QJLQH &RROLQJ  &RROLQJ 6\VWHP   Component Location Index ......................10-2 Radiator Cap Test.......................... 10-3 Radiator Test ..........................10-3 Fan Motor Test..........................
  • Page 11 7DEOH 2I &RQWHQWV Secondary HO2S Replacement....................11-122 97(&97&   Component Location Index......................11-123 DTC Troubleshooting......................... 11-124 VTC Oil Control Solenoid Valve Test..................11-137 CMP Sensor Replacement ......................11-138 VTEC Solenoid Valve Removal/Inspection................11-138 ,GOH &RQWURO 6\VWHP   Component Location Index......................11-139 DTC Troubleshooting.........................
  • Page 12 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP   Component Location Index ......................11-191 DTC Troubleshooting......................... 11-193 Evaporative Emission (EVAP) System Troubleshooting............11-195 EVAP Two Way Valve Test ....................... 11-198 EVAP Canister Replacement..................... 11-199 &OXWFK  6SHFLDO 7RROV   &RPSRQHQW /RFDWLRQ ,QGH[   &OXWFK 3HGDO DQG &OXWFK 3HGDO 3RVLWLRQ 6ZLWFK $GMXVWPHQW  ...
  • Page 13 7DEOH 2I &RQWHQWV Gearshift Mechanism Replacement..................... 13-55 07 'LIIHUHQWLDO   Component Location Index......................13-56 Backlash Inspection........................13-58 Driven Gear/Carrier Replacement ....................13-58 Carrier Bearings Replacement ....................13-59 Oil Seal Replacement ........................13-60 Differential Thrust Clearance Adjustment ..................13-61 7UDQVIHU $VVHPEO\   Backlash Inspection on Car ......................
  • Page 14 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV ATF Replacement ........................14-131 Transfer Assembly Inspection....................14-132 Transfer Assembly Removal...................... 14-133 Transfer Assembly Installation....................14-134 Transmission Removal ......................14-135 Transmission Installation ......................14-143 ATF Cooler Hoses Replacement ....................14-151 Shift Lever Removal........................14-152 Shift Lever Installation........................
  • Page 15 7DEOH 2I &RQWHQWV Shift Solenoid Valves Installation....................14-213 7RUTXH &RQYHUWHU +RXVLQJ   Mainshaft Bearing and Oil Seal Replacement ................14-214 Countershaft Bearing Replacement................... 14-215 Secondary Shaft Bearing Replacement..................14-216 Control Shaft Oil Seal Replacement ..................14-217 6KDIWV DQG &OXWFKHV   Mainshaft Disassembly, Inspection and Reassembly..............
  • Page 16 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV Transfer Housing Tapered Roller Bearing Outer Race Replacement........14-280 Reassembly ..........................14-281 5HDU 'LIIHUHQWLDO  6SHFLDO 7RROV   6\VWHP 'HVFULSWLRQ   'XDO 3XPS 6\VWHP )XQFWLRQ 7HVW   Automatic Transmission......................... 15-9 Manual Transmission........................
  • Page 17 7DEOH 2I &RQWHQWV 3URSHOOHU 6KDIW ,QVWDOODWLRQ   6WHHULQJ  3RZHU 6WHHULQJ   Special Tools ..........................17-2 Component Location Index......................17-3 Symptom Troubleshooting Index ....................17-4 Hard Steering Troubleshooting...................... 17-6 Steering Wheel Rotational Play Check ..................17-7 Power Assist Check........................17-7 Steering Linkage and Gearbox Inspection..................
  • Page 18 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV Stabilizer Bar Replacement ......................18-32 Stabilizer Link Replacement ......................18-33 Upper Arm Replacement ......................18-34 Trailing Arm Replacement ......................18-35 Damper/Spring Replacement....................... 18-36 %UDNHV  $ &RQYHQWLRQDO %UDNH &RPSRQHQWV  $ Special Tools ..........................19A-2 Component Location Index ......................
  • Page 19 7DEOH 2I &RQWHQWV ABS Modulator-Control Unit Removal and Installation .............. 19B-36 Wheel Sensor Inspection ......................19B-38 Wheel Sensor Replacement ...................... 19B-39 %RG\  'RRUV   Component Location Index - Front Door ..................20-2 Component Location Index - Rear Door ..................20-6 Front Door Panel Removal/Installation ..................
  • Page 20 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV Sunshade Replacement....................... 20-67 Motor Replacement........................20-68 Frame and Drain Tube Replacement................... 20-69 Drain Channel Slider and Cable Assembly Replacement............20-71 Position Switch Adjustment......................20-73 Closing Force and Opening Drag Check ..................20-74 ,QWHULRU 7ULP   Component Location Index ......................
  • Page 21 7DEOH 2I &RQWHQWV Hood Seal Replacement ......................20-133 Hood Insulator Replacement ..................... 20-134 7DLOJDWH   Tailgate Adjustment ........................20-135 Tailgate Striker Adjustment......................20-136 Tailgate Wedge Adjustment....................... 20-136 Tailgate Support Strut Replacement..................20-137 Tailgate Weatherstrip Replacement ..................20-137 )XHO )LOO 'RRU   Adjustment..........................
  • Page 22 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV Special Tools ..........................21-2 SUPPLEMENAL RESTRAINT SYSTEM (SRS) (If HVAC maintenance is required)..... 21-2 Component Location Index ......................21-3 General Troubleshooting Information .................... 21-4 DTC Troubleshooting Index ......................21-5 Symptom Troubleshooting Index ....................21-6 System Description ........................
  • Page 23 7DEOH 2I &RQWHQWV &OLPDWH &RQWURO   Component Location Index......................21-60 General Troubleshooting Information ..................21-63 DTC Troubleshooting Index......................21-64 Symptom Troubleshooting Index ....................21-65 System Description........................21-66 Circuit Diagram ..........................21-67 DTC Troubleshooting........................21-69 Recirculation Control Motor Circuit Troubleshooting ..............21-83 Climate Control Power and Ground Circuits Troubleshooting .............
  • Page 24 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV *URXQG 'LVWULEXWLRQ  $ Circuit Identification........................22A-48 8QGHUGDVK )XVH5HOD\ %R[  $ Removal and Installation......................22A-58 %DWWHU\  $ Battery Test..........................22A-59 5HOD\V  $ Power Relay Test........................22A-60 ,JQLWLRQ 6ZLWFK  $ Test ............................
  • Page 25 7DEOH 2I &RQWHQWV Hazard Warning Switch Test ....................22A-105 ,QWHULRU /LJKWV $ Component Location Index...................... 22A-106 Circuit Diagram ........................22A-107 Spotlights Test/Replacement ....................22A-108 Ceiling Light Test/Replacement ....................22A-109 Glove Box Light Test/Replacement ..................22A-109 Hatch Glass Latch Switch Test ....................22A-110 Tailgate Switch Test/Replacement ..................
  • Page 26 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV Horn Test/Replacement ......................22A-141 Horn Switch Test ........................22A-142 3RZHU :LQGRZV  $ Component Location Index ...................... 22A-143 Circuit Diagram - With UP-AUTO Function ................22A-144 Circuit Diagram - Without UP-AUTO Function ................ 22A-146 Master Switch Input Test - With UP-AUTO Function ..............
  • Page 27 7DEOH 2I &RQWHQWV Circuit Diagram ........................22A-196 Security Control Unit Input Test ....................22A-199 Door Lock Knob Switch Test ....................22A-202 Hood Switch Test ........................22A-204 Door Key Cylinder Switch Test ....................22A-204 Tailgate Lock Knob Switch Test ..................... 22A-205 Security Horn Test ........................
  • Page 28 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV AVN Unit Inputs and Outputs for Connector A (12P)..............22B-8 AVN Inputs and Outputs for GPS antenna 2P Connector ............22B-9 Overview ............................ 22B-10 Navigation Function ........................22B-11 &LUFXLW 'LDJUDP  % 6\PSWRP 7URXEOHVKRRWLQJ  % No picture is shown on the display ....................
  • Page 29 7DEOH 2I &RQWHQWV General Troubleshooting Information ..................23-25 DTC Troubleshooting Index......................23-31 Symptom Troubleshooting Index ....................23-38 System Description........................23-39 Circuit Diagram ..........................23-41 Connectors ..........................23-43 DTC Troubleshooting........................23-45 SRS Indicator Circuit Troubleshooting..................23-124 Component Replacement/Inspection After Deployment............23-134 Driver’s Airbag Replacement .....................
  • Page 30 +RQGD &59 6KRS 0DQXDO 7DEOH 2I &RQWHQWV 3RZHU :LQGRZ &LJDUHWWH /LJKWHU $FFHVVRU\ 3RZHU 6RFNHW   1DYLJDWLRQ 6\VWHP 6WHUHR 6RXQG 6\VWHP   6HDW +HDWHU :LSHUV:DVKHUV +HDGOLJKW :DVKHU   :LSHUV:DVKHUV :LQGVKLHOG 5HDU   0XOWLSOH[ &RQWURO 6\VWHP )RJ /LJKW &RQWURO ,PPRELOL]HU &RQWURO ,QWHUORFN &RQWURO ,QWHUPLWWHQW :LSHU &RQWURO (QWU\ /LJKWV &RQWURO   .H\OHVV3RZHU 'RRU /RFN 6\VWHP :LWK 6XSHU ORFNLQJ 6\VWHP   .H\OHVV3RZHU 'RRU /RFN 6\VWHP :LWKRXW 6XSHU ORFNLQJ 6\VWHP  ...
  • Page 31 ,QGH[ ,QGH[ 1XPHULFV QG &OXWFK 3UHVVXUH 6ZLWFK Replacement ........................... 14-121 UG &OXWFK 3UHVVXUH 6ZLWFK Replacement ........................... 14-121 UGWK &OXWFK $VVHPEO\ Disassembly ............................ 14-235 Inspection ............................14-240 Reassembly ............................. 14-247 $& Circuit Diagram ..........................21-37 Component Location Index ........................ 21-31 Description ............................21-36 Test ..............................
  • Page 32 +RQGD &59 6KRS 0DQXDO ,QGH[ Inspection ............................14-242 $7 &OXWFK 3UHVVXUH &RQWURO 6ROHQRLG 9DOYHV Replacement ........................14-117, 14-119 Test .............................14-116, 14-118 $7 &OXWFK :DYHGSODWH Inspection ............................14-241 $7 &RXQWHUVKDIW $VVHPEO\ Disassembly/Inspection/Reassembly ....................14-221 $7 'LIIHUHQWLDO Component Location Index ......................14-264 $7 *HDU 3RVLWLRQ ,QGLFDWRU Input Test ............................
  • Page 33 ,QGH[ $LU &OHDQHU Replacement ........................... 11-182 $LU &OHDQHU (OHPHQW Replacement ........................... 11-182 $LU 0L[ &RQWURO 0RWRU Replacement ............................. 21-21 Test ..............................21-21 $LUEDJ 'ULYHU¶V Repair .............................. 23-138 Replacement ........................... 23-135 $LUEDJ )URQW 3DVVHQJHU¶V Replacement ........................... 23-136 $OWHUQDWRU Overhaul ............................04-48 Replacement .............................
  • Page 34 +RQGD &59 6KRS 0DQXDO ,QGH[ Test ..............................14-107 %DFN8S /LJKW 6ZLWFK Test ..............................13-4 %DFNXS /LJKWV Circuit Diagram ..........................22A-91 %DOO -RLQWV Removal ............................. 18-10 %DWWHU\ Test ..............................22A-59 %ORZHU 0RWRU Replacement ............................21-27 %ORZHU 3RZHU 7UDQVLVWRU Test ..............................21-24 %ORZHU 8QLW Removal/Installation ..........................
  • Page 35 ,QGH[ Adjustment ............................19A-5 %UDNH 3HGDO 3RVLWLRQ 6ZLWFK Test ..............................22A-99 %UDNH 3HGDO 3RVLWLRQ 6ZLWFK 6LJQDO &LUFXLW Troubleshooting ..........................11-146 %UDNH 6\VWHP ,QGLFDWRU &LUFXLW Circuit Diagram Convetional Brake Components ................19A-10 Troubleshooting ABS/TCS Components ..................19B-34 %XOE *DXJH Replacement ...........................22A-73 %XPSHU )URQW Removal/Installation ........................20-130 %XPSHU 5HDU Removal/Installation ........................
  • Page 36 +RQGD &59 6KRS 0DQXDO ,QGH[ &OLPDWH &RQWURO 8QLW %XOE Replacement ............................21-91 &OXWFK Component Location Index ........................12-3 Replacement ............................12-11 &OXWFK 0DVWHU &\OLQGHU Overhaul .............................. 12-6 Replacement ............................12-5 &OXWFK 3HGDO Adjustment ............................12-4 &OXWFK 6ODYH &\OLQGHU Overhaul ............................12-10 Replacement ............................
  • Page 37 ,QGH[ &RXQWHUVKDIW %HDULQJ 7RUTXH &RQYHUWHU +RXVLQJ Replacement ........................... 14-215 &RXQWHUVKDIW %HDULQJV Replacement ............................. 13-46 &RXQWHUVKDIW 5HYHUVH 6HOHFWRU +XE Installation .......................... 14-224, 14-226 Removal ..........................14-223, 14-225 &RZO &RYHU Replacement ........................... 20-140 &UDQNVKDIW Inspection ............................07-14 Installation ............................07-24 Removal ............................07-12 &UDQNVKDIW 0DLQ %HDULQJV Replacement ............................
  • Page 38 +RQGD &59 6KRS 0DQXDO ,QGH[ 'DPSHUV )URQW Repair ..............................18-11 Replacement ............................18-21 'DPSHUV 5HDU Replacement ............................18-36 'DVK 9HQWV Removal/Installation .......................... 20-96 'DVKERDUG Removal/Installation .......................... 20-96 'DVKERDUG &HQWHU /RZHU &RYHU A/T Removal/Installation ........................20-91 M/T Removal/Installation ........................20-93 'DVKERDUG &HQWHU 3DQHO Removal/Installation ..........................
  • Page 39 ,QGH[ Replacement ........................... 14-267 'LIIHUHQWLDO 2LO 6HDOV 07 Replacement ............................. 13-60 'LIIHUHQWLDO 3LQLRQ *HDUV 07 Inspection ............................13-58 '/& &LUFXLW Troubleshooting ..........................11-114 'RRU &KDQQHO 7DSHV 2XWHU Replacement Front Doors ......................... 20-19 Replacement Rear Doors ........................20-32 'RRU *ODVV Adjustment ............................20-34 Replacement Front Doors .........................
  • Page 40 +RQGD &59 6KRS 0DQXDO ,QGH[ 'RRU :HDWKHUVWULSV Replacement Front Doors ........................20-18 Replacement Rear Doors ........................20-30 'ULYH %HOW Inspection ............................04-43 Replacement ............................04-44 'ULYH %HOW $XWRWHQVLRQHU Inspection ............................04-44 Replacement ............................04-45 '7& 7URXEOHVKRRWLQJ ,QGH[HV ABS/TCS Components ........................19B-10 Automatic Climate Control .........................
  • Page 41 ,QGH[ (9$3 &RQWURO 6\VWHP Component Location Index ......................11-191 Troubleshooting ..........................11-195 (9$3 7ZR :D\ 9DOYH Test ..............................11-198 (YDSRUDWRU 7HPSHUDWXUH 6HQVRU Replacement ............................. 21-44 Test ..............................21-44 ([KDXVW 0DQLIROG Removal/Installation ..........................09-8 ([KDXVW 3LSH Replacement ............................09-9 )DQ &RQWUROV Circuit Diagram ..........................
  • Page 42 +RQGD &59 6KRS 0DQXDO ,QGH[ Replacement ............................ 23-147 )URQW 6SHDNHUV Replacement ..........................22A-120 )URQW 6XVSHQVLRQ Component Location Index ........................18-3 )XHO DQG (PLVVLRQV Description ............................11-10 )XHO )LOO 'RRU Adjustment ............................20-138 )XHO )LOO 'RRU 2SHQHU &DEOH Replacement ............................ 20-160 )XHO )LOWHU Replacement ............................
  • Page 43 ,QGH[ *DXJH $VVHPEO\ Replacement ...........................22A-74 *DXJHV Circuit Diagram ..........................22A-68 Component Location Index ......................22A-64 How-to Information ..........................22A-66 *HQHUDO ,QIRUPDWLRQ 6HFWLRQ ......................01- *ORYH %R[ Removal/Installation .......................... 20-95 *ORYH %R[ /LJKW Test/Replacement .........................22A-109 *36 $QWHQQD Removal/Installation ........................22B-26 *ULOOH Replacement ........................... 20-139 *URXQG 'LVWULEXWLRQ Circuit Diagram ..........................22A-48 +DWFK *ODVV Adjustment ............................
  • Page 44 +RQGD &59 6KRS 0DQXDO ,QGH[ How-to Information ..........................22A-97 Replacement ............................22A-96 +HDGOLJKW $GMXVWHU 6ZLWFK Test ..............................22A-95 +HDGOLJKW $GMXVWHU 8QLW Troubleshooting ..........................22A-94 +HDGOLJKW :DVKHU &RQWURO 8QLW Input Test ............................22A-218 +HDGOLJKWV Circuit Diagram ....................22A-82, 22A-86, 22A-89 +HDGOLQHU Removal/Installation .......................... 20-81 +HDWHU &RQWURO 3DQHO Removal and Installation Heating/Ventilation ..................
  • Page 45 ,QGH[ +RRG 2SHQHU &DEOH Component Location Index ......................20-158 Replacement ........................... 20-159 +RRG 6HDO Replacement ........................... 20-133 +RRG 6ZLWFK Test ..............................22A-204 +RUQ Test/Replacement .........................22A-141 +RUQ 6ZLWFK Test ..............................22A-142 +RUQV Circuit Diagram ..........................22A-141 Component Location Index ......................22A-140 ,$7 ,QWDNH $LU 7HPSHUDWXUH 6HQVRU Replacement ...........................
  • Page 46 +RQGD &59 6KRS 0DQXDO ,QGH[ ,PPRELOL]HU 6\VWHP Circuit Diagram ..........................22A-189 Component Location Index ......................22A-186 Description .............................22A-187 Troubleshooting ..........................22A-190 ,05& ,QWDNH 0DQLIROG 5XQQHU &RQWURO 9DOYH Replacement ............................ 11-187 ,QFDU 7HPSHUDWXUH 6HQVRU Replacement ............................21-88 Test ..............................21-88 ,QQHU )HQGHU )URQW Replacement ............................ 20-155 ,QVLGH 5HDUYLHZ 0LUURU Replacement ............................
  • Page 47 ,QGH[ Circuit Diagram ..........................22A-196 Component Location Index .................... 22A-158, 22A-192 Description .............................22A-195 .H\OHVV 5HFHLYHU 8QLW Input Test ............................22A-165 .QRFN 6HQVRU Replacement ........................... 11-121 .QXFNOHV Replacement, Front Suspension ....................... 18-12 Replacement, Rear Suspension ......................18-27 /LFHQVH 3ODWH /LJKW Replacement ...........................22A-99 /LJKWV ([WHULRU Component Location Index ......................22A-79 /LJKWV ,QWHULRU Circuit Diagram ..........................22A-107...
  • Page 48 +RQGD &59 6KRS 0DQXDO ,QGH[ Reassembly ............................13-31 07 5HYHUVH 6KLIW )RUN Inspection ............................13-21 07 6KLIW /HYHU Disassembly/Reassembly ........................13-23 Inspection ............................13-22 Replacement ............................13-55 0DLQ 9DOYH %RG\ Disassembly/Inspection/Reassembly ....................14-209 Installation ...........................14-208, 14-252 Removal ............................14-205 Repair .............................. 14-207 0DLQVKDIW UG *HDU Inspection ............................
  • Page 49 ,QGH[ 0XOWLSOH[ &RQWURO 8QLW Input Test, Entry Light Control System ..................22A-114 Input Test, Keyless Entry/Security Alarm System ............22A-166, 22A-169 Input Test, Multiplex Control System .....................22A-235 Input Test, Wiper/Washer ......................22A-216 1DYLJDWLRQ Adjustment ............................22B-27 Circuit Diagram ..........................22B-15 Component Location Index ........................22B-3 Description ............................22B-7 How-to Information ..........................22B-4 Repair ..............................22B-25...
  • Page 50 +RQGD &59 6KRS 0DQXDO ,QGH[ Replacement ............................ 23-146 2XWVLGH $LU 7HPSHUDWXUH 'LVSOD\ Test ..............................22A-78 2XWVLGH $LU 7HPSHUDWXUH 6HQVRU Replacement ............................21-89 Test ..............................21-89 2XWVLGH 0LUURU +ROGHUV Replacement ............................20-40 2XWVLGH 3RZHU 0LUURU $FWXDWRUV Replacement ..........................22A-137 Test ..............................22A-136 2XWVLGH 3RZHU 0LUURU 6ZLWFK Test/Replacement ..........................22A-135 2XWVLGH 3RZHU 0LUURUV Circuit Diagram ......................
  • Page 51 ,QGH[ Installation ............................07-23 Replacement ............................. 07-18 3RZHU 'LVWULEXWLRQ Circuit Diagram ..........................22A-40 3RZHU 5HOD\ Test ..............................22A-60 3RZHU 6WHHULQJ )OXLG Replacement ............................. 17-11 3RZHU 6WHHULQJ /LQHV DQG +RVHV Replacement ............................. 17-12 3RZHU 6WHHULQJ 3XPS Overhaul ............................17-14 Replacement ............................. 17-13 Test ..............................17-9 3RZHU :LQGRZ 0RWRU 'ULYHU¶V Test ..............................22A-154 3RZHU :LQGRZ 0RWRUV 3DVVHQJHU¶V...
  • Page 52 +RQGD &59 6KRS 0DQXDO ,QGH[ Test ..............................10-3 5DGLDWRU DQG &RQGHQVHU )DQV &RPPRQ &LUFXLW Troubleshooting ..........................21-39 5DGLDWRU &DS Test ..............................10-3 5DGLDWRU )DQ $VVHPEO\ Test ..............................10-4 5DGLDWRU )DQ &LUFXLW Troubleshooting ..........................10-14 5DGLDWRU )DQ 6ZLWFK Replacement ............................10-17 Test ..............................
  • Page 53 ,QGH[ 5HFLUFXODWLRQ &RQWURO 0RWRU Replacement ............................. 21-23 Test ..............................21-23 5HFLUFXODWLRQ &RQWURO 0RWRU &LUFXLW Troubleshooting ........................21-18, 21-83 5HIULJHUDQW Replacement ............................. 21-53 Test ..............................21-56 5HIULJHUDQW 2LO Replacement ............................. 21-33 5HJXODWRU 9DOYH %RG\ Disassembly/Inspection/Reassembly ....................14-211 5HYHUVH /RFN 6\VWHP &LUFXLW Troubleshooting ..........................
  • Page 54 +RQGD &59 6KRS 0DQXDO ,QGH[ Replacement ............................ 20-110 6HDW &RYHU 5HDU Replacement Left ..........................20-123 Replacement Right .......................... 20-117 6HDW +HDWHU (OHPHQWV Test ..............................22A-184 6HDW +HDWHU 5HOD\ Test ..............................22A-184 6HDW +HDWHU 6ZLWFKHV Test/Replacement ..........................22A-185 6HDW +HDWHUV Circuit Diagram ..........................22A-183 Component Location Index ......................22A-182 6HDW )URQW Disassembly/Reassembly With Manual Height Adjustable .............
  • Page 55 ,QGH[ Test A/T Electronic Control System ....................14-112 Test Torque Converter ........................14-109 6KLIW )RUNV Disassembly/Reassembly ......................... 13-25 Inspection ............................13-24 6KLIW /RFN 6ROHQRLG ........................14- Test/Replacement 6KLIW /RFN 6\VWHP &LUFXLW Troubleshooting ..........................14-175 6LGH $LUEDJ 'ULYHU¶V Replacement ........................... 23-137 6LGH ,PSDFW 6HQVRUV Replacement ...........................
  • Page 56 +RQGD &59 6KRS 0DQXDO ,QGH[ Component Location Index ........................17-3 Inspection ............................17-7 Troubleshooting ........................... 17-6 6WHHULQJ &ROXPQ Inspection ............................17-25 Inspection/Adjustment ........................17-26 Removal/Installation .......................... 17-24 6WHHULQJ *HDUER[ Installation ............................17-51 Overhaul ............................17-33 Removal ............................. 17-29 6WHHULQJ +DQJHU %HDP Replacement ............................
  • Page 57 ,QGH[ Replacement ............................. 20-67 6XQURRI 6ZLWFK Test/Replacement .........................22A-129 6XSHU /RFNLQJ &RQWURO 8QLW Input Test ............................22A-172 6XVSHQVLRQ Adjustment ............................18-4 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[HV A/C ..............................21-35 ABS/TCS Components ........................19B-11 Automatic Climate Control ......................... 21-65 Automatic Transaxle ..........................14-8 Cruise Control System ........................04-55 Fan Controls ............................
  • Page 58 +RQGD &59 6KRS 0DQXDO ,QGH[ Replacement ............................ 20-137 7DLOJDWH 6ZLWFK Test/Replacement ..........................22A-110 7DLOJDWH :HDWKHUVWULS Replacement ............................ 20-137 7DLOJDWH :HGJH Adjustment ............................20-136 7DLOOLJKW Replacement ............................22A-98 7'& 6HQVRUV Replacement ............................ 11-120 7KHUPRVWDW Replacement ............................10-8 Test ..............................10-4 7KURWWOH %RG\ Disassembly/Reassembly ........................ 11-186 Removal/Installation ........................
  • Page 59 ,QGH[ 7UDQVIHU 'ULYH *HDU Inspection ............................13-67 7UDQVIHU 'ULYH *HDU %HDULQJ Replacement Transfer Assembly ..................13-71, 14-279 7UDQVIHU 'ULYHQ *HDU %HDULQJ Removal/Installation Transfer Assembly ..................14-279 Replacement Transfer Assembly ...................... 13-72 7UDQVIHU +ROGHU Disassembly Transfer Assembly ..................13-70, 14-277 7UDQVIHU +ROGHU 7DSHUHG 5ROOHU %HDULQJ Replacement ...........................
  • Page 60 +RQGD &59 6KRS 0DQXDO ,QGH[ 9DOYH *XLGHV Inspection ............................06-33 Replacement ............................06-34 9DOYH 6HDWV Repair ..............................06-36 9DOYHV Adjustment ............................06-9 Inspection ............................06-33 Installation ............................06-38 Removal ............................. 06-32 9HKLFOH 6SHHG 6LJQDO &LUFXLW Troubleshooting ..........................22A-75 Replacement ............................22A-77 97& $FWXDWRU Inspection ............................
  • Page 61 ,QGH[ :KHHO 6SHHG 6HQVRUV Inspection ............................19B-38 Replacement ...........................19B-39 :KHHOV DQG 7LUHV Inspection ............................18-9 :LQGRZV Component Location Index ........................ 20-43 :LQGVKLHOG *ODVV Replacement ............................. 20-45 :LQGVKLHOG 6LGH 7ULP Replacement ........................... 20-142 :LQGVKLHOG 6LGH 7ULP 5HWDLQHUV Installation ............................20-50 :LSHU /LIWHU 5HDU :LQGRZ Replacement ...........................
  • Page 62 +RQGD &59 6KRS 0DQXDO ,QGH[ PGM-FI System, Immobilizer System ....................78-98 Power Mirror ............................78-42 Power Window, Cigarette Lighter, Accessory Power Socket ............78-50 Seat Heater, Wipers/Washers (Headlight Washer) ................78-58 Security Alarm System (With Super Locking System) ............... 78-78 Security Alarm System (Without Super Locking System) ..............
  • Page 63 *HQHUDO ,QIRUPDWLRQ 8uh††v†ÃhqÃ@tvrÃIˆ€ir…†   ! Dqr‡vsvph‡v‚ÃIˆ€ir…ÃG‚ph‡v‚†    # Xh…vt8hˆ‡v‚ÃGhiryÃG‚ph‡v‚†    $ Gvs‡ÃhqÃTˆƒƒ‚…‡ÃQ‚v‡†   & U‚vt    ' Tr…‰vprÃQ…rphˆ‡v‚†    ( 6ii…r‰vh‡v‚†    ...
  • Page 64 U…h†€v††v‚ÃU’ƒr Z2M1: 5-speed manual EX, RV-Si Z2M3: 5-speed manual RV-Si, RV-SiH MCVA: 4-speed Automatic (2WD) Av‘rqÃ8‚qrÂ…Ã8urpxÃ9vtv‡ MRVA: 4-speed Automatic (4WD) H‚qryÃ`rh…Ã8‚qr Tr…vhyÃIˆ€ir… 2: 2002 Ahp‡‚…’Ã8‚qr C: Saitama Factory in Japan (Sayama) U: Honda of the U.K. Manufacturing (England) Tr…vhyÃIˆ€ir… ...
  • Page 65 &KDVVLV DQG (QJLQH 1XPEHUV &KDVVLV DQG (QJLQH 1XPEHUV FRQW¶G $SSOLFDEOH $UHD &RGH9,1(QJLQH 1XPEHU7UDQVPLVVLRQ 1XPEHU /LVW HP9@G 6QQGD867G@Ã BS69@Ã US6ITHDTTDPIÃ W@CD8G@ÃD9@IUDAD86UDPIÃ IVH7@S @IBDI@ÃIVH7@S US6ITHDTTDPIÃ 6S@6Ã8P9@ I6H@ U`Q@ IVH7@S CR-V SHSRD87402U000001- K20A4-1000001- Z2M1-1500001- SHSRD88402U000001- K20A4-1000001- MRVA-1000001- SHSRD87502U000001- K20A4-1000001- Z2M1-1500001- SHSRD88502U000001- K20A4-1000001- MRVA-1000001- SHSRD87602U000001- K20A4-1000001- Z2M1-1500001-...
  • Page 66 *HQHUDO ,QIRUPDWLRQ ,GHQWLILFDWLRQ 1XPEHU /RFDWLRQV ,GHQWLILFDWLRQ 1XPEHU /RFDWLRQV 8uh††v†ÃIˆ€ir…ÃhqÃ@tvrÃIˆ€ir…à WruvpyrÃDqr‡vsvph‡v‚ÃIˆ€ir…ÃWDIà WruvpyrÃDqr‡vsvph‡v‚Ã 7ˆvy‡Ã9h‡rÃhqÃWruvpyrÇ’ƒrà Iˆ€ir…ÃWDI @‘prƒ‡ÃF`À‚qry 6ˆ‡‚€h‡vpà HhˆhyÃU…h†€v††v‚Ã @tvrÃIˆ€ir… U…h†€v††v‚ÃIˆ€ir… Iˆ€ir… 8r…‡vsvph‡v‚ÃQyh‡rà F`À‚qry ...
  • Page 67 :DUQLQJ&DXWLRQ /DEHO /RFDWLRQV :DUQLQJ&DXWLRQ /DEHO /RFDWLRQV NOTE: ‡ The illustration shows the LHD model; RHD is symmetrical. ‡ SIDE AIRBAG INFORMATION labels are located on the driver’s and passenger’s doorjamb. TSTÃDIAPSH6UDPI GC9À‚qry TSTÃDIAPSH6UDPIà SC9À‚qry Q6TT@IB@SÃ6DS76Bà 8CDG9ÃT@6UÃ86VUDPI SC9À‚qry Q6TT@IB@SÃ6DS76B 8CDG9ÃT@6UÃ86VUDPI GC9À‚qry ASPIUÃQ6TT@IB@SÃ...
  • Page 68 *HQHUDO ,QIRUPDWLRQ :DUQLQJ&DXWLRQ /DEHO /RFDWLRQV :DUQLQJ&DXWLRQ /DEHO /RFDWLRQV FRQW¶G @IBDI@Ã8PPG6IUÃ DIAPSH6UDPI TSTÃX6SIDIB 76UU@S`Ã86VUDPI 6DSÃ8PI9DUDPIDIBÃ DIAPSH6UDPI S69D6UPSÃ86QÃ86V UDPI 9SDW@S·TÃ9PPSE6H7) U`S@ÃDIAPSH6UDPI NOTE: The illustration shows the LHD model; RHD is symmetrical. ...
  • Page 69 /LIW DQG 6XSSRUW 3RLQWV /LIW DQG 6XSSRUW 3RLQWV )ORRU -DFN NOTE: If you are going to remove heavy components such as suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands.  Block the rear wheels when raising the front of the When substantial weight is removed from the rear of the vehicle;...
  • Page 70 *HQHUDO ,QIRUPDWLRQ 7RZLQJ 7RZLQJ :KHHO /LIW (TXLSPHQW The tow truck uses two pivoting If the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with arms that go under the tires (front or rear) and lift them off just a rope or chain.
  • Page 71 6HUYLFH 3UHFDXWLRQV 6HUYLFH 3UHFDXWLRQV :' PRGHO ,QIRUPDWLRQ 6SHHGRPHWHU 7HVWLQJ 3URFHGXUHV  Set the free rollers according to the wheel base and The 4WD CR-V does not have the feature that mechanically switches between 4WD (four-wheel drive) tread of the vehicle. and 2WD (front-wheel drive).
  • Page 72 *HQHUDO ,QIRUPDWLRQ 6HUYLFH 3UHFDXWLRQV 6HUYLFH 3UHFDXWLRQV FRQW¶G *HQHUDO ‡ Mark or place all removed parts in order in a parts rack so they can be reassembled in their original places. &$87,21 Observe all safety precautions and notes while working. ‡ Protect all painted surfaces and seats against dirt and scratches with a clean cloth or vinyl cover.
  • Page 73 ± Clean all disassembled parts only in clean BRAKE FLUID. Blow open all holes and passages with compressed air. ‡ Use genuine HONDA parts and lubricants or those ± Keep disassembled parts from air-borne dust and equivalent. When parts are to be reused, they must be abrasives.
  • Page 74 *HQHUDO ,QIRUPDWLRQ 6HUYLFH 3UHFDXWLRQV FRQW¶G 6HUYLFH 3UHFDXWLRQV FRQW¶G (OHFWULFDO 7URXEOHVKRRWLQJ ,QIRUPDWLRQ ‡ Some connectors have a clip on their side used to attach them to a mounting bracket on the body or on another component. This clip has a pull type lock. %HIRUH 7URXEOHVKRRWLQJ ‡...
  • Page 75 6HUYLFH 3UHFDXWLRQV FRQW¶G ‡ Check for loose retainer (A) and rubber seals (B). +DQGOLQJ :LUHV DQG +DUQHVVHV ‡ Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations. ‡ Remove clips carefully; don’t damage their locks (A). ‡...
  • Page 76 For female connectors, just touch lightly with the tester probe and do not insert the probe. ‡ Refer to the instructions in the Honda Terminal Kit for identification and replacement of connector terminals. U@TU@SÃQSP7@ SV77@SÃT@6G...
  • Page 77 6HUYLFH 3UHFDXWLRQV FRQW¶G )LYHVWHS 7URXEOHVKRRWLQJ :LUH &RORU &RGHV  Verify The Complaint The following abbreviations are used to identify wire colors in the circuit schematics: Turn on all the components in the problem circuit to verify the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have White narrowed down the problem area.
  • Page 78 *HQHUDO ,QIRUPDWLRQ $EEUHYLDWLRQV $EEUHYLDWLRQV List of automotive abbreviations which may be used in shop manual. Evaporator Pressure Regulator Electrical Power Steering Anti-lock Brake System EVAP Evaporative Air Conditioning, Air Conditioner Exhaust Air Cleaner Air Fuel Ratio Front Automatic Locking Retractor Fuel Injection Air Alternator Front Left...
  • Page 79 $EEUHYLDWLRQV Manifold Absolute Pressure SPEC Specification MAX. Maximum Sun Roof Mainshaft Brake System Supplemental Restraint System Motor Check Standard Moment Control Unit Switch Malfunction Indicator Lamp MIN. Minimum Torque Multi Point Injection Throttle Body Manual Steering Timing Belt Manual Transmission Torque Converter Transmission Control Module Neutral...
  • Page 81 6SHFLILFDWLRQV T‡hqh…q†ÃhqÃTr…‰vprÃGv€v‡†  !! Engine Electrical ................................ 02-2 Engine Assembly ............................... 02-2 Cylinder Head ................................02-3 Engine Block ................................02-4 Engine Lubrication ..............................02-5 Cooling ..................................02-6 Fuel and Emissions ..............................02-6 Clutch ..................................02-6 Manual Transmission and M/T Differential......................... 02-7 Automatic Transmission and A/T Differential ......................
  • Page 82 6SHFLILFDWLRQV 6WDQGDUGV DQG 6HUYLFH /LPLWV 6WDQGDUGV DQG 6HUYLFH /LPLWV (QJLQH (OHFWULFDO D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Ignition coil Rated voltage 12 V Firing order 1 - 3 - 4 - 2 Spark plug Type NGK: ZFR6K-11 DENSO: KJ20DR-M11 1.0 - 1.1 mm (0.039 - 0.043 in.) ———...
  • Page 83 6WDQGDUGV DQG 6HUYLFH /LPLWV &\OLQGHU +HDG D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Head Warpage ——— 0.05 mm (0.002 in.) Height 103.95 - 104.05 mm ——— (4.093 - 4.096 in.) Camshaft End play 0.05 - 0.20 mm (0.002 - 0.008 in.) 0.4 mm (0.02 in.) Camshaft-to-holder oil No.1 journal 0.030 - 0.069 mm...
  • Page 84 6SHFLILFDWLRQV 6WDQGDUGV DQG 6HUYLFH /LPLWV (QJLQH %ORFN D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Block Warpage of deck 0.07 mm (0.003 in.) max. 0.10 mm (0.004 in.) Bore diameter A or l 86.010 - 86.020 mm 86.070 mm (3.3886 in.) (K20A4, K20A5 engines) (3.3862 - 3.3866 in.) B or ll 86.000 - 86.010 mm...
  • Page 85 6WDQGDUGV DQG 6HUYLFH /LPLWV D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Crankshaft Main journal diameter No. 1 journal 54.984 - 55.008 mm (2.1648 - 2.1657 in.) ——— No. 2 journal No. 4 journal No. 5 journal No. 3 journal 54.976 - 55.000 mm (2.1644 - 2.1654 in.) ———...
  • Page 86 6SHFLILFDWLRQV 6WDQGDUGV DQG 6HUYLFH /LPLWV &RROLQJ D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Radiator Coolant capacity for M/T: engine 7.1 L (7.5 US qt, 6.2 Imp qt) K20A4 and K20A5 overhaul engines M/T: coolant change 5.4 L (5.7 US qt, 4.8 Imp qt) (including engine, heater, A/T: engine overhaul 7.0 (7.4 US qt, 6.2 lmp qt)
  • Page 87 6WDQGDUGV DQG 6HUYLFH /LPLWV 0DQXDO 7UDQVPLVVLRQ DQG 07 'LIIHUHQWLDO D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Transmission Capacity 4WD at fluid change 1.9 L (2.0 US qt, 1.7 Imp qt) fluid 4WD at overhaul 2.3 L (2.4 US qt, 2.0 Imp qt) 2WD at fluid change 1.9 L (2.0 US qt, 1.7 Imp qt) 2WD at overhaul...
  • Page 88 6SHFLILFDWLRQV 6WDQGDUGV DQG 6HUYLFH /LPLWV 0DQXDO 7UDQVPLVVLRQ DQG 07 'LIIHUHQWLDO FRQW G D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Reverse idler I.D. 20.016 - 20.043 mm (0.7880 - 0.7891 in.) 20.90 mm (0.832 in.) gear Gear-to-reverse gear 0.036 - 0.084 mm (0.0014 - 0.0033 in.) 0.16 mm (0.006 in.) shaft clearance Synchro ring...
  • Page 89 Tr…‰vprÃGv€v‡ Capacity 4WD at fluid change 3.1 L (3.3 US qt, 2.7 Imp qt) (Automatic Use Genuine Honda ATF- 2WD at fluid change 2.9 L (3.1 US qt, 2.6 Imp qt) Transmission 4WD at overhaul 7.2 L (7.6 US qt, 6.3 Imp qt)
  • Page 90 6SHFLILFDWLRQV 6WDQGDUGV DQG 6HUYLFH /LPLWV $XWRPDWLF 7UDQVPLVVLRQ DQG $7 'LIIHUHQWLDO FRQW G D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃG v€v‡ Clutch K20A4 3rd and 4th clutch end Mark 11 3.1 mm (0.122 in.) When discolored and K20A5 plate thickness Mark 12 3.2 mm (0.126 in.) When discolored engine models Mark 13...
  • Page 91 6WDQGDUGV DQG 6HUYLFH /LPLWV D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃG v€v‡ Mainshaft Diameter of needle bearing at stator shaft 22.984 - 23.000 mm (0.905 - 0.906 in.) When worn or damaged contact area at 3rd gear 51.975 - 51.991 mm (2.046 - 2.047 in.) When worn or damaged at 4th gear collar 33.975 - 33.991 mm (1.3376 - 1.3382 in.)
  • Page 92 6SHFLILFDWLRQV 6WDQGDUGV DQG 6HUYLFH /LPLWV $XWRPDWLF 7UDQVPLVVLRQ DQG $7 'LIIHUHQWLDO FRQW G D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Secondary Diameter of needle bearing at 1st gear 39.986 - 39.999 mm When worn or damaged shaft contact area (1.5742 - 1.5748 in.) at 2nd gear 39.986 - 39.999 mm (1.5742 - 1.5748 in.) When worn or damaged I.D.
  • Page 93 6WDQGDUGV DQG 6HUYLFH /LPLWV D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃG v€v‡ Idler gear shaft Diameter of needle bearing End cover side 32.003 - 32.013 mm (1.2600 - 1.2604 in.) When worn or damaged contact area Thickness of cotters 1.39 - 1.42 mm (0.0547 - 0.0559 in.) ———...
  • Page 94 6SHFLILFDWLRQV 6WDQGDUGV DQG 6HUYLFH /LPLWV $XWRPDWLF 7UDQVPLVVLRQ DQG $7 'LIIHUHQWLDO FRQW G D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Xv…rÃ9vh€r‡r… P9 A…rrÃGrt‡u I‚ÂsÃ8‚vy Regulator valve Stator reaction spring 4.5 mm 35.4 mm 30.3 mm 1.92 body springs (0.177 in.) (1.394 in.) (1.193 in.) (see page 14- Regulator valve spring A 1.9 mm 14.7 mm...
  • Page 95 Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Differential Capacity at fluid change 1.0 L (1.1 US qt, 0.9 Imp qt) fluid Use genuine Honda DPSF at overhaul 1.2 L (1.3 US qt, 1.1 Imp qt) 6WHHULQJ D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃGv€v‡ Steering wheel Rotational play measured 0 - 10 mm (0 - 0.39 in.)
  • Page 96 6SHFLILFDWLRQV 6WDQGDUGV DQG 6HUYLFH /LPLWV %UDNHV D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ T‡hqh…qÂ…ÃIr Tr…‰vprÃG v€v‡ Parking brake Distance travelled when 5 - 9 clicks lever lever pulled with 196 N (20 kgf, 44 lbs) of force Brake pedal Pedal height (carpet 173 mm (6 13/16 in.) removed) Free play 1 - 5 mm (0.04 - 0.2 in.)
  • Page 97 'HVLJQ 6SHFLILFDWLRQV 'HVLJQ 6SHFLILFDWLRQV D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ Tƒrpvsvph‡v‚ Dimensions Overall length European models 4,575 mm (180.1 in.) KQ (RVi) 4,535 mm (178.5 in.) KQ (RVSi) 4,565 mm (179.7 in.) KH (South America) 4,535 mm (178.5 in.) KH (China) 4,570 mm (179.9 in.) KK (LX) 4,535 mm (178.5 in.) KK (EX)
  • Page 98 6SHFLILFDWLRQV 'HVLJQ 6SHFLILFDWLRQV D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ Tƒrpvsvph‡v‚ Engine Type Water cooled, 4-stroke DOHC VTEC engine Cylinder arrangement Inline 4-cylinder, transverse Bore and stroke K20A4, K20A5 86 X 86 mm (3.39 X 3.39 in.) engines K24A1 engine 87 X 99 mm (3.43 X 3.90 in.) Displacement K20A4, K20A5 1,998 cm...
  • Page 99 'HVLJQ 6SHFLILFDWLRQV D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ Tƒrpvsvph‡v‚ Z2M3 Type Synchronized, 5-speed forward, 1 reverse Manual Primary reduction Direct 1:1 Transmission Gear ratio 3.533 1.880 1.212 0.921 0.738 Reverse 3.583 Transfer gear Type Hypoid gear Gear ratio 0.904 Differential final gear Type Single helical gear Gear ratio 4.764...
  • Page 100 6SHFLILFDWLRQV 'HVLJQ 6SHFLILFDWLRQV D‡r€ Hrh†ˆ…r€r‡ Rˆhyvsvph‡v‚ Tƒrpvsvph‡v‚ Tyres Size of front and rear tires 205/70R15 95S Size of spare tire Regular type 205/70R15 95S Compact type T145/80 D16 Air Condition- Compressor Type Scroll Number of cylinder ——— Capacity 85.7 m (5.23 cu in.)/rev.
  • Page 101 %RG\ 6SHFLILFDWLRQV %RG\ 6SHFLILFDWLRQV *:Overall length: Refer to Design Spec. (see page 02-17). ...
  • Page 103 0DLQWHQDQFH Gˆi…vph‡†ÃhqÃAyˆvq†   "! Hhv‡rhprÃTpurqˆyrÃs‚…ÃI‚…€hyÃ8‚qv‡v‚†   "# @ˆ…‚ƒrhÃH‚qry Listed by Maintenance Item ............................03-4 Hhv‡rhprÃTpurqˆyrÃs‚…ÃTr‰r…rÃ8‚qv‡v‚†   "% @ˆ…‚ƒrhÃH‚qry Listed by Maintenance Item ............................03-6 Hhv‡rhprÃTpurqˆyrÃs‚…ÃI‚…€hyÃ8‚qv‡v‚†   "' 6ˆ†‡…hyvhÃhqÃIrÃarhyhqÃH‚qry† Listed by Maintenance Item ............................03-8 Hhv‡rhprÃTpurqˆyrÃs‚…ÃTr‰r…rÃ8‚qv‡v‚†   "  6ˆ†‡…hyvhÃhqÃIrÃarhyhqÃH‚qry† Listed by Maintenance Item .............................
  • Page 104 Manual Transmission Genuine Honda Manual Transmission Fluid (MTF) Always use genuine Honda MTF. Using motor oil can cause stiffer shifting because it does contain the proper additives. Automatic Transmission Genuine Honda ATF-Z1 Always use genuine Honda ATF-Z1.
  • Page 105 /XEULFDQWV DQG )OXLGV ...
  • Page 106 0DLQWHQDQFH 0DLQWHQDQFH 6FKHGXOH IRU 1RUPDO &RQGLWLRQV 0DLQWHQDQFH 6FKHGXOH IRU 1RUPDO &RQGLWLRQV (XURSHDQ 0RGHO /LVWHG E\ 0DLQWHQDQFH ,WHP Follow the Normal Conditions Maintenance Schedule if the severe driving conditions specified in the Severe Conditions Maintenance Schedule (see page 03-6) do not apply. Service at the indicated distance or time km x 1,000 whichever comes first.
  • Page 107 Replace brake fluid Every 3 years Use only DOT 3 or DOT 4 brake fluid. We recommend Genuine ‡ Honda Brake Fluid. Check that brake fluid level between the upper and lower marks on the reservoir (see page 19A-9). ...
  • Page 108 0DLQWHQDQFH 0DLQWHQDQFH 6FKHGXOH IRU 6HYHUH &RQGLWLRQV 0DLQWHQDQFH 6FKHGXOH IRU 6HYHUH &RQGLWLRQV (XURSHDQ 0RGHO /LVWHG E\ 0DLQWHQDQFH ,WHP Follow the Severe Conditions Maintenance Schedule if the customer’s vehicle is driven MAINLY under one or more of the following conditions: - Driving less than 8 km (5 miles) per trip or, in freezing temperatures, driving less than 16 km (10 miles) per trip. - Driving in extremely hot over 35 °C (95 °F) conditions.
  • Page 109 Replace brake fluid Every 3 years Use only DOT 3 or DOT 4 brake fluid. We recommend genuine ‡ Honda Brake Fluid. Check that brake fluid level between the upper and lower marks on the reservoir (see page 19A-9). ...
  • Page 110 Inspect idle speed (see page 11-148) Replace engine coolant At 200,000 km (120,000 miles) or 10 years, then replace every Use Honda All Season Antifreeze/Coolant Type 2 (see page 10-6) 100,000 km (60,000 miles) or 5 years ‡ Replace manual transmission fluid Use genuine Honda manual Transmission Fluid (MTF) ‡...
  • Page 111 0DLQWHQDQFH 6FKHGXOH IRU 1RUPDO &RQGLWLRQV Service at the indicated distance or time km x 1,000 whichever comes first. miles x 1,000 months Wv†ˆhyy’Ãv†ƒrp‡Ã‡urÃs‚yy‚vtÃv‡r€†) Check for correct installation and position, check for cracks, deterioration, rust, and leaks. ‡ Check tightness of screws, nuts, and joints. If necessary, retighten. ‡...
  • Page 112 Inspect idle speed (see page 11-148) Replace engine coolant At 200,000 km (120,000 miles) or 10 years, then replace every Use Honda All Season Antifreeze/Coolant Type 2 (see page 10-6) 100,000 km (60,000 miles) or 5 years ‡ Replace manual transmission fluid Use genuine Honda manual Transmission Fluid (MTF) ‡...
  • Page 113 0DLQWHQDQFH 6FKHGXOH IRU 6HYHUH &RQGLWLRQV Service at the indicated distance or time km x 1,000 whichever comes first. miles x 1,000 months Check lights alignment (see page 22A-96). Check for road stability, noise, vibrations and dashboard operation. ‡ Test drive Check for road stability, noise, vibrations and dashboard operation.
  • Page 114 K24A5 engine model Replace engine coolant At 200,000 km (120,000 miles) or 10 years, then replace every Use Honda All Season Antifreeze/Coolant Type 2 (see page 10-6) 100,000 km (60,000 miles) or 5 years ‡ Replace manual transmission fluid...
  • Page 115 Replace brake fluid Every 3 years Use only DOT 3 or DOT 4 brake fluid. We recommend Genuine ‡ Honda Brake Fluid. Check that brake fluid level is between upper and lower marks on the ‡ reservoir. (see page 19A-9)
  • Page 117 (QJLQH (OHFWULFDO TƒrpvhyÃU‚‚y†  #! T‡h…‡vtÃT’†‡r€   #" Component Location Index ............................04-3 Circuit Diagram ................................04-4 Starter Circuit Troubleshooting........................... 04-5 Starter Solenoid Test ..............................04-6 Starter Performance Test ............................04-7 Starter Replacement ..............................04-9 Starter Overhaul ............................... 04-10 Dtv‡v‚ÃT’†‡r€...
  • Page 118 (QJLQH (OHFWULFDO 6SHFLDO 7RROV 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07WAJ-0010100 DLC Pin Box 07746-0010400 Driver Attachment, 52 x 55 mm 07749-0010000 Handle Driver " " ...
  • Page 119 6WDUWLQJ 6\VWHP 6WDUWLQJ 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ VI9@S96TCÃAVT@ÃS@G6`Ã7PY " Test, page 14-168; Replacement, page 14-169 US6ITHDTTDPIÃS6IB@ÃTXDU8CÃ6U Starter Circuit Troubleshooting, page 04-5; Solenoid Test, page 04-6; TU6SU@S Performance, page 04-7; Replacement, page 04-9; Overhaul, page 04-10 Test, page 22A-60 " TU6SU@SÃ8VUÃS@G6`Ã6UÃ ...
  • Page 120 (QJLQH (OHFWULFDO 6WDUWLQJ 6\VWHP &LUFXLW 'LDJUDP VI9@SCPP9ÃAVT@S@G6`à DBIDUDPIÃTXDU8C 76UU@S` VI9@S96TCÃAVT@S@G6`Ã7PY TU6SU@Sà 8VUÃS@G6` 62/(12,' US6ITHDTTDPIà S6IB@ÃTXDU8Cà PIÃ)ÃbQdÃbId TU6SU@SÃF@ÃFBà TU6SU@SÃ@‘prƒ‡Ã FSÃFTÃFaÀ‚qry† F@ÃFBÃFSÃFTÃFaà €‚qry† ...
  • Page 121 6WDUWLQJ 6\VWHP 6WDUWHU &LUFXLW 7URXEOHVKRRWLQJ  Check the battery condition. Check electrical NOTE: ‡ Air temperature must be between 15° and 38°C (59° connections at the battery, the negative battery and 100°F) during this procedure. cable to body, the engine ground cables and the ‡...
  • Page 122 (QJLQH (OHFWULFDO 6WDUWLQJ 6\VWHP 6WDUWHU &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G 6WDUWHU 6ROHQRLG 7HVW $OWHUQDWH 3URFHGXUH FRQW¶G .( .* .5 .6 .= PRGHOV  Check the following items in the order listed until  Check the hold-in coil for continuity between the S you find the open circuit.
  • Page 123 6WDUWLQJ 6\VWHP 6WDUWHU 3HUIRUPDQFH 7HVW ([FHSW .( .* .5 .6 .= PRGHOV  Clamp the starter firmly in a vise.  Disconnect the wire from the S terminal (A).  Connect the starter to the battery as described in the diagram below, and confirm that the motor  Make the connections as described below using as starts and keeps rotating.
  • Page 124 (QJLQH (OHFWULFDO 6WDUWLQJ 6\VWHP 6WDUWHU 3HUIRUPDQFH 7HVW FRQW¶G .( .* .5 .6 .= PRGHOV  Disconnect the battery from the body. If the pinion retracts immediately, it is working properly.  Disconnect the wires from the S terminal and the M terminal.
  • Page 125 6WDUWLQJ 6\VWHP 6WDUWHU 5HSODFHPHQW  Disconnect the battery negative cable, then F@ÃFBÃFSÃFTÃFaÀ‚qry†) disconnect the positive cable.  Disconnect the knock sensor connector.  Disconnect the bolt securing the harness bracket.  Remove the two bolts holding the starter, then  Disconnect the starter cable (A) from the B terminal remove the starter.
  • Page 126 (QJLQH (OHFWULFDO 6WDUWLQJ 6\VWHP 6WDUWHU 2YHUKDXO 'LVDVVHPEO\5HDVVHPEO\([FHSW .( .* .5 .6 .= PRGHOV SDIBÃB@6SÃCPG9@S TXDU8CÃQGVIB@S B@6SÃQGVIB@S B@6SÃ8PW@SÃ6TT@H7G` QVTCÃIVU 7SVTCÃCPG9@S 7SVTCÃ TQSDIB TXDU8CÃTC6AU 9SDW@ÃQG6U@ QG6I@U6S`ÃB@6S HPG`79@IVHÃ @I9Ã8PW@S 9DTVGAD9@ 6SH6UVS@ÃCPVTDIB HPG`79@IVHÃ 6SH6UVS@ 9DTVGAD9@ ...
  • Page 127 6WDUWLQJ 6\VWHP 'LVDVVHPEO\5HDVVHPEO\.( .* .5 .6 .= PRGHOV TU6SU@SÃTPG@IPD9 HPG`79@IVHÃ 9DTVGAD9@ TPG@IPD9ÃG@W@S B@6SÃCPVTDIB PW@SSVIIDIBÃ 8GVU8CÃ6TT@H7G` 7SVTC 6SH6UVS@ÃCPVTDIB 6SH6UVS@ HPG`79@IVHÃ 9DTVGAD9@ HPG`79@IVHÃ 9DTVGAD9@ @I9Ã8PW@S 7SVTCÃCPG9@S (cont’d) ...
  • Page 128 (QJLQH (OHFWULFDO 6WDUWLQJ 6\VWHP 6WDUWHU 2YHUKDXO FRQW¶G $UPDWXUH ,QVSHFWLRQ DQG 7HVW  Check the commutator diameter. If the diameter is below the service limit, replace the armature.  Remove the starter (see page 04-9). 8‚€€ˆ‡h‡‚…Ã9vh€r‡r…)  Disassemble the starter as shown at the beginning @‘prƒ‡ÃF@ÃFBÃFSÃFTÃFaÀ‚qry†) of this procedure.
  • Page 129 6WDUWLQJ 6\VWHP  Check the mica depth (A). If the mica is too high  Place the armature (A) on an armature tester (B). (B), undercut the mica with a hacksaw blade to the Hold a hacksaw blade (C) on the armature core. If proper depth.
  • Page 130 (QJLQH (OHFWULFDO 6WDUWLQJ 6\VWHP 6WDUWHU 2YHUKDXO FRQW¶G 6WDUWHU %UXVK ,QVSHFWLRQ 6WDUWHU %UXVK +ROGHU 7HVW  Measure the brush length. If it is not within the  Check that there is no continuity between the (+) service limit, replace the brush holder assembly. brush holder (A) and (-) brush holder (B).
  • Page 131 6WDUWLQJ 6\VWHP %UXVK 6SULQJ ,QVSHFWLRQ .( .* .5 .6 .= 2YHUUXQQLQJ &OXWFK ,QVSHFWLRQ ([FHSW .( .* .5 PRGHOV .6 .= PRGHOV  Insert the brush (A) into the brush holder, and bring  Holding the drive gear (A), turn the gear shaft (B) the brush into contact with the commutator, then clockwise.
  • Page 132 (QJLQH (OHFWULFDO 6WDUWLQJ 6\VWHP 6WDUWHU 2YHUKDXO FRQW¶G 2YHUUXQQLQJ &OXWFK ,QVSHFWLRQ .( .* .5 .6 .= 6WDUWHU 5HDVVHPEO\ ([FHSW .( .* .5 .6 .= PRGHOV PRGHOV  Slide the overrunning clutch along the shaft.  Install the brush into the brush holder, and set the Replace it, if it does not slide smoothly.
  • Page 133 6WDUWLQJ 6\VWHP 6WDUWHU 5HDVVHPEO\ .( .* .5 .6 .= PRGHOV  Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there. NOTE: To seat the new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature.
  • Page 134 (QJLQH (OHFWULFDO ,JQLWLRQ 6\VWHP ,JQLWLRQ 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ Inspection, page 04-23 TQ6SFÃQGVB Ignition Timing Inspection, page 04-20 DBIDUDPIÃ8PDG Removal/Installation, page 04-21 Troubleshooting, page 04-21 ...
  • Page 135 ,JQLWLRQ 6\VWHP &LUFXLW 'LDJUDP VI9@SCPP9ÃAVT@S@G6`à DBIDUDPIÃTXDU8C 76UU@S` VI9@S96TCà AVT@S@G6`Ã7PY DBIDUDPIà 8PDGT TQ6SFà QGVBT D8H)ÃDtv‡v‚Ã8‚‡…‚yÃH‚qˆyr ...
  • Page 136 (A) to the data link connector (16P) (B).  If the ignition timing differs from the specification, replace the Engine Control Module (ECM)/ Powertrain Control Module (PCM) (see page 11-4).  Disconnect the special tool/Honda PGM Tester and the timing light. ...
  • Page 137 ,JQLWLRQ 6\VWHP ,JQLWLRQ &RLO 5HPRYDO,QVWDOODWLRQ ,JQLWLRQ &RLO 7URXEOHVKRRWLQJ  Remove the ignition coil cover (A), then remove the  Remove the four ignition coils (see page 04-21). ignition coils (B).  Remove the spark plugs from the cylinder head, and inspect the spark plug (see page 04-23).
  • Page 138 (QJLQH (OHFWULFDO ,JQLWLRQ 6\VWHP ,JQLWLRQ &RLO 7URXEOHVKRRWLQJ FRQW¶G  Turn the ignition switch OFF.  Connect the ignition coil 3P connector terminal No. 1 and body ground with a jumper wire.  Check for continuity between the ignition coil 3P connector terminal No.
  • Page 139 ,JQLWLRQ 6\VWHP 6SDUN 3OXJ ,QVSHFWLRQ  Inspect the electrodes and ceramic insulator.  Replace the plug at the specified interval, or if the center electrode is rounded (A). Use only the spark Burned or worn electrodes may be caused by: plugs listed below.
  • Page 140 (QJLQH (OHFWULFDO &KDUJLQJ 6\VWHP &KDUJLQJ 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ 8C6SBDIBÃT`TU@HÃDI9D86UPS DÃ‡urÃthˆtrÃh††r€iy’ VI9@SCPP9ÃAVT@S@G6`Ã7PYÃCh†Ã iˆvy‡vÃ@G@8USD86GÃGP69Ã9@U@8UPSà @G9ÃVIDU " Test, page 22A-59 76UU@S` Troubleshooting, page 04-26; Replacement, page 04-32; Overhaul, page 04-34 6GU@SI6UPS Inspection, page 04-29; Replacement, page 04-30 " 9SDW@Ã7@GU Inspection, page 04-30; Replacement, page 04-31 6VUPU@ITDPI@S ...
  • Page 141 &KDUJLQJ 6\VWHP &LUFXLW 'LDJUDP VI9@SCPP9ÃAVT@S@G6`Ã7PY 76UU@S` DBIDUDPIÃ @G9ÃVIDU TXDU8C VI9@S96TCÃ AVT@S@G6`Ã7PY 6GU@SI6UPS WPGU6B@ÃS@BVG6UPS AD@G9ÃXDI9DIB S@8UDAD@S ...
  • Page 142 (QJLQH (OHFWULFDO &KDUJLQJ 6\VWHP &KDUJLQJ &LUFXLW 7URXEOHVKRRWLQJ  Disconnect the engine wire harness 6P connector If the charging system indicator does not come on or does not go off, or the battery is dead or low, test the following from the starter sub-harness 6P connector. items in the order listed below:  Measure the voltage at the No.
  • Page 143 &KDUJLQJ 6\VWHP  Check continuity between the ECM/PCM connector $OWHUQDWRU DQG 5HJXODWRU &LUFXLW 7HVW terminal B10 and engine wire harness 6P  Be sure the battery is sufficiently charged and in connector terminal No. 6. good condition (see page 22A-59).  Raise the hoist to full height.
  • Page 144 (QJLQH (OHFWULFDO &KDUJLQJ 6\VWHP &KDUJLQJ &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G $OWHUQDWRU DQG 5HJXODWRU &LUFXLW 7HVW FRQW¶G $OWHUQDWRU &RQWURO 6\VWHP 7HVW  Start the engine. Hold the engine at 3,000 rpm  Check for proper operation of the Electrical Load (min ) with no load (in Park or Neutral) until the Detector (ELD) by checking the Malfunction radiator fan comes on then let it idle.
  • Page 145 &KDUJLQJ 6\VWHP 'ULYH %HOW ,QVSHFWLRQ  Check for continuity between ECM/PCM connector Check that the auto-tensioner indicator (A) is within the terminal B18 and body ground. standard range (B) as shown. If it is out of the standard range, replace the drive belt (see page 04-30).
  • Page 146 (QJLQH (OHFWULFDO &KDUJLQJ 6\VWHP 'ULYH %HOW 5HSODFHPHQW 'ULYH %HOW $XWRWHQVLRQHU ,QVSHFWLRQ  Remove the splash shield (see step 21 on  Check whether there is a change in the position of page 05- the auto-tensioner indicator before starting the engine and after starting the engine. If there is a  Move the auto-tensioner (A) to relieve tension from change in the position, replace the auto-tensioner.
  • Page 147 &KDUJLQJ 6\VWHP 'ULYH %HOW $XWRWHQVLRQHU 5HSODFHPHQW  Remove the auto-tensioner (see page 04-31).  Remove the drive belt (see page 04-30).  Install the tensioner pulley.  Remove the Power Steering (P/S) pump without disconnecting the P/S hoses.  Clamp the auto-tensioner (A) by using two 8 mm bolts (B) and a vise (C) as shown.
  • Page 148 (QJLQH (OHFWULFDO &KDUJLQJ 6\VWHP 'ULYH %HOW $XWRWHQVLRQHU 5HSODFHPHQW $OWHUQDWRU 5HSODFHPHQW FRQW¶G  Disconnect the battery negative cable, then  Remove the auto-tensioner. disconnect the positive cable.  Remove the bolt (A) securing the battery clamp, then remove the bulkhead cover (B).  Remove the upper bracket and cushion.
  • Page 149 &KDUJLQJ 6\VWHP  Remove the gasket (A), then remove the Positive  Disconnect the alternator connector (A), BLK wire Crankcase Ventilation (PCV) valve holder (B) with (B) and harness clamp (C) from the alternator. a hex wrench.  Remove the alternator.  Remove the three bolts securing the alternator.
  • Page 150 (QJLQH (OHFWULFDO &KDUJLQJ 6\VWHP $OWHUQDWRU 2YHUKDXO ([SORGHG 9LHZ 9SDW@@I9ÃCPVTDIB ASPIUÃ7@6SDIB 7@6SDIBÃS@U6DI@S QVGG@`ÃGP8FIVU U@SHDI6GÃDITVG6UPS QVGG@` S@6SÃCPVTDIBÃ6TT@H7G` S@6SÃ7@6SDIB SPUPS ...
  • Page 151 &KDUJLQJ 6\VWHP 6SHFLDO 7RROV 5HTXLUHG  Separate the rear housing from the drive-end ‡ Handle driver 07749-0010000 housing by inserting a flat tip screwdriver into the ‡ Driver attachment, 52 x 55 mm 07746-0010400 openings and prying them apart. NOTE: Be careful not to damage the stator with the tip NOTE: Refer to the Exploded View as needed during this of the screwdriver.
  • Page 152 (QJLQH (OHFWULFDO &KDUJLQJ 6\VWHP $OWHUQDWRU 2YHUKDXO FRQW¶G  If you are not replacing the front bearing and/or  Remove the rear bearing using the puller as rear bearing, go to step 15. Clamp the rotor in a shown. soft-jawed vise, then remove the pulley locknut.  Use a hand press to install the new rear bearing.
  • Page 153 &KDUJLQJ 6\VWHP  Remove the front bearing retainer plate.  With a hammer and the special tools, install a new front bearing in the drive-end housing.  Support the drive-end housing in a vise, and drive out the front bearing with a brass drift and hammer. $OWHUQDWRU %UXVK ,QVSHFWLRQ  Measure the length of both brushes with a vernier caliper.
  • Page 154 (QJLQH (OHFWULFDO &KDUJLQJ 6\VWHP $OWHUQDWRU 2YHUKDXO FRQW¶G 5RWRU 6OLS 5LQJ 7HVW  Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50 - 60°C, 129 - 140°F).  Check that there is continuity between the slip rings  Put the rear housing assembly (A) and drive-end (A).
  • Page 155 &UXLVH &RQWURO &UXLVH &RQWURO &RPSRQHQW /RFDWLRQ ,QGH[ " 8SVDT@Ã8PIUSPGÃDI9D86UPSÃ7ˆvy‡Ãv‡‚ÃthˆtrÃh††r€iy’ Test/Replacement, page 04-46 8SVDT@Ã8PIUSPGÃT@US@TVH@86I8@GÃTXDU8C Test, page 22A-99; Pedal Height Adjustment, page 19A-5 " 7S6F@ÃQ@96GÃQPTDUDPIÃTXDU8C Test, page 04-49; Clutch Pedal Adjustment, page 12-4 8GVU8CÃQ@96GÃQPTDUDPIÃTXDU8CÃHU Test/Replacement, page 04-46 8SVDT@Ã8PIUSPGÃH6DIÃTXDU8C Input Test, page 04-44 8SVDT@Ã8PIUSPGÃVIDU &...
  • Page 156 (QJLQH (OHFWULFDO &UXLVH &RQWURO &LUFXLW 'LDJUDP VI9@S96TCÃAVT@ S@G6`Ã7PY VI9@SCPP9ÃAVT@S@G6`Ã7PY DBIDUDPIÃTXDU8C 76UU@S` 8PH7DI6UDPIÃGDBCUà TXDU8C CPSIà S@G6` 8SVDT@à 867G@à 8PIUSPGà S@@G H6DIÃTXDU8C DI9D86UPSà GDBCUà GDBCUà '#ÃX '#ÃX CPSIÃTXDU8C CPSI 8SVDT@à 8PIUSPGà &$1 T@U &(/ 680( S@TVH@ 86I8@Gà TXDU8C 7S6F@à 8SVDT@à ‡Ã@8HQ8H Q@96Gà 8PIUSPGÃ...
  • Page 157 &UXLVH &RQWURO 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ NOTE: ‡ The numbers in the table show the troubleshooting sequence. ‡ Before troubleshooting. ‡ check the No. 10 (7.5A) and No. 4 (10A) fuses in the under-dash fuse/relay box, and the No. 7 (15A) fuse in the under- hood fuse/relay box.
  • Page 158 (QJLQH (OHFWULFDO &UXLVH &RQWURO 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ FRQW¶G T’€ƒ‡‚€ 9vht‚†‡vpÃ…‚prqˆ…r 6y†‚ÃpurpxÃs‚… Set speed, does not cancel when Check main switch (see page 04-46) Short to power in the LT main switch is pushed OFF Check control unit (see page 04-44) GRN wire.
  • Page 159 &UXLVH &RQWURO &UXLVH &RQWURO &RPPXQLFDWLRQ &LUFXLW 7URXEOHVKRRWLQJ  Start the engine.  Connect a voltmeter between cruise control unit 14P connector terminal No. 8 and body ground.  Turn on the cruise control main switch, then drive Test-drive the vehicle at speeds over 25 mph (40 the vehicle to speeds over 25 mph (40 km/h) with km/h) with the cruise control set, and watch the the cruise control.
  • Page 160 (QJLQH (OHFWULFDO &UXLVH &RQWURO &RQWURO 8QLW ,QSXW 7HVW SRS components are located in this area. Review the SRS component locations (see page 23-14) and precautions and procedures (see page 23-16) in the SRS section before performing repairs or service.  Disconnect the 14P connector from the control unit.  Inspect the connector and socket terminals to be sure they are all making good contact.
  • Page 161 &UXLVH &RQWURO Q‚††viyrÃphˆ†rÃvsÃ…r†ˆy‡Ãv†Ã‚‡Ã 8h‰v‡’ Xv…r Ur†‡Ã8‚qv‡v‚ Ur†‡)Ã9r†v…rqÃSr†ˆy‡ ‚i‡hvrq GRY/RED Set button pushed Check for voltage to ground: Blown No. 7 (15A) fuse in the under- ‡ There should be battery voltage. hood fuse/relay box When testing terminal No. 6, Faulty horn relay ‡...
  • Page 162 (QJLQH (OHFWULFDO &UXLVH &RQWURO 0DLQ 6ZLWFK 7HVW5HSODFHPHQW 6HW5HVXPH&DQFHO 6ZLWFK 7HVW 5HSODFHPHQW  Detach the three clips (A), to create clearance between the dashboard and dashboard panel.  Remove the two screws, then remove the switch. Terminal side of Terminal side of male terminals male terminals  Check for continuity between the terminals in each...
  • Page 163 &UXLVH &RQWURO $FWXDWRU 7HVW  Disconnect the 4P connector (A) from the actuator  Check the operation of the actuator motor in each (B). output linkage position according to the table. You should be able to hear the motor. Battery power Output linkage position polarities FULL...
  • Page 164 (QJLQH (OHFWULFDO &UXLVH &RQWURO $FWXDWRU&DEOH 5HSODFHPHQW  Remove the throttle cable cover (A), fully open the  Remove the actuator cover (A), then remove the cruise control link by hand, then remove the cruise actuator cable (B) from the actuator. control cable (B) from link.
  • Page 165 &UXLVH &RQWURO $FWXDWRU &DEOH $GMXVWPHQW &OXWFK 3HGDO 3RVLWLRQ 6ZLWFK 7HVW  Check that the actuator cable (A) moves smoothly  Disconnect the 2P connector from the clutch pedal with no binding or sticking. position switch (A). 8GVU8CÃQ@96GÃQPTDUDPIÃTXDU8CÃ!QÃ8PII@ 8UPS Terminal side of male terminals  Measure the amount of movement of the output linkage (B) until the engine speed starts to...
  • Page 167 (QJLQH 0HFKDQLFDO @tvrÃ6††r€iy’   $! Special Tools ................................05-2 Engine Removal................................. 05-3 Engine Installation ..............................05-10...
  • Page 168 (QJLQH 0HFKDQLFDO (QJLQH $VVHPEO\ (QJLQH $VVHPEO\ 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07KAK-SJ40101 Engine Tilt Hanger Set ...
  • Page 169 (QJLQH $VVHPEO\ (QJLQH 5HPRYDO 6SHFLDO 7RROV 5HTXLUHG  Disconnect the Intake Air Temperature (IAT) sensor ‡ Engine tilt hanger set 07KAK-SJ40101 connector (A), and remove the breather hose (B), then remove the air cleaner housing (C). NOTE: ‡ Use fender covers to avoid damaging painted surfeces. ‡...
  • Page 170 (QJLQH 0HFKDQLFDO (QJLQH $VVHPEO\ (QJLQH 5HPRYDO FRQW¶G  Remove the battery cables (A) from the under-  Disconnect the Engine Control Module (ECM)/ hood fuse/relay box, then remove the harness Powertrain Control Module (PCM) connectors (A) clamps (B) and ground cable (C). and main wire harness connector (B).
  • Page 171 (QJLQH $VVHPEO\  Remove the harness clamps (A) and grommet (B),  Relieve fuel pressure (see page 11-154). then pull the engine wire harness through the  Disconnect the fuel feed hose (see page 11-161). bulkhead.  Remove the Evaporative Emission (EVAP) canister GC9À‚qry†) hose (A) and brake booster vacuum hose (B).
  • Page 172 (QJLQH 0HFKDQLFDO (QJLQH $VVHPEO\ (QJLQH 5HPRYDO FRQW¶G  Remove the radiator cap.  Disconnect the primary Heated Oxygen Sensor (primary HO2S) connector (A) (Except K20A5  Raise the hoist to full height. engine).  Remove the front tires/wheels.  Remove the splash shield.  Disconnect the secondary Heated Oxygen Sensor (secondary HO2S) connector (B) (KE, KG, KS, KR, KU, KZ, KQ, FO models).
  • Page 173 (QJLQH $VVHPEO\  Remove the lower hose.  Lower the hoist.  Remove the upper hose (A) and heater hoses (B).  Remove the ATF filter mounting bolt (A) (A/T).  Attach the engine tilt hanger set (Commercially available tool for EU models) to the engine as shown.
  • Page 174 (QJLQH 0HFKDQLFDO (QJLQH $VVHPEO\ (QJLQH 5HPRYDO FRQW¶G  Remove the transmission mount bracket support  Remove the upper bracket mounting bolt and nut. bolt/nuts. HU)  Make sure the hoist brackets are positioned properly. Raise the hoist to full height. 6U)  Remove the rear mount mounting bolts.
  • Page 175 (QJLQH $VVHPEO\  Remove the front mount mounting bolt.  Disconnect the compressor clutch connector (A), then remove the A/C compressor (B) without disconnecting the A/C hoses.  Use a marker to make alignment marks on the reference lines (A) that align with the centers of the  Check that the engine/transmission is completely rear sub-frame mounting bolts (B).
  • Page 176 (QJLQH 0HFKDQLFDO (QJLQH $VVHPEO\ (QJLQH ,QVWDOODWLRQ  Install the accessory brackets, and tighten their bolts and nuts to the specified torques. @IBDI@ÃHPVIUÃ7S68F@U 68Ã8PHQS@TTPSÃ7S68F@U TUDAA@I@S F!# 6 ÃrtvrÃHU ...
  • Page 177 (QJLQH $VVHPEO\  Position the engine under the vehicle. Attach the  Install the sub-frame (A). Align the reference lines chain hoist to the engine, then lift the engine into (B) on the sub-frame with the bolt head center, then position in the vehicle.
  • Page 178 (QJLQH 0HFKDQLFDO (QJLQH $VVHPEO\ (QJLQH ,QVWDOODWLRQ FRQW¶G  Tighten the rear mount mounting bolts.  Tighten the transmission mount bracket support bolt/nuts. HU)  Lower the hoist.  Tighten the upper bracket mounting bolt and nut. 6U) ...
  • Page 179 (QJLQH $VVHPEO\  Remove the chain hoist from the engine.  Install the lower radiator hose.  Raise the hoist to full height.  Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring ’’clicks’’...
  • Page 180 (QJLQH 0HFKDQLFDO (QJLQH $VVHPEO\ (QJLQH ,QVWDOODWLRQ FRQW¶G  Install the splash shield.  Install the Power Steering (P/S) pump.  Install the drive belt.  Lower the hoist.  Install the throttle cable (see page 11-184), then  Install the upper radiator hose (A) and heater hoses adjust the cable (see page 11-183).
  • Page 181 (QJLQH $VVHPEO\  Push the Engine Control Module (ECM)/Power  Connect the ECM/PCM connectors (A) and main train Control Module (PCM) connectors through the wire harness connector (B). bulkhead, then install the grommet (A). GC9À‚qry†) GC9À‚qry†) SC9À‚qry†) SC9À‚qry†)  Install the harness clamps (B). (cont’d) ...
  • Page 182 (QJLQH 0HFKDQLFDO (QJLQH $VVHPEO\ (QJLQH ,QVWDOODWLRQ FRQW¶G  Install the brake booster vacuum hose (A) and the  Install the battery cables (A) on the under-hood Evaporative Emission (EVAP) canister hose (B). fuse/relay box, then install the harness clamps (B).  Connect the fuel feed hose (see page 11-162).
  • Page 183 (QJLQH $VVHPEO\  Install the air cleaner housing (A) and connect the  Install the battery. Clean the battery posts and Intake Air Temperature (IAT) sensor connector (B). cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.  Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch (A/T).
  • Page 185 (QJLQH 0HFKDQLFDO 8’yvqr…ÃCrhq   %! Special Tools ................................06-2 Component Location Index ............................06-3 Engine Compression Inspection ..........................06-6 VTEC Rocker Arm Test .............................. 06-7 VTC Actuator Inspection ............................06-8 Valve Clearance Adjustment ............................06-9 Crankshaft Pulley Removal and Installation......................06-11 Cam Chain Removal ..............................
  • Page 186 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &\OLQGHU +HDG 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07HAH-PJ70100 Valve Guide Reamer, 5.525 mm 07JAA-0010200 Socket Wrench, 19 mm 07JAB-0010200 Handle " 07JAB-0010400 Pulley Holder Attachment, HEX 50 mm 07LAJ-PR30101 Valve Inspection Set 07ZAJ-PNA0101 VTEC Air Adapter 07ZAJ-PNA0200 VTEC Air Stopper &...
  • Page 187 &\OLQGHU +HDG &RPSRQHQW /RFDWLRQ ,QGH[ DBIDUDPIÃ8PDGÃ8PW@S 86HÃ8C6DIÃBVD9@Ã7 86HÃ8C6DIÃBVD9@Ã6 PSDIB W6SD67G@ÃW6GW@Ã UDHDIBÃ8PIUSPGÃWU8Ã PDGÃ8PIUSPGÃ TPG@IPD9ÃW6GW@ " U@ITDPI@SÃ6SH 8C6DIÃ86T@ 8S6IFTC6AUÃ QPTDUDPIÃ8FQÃ T@ITPS PSDIB 8C6DIÃ86T@Ã8PW@S Removal, page 06-23 8`GDI9@SÃC@69Ã8PW@S Installation, page 06-42 Removal, page 06-12 86HÃ8C6DI Installation, page 06-15 Inspection, page 06-22 Replacement, page 06-11 "...
  • Page 188 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &RPSRQHQW /RFDWLRQ ,QGH[ FRQW¶G 86HTC6AUÃCPG9@S 86HÃ8C6DIÃBVD9@Ã QVGT@ÃQG6U@ 9PX@GÃQDI 86HTC6AUÃQPTDUDPIÃ8HQÃ T@ITPS UPQÃ9@69Ã8@IU@SÃU98Ã T@ITPS " PSDIBT @YC6VTUÃ86HTC6AU 9PX@GÃQDI Inspection, page 06-30 DIU6F@Ã86HTC6AU Removal, page 06-25 WU8Ã68UV6UPS Installation, page 06-26 Removal, page 06-25 " @YC6VTUÃ86HTC6AUÃTQSP8F@U Installation, page 06-26 Overhaul, page 06-28 SP8F@SÃ6SHÃ6TT@H7G` Inspection,...
  • Page 189 &\OLQGHU +HDG DIU6F@ÃW6GW@ÃTQSDIB @YC6VTUÃW6GW@Ã W6GW@ÃF@@Q@ST TQSDIB " @YC6VTUÃW6GW@Ã TQSDIBÃS@U6DI@S T@6G DIE@8UPSÃ76T@ @YC6VTUÃ W6GW@ÃBVD9@ W6GW@ÃTQSDIBÃT@6U B6TF@U WU8ÃTUS6DI@S WU8ÃADGU@S C@6UÃTCD@G9 WU@8ÃTPG@IPD9ÃW6GW@ 8`GDI9@SÃC@69ÃB6TF@U WU@8ÃTPG@IPD9ÃW6GW@ÃADGU@S Inspection, page 06-40 8`GDI9@SÃC@69Ã7PGU Replacement, page 06-32 DIU6F@ÃW6GW@ÃTQSDIB Replacement, page 06-34 " DIU6F@ÃW6GW@ÃBVD9@ Removal, page 06-34 8`GDI9@SÃC@69 Inspection, page 06-26 Installation, page 06-40 Removal,...
  • Page 190 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG (QJLQH &RPSUHVVLRQ ,QVSHFWLRQ  Warm up the engine to normal operating  Connect a tachometer. temperature (cooling fan comes on).  Open the throttle fully, then crank the engine with  Turn the ignition switch OFF. the starter motor and measure the compression.
  • Page 191 &\OLQGHU +HDG 97(& 5RFNHU $UP 7HVW 6SHFLDO 7RROV 5HTXLUHG  Repeat step 3 on the remaining intake primary ‡ Valve inspection set 07LAJ-PR30101 rocker arms with each piston at TDC. When all the ‡ VTEC air adapter 07ZAJ-PNA0101 primary rocker arms pass the test, go to step 5. ‡...
  • Page 192 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG 97(& 5RFNHU $UP 7HVW FRQW¶G W 97& $FWXDWRU ,QVSHFWLRQ  Loosen the valve on the regulator, and apply the  Remove the cylinder head cover (see page 06-23). specified air pressure.  Remove the auto-tensioner (see page 06-19).
  • Page 193 &\OLQGHU +HDG 9DOYH &OHDUDQFH $GMXVWPHQW  Apply air to the advance hole to release the lock. NOTE: Adjust the valves only when the cylinder head temperature is less than 38°C (100°F).  Remove the cylinder head cover (see page 06-23).  Set the No.
  • Page 194 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG 9DOYH &OHDUDQFH $GMXVWPHQW FRQW¶G  Select the correct thickness feeler gauge for the  If you feel too much or too little drag, loosen the valves you’re going to check. locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct.
  • Page 195 &\OLQGHU +HDG &UDQNVKDIW 3XOOH\ 5HPRYDO DQG ,QVWDOODWLRQ  Rotate the crankshaft 180° clockwise camshaft 6SHFLDO 7RROV 5HTXLUHG ‡ Handle 07JAB-0010200 pulley turns 90°). ‡ Pulley holder attachment, HEX 50 mm 07JAB-0010400 ‡ Socket wrench, 19 mm 07JAA-0010200 5HPRYDO  Remove front tires/wheels.  Remove the splash shield (see step 3 on page 06- 12).
  • Page 196 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &UDQNVKDIW 3XOOH\ 5HPRYDO DQG ,QVWDOODWLRQ &DP &KDLQ 5HPRYDO FRQW¶G NOTE: Keep the cam chain away from magnetic fields. ,QVWDOODWLRQ  Turn the crankshaft pulley so its Top Dead Center  Clean the crankshaft pulley (A), crankshaft (B), bolt (TDC) mark (A) lines up with the pointer (B).
  • Page 197 &\OLQGHU +HDG  Disconnect the Crankshaft Position (CKP) sensor  Remove the side engine mount bracket. connector (A) and Variable Valve Timing Control (VTC) oil control solenoid valve connector (B).  Remove the chain case.  Remove the VTC oil control solenoid valve (see step 1 on page 11-137).
  • Page 198 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &DP &KDLQ 5HPRYDO FRQW¶G  Loosely install the crankshaft pulley.  Remove the auto-tensioner.  Turn the crankshaft counterclockwise to compress the auto-tensioner.  Remove the cam chain guide B.  Align the holes on the lock (A) and the auto- tensioner (B), then insert a 1.5 mm (0.06 in.) diameter pin (C) into the holes.
  • Page 199 &\OLQGHU +HDG &DP &KDLQ ,QVWDOODWLRQ  Remove the cam chain guide A (A) and tensioner NOTE: Keep the cam chain away from magnetic fields. arm (B).  Set the crankshaft to Top Dead Center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the cylinder block.
  • Page 200 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &DP &KDLQ ,QVWDOODWLRQ FRQW¶G  Install the cam chain on the crankshaft sprocket  Install the cam chain guide A (A) and tensioner arm with the colored piece (A) aligned with the punch (B). mark (B) on the crankshaft sprocket.  Install the cam chain on the VTC actuator and exhaust camshaft sprocket with the punch marks (A) aligned with the two colored pieces (B).
  • Page 201 &\OLQGHU +HDG  Install the cam chain guide B.  Remove old liquid gasket from the chain case mating surfaces, bolts, and bolt holes.  Clean and dry the chain case mating surfaces.  Apply liquid gasket, P/N 08C70-K0234M, 08C70- K0334M or 08C70-X0331S, evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes.
  • Page 202 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &DP &KDLQ ,QVWDOODWLRQ FRQW¶G  Install the new O-ring (A) on the chain case. Set the  Install the side engine mount bracket. edge of the chain case (B) to the edge of the oil pan (C), then install the chain case on the cylinder block (D).
  • Page 203 &\OLQGHU +HDG $XWR7HQVLRQHU 5HPRYDO,QVWDOODWLRQ  Install the VTC oil control solenoid valve (see step 5HPRYDO 1 on page 11-137).  Remove the chain case cover.  Connect the Crankshaft Position (CKP) sensor connector (A) and VTC oil control solenoid valve connector (B).
  • Page 204 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG $XWR7HQVLRQHU 5HPRYDO,QVWDOODWLRQ FRQW¶G 5HPRYDO FRQW¶G ,QVWDOODWLRQ  Align the holes on the lock (A) and the auto-  Install the auto-tensioner. tensioner (B), then insert a 1.5 mm (0.06 in.) diameter pin (C) into the holes. Turn the crankshaft clockwise to secure the pin.
  • Page 205 &\OLQGHU +HDG &KDLQ &DVH 2LO 6HDO ,QVWDOODWLRQ  Remove old liquid gasket from the chain case 6SHFLDO 7RROV 5HTXLUHG ‡ Handle driver 07749-0010000 cover mating surfaces, bolts and bolt holes. ‡ Driver attachment, 52 x 55 mm 07746-0010400  Clean and dry the chain case cover mating  Use the special tools to drive a new oil seal surfaces.
  • Page 206 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &DP &KDLQ ,QVSHFWLRQ  Remove the front tires/wheels.  Remove old liquid gasket from the chain case mating surfaces, bolts and bolt holes.  Remove the splash shield (see step 3 on page 06-  Clean and dry the chain case mating surfaces. 12).
  • Page 207 &\OLQGHU +HDG &\OLQGHU +HDG &RYHU 5HPRYDO  Remove the intake manifold cover.  Remove the cylinder head cover.  Remove the four ignition coils (see page 04-21).  Remove the bolt (A) securing the power steering hose bracket.  Remove the dipstick (B) and breather hose (C). ...
  • Page 208 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &\OLQGHU +HDG 5HPRYDO  Remove the engine wire harness connectors and NOTE: ‡ Use fender covers to avoid damaging painted surfaces. wire harness clamps from the cylinder head. ‡ To avoid damage, unplug the wiring connectors carefully ‡...
  • Page 209 &\OLQGHU +HDG 97& $FWXDWRU ([KDXVW &DPVKDIW 6SURFNHW 5HSODFHPHQW  Remove the rocker arm assembly (see page 06- 27). 5HPRYDO  Remove the cylinder head bolts. To prevent  Remove the cam chain (see page 06-12). warpage, unscrew the bolts in sequence 1/3 turn at  Hold the camshaft with an open-end wrench, then a time;...
  • Page 210 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG 97& $FWXDWRU ([KDXVW &DPVKDIW 6SURFNHW &\OLQGHU +HDG ,QVSHFWLRQ IRU :DUSDJH 5HSODFHPHQW FRQW¶G  Remove the cylinder head (see page 06-24). ,QVWDOODWLRQ  Inspect the camshaft (see page 06-30).  Install the VTC actuator and exhaust camshaft  Check the cylinder head for warpage.
  • Page 211 &\OLQGHU +HDG 5RFNHU $UP $VVHPEO\ 5HPRYDO  Remove the cam chain  Remove the cam chain guide B, camshaft holders, (see page 06-12). and camshafts.  Loosen the rocker arm adjusting screws (A).  Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B).
  • Page 212 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG 5RFNHU $UPV DQG 6KDIWV 'LVDVVHPEO\5HDVVHPEO\ NOTE: ‡ Identify parts as they are removed to ensure reinstallation in original location. ‡ Inspect the rocker shafts and rocker arms (see page 06-29). ‡ The rocker arms must be installed in the same positions if reused. ‡...
  • Page 213 &\OLQGHU +HDG 5RFNHU $UPV DQG 6KDIWV ,QVSHFWLRQ  Remove the rocker arm assembly  Measure the inside diameter of the rocker arm, and (see page 06- 27). check it for an out-of-round condition.  Measure the diameter of the shaft at the first rocker S‚pxr…Ã6…€‡‚Tuhs‡Ã8yrh…hpr) location.
  • Page 214 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG 5RFNHU $UPV DQG 6KDIWV ,QVSHFWLRQ FRQW¶G &DPVKDIW ,QVSHFWLRQ  Inspect the rocker arm pistons (A). Push each NOTE: Do not rotate the camshaft during inspection. piston manually.  Remove the rocker arm assembly (see page 06- If it does not move smoothly, replace the rocker 27).
  • Page 215 &\OLQGHU +HDG  Seat the camshaft by pushing it away from the  Unscrew the camshaft holder bolts two turns at a camshaft pulley end of the cylinder head. time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head.  Zero the dial indicator against the end of the  Lift the camshafts out of the cylinder head, wipe camshaft, then push the camshaft back and forth...
  • Page 216 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &DPVKDIW ,QVSHFWLRQ FRQW¶G 9DOYHV 6SULQJV DQG 9DOYH 6HDOV 5HPRYDO  Check the total runout with the camshaft supported 6SHFLDO 7RROV 5HTXLUHG ‡ Valve spring compressor attachment 07757-PJ10100 on V-blocks. ‡ Valve spring compressor 07757-0010000 ‡ If the total runout of the camshaft is within the service limit, replace the cylinder head.
  • Page 217 &\OLQGHU +HDG 9DOYH ,QVSHFWLRQ 9DOYH 6WHPWR*XLGH &OHDUDQFH ,QVSHFWLRQ  Remove the valves  Remove the valves (see page 06-32). (see page 06-32).  Measure the valve in these areas.  Slide the valve out of its guide about 10 mm, then measure the guide-to-stem clearance with a dial D‡hxrÃWhy‰rÃ9v€r†v‚†) indicator while rocking the stem in the direction of...
  • Page 218 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG 9DOYH *XLGH 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Working from the camshaft side, use the driver and ‡ Valve guide driver, 5.5 mm 07742-0010100 an air hammer to drive the guide about 2 mm (0.1 ‡ Valve guide reamer, 5.525 mm 07HAH-PJ70100 in.) towards the combustion chamber.
  • Page 219 &\OLQGHU +HDG  Apply a thin coat of clean engine oil to the outside  Coat both reamer and valve guide with cutting oil. of the new valve guide. Install the guide from the  Rotate the reamer clockwise the full length of the camshaft side of the head;...
  • Page 220 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG 9DOYH 6HDW 5HFRQGLWLRQLQJ  Inspect valve stem-to-guide clearance  Make one more very light pass with the 45° cutter (see page 06-33). If the valve guides are worn, replace them to remove any possible burrs caused by the other (see page 06-34) before cutting the valve seats.
  • Page 221 &\OLQGHU +HDG  Insert the intake and exhaust valves in the head, and measure valve stem installed height (A). D‡hxrÃWhy‰rÃT‡r€ÃD†‡hyyrqÃCrvtu‡) T‡hqh…qÃIr) #'ÃÃ# À€Ã %%Ãà #Ãv @‘uhˆ†‡ÃWhy‰rÃT‡r€ÃD†‡hyyrqÃCrvtu‡) T‡hqh…qÃIr) $#%ÃÃ$#'À€Ã $ÃÃ! $&Ãv  If valve stem installed height is over the standard, replace the valve and recheck.
  • Page 222 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG 9DOYHV 6SULQJV DQG 9DOYH 6HDOV ,QVWDOODWLRQ 6SHFLDO 7RROV 5HTXLUHG  Install the valve spring. Place the end of the valve ‡ Stem seal driver 07PAD-0010000 spring with closely wound coils toward the cylinder ‡ Valve spring compressor attachment 07757-PJ10100 head.
  • Page 223 &\OLQGHU +HDG 5RFNHU $UP $VVHPEO\ ,QVWDOODWLRQ  Clean and dry the No. 5 rocker shaft holder mating  Remove the bolts from the rocker shaft holder. surface.  Punch marks on the Variable Valve Timing Control  Apply liquid gasket, P/N 08C70-K0234M, 08C70- (VTC) actuator and exhaust camshaft sprocket are K0334M or 08C70-X0331S, evenly to the cylinder facing up, then set the camshafts (A) in the holder.
  • Page 224 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &\OLQGHU +HDG ,QVWDOODWLRQ  Measure the diameter of each cylinder head bolt at Install the cylinder head in the reverse order of removal: point A and point B.  Clean the cylinder head and block surface.  Install the new cylinder head gasket (A) and dowel pins (B) on the cylinder block.
  • Page 225 &\OLQGHU +HDG  Apply engine oil to the bolt threads and under the  Install the rocker arm assembly (see page 06-39). bolt heads of all the cylinder head bolts.  Tighten the connecting pipe mounting bolt (A) and  Tighten the cylinder head bolts in sequence to 39 brake booster vacuum line mounting bolts (B), then N·m (4.0 kgf·m, 29 lbf·ft).
  • Page 226 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &\OLQGHU +HDG ,QVWDOODWLRQ FRQW¶G &\OLQGHU +HDG &RYHU ,QVWDOODWLRQ  Install the water bypass hose.  Thoroughly clean the head cover gasket and the groove.  Install the head cover gasket (A) in the groove of the cylinder head cover (B).  Install the intake manifold (see page 09-5).
  • Page 227 &\OLQGHU +HDG  Set the spark plug seals (A) on the spark plug  Tighten the bolts in two or three steps. In the final tubes. Once the cylinder head cover (B) is on the step, tighten all bolts, in sequence, to 12 N·m (1.2 cylinder head, slide the cover slightly back and kgf·m, 8.7 lbf·ft).
  • Page 228 (QJLQH 0HFKDQLFDO &\OLQGHU +HDG &\OLQGHU +HDG &RYHU ,QVWDOODWLRQ FRQW¶G  Install the four ignition coils (see page 04-21).  Check that all tubes, hoses, and connectors are installed correctly.  Install the intake manifold cover.  After assembly, wait at least 30 minutes before filling the engine with oil.
  • Page 229 (QJLQH 0HFKDQLFDO @tvrÃ7y‚px   &! Special Tools ................................07-2 Component Location Index ............................07-3 Connecting Rod and Crankshaft End Play Inspection ....................07-5 Crankshaft Main Bearing Replacement ........................07-6 Connecting Rod Bearing Replacement........................07-8 Oil Pan Removal ..............................07-11 Crankshaft and Piston Removal..........................
  • Page 230 (QJLQH 0HFKDQLFDO (QJLQH %ORFN (QJLQH %ORFN 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07ZAD-PNA0100 Oil Seal Driver Attachment 96 07746-0010700 Driver Attachment, 24 x 26 mm 07749-0010000 Handle Driver " " ...
  • Page 231 (QJLQH %ORFN &RPSRQHQW /RFDWLRQ ,QGH[ 76AAG@ÃQG6U@ GPX@SÃ7GP8F 9SDW@ÃQG6U@Ã6U 9PX@GÃQDI " AG`XC@@GÃHU UCSVTUÃX6TC@ST Installation, step 21 on page 07-26 8S6IFTC6AUÃ PDGÃT@6GÃUS6ITHDTTDPIÃ@I9 End play, page 07-5; Runout, page 07-14; Out-of-Round, page 07-14; Removal, page 8S6IFTC6AU 07-12; Installation, page 07-24 Oil clearance, page 07-6;...
  • Page 232 (QJLQH 0HFKDQLFDO (QJLQH %ORFN &RPSRQHQW /RFDWLRQ ,QGH[ FRQW¶G & " Replacement, page 07-21 QDTUPIÃSDIBT Removal, page 07-18; Inspection, page 07-19; Installation, page 07-20 QDTUPIÃQDI Cylinder bore inspection, page 07-15; Warpage inspection, page 07-15; Cylinder bore honing, page " @IBDI@Ã7GP8F 07-17; Ridge removal, step 13 on page 07-13 8PII@8UDIBÃSP9Ã7@6SDIBÃ86Q Inspection,...
  • Page 233 (QJLQH %ORFN &RQQHFWLQJ 5RG DQG &UDQNVKDIW (QG 3OD\ ,QVSHFWLRQ  Remove the oil pump  Push the crankshaft firmly away from the dial (see page 08-11). indicator, and zero the dial against the end of the  Remove the baffle plate (see step 6 on page 07- crankshaft.
  • Page 234 (QJLQH 0HFKDQLFDO (QJLQH %ORFN &UDQNVKDIW 0DLQ %HDULQJ 5HSODFHPHQW 0DLQ %HDULQJ &OHDUDQFH ,QVSHFWLRQ  If the plastigage measures too wide or too narrow, remove the crankshaft, and remove the upper half  To check main bearing-to-journal oil clearance, of the bearing. Install a new, complete bearing with remove the lower block and bearing halves (see the same color code(s), and recheck the clearance.
  • Page 235 (QJLQH %ORFN 0DLQ %HDULQJ 6HOHFWLRQ 0DLQ -RXUQDO &RGH /RFDWLRQ &UDQNVKDIW %RUH &RGH /RFDWLRQ  The main journal codes are stamped on the crankshaft.  Numbers or letters or bars have been stamped on the end of the block as a code for the size of each of the five main journal bores.
  • Page 236 (QJLQH 0HFKDQLFDO (QJLQH %ORFN &UDQNVKDIW 0DLQ %HDULQJ 5HSODFHPHQW &RQQHFWLQJ 5RG %HDULQJ 5HSODFHPHQW FRQW¶G 5RG %HDULQJ &OHDUDQFH ,QVSHFWLRQ 0DLQ %HDULQJ 6HOHFWLRQ FRQW¶G  Remove the oil pump (see page 08-11).  Use the crank bore codes and crank journal codes  Remove the baffle plate (see step 6 on page 07- to select the appropriate replacement bearings 12).
  • Page 237 (QJLQH %ORFN  If the plastigage measures too wide or too narrow, 5RG %HDULQJ 6HOHFWLRQ remove the upper half of the bearing, install a new,  Inspect each connecting rod for cracks and heat complete bearing with the same color code(s), and damage.
  • Page 238 (QJLQH 0HFKDQLFDO (QJLQH %ORFN &RQQHFWLQJ 5RG %HDULQJ 5HSODFHPHQW FRQW¶G 5RG %HDULQJ 6HOHFWLRQ FRQW¶G  Use the big end bore codes and rod journal codes to select appropriate replacement bearings from &RQQHFWLQJ 5RG -RXUQDO &RGH /RFDWLRQ the following table.  The connecting rod journal codes are stamped on NOTE: Color code is on the edge of the bearing.
  • Page 239 (QJLQH %ORFN 2LO 3DQ 5HPRYDO  If the engine is still in the vehicle, remove the sub-  Remove the bolts/nuts securing the oil pan. frame.  Drive an oil pan seal cutter between the oil pan and 1 Drain the engine oil (see page 08-5).
  • Page 240 (QJLQH 0HFKDQLFDO (QJLQH %ORFN &UDQNVKDIW DQG 3LVWRQ 5HPRYDO  Remove the engine assembly  Remove the bearing cap bolts. To prevent (see page 05-3). warpage, unscrew the bolts in sequence 1/3 turn at  Remove the transmission: a time: repeat the sequence until all bolts are ‡...
  • Page 241 (QJLQH %ORFN  Remove the rod caps/bearings. Keep all caps/  Use the wooden handle of a hammer (A) to drive bearings in order. out the pistons (B).  Lift the crankshaft out of the engine, being careful not to damage the journals.  Reinstall the lower block and bearings on the engine in the proper order.
  • Page 242 (QJLQH 0HFKDQLFDO (QJLQH %ORFN &UDQNVKDIW ,QVSHFWLRQ 2XWRI5RXQG DQG 7DSHU 6WUDLJKWQHVV  Remove the crankshaft from the cylinder block  Place the cylinder block on the surface plate. (see page 07-12).  Clean and install the bearings on the No. 1 and  Clean the crankshaft oil passages with pipe No.
  • Page 243 (QJLQH %ORFN %ORFN DQG 3LVWRQ ,QVSHFWLRQ  Remove the crankshaft and pistons (see page 07- 12). TFDSUÃ9D6H@U@S QPDIUÃ6  Check the piston for distortion or cracks.  Measure the piston diameter at a point A from the bottom of the skirt. There are two standard-size pistons (No Letter or A, and B).
  • Page 244 (QJLQH 0HFKDQLFDO (QJLQH %ORFN %ORFN DQG 3LVWRQ ,QVSHFWLRQ FRQW¶G  Measure wear and taper in direction X and Y at  Scored or scratched cylinder bores must be honed. three levels in each cylinder as shown. If  Check the top of the block for warpage. Measure measurements in any cylinder are beyond the along the edges and across the center as shown.
  • Page 245 (QJLQH %ORFN &\OLQGHU +RQLQJ  Calculate the difference between the cylinder bore Only a scored or scratched cylinder bore must be honed. diameter and the piston diameter. If the clearance  Measure the cylinder bores (see step 4 on page is near or exceeds the service limit, inspect the 07-16).
  • Page 246 (QJLQH 0HFKDQLFDO (QJLQH %ORFN 3LVWRQ 3LQ DQG &RQQHFWLQJ 5RG 5HSODFHPHQW 'LVDVVHPEO\  Heat the piston and connecting rod assembly to about 70°C (158°F), then remove the piston pin.  Remove the piston from the cylinder block (see page 07-12).  Apply engine oil to the piston pin snap rings (A), and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B).
  • Page 247 (QJLQH %ORFN ,QVSHFWLRQ  Check the difference between the piston pin diameter and piston pin hole diameter in the piston. NOTE: Inspect the piston, piston pin, and connecting rod when they are at room temperature. Qv†‡‚ÃQv‡‚Qv†‡‚Ã8yrh…hpr) T‡hqh…qÃIr) Ã$Ç‚Ã!À€Ã  Measure the diameter of the piston pin. Ã!Ç‚Ã'Ãv Tr…‰vprÃGv€v‡) $À€Ã!Ãv...
  • Page 248 (QJLQH 0HFKDQLFDO (QJLQH %ORFN 3LVWRQ 3LQ DQG &RQQHFWLQJ 5RG 5HSODFHPHQW FRQW¶G 5HDVVHPEO\  Install the piston pin (A). Assemble the piston (B) and connecting rod (C) with the arrow (D) and the  Install a piston pin snap ring (A). embossed mark (E) on the same side.
  • Page 249 (QJLQH %ORFN 3LVWRQ 5LQJ 5HSODFHPHQW  Remove the piston from the cylinder block  Using a piston, push a new ring (A) into the cylinder (see page 07-12). bore 15 - 20 mm (0.6 - 0.8 in.) from the bottom.  Using a ring expander (A), remove the old piston rings (B).
  • Page 250 (QJLQH 0HFKDQLFDO (QJLQH %ORFN 3LVWRQ 5LQJ 5HSODFHPHQW FRQW¶G  Install the top ring and second ring as shown.The  Position the ring end gaps as shown: top ring (A) has a T or 1R mark and the second ring 9PÃIPU†v‡v‚Ãh’Ã…vtÃthƒÃ (B) has a 2T or 2R mark.
  • Page 251 (QJLQH %ORFN 3LVWRQ ,QVWDOODWLRQ ,I WKH FUDQNVKDIW LV DOUHDG\ LQVWDOOHG ,I WKH FUDQNVKDIW LV QRW LQVWDOOHG  Set the crankshaft to Bottom Dead Center (BDC)  Remove the connecting rod caps, then install the for each cylinder. ring compressor, and check that the bearing is securely in place.
  • Page 252 (QJLQH 0HFKDQLFDO (QJLQH %ORFN &RQQHFWLQJ 5RG %ROW ,QVSHFWLRQ &UDQNVKDIW ,QVWDOODWLRQ  Measure the diameter of each connecting rod bolt 6SHFLDO 7RROV 5HTXLUHG ‡ Handle driver 07749-0010000 at point A and point B. ‡ Driver attachment, 24 x 26 mm 07746-0010700 ‡...
  • Page 253 (QJLQH %ORFN  Install the bearing halves in the cylinder block and  Tighten the connecting rod bolts to 20 N·m (2.0 connecting rods. kgf·m, 14 lbf·ft).  Apply a coat of engine oil to the main bearings and  Tighten the connecting rod bolts an additional 90°. rod bearings.
  • Page 254 (QJLQH 0HFKDQLFDO (QJLQH %ORFN &UDQNVKDIW ,QVWDOODWLRQ FRQW¶G  Put the lower block on the cylinder block.  Use the special tools to drive a new oil seal squarely into the block to the specified installed  Tighten the bearing cap bolts in sequence to height.
  • Page 255 (QJLQH %ORFN 2LO 3DQ ,QVWDOODWLRQ  Install the baffle plates.  Remove old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes.  Clean and dry the oil pan mating surfaces.  Apply liquid gasket, P/N 08C70-K0334M or 08C70- X0331S, evenly to the cylinder block mating surface of the oil pan and to the inner threads of the bolt holes.
  • Page 256 (QJLQH 0HFKDQLFDO (QJLQH %ORFN 2LO 3DQ ,QVWDOODWLRQ FRQW¶G  Install the stiffener (K24A1 engine M/T).  If the engine is still in the vehicle, install the sub- frame. 1 Install the sub-frame. Align the reference lines on the sub-frame with the bolt head center, then tighten the bolts (see step 4 on page 05-11).
  • Page 257 (QJLQH 0HFKDQLFDO @tvrÃGˆi…vph‡v‚   '! Special Tools ................................08-2 Component Location Index ............................08-3 Oil Pressure Switch Test ............................08-4 Oil Pressure Test ................................ 08-4 Engine Oil Replacement ............................08-5 Engine Oil Filter Replacement ........................... 08-6 Oil Filter Holder Replacement ............................ 08-9 Oil Pump Overhaul..............................
  • Page 258 (QJLQH 0HFKDQLFDO (QJLQH /XEULFDWLRQ (QJLQH /XEULFDWLRQ 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07HAA-PJ70100 Oil Filter Wrench 07406-0030000 Oil Pressure Gauge Attachment 07506-3000001 Oil Pressure Gauge " 07744-0010500 Pin Driver, 6.0 mm 07912-6110001 Oil Filter Wrench " ...
  • Page 259 (QJLQH /XEULFDWLRQ &RPSRQHQW /RFDWLRQ ,QGH[ X6TC@S 9S6DIÃ7PGU 76AAG@ÃQG6U@ PDGÃQVHQÃ8C6DIÃ PDGÃ8PIUSPGÃ U@ITDPI@S PSDAD8@ " 8S6IFTC6AUÃ TQSP8F@U PDGÃQVHQÃ8C6DIÃBVD9@ Removal, page 07-11; Installation, page 07-27 PDGÃQ6I Overhaul, page 08-10 PDGÃQVHQ Replacement, page 08-9 " PDGÃADGU@SÃCPG9@S Replacement, page 08-6 PDGÃADGU@S Circuit Diagram, page 22A-68; Switch Test, page 08-4;...
  • Page 260 If the oil pressure warning light stays on with the engine running, check the engine oil level. If the oil level is correct:  Connect a tachometer or a Honda PGM Tester.  Remove the engine oil pressure switch, and install an the special tools.
  • Page 261 (QJLQH /XEULFDWLRQ (QJLQH 2LO 5HSODFHPHQW  Warm up the engine.  Remove the drain bolt (A), and drain the engine oil. Do not overtighten.  Reinstall the drain bolt with a new washer (B).  Refill with the recommended oil (see page 03-2).
  • Page 262 (QJLQH 0HFKDQLFDO (QJLQH /XEULFDWLRQ (QJLQH 2LO )LOWHU 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  If 4 numbers or marks (1 to 4 or ) are ‡ Oil filter wrench 07HAA-PJ70100 printed around the outside of the filter, use the ‡ Oil filter wrench 07912-6110001 following procedure to tighten the filter.
  • Page 263 (QJLQH /XEULFDWLRQ -$3$10$'( (QJLQH 2LO )LOWHU  If 8 numbers (1 to 8) are printed around the outside   WXUQ W\SH of the filter, use the following procedure to tighten the filter.  Remove the oil filter with the special oil filter ‡...
  • Page 264 (QJLQH 0HFKDQLFDO (QJLQH /XEULFDWLRQ (QJLQH 2LO )LOWHU 5HSODFHPHQW FRQW¶G )5$1&(0$'( (QJLQH 2LO )LOWHU  If 4 numbers (1 to 4) are printed around the outside   WXUQ W\SH of the filter, use the following procedure to tighten the filter.  Remove the oil filter with the commercially ‡...
  • Page 265 (QJLQH /XEULFDWLRQ 2LO )LOWHU +ROGHU 5HSODFHPHQW  Remove the oil filter (see page 08-6).  Remove the oil filter holder.  Tighten the new oil filter holder to 49 N·m (5.0 kgf·m, 36 lbf·ft) ...
  • Page 266 (QJLQH 0HFKDQLFDO (QJLQH /XEULFDWLRQ 2LO 3XPS 2YHUKDXO ([SORGHG 9LHZ %Ñà À€ · !ÃI € 76AAG@ÃQG6U@ · ·  !Ãxts €Ã'&Ãyis s‡ 'Ñà !$À€ · !&ÃI € %Ñà À€Ã · · · !'Ãxts €Ã!Ãyis s‡ !ÃI € Apply engine oil to the ·...
  • Page 267 (QJLQH /XEULFDWLRQ 6SHFLDO 7RROV 5HTXLUHG  Remove the oil pump sprocket (A), then remove Pin driver, 6.0 mm 07744-0010500 the oil pump (B). 2LO 3XPS 5HPRYDO  Set the No. 1 piston at Top Dead Center (TDC) (see step 1 on page 06-12).
  • Page 268 (QJLQH 0HFKDQLFDO (QJLQH /XEULFDWLRQ 2LO 3XPS 2YHUKDXO FRQW¶G 2LO 3XPS ,QVSHFWLRQ  Check the housing-to-rotor axial clearance between the rotor (A) and pump housing (B). If the  Remove the pump housing. housing-to-rotor axial clearance exceeds the service limit, replace the oil pump. C‚ˆ†vt‡‚S‚‡‚…Ã6‘vhyÃ8yrh…hpr T‡hqh…qÃIr)Ã...
  • Page 269 (QJLQH /XEULFDWLRQ %DODQFHU 6KDIW ,QVSHFWLRQ  Remove the baffle plate (A) and upper balancer shaft holder (B), then remove the front balancer  Seat the balancer shaft by pushing it away from the shaft (C) and rear balancer shaft (D). oil pump sprocket end of the oil pump.
  • Page 270 (QJLQH 0HFKDQLFDO (QJLQH /XEULFDWLRQ 2LO 3XPS 2YHUKDXO FRQW¶G  Measure the inner diameter of the No. 1 bearing for  Measure the diameters of the No. 1 journals on the the front balancer shaft hole and the rear balancer front balancer shaft and rear balancer shaft. shaft hole.
  • Page 271 (QJLQH /XEULFDWLRQ  Clean each balancer shaft No. 2 journals and  Align the punch mark on the rear balancer shaft bearings half with a clean shop towel. with the center of the two punch marks on the front balancer shaft, then install the balancer shafts on  Place one strip of plastigage across each journal.
  • Page 272 (QJLQH 0HFKDQLFDO (QJLQH /XEULFDWLRQ 2LO 3XPS 2YHUKDXO FRQW¶G  Install the pump housing. 2LO 3XPS ,QVWDOODWLRQ  Check the No. 1 piston at TDC (see step 1 on page 06-12).  Align the dowel pin (A) on the rear balancer shaft with the mark (B) on the oil pump.
  • Page 273 (QJLQH /XEULFDWLRQ  Apply engine oil to the threads of the oil pump  Squeeze the new oil pump chain tensioner (A), sprocket mounting bolt (A). then install the set clip (B) on it as shown. NOTE: The set clip is supplied with the oil pump chain tensioner.
  • Page 274 (QJLQH 0HFKDQLFDO (QJLQH /XEULFDWLRQ 2LO 3XPS 2YHUKDXO FRQW¶G 2LO 3UHVVXUH 6ZLWFK 5HSODFHPHQW  Remove the set clip from the oil pump chain  Disconnect the oil pressure switch connector, then tensioner. remove the oil pressure switch.  Apply liquid gasket to the oil pressure switch  Install the oil pan (see page 07-27).
  • Page 275 (QJLQH 0HFKDQLFDO D‡hxrÃHhvs‚yqÃhqÃ@‘uhˆ†‡ÃT’†‡r€   (! Intake Manifold Removal and Installation........................09-2 Exhaust Manifold Removal and Installation ....................... 09-8 Exhaust Pipe and Muffler Replacement ........................09-9...
  • Page 276 (QJLQH 0HFKDQLFDO ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP ,QWDNH 0DQLIROG 5HPRYDO DQG ,QVWDOODWLRQ ([SORGHG 9LHZ DIU6F@ÃH6IDAPG9 Replace if cracked or if mating surface is damaged. UCSPUUG@Ã7P9` PSDIB Replace. PSDIBT Replace. B6TF@U Replace. DIE@8UPSÃ76T@ Replace if cracked or if mating surface is damaged.
  • Page 277 ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP 5HPRYDO  Remove the throttle cover (A). Fully open the throttle link and cruise control link by hand, then  Remove the intake manifold cover. remove the throttle cable (B) and cruise control cable (C) from the links. Loosen the locknuts (D), and remove the cables from the bracket.
  • Page 278 (QJLQH 0HFKDQLFDO ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP ,QWDNH 0DQLIROG 5HPRYDO DQG ,QVWDOODWLRQ FRQW¶G 5HPRYDO FRQW¶G  Remove the bolt (A) securing the battery clamp, then remove the bulkhead cover (B).  Remove the water bypass hoses, then plug the water bypass hoses.  Disconnect the Intake Manifold Runner Control (IMRC) valve actuator control solenoid valve  Remove the harness clamps.
  • Page 279 ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP  Remove the intake air duct mounting bolts (A) and ,QVWDOODWLRQ upper bracket and cushion (B), then remove the  Install the intake manifold (A) and tighten the bolts/ bulkhead (C). nuts in a crisscross pattern in two or three steps, beginning with the inner bolt.
  • Page 280 (QJLQH 0HFKDQLFDO ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP ,QWDNH 0DQLIROG 5HPRYDO DQG ,QVWDOODWLRQ FRQG¶W ,QVWDOODWLRQ FRQW¶G  Connect the Intake Manifold Runner Control (IMRC) valve actuator control solenoid valve  Connect the harness clamps. connector (A), then install the Positive Crankcase Ventilation (PCV) hose (B) and IMRC valve actuator control solenoid valve mounting bolt (C).
  • Page 281 ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP  Install the Evaporative Emission (EVAP) canister  Install the intake manifold cover. hose (A) and brake booster vacuum hose (B).  Install the throttle cable (see page 11-184), then  Clean up any spilled engine coolant. adjust the cable (see page 11-183).
  • Page 282 (QJLQH 0HFKDQLFDO ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP ([KDXVW 0DQLIROG 5HPRYDO DQG ,QVWDOODWLRQ  Remove the VTEC solenoid valve (see page 11-138).  Remove the driveshaft heat cover (see page 16-19).  Remove the cover and exhaust manifold bracket, then remove the exhaust manifold. @YC6VTUÃH6IDAPG9 B6TF@U Replace.
  • Page 283 ,QWDNH 0DQLIROG DQG ([KDXVW 6\VWHP ([KDXVW 3LSH DQG 0XIIOHU 5HSODFHPHQW NOTE: Use new gaskets and self-locking nuts when reassembling. B6TF@U HVAAG@S Replace. C@6UÃTCD@G9 T@GAGP8FDIBÃIVU Replace. Tighten the bolts in steps, alternating side-to-side Replace. @YC6VTUÃQDQ@Ã7 B6TF@U Replace. UCS@@ÃX6`Ã86U6G`UD8Ã8PIW@SU@Sà UX8F!6#ÃF!#6 Ãrtvr† @YC6VTUÃ8C6H7@SÃF!6$Ãrtvr T@8PI96S`ÃC@6U@9Ã...
  • Page 285 (QJLQH &RROLQJ 8‚‚yvtÃT’†‡r€   Component Location Index ............................10-2 Radiator Cap Test ..............................10-3 Radiator Test ................................10-3 Fan Motor Test ................................10-4 Thermostat Test................................10-4 Water Pump Inspection .............................. 10-5 Water Pump Replacement ............................10-5 Coolant Check................................10-6 Coolant Replacement..............................
  • Page 286 (QJLQH &RROLQJ &RROLQJ 6\VWHP &RROLQJ 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ & " Inspection, page 10-5; Replacement, page 10-5 X6U@SÃQVHQ Replacement, page 10-10; Fan Motor Test, page 10-4 68Ã8PI9@IT@SÃA6IÃ6TT@H7G` Test, page 10-17; Replacement, page 10-17 " S69D6UPSÃA6IÃTXDU8C Replacement, page 10-10; Fan Motor Test, page 10-4 S69D6UPSÃA6IÃ6TT@H7G` Replacement...
  • Page 287 &RROLQJ 6\VWHP 5DGLDWRU &DS 7HVW 5DGLDWRU 7HVW  Remove the radiator cap (A), wet its seal with  Wait until the engine is cool, then carefully remove engine coolant, then install it on the pressure tester the radiator cap and fill the radiator with engine (B) (commercially available).
  • Page 288 (QJLQH &RROLQJ &RROLQJ 6\VWHP )DQ 0RWRU 7HVW 7KHUPRVWDW 7HVW  Disconnect the 2P connectors from the radiator fan Replace the thermostat if it is open at room temperature. motor and condenser fan motor. To test a closed thermostat:  Suspend the thermostat (A) in a container of water. Do not let the thermometer (B) touch the bottom of Terminal side of the hot container.
  • Page 289 &RROLQJ 6\VWHP :DWHU 3XPS ,QVSHFWLRQ :DWHU 3XPS 5HSODFHPHQW  Remove the drive belt  Remove the drive belt (see page 04-30). (see page 04-30).  Turn the water pump pulley counterclockwise.  Drain the engine coolant (see page 10-6). Check that it turns freely.  Remove the crankshaft pulley (see page 06-11).
  • Page 290 (QJLQH &RROLQJ &RROLQJ 6\VWHP &RRODQW &KHFN &RRODQW 5HSODFHPHQW  Look at the coolant level in the reserve tank. Make  Start the engine. Set the heater temperature control sure it is between the MAX mark (A) and MIN mark dial to maximum heat, then turn off the ignition (B).
  • Page 291 NOTE:  Install the splash shield (see step 22 on page 05- ‡ Always use genuine Honda All Season Antifreeze/ 14). Coolant Type 2. Using a non-Honda coolant can  Install the bulkhead cover (see step 4 on page 09- result in corrosion, causing the cooling system to malfunction or fail.
  • Page 292 (QJLQH &RROLQJ &RROLQJ 6\VWHP 7KHUPRVWDW 5HSODFHPHQW  Drain the engine coolant (see page 10-6).  Remove the splash shield (see step 21 on page 05-6).  Remove the lower hose, then remove the thermostat. PSDIB Replace. UC@SHPTU6U GPX@SÃCPT@  Install the thermostat with a new O-ring, then install the lower hose.  Install the splash shield (see step 22 on page 05-14).
  • Page 293 &RROLQJ 6\VWHP :DWHU 3DVVDJH ,QVWDOODWLRQ :DWHU 2XWOHW ,QVWDOODWLRQ  Clean and dry the water passage mating surfaces. Install the water outlet (A) with a new O-ring (B).  Apply liquid gasket, 08C70-K0234M, 08C70- K0334M or 08C70-X0331S, evenly to the cylinder block mating surface of the water passage and to the inner threads of the bolt holes.
  • Page 294 (QJLQH &RROLQJ &RROLQJ 6\VWHP 5DGLDWRU DQG )DQV 5HSODFHPHQW  Drain the engine coolant (see page 10-6).  Remove the bulkhead cover (see step 7 on page 09-4).  Remove the upper bracket cushion, then remove the bulkhead (see step 9 on page 09-5).
  • Page 295 )DQ &RQWUROV )DQ &RQWUROV &RPSRQHQW /RFDWLRQ ,QGH[ " VI9@SCPP9ÃAVT@S@G6`Ã7PY Test, page 21-38 8PI9@IT@SÃA6IÃS@G6` Test, page 10-14 " S69D6UPSÃA6IÃS@G6` Motor Test, page 10-4 8PI9@IT@SÃA6IÃ6TT@H7G` Test, page 10-17; Replacement, page 10-17 S69D6UPSÃA6IÃTXDU8C Motor Test, page 10-4 S69D6UPSÃA6IÃ6TT@H7G` ...
  • Page 296 (QJLQH &RROLQJ )DQ &RQWUROV 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ Before performing any troubleshooting procedures check: ‡ Fuses ‡ Grounds ‡ Cleanliness and tightness of all connectors 6<03720 352&('85( Radiator fan does not run at all Radiator Fan Circuit Troubleshooting (see page 10-14). Radiator fan does not run for engine cooling, but it runs with A/C Radiator Fan Switch Circuit Troubleshooting (Open) (see page...
  • Page 297 )DQ &RQWUROV &LUFXLW 'LDJUDP VI9@S96TC DBIDUDPIÃTXDU8C VI9@SCPP9ÃAVT@S@G6`Ã7PY AVT@S@G6`Ã7PY 76UU@S` 8PI9@IT@Sà S69D6UPSà A6IÃS@G6` A6IÃS@G6` 6DSà 8PI9DUDPIDIBà T`TU@H S69D6UPSà S69D6UPSÃA6Ià 8PI9@IT@Sà A6Ià A6Ià TXDU8C HPUPS HPUPS b8y‚†rq)Ã6i‚‰rà ("ƒ8à ((ƒAd ...
  • Page 298 (QJLQH &RROLQJ )DQ &RQWUROV 5DGLDWRU )DQ &LUFXLW 7URXEOHVKRRWLQJ  Check the No. 4 (20A) fuse in the under-hood fuse/  Connect the No. 1 and No. 2 terminals of the relay box, and the No. 14 (10A) fuse in the under- radiator fan relay 4P socket with a jumper wire.
  • Page 299 )DQ &RQWUROV  Disconnect the radiator fan motor 2P connector.  Reinstall the radiator fan relay.  Check for continuity between the No. 1 terminal of  Disconnect the radiator fan switch 2P connector. the radiator fan relay 4P socket and the No. 2  Connect the No.
  • Page 300 (QJLQH &RROLQJ )DQ &RQWUROV 5DGLDWRU )DQ 6ZLWFK &LUFXLW 7URXEOHVKRRWLQJ 5DGLDWRU )DQ 6ZLWFK &LUFXLW 7URXEOHVKRRWLQJ 2SHQ 6KRUW  Disconnect the radiator fan switch 2P connector.  Remove the radiator fan relay from the under-hood fuse/relay box, and test it (see page 10-17).
  • Page 301 )DQ &RQWUROV 5DGLDWRU )DQ 6ZLWFK 7HVW 5DGLDWRU )DQ 6ZLWFK 5HSODFHPHQW  Disconnect the radiator fan switch connector, then NOTE: Bleed air from the cooling system after installing the radiator fan switch (see page 10-6). remove the radiator fan switch (A).  Remove the radiator fan switch from the radiator (see page 10-17).
  • Page 303 (QJLQH &RROLQJ 8‚‚yvtÃT’†‡r€   Component Location Index ............................10-2 Radiator Cap Test ..............................10-3 Radiator Test ................................10-3 Fan Motor Test ................................10-4 Thermostat Test................................10-4 Water Pump Inspection .............................. 10-5 Water Pump Replacement ............................10-5 Coolant Check................................10-6 Coolant Replacement..............................
  • Page 304 (QJLQH &RROLQJ &RROLQJ 6\VWHP &RROLQJ 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ & " Inspection, page 10-5; Replacement, page 10-5 X6U@SÃQVHQ Replacement, page 10-10; Fan Motor Test, page 10-4 68Ã8PI9@IT@SÃA6IÃ6TT@H7G` Test, page 10-17; Replacement, page 10-17 " S69D6UPSÃA6IÃTXDU8C Replacement, page 10-10; Fan Motor Test, page 10-4 S69D6UPSÃA6IÃ6TT@H7G` Replacement...
  • Page 305 &RROLQJ 6\VWHP 5DGLDWRU &DS 7HVW 5DGLDWRU 7HVW  Remove the radiator cap (A), wet its seal with  Wait until the engine is cool, then carefully remove engine coolant, then install it on the pressure tester the radiator cap and fill the radiator with engine (B) (commercially available).
  • Page 306 (QJLQH &RROLQJ &RROLQJ 6\VWHP )DQ 0RWRU 7HVW 7KHUPRVWDW 7HVW  Disconnect the 2P connectors from the radiator fan Replace the thermostat if it is open at room temperature. motor and condenser fan motor. To test a closed thermostat:  Suspend the thermostat (A) in a container of water. Do not let the thermometer (B) touch the bottom of Terminal side of the hot container.
  • Page 307 &RROLQJ 6\VWHP :DWHU 3XPS ,QVSHFWLRQ :DWHU 3XPS 5HSODFHPHQW  Remove the drive belt  Remove the drive belt (see page 04-30). (see page 04-30).  Turn the water pump pulley counterclockwise.  Drain the engine coolant (see page 10-6). Check that it turns freely.  Remove the crankshaft pulley (see page 06-11).
  • Page 308 (QJLQH &RROLQJ &RROLQJ 6\VWHP &RRODQW &KHFN &RRODQW 5HSODFHPHQW  Look at the coolant level in the reserve tank. Make  Start the engine. Set the heater temperature control sure it is between the MAX mark (A) and MIN mark dial to maximum heat, then turn off the ignition (B).
  • Page 309 NOTE:  Install the splash shield (see step 22 on page 05- ‡ Always use genuine Honda All Season Antifreeze/ 14). Coolant Type 2. Using a non-Honda coolant can  Install the bulkhead cover (see step 4 on page 09- result in corrosion, causing the cooling system to malfunction or fail.
  • Page 310 (QJLQH &RROLQJ &RROLQJ 6\VWHP 7KHUPRVWDW 5HSODFHPHQW  Drain the engine coolant (see page 10-6).  Remove the splash shield (see step 21 on page 05-6).  Remove the lower hose, then remove the thermostat. PSDIB Replace. UC@SHPTU6U GPX@SÃCPT@  Install the thermostat with a new O-ring, then install the lower hose.  Install the splash shield (see step 22 on page 05-14).
  • Page 311 &RROLQJ 6\VWHP :DWHU 3DVVDJH ,QVWDOODWLRQ :DWHU 2XWOHW ,QVWDOODWLRQ  Clean and dry the water passage mating surfaces. Install the water outlet (A) with a new O-ring (B).  Apply liquid gasket, 08C70-K0234M, 08C70- K0334M or 08C70-X0331S, evenly to the cylinder block mating surface of the water passage and to the inner threads of the bolt holes.
  • Page 312 (QJLQH &RROLQJ &RROLQJ 6\VWHP 5DGLDWRU DQG )DQV 5HSODFHPHQW  Drain the engine coolant (see page 10-6).  Remove the bulkhead cover (see step 7 on page 09-4).  Remove the upper bracket cushion, then remove the bulkhead (see step 9 on page 09-5).
  • Page 313 )DQ &RQWUROV )DQ &RQWUROV &RPSRQHQW /RFDWLRQ ,QGH[ " VI9@SCPP9ÃAVT@S@G6`Ã7PY Test, page 21-38 8PI9@IT@SÃA6IÃS@G6` Test, page 10-14 " S69D6UPSÃA6IÃS@G6` Motor Test, page 10-4 8PI9@IT@SÃA6IÃ6TT@H7G` Test, page 10-17; Replacement, page 10-17 S69D6UPSÃA6IÃTXDU8C Motor Test, page 10-4 S69D6UPSÃA6IÃ6TT@H7G` ...
  • Page 314 (QJLQH &RROLQJ )DQ &RQWUROV 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ Before performing any troubleshooting procedures check: ‡ Fuses ‡ Grounds ‡ Cleanliness and tightness of all connectors 6<03720 352&('85( Radiator fan does not run at all Radiator Fan Circuit Troubleshooting (see page 10-14). Radiator fan does not run for engine cooling, but it runs with A/C Radiator Fan Switch Circuit Troubleshooting (Open) (see page...
  • Page 315 )DQ &RQWUROV &LUFXLW 'LDJUDP VI9@S96TC DBIDUDPIÃTXDU8C VI9@SCPP9ÃAVT@S@G6`Ã7PY AVT@S@G6`Ã7PY 76UU@S` 8PI9@IT@Sà S69D6UPSà A6IÃS@G6` A6IÃS@G6` 6DSà 8PI9DUDPIDIBà T`TU@H S69D6UPSà S69D6UPSÃA6Ià 8PI9@IT@Sà A6Ià A6Ià TXDU8C HPUPS HPUPS b8y‚†rq)Ã6i‚‰rà ("ƒ8à ((ƒAd ...
  • Page 316 (QJLQH &RROLQJ )DQ &RQWUROV 5DGLDWRU )DQ &LUFXLW 7URXEOHVKRRWLQJ  Check the No. 4 (20A) fuse in the under-hood fuse/  Connect the No. 1 and No. 2 terminals of the relay box, and the No. 14 (10A) fuse in the under- radiator fan relay 4P socket with a jumper wire.
  • Page 317 )DQ &RQWUROV  Disconnect the radiator fan motor 2P connector.  Reinstall the radiator fan relay.  Check for continuity between the No. 1 terminal of  Disconnect the radiator fan switch 2P connector. the radiator fan relay 4P socket and the No. 2  Connect the No.
  • Page 318 (QJLQH &RROLQJ )DQ &RQWUROV 5DGLDWRU )DQ 6ZLWFK &LUFXLW 7URXEOHVKRRWLQJ 5DGLDWRU )DQ 6ZLWFK &LUFXLW 7URXEOHVKRRWLQJ 2SHQ 6KRUW  Disconnect the radiator fan switch 2P connector.  Remove the radiator fan relay from the under-hood fuse/relay box, and test it (see page 10-17).
  • Page 319 )DQ &RQWUROV 5DGLDWRU )DQ 6ZLWFK 7HVW 5DGLDWRU )DQ 6ZLWFK 5HSODFHPHQW  Disconnect the radiator fan switch connector, then NOTE: Bleed air from the cooling system after installing the radiator fan switch (see page 10-6). remove the radiator fan switch (A).  Remove the radiator fan switch from the radiator (see page 10-17).
  • Page 321 )XHO DQG (PLVVLRQV AˆryÃhqÃ@€v††v‚†ÃT’†‡r€†   QBHADÃT’†‡r€   WU@8WU8    !" DqyrÃ8‚‡…‚yÃT’†‡r€    "( AˆryÃTˆƒƒy’ÃT’†‡r€    #( D‡hxrÃ6v…ÃT’†‡r€   &% 8h‡hy’‡vpÃ8‚‰r…‡r…ÃT’†‡r€    '' Q8WÃT’†‡r€    ( @‰hƒ‚…h‡v‰rÃ@€v††v‚Ã8‚‡…‚yÃT’†‡r€ ...
  • Page 322 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV )XHO DQG (PLVVLRQV 6\VWHPV 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07LAA-PT50101 Sensor Socket Wrench 07NAJ-P070100 Oil Pressure Gauge Attachment 07VAJ-0040100 Fuel Pressure Gauge Attachment " 07WAA-0010100 Adjustable Ring Wrench 07ZAJ-S5A0100 Fuel Pressure Gauge Set 07ZAJ-S7C0100 Fuel Hose Attachment 07ZAJ-S7C0200...
  • Page 323 ‡ Freeze frame data indicates the engine conditions when the first malfunction, misfire or fuel trim malfunction was detected. ‡ The scan tool and the Honda PGM Tester can read the DTC, freeze frame data, current data, and other Engine Control Module (ECM)/Powertrain Control Module (PCM) data.
  • Page 324 You can reset the ECM/PCM in either of 2 ways: If the inspection for a trouble code requires voltage or resistance checks at the ECM/PCM connectors, remove ‡ Use the scan tool or Honda PGM Tester to clear the the ECM/PCM and test it: ECM’s/PCM’s memory.
  • Page 325  Install a known-good ECM/PCM in the vehicle.  Reconnect the negative cable to the battery.  Rewrite the immobilizer code with the ECM/PCM replacement procedure on the Honda PGM Tester. It allows you to start the engine.  After completing your tests, reinstall the original...
  • Page 326 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV '7& 7URXEOHVKRRWLQJ ,QGH[ TphÃ‡‚‚yÃ9U8ÃC‚qhÃ9U8 9r‡rp‡v‚ÃD‡r€ Qhtr P0010 (56-1) VTC Oil Control Solenoid Valve Malfunction (see page 11-124) P0011 (56-2) VTC System Malfunction (see page 11-126) P0107 (3-1) Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage (see page 11-62)) P0108 (3-2)
  • Page 327 )XHO DQG (PLVVLRQV 6\VWHPV TphÃ‡‚‚yÃ9U8ÃC‚qhÃ9U8 9r‡rp‡v‚ÃD‡r€ Qhtr P0325 (23-1) Knock Sensor Circuit Malfunction (see page 11-87) P0335 (4-1) Crankshaft Position (CKP) Sensor No Signal (see page 11-88) P0336 (4-2) Crankshaft Position (CKP) Sensor Intermittent Interruption (see page 11-88) P0340 (57-1) Camshaft Position (CMP) Sensor No Signal (see page 11-128) P0341 (57-3)
  • Page 328 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ When the vehicle has one of these symptoms, check the Diagnostic Trouble Code (DTC) with the scan tool. If there is no DTC, do the diagnostic procedure for the symptom, in the sequence listed, until you find the cause. T’€ƒ‡‚€...
  • Page 329 )XHO DQG (PLVVLRQV 6\VWHPV T’€ƒ‡‚€ 9vht‚†‡vpÃ…‚prqˆ…r 6y†‚ÃpurpxÃs‚… ‡ Misfire or rough running Check the spark plugs (see page 04-23).* Low compression (MIL works OK, no DTCs set) Test the fuel pressure (see page 11-154). ‡ Valve clearance Test the injectors (see page 11-116).* ‡...
  • Page 330 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV (OHFWURQLF &RQWURO 6\VWHP The functions of the fuel and emission control systems are managed by the Engine Control Module (ECM) on vehicles with manual transmissions or the Powertrain Control Module (PCM) on vehicles with automatic transmissions. )DLOVDIH )XQFWLRQ When an abnormality occurs in a signal from a sensor, the ECM/PCM ignores that signal and assumes a pre-programmed value for that sensor that allows the engine to continue to run.
  • Page 331 (&03&0 'DWD You can retrieve data from the ECM/PCM by connecting the scan tool or the Honda PGM Tester to the Data Link Connector (DLC). The items listed in the table below conform to SAE recommended practice. The Honda PGM Tester also reads data beyond that recommended by SAE so that this data may help you find the causes of intermittent problems.
  • Page 332 Ignition timing is the ignition advance angle set by the ECM/ At idle speed: 8° ± 2° PCM. The ECM/PCM matches ignition timing to the driving BTDC when the SCS conditions. service signal line is jumped with the Honda PGM tester ...
  • Page 333 )XHO DQG (PLVVLRQV 6\VWHPV (&03&0 ,QSXWV DQG 2XWSXWV DW &RQQHFWRU $ 3 Xv…rÆvqrÂsÃsr€hyrÇr…€vhy† NOTE: Standard battery voltage is 12 V. Ur…€vhyà Xv…rÃp‚y‚… Ur…€vhyÁh€r 9r†p…vƒ‡v‚ Tvthy ˆ€ir… BLK/WHT PO2SHTC (PRIMARY HEATED Drives Primary HO2S heater With ignition switch ON (II): battery voltage OXYGEN SENSOR HEATER With fully warmed up engine running: duty CONTROL)
  • Page 334 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G (&03&0 ,QSXWV DQG 2XWSXWV DW &RQQHFWRU % 3 Xv…rÆvqrÂsÃsr€hyrÇr…€vhy† NOTE: Standard battery voltage is 12 V. Ur…€vhyà Xv…rÃp‚y‚… Ur…€vhyÁh€r 9r†p…vƒ‡v‚ Tvthy ˆ€ir… BLU/WHT VTC+ (VTC OIL CONTROL Drives VTC oil control With ignition switch ON (II): 0 V SOLENOID VALVE +SIDE) solenoid valve...
  • Page 335 )XHO DQG (PLVVLRQV 6\VWHPV 3&0 ,QSXWV DQG 2XWSXWV DW &RQQHFWRU & 3 Xv…rÆvqrÂsÃsr€hyrÇr…€vhy† NOTE: Standard battery voltage is 12 V. Ur…€vhyà Xv…rà Ur…€vhyÁh€r 9r†p…vƒ‡v‚ Tvthy ˆ€ir… p‚y‚… WHT/BLK LSA- (A/T PRESSURE Ground for A/T pressure CONTROL SOLENOID VALVE A control solenoid valve A -SIDE) SHC (SHIFT SOLENOID VALVE Drives shift solenoid valve C...
  • Page 336 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G 3&0 ,QSXWV DQG 2XWSXWV DW &RQQHFWRU ' 3 Xv…rÆvqrÂsÃsr€hyrÇr…€vhy† NOTE: Standard battery voltage is 12 V. Ur…€vhyà Xv…rà Ur…€vhyÁh€r 9r†p…vƒ‡v‚ Tvthy ˆ€ir… p‚y‚… ODSW (OVER-DRIVE SWITCH) Detects over-drive switch With Over-Drive OFF (O/D OFF indicator light signal turned ON): about 0 V With Over-Drive ON (O/D OFF indicator light turned...
  • Page 337 )XHO DQG (PLVVLRQV 6\VWHPV (&03&0 ,QSXWV DQG 2XWSXWV DW &RQQHFWRU ( 3 Xv…rÆvqrÂsÃsr€hyrÇr…€vhy† NOTE: Standard battery voltage is 12 V. Ur…€vhyà Xv…rÃp‚y‚… Ur…€vhyÁh€r 9r†p…vƒ‡v‚ Tvthy ˆ€ir… GRN/YEL IMO FPR (IMMOBILIZER Drives PGM-FI main ralay 2 0 V for 2 seconds after turning ignition switch ON (II), FUEL PUMP RELAY) then battery voltage WHT/RED...
  • Page 338 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G 9DFXXP +RVH 5RXWLQJ @W6QPS6UDW@Ã@HDTTDPIÃ@W6QÃ 86IDTU@SÃQVSB@ÃW6GW@ ASPIUÃPAÃ DIU6F@ÃH6IDAPG9Ã W@CD8G@ SVII@SÃ8PIUSPGÃ U‚ÃDIU6F@Ã6DSÃ9V8U DHS8Ã68UV6UPS U‚Ã@W6QPS6UDW@Ã @HDTTDPIÃ@W6QÃ 86IDTU@S DIU6F@Ã6DSÃ7`Q6TTÃ 8PIUSPGÃUC@SH6GÃ W6GW@ DIU6F@ÃH6IDAPG9Ã SVII@SÃ8PIUSP GÃDHS8Ã DIU6F@ÃH6IDAPG9Ã TPG@IPD9ÃW6GW@ SVII@SÃ8PIUSPGÃ DHS8Ã8C@8FÃW6GW@ ...
  • Page 339 )XHO DQG (PLVVLRQV 6\VWHPV 9DFXXP 'LVWULEXWLRQ @IBDI@Ã 8PPG6IU @IBDI@Ã8PPG6IU : KG, Ks, KE, KR, KU, KZ, FO, KQ models : except KZ, PH, FO, IN, MA models : KN, KM, KY, MA, PH, IN, KK models : KZ, PH, FO, IN, MA models : without TWC model "...
  • Page 340 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G 3*0), 6\VWHP (QJLQH &RRODQW 7HPSHUDWXUH (&7 6HQVRU The ECT sensor is a temperature dependent resistor The Programmed Fuel Injection (PGM-FI) system is a (thermistor). The resistor of the thermistor decreases as sequential multiport fuel injection system.
  • Page 341 )XHO DQG (PLVVLRQV 6\VWHPV ,QWDNH $LU 7HPSHUDWXUH ,$7 6HQVRU 3ULPDU\ +HDWHG 2[\JHQ 6HQVRU 3ULPDU\ +26 The IAT sensor is a temperature dependent resistor The primary HO2S detects the oxygen content in the (thermistor). The resistance of the thermistor decreases as exhaust gas and sends signals to the ECM/PCM which the intake air temperature increases.
  • Page 342 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G 3*0), 6\VWHP FRQW¶G 7KURWWOH 3RVLWLRQ 73 6HQVRU The TP sensor is a potentiometer connected to the throttle valve shaft. As the throttle position changes, the sensor varies the signal voltage to the ECM/PCM. The TP sensor is not replaceable apart from the throttle body.
  • Page 343 )XHO DQG (PLVVLRQV 6\VWHPV 97(&97& ‡ The i-VTEC has a VTC (Variable Valve Timing Control) mechanism on the intake camshaft in addition to the usual VTEC. This mechanism improves fuel efficiency and reduces exhaust emissions at all levels of engine speed, vehicle speed, and engine load.
  • Page 344 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G 97(&97& 97& V\VWHP ‡ The VTC system makes continuous intake valve timing changes based on operating conditions. ‡ Intake valve timing to allow the engine to produce maximum power. ‡ Cam angle is advanced to obtain the EGR effect and reduce the pumping loss. The intake valve is closed quickly to reduce the entry of the air/fuel mixture into the intake port and improve the charging effect.
  • Page 345 )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'LDJUDP 8HQÃT@ITPS A…‚€ÃI‚Ã#Ã688à  6Ãsˆ†r DIU6F@Ã86HTC6AU W6SDPVTà 69W6I8@ S@U6S9 T@ITPST WU8à WU8ÃS@U6S9 69W6I8@à 8C6H7@S 8C6H7@S CPVTDIB WU8Ã68UV6UPS W6I@ 9S6DI 9S6DI W6I@ A…‚€Ã PDGÃQVHQ WU8ÃPDGÃ8PIUSPGà TPG@IPD9ÃW6GW@ CPVTDIB WU@8ÃPDG QDTUPI QS@TTVS@ TXDU8C A…‚€Ã‚vyà QVHQ WU@8à TPG@IPD9à TQPPGà W6GW@ SP8F@SÃ6SHT W6GW@...
  • Page 346 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G ,GOH &RQWURO 6\VWHP )XHO 6XSSO\ 6\VWHP )XHO &XWRII &RQWURO When the engine is cold, the A/C compressor is on, the transmission is in gear, the brake pedal is pressed, the During deceleration with the throttle valve closed, current power steering load is high, or the alternator is charging, to the injectors is cut off to improve fuel economy at...
  • Page 347 )XHO DQG (PLVVLRQV 6\VWHPV ,QWDNH $LU 6\VWHP ,QWDNH $LU %\SDVV &RQWURO 7KHUPDO 9DOYH When the engine is running, the intake air bypass control Refer to the System Diagram to see the functional layout thermal valve sends air to the injector. of the system.
  • Page 348 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G &DWDO\WLF &RQYHUWHU 6\VWHP 3RVLWLYH &UDQNFDVH 9HQWLODWLRQ 3&9 6\VWHP 7KUHH :D\ &DWDO\WLF &RQYHUWHU 7:& The PCV valve prevents blow-by gasses from escaping The TWC converts hydrocarbons (HC), carbon monoxide into the atmosphere by venting them into the intake (CO), and oxides of nitrogen (NOx) in the exhaust gas to manifold.
  • Page 349 )XHO DQG (PLVVLRQV 6\VWHPV ,GOH &RQWURO 6\VWHP 'LDJUDP The idle speed of the engine is controlled by the Idle Air Control (IAC) valve: ‡ After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idle speed.
  • Page 350 )XHO DQG (PLVVLRQV )XHO DQG (PLVVLRQV 6\VWHPV 6\VWHP 'HVFULSWLRQV FRQW¶G ,QWDNH 0DQLIROG 5XQQHU &RQWURO ,05& 6\VWHP Satisfactory power performance is achieved by closing and opening the Intake Manifold Runner Control (IMRC) valve. High torque at low engine speed is achieved when the valve is closed, whereas high power at high engine is achieved when the valve is opened.
  • Page 351 )XHO DQG (PLVVLRQV 6\VWHPV (YDSRUDWLYH (PLVVLRQ (9$3 &RQWURO 'LDJUDP The EVAP controls minimize the amount of fuel vapor escaping to the atmosphere. Vapor from the fuel tank is temporarily stored in the EVAP canister until it can be purged from the EVAP canister into the engine and burned. ‡...
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  • Page 379 3*0), 6\VWHP 3*0), 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ " & *: The illustration shows LHD model Troubleshooting, page 11-100; Replacement, page 11-120 UPQÃ9@69Ã8@IU@SÃU98ÃT@ITPS Troubleshooting, page 11-97 @G@8USD86GÃGP69Ã9@U@8UPSÃ@G9 Troubleshooting, page 11-64; Replacement, page 11-121 " DIU6F@Ã6DSÃU@HQ@S6UVS@ÃD6UÃT@ITPS Troubleshooting, page 11-66; Replacement, page 11-120 @IBDI@Ã8PPG6IUÃU@HQ@S6UVS@Ã@8UÃT@ITPS Troubleshooting, page 11-62...
  • Page 380 )XHO DQG (PLVVLRQV 3*0), 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ FRQW¶G .* .6 .( .5 .8 .= )2 .4 PRGHOV .1 .0 .< 0$ 3+ ,1 .. PRGHOV " Troubleshooting, page 11-71; Replacement, page 11-119 QSDH6S`ÃC@6U@9ÃPY`B@IÃT@ITPSÃ QSDH6S`ÃCP!TÃT@ITPSÃ  Troubleshooting, page 11-76; Replacement, page 11-122 T@8PI96S`ÃC@6U@9ÃPY`B@IÃT@ITPSÃ...
  • Page 381 3*0), 6\VWHP *: The illustration shows KG, KS, KE, KR models. " *: The illustration shows LHD model Test, page 11-116; Replacement, page 11-117 DIE@8UPST General Troubleshooting Information, page 11-3; Troubleshooting, page 11-101 @IBDI@Ã8PIUSPGÃHP9VG@ÃÃ QPX@SUS6DIÃ8PIUSPG ÃHP9VG@Ã@8HQ8H Troubleshooting, page 11-102 " DI@SUD6ÃTXDU8C Troubleshooting, page 11-94...
  • Page 382 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ '7& 3   0$3 6HQVRU &LUFXLW /RZ 9ROWDJH ,V WKHUH DERXW  9" <HV Repair open in the wire between ECM/PCM  Turn the ignition switch ON (II). (A21) and the MAP sensor.  Check the MAP with the scan tool. 1R Substitute a known-good ECM/PCM and ,V DERXW  N3D  PP+J  LQ+J RU  9 recheck...
  • Page 383 3*0), 6\VWHP '7& 3   0$3 6HQVRU &LUFXLW +LJK 9ROWDJH  Measure voltage between MAP sensor 3P connector terminals No. 1 and No. 3.  Start the engine. Hold the engine at 3,000 rpm (min ) with no load (in Park or neutral) until the H6QÃT@ITPSÃ"QÃ8PII@8UPS radiator fan comes on, then let it idle with no load.
  • Page 384 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   ,$7 6HQVRU &LUFXLW /RZ 9ROWDJH  Check the temperature reading on the scan tool. Be aware that if the engine is warm, the reading will  Turn the ignition switch ON (II). be higher than ambient temperature.
  • Page 385 3*0), 6\VWHP '7& 3   ,$7 6HQVRU &LUFXLW +LJK 9ROWDJH  Check the IAT with the scan tool. ,V ƒ& ƒ) RU OHVV RU //LPLW LQ +RQGD PRGH RI  Turn the ignition switch ON (II). 3*0 7HVWHU RU  9 LQGLFDWHG"  Check the IAT with the scan tool.
  • Page 386 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   (&7 6HQVRU &LUFXLW /RZ 9ROWDJH  Check for continuity between ECT sensor 2P connector terminal No. 1 and body ground.  Turn the ignition switch ON (II).  Check the ECT with the scan tool. @8UÃT@ITPSÃ!QÃ8PII@8UPS ,V ƒ&...
  • Page 387 3*0), 6\VWHP '7& 3   (&7 6HQVRU &LUFXLW +LJK 9ROWDJH  Check the ECT with the scan tool. ,V ƒ& ƒ) RU OHVV RU //LPLW LQ +RQGD PRGH RI  Turn the ignition switch ON (II). 3*0 7HVWHU RU  9 LQGLFDWHG"  Check the ECT with the scan tool.
  • Page 388 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   73 6HQVRU &LUFXLW /RZ 9ROWDJH  At the sensor side, measure resistance between TP sensor 3P connector terminals No. 1 and No. 3  Turn the ignition switch ON(II). with the throttle fully closed.
  • Page 389 3*0), 6\VWHP  At the wire harness side, check for continuity  At the wire harness side, check for continuity between TP sensor 3P connector terminal No. 2 between TP sensor 3P connector terminals No. 2 and body ground. and body ground. UQÃT@ITPSÃ"QÃ8PII@8UPS UQÃT@ITPSÃ"QÃ8PII@8UPS Wire side of female terminals...
  • Page 390 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   73 6HQVRU &LUFXLW +LJK 9ROWDJH  Measure voltage between ECM/PCM connector terminals A10 and A20.  Turn the ignition switch ON (II).  Check the throttle position with the scan tool. @8HQ8HÃ8PII@8UPSÃ6Ã"...
  • Page 391 3*0), 6\VWHP '7& 3   3ULPDU\ +26 6HQVRU  &LUFXLW  Turn the ignition switch OFF. /RZ 9ROWDJH  Disconnect the negative cable from the battery.  Reset the ECM/PCM (see page 11-4)  Disconnect ECM/PCM connector A (31P).  Start the engine. Hold the engine at 3,000 rpm  Check for continuity between primary HO2S (min ) with no load (in Park or neutral) until the...
  • Page 392 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   3ULPDU\ +26 6HQVRU  &LUFXLW  Turn the ignition switch OFF. +LJK 9ROWDJH  Connect ECM/PCM connector terminals A6 and E4  Reset the ECM/PCM (see page 11-4). with a jumper wire.  Start the engine.
  • Page 393 3*0), 6\VWHP '7& 3   3ULPDU\ +26 6HQVRU  6ORZ 5HVSRQVH NOTE: If DTC P0131, P0132 and/or P0135 are stored at the same time as DTC P0133, troubleshoot those DTCs first, then recheck for DTC P0133.  Reset the ECM/PCM (see page 11-4).
  • Page 394 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   3ULPDU\ +26 6HQVRU  +HDWHU  Check for continuity between body ground and &LUFXLW 0DOIXQFWLRQ primary HO2S (Sensor 1) 4P connector terminals No. 3.  Reset the ECM/PCM (see page 11-4).
  • Page 395 3*0), 6\VWHP  Measure voltage between between body ground  Substitute a known-good primary HO2S (Sensor 1) and ECM/PCM connector terminal A1. and recheck. ,V '7& 3 LQGLFDWHG" @8HQ8HÃ8PII@8UPSÃ6Ã" Q <HV Substitute a known-good ECM/PCM and recheck (see page 11-5). If the symptom/ indication goes away with a known-good ECM/PCM, replace the original ECM/PCM.
  • Page 396 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   6HFRQGDU\ +26 6HQVRU   Check for continuity between secondary HO2S &LUFXLW /RZ 9ROWDJH (Sensor 2) 4P connector terminal No. 2 and body ground.  Reset the ECM/PCM (see page 11-4).
  • Page 397 3*0), 6\VWHP '7& 3   6HFRQGDU\ +26 6HQVRU   Check the secondary HO2S (Sensor 2) output &LUFXLW +LJK 9ROWDJH voltage with the scan tool. ,V WKHUH  9 RU PRUH"  Reset the ECM/PCM (see page 11-4). <HV Go to step 9.  Start the engine.
  • Page 398 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   6HFRQGDU\ +26 6HQVRU   Check continuity between body ground and +HDWHU &LUFXLW 0DOIXQFWLRQ secondary HO2S (Sensor 2) 4P connector terminals No. 3 and No. 4 individually.  Reset the ECM/PCM (see page 11-4).
  • Page 399 3*0), 6\VWHP  Check for continuity between ECM/PCM connector  Turn the ignition switch OFF. terminal E6 and body ground.  Reconnect the secondary HO2S (Sensor 2) 4P connector. @8HQ8HÃ8PII@8UPSÃ@Ã" Q  Disconnect the negative cable from the battery.  Disconnect ECM/PCM connector E (31P).  Reconnect the negative cable to the battery.
  • Page 400 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   )XHO 6\VWHP 7RR /HDQ  With a vacuum pump (A), apply vacuum to the evaporative emission (EVAP) canister purge valve '7& 3   )XHO 6\VWHP 7RR 5LFK (B) from the evaporative emission (EVAP) canister side.
  • Page 401 3*0), 6\VWHP '7& 3 [  5DQGRP PLVILUH DQG DQ\ &RPELQDWLRQ RI WKH )ROORZLQJ '7& 3   1R  &\OLQGHU 0LVILUH '7& 3   1R  &\OLQGHU 0LVILUH '7& 3   1R  &\OLQGHU 0LVILUH '7& 3   1R  &\OLQGHU 0LVILUH NOTE: ‡...
  • Page 402 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   1R  &\OLQGHU 0LVILUH  Determine which cylinder(s) had the misfire. 'RHV WKH PLVILUH RFFXU LQ WKH RWKHU F\OLQGHU ZKRVH '7& 3   1R  &\OLQGHU 0LVILUH LJQLWLRQ FRLO ZDV H[FKDQJHG" <HV Replace the faulty ignition coil.
  • Page 403 3*0), 6\VWHP  Test-drive the vehicle several times in the range of  Measure voltage between ignition coil 3P the freeze data or under various conditions if there connector terminal No. 3 and body ground. was no freeze data. DBIDUDPIÃ8PDGÃ"QÃ8PII@8UPSÃ  Check for a DTC or Temporary DTC with the scan Tool.
  • Page 404 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G  Check for continuity between body ground and the  Check for continuity between body ground and the appropriate ECM/PCM connector terminal appropriate ECM/PCM connector terminal (see table). (see table). @8HQ8HÃ8PII@8UPSÃ6Ã" Q @8HQ8HÃ8PII@8UPSÃ6Ã"...
  • Page 405 3*0), 6\VWHP  Measure voltage between body ground and the  Exchange the injector from the problem cylinder appropriate ECM/PCM connector terminal with one from another cylinder. (see table).  Let the engine idle for 2 minutes. @8HQ8HÃ8PII@8UPSÃ7Ã!#Q  Test-drive the vehicle several times in the range of the freeze data or under various conditions if there was no freeze data.
  • Page 406 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G  Measure voltage between injector 2P connector  Connect the appropriate injector 2P connector terminal No. 1 and body ground. terminal No. 2 to body ground with a jumper wire (see table). DIE@8UPSÃ!QÃ8PII@8UPS DIE@8UPSÃ!QÃ8PII@8UPS EVHQ@SÃ...
  • Page 407 3*0), 6\VWHP '7& 3   0DOIXQFWLRQ LQ .QRFN 6HQVRU  Connect starter sub-harness 6P connector terminal &LUFXLW No. 5 to body ground with a jumper wire.  Reset the ECM/PCM (see page 11-4). TU6SU@SÃTV7C6SI@TTÃ%QÃ8PII@8UPS  Start the engine. Hold the engine at 3,000 rpm (min ) with no load (in Park or neutral) until the radiator fan comes on, then let it idle.
  • Page 408 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   &.3 6HQVRU 1R 6LJQDO  Measure voltage between CKP sensor 3P connector terminal No. 1 and body ground. '7& 3   &.3 6HQVRU ,QWHUPLWWHQW ,QWHUUXSWLRQ 8FQÃT@ITPSÃ"QÃ8PII@8UPS  Reset the ECM/PCM (see page 11-4).
  • Page 409 3*0), 6\VWHP  Measure voltage between ECM/PCM connector terminal A7 and body ground. @8HQ8HÃ8PII@8UPSÃ6Ã" Q Wire side of female terminals ,V WKHUH DERXW  9" <HV Repair open in the wire between the ECM/ PCM (A7) and the CKP sensor. 1R Go to step 11.
  • Page 410 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   966 &LUFXLW 0DOIXQFWLRQ  Turn the ignition switch OFF.  Disconnect the negative cable from the battery. '7& 3   966 5DQJH3HUIRUPDQFH 3UREOHP  Disconnect ECM/PCM connector A (31P).  Test-drive the vehicle.
  • Page 411 3*0), 6\VWHP '7& 3   (&03&0 3RZHU 6RXUFH &LUFXLW  Remove the glove box (see page 20-95). 8QH[SHFWHG 9ROWDJH  Remove the PGM-FI main relay 1 (A).  Reset the ECM/PCM (see page 11-4).  Turn the ignition switch OFF.  Wait 5 seconds.
  • Page 412 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G  Measure voltage between ECM/PCM connector  Remove the glove box (see page 20-95). terminal E7 and body ground.  Remove the PGM-FI main relay 1 (A). @8HQ8HÃ8PII@8UPSÃ@Ã" Q Wire side of female terminals ,V WKHUH EDWWHU\ YROWDJH"...
  • Page 413 3*0), 6\VWHP '7& 3   %$52 6HQVRU &LUFXLW /RZ 9ROWDJH '7& 3   %$52 6HQVRU &LUFXLW +LJK 9ROWDJH  Reset the ECM/PCM (see page 11-4).  Turn the ignition switch ON (II). ,V '7& 3 RU 3 LQGLFDWHG" <HV Substitute a known-good ECM/PCM and recheck (see page 11-5).
  • Page 414 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   ,0$ &LUFXLW /RZ 9ROWDJH  At the wire harness side, check for continuity between IMA 3P connector terminal No. 2 and  Reset the ECM/PCM (see page 11-4). body ground.  Start the engine, then let it idle for more than 5 DH6Ã"QÃ8PII@8UPS seconds.
  • Page 415 3*0), 6\VWHP  Measure voltage between ECM/PCM connector '7& 3   ,0$ &LUFXLW +LJK 9ROWDJH terminals E4 and E15.  Reset the ECM/PCM (see page 11-4).  Start the engine, then let it idle for more than 5 @8HQ8HÃ8PII@8UPSÃ@Ã" Q seconds.
  • Page 416 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G  Measure voltage between ECM/PCM connector  At the wire harness side, check for continuity terminals E4 and E5. between IMA 3P connector terminals No. 2 and body ground. @8HQ8HÃ8PII@8UPSÃ@Ã" Q DH6Ã"QÃ8PII@8UPS Wire side of female terminals Wire side of female terminals ,V WKHUH DERXW  9"...
  • Page 417 3*0), 6\VWHP '7& 3   (/' &LUFXLW /RZ 9ROWDJH  Turn the ignition switch OFF.  Reset the ECM/PCM  Disconnect the negative cable from the battery. (see page 11-4).  Start the engine.  Disconnect ECM/PCM connector E (31P).  Turn on the headlights.
  • Page 418 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   (/' &LUFXLW +LJK 9ROWDJH  Turn the ignition switch OFF.  Reset the ECM/PCM  Connect ELD 3P connector terminal No. 3 to body (see page 11-4). ground with a jumper wire.  Start the engine.
  • Page 419 3*0), 6\VWHP  Check for continuity between ELD 3P connector terminal No. 2 and body ground. @G9Ã"QÃ8PII@8UPS Wire side of female terminals ,V WKHUH FRQWLQXLW\" <HV Go to step 14. 1R Repair open in the wire between ELD and G201.  Reconnect the ELD 3P connector and ECM/PCM connector E (31P).
  • Page 420 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   7'& 6HQVRU ,QWHUPLWWHQW  Measure voltage between TDC sensor 3P ,QWHUUXSWLRQ connector terminal No. 1 and body ground. '7& 3   7'& 6HQVRU 1R 6LJQDO U98ÃT@ITPSÃ"QÃ8PII@8UPS  Reset the ECM/PCM (see page 11-4).
  • Page 421 3*0), 6\VWHP  Measure voltage between ECM/PCM connector '7& 3   0DOIXQFWLRQ LQ (&03&0 ,QWHUQDO &LUFXLW terminal A26 and body ground.  Reset the ECM/PCM (see page 11-4). @8HQ8HÃ8PII@8UPSÃ6Ã" Q  Turn the ignition switch ON (II).  Wait 40 seconds. ,V '7&...
  • Page 422 ‡ An intermittent short in the wire between the ECM/ 11-114). PCM (E31) and the gauge assembly.  Check the scan tool/Honda PGM Tester for DTCs. 1R If the MIL is always off, go to step 6. But if the $UH DQ\ '7&V LQGLFDWHG"...
  • Page 423 3*0), 6\VWHP  KG, KS, KE, KR models:  Turn the ignition switch OFF. Turn the ignition switch OFF and press the inertia  Turn the ignition switch ON(II). switch button. ,V WKH ORZ RLO SUHVVXUH OLJKW RQ"  KG, KS, KE, KR models: <HV Go to step 15.
  • Page 424 )XHO DQG (PLVVLRQV 3*0), 6\VWHP 0,/ &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G  Turn the ignition switch OFF. Connect ECM/PCM  Remove the glove box (see page 20-95), PGM-FI connector terminal E31 to body ground with a main relay 1 (A). jumper wire. @8HQ8HÃ8PII@8UPSÃ@Ã"...
  • Page 425 )XHO DQG (PLVVLRQV 3*0), 6\VWHP  Disconnect each of the component or the  Check for continuity between PGM-FI main relay 1 connector sensors below, one at a time, and check 4P connector terminals No. 1 and body ground. for continuity between the PGM-FI main relay 1 4P QBHADÃH6DIÃS@G6`Ã...
  • Page 426 3*0), 6\VWHP 0,/ &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G  Check for continuity between ECM/PCM connector  Check for continuity between ECM/PCM connector terminal E9 and body ground. terminal E9 and body ground. @8HQ8HÃ8PII@8UPSÃ@Ã" Q @8HQ8HÃ8PII@8UPSÃ@ Ã" Q Wire side of female terminals Wire side of female terminals ,V WKHUH FRQWLQXLW\"...
  • Page 427 3*0), 6\VWHP  Check for continuity between fuel pump 5P  Check for continuity between fuel pump 5P connector terminal No. 5 and body ground. connector terminal No. 5 and body ground. AV@GÃQVHQÃ$QÃ8PII@8UPS AV@GÃQVHQÃ$QÃ8PII@8UPS AV@GÃQVHQÃ AV@GÃQVHQÃ `@GBSI `@GBSI Wire side of female terminals Wire side of female terminals ,V WKHUH FRQWLQXLW\"...
  • Page 428 )XHO DQG (PLVVLRQV 3*0), 6\VWHP 0,/ &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G  Measure voltage between ECM/PCM connector  Measure voltage between PGM-FI main relay 1 4P terminal E7 and body ground. connector terminal No. 4 and body ground. QBHADÃH6DIÃS@G6`Ã Ã @8HQ8HÃ8PII@8UPSÃ@Ã" Q #QÃ8PII@8UPS Wire side of female terminals ,V WKHUH EDWWHU\ YROWDJH"...
  • Page 429 3*0), 6\VWHP  Disconnect the negative cable from the battery.  Measure voltage between PGM-FI main relay 1 4P connector terminal No. 2 and body ground.  Reconnect ECM/PCM connector E (31P).  Reconnect the negative cable to the battery. QBHADÃH6DIÃS@G6`Ã...
  • Page 430 )XHO DQG (PLVVLRQV 3*0), 6\VWHP 0,/ &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G  Measure voltage between body ground and ECM/  Turn the ignition switch OFF. PCM connector terminals A4, A5, A23 and A24  Disconnect the 3P connector from each of these individually.
  • Page 431 3*0), 6\VWHP  Check for continuity between ECM/PCM connector  Turn the ignition switch OFF. terminal A21 and body ground.  Disconnect the 3P connector from each of these sensors, one at a time, and measure voltage @8HQ8HÃ8PII@8UPSÃ6Ã" Q between body ground and ECM/PCM connector terminal A20 with the ignition switch ON (II).
  • Page 432 )XHO DQG (PLVVLRQV 3*0), 6\VWHP 0,/ &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G  Check for continuity between ECM/PCM connector  Measure voltage between body ground and ECM/ terminal A20 and body ground. PCM connector terminal E5. @8HQ8HÃ8PII@8UPSÃ6Ã" Q @8HQ8HÃ8PII@8UPSÃ@Ã" Q Wire side of female terminals Wire side of female terminals ,V WKHUH DERXW  9"...
  • Page 433 3*0), 6\VWHP  Turn the ignition switch OFF.  Check for continuity between ECM/PCM connector terminal E29 and body ground.  Turn the ignition switch ON (II).  Measure voltage between ECM/PCM connector @8HQ8HÃ8PII@8UPSÃ@ Ã" Q terminal E29 and body ground. @8HQ8HÃ8PII@8UPSÃ@Ã"...
  • Page 434 )XHO DQG (PLVVLRQV 3*0), 6\VWHP '/& &LUFXLW 7URXEOHVKRRWLQJ  Turn the ignition switch ON (II).  Measure voltage between DLC terminals No. 5 and No. 16.  Measure voltage between data link connector (DLC) terminal No. 16 and body ground. 96U6ÃGDIFÃ8PII@8UPSÃ9G8 96U6ÃGDIFÃ8PII@8UPSÃ9G8 Terminal side of female terminals...
  • Page 435 3*0), 6\VWHP  Disconnect ECM/PCM connector E (31P). Make ,V WKHUH FRQWLQXLW\" sure the Honda PGM Tester is disconnected from <HV Substitute a known-good ECM/PCM, and the DLC. recheck (see page 11-5). If the symptom/  Check for continuity between DLC terminal No. 7 indication goes away with a known-good and body ground.
  • Page 436 )XHO DQG (PLVVLRQV 3*0), 6\VWHP ,QMHFWRU 7HVW  Turn the ignition switch OFF. NOTE: Check the following items before testing: idle speed, ignition timing and idle CO%.  Remove the engine cover.  Try to start the engine.  Remove the injector connector. 'RHV WKH HQJLQH VWDUW"...
  • Page 437 3*0), 6\VWHP ,QMHFWRU 5HSODFHPHQW  Relieve fuel pressure (see page 11-154).  Disconnect the connectors from the injectors (A), ground cable (B).  Disconnect the quick-connect fittings (C).  Remove the fuel rail mounting nuts (D) from the fuel rail (E).  Remove the injector clip (F) from the injector.
  • Page 438 )XHO DQG (PLVVLRQV 3*0), 6\VWHP ,QMHFWRU 5HSODFHPHQW FRQW¶G  Coat the new O-rings (A) with clean engine oil, and insert the injectors (B) into the fuel rail (C). r‘prƒ‡ÃFUÃFQ ÃFXà DIÀ‚qry†  Install the injector clip (D).  Coat the injector O-ring (E) with clean engine oil.  To prevent damage to the O-rings, install the injectors in the fuel rail first, then install them in the injector base (F).
  • Page 439 3*0), 6\VWHP 3ULPDU\ +26 5HSODFHPHQW &.3 6HQVRU 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Disconnect the CKP 3P connector. O2 sensor wrench 07LAA-PT50101  Remove the CKP sensor (A).  Disconnect the primary HO2S 4P connector (A), then remove the primary HO2S (B). .* .6 .( .5 .8 .= )2 .4 PRGHOV  Install the part in the reverse order of removal with a new O-ring (B).
  • Page 440 )XHO DQG (PLVVLRQV 3*0), 6\VWHP (&7 6HQVRU 5HSODFHPHQW 7'& 6HQVRU 5HSODFHPHQW  Remove the air cleaner  Remove the air cleaner (see page 11-182). (see page 11-182).  Disconnect the ECT sensor 2P connector.  Disconnect the TDC sensor 3P connector.  Remove the ECT sensor (A).
  • Page 441 3*0), 6\VWHP ,$7 6HQVRU 5HSODFHPHQW .QRFN 6HQVRU 5HSODFHPHQW  Disconnect the IAT sensor 2P connector.  Remove the splash shield.  Remove the clip (A) and the IAT sensor (B).  Disconnect the knock sensor 1P connector.  Remove the knock sensor (A).  Install the part in the reverse order of removal.
  • Page 442 )XHO DQG (PLVVLRQV 3*0), 6\VWHP 6HFRQGDU\ +26 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG O2 sensor wrench 07LAA-PT50101  Disconnect the secondary HO2S 4P connector (A), then remove the secondary HO2S (B).  Install the secondary HO2S in the reverse order of removal. ...
  • Page 443 97(&97& 97(&97& &RPSRQHQW /RFDWLRQ ,QGH[ " Troubleshooting, page 11-130; Removal/Inspection, page 11-138 WU@8ÃTPG@IPD9ÃW6GW@ Troubleshooting, page 11-128; Replacement, page 11-138 86HTC6AUÃQPTDUDPIÃ8HQÃT@ITPS Troubleshooting, page 11-124; Test, page 11-137 " WU8ÃPDGÃ8PIUSPGÃTPG@IPD9ÃW6GW@ *: The illustration shows LHD model ...
  • Page 444 )XHO DQG (PLVVLRQV 97(&97& '7& 7URXEOHVKRRWLQJ '7& 3   97& 2LO &RQWURO 6ROHQRLG 9DOYH  Measure resistance between VTC oil control 0DOIXQFWLRQ solenoid valve 2P terminal No. 1 and No. 2.  Reset the ECM/PCM (see page 11-4). WU8ÃPDGÃ8PIUSPGÃTPG@IPD9ÃW6GW@Ã!QÃ8PII@8UPS  Start the engine. Hold the engine at 3,000 rpm with no load (in park or neutral) until the radiator fan comes on, then let it idle.
  • Page 445 97(&97&  Check for continuity between ECM/PCM connector  Check for continuity between ECM/PCM connector terminals B1, B23, and body ground. terminals B1 and B23 and body ground individually. @8HQ8HÃ8PII@8UPSÃ7Ã!#Q @8HQ8HÃ8PII@8UPSÃ7Ã!#Q Wire side of female terminals Wire side of female terminals ,V WKHUH FRQWLQXLW\"...
  • Page 446 )XHO DQG (PLVVLRQV 97(&97& '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   97& 6\VWHP 0DOIXQFWLRQ  Check the VTC oil control solenoid valve (see page 11-137).  Reset the ECM/PCM (see page 11-4). ,V WKH 97& RLO FRQWURO VROHQRLG YDOYH 2."  Start the engine. Hold the engine at 3,000 rpm <HV Go to step 10.
  • Page 447 97(&97&  Connect the ECM/PCM connector terminal A3 and B1 with a jumper wire for below 1 minute. NOTE: Do not jump for above 1 minute. @8HQ8HÃ8PII@8UPST EVHQ@SÃXDS@ Wire side of female terminals 'LG WKH HQJLQH VWDOO RU UXQ URXJK" <HV Test-drive at a steady speed between 30 60 km/h (19 37 mph) for 10 minutes.
  • Page 448 )XHO DQG (PLVVLRQV 97(&97& '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   &03 6HQVRU 1R 6LJQDO  Measure voltage between CMP sensor 3P connector terminal No. 1 and body ground. '7& 3   &03 6HQVRU ,QWHUPLWWHQW ,QWHUUXSWLRQ 8HQÃT@ITPSÃ"QÃ8PII@8UPS  Reset the ECM/PCM (see page 11-4).
  • Page 449 97(&97&  Measure voltage between ECM/PCM connector '7& 3   97& 3KDVH *DS terminal A25 and body ground.  Reset the ECM/PCM (see page 11-4).  Start the engine. @8HQ8HÃ8PII@8UPSÃ6Ã" Q ,V '7& 3 LQGLFDWHG" <HV Go to step 3. 1R Intermittent failure, system is OK at this time.
  • Page 450 )XHO DQG (PLVVLRQV 97(&97& '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3   97(& 6\VWHP 0DOIXQFWLRQ  Turn the ignition switch OFF. 6SHFLDO 7RROV 5HTXLUHG  Disconnect the VTEC solenoid valve 2P connector. ‡ Oil Pressure gauge attachment 07NAJ-P070100  Check for resistance between VTEC solenoid valve ‡...
  • Page 451 97(&97&  Connect VTEC solenoid valve 2P connector  Install the special tools as shown. terminal No. 2 to body ground with a jumper wire. WU@8ÃTPG@IPD9ÃW6GW@Ã!QÃ8PII@8UPS EVHQ@SÃ XDS@ Wire side of female terminals  Check for continuity between ECM/PCM connector terminal B15 and body ground.
  • Page 452 )XHO DQG (PLVVLRQV 97(&97& '7& 7URXEOHVKRRWLQJ FRQW¶G  Turn the ignition switch OFF.  Disconnect the VTEC solenoid valve 2P connector.  Attach the battery positive terminal to VTEC solenoid valve 2P connector terminal No. 2. WU@8ÃTPG@IPD9ÃW6GW@Ã!QÃ8PII@8UPS Terminal side of male terminals 76UU@S`  Start the engine, then connect the battery negative...
  • Page 453 97(&97& '7& 3   97(& 6\VWHP 0DOIXQFWLRQ  Disconnect the VTEC oil pressure switch 2P connector. 6SHFLDO 7RROV 5HTXLUHG ‡ Oil Pressure gauge attachment 07NAJ-P070100  Check for continuity on VTEC oil pressure switch ‡ Low pressure gauge 07406-0070001 between the VTEC oil pressure switch 2P ‡...
  • Page 454 )XHO DQG (PLVVLRQV 97(&97& '7& 7URXEOHVKRRWLQJ FRQW¶G  Measure voltage between ECM/PCM connector  Measure voltage between VTEC oil pressure terminal B9 and body ground. switch 2P connector terminals No. 1 and No. 2. @8HQ8HÃ8PII@8UPSÃ7Ã!#Q WU@8ÃPDGÃQS@TTVS@ÃTXDU8CÃC6SI@TTÃ!QÃ8PII@8UPS Wire side of female terminals Wire side of female terminals ,V WKHUH EDWWHU\ YROWDJH"...
  • Page 455 97(&97&  Remove the VTEC oil pressure switch (A) and  Turn the ignition switch OFF. install the special tools as shown, then reinstall the  Disconnect the VTEC solenoid valve 2P connector. VTEC oil pressure switch.  Attach the battery positive terminal to the VTEC solenoid valve 2P connector terminal No.
  • Page 456 )XHO DQG (PLVVLRQV 97(&97& '7& 7URXEOHVKRRWLQJ FRQW¶G  Reconnect the negative cable to the battery.  Connect VTEC solenoid valve 2P connector terminal No. 2 to body ground with a jumper wire.  Disconnect ECM/PCM connector B (24P).  Check for continuity between ECM/PCM connector WU@8ÃTPG@IPD9ÃW6GW@Ã!QÃ8PII@8UPS terminal B15 and body ground.
  • Page 457 97(&97& 97& 2LO &RQWURO 6ROHQRLG 9DOYH 7HVW  Remove the VTC oil control solenoid valve (A).  Connect the battery positive terminal to the VTC oil control solenoid valve 2P connector terminal No. 2. NOTE: Install the part in the reverse order of removal with a new O-ring (B), then check these items: WU8ÃPDGÃ8PIUSPGÃTPG@IPD9ÃW6GW@Ã!QÃ8P II@8UPS ‡...
  • Page 458 )XHO DQG (PLVVLRQV 97(&97& &03 6HQVRU 5HSODFHPHQW 97(& 6ROHQRLG 9DOYH 5HPRYDO,QVSHFWLRQ  Remove the air cleaner  Disconnect the VTEC solenoid valve 2P connector. (see page 11-182).  Disconnect the CMP sensor 3P connector.  KG, KS, KE, KR, KU (Hong Kong) models: Disconnect the VTEC oil pressure switch 2P  Remove the CMP sensor (A).
  • Page 459 ,GOH &RQWURO 6\VWHP ,GOH &RQWURO 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ *: The illustration shows LHD model. Troubleshooting, page 11-145 QPX@SÃTU@@SDIBÃQS@TTVS@ÃQTQÃTXDU8C Troubleshooting, page 11-140 D9G@Ã6DSÃ8PIUSPGÃD68ÃW6GW@ ...
  • Page 460 )XHO DQG (PLVVLRQV ,GOH &RQWURO 6\VWHP '7& 7URXEOHVKRRWLQJ '7& 3   ,$& 9DOYH &LUFXLW 0DOIXQFWLRQ  Check for continuity between body ground and IAC valve 3P connector terminal No. 1.  Reset the ECM/PCM (see page 11-4).  Turn the ignition switch ON (II). D68ÃW6GW@Ã"QÃ8PII@8UPS ,V '7&...
  • Page 461 ,GOH &RQWURO 6\VWHP  Connect IAC valve 3P connector terminal No. 3  Measure voltage between body ground and ECM/ and body ground with a jumper wire. PCM connector terminal A12. D68ÃW6GW@Ã"QÃ8PII@8UPS @8HQ8HÃ8PII@8UPSÃ6Ã" Q EVHQ@SÃXDS@ Wire side of female terminals Wire side of female terminals  Check for continuity between ECM/PCM connector ,V WKHUH EDWWHU\ YROWDJH"...
  • Page 462 )XHO DQG (PLVVLRQV ,GOH &RQWURO 6\VWHP $& 6LJQDO &LUFXLW 7URXEOHVKRRWLQJ  Turn the ignition switch ON (II).  Momentarily connect the under-hood fuse/relay box 14P connector terminal No. 10 to body ground  Momentarily connect ECM/PCM connector with a jumper wire several times. terminals A24 and E18 with a jumper wire several times.
  • Page 463 ,GOH &RQWURO 6\VWHP $OWHUQDWRU )5 6LJQDO &LUFXLW 7URXEOHVKRRWLQJ  Disconnect the alternator 4P connector.  Connect alternator 4P connector terminal No. 4 and body ground with a jumper wire.  Turn the ignition switch ON (II).  Measure voltage between ECM/PCM connector 6GU@SI6UPSÃ#QÃ8PII@8UPS terminals A24 and B13.
  • Page 464 )XHO DQG (PLVVLRQV ,GOH &RQWURO 6\VWHP $OWHUQDWRU )5 6LJQDO &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G  Check for continuity between body ground and ECM/PCM connector terminal B13. @8HQ8HÃ8PII@8UPSÃ6Ã!#Q Wire side of female terminals ,V WKHUH FRQWLQXLW\" <HV Repair short in the wire between the ECM/ PCM (B13) and the alternator.
  • Page 465 ,GOH &RQWURO 6\VWHP 363 6ZLWFK 6LJQDO &LUFXLW 7URXEOHVKRRWLQJ  Turn the ignition switch ON (II).  At the harness side, connect PSP switch 2P connector terminals No. 1 and No. 2 with a jumper  Measure voltage between ECM/PCM connector wire.
  • Page 466 )XHO DQG (PLVVLRQV ,GOH &RQWURO 6\VWHP 363 6ZLWFK 6LJQDO &LUFXLW 7URXEOHVKRRWLQJ %UDNH 3HGDO 3RVLWLRQ 6ZLWFK 6LJQDO &LUFXLW FRQW¶G 7URXEOHVKRRWLQJ  Measure voltage between ECM/PCM connector  Check the brake lights. terminals A24 and E16. $UH WKH EUDNH OLJKWV RQ ZLWKRXW SUHVVLQJ WKH EUDNH SHGDO"...
  • Page 467 ,GOH &RQWURO 6\VWHP  Inspect the No. 7 HORN, STOP (15A) fuse in the under-hood fuse/relay box. ,V WKH IXVH 2." <HV Repair open in the wire between the brake pedal position switch and the No. 7 HORN, STOP (15A) fuse. Inspect the brake pedal position switch (see page 19A-5).
  • Page 468 Symptom Troubleshooting Index.  Reconnect the EVAP canister purge valve 2P connector. NOTE: You can use the scan tool or Honda PGM Tester to inspect idle speed.  Start the engine. Hold the engine at 3,000 rpm...
  • Page 469 )XHO 6XSSO\ 6\VWHP )XHO 6XSSO\ 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ .* .6 .( .5 PRGHOV AV@GÃADGGÃ86Q " AV@GÃS6DG AV@GÃA@@9ÃQDQ@ AV@GÃW6QPSÃQDQ@ Precautions, page 11-160; Removal, page 11-161; Installation, page 11-162 AV@GÃUV7@RVD8F8PII@8UÃADUUDIBT Replacement, page 11-169 AV@GÃU6IF Precautions, page 11-160; Removal, page 11-161; Installation, page 11-162 "...
  • Page 470 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ FRQW¶G .= PRGHO AV@GÃADGGÃ86Q AV@GÃS6DG " AV@GÃW6QPSÃQDQ@ AV@GÃA@@9ÃQDQ@ Precautions, page 11-160; Removal, page 11-161; Installation, page 11-162 AV@GÃUV7@RVD8F8PII@8U ÃADUUDIBT Replacement, page 11-169 AV@GÃU6IF Precautions, page 11-160; Removal, page 11-161; Installation, page 11-162 "...
  • Page 471 )XHO 6XSSO\ 6\VWHP )XHO 3XPS &LUFXLW 7URXEOHVKRRWLQJ  Measure voltage between PGM-FI main relay 2 4P If you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is on, you will hear some connector terminal No.
  • Page 472 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO 3XPS &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G  Reinstall the PGM-FI main relay 2.  Turn the ignition switch OFF.  Reconnect the negative cable to the battery.  Fold the rear seats forward, and pull back the carpet to expose the access panel.
  • Page 473 )XHO 6XSSO\ 6\VWHP  Connect PGM-FI main relay 2 4P connector  Check for continuity between fuel pump 5P terminals No. 1 and No. 2 with a jumper wire. connector terminal No. 4 and body ground. QBHADÃH6DIÃS@G6`Ã!Ã#QÃ8P II@8UPS AV@GÃQVHQÃ$QÃ8PII@8UPS AV@G QVHQ `@GBSI EVHQ@S...
  • Page 474 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO 3UHVVXUH 5HOLHYLQJ )XHO 3UHVVXUH 7HVW 6SHFLDO 7RROV 5HTXLUHG Before disconnecting fuel lines or hoses, release pressure ‡ Fuel pressure gauge 07406-0040002 from the system by loosening the fuel pulsation damper on ‡ Fuel pressure gauge attachment 07VAJ-0040100 top of the fuel rail.
  • Page 475 )XHO 6XSSO\ 6\VWHP  Attach the fuel pressure gauge.  Start the engine and let it idle. ‡ If the engine starts, go to step 11. ‡ If the engine does not start, go to step 10.  Check to see if the fuel pump is running: listen to the fuel fill port with the fuel fill cap removed.
  • Page 476 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO /LQH ,QVSHFWLRQ Check the fuel system lines, hoses, and fuel filter for damage, leaks, and deterioration. Replace any damaged parts. .* .6 .( .5 PRGHOV Make sure the connection is secure and the quick-connect fitting cover is firmly locked into place.
  • Page 477 )XHO 6XSSO\ 6\VWHP .= PRGHO Make sure the connection is secure and the quick-connect fitting cover is firmly locked into place. (cont’d) ...
  • Page 478 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO /LQH ,QVSHFWLRQ FRQW¶G Check all clamps and retighten if necessary. : Do not disconnect the hose from the pipe at these joints. .* .6 .( .5 PRGHOV U‚Ã@W6QPS6UDW@Ã @HDTTDPIÃ@W6QÃ 86IDTU@SÃQVSB@ÃW6GW@ U‚ÃAV@GÃS6DG 76T@ÃB6TF@U Replace. ([FHSW .* .6 .( .5 .= PRGHOV U‚Ã@W6QPS6UDW@Ã...
  • Page 479 )XHO 6XSSO\ 6\VWHP .= PRGHO U‚Ã@W6QPS6UDW@Ã @HDTTDPIÃ@W6QÃ 86IDTU@SÃQVSB@ÃW6GW@ U‚ÃAV@GÃS6DG 76T@ÃB6TF@U Replace. There should be no clearance. When installing the fuel fill tube, align the marks on the tube and the pipe. ...
  • Page 480 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO 7XEH4XLFN&RQQHFW )LWWLQJV 3UHFDXWLRQ ([FHSW .* .6 .( .5 .= PRGHOV The fuel tube/quick-connect fittings connect the fuel rail (A) to fuel feed hose (B), the fuel feed hose (B) to the fuel line (C), and the fuel tube (D) to the fuel tank unit (E) and fuel tube (F) to the fuel filter (G).
  • Page 481 )XHO 6XSSO\ 6\VWHP )XHO 7XEH4XLFN&RQQHFW )LWWLQJV 5HPRYDO .= PRGHO  Relieve the fuel pressure (see page 11-154).  Check the fuel quick-connect fitting for dirt, and clean if necessary.  Hold the connector (A) with one hand and squeeze the retainer tabs (B) with the other hand to release them from the locking pawls (C).
  • Page 482 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO 7XEH4XLFN&RQQHFW )LWWLQJV 5HPRYDO )XHO 7XEH4XLFN&RQQHFW )LWWLQJV FRQW¶G ,QVWDOODWLRQ  Check the contact area (A) of the pipe (B) for dirt  Check the contact area (A) of the pipe (B) for dirt and damage. and damage, and clean if necessary.
  • Page 483 )XHO 6XSSO\ 6\VWHP  Before connecting a new fuel tube/quick-connect ([FHSW .* .6 .( .5 .= PRGHOV fitting assembly (A), remove the old retainer (B) from the mating pipe. .= PRGHO .* .6 .( .5 PRGHOV 3+ )2 ,1 0$ PRGHOV (cont’d) ...
  • Page 484 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO 7XEH4XLFN&RQQHFW )LWWLQJV ,QVWDOODWLRQ FRQW¶G .= PRGHO  Make sure the connection is secure and that the pawls are firmly locked into place; check visually and by pulling the connector.  Reconnect the negative cable to the battery, and  Align the quick-connect fittings with the pipe (A), turn the ignition switch ON (II).
  • Page 485 )XHO 6XSSO\ 6\VWHP )XHO 3UHVVXUH 5HJXODWRU 5HSODFHPHQW ([FHSW .= PRGHO .= PRGHO  Remove the fuel pump  Remove the fuel pump (see page 11-167). (see page 11-167).  Remove the clip (A).  Remove the bracket (A).  Remove the fuel pressure regulator (B).  Install the part in the reverse order of removal with new O-rings (C).
  • Page 486 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO )LOWHU 5HSODFHPHQW ([FHSW .* .6 .( .5 PRGHOV The fuel filter should be replaced whenever the fuel pressure drops below the specified value (330  380 kPa  Relieve fuel pressure (see page 11-154).
  • Page 487 )XHO 6XSSO\ 6\VWHP )XHO 3XPS)XHO *DXJH 6HQGLQJ 8QLW 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Remove the locknut (A) and the fuel pump Adjustable ring wrench 07WAA-0010100 assembly. ([FHSW .= PRGHO  Relieve the fuel pressure (see page 11-154).  Remove the fuel fill cap.  Fold the rear seats forward, and pull back the carpet to expose the access panel.
  • Page 488 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO 3XPS)XHO *DXJH 6HQGLQJ 8QLW 5HSODFHPHQW FRQW¶G .= PRGHO  Remove the strainer case (A), the fuel gauge sending unit (B), the wire harness (C).  Relieve the fuel pressure (see page 11-154).  Remove the fuel fill cap.  Fold the rear seats forward, and pull back the carpet to expose the access panel.
  • Page 489 )XHO 6XSSO\ 6\VWHP )XHO 7DQN 5HSODFHPHQW ([FHSW .= PRGHO  Drain the fuel tank: Remove the fuel pump assembly (see page 11-167). Using a hand pump, hose and container suitable for gasoline, draw the fuel from the fuel tank.  Jack up the vehicle, and support it with jackstands.  4WD model: Remove the propeller shaft (see page...
  • Page 490 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO 7DQN 5HSODFHPHQW FRQW¶G ([FHSW .* .6 .( .5 PRGHOV  Loosen the Evaporative Emission (EVAP) canister bracket bolt.  Remove the fuel tank guard (B).  Loosen the clamp (C).  Disconnect the fuel vapor hose (D), hoses (E) and wire stay bolts (F). Slide back the clamps, then twist the hoses as you pull to avoid damaging them.
  • Page 491 )XHO 6XSSO\ 6\VWHP .= PRGHO  Relieve the fuel pressure (see page 11-154).  Fold the rear seats forward, and pull back the carpet to expose the access panel.  Remove the access panel, disconnect the quick connect fittings from the fuel pump.  Jack up the vehicle, and support it with jackstands.
  • Page 492 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO 7DQN 5HSODFHPHQW FRQW¶G  Loosen the Evaporative Emission (EVAP) canister bracket bolt.  Remove the fuel tank guard (C).  Loosen the clamp (D).  Disconnect the fuel vapor hose (E) and hoses (F) and wire stay bolts (G). Slide back the clamps, then twist the hoses as you pull to avoid damaging them.
  • Page 493 )XHO 6XSSO\ 6\VWHP )XHO *DXJH 6HQGLQJ 8QLW 7HVW 6SHFLDO 7RROV 5HTXLUHG  Measure voltage between the fuel pump 5P Adjustable ring wrench 07WAA-0010100 connector terminals No. 1 and No. 2 with the ignition switch ON (II). There should be battery NOTE: For the fuel gauge system circuit diagram, refer to voltage.
  • Page 494 )XHO DQG (PLVVLRQV )XHO 6XSSO\ 6\VWHP )XHO *DXJH 6HQGLQJ 8QLW 7HVW FRQW¶G  Check that the pointer of the fuel gauge indicates  Measure the resistance between the No. 1 and ’’F’’. No. 2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions.
  • Page 495 )XHO 6XSSO\ 6\VWHP /RZ )XHO ,QGLFDWRU /LJKW 7HVW  Do the fuel gauge sending unit test (see page 11- 173). ‡ If the system is OK, go to step 2. ‡ If the system has any malfunction, repair it.  Turn the ignition switch OFF. Remove the No. 9 BACK UP (10A) fuse from the under-hood fuse/ relay box for at least 30 seconds, then reinstall it.
  • Page 496 )XHO DQG (PLVVLRQV ,QWDNH $LU 6\VWHP ,QWDNH $LU 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ " *: The illustration shows LHD model. Adjustment, page 11-183; Removal/Installation, page 11-184 UCSPUUG@Ã867G@ Replacement, page 11-182 6DSÃ8G@6I@S Replacement, page 11-182 6DSÃ8G@6I@SÃ@G@H@IU Test, page 11-181 " DIU6F@Ã6DSÃ7`Q6TTÃ8PIUSPGÃUC@SH6GÃW6GW@ Test, page 11-180;...
  • Page 497 ,QWDNH $LU 6\VWHP ,05& 6\VWHP 7URXEOHVKRRWLQJ  Start the engine and allow it to idle.  Disconnect the lower vacuum hose (A) from IMRC solenoid valve (B), and connect the vacuum pump/  Disconnect the vacuum hose (A) from Intake gauge (C) to the hose.
  • Page 498 )XHO DQG (PLVVLRQV ,QWDNH $LU 6\VWHP ,05& 6\VWHP 7URXEOHVKRRWLQJ FRQW¶G  Turn the ignition switch OFF.  Raise engie speed to 5,000 rpm (min ), then measure voltage between IMRC solenoid valve 2P  Disconnect the negative cable from the battery. connector terminal No.
  • Page 499 ,QWDNH $LU 6\VWHP  Turn the ignition switch OFF.  Connect the vacuum pump/gauge (A) to the IMRC actuator (B), then apply vacuum.  Disconnect the negative cable from the battery.  Disconnect ECM/PCM connector B (24P).  Connect IMRC solenoid valve 2P connector terminal No.
  • Page 500 ‡ If the throttle valve and shaft are OK, go to step 3.  Connect the scan tool/Honda PGM Tester to the Data Link Connector (DLC).  Turn the ignition switch ON (II).
  • Page 501 ,QWDNH $LU 6\VWHP ,QWDNH $LU %\SDVV &RQWURO 7KHUPDO 9DOYH 7HVW  Start the engine. Then let it idle.  Raise and lower the engine speed, and make sure the vacuum gauge reading does not change as the NOTE: The engine coolant temperature must be rpm changes.
  • Page 502 )XHO DQG (PLVVLRQV ,QWDNH $LU 6\VWHP $LU &OHDQHU 5HSODFHPHQW $LU &OHDQHU (OHPHQW 5HSODFHPHQW  Remove the clamp (A), the nuts (B), and the bolts  Disconnect the PCV hose (A). Open the air cleaner (C). housing cover (B).  Remove the air cleaner (D).  Remove the air cleaner (C) from the air clenaer housing (D).
  • Page 503 ,QWDNH $LU 6\VWHP 7KURWWOH &DEOH $GMXVWPHQW  Remove the throttle linkage cover grommet (A).  If the deflection is not within spec (10 12 mm, 3/8 1/2 in.), remove the throttle linkage cover (A).  Check cable free play at the throttle linkage. Cable  Loosen the locknut (A), turn the adjusting nut (B) deflection (A) should be 10 12 mm (3/8...
  • Page 504 )XHO DQG (PLVVLRQV ,QWDNH $LU 6\VWHP 7KURWWOH &DEOH 5HPRYDO,QVWDOODWLRQ  Remove the throttle linkage cover (A).  Remove the throttle cable (A) from the accelerator pedal (B).  Fully open the throttle valve, then remove the throttle cable (A) from the throttle link (B).  Install in the reverse order of removal.
  • Page 505 ,QWDNH $LU 6\VWHP 7KURWWOH %RG\ 5HPRYDO,QVWDOODWLRQ NOTE: ‡ Do not adjust the throttle stop screw. ‡ After reassembly, adjust the throttle cable (see page 11-183). ‡ The Throttle Position (TP) sensor is not removable. UCSPUUG@ÃQPTDUDPIÃUQÃT@ITPS UCSPUUG@Ã GDIF6B@Ã H6IDAPG9Ã67TPGVU@Ã 8PW@S QS@TTVS@ÃH6QÃ T@ITPS B6TF@U Replace.
  • Page 506 )XHO DQG (PLVVLRQV ,QWDNH $LU 6\VWHP 7KURWWOH %RG\ 'LVDVVHPEO\5HDVVHPEO\ H6QÃT@ITPS @W6QÃ86IDTU@SÃ QVSB@ÃW6GW@ PSDIB Replace. UQÃT@ITPS UCSPUUG@Ã7P9` PSDIB Replace. D68ÃW6GW@ ...
  • Page 507 ,QWDNH $LU 6\VWHP ,05& 9DOYH 5HSODFHPHQW  Remove the intake manifold  Turn the IMRC actuator assembly (A), and set the (see page 09-2). bolt holes.  Disconnect the vacuum hose (A). NOTE: When turning the IMRC actuator assembly, make sure the stopper (B) and groove (C) are fit.  Remove the bolts (B).
  • Page 508 )XHO DQG (PLVVLRQV &DWDO\WLF &RQYHUWHU 6\VWHP &DWDO\WLF &RQYHUWHU 6\VWHP '7& 7URXEOHVKRRWLQJ &DWDO\WLF &RQYHUWHU ,QVSHFWLRQ '7& 3   &DWDO\WLF 6\VWHP (IILFLHQF\ If excessive exhaust system back-pressure is suspected, %HORZ 7KUHVKROG remove the TWC from the vehicle. Using a flashlight (A) and plug (B) (KG, KS, KE, KR, KU, KZ, FO, KQ models) make a visual check for plugging, NOTE: If some of the DTCs listed below are stored at the melting or cracking of the catalyst.
  • Page 509 &DWDO\WLF &RQYHUWHU 6\VWHP 7DLOSLSH (PLVVLRQV 7HVW  Connect a tachometer.  Start the engine. Hold the engine at 3,000 rpm (min ) with no load (in Park or neutral) until the radiator fan comes on, then let it idle.  Check the idle speed (see page 11-148).
  • Page 510 )XHO DQG (PLVVLRQV 3&9 6\VWHP 3&9 6\VWHP 3&9 9DOYH ,QVSHFWLRQ DQG 7HVW  Check the PCV valve (A), hoses (B) and connections for leaks or restrictions.  At idle, make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake manifold is lightly pinched (A) with your fingers or pliers.
  • Page 511 (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ *: The illustration shows LHD model. Troubleshooting, (see page 11-193) @W6QPS6UDW@Ã@HDTTDPIÃ@W6QÃ86IDTU@SÃQVSB@ÃW6GW@ .* .6 .( .5 PRGHOV Test, page 11-198 @W6QPS6UDW@Ã@HDTTDPIÃ@W6QÃUXPÃX6`ÃW6GW@ Troubleshooting, page 11-195; Replacement, page 11-199 @W6QPS6UDW@Ã@HDTTDPIÃ@W6QÃ86IDTU@S (cont’d) ...
  • Page 512 )XHO DQG (PLVVLRQV (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ FRQW¶G ([FHSW .* .6 .( .5 .= PRGHOV Test, page 11-198 @W6QPS6UDW@Ã@HDTTDPIÃ@W6QÃUXPÃX6`ÃW6GW@ Troubleshooting, page 11-195; Replacement, page 11-199 @W6QPS6UDW@Ã@HDTTDPIÃ@W6QÃ86IDTU@S .= PRGHO Test, page 11-198 @W6QPS6UDW@Ã@HDTTDPIÃ@W6QÃUXPÃX6`ÃW6GW@ Troubleshooting, page 11-195; Replacement, page 11-199 @W6QPS6UDW@Ã@HDTTDPIÃ@W6QÃ86IDTU@S ...
  • Page 513 (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP '7& 7URXEOHVKRRWLQJ '7& 3   $ HOHFWULFDO SUREOHP LQ WKH (9$3  Check for continuity between EVAP canister purge &DQLVWHU 3XUJH 9DOYH FLUFXLW valve 2P connector terminal No. 2 and body ground.  Reset the ECM/PCM (see page 11-4).
  • Page 514 )XHO DQG (PLVVLRQV (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP '7& 7URXEOHVKRRWLQJ FRQW¶G  Turn the ignition switch OFF.  Measure voltage between ECM/PCM connector terminals A5 and B21.  Disconnect the EVAP canister purge valve 2P connector. @8HQ8HÃ8PII@8UPST  Turn the ignition switch ON (II).  At the hamess side, measure voltage between EVAP canister purge valve 2P connector terminal No.
  • Page 515 (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP (YDSRUDWLYH (PLVVLRQ (9$3 6\VWHP 7URXEOHVKRRWLQJ  Disconnect the vacuum hose (A) from the EVAP  Disconnect the purge air hose (A) from the EVAP canister (B) and connect a vacuum pump/gauge canister and connect a vacuum pressure gauge 0 - (C) to the hose.
  • Page 516 )XHO DQG (PLVVLRQV (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP (YDSRUDWLYH (PLVVLRQ (9$3 6\VWHP 7URXEOHVKRRWLQJ FRQW¶G  Inspect the No. 4 ACG (10A) fuse in the under-  Check for continuity between EVAP canister purge dash fuse/relay box. valve 2P connector terminal No. 2 and body ground.
  • Page 517 (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP  Turn the ignition switch ON (II).  Measure voltage between ECM/PCM connector terminal B21 and body ground.  At the harness side, measure voltage between EVAP canister purge valve 2P connector terminals @8HQ8HÃ8PII@8UPSÃ7Ã!#Q No. 1 and No. 2. @W6QÃ86IDTU@SÃQVSB@ÃW6GW@Ã!QÃ8PII@8UPS Wire side of female terminals Wire side of female terminals...
  • Page 518 )XHO DQG (PLVVLRQV (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP (9$3 7ZR :D\ 9DOYH 7HVW  Remove the fuel cap.  Move the vacuum pump hose from the vacuum fitting to the pressure fitting, and move the vacuum  Disconnect the vapor line from the EVAP two way gauge hose from the vacuum side to the pressure valve (A).
  • Page 519 (YDSRUDWLYH (PLVVLRQ &RQWURO 6\VWHP (9$3 &DQLVWHU 5HSODFHPHQW  Remove the vacuum hoses (A) and drain hose (B).  Remove the bolt (D).  Remove the cover (C).  Remove the EVAP canister (E).  Install the parts in the reverse order of removal. ([FHSW .= PRGHO .= PRGHO ...
  • Page 521 &OXWFK TƒrpvhyÃU‚‚y†  8‚€ƒ‚r‡ÃG‚ph‡v‚ÃDqr‘   !" 8yˆ‡puÃQrqhyÃhqÃ8yˆ‡puÃQrqhyÃQ‚†v‡v‚ÃTv‡puÃ6qwˆ†‡€r‡   8yˆ‡puÃHh†‡r…Ã8’yvqr…ÃSrƒyhpr€r‡   8yˆ‡puÃHh†‡r…Ã8’yvqr…ÃP‰r…uhˆy   Tyh‰rÃ8’yvqr…ÃSrƒyhpr€r‡   Tyh‰rÃ8’yvqr…ÃP‰r…uhˆy   !  8yˆ‡puÃSrƒyhpr€r‡  ...
  • Page 522 &OXWFK 6SHFLDO 7RROV 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07LAB-PV00100 or 07924-PD20003 Ring Gear Holder 07PAF-0020000 Clutch Alignment Tool Set ...
  • Page 523 &RPSRQHQW /RFDWLRQ ,QGH[ &RPSRQHQW /RFDWLRQ ,QGH[ S@T@SWPDS S@T@SWPDSÃCPT@ GP8FÃQDI PSDIB Q@96GÃQDI Replace. S@U6DIDIBÃ8GDQ " Replace. HUÃ6TT@H7G` & 8GVU8CÃCPT@Ã8GDQ PSDIB Replace. SPGGÃQDI 8GVU8CÃCPT@ Adjustment, page 12-4 8GVU8CÃQ@96GÃQPTDUDPIÃTXDU8C Adjustment, page 12-4 8GVU8CÃQ@96G Replacement, page 12-5; Overhaul, page 12-6 " 8GVU8CÃH6TU@SÃ8`GDI9@S Removal, page 12-11;...
  • Page 524 &OXWFK &OXWFK 3HGDO DQG &OXWFK 3HGDO 3RVLWLRQ 6ZLWFK $GMXVWPHQW &OXWFK 3HGDO DQG &OXWFK 3HGDO 3RVLWLRQ 6ZLWFK $GMXVWPHQW  Tighten locknut (D). NOTE: ‡ To check the clutch pedal position switch (see page 04-  With the clutch pedal released, turn the clutch 49).
  • Page 525 &OXWFK 0DVWHU &\OLQGHU 5HSODFHPHQW &OXWFK 0DVWHU &\OLQGHU 5HSODFHPHQW  Remove the clutch master cylinder (A). NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.  Remove the brake fluid from the clutch master cylinder reservoir with a syringe.
  • Page 526 &OXWFK &OXWFK 0DVWHU &\OLQGHU 2YHUKDXO &OXWFK 0DVWHU &\OLQGHU 2YHUKDXO ([SORGHG YLHZ NOTE: ‡ When attaching the reservoir hose, align the yellow mark on the hose to the rib on reservoir connection area. ‡ When attaching the reservoir hose, align the blue mark on the hose to rip on the clutch master cylinder connection area. Clip catches shall be on arrow marked side Clip catches shall be on...
  • Page 527 &OXWFK 0DVWHU &\OLQGHU 2YHUKDXO  Slide the piston assembly into the clutch master NOTE: ‡ Refer to the Exploded View, as needed during this cylinder. procedure. ‡ Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.
  • Page 528 &OXWFK 6ODYH &\OLQGHU 5HSODFHPHQW 6ODYH &\OLQGHU 5HSODFHPHQW  Remove the mounting bolts (A) and the slave NOTE: ‡ Use fender covers to avoid damaging painted surfaces. cylinder (B). ‡ Do not spill brake fluid on the vehicle; it may damage the paint;...
  • Page 529 ‡ Refill the clutch master cylinder with fluid when done. ‡ Always use only Genuine Honda DOT 3 or 4 brake fluid.  Install the clutch line bracket and battery tray.  Install the intake air duct (see step 38 on page 05- 16).
  • Page 530 &OXWFK 6ODYH &\OLQGHU 2YHUKDXO 6ODYH &\OLQGHU 2YHUKDXO TG6W@Ã8`GDI9@SÃ7P9` Check the cylinder wall for 7G@@9@SÃT8S@X scoring and wear. 'ÃI ‡ €Ã'Ãxts ‡ €Ã$'Ãyis ‡ s‡ PSDIB Replace. 7G@@9@SÃT8S@Xà 7…hxrÃ6††r€iy’ÃGˆir SPGGÃQDIT QDTUPIÃ8VQ Replace. Replace. TG6W@Ã8`GDI9@SÃTQSDIB Install with small end facing piston. TG6W@Ã8`GDI9@SÃQ DTUPI Check for wear and damage.
  • Page 531 &OXWFK 5HSODFHPHQW &OXWFK 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Install the special tools. ‡ Clutch alignment tool set 07PAF-0020000 ‡ Ring gear holder 07LAB-PV00100 or 07924-PD20003 3UHVVXUH 3ODWH DQG &OXWFK 'LVF 5HPRYDO  Check the diaphragm spring fingers for height using the dial indicater (A). If the height is more than the service limit, replace the pressure plate.
  • Page 532 &OXWFK &OXWFK 5HSODFHPHQW &OXWFK 5HSODFHPHQW FRQW¶G 3UHVVXUH 3ODWH DQG &OXWFK 'LVF 5HPRYDO FRQW¶G  Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch  Inspect for warpage using a straight edge (A) and disc.
  • Page 533 &OXWFK 5HSODFHPHQW )O\ZKHHO ,QVSHFWLRQ )O\ZKHHO 5HSODFHPHQW  Inspect the ring gear teeth for wear and damage.  Install the special tool.  Inspect the clutch disc mating surface on the flywheel for wear, cracks and burning.  Measure the flywheel (A) runout using a dial indicator (B) through at least two full turns with the engine installed.
  • Page 534 &OXWFK &OXWFK 5HSODFHPHQW &OXWFK 5HSODFHPHQW FRQW¶G &OXWFK 'LVF DQG 3UHVVXUH 3ODWH ,QVWDOODWLRQ  Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent  Install the ring gear holder. warping the diaphragm spring. QS@TTVS@ÃQG6U@ÃHPVIUDIBÃ7PGUÃUPSRV@)à !$ÃI‡€Ã!%Ãxts ‡...
  • Page 535 &OXWFK 5HSODFHPHQW 5HOHDVH %HDULQJ 5HSODFHPHQW  Apply Urea Grease UM264 (P/N 41211-PY5-305) to the release fork (A), the release fork bolt (B), the  Remove the release fork boot (A) from the clutch release bearing (C), and the release bearing guide housing (B).
  • Page 537 07  07 'LIIHUHQWLDO HhˆhyÃU…h†€v††v‚   "! 4WD (Four-wheel Drive) Model Precautions......................13-2 Special Tools ................................13-3 Transmission Fluid Inspection and Replacement....................... 13-4 Back-Up Light Switch Test ............................13-4 Transmission Removal............................... 13-5 Transmission Installation............................13-10 Transmission Disassembly............................13-15 Reverse Shift Fork Clearance Inspection......................... 13-21 Shift Lever Clearance Inspection ..........................
  • Page 538 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 0DQXDO 7UDQVPLVVLRQ :' )RXUZKHHO 'ULYH 0RGHO 3UHFDXWLRQV 7HVWLQJ 3URFHGXUHV  Set the free rollers according to the wheel base and This 4WD model does not have the feature that tread of the vehicle. mechanically switches between 4WD and 2WD (front- wheel drive).
  • Page 539 0DQXDO 7UDQVPLVVLRQ 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07GAJ-PG20110 Mainshaft Holder 07GAJ-PG20130 Mainshaft Base 07JAC-PH80100 Adjustable Bearing Puller, 20 - 40 mm " 07JAC-PH80200 Bearing Remover Shaft 07JAD-PH80101 Oil Seal Driver Attachment 07JAD-PL90100 Oil Seal Driver 07JAF-SJ80110 Installer Shaft 14 x 165 mm &...
  • Page 540 'Ãy€ƒÃ„‡Ãh‡Ã‚‰r…uhˆy #X9À‚qry) (à Ã!ÃVTćà &Ãy€ƒÃ„‡Ãh‡ÃsyˆvqÃpuhtr !"à Ã!#ÃVTćÃ!Ãy€ƒÃ„‡Ãh‡Ã‚‰r…uhˆy Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the proper additives.  Reinstall the oil filler plug with a new washer. ...
  • Page 541 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HPRYDO  Remove the cable bracket (A), then disconnect the NOTE: Use fender covers to avoid damaging painted surfaces. cables (B) from the top of the transmission housing. Carefully remove both cables and the bracket  Write down the frequencies for the radio’s preset together so as not to bend the cables.
  • Page 542 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HPRYDO FRQW¶G  Remove the harness cover (A), water pipe  Remove the transmission mount bracket (A) and mounting bolts (B), and loosen the air cleaner transmission mounting bolt (B). housing mounting bracket bolt (C). Lower the water pipe slightly.
  • Page 543 0DQXDO 7UDQVPLVVLRQ  Remove the driveshafts  Support the subframe with a 4 x 4 x 40 in. piece of (see page 16-3). wood and a jack.  Remove the intermediate shaft (see page 16-19).  For 4WD models, remove the propeiler shaft (see page 16-33).
  • Page 544 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HPRYDO FRQW¶G  Remove the clutch cover.  Remove the harness clamp (A).  Remove the front engine mount (B).  O PRGHO  Place the transmission jack under the transmission  O PRGHO and remove the four lower transmission mounting bolts.
  • Page 545 0DQXDO 7UDQVPLVVLRQ  Remove the two lower transmission mounting  Remove the boot (A), the release fork (B), and the bolts. release bearing (C) from the transmission (D).  Pull the transmission away from the engine until the transmission mainshaft clears the clutch pressure plate, then lower the transmission on the transmission jack.
  • Page 546 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ ,QVWDOODWLRQ  Check the two dowel pins are installed in the clutch  Install the two lower transmission mounting bolts. housing.  Apply Urea Grease UM264 (P/N 41211-PY5-305) to the release fork (A) and the release bearing (B). Install the release fork and the release bearing.
  • Page 547 0DQXDO 7UDQVPLVVLRQ  Install the front engine mount (A).  O PRGHO  Install the harness clamp (B).  Install the clutch cover.  O PRGHO  Support the subframe with a 4 x 4 x 40 in. piece of wood and a jack.
  • Page 548 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ ,QVWDOODWLRQ FRQW¶G  Install the front suspension subframe (A) in its  Loosely tighten the front engine mount bracket original position by aligning the marks (B) you mounting bolt. made in the removal procedure.  Install the intermediate shaft (see page 16-23).
  • Page 549 0DQXDO 7UDQVPLVVLRQ  Loosen the front engine mount bracket mounting  Install the two upper transmission mounting bolts. bolt, then tighten the front engine mount bracket mounting bolt.  Install the splash shield.  Remove the chain hoist.  Install the air cleaner housing mounting bracket bolt (A), water pipe mounting bolts (B), harness cover (C).
  • Page 550 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ ,QVWDOODWLRQ FRQW¶G  Apply Urea Grease UM264 (P/N 41211-PY5-305)  Install the transmission ground cable (A). to the end of the cylinder rod. Install the slave cylinder. Take care not to bend the clutch line.  Install the cable bracket (A) and cables (B).
  • Page 551 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 'LVDVVHPEO\ ([SORGHG 9LHZ&OXWFK +RXVLQJ :' PRGHO & " & !& " " !" " 9DAA@S@IUD6GÃ6TT@H7G` # ÑÃ!À€Ã9PX@GÃQDI !" S@W@ST@ÃGP8FÃ86H À€ÃAG6IB@Ã7PGU " H6BI@U " $ÑÃ$'ÑÃ'À€ÃPDGà T@6G Replace. ##ÃIÀÃ#$ÃxtsÀÃ""ÃyisÃs‡ " US6ITA@SÃ6TT@H7G` H6DITC6AUÃ6TT@H7G` 768FVQÃGDBCUÃTXDU8C !(ÃIÀÃ"ÃxtsÀÃ!!ÃyisÃs‡ PSDIB !'À€ÃX6TC@S PSDIB Replace. Replace. ÑÃ!À€Ã9PX@GÃQDI !'À€Ã...
  • Page 552 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 'LVDVVHPEO\ FRQW¶G ([SORGHG 9LHZ&OXWFK +RXVLQJ FRQW¶G :' PRGHO " & & !& " !" " 9DAA@S@IUD6GÃ6TT@H7G` #à ‘Ã!À€Ã9PX@GÃQDI S@W @ST@ÃTC6AUÃAPSF À€ÃAG6IB@Ã7PGU H6BI@U S@W@ST@ÃGP8FÃ86H ##ÃIÀÃ#$ÃxtsÀÃ""ÃyisÃs‡ " TD9@Ã8PW@S " H6DITC6AUÃ6TT@H7G` !" "$ ÑÃ$'ÑÃ'À€ÃPDGÃT@6G Replace. PSDIB !'À€ÃX6TC@S 768FVQ ÃGDBCUÃTXDU8C Replace.
  • Page 553 0DQXDO 7UDQVPLVVLRQ ([SORGHG 9LHZ7UDQVPLVVLRQ +RXVLQJ !" " & & & & " US6ITHDTTDPIÃCPVTDIB 'À€ÃTCDH 8GVU8CÃGDI@Ã8GDQÃ7S68F@U À€ÃX6TC@S 'Ñà #À€Ã9PX@GÃQDI !À€ÃX 6TC@S Replace. Replace. " Ñà !$À€ÃAG6IB@Ã7PGU 8C6IB@ÃG@W@SÃ6TT@H7G` ADGG@SÃQGVB ##ÃIÀÃ#$ÃxtsÀÃ""ÃyisÃs‡ ##ÃIÀÃ#$ÃxtsÀÃ""ÃyisÃs‡ 'Ñà !$À€ÃAG6IB@Ã7PGU " %Ñà À€ÃAG6IB@Ã7PGU #ÑÃ$%ÑÃ'À€ÃPDGà T@6G Replace. !&ÃIÀÃ!'ÃxtsÀÃ!ÃyisÃs‡ !ÃIÀà !ÃxtsÀÃ(ÃyisÃs‡ US6ITHDTTDPIÃC6IB@SÃ6 9@U@IUÃ7PGU !"...
  • Page 554 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 'LVDVVHPEO\ FRQW¶G  Remove the detent bolts (A), springs, steel balls NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the and back-up light switch (B). workbench.
  • Page 555 0DQXDO 7UDQVPLVVLRQ  Remove the change lever assembly (A), 8 x 14 mm  Remove the 8 mm flange bolts in a crisscross dowel pins (B), clutch line clip bracket (C) and pattern in several steps. interlock bolt (D).  Remove the transmission hanger A and transmisson hanger B.
  • Page 556 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 'LVDVVHPEO\ FRQW¶G  Remove the reverse lock cam.  Remove the reverse shift fork.  Apply tape to the mainshaft splines to protect the  Remove the reverse idler gear (A) and reverse seal, then remove the mainshaft assembly (A) and gear shaft (B).
  • Page 557 0DQXDO 7UDQVPLVVLRQ 5HYHUVH 6KLIW )RUN &OHDUDQFH ,QVSHFWLRQ  Remove the differential assembly (A) and magnet  Measure the clearance between the reverse idler (B). gear (A) and the reverse shift fork (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2.
  • Page 558 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 6KLIW /HYHU &OHDUDQFH ,QVSHFWLRQ  Measure the clearance between shift lever (A) and the select lever (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step T‡hqh…q) $ÃÃ!$À€Ã!Ãà Ãv...
  • Page 559 0DQXDO 7UDQVPLVVLRQ &KDQJH /HYHU $VVHPEO\ 'LVDVVHPEO\5HDVVHPEO\ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricate to any contact surface. 7S@6UC@SÃ86Q Turn the toward the rear of the vehicle, and install it. T@G@8UÃG@W@S Be careful not to damage the dust seal when installing it. 9VTUÃT@6G Replace.
  • Page 560 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 6KLIW )RUNV &OHDUDQFH ,QVSHFWLRQ  Measure the clearance between the shift fork (A) NOTE: The synchro sleeve and synchro hub should be replaced as a set. and the shift arm (B). If the clearance exceeds the service limit, go to step 4.
  • Page 561 0DQXDO 7UDQVPLVVLRQ 6KLIW )RUNV 'LVDVVHPEO\5HDVVHPEO\ Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. "#ÃTCDAUÃAPSF $UCÃTCDAUÃAPSF !ÃTCDAUÃAPSF $SÃTCDAUÃQD@8@ $ÑÃ!$À€ÃTQSDIBÃQDI Replace. QDIÃ9SDW@SÃ$€€ ...
  • Page 562 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW $VVHPEO\ &OHDUDQFH ,QVSHFWLRQ  Measure the clearance between 4th gear (A) and NOTE: If replacement is required, always replace the synchro sleeve and hub as a set. the spacer collar (B) with a dial indicator (C). If the clearance is more than the service limit, go to step  Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft...
  • Page 563 0DQXDO 7UDQVPLVVLRQ  Measure the thickness of 4th gear.  Measure distance b on the distance collar. ‡ If the thickness of 4th gear is less than the service ‡ If distance [b] is not within the standard, replace the limit, replace 4th gear with a new one.
  • Page 564 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW $VVHPEO\ &OHDUDQFH ,QVSHFWLRQ 0DLQVKDIW 'LVDVVHPEO\ FRQW¶G  Remove the angular ball bearing (A) and the  Measure the thickness of the MBS distance collar. tapered cone ring using a commercially available bearing separator (B) and a commercially available ‡...
  • Page 565 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW ,QVSHFWLRQ  Support the 3rd gear (A) on steel blocks, and press  Inspect the gear surface and bearing surface for the mainshaft out of the 3rd/4th synchro hub (B). wear and damage, then measure the mainshaft at Use of a jaw-type puller can damage the gear points A, B, and C.
  • Page 566 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW ,QVSHFWLRQ FRQW¶G  Inspect the runout by supporting both ends of the mainshaft. Rotate the mainshaft two complete revolutions when measuring the runout. If the runout is more than the service limit, replace the mainshaft with a new one.
  • Page 567 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW 5HDVVHPEO\ ([SORGHG 9LHZ "S9#UCÃ 6IBVG6SÃ76GGÃ7@6SDIB T`I8CSPÃ Check for wear and operation. TG@@W@ Note the direction of installation. "S9#UCÃ U6Q@S@9Ã8PI@ÃSDIB T`I8CSPÃ 9DTU6I8@Ã8PGG6S T`I8CSPÃ T`I8CSPÃSDIB TQSDIB T`I8CSPÃTQSDIB 9PV7G@Ã8PI@Ã $UCÃT`I8CSPÃTG@@W@ T`I8CSP $UCÃT`I8CSPÃCV7 T`I8CSPÃTQSDIB "S9ÃB@6S T`I8CSPÃSDIB I@@9G@Ã7@6SDIB Check for wear and operation.
  • Page 568 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW 5HDVVHPEO\ FRQW¶G 6SHFLDO 7RROV 5HTXLUHG  Install the 3rd/4th synchro hub (A) using the special ‡ Driver, 40 mm I.D. 07746-0030100 tool. ‡ Attachment, 30 mm I.D. 07746-0030300 NOTE: ‡ Refer to the Exploded View as needed during this procedure.
  • Page 569 0DQXDO 7UDQVPLVVLRQ  Install the synchro spring (A).  Install the 5th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in 5th/6th synchro hub (C).  Install the 5th synchro hub (A) using the special tools.
  • Page 570 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW 5HDVVHPEO\ FRQW¶G &RXQWHUVKDIW $VVHPEO\ &OHDUDQFH ,QVSHFWLRQ  Install the synchro spring (A).  Measure the clearance between the 1st gear (A) and the distance collar (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2.
  • Page 571 0DQXDO 7UDQVPLVVLRQ  Measure the thickness of the 1st gear.  Measure the thickness of the distance collar. ‡ If the thickness of 1st gear is less than the service ‡ If the thickness is not within the standard, replace limit, replace 1st gear with a new one.
  • Page 572 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ &RXQWHUVKDIW 'LVDVVHPEO\  Securely clamp the countershaft assembly in a  Support 4th gear (A) on steel blocks (B), then use a bench vise with wood blocks. press (C) and an attachment (D) to press the countershaft (E) out of the 5th gear.
  • Page 573 0DQXDO 7UDQVPLVVLRQ &RXQWHUVKDIW ,QVSHFWLRQ  Inspect the gear surface and bearing surface for wear and damage, then measure the countershaft at points A, B, and C. If any part of the countershaft is less than the service limit, replace it with a new one.
  • Page 574 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ &RXQWHUVKDIW 5HDVVHPEO\ ([SORGHG 9LHZ TQ@8D6GÃ7PGU Replace. 'ÃIÀà !xtsÀÃ'&ÃyisÃs‡ 76GGÃ7@6SDIB Check for wear and operation. Note the direction of installation. S@W@ST@ÃB@6S "$À€ÃTCDH TU!I9ÃT`I8CSPÃCV7 T`I8CSPÃTQSDIB 9DTU6I8@Ã8PGG6S USDQG@Ã8PI@ÃT`I8CSP $UCÃB@6S TUÃB@6S #UCÃB@6S "S9ÃB@6S I@@9G@Ã7@6SDIB Check for wear and operation. !I9ÃB@6S I@@9G@Ã7@6SDIB Check for wear and operation.
  • Page 575 0DQXDO 7UDQVPLVVLRQ 6SHFLDO 7RROV 5HTXLUHG  Install the synchro spring (A). ‡ Attachment, 42 x 47 mm 07746-0010300 ‡ Driver, 40 mm I.D. 07746-0030100 ‡ Attachment, 30 mm 07746-0030300 ‡ Driver 07749-0010000 NOTE: Refer to the Exploded View as needed during this procedure.
  • Page 576 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ &RXQWHUVKDIW 5HDVVHPEO\ FRQW¶G  Install the needle bearing.  Install the 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.  Install the 2nd gear (A) by aligning the synchro cone fingers (B) with 2nd gear grooves (C).
  • Page 577 0DQXDO 7UDQVPLVVLRQ  Install the distance collar (A), 35 mm shim, and old  If the clearance is more than the standard, select a ball bearing (B) using a special tools and a press new shim from the following table. If the clearance (C).
  • Page 578 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ &RXQWHUVKDIW 5HDVVHPEO\ FRQW¶G  Support ball bearing (A) on steel blocks (B), then  Tighten the new special bolt (A) (left-hand threads). use a press (C) and an attachment (D) to press the countershaft (E) out of the ball bearing.  Replace the 35 mm shim selected in step 16, then recheck the clearance.
  • Page 579 0DQXDO 7UDQVPLVVLRQ 6\QFKUR 6OHHYH DQG +XE ,QVSHFWLRQ DQG 6\QFKUR 5LQJ DQG *HDU ,QVSHFWLRQ 5HDVVHPEO\  Inspect the inside of each synchro ring (A) for wear.  Inspect gear teeth on all synchro hubs and synchro Inspect the teeth (B) on each synchro ring for wear (rounded off).
  • Page 580 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 6\QFKUR 5LQJ DQG *HDU ,QVSHFWLRQ FRQW¶G  Inspect the thrust surface (D) on each gear hub for  Measure the clearance between each gear (A) and wear. its synchro ring (B) all the way around. Hold the synchro ring against the gear evenly while measuring the clearance.
  • Page 581 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW %HDULQJ DQG 2LO 6HDO 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Drive the new oil seal in from the transmission side ‡ Adjustable bearing puller, 25 - 40 mm 07JAC-PH80100 using the special tools. ‡ Bearing remover shaft 07JAC-PH80200 ‡...
  • Page 582 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ &RXQWHUVKDIW %HDULQJ 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Position the oil guide plate C and new needle ‡ Adjustable bearing puller, 25 - 40 mm 07JAC-PH80100 bearing (A) in the bore of the clutch housing (B). ‡...
  • Page 583 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW 7KUXVW &OHDUDQFH $GMXVWPHQW 6SHFLDO 7RROV 5HTXLUHG  Measure distance [b] between the end of the clutch ‡ Mainshaft base 07GAJ-PG20130 housing (A) and bearing inner race (B) with a ‡ Mainshaft holder 07GAJ-PG20110 straight edge and depth gauge. Measure at three locations and average the readings.
  • Page 584 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 0DLQVKDIW 7KUXVW &OHDUDQFH $GMXVWPHQW FRQW¶G  Install the 72 mm shim (A) selected and oil guide  PP 6KLP plate M in the transmission housing (B). Qh…‡ÃIˆ€ir… Uuvpxr†† 23931-P21-000 0.60 mm (0.0236 in.) 23932-P21-000 0.63 mm (0.0248 in.) 23933-P21-000 0.66 mm (0.0260 in.)
  • Page 585 0DQXDO 7UDQVPLVVLRQ  Attach the special tool to the mainshaft as follows:  Zero a dial gauge (A) on the end of the mainshaft. ‡ Back-out the mainshaft holder bolt (A) and loosen the two hex bolts (B). ‡ Fit the holder over the mainshaft so its lip is towards the transmission.
  • Page 586 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HDVVHPEO\  Install the reverse shift fork. NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.  Install the magnet (A) and differential assembly (B).  Install the reverse idler gear (A) and reverse gear shaft (B) by aligning the mark (C) with reverse gear shaft hole (D).
  • Page 587 0DQXDO 7UDQVPLVVLRQ  Install the reverse lock cam.  Remove the dirt and oil from the tramsmission housing sealing surface. Apply liquid gasket (P/N 08C70-K0234M) to the sealing surface. Be sure to seal the entire circumference of the bolt holes to prevent oil leakage.
  • Page 588 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HDVVHPEO\ FRQW¶G  Install the 14 x 20 mm dowel pins (A).  Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (C). Release the snap ring so it seats in the groove of the countershaft bearing.
  • Page 589 0DQXDO 7UDQVPLVVLRQ  Remove the dirt and oil from the shift lever cover  Install the drain plug (A), filler plug (B) and 10 mm sealing surface. Apply liquid gasket (P/N 08C70- flange bolt (C) with new washers. K0234M) to the sealing surface. NOTE: If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings.
  • Page 590 07  07 'LIIHUHQWLDO 0DQXDO 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HDVVHPEO\ FRQW¶G  Install the vehicle speed sensor (VSS) (A) and O-  Install the 10 x 20 mm dowel pin (A), O-ring (B), ring (B). and transfer assembly (C). (4WD model)  Install the O-ring (A) and side cover (B). (2WD model) ...
  • Page 591 0DQXDO 7UDQVPLVVLRQ *HDUVKLIW 0HFKDQLVP 5HSODFHPHQW TCDAÃG@W@SÃFIP7 'ÃIÀÃ'ÃxtsÀÃ$'ÃyisÃs‡ TCDAUÃG@W@SÃCPVTDIB TCDAÃ867G@Ã8GDQ Replace. 8PUU@SÃQDI Replace. X6TC@S T@G@8UÃGP8FÃQDI TDGD8PI@ÃBS@6T@ 8PUU@SÃQDI Replace. [b] Remove the shift cable from the shift lever bracket. TCDAUÃ867G@ [a] Rotate the shift cable toward the opening. TCDAUÃ867G@Ã8GDQ Replace. 8PUU@SÃQDI Replace. 8PUU@SÃQDI Replace.
  • Page 592 07  07 'LIIHUHQWLDO 07 'LIIHUHQWLDO 07 'LIIHUHQWLDO &RPSRQHQW /RFDWLRQ ,QGH[ :' PRGHO " Replacement, page 13-59 76GGÃ7@6SDIB Backlash Inspection, page 13-58; Replacement, page 13-58 9DAA@S@IUD6GÃ86SSD@S Replacement, page 13-58 " ADI6GÃ9SDW@IÃB@6S Replacement, page 13-58 US6ITA@SÃ9SDW@IÃB@6S Replacement, page 13-59 76GGÃ7@6SDIB ...
  • Page 593 07 'LIIHUHQWLDO :' PRGHO " Replacement, page 13-59 76GGÃ7@6SDIB Backlash Inspection, page 13-58; Replacement, page 13-58 9DAA@S@IUD6GÃ86SSD@S Replacement, page 13-58 " ADI6GÃ9SDW@IÃB@6S Replacement, page 13-59 76GGÃ7@6SDIB ...
  • Page 594 07  07 'LIIHUHQWLDO 07 'LIIHUHQWLDO %DFNODVK ,QVSHFWLRQ 'ULYHQ *HDU&DUULHU 5HSODFHPHQW  Remove the bolts (left-hand threads) in a NOTE: 4WD model is shown, 2WD model is similar. crisscross pattern in several steps, then remove the  Place the differential assembly on V-blocks (A), transfer driven gear (A), final driven gear (B) from and install both axles.
  • Page 595 07 'LIIHUHQWLDO &DUULHU %HDULQJV 5HSODFHPHQW 6SHFLDO 7RRO 5HTXLUHG  Install the new bearings (A) with the special tool Driver, 40 mm I.D. 07746-0030100 and a press. Press each bearing on until it bottoms. There should be no clearance between the NOTE: 4WD model is shown, 2WD model is similar.
  • Page 596 07  07 'LIIHUHQWLDO 07 'LIIHUHQWLDO 2LO 6HDO 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Install the new oil seal in the transmission housing ‡ Driver 07749-0010000 with the special tools. ‡ Oil seal driver attachment 07NAD-P200100  Remove the differential assembly.  Remove the oil seal (A) from the transmission housing (B).
  • Page 597 07 'LIIHUHQWLDO 'LIIHUHQWLDO 7KUXVW &OHDUDQFH $GMXVWPHQW 6SHFLDO 7RRO 5HTXLUHG  Install the transmission housing onto the clutch Driver, 40 mm I.D. 07746-0030100 housing, then tighten the 8 mm flange bolts in a crisscross pattern in several steps.  Install the 80 mm shim that’s the same size as the one you removed.
  • Page 598 07  07 'LIIHUHQWLDO 07 'LIIHUHQWLDO 'LIIHUHQWLDO 7KUXVW &OHDUDQFH $GMXVWPHQW FRQW¶G  If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 5 is within the standard, go to step 9.
  • Page 599 7UDQVIHU $VVHPEO\ 7UDQVIHU $VVHPEO\ %DFNODVK ,QVSHFWLRQ RQ &DU  Before reinstalling the propeller shaft, check the transfer assembly oil seal for damage and fluid leaks.  Raise the front of the vehicle, and support it with ‡ If the seal is leaking, remove the transfer assembly safety stands (see section 01).
  • Page 600 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 5HPRYDO 7UDQVIHU ,QVWDOODWLRQ NOTE: Make sure the lifts, jacks, and safety stands are NOTE: ‡ While installing the transfer assembly on the placed properly (see page 01-7). transmission, do not allow dust or other foreign particles  Raise the front of the vehicle, and support it with to enter the transmission.
  • Page 601 7UDQVIHU $VVHPEO\ 7UDQVIHU 2YHUKDXO ([SORGHG 9LHZ " & " !& & !" (cont’d) ...
  • Page 602 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ ([SORGHG 9LHZ FRQW¶G US6ITA@SÃCPVTDIB 9PX@GÃQDI PDGÃT@6G Replace. !!À€ÃGP8FIVU PSDIB U6Q@S@9ÃSPGG@SÃ7@6SDIB Replace. Replace. " 8PID86GÃTQSDIBÃX6TC@S " US6ITA@SÃCPG9@S !" U6Q@S@9ÃSPGG@SÃ7@6SDI BÃPVU@SÃS68@ Replace. U6Q@S@9ÃSPGG@SÃ7@6SDIB %À€ÃAG6IB@Ã7PGUT US6ITA@SÃTQ68@S Replace. !$À€ÃUCSVTUÃTCDH US6ITA@SÃTC6AUÃ6TT@H7G` U6Q@S@9ÃSPGG@SÃ7@6SDI BÃPVU@SÃS68@ US6ITA@SÃ8PGG6S !!À€ÃGP8FIVU U6Q@S@9ÃSPGG@SÃ7@6SDIB Replace. & US6ITA@SÃ9SDW@ÃB@6S &...
  • Page 603 7UDQVIHU $VVHPEO\ 7UDQVIHU ,QVSHFWLRQ 7UDQVIHU *HDU +\SRLG JHDU %DFNODVK 0HDVXUHPHQW 7UDQVIHU 'ULYH *HDU 7RRWK &RQWDFW ,QVSHFWLRQ  Set a dial indicator (A) on the companion flange (B)  Remove the transfer from the vise. as shown.  Remove the transfer holder assembly (A) from the transfer housing (B), then remove the dowel pin (C) and O-ring (D).
  • Page 604 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 'LVDVVHPEO\ 6SHFLDO 7RROV 5HTXLUHG  Secure the transfer housing (A) in a bench vise (B) Companion Flange Holder 07PAB-0020000 with soft jaws. NOTE: To prevent damage to the transfer housing,  Remove the transfer holder assembly (A) from the always use soft jaws or equivalent materials between transfer housing (B).
  • Page 605 7UDQVIHU $VVHPEO\  Remove the transfer driven gear locknut (A),  Remove the oil seal (A) and the tapered roller conical spring washer (B), back-up ring (C), O-ring bearing (B) from the transfer housing (C). (D) and companion flange (E).  Remove the transfer driven gear (A), then remove the transfer spacer (B) from the transfer driven gear.
  • Page 606 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU +ROGHU 'LVDVVHPEO\  Cut the lock tabs of the locknut using a chisel. Keep  Remove the locknut (A), conical spring washer (B), all of the chiseled particles out of the transfer shaft. tapered roller bearing (C), 25 mm thrust shim (D), transfer shaft collar (E), transfer drive gear (F), and transfer shaft assembly (G) from the transfer holder...
  • Page 607 7UDQVIHU $VVHPEO\ 7UDQVIHU +ROGHU 7DSHUHG 5ROOHU %HDULQJ 7UDQVIHU 'ULYH *HDU %HDULQJ 5HSODFHPHQW 2XWHU 5DFH 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG ‡ Attachment, 37 x 40 mm 07746-0010200 6SHFLDO 7RROV 5HTXLUHG ‡ Attachment, 42 x 47 mm 07746-0010300 ‡ Attachment, 72 x 75 mm 07746-0010600 ‡...
  • Page 608 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 'ULYHQ *HDU %HDULQJ 5HSODFHPHQW 7UDQVIHU +RXVLQJ %HDULQJ 2XWHU 5DFH 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG ‡ Driver, 40 mm I.D 07746-0030100 6SHFLDO 7RROV 5HTXLUHG ‡ Attachment, 35 mm I.D 07746-0030400 ‡ Installer shaft, 14 x 165 mm 07JAF-SJ80110 ‡...
  • Page 609 7UDQVIHU $VVHPEO\ 7UDQVIHU 5HDVVHPEO\  Install the 52 mm tapered roller bearing outer race 6SHFLDO 7RROV 5HTXLUHG using the special tools. ‡ Oil seal driver attachment 07JAD-PH80101 ‡ Companion flange holder 07PAB-0020000 ‡ Attachment, 72 x 75 mm 07746-0010600 ‡ Driver, 40 mm I.D 07746-0030100 ‡...
  • Page 610 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 5HDVVHPEO\ FRQW¶G  PP 7KUXVW 6KLP 6HOHFWLRQ 7+5867 6+,0  PP  Select the 35 mm thrust shim if the transfer driven Qh…‡ÃIˆ€ir… Uuvpxr†† gear shaft or the tapered roller bearing on the 41361-PS3-000 0.72 mm (0.028 in.) transfer driven gear shaft is replaced.
  • Page 611 7UDQVIHU $VVHPEO\ 7UDQVIHU *HDU %DFNODVK ,QVSHFWLRQ DQG 7UDQVIHU *HDU 7RRWK  Install the transfer driven gear (A) in the transfer &RQWDFW ,QVSHFWLRQ housing (B). Do not install the transfer spacer on the transfer driven gear shaft in this step.  Install the 35 mm thrust shim (A) on the transfer driven gear (B), then install the tapered roller bearing (C) using the special tools and a press.
  • Page 612 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 5HDVVHPEO\ FRQW¶G  PP 7KUXVW 6KLP 6HOHFWLRQ FRQW¶G  Install the transfer shaft assembly (A) in the transfer holder (B), then install the transfer drive  Secure the transfer housing (A) in a bench vise (B) gear (C), transfer collar (D), 25 mm thrust shim (E), with soft jaws, then install the special tool on the tapered roller bearing (F), conical spring washer...
  • Page 613 7UDQVIHU $VVHPEO\  Apply Prussian Blue to both sides of the transfer  Check the transfer gear tooth contact pattern. drive gear teeth lightly and evenly.  Install the dowel pin (A) and transfer holder 8PSS@8UÃUPPUCÃ8PIU68UÃQ6UU@SI assembly (B) to the transfer housing (C). NOTE: Temporarily install the transfer holder assembly without the O-ring.
  • Page 614 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 5HDVVHPEO\ FRQW¶G  PP 7KUXVW 6KLP 6HOHFWLRQ FRQW¶G ‡ )DFH &RQWDFW Use a thicker thrust shim to move the transfer drive  If the transfer gear tooth contact is incorrect, adjust gear away from the transfer driven gear shaft. Face the transfer gear tooth contact with a 35 mm or 25 contact must be adjusted within the limits of the mm thrust shim.
  • Page 615 7UDQVIHU $VVHPEO\  Remove the transfer holder assembly (A) from the  Remove the locknut (A), conical spring washer (B) transfer housing (B). and companion flange (C) from the transfer driven gear (D).  Remove the transfer driven gear (A) from the transfer housing (B).
  • Page 616 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 5HDVVHPEO\ FRQW¶G  PP 7KUXVW 6KLP 6HOHFWLRQ FRQW¶G  Install the special tool on the companion flange, then tighten the transfer driven gear shaft locknut  Install the companion flange (A), O-ring (B), back- while measuring the starting torque of the transfer up ring (C), conical spring washer (D) and locknut driven gear shaft.
  • Page 617 7UDQVIHU $VVHPEO\  Install the dowel pin (A) to the transfer housing (B),  Remove the transfer holder assembly from the then install the transfer holder assembly (C). transfer housing. NOTE: Temporarily install the transfer holder  If the measurement is not within the specification, assembly without the O-ring.
  • Page 618 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 5HDVVHPEO\ FRQW¶G  PP 7KUXVW 6KLP 6HOHFWLRQ FRQW¶G  Measure the thickness of the removed 76 mm thrust shim, and select a new 76 mm shim.  Remove the locknut (A) and transfer shaft assembly (B) from the transfer holder (C).
  • Page 619 7UDQVIHU $VVHPEO\  Install the 76 mm thrust shim (A) in the transfer  Hold the transfer shaft (A) with a 14 mm Allen holder (B). wrench (B) clamped in a bench vise then tighten the locknut. NOTE: Do not stake the locknut in this step. UDBCU@IDIBÃUPSRV@) 'ÃI€Ã !Ãxts€Ã'%'ÃyisÂs‡...
  • Page 620 07  07 'LIIHUHQWLDO 7UDQVIHU $VVHPEO\ 7UDQVIHU 5HDVVHPEO\ FRQW¶G  PP 7KUXVW 6KLP 6HOHFWLRQ FRQW¶G  Remove the transfer holder assembly from the transfer housing.  Stake the locknut on the transfer shaft using a 3.5 mm punch.  Coat the new O-ring (A) with MTF, install it on the transfer holder, then install the dowel pin (B) and transfer holder assembly (C) to the transfer housing (D).
  • Page 621 $XWRPDWLF 7UDQVPLVVLRQ 6ˆ‡‚€h‡vpÃU…h†€v††v‚   6UÃBrh…ÃQ‚†v‡v‚ÃDqvph‡‚…   # %$ 6UÃD‡r…y‚pxÃT’†‡r€   # &! U…h†€v††v‚Ã@qÃ8‚‰r…   # (! U…h†€v††v‚ÃC‚ˆ†vt   # (' Why‰rÃ7‚q’   #!$ U‚…„ˆrÃ8‚‰r…‡r…ÃC‚ˆ†vt   #! # Tuhs‡†ÃhqÃ8yˆ‡pur†   #! ' 6UÃ9vssr…r‡vhy   #!%# U…h†sr…Ã6††r€iy’...
  • Page 622 $XWRPDWLF 7UDQVPLVVLRQ $XWRPDWLF 7UDQVPLVVLRQ 6HUYLFH 3UHFDXWLRQV IRU :' 0RGHO  Set the free rollers according to the wheel base and tread of the vehicle. This 4WD model does not have the feature that  Move the vehicle to position the front wheels on the mechanically switches between 4WD (four-wheel drive) speedometer tester and the rear wheels on the free and 2WD (front-wheel drive).
  • Page 623 $XWRPDWLF 7UDQVPLVVLRQ 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07GAD-SD40101 Driver Attachment, 78 x 90 mm 07HAC-PK40102 Housing Puller 07HAJ-PK40201 Preload Inspection Tool " 07JAC-PH80000 Adjustable Bearing Remover Set 07JAC-PH80100 Bearing Remover Attachment 07JAC-PH80200 Remover Handle Assembly 07741-0010201 Remover Weight 07JAD-PH80101 Oil Seal Driver Attachment 07JAF-SJ80110 Installer Shaft 14 x 165 mm...
  • Page 624 OBD Scan Tool or Honda PGM Tester (B), it will data, or at speeds over 30 mph (50 km/h), and then indicate the Diagnostic Trouble Code (DTC) when the recheck for DTC(s).
  • Page 625 $XWRPDWLF 7UDQVPLVVLRQ +RZ WR 7URXEOHVKRRW &LUFXLWV DW WKH 3&0  Inspect the circuit on the PCM, according to the DTC troubleshooting with a digital multitester (A)  Remove the glove box stops, then bring the glove and tapered tip probe (B) as shown. box down.
  • Page 626  Turn the ignition switch OFF.  Turn the ignition switch OFF.  Remove the No. 6 ECU fuse (15A) (A) from the  Disconnect the Honda PGM tester (A) from the under-hood fuse/relay box (B) for more than 10 DLC (B).
  • Page 627 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ ,QGH[ 9r‡rp‡v‚ÃD‡r€ b9dà Qhtr T6@Ã8‚qr Dqvph‡‚… C‚qhÃ8‚qr P0710 (28) ATF temperature sensor Blinks (see page 14-66) P0715 (15) Mainshaft speed sensor Blinks (see page 14-68) P0720 (9) Countershaft speed sensor Blinks (see page 14-71) P0745 (76) Hydraulic control system of A/T clutch pressure control Blinks (see page 14-75)
  • Page 628 $XWRPDWLF 7UDQVPLVVLRQ 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ These symptom DO NOT trigger Diagnostic Trouble Codes (DTCs) or cause the [D] indicator to blink. If the Malfunction Indicator Lamp (MIL) was reported ON or the [D] indicator has been blinking, check for DTCs. But if the vehicle has one of the systems in the following chart, check the probable cause(s) for it, in the sequence listed, until you find the problem.
  • Page 629 $XWRPDWLF 7UDQVPLVVLRQ T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Engine runs, but vehicle Low ATF level Check ATF level and check ATF cooler lines for leakage and does not move in any gear Shift cable broken or out of loose connections. If necessary, flush ATF cooler lines. ‡...
  • Page 630 $XWRPDWLF 7UDQVPLVVLRQ 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ FRQW¶G T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Vehicle moves in [D], [1], 2nd accumulator defective Check the 2nd clutch pressure. ‡ [R], but not in [2] position 2nd gears worn or damaged Inspect the clutch piston and O-rings. Check the spring 2nd clutch defective retainer and retainer seal for wear and damage.
  • Page 631 $XWRPDWLF 7UDQVPLVVLRQ T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Poor acceleration; flares on Check the 2nd clutch pressure. ‡ starting off in [D] position: Inspect the clutch piston and O-rings. Check the spring Stall spee4d high when retainer and retainer seal for wear and damage. Inspect the starting off in [2] position clutch end plate-to-top disc clearance.
  • Page 632 $XWRPDWLF 7UDQVPLVVLRQ 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ FRQW¶G T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Engine idle vibration Low ATF level Check ATF level and check ATF cooler lines for leakage and Shift solenoid valve E defective loose connections. If necessary, flush ATF cooler lines. ‡...
  • Page 633 $XWRPDWLF 7UDQVPLVVLRQ T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Late shift from [N] position Shift solenoid valve E defective Check the [D] indicator indication, check for loose connectors. to [D] position, or excessive A/T clutch pressure control Inspect the solenoid valve filter/gasket and O-rings for wear shock when shifted into [D] solenoid valve A defective and damage, and inspect the solenoid valves for seizure.
  • Page 634 $XWRPDWLF 7UDQVPLVVLRQ 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ FRQW¶G T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† No shift Mainshaft speed sensor defective Check the [D] indicator indication, and check for loose connectors. Countershaft speed sensor Check the mainshaft and countershaft speed sensor installation. defective ‡ Excessive shock or flares A/T clutch pressure control Check the [D] indicator indication, check for loose connectors.
  • Page 635 $XWRPDWLF 7UDQVPLVVLRQ T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Excessive shock or flares A/T clutch pressure control Check the [D] indicator indication, and check for loose on 2-3 upshift or 3-2 solenoid valves B and C defective connectors. Inspect the solenoid valve filter/gasket for wear downshift 3rd clutch pressure switch and damage, and inspect the solenoid valves for seizure.
  • Page 636 $XWRPDWLF 7UDQVPLVVLRQ 6\SWRP 7URXEOHVKRRWLQJ ,QGH[ FRQW¶G T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Noise from transmission in ATF pump worn or binding Improper alignment of ATF pump and torque converter all shift lever positions Mainshaft bearing, countershaft housing may cause ATF pump seizure. The symptoms are bearing, or secondary shaft mostly an rpm-related ticking noise or a high pitched squeak.
  • Page 637 $XWRPDWLF 7UDQVPLVVLRQ T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Shift lever does not operate Transmission range switch Check the [D] indicator indication, and check for loose smoothly defective or out of adjustment connectors. Inspect the transmission range switch for Shift cable broken out of operation.
  • Page 638 $XWRPDWLF 7UDQVPLVVLRQ 6\SWRP 7URXEOHVKRRWLQJ ,QGH[ FRQW¶G T’€ƒ‡‚€ Q…‚ihiyrÃphˆ†r† I‚‡r† ‡ Lock-up clutch does not Shift solenoid valve E defective Check the [D] indicator indication, and check for loose engage A/T clutch pressure control connectors. Inspect the solenoid valve filter/gasket for wear solenoid valve A defective and damage, and inspect the solenoid valves for seizure.
  • Page 639 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ *HQHUDO 2SHUDWLRQ The automatic transmission is a combination of a 3-element torque converter and triple-shaft electronically controlled unit which provides 4 speeds forward and 1 reverse. The entire unit is positioned in line with the engine. 7RUTXH &RQYHUWHU *HDUV DQG &OXWFKHV The torque converter consists of a pump, turbine, and stator assembly in a single unit.
  • Page 640 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G *HQHUDO 2SHUDWLRQ FRQW¶G *HDU 6HOHFWLRQ The shift lever has six positions: [P] PARK, [R] REVERSE, [N] NEUTRAL, [D] DRIVE 1st through 4th gear range with Over- drive mode, and 1st through 3rd gear range with Over-drive OFF mode, [2] 2nd gear, and [1] 1st gear. Q‚†v‡v‚...
  • Page 641 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ &XWDZD\ 9LHZ NOTE: The illustration shows 4WD transmission on K20A4 and K20A5 engine models; 2WD does not have the transfer mechanism, K24A1 engine model is similar. ,GOHU *HDUV 6HFWLRQ &XWZD\ 9LHZ S@W@ST@ÃD9G@SÃB@6S #UCÃ8GVU8C UPSRV@Ã8PIW@IU@S H6DITC6AUÃS@W@ST@Ã "S9Ã8GVU8C H6DITC6AUÃD9G@SÃ B@6S B@6S H6DITC6AUÃ...
  • Page 642 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G &OXWFKHV The 4-speed automatic transmission uses hydraulically-actuated clutches to engage or disengage the transmission gears. When hydraulic pressure is introduced into the clutch drum, the clutch piston moves. This presses the friction discs and steel plates together, locking them so they don’t slip.
  • Page 643 $XWRPDWLF 7UDQVPLVVLRQ >3@ 3RVLWLRQ Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft is locked by the park pawl interlocking the park gear. >1@ 3RVLWLRQ Engine power transmitted from the torque converter drives the mainshaft idler gear, the idler shaft idler gear, and the secondary shaft idler gear, but hydraulic pressure is not applied to the clutches.
  • Page 644 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G 3RZHU )ORZ VW *HDU ‡ Hydraulic pressure is applied to the 1st clutch, then the 1st clutch engages the secondary shaft 1st gear with the secondary shaft. ‡ The mainshaft idler gear drives the secondary shaft via the idler shaft idler gear and the secondary shaft idler gear. ‡...
  • Page 645 $XWRPDWLF 7UDQVPLVVLRQ QG *HDU ‡ Hydraulic pressure is applied to the 2nd clutch, then the 2nd clutch engages the secondary shaft 2nd gear with the secondary shaft. ‡ The mainshaft idler gear drives the secondary shaft via the idler shaft idler gear and the secondary shaft idler gear. ‡...
  • Page 646 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G 3RZHU )ORZ FRQW¶G UG *HDU ‡ Hydraulic pressure is applied to the 3rd clutch, then the 3rd clutch engages the mainshaft 3rd gear with the mainshaft. ‡ The mainshaft 3rd gear drives the countershaft 3rd gear and the countershaft. ‡...
  • Page 647 $XWRPDWLF 7UDQVPLVVLRQ WK *HDU ‡ Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft 4th gear while the shift lever is in the [D], [2], [1] position (forward range). ‡ Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft 4th gear with the mainshaft. ‡...
  • Page 648 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G 3RZHU )ORZ FRQW G >5@ 3RVLWLRQ ‡ Hydraulic pressure is applied to the servo valve to engage the reverse selector with the countershaft reverse gear while the shift lever is in the [R] position. ‡ Hydraulic pressure is also applied to the 4th clutch, then the 4th clutch engages the mainshaft reverse gear with the mainshaft.
  • Page 649 $XWRPDWLF 7UDQVPLVVLRQ (OHFWURQLF &RQWURO 6\VWHP )XQFWLRQDO 'LDJUDP The electronic control system consists of the Powertrain Control Module (PCM), sensors, and solenoid valves. Shifting and lock-up are electronically controlled for comfortable driving under all conditions. The PCM inputs signals from the sensors, switches, and other control units, perform processing data, and outputs signals for engine control system and A/T control system.
  • Page 650 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G (OHFWURQLF &RQWURO 6\VWHP FRQW G (OHFWURQLF &RQWUROV /RFDWLRQ NOTE: The illustrations shows LHD model; RHD model is similar. TCDAUÃGP8FÃTPG@IPD9 Q6SFÃQDIÃTXDU8C PW@S9SDW@Ã P9ÃTXDU8C VI9@S96TCÃAVT@ S@G6`Ã7PY QPX@SUS6DIÃ8PIUS PGÃHP9VG@ÃQ8H 96U6ÃGDIFÃ8PII@8UPSÃ  %Q !I9Ã8GVU8CÃQS@TTVS@ÃTXDU8C 8PVIU@STC6AUÃTQ@@9ÃT@ITPS H6DITC6AUÃTQ@@9ÃT@ITPS 6UÃ8GVU8CÃQS@TTVS@Ã8PIUSPGÃ TPG@IPD9ÃW6GW@Ã6 US6ITHDTTDPIÃS6IB@ÃTXDU8C "S9Ã8GVU8CÃQS@TTVS@Ã TXDU8C TCDAUÃTPG@IPD9ÃW6GW@Ã8 TCDAUÃTPG@IPD9ÃW6GW@Ã7...
  • Page 651 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW &RQWURO The PCM instantly determines which gear should be selected by various signals sent from sensors and switches, and it actuates the shift solenoid valves A, B, C, and E to control shifting. Also, a Grade Logic Control System has been adopted to control shifting in [D] position. The PCM compares actual driving conditions with memorized driving conditions, based on the input from the throttle position sensor, the engine coolant temperature sensor, the barometric pressure sensor, the brake pedal position switch signal, and the shift lever position signal, to control shifting while vehicle is ascending or descending a slope.
  • Page 652 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G (OHFWURQLF &RQWURO 6\VWHP FRQW G The PCM turns the shift solenoid valves A, B, C, and E ON and OFF to control shifting transmission gear. The combination of driving signals to shift solenoid valves A, B, C, and E are shown in table below. Q‚†v‡v‚...
  • Page 653 $XWRPDWLF 7UDQVPLVVLRQ *UDGH /RJLF &RQWURO 6†prqvtÃ8‚‡…‚y When the PCM determines that the vehicle is climbing a hill in [D] position, the system extends the engagement area of 2nd, and 3rd gears to prevent the transmission from frequently shifting between 2nd and 3rd gears, and between 3rd and 4th gears, so the vehicle can run smooth and have more power when needed.
  • Page 654 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G (OHFWURQLF &RQWURO 6\VWHP FRQW G &OXWFK 3UHVVXUH &RQWURO The PCM actuates the A/T clutch pressure control solenoid valves A, B and C to control the clutch pressure. When shifting between lower and higher gears, the clutch pressure regulated by the A/T clutch pressure control solenoid valves A, B, and C engage and disengage the clutch smoothly.
  • Page 655 $XWRPDWLF 7UDQVPLVVLRQ /RFNXS &RQWURO The shift solenoid valve E controls the hydraulic pressure to switch the lock-up shift valve and lock-up ON and OFF. The PCM actuates the shift solenoid valve E and the A/T clutch pressure control solenoid valve A to control the torque converter clutch lock-up.
  • Page 656 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G (OHFWURQLF &RQWURO 6\VWHP FRQW G 3&0 (OHFWULFDO &RQQHFWLRQV DBIDUDPIÃTXDU8C 76UU@S` 6UÃ8GVU8CÃQS@TTVS@à H6DIà 8PIUSPGÃTPG@IPD9à DB ÃCPUÃvÃPIÃDDÃhqà S@G6`à W6GW@Ã6 TU6SUÃDDD 7S6F@ÃQ@96Gà 6UÃ8GVU8CÃQS@TTVS@à QPTDUDPIÃTXDU8C 8PIUSPGÃTPG@IPD9à W6GW@Ã7 7S6F@ÃGDBCUT 6UÃ8GVU8CÃQS@TTVS@à 8PIUSPGÃTPG@IPD9à W6GW@Ã8 96U6ÃGDIFÃ8PII@8UPS TCDAUÃTPG@IPD9ÃW6GW@Ã6 HVGUDQG@YÃ8PIUSPGÃVIDU TCDAUÃTPG@IPD9ÃW6GW@Ã7 B6VB@Ã6TT@H7G` TCDAUÃTPG@IPD9ÃW6GW@Ã8 8‚‡…‚yÃhqÃ9v€€vtÃ8v…pˆv‡ TCDAUÃTPG@IPD9ÃW6GW@Ã@ P9à 9…v‰r…...
  • Page 657 $XWRPDWLF 7UDQVPLVVLRQ 3&0 ,QSXWV DQG 2XWSXWV The PCM terminal voltage and measuring conditions are shown for the connector terminals that are related to the A/T control system. The other PCM terminal voltage and measuring conditions are described in section 11 (see section 11).
  • Page 658 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G (OHFWURQLF &RQWURO 6\VWHP FRQW G 3&0 ,QSXWV DQG 2XWSXWV FRQW G Q8HÃ8‚rp‡‚…ÃUr…€vhyÃG‚ph‡v‚† Q8HÃ8PII@8UPSÃ8 Ã!!Q Ur…€vhyà Xv…rÃ8‚y‚… Tvthy 9r†p…vƒ‡v‚ Hrh†ˆ…vtÃ8‚qv‡v‚†Ur…€vhyÃW‚y‡htr Iˆ€ir… WHT/BLK LS A- A/T clutch pressure control solenoid With ignition switch ON (II): 0 V valve A power supply negative electrode SH C Shift solenoid valve C control...
  • Page 659 $XWRPDWLF 7UDQVPLVVLRQ Q8HÃ8PII@8UPSÃ8Ã!!Q Ur…€vhyà Xv…rÃ8‚y‚… Tvthy 9r†p…vƒ‡v‚ Hrh†ˆ…vtÃ8‚qv‡v‚†Ur…€vhyÃW‚y‡htr Iˆ€ir… BLK/RED LS B- A/T clutch pressure control solenoid With ignition switch ON (II): 0 V valve B power supply negative electrode BLU/WHT OP3SW 3rd clutch pressure switch signal With ignition switch ON (II): About 5 V input (No 3rd clutch pressure) With 3rd clutch pressure: About 0 V...
  • Page 660 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G (OHFWURQLF &RQWURO 6\VWHP FRQW G 3&0 ,QSXWV DQG 2XWSXWV FRQW G Q8HÃ8‚rp‡‚…ÃUr…€vhyÃG‚ph‡v‚† Q8HÃ8PII@8UPSÃ@Ã!Q Ur…€vhyà Xv…rÃ8‚y‚… Tvthy 9r†p…vƒ‡v‚ Hrh†ˆ…vtÃ8‚qv‡v‚†Ur…€vhyÃW‚y‡htr Iˆ€ir… RED/YEL MRLY Power supply circuit from main With ignition switch ON (II): 0 V relay 1 With ignition switch OFF: Battery voltage YEL/BLK Power supply circuit for solenoid With ignition switch ON (II): Battery voltage...
  • Page 661 $XWRPDWLF 7UDQVPLVVLRQ +\GUDXOLF &RQWUROV The valve body includes the main valve body, the regulator valve body, and the servo body. The ATF pump is driven by splines on the left end of the torque converter which is attached to the engine. Fluid flows through the regulator valve to maintain specified pressure through the main valve body to the manual valve, directing pressure to the shift valves and to each of the clutches via the solenoid valves.
  • Page 662 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF &RQWUROV FRQW G 0DLQ 9DOYH %RG\ The main valve body contains the manual valve, the shift valves A, B, C, and E, the relief valve, the lock-up control valve, the cooler check valve, the servo control valve, and the ATF pump gears. The primary function of the main valve body is to switch fluid pressure on and off and to control hydraulic pressure going to the hydraulic control system.
  • Page 663 $XWRPDWLF 7UDQVPLVVLRQ 5HJXODWRU 9DOYH The regulator valve maintains a constant hydraulic pressure from the ATF pump to the hydraulic control system, while also furnishing fluid to the lubrication system and torque converter. The fluid from the ATF pump flows through B and B’. Fluid entering from B flows through the valve orifice to the A cavity.
  • Page 664 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF &RQWUROV FRQW G 6HUYR %RG\ The servo body contains the servo valve, the clutch pressure back-up (CPB) valve, accumulators for 2nd, 3rd, and 4th, and shift solenoid valves for A, B, C, and E. TCDAUÃTPG@IPD9ÃW6GW@Ã6 TCDAUÃTPG@IPD9ÃW6GW@Ã@ TCDAUÃTPG@IPD9ÃW6GW@Ã7 TCDAUÃTPG@IPD9ÃW6GW@Ã8...
  • Page 665 $XWRPDWLF 7UDQVPLVVLRQ +\GUDXOLF )ORZ 'LVWULEXWLRQ RI +\GUDXOLF 3UHVVXUH As the engine turns, the ATF pump starts to operate. Automatic transmission fluid (ATF) is drawn through the ATF strainer (filter) and discharged into the hydraulic circuit. Then, ATF flowing from the ATF pump becomes line pressure that’s regulated by the regulator valve.
  • Page 666 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF )ORZ FRQW G >1@ 3RVLWLRQ The PCM controls the shift solenoid valves. The conditions of the shift solenoid valves and positions of the shift valves are as follows: ‡ Shift solenoid valve A: OFF Shift valve A remains in right side ‡...
  • Page 667 $XWRPDWLF 7UDQVPLVVLRQ >'@ 3RVLWLRQ VW JHDU VKLIWLQJ IURP >1@ SRVLWLRQ Shift solenoid valves remain the same as in [N] position, when shifting to [D] position from [N]. The manual valve is moved to [D] position, and switches the port of line pressure (4) leading to the A/T clutch pressure control solenoid valves. Hydraulic pressure line to the 1st clutch from the A/T clutch pressure control solenoid valve A is created as shift solenoid valve A is OFF, B and C remain ON.
  • Page 668 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF )ORZ FRQW G >'@ 3RVLWLRQ 'ULYLQJ LQ VW JHDU The PCM turns shift solenoid valves A ON, and remains B and C ON, E OFF. Shift solenoid valve A pressure (SA) is applied to the right side of the shift valve A. The shift valve A is moved to the left side to uncover the port of line pressure leadin g to the 1st clutch, and to cover the ports of A/T clutch pressure control solenoid valve pressures.
  • Page 669 $XWRPDWLF 7UDQVPLVVLRQ >'@ 3RVLWLRQ 6KLIWLQJ EHWZHHQ VW JHDU DQG QG JHDU As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valves A OFF, and remains B and C ON, E OFF. Shift solenoid valve A pressure (SA) in the right side of the shift valve A is released. The shift valve A is moved to the right side to uncover the ports of A/T clutch pressure control solenoid valves pressures leading to the 1st, 2nd, and 3rd clutches.
  • Page 670 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF )ORZ FRQW G >'@ 3RVLWLRQ 'ULYLQJ LQ QG JHDU The PCM turns shift solenoid valves C OFF and remains A and E OFF, B ON. Shift solenoid valve C pressure (SC) in the right side of the shift valve C is released. The shift valve C is moved to the right side to switch the ports. This movement covers A/T clutch pressure control solenoid valves pressures to stop at the shift valve C and B, and uncover the port of line pressure leading to the 2nd clutch.
  • Page 671 $XWRPDWLF 7UDQVPLVVLRQ >'@ 3RVLWLRQ 6KLIWLQJ EHWZHHQ QG JHDU DQG UG JHDU As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valves C ON, and remains A and E OFF, B ON. Shift solenoid valve C pressure (SC) is applied to the right side of the shift valve C. The shift valve C is moved to the left side to uncover the ports of A/T clutch pressure control solenoid valves pressures leading to the 1st, 2nd, and 3rd clutches.
  • Page 672 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF )ORZ FRQW G >'@ 3RVLWLRQ 'ULYLQJ LQ UG JHDU The PCM turns shift solenoid valves B OFF, and remains A and E OFF, C ON. Shift solenoid valve B pressure (SB) in the right side of the shift valve B is released, and the shift valve B is moved to the right side. This movement switches the port of A/T clutch pressure control solenoid valve C pressure leading to the 3rd clutch.
  • Page 673 $XWRPDWLF 7UDQVPLVVLRQ >'@ 3RVLWLRQ 6KLIWLQJ EHWZHHQ UG JHDU DQG WK JHDU As the speed of the vehicle reaches the prescribed value, the PCM turns shift solenoid valves C OFF, and remains A, B and E OFF. Shift solenoid valve C pressure (SC) in the right side of the shift valve C is released. The shift valve C is moved to the right side to uncover the ports of A/T clutch pressure control solenoid valves A and B pressures leading to the 2nd and 4th clutches.
  • Page 674 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF )ORZ FRQW G >'@ 3RVLWLRQ 'ULYLQJ LQ WK JHDU The PCM turns shift solenoid valves A ON, and remains B, C and E OFF. Shift solenoid valve A pressure (SA) is applied to the right side of the shift valve A. The shift valve A is moved to the left side to cover the ports of A/T clutch pressure control solenoid valves A and C pressure leading to the 2nd and 3rd clutches.
  • Page 675 $XWRPDWLF 7UDQVPLVVLRQ >@ 3RVLWLRQ The PCM controls the shift solenoid valves. The conditions of the shift solenoid valves and positions of the shift valves are as follows: ‡ Shift solenoid valve A: OFF Shift valve A remains in right side ‡...
  • Page 676 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF )ORZ FRQW G >@ 3RVLWLRQ The PCM controls the shift solenoid valves. The conditions of the shift solenoid valves and positions of the shift valves are as follows: ‡ Shift solenoid valve A: ON Shift valve A moves to left side ‡...
  • Page 677 $XWRPDWLF 7UDQVPLVVLRQ >5@ 3RVLWLRQ 6KLIWLQJ WR >5@ SRVLWLRQ IURP >3@ RU >1@ SRVLWLRQ When shifting in [R] position, the PCM turns shift solenoid valves B and E ON, A and C OFF. Shift solenoid valve B pressure (SB) is applied to the right side of the shift valve B, and the shift valve B is moved to left side. Shift solenoid valve E pressure (SE) is applied to the left side of the shift valve E, and the shift valve E is moved to the right side.
  • Page 678 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G +\GUDXOLF )ORZ FRQW G >5@ 3RVLWLRQ 'ULYLQJ LQ UHYHUVH JHDU After starting off in reverse gear, the PCM turns shift solenoid valves A ON, and remains B and E ON, C OFF. Shift solenoid valve A pressure (SA) is applied to the right side of the shift valve A to cover the port of A/T clutch pressure control solenoid valve A pressure, and to uncover the port of line pressure leading to the 4th clutch creating full line pressure.
  • Page 679 $XWRPDWLF 7UDQVPLVVLRQ >3@ 3RVLWLRQ Shift solenoid valves B and E are turned ON, and A, and C OFF by the PCM. Line pressure (1) flows to the shift solenoid valves and the A/T clutch pressure control solenoid valve A. Line pressure (3) changes to (3’) at the shift valve E, and flows to the servo valve.
  • Page 680 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G /RFNXS 6\VWHP The lock-up mechanism of the torque converter clutch operates in [D] position (3rd and 4th) and [D] position over-drive off mode (3rd). The pressurized fluid is drained from the back of the torque converter through a fluid passage, causing the torque converter clutch piston to be held against the torque converter cover.
  • Page 681 $XWRPDWLF 7UDQVPLVVLRQ 1R /RFNXS Shift solenoid valve E is turned OFF by the PCM, and shift solenoid valve E pressure (SE) is not applied to the lock-up shift valve. The lock-up shift valve stays in the right side to uncover the ports of torque converter pressure leading to the left side of the torque converter and releasing from the right side of the torque converter.
  • Page 682 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G /RFNXS 6\VWHP FRQW G 3DUWLDO /RFNXS As the speed of the vehicle reaches the prescribed value, shift solenoid valve E is turned ON by the PCM, and shift solenoid valve E pressure (SE) is applied to the right side of the lock-up shift valve. The lock-up shift valve is moved to the left side to switch the port of torque converter pressure (91) leading to the right side of the torque converter, and the port of torque converter pressure (94) releasing from the left side of the torque converter.
  • Page 683 $XWRPDWLF 7UDQVPLVVLRQ )XOO /RFNXS When the vehicle speed further increased, the PCM controls the A/T clutch pressure control solenoid valve A to increase A/ T clutch pressure control solenoid valve A pressure (55), and the lock-up control valve is moved to the left by pressure increased amount.
  • Page 684 $XWRPDWLF 7UDQVPLVVLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G &LUFXLW 'LDJUDP  3&0 $7 &RQWURO 6\VWHP DBIDUDPIà VI9@SCPP9ÃAVT@ VI9@S96TCÃAVT@ TXDU8C S@G6`Ã7PY S@G6`Ã7PY 76UU@S` HVGUDQG@Yà 8PIUSPGÃVIDUà P9ÃTXDU8C @‘prƒ‡ÃFTÀ‚qryà QBHADÃH6DIà ‚…à S@G6`à DIU@SGP8Fà HVGUDQG@Yà 8PIUSPGÃVIDUà 8PIUSPGÃVIDU FTÀ‚qry 7S6F@ÃQ@96Gà QPTDUDPIÃTXDU8C HVGUDQG@Yà 8PIUSPGà VIDU QPX@SUS6DIÃ8PIUSPGÃHP9VG@à Q8H VI9@S96TCÃAVT@ S@G6`Ã7PYà B6VB@Ã6TT@H7G` I‚Ã...
  • Page 685 $XWRPDWLF 7UDQVPLVVLRQ 6UÃ8GVU8Cà 6UÃ8GVU8Cà 6UÃ8GVU8Cà QS@TTVS@à QS@TTVS@à QS@TTVS@à 8PIUSPGà 8PIUSPGà 8PIUSPGà !I9Ã8GVU8Cà "S9Ã8GVU8Cà TPG@IPD9à TPG@IPD9à TPG@IPD9à QS@TTVS@à QS@TTVS@à W6GW@Ã6 W6GW@Ã7 W6GW@Ã8 TXDU8C TXDU8C 8SVDT@à 96U6ÃGDIFà 8PIUSPGÃVIDU 8PII@8UPSà %Q ‚Ã†‚€rÇ’ƒr† QPX@SUS6DIÃ8PIUSPGÃHP9VG@ÃQ8H 6UAà U@HQ@S6UVS@à UCSPUUG@à H6DITC6AUà H6IDAPG9à 8PVIU@STC6AUà T@ITPS TCDAUÃTPG@IPD9à QPTDUDPIà TQ@@9ÃT@ITPS 67TPGVU@Ã...
  • Page 686 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ '7& 3 3UREOHP LQ $7) 7HPSHUDWXUH 6HQVRU  Turn the ignition switch OFF. &LUFXLW  Disconnect the battery nagative terminal. NOTE: Record all freeze data before you troubleshoot.  Disconnect PCM connector A (31P).  Turn the ignition switch OFF.  Check for continuity between the No.
  • Page 687 $XWRPDWLF 7UDQVPLVVLRQ  Measure the voltage between the No. 6 and No. 7  Measure the voltage between PCM connector terminals of the shift solenoid harness connector. terminal C14 and body ground. TCDAUÃTPG@IPD9ÃC6SI@TTÃ8PII@8UPS Q8HÃ8PII@8UPSÃ8 Ã!!Q Wire side of female terminals Wire side of female terminals ,V WKHUH DERXW  9"...
  • Page 688 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 3UREOHP LQ 0DLQVKDIW 6SHHG 6HQVRU  Turn the ignition switch ON (II). &LUFXLW  Measure the voltage between the No. 1 terminal of the mainshaft speed sensor connector and body NOTE: Record all freeze data before you troubleshoot. ground.
  • Page 689 $XWRPDWLF 7UDQVPLVVLRQ  Check for continuity between the No. 3 terminal of  Connect the mainshaft speed sensor connector. the mainshaft speed sensor connector and body  Measure the voltage between PCM connector ground. terminals C7 and A23 or A24. H6DITC6AUÃTQ@@9ÃT@ITPSÃ8PII@8UPS Q8HÃ8PII@8UPST Wire side of female terminals...
  • Page 690 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G  Measure the voltage between PCM connector  Measure the voltage between PCM connector terminal A20 and A23 or A24. terminal C7 and A23 or A24. Q8HÃ8PII@8UPSÃ6Ã" Q Q8HÃ8PII@8UPST Wire side of female terminals Wire side of female terminals ,V WKHUH DERXW  9"...
  • Page 691 $XWRPDWLF 7UDQVPLVVLRQ '7& 3 3UREOHP LQ &RXQWHUVKDIW 6SHHG 6HQVRU  Turn the ignition switch ON (II). &LUFXLW  Measure the voltage between the No. 1 terminal of the countershaft speed sensor connector and body NOTE: Record all freeze data before you troubleshoot. ground.
  • Page 692 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G  Check for continuity between the No. 3 terminal of  Connect the countershaft speed sensor connector. the countershaft speed sensor connector and body  Measure the voltage between PCM connector ground. terminals C15 and A23 or A24. 8PVIU@STC6AUÃTQ@@9ÃT@ITPSÃ8PII@8UPS Q8HÃ8PII@8UPST Wire side of female terminals...
  • Page 693 $XWRPDWLF 7UDQVPLVVLRQ  For 4WD model: Raise the vehicle, make sure it is  Measure the voltage between PCM connector securely supported, and allow the all four wheels to terminals A21 and A23 or A24. rotate freely. For 2WD model: Raise the front of the vehicle, Q8HÃ8PII@8UPSÃ6 Ã"...
  • Page 694 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G  Turn the ignition switch OFF.  Measure the voltage between PCM connector terminals C15 and A23 or A24.  Disconnect the battery negative terminal.  Disconnect PCM connector A (31P). Q8HÃ8PII@8UPST  Check for continuity between PCM connector terminal A21 and body ground.
  • Page 695 $XWRPDWLF 7UDQVPLVVLRQ '7& 3 3UREOHP LQ +\GUDXOLF &RQWURO 6\VWHP RI $7 &OXWFK 3UHVVXUH &RQWURO 6ROHQRLG 9DOYH $ &LUFXLW NOTE: Record all freeze data before you troubleshoot.  Check the fuel and emissions system problem or A/ T system problem is indicated by the DTC. ,V WKHUH DQ\ RI WKH '7&"...
  • Page 696 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 3UREOHP LQ $7 &OXWFK 3UHVVXUH  Disconnect the battery negative terminal. &RQWURO 6ROHQRLG 9DOYH $ &LUFXLW  Disconnect PCM connectors B (24P) and C (22P). NOTE: Record all freeze data before you troubleshoot.  Check for continuity between PCM connector  Disconnect the A/T clutch pressure control solenoid terminals B14 and body ground, and between C1...
  • Page 697 $XWRPDWLF 7UDQVPLVVLRQ  Connect the A/T clutch pressure control solenoid  Disconnect PCM connector A (31P). valve A connector.  Check for continuity between PCM connector  Measure the resistance between PCM connector terminals A23 and body ground, and between A24 terminals B14 and C1.
  • Page 698 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 3UREOHP LQ +\GUDXOLF &RQWURO 6\VWHP  Start the engine, and shift to [1] position. Start the RI 6KLIW 6ROHQRLG 9DOYH $ &LUFXLW vehicle off in [1] position, drive at 25 mph (40 km/h) for 10 seconds, shift into [2] position, drive at NOTE: Record all freeze data before you troubleshoot.
  • Page 699 $XWRPDWLF 7UDQVPLVVLRQ '7& 3 3UREOHP LQ 6KLIW 6ROHQRLG 9DOYH $  Check for continuity between PCM connector &LUFXLW terminals C6 and A23 or A24. NOTE: Record all freeze data before you troubleshoot. Q8HÃ8PII@8UPST  Turn the ignition switch OFF.  Disconnect the battery negative terminal.  Disconnect PCM connectors A (31P) and C (22P).
  • Page 700 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G  Disconnect the shift solenoid harness connector.  Check for continuity between PCM connector terminal C6 and the No. 5 terminal of the shift solenoid harness connector. Q8HÃ8PII@8UPSÃ8 Ã!!Q TCDAUÃTPG@IPD9Ã C6SI@TTÃ 8PII@8UPS Wire side of female terminals ,V WKHUH FRQWLQXLW\"...
  • Page 701 $XWRPDWLF 7UDQVPLVVLRQ '7& 3 3UREOHP LQ 6KLIW 6ROHQRLG 9DOYH %  Check for continuity between PCM connector &LUFXLW terminals C4 and A23 or A24. NOTE: Record all freeze data before you troubleshoot. Q8HÃ8PII@8UPST  Turn the ignition switch OFF.  Disconnect the battery negative terminal.  Disconnect PCM connectors A (31P) and C (22P).
  • Page 702 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G  Disconnect the shift solenoid harness connector.  Check for continuity between PCM connector terminal C4 and No. 2 terminal of the shift solenoid harness connector. Q8HÃ8PII@8UPSÃ8Ã!!Q TCDAUÃTPG@IPD9Ã C6SI@TTÃ 8PII@8UPS Wire side of female terminals ,V WKHUH FRQWLQXLW\"...
  • Page 703 $XWRPDWLF 7UDQVPLVVLRQ '7& 3 3UREOHP LQ 6KLIW 6ROHQRLG 9DOYH &  Check for continuity between PCM connector &LUFXLW terminals C2 and A23 or A24. NOTE: Record all freeze data before you troubleshoot. Q8HÃ8PII@8UPST  Turn the ignition switch OFF.  Disconnect the battery negative terminal.  Disconnect PCM connectors A (31P) and C (22P).
  • Page 704 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G  Disconnect the shift solenoid harness connector.  Check for continuity between PCM connector terminal C2 and the No. 1 terminal of the shift solenoid harness connector. TCDAUÃTPG@IPD9Ã Q8HÃ8PII@8UPSÃ8Ã!!Q C6SI@TTÃ 8PII@8UPS Wire side of female terminals ,V WKHUH FRQWLQXLW\"...
  • Page 705 $XWRPDWLF 7UDQVPLVVLRQ '7& 3 3UREOHP LQ 6KLIW 6ROHQRLG 9DOYH (  Check for continuity between PCM connector &LUFXLW terminals C3 and A23 or A24. NOTE: Record all freeze data before you troubleshoot. Q8HÃ8PII@8UPST  Turn the ignition switch OFF.  Disconnect the battery negative terminal.  Disconnect PCM connectors A (31P) and C (22P).
  • Page 706 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G  Disconnect the shift solenoid harness connector.  Check for continuity between PCM connector terminal C3 and the No. 3 terminal of the shift solenoid harness connector. TCDAUÃTPG@IPD9Ã Q8HÃ8PII@8UPSÃ8Ã!!Q C6SI@TTÃ 8PII@8UPS Wire side of female terminals ,V WKHUH FRQWLQXLW\"...
  • Page 707 $XWRPDWLF 7UDQVPLVVLRQ '7& 3 3UREOHP LQ +\GUDXOLF &RQWURO 6\VWHP RI $7 &OXWFK 3UHVVXUH &RQWURO 6ROHQRLG 9DOYH % &LUFXLW NOTE: Record all freeze data before you troubleshoot.  Check the fuel and emissions system problem or A/T system problem is indicated by the DTC. ,V WKHUH DQ\ RI WKH '7&"...
  • Page 708 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 3UREOHP LQ $7 &OXWFK 3UHVVXUH  Disconnect the battery negative terminal. &RQWURO 6ROHQRLG 9DOYH % &LUFXLW  Disconnect PCM connectors B (24P) and C (22P). NOTE: Record all freeze data before you troubleshoot.  Check for continuity between PCM connector  Disconnect the A/T clutch pressure control solenoid terminals B16 and body ground, and between C8...
  • Page 709 $XWRPDWLF 7UDQVPLVVLRQ  Connect the A/T clutch pressure control solenoid  Disconnect PCM connector A (31P). valve B connector.  Check for continuity between PCM connector  Measure the resistance between PCM connector terminals A23 and body ground, and between A24 terminals B16 and C8.
  • Page 710 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 0HFKDQLFDO 3UREOHP LQ +\GUDXOLF  Replace the shift solenoid valves A, B, C and E &RQWURO 6\VWHP (see page 14-114).  Reset the PCM memory by removing the No. 6 NOTE: ‡ Record all freeze data before you troubleshoot. ECU (15A) fuse in the under-hood fuse/relay box ‡...
  • Page 711 $XWRPDWLF 7UDQVPLVVLRQ '7& 3 3UREOHP LQ +\GUDXOLF &RQWURO 6\VWHP  Reset the PCM memory by removing the No. 6 RI $7 &OXWFK 3UHVVXUH &RQWURO 6ROHQRLG 9DOYH & ECU (15A) fuse in the under-hood fuse/relay box &LUFXLW for more than 10 seconds.  Start the vehicle off in [2] position, accelerate to NOTE: Record all freeze data before you troubleshoot.
  • Page 712 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 3UREOHP LQ $7 &OXWFK 3UHVVXUH  Disconnect the battery negative terminal. &RQWURO 6ROHQRLG 9DOYH & &LUFXLW  Disconnect PCM connectors B (24P) and C (22P). NOTE: Record all freeze data before you troubleshoot.  Check for continuity between PCM connector  Disconnect the A/T clutch pressure control solenoid terminals B24 and body ground, and between C16...
  • Page 713 $XWRPDWLF 7UDQVPLVVLRQ  Connect the A/T clutch pressure control solenoid  Disconnect PCM connector A (31P). valve C connector.  Check for continuity between PCM connector  Measure the resistance between PCM connector terminals A23 and body ground, and between A24 terminals B24 and C16.
  • Page 714 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 3UREOHP LQ QG &OXWFK 3UHVVXUH 6ZLWFK  Measure the voltage between the 2nd clutch &LUFXLW pressure switch connector terminal and body ground. NOTE: Record all freeze data before you troubleshoot.  Disconnect the 2nd clutch pressure switch. !I9Ã8GVU8CÃQS@TTVS@ÃTXDU8CÃ8PII@8UPS  Turn the ignition switch ON (II).
  • Page 715 $XWRPDWLF 7UDQVPLVVLRQ  Connect the 2nd clutch pressure switch connector.  Raise the front of the vehicle, make sure it is securely supported, and allow the front wheels to rotate freely.  Start the engine, and shift into [2] position.  Drive the vehicle in 2nd gear for more than five seconds.
  • Page 716 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 3UREOHP LQ UG &OXWFK 3UHVVXUH 6ZLWFK  Measure the voltage between the 3rd clutch &LUFXLW pressure switch connector terminal and body ground. NOTE: Record all freeze data before you troubleshoot.  Disconnect the 3rd clutch pressure switch. "S9Ã8GVU8CÃQS@TTVS@ÃTXDU8CÃ8PII@8UPS  Turn the ignition switch ON (II).
  • Page 717 $XWRPDWLF 7UDQVPLVVLRQ  Connect the 3rd clutch pressure switch connector.  For 4WD model: Raise the vehicle, make sure it is securely supported, and allow the all four wheels to rotate freely. For 2WD model: Raise the front of the vehicle, make sure it is securely supported, and allow the front wheels to rotate freely.
  • Page 718 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 6KRUW LQ 7UDQVPLVVLRQ 5DQJH 6ZLWFK  Turn the ignition switch ON (II). &LUFXLW  Shift to all positions other than [P]. NOTE: Record all freeze data before you troubleshoot.  Measure the voltage between PCM connector  Turn the ignition switch ON (II).
  • Page 719 $XWRPDWLF 7UDQVPLVVLRQ  Shift to all positions other than [R].  Measure the voltage between PCM connector terminals C12 and A23 or A24.  Measure the voltage between PCM connector terminals D5 and A23 or A24. Q8HÃ8PII@8UPST Q8HÃ8PII@8UPST Wire side of female terminals ,V WKHUH DERXW  9"...
  • Page 720 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G  Shift to all positions other than [N].  Shift to all positions other than [D].  Measure the voltage between PCM connector  Measure the voltage between PCM connector terminals D4 and A23 or A24. terminals D10 and A23 or A24.
  • Page 721 $XWRPDWLF 7UDQVPLVVLRQ  Shift to all positions other than [2].  Shift to all positions other than [1].  Measure the voltage between PCM connector  Measure the voltage between PCM connector terminals C11 and A23 or A24. terminals C19 and A23 or A24. Q8HÃ8PII@8UPST Q8HÃ8PII@8UPST Wire side of female terminals...
  • Page 722 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 2SHQ LQ 7UDQVPLVVLRQ 5DQJH 6ZLWFK  Connect the transmission range switch connector. &LUFXLW  Check for continuity between PCM connector terminals A23 and body ground, and between A24 NOTE: Record all freeze data before you troubleshoot. and body ground.
  • Page 723 $XWRPDWLF 7UDQVPLVVLRQ  Turn the ignition switch ON (II).  Shift to [D] position.  Measure the voltage between PCM connector terminals D10 and A23 or A24. Q8HÃ8PII@8UPST Wire side of female terminals ,V WKHUH YROWDJH" <HV Repair open in the wire between PCM connector terminal D10 and the transmission range switch.
  • Page 724 $XWRPDWLF 7UDQVPLVVLRQ '7& 7URXEOHVKRRWLQJ FRQW¶G '7& 3 3UREOHP LQ $73 596 6LJQDO &LUFXLW RI  Turn the ignition switch OFF. 7UDQVPLVVLRQ 5DQJH 6ZLWFK  Check for continuity between PCM connector terminals A23 and body ground, and between A24 NOTE: Record all freeze data before you troubleshoot. and body ground.
  • Page 725 $XWRPDWLF 7UDQVPLVVLRQ  Turn the ignition switch ON (II).  Turn the ignition switch OFF.  Shift to [R] position.  Disconnect the transmission range switch connector.  Measure the voltage between PCM connector  Check for continuity between the No. 1 and No. 10 terminals C12 and A23 or A24.
  • Page 726 $XWRPDWLF 7UDQVPLVVLRQ 2YHUGULYH 2' 6ZLWFK &LUFXLW 7URXEOHVKRRWLQJ  Turn the ignition switch OFF.  Measure the voltage between No. 6 terminal and body ground.  Disconnect the O/D switch/shift lock solenoid/park pin switch connector (see page 14-124). P9ÃTXDU8CTCDAUÃGP8FÃTPG@IPD9  Check for continuity between the No. 5 and No. 6 Q6SFÃQDIÃTXDU8CÃ8PII@8UPS terminals of the O/D switch/shift lock solenoid/park pin switch connector while pushing the O/D switch...
  • Page 727 Start the engine, then shift to [D] position while pressing the brake pedal. Press the accelerator pedal, and release it suddenly. The engine should not stall.  If the Honda PGM Tester is available, connect the Honda PGM Tester to the DLC (see page 14-4), and go to the PGM-FI Data List, then go to step 8.
  • Page 728 $XWRPDWLF 7UDQVPLVVLRQ 5RDG 7HVW FRQW¶G  Test-drive the vehicle on a flat road in the [D] position, check for abnormal noise and clutch slippage. While driving, check that the shift points occur at the proper speeds by monitoring the throttle position sensor voltage and comparing your shift point speeds and voltage to those in the table.
  • Page 729 $XWRPDWLF 7UDQVPLVVLRQ 6WDOO 6SHHG 7HVW  Set the parking brake, and block all four wheels.  If the measurements are out of the service limit, problems and probable causes are listed in the  Connect a tachometer to the engine, and start the table below: engine.
  • Page 730 $XWRPDWLF 7UDQVPLVVLRQ 3UHVVXUH 7HVWV 6SHFLDO 7RROV 5HTXLUHG  Remove the air cleaner housing, and connect the oil pressure gauge to the 2nd clutch pressure A/T oil pressure gauge set 07406-0020004 inspection hole (C). Then temporarily reinstall the  Before testing, be sure the transmission fluid filled air cleaner housing.
  • Page 731 $XWRPDWLF 7UDQVPLVVLRQ  If the measurements are out of service limit,  Start the engine, and run it at 2,000 rpm (min problems and probable causes are listed in the  Shift to [N] or [P] position, and measure line table below: pressure at the line pressure inspection hole (A).
  • Page 732 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW 6ROHQRLG 9DOYHV 7HVW  Remove the drain plug (A), and drain the automatic  Place the transmission jack under the transmission, transmission fluid (ATF). and lift it up create clearance between the transmission and front sub-frame.  Disconnect the shift solenoid harness connector.  Remove the bolt (A) securing the bracket (B) of the AFT cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing...
  • Page 733 $XWRPDWLF 7UDQVPLVVLRQ  Remove the bolt (A), and remove the shift solenoid  Replace the solenoid harness if the tests results harness connector (B). are OK.  Install the new O-ring on the shift solenoid harness connector, and install the connector in the transmission housing.
  • Page 734 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW 6ROHQRLG 9DOYHV 5HSODFHPHQW  Remove the drain plug (A), and drain the automatic  Place the transmission jack under the transmission, transmission fluid (ATF). and lift it up to create clearance between the transmission and front sub-frame.  Remove the bolt (A) securing the bracket (B) of the ATF cooler inlet line (C) on the shift solenoid valve cover (D), and remove the line bolt (E) with sealing...
  • Page 735 $XWRPDWLF 7UDQVPLVVLRQ  Disconnect the shift solenoid valve connectors.  Connect the solenoid valve B connector (ORN wire), solenoid valve C connector (GRN wire), and  Remove the bolts, and hold the shift solenoid valve solenoid valve E connector (RED wire). body, then remove them.
  • Page 736 $XWRPDWLF 7UDQVPLVVLRQ $7 &OXWFK 3UHVVXUH &RQWURO 6ROHQRLG 9DOYH $ 7HVW  Remove the air cleaner housing.  Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt.  Disconnect the A/T clutch pressure control solenoid  Connect the No.
  • Page 737 $XWRPDWLF 7UDQVPLVVLRQ $7 &OXWFK 3UHVVXUH &RQWURO 6ROHQRLG 9DOYH $ 5HSODFHPHQW  Remove the air cleaner housing.  Clean the mounting surface and fluid passage of the A/T clutch pressure control solenoid valve A  Disconnect the A/T clutch pressure control solenoid and transmission housing.
  • Page 738 $XWRPDWLF 7UDQVPLVVLRQ $7 &OXWFK 3UHVVXUH &RQWURO 6ROHQRLG 9DOYHV % DQG & 7HVW  Remove the air cleaner housing.  Check the fluid passage of the A/T clutch pressure control solenoid valve for dust or dirt.  Disconnect the A/T clutch pressure control solenoid  Connect the No.
  • Page 739 $XWRPDWLF 7UDQVPLVVLRQ $7 &OXWFK 3UHVVXUH &RQWURO 6ROHQRLG 9DOYHV % DQG & 5HSODFHPHQW  Remove the air cleaner housing.  Clean the mounting surface and fluid passage of the A/T clutch pressure control solenoid valves B  Disconnect the A/T clutch pressure control solenoid and C and transmission housing.
  • Page 740 $XWRPDWLF 7UDQVPLVVLRQ 0DLQVKDIW DQG &RXQWHUVKDIW 6SHHG 6HQVRUV 5HSODFHPHQW  Disconnect the mainshaft speed sensor connector and countershaft speed sensor connector.  Remove the mainshaft speed sensor (A) and countershaft speed sensor (B).  Install the new O-ring (C) on the mainshaft speed sensor, and install the mainshaft speed sensor in the transmission housing.
  • Page 741 $XWRPDWLF 7UDQVPLVVLRQ QG &OXWFK 3UHVVXUH 6ZLWFK 5HSODFHPHQW UG &OXWFK 3UHVVXUH 6ZLWFK 5HSODFHPHQW  Remove the air cleaner housing.  Disconnect the connector from the 3rd clutch pressure switch (A).  Disconnect the connector from the 2nd clutch pressure switch (A).  Replace the 3rd clutch pressure switch ,then install a new one with a new sealing washer (B).
  • Page 742 $XWRPDWLF 7UDQVPLVVLRQ $7) 7HPSHUDWXUH 6HQVRU 7HVW5HSODFHPHQW  Remove the drain plug (A), and drain the automatic  Place the transmission jack under the transmission, transmission fluid (ATF). and lift it up to create clearance between the transmission and front sub-frame.  Disconnect the shift solenoid harness connector.
  • Page 743 $XWRPDWLF 7UDQVPLVVLRQ  Remove the bolt (A), and remove the shift solenoid  Connect the shift solenoid valve A connector with harness connector (B). the ATF temperature sensor (F) on the new solenoid harness.  Measure ATF temperature sensor resistance between the No.
  • Page 744 $XWRPDWLF 7UDQVPLVVLRQ 2' 6ZLWFK 7HVW5HSODFHPHQW  Remove the ash tray, front console box, heater  Shift the shift lever to [R] position. control panel (see page 20-91), driver’s dashboard  Slide the lock tab (A) down on the shift cable and lower cover (see page 20-88), and dashboard...
  • Page 745 $XWRPDWLF 7UDQVPLVVLRQ  Rotate the socket holder (A) on the shift cable (B) a  Remove the shift lever assembly. quarter turn; the tab (C) on the socket holder will be NOTE: The illustration shows LHD model; RHD is in the opening (D) of the socket holder bracket (E). symmetrical.
  • Page 746 $XWRPDWLF 7UDQVPLVVLRQ 2' 6ZLWFK 7HVW5HSODFHPHQW FRQW¶G  Remove the shift lever knob (A), then remove the  Pull the O/D switch harnesses (A) from shift lever O/D switch (B) from the knob. bracket side, and remove them. Leave the harness tube (B) while removing the harnesses.
  • Page 747 $XWRPDWLF 7UDQVPLVVLRQ  Insert the new O/D switch harness terminals (A) in  Install the O/D switch harness terminals in the new preserved harness tube (B), then tie a string (C) O/D switch. Both harness terminals can be over the tube not to allow the terminals out of the installed in either cavities.
  • Page 748 $XWRPDWLF 7UDQVPLVVLRQ 2' 6ZLWFK 7HVW5HSODFHPHQW FRQW¶G  Align the marks (A) on the harnesses, and tie the  Turn the ignition switch ON (II), and verify that the harness band (B) over the marks. Clamp the O/D [R] position indicator comes on. switch harness (C) at 15 mm (0.6 in.) (D) from the  If necessary, push the shift cable until it stops, then harness band.
  • Page 749 $XWRPDWLF 7UDQVPLVVLRQ  Rotate the socket holder (A) on the shift cable (B)  Install the shift cable end (A) in the shift cable end to face the tab (C) on the holder opposite to the holder (B). Keep the shift cable end and end holder opening (D) in the socket holder bracket (E).
  • Page 750 Genuine Honda ATF-Z1 Automatic  Remove the dipstick (yellow loop) (A) from the Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. transmission, and wipe it with a clean cloth.  Insert the dipstick (A) back into the transmission with facing the handle toward the breathe tube (B).
  • Page 751  Refill transmission with the recommended fluid amount through the dipstick hole until the lever reaches the upper mark on the dipstick. Always use Genuine Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. 6ˆ‡‚€h‡vpÃU…h†€v††v‚ÃAyˆvqÃ8hƒhpv‡’) #X9) "...
  • Page 752 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVIHU $VVHPEO\ ,QVSHFWLRQ  Rise the vehicle, and make sure it is supported  If the measurement is out of standard, remove the securely. transfer assembly, and adjust the transfer gear backlash (see page 14-281).  Shift the transmission into the [N] position.  Check for fruid leaks between the masting faces of  Make a reference mark (A) across the propeller the transfer assembly and transmission.
  • Page 753 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVIHU $VVHPEO\ 5HPRYDO  Raise the vehicle, and make sure it is supported  Remove the transfer assembly. securely.  Remove the drain plug (A), and drain the automatic transmission fluid (ATF). Reinstall the drain plug with a new sealing washer (B).  Make a reference mark (A) across the propeller shaft (B) and the transfer companion flange (C).
  • Page 754 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVIHU $VVHPEO\ ,QVWDOODWLRQ  Clean the area where the trainer assembly contacts  Install the propeller shaft (A) to the transfer the transmission with solvent or carburetor cleaner, companion flange (B) by aligning the reference and dry with compressed air. Then apply mark (C).
  • Page 755 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HPRYDO  Raise the vehicle, and make sure it is securely  Remove the transmission ground terminal (A). supported.  Remove the splash shield.  Remove the drain plug (A), and drain the automatic transmission fluid (ATF). Reinstall the drain plug with a new sealing washer (B).
  • Page 756 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HPRYDO FRQW¶G  Disconnect the 3rd clutch pressure switch  Remove the ATF cooler hoses (A) from the ATF connector. cooler lines (B). Turn the ends of the ATF cooler hoses up to prevent ATF from flowing out, then plug the ATF cooler hoses and lines.
  • Page 757 $XWRPDWLF 7UDQVPLVVLRQ  Insert a 5 mm Allen wrench (A) in the top of the ball  Remove the shift cable for 4WD model. joint pin (B), and remove the nut (C), then separate 1 Remove the bolts (A) securing the shift cable the stabilizer link (D) from the lower arm.
  • Page 758 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HPRYDO FRQW¶G  Remove the shift cable for 2WD model.  Disconnect the ATF cooler hose (A) from the ATF cooler line (B), then plug the end of the hose. 1 Remove the shift cable cover (A). 2 Remove the spring clip (B) and control pin (C), then separate the shift cable (D) from the control lever (E).
  • Page 759 $XWRPDWLF 7UDQVPLVVLRQ  Make the appropriate reference lines at positions A  Remove the four sub-frame mounting bolts, then and B that line up with the center of the sub-frame lower the sub-frame. mounting bolts (C). Replace. Replace.  Support the sub-frame (A) with a 4 x 4 x 40 in.  For 4WD model;...
  • Page 760 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HPRYDO FRQW¶G  Pry the left driveshaft out of the differential  Place a jack under the transmission. (see page 16-3).  Remove the transmission housing mounting bolts.  Remove the driveshafts from the differential and intermediate shaft.  Remove the transmission mount bracket bolt (A) and nuts (B), then remove the transmission mount  Remove the intermediate shaft cover (A).
  • Page 761 $XWRPDWLF 7UDQVPLVVLRQ  Remove the transmission housing mounting bolts  Remove the torque converter assembly. located on front lower of the transmission.  Remove the front mount.  Remove the stiffener (A), then remove the transmission housing mounting bolts (B) located on rear lower of the transmission.
  • Page 762 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ 5HPRYDO FRQW¶G  Remove the rear mount/bracket.  Inspect the drive plate, and replace it if it’s damaged. NOTE: The illustration shows the 4WD model; 2WD model is similar.  Remove the air cleaner housing mounting bracket. ...
  • Page 763 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ ,QVWDOODWLRQ  Install the air cleaner housing mounting bracket.  Install the rear mount/bracket. NOTE: The illustration shows the 4WD model; 2WD model is similar.  Install the front mount.  Install the torque converter assembly (A) on the mainshaft (B) with the new O-ring (C).
  • Page 764 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ ,QVWDOODWLRQ FRQW¶G  Place the transmission on a jack, and raise the  Install the transmission housing mounting bolts. transmission to the engine level.  Attach the transmission to the engine, then install the transmission housin mounting bolts.  Install the transmission mount bracket.
  • Page 765 $XWRPDWLF 7UDQVPLVVLRQ  Install the new set ring (A) on the intermediate shaft  Install the new set ring (A) on the left driveshaft (B). (B).  Install the right and left driveshaft (see page 16-17). While installing the left driveshaft in the differential, be sure not to allow dust or other foreign particles to enter the transmission.
  • Page 766 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ ,QVWDOODWLRQ FRQW¶G  Install the propeller shaft (A) to the transfer  Loosely install the new sub-frame mounting bolts. companion flange (B) by aligning the reference mark (C).  Support the sub-frame (A) with a 4 x 4 x 40 in. piece of wood (B), and lift it up to body.
  • Page 767 $XWRPDWLF 7UDQVPLVVLRQ  Install the rear mount bolts.  Install the shift cable for 4WD model. 1 Face the dot (A) on the shift cable (B) down, then install the shift cable bracket (C) on the shift cable. 2 Attach the shift cable end (D) to the control lever (E), then insert the control pin (F) into the control lever hole through the shift cable end.
  • Page 768 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ ,QVWDOODWLRQ FRQW¶G  Install the shift cable for 2WD model.  Attach the torque converter to the drive plate with eight bolt (A). Rotate the crankshaft pulley as 1 Attach the shift cable end (A) to the control lever (B), necessary to tighten the bolts to 1/2 of the specified then insert the control pin (C) into the control lever torque, then to the final torque, in a crisscross...
  • Page 769 $XWRPDWLF 7UDQVPLVVLRQ  Connect the ATF cooler hoses (A) to the ATF  Connect the 3rd clutch pressure switch connector. cooler lines (B) (see page 14-151).  Install the splash shield.  Remove the hoist from the hoisting bracket (A), and remove the hoisting bracket and collar (B) (if  Connect the shift solenoid harness connector (A), installed) from the engine.
  • Page 770 $XWRPDWLF 7UDQVPLVVLRQ 7UDQVPLVVLRQ ,QVWDOODWLRQ FRQW¶G  Connect the transmission range switch connector  Install the battery base, then install the harness (A), and install it on its bracket (B). clamp on the clamp bracket on the base.  Refill the transmission with ATF (see page 14-131).
  • Page 771 $XWRPDWLF 7UDQVPLVVLRQ $7) &RROHU +RVHV 5HSODFHPHQW  Insert the ATF cooler hoses (A) to the ATF filter (B) at 5 6 mm (0.20 0.24 in.) (C) away from the ATF filter surfaces.  Secure the hoses with the clips (D) at 10 12 mm (0.4 0.5 in.) (E) away from the ATF filter surfaces.
  • Page 772 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW /HYHU 5HPRYDO  Remove the ash tray, front console box, heater  Rotate the socket holder (A) on the shift cable (B) a control panel (see page 20-91), driver’s dashboard quarter turn; the tab (C) on the socket holder will be lower cover (see page 20-88), and dashboard...
  • Page 773 $XWRPDWLF 7UDQVPLVVLRQ  Remove the shift lever assembly. NOTE: The illustration shows LHD model; RHD is symmetrical. ...
  • Page 774 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW /HYHU ,QVWDOODWLRQ  Install the shift lever assembly.  Turn the ignition switch ON (II), and verify that the [R] position indicator comes on. NOTE: The illustration shows LHD model; RHD is symmetrical.  If necessary, push the shift cable until it stops, then release it.
  • Page 775 $XWRPDWLF 7UDQVPLVVLRQ  Rotate the socket holder (A) on the shift cable (B)  Install the shift cable end (A) in the shift cable end to face the tab (C) on the holder opposite to the holder (B). Keep the shift cable end and end holder opening (D) in the socket holder bracket (E).
  • Page 776 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW /HYHU 'LVDVVHPEO\5HDVVHPEO\ NOTE: The illustration shows the LHD model: RHD is symmetrical. TCDAUÃGP8FÃTPG@IPD9à TCDAUÃGP8FÃTPG@IPD9à QGVIB@S TCDAUÃGP8FÃS@G@6T@ TCDAUÃG@W@SÃGDIFÃ7VTCDIB QGVIB@SÃTQSDIB TCDAUÃGP8FÃS@G@6T@ÃTQSDIB TCDAUÃG@W@SÃGDIF G@W@SÃ8PW@S X6TC@S TCDAUÃG@W@SÃFIP7 P9ÃTXDU8C T@GAGP8FDIBÃIVUà ('ÃIÀà ÃxtsÀÃ&!ÃyisÃs‡ C6SI@TTÃ8G6HQ T8S@XÃ"ÑÃ$À€ %Ñà À€ #ÃIÀÃ#ÃxtsÀÃ"ÃyisÃs‡ ('ÃIÀà ÃxtsÀÃ&!ÃyisÃs‡ Apply non-hardening thread lock Q6SFÃQDIÃTXDU8C sealent.
  • Page 777 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW &DEOH 5HSODFHPHQW  Raise the front of the vehicle, and make sure it is  Rotate the socket holder (A) on the shift cable (B) a securely supported, or lift the vehicle up. quarter turn; the tab (C) on the socket holder will be in the opening (D) of the socket holder bracket (E).
  • Page 778 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW &DEOH 5HSODFHPHQW FRQW¶G  For RHD model; Remove the shift cable from the  Replace the shift cable for 4WD model. clamp. 1 Remove the bolts (A) securing the shift cable NOTE: The LHD model doesn’t have shift cable bracket (B), then remove the shift cable cover (C).
  • Page 779 $XWRPDWLF 7UDQVPLVVLRQ  Replace the shift cable for 2WD model.  Install the shift cable bracket (A) on the body, then install the grommet (B) in its hole (C). 1 Remove the shift cable cover (A). 2 Remove the spring clip (B) and control pin (C), then separate the shift cable (D) from the control lever (E).
  • Page 780 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW &DEOH 5HSODFHPHQW FRQW¶G  Turn the ignition switch ON (II), and verify that the  Rotate the socket holder (A) on the shift cable (B) [R] position indicator comes on. to face the tab (C) on the holder opposite to the opening (D) in the socket holder bracket (E).
  • Page 781 $XWRPDWLF 7UDQVPLVVLRQ  Install the shift cable end (A) in the shift cable end  Remove the 6.0 mm (0.24 in.) pin that was installed holder (B). Keep the shift cable end and end holder to hold the shift lever. free of grease.
  • Page 782 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW &DEOH $GMXVWPHQW  Remove the ash tray, front console box, heater  Rotate the socket holder (A) on the shift cable (B) a control panel (see page 20-91), driver’s dashboard quarter turn; the tab (C) on the socket holder will be lower cover (see page 20-88), and dashboard...
  • Page 783 $XWRPDWLF 7UDQVPLVVLRQ  Push the shift cable down until it stops, then  Rotate the socket holder (A) on the shift cable (B) release it. Pull the shift cable back one step so that to face the tab (C) on the holder opposite to the the shift cable is in [R].
  • Page 784 $XWRPDWLF 7UDQVPLVVLRQ 6KLIW &DEOH $GMXVWPHQW FRQW¶G  Install the shift cable end (A) in the shift cable end  Remove the 6.0 mm (0.24 in.) pin that was installed holder (B). Keep the shift cable end and end holder to hold the shift lever. free of grease.
  • Page 785 $7 *HDU 3RVLWLRQ ,QGLFDWRU $7 *HDU 3RVLWLRQ ,QGLFDWRU &RPSRQHQW /RFDWLRQ ,QGH[ NOTE: The illustration shows the LHD model; RHD is symmetrical. NOTE: The illustration shows the LHD model; RHD is similar. " Indicator Input test, page 14-167; Indicator Bulb Replacement, page 14-171 6UÃB@6SÃQPTDUDPIÃDI9D86UPS QPX@SUS6DIÃ8PIUSPG ÃHP9VG@ÃQ8H...
  • Page 786 $7 *HDU 3RVLWLRQ ,QGLFDWRU &LUFXLW 'LDJUDP VI9@S96TCÃAVT@ VI9@SCPP9ÃAVT@S@G6`Ã DBIDUDPIÃTXDU8C S@G6`Ã7PY 76UU@S` P9ÃTXDU8C HVGDQG@YÃ8PIUSPGÃ VIDU QPX@SUS6DIÃ8PIUPG@ÃHP9VG@ÃQ8H B6VB@Ã6TT@H7G` TU6SU@SÃ 8VUÃ S@G6` 9DHHDIBÃ 8DS8VDU US6ITHDTTPIÃS6IB@ÃTXDU8C ...
  • Page 787 $7 *HDU 3RVLWLRQ ,QGLFDWRU ,QGLFDWRU ,QSXW 7HVW  If the MIL has been reported, check for a DTC, and  Check for voltage A18 terminal (YEL) and ground repair the system as indicated by DTC. with the ignition switch ON (II). There should be battery voltage.
  • Page 788 $7 *HDU 3RVLWLRQ ,QGLFDWRU 7UDQVPLVVLRQ 5DQJH 6ZLWFK 7HVW  Remove the transmission range switch harness  If there is no continuity between any terminals, connector (A) from the connector bracket (B), then remove the transmission range switch cover, and disconnect the connector. disconnect the connect at the switch.
  • Page 789 $7 *HDU 3RVLWLRQ ,QGLFDWRU 7UDQVPLVVLRQ 5DQJH 6ZLWFK 5HSODFHPHQW  Raise the vehicle, and make sure it is securely  Make sure that the control shaft is in [N] position. If supported. necessary, move the shift lever to [N] position.  Shift to [N] position.  Remove the transmission range switch cover.
  • Page 790 $7 *HDU 3RVLWLRQ ,QGLFDWRU 7UDQVPLVVLRQ 5DQJH 6ZLWFK 5HSODFHPHQW FRQW¶G  Install the transmission range switch (A) gently on  Connect the connector securely, then install the the control shaft (B) with holding the [N] position transmission range switch cover (A). with the 2.0 mm (0.08 in.) blade (C).
  • Page 791 $7 *HDU 3RVLWLRQ ,QGLFDWRU ,QGLFDWRU %XOE 5HSODFHPHQW  Remove the gauge assembly.  Replace the bulb (A) at the gauge assembly (B). ...
  • Page 792 $7 ,QWHUORFN 6\VWHP $7 ,QWHUORFN 6\VWHP &RPSRQHQW /RFDWLRQ ,QGH[ /+' 0RGHO TU@@SDIBÃGP8FÃ6TT@H7G`ÃF@`Ã Q6SFÃQDIÃTXDU8C Test/Replacement, page 14-187 DIU@SGP8FÃTPG@IPD9 System circuit troubleshooting, TCDAUÃGP8FÃTPG@IPD9 page 14-179 System circuit troubleshooting, page 14-175 Test, page 14-181 Test/Replacement, page 14-182 DIU@SGP8FÃ8PIUSPGÃVIDUÃFTÃHP9@G Input test, page 14-180 VI9@S96TCÃAVT@S@G6`Ã7PYÃ I‚Ã...
  • Page 793 $7 ,QWHUORFN 6\VWHP &LUFXLW 'LDJUDP ([FHSW .6 0RGHO VI9@SCPP9ÃAVT@S@G6`Ã DBIDUDPIÃ VI9@S96TCÃAVT@ TXDU8C S@G6`Ã7PY 76UU@S` TCDAUÃGP8FÃ TPG@IPD9 7S6F@ÃQ@96GÃ F@`Ã QPTDUDPIÃTXDU8C Q6SFÃ DIU@S QDIÃ GP8FÃ TXDU8C S@G6` F@`Ã DIU@S GP8FÃ TPG@IPD9 TCDAUÃGP8FÃ TPG@IPD9 HVGUDQG@YÃ8PIUSPGÃVIDU bIdÃQPTDUDPIÃ bQdÃQPTDUDPI US6ITHDTTDPIÃS6IB@ÃTXDU8C QPX@SUS6DIÃ8PIUSPGÃHP9VG@ÃQ8H (cont’d) ...
  • Page 794 $7 ,QWHUORFN 6\VWHP &LUFXLW 'LDJUDP FRQW¶G .6 0RGHO VI9@S96TCÃAVT@ VI9@SCPP9ÃAVT@S@G6`Ã DBIDUDPIÃ S@G6`Ã7PY TXDU8C 76UU@S` TCDAUÃGP8FÃ TPG@IPD9 F@`Ã DIU@SGP8FÃ S@G6` Q6SFÃ QDIÃ TXDU8C TCDAUÃ GP8FÃ S@G6` 7S6F@Ã TCDAUÃ QQDIÃ F@`ÃGP8FÃ Q@96GÃ GP8FÃ TXDU8C QPTDUDPIÃ TPG@IPD9 TXDU8C DIU@SGP8FÃ8PIUSPGÃVIDU US6ITHDTTDPIÃ S6IB@ÃTXDU8CÃ bIdÃQPTDUDPI QPX@SUS6DIÃ8PIUSPGÃHP9VG@ÃQ8H ...
  • Page 795 $7 ,QWHUORFN 6\VWHP 6KLIW /RFN 6\VWHP &LUFXLW 7URXEOHVKRRWLQJ  Press the brake pedal.  Disconnect PCM connectors A (31P) and E (31P). $UH WKH EUDNH OLJKWV 21"  Reconnect the battery negative terminal. <HV Go to step 2.  Press the brake pedal, and measure the voltage between PCM connector terminals E22 and A23 or 1R Repair faulty brake light circuit.
  • Page 796 $7 ,QWHUORFN 6\VWHP 6KLIW /RFN 6\VWHP &LUFXLW 7URXEOHVKRRWLQJ FRQW¶G  Remove the under-dash fuse/relay box, and  Disconnect the O/D switch/shift lock solenoid/park disconnect the No. 10 connector (13P) from the pin switch connector (see page 14-152). fuse/relay box.  Turn the ignition switch ON (II).  Measure the voltage between the No.
  • Page 797 $7 ,QWHUORFN 6\VWHP  Measure the voltage between the No. 3 and No. 4  Connect the battery positive terminal to the No. 4 terminals of the O/D switch/shift lock solenoid/park terminal of the O/D switch/shift lock solenoid/park pin switch connector while pressing the brake pin switch connector, and connect the battery pedal.
  • Page 798 $7 ,QWHUORFN 6\VWHP 5HYHUVH /RFN 6\VWHP &LUFXLW 7URXEOHVKRRWLQJ  Check whether the DTC 1705 or 1706 is indicated. ,V HLWKHU '7& LQGLFDWHG" <HV Perform the Troubleshooting Flowchart for the indicated Code(s). 1R Go to step 2.  Turn the ignition switch OFF.  Shift the shift lever to the [P] position while pushing the shift lock release.
  • Page 799 $7 ,QWHUORFN 6\VWHP .H\ ,QWHUORFN 6\VWHP &LUFXLW 7URXEOHVKRRWLQJ  Disconnect the steering lock assembly connector.  Measure the voltage between the No. 1 terminal of the O/D switch/shift lock solenoid/park pin switch  Check if the ignition key can be turned to LOCK (0) connector and body ground.
  • Page 800 $7 ,QWHUORFN 6\VWHP ,QWHUORFN &RQWURO 8QLW ,QSXW 7HVW .6 0RGHO  Turn the ignition switch ON (II), and shift the shift lever in [P] position.  Disconnect interlock control unit connector.  Press the brake pedal, release the accelerator  Inspect the connector and connector terminals to pedal, and measure the voltage between interlock be sure they are making good contact.
  • Page 801 $7 ,QWHUORFN 6\VWHP .H\ ,QWHUORFN 6ROHQRLG 7HVW  Remove the driver’s dashboard lower cover and lower steering column cover.  Disconnect steering lock assembly connector.  Insert the ignition key in the key cylinder, then turn the ignition key to ACC (I).  Connect the battery positive terminal to steering lock assembly connector terminal No.
  • Page 802 $7 ,QWHUORFN 6\VWHP 6KLIW /RFN 6ROHQRLG 7HVW5HSODFHPHQW  Remove the ash tray, front console box, heater  Shift the shift lever to [R] position. control panel (see page 20-91), driver’s dashboard  Slide the lock tab (A) down on the shift cable end lower cover (see page 20-88), and dashboard...
  • Page 803 $7 ,QWHUORFN 6\VWHP  Rotate the socket holder (A) on the shift cable (B) a  Remove the shift lever assembly. quarter turn; the tab (C) on the socket holder will be NOTE: The illustration shows LHD model; RHD is in the opening (D) of the socket holder bracket (E).
  • Page 804 $7 ,QWHUORFN 6\VWHP 6KLIW /RFN 6ROHQRLG 7HVW5HSODFHPHQW FRQW¶G  Remove the shift lever cover.  Install the O/D switch harness terminals (A) in the No. 5 and No. 6 cavities. Both of O/D switch  Remove the shift lock solenoid. harness terminals can be installed in No.
  • Page 805 $7 ,QWHUORFN 6\VWHP  Align the marks (A) on the harnesses, and tie the  Turn the ignition switch ON (II), and verify that the harness band (B) over the marks. Clamp the O/D [R] position indicator comes on. switch harness (C) at 15 mm (0.6 in.) (D) from the  If necessary, push the shift cable until it stops, then harness band.
  • Page 806 $7 ,QWHUORFN 6\VWHP 6KLIW /RFN 6ROHQRLG 7HVW5HSODFHPHQW FRQW¶G  Rotate the socket holder (A) on the shift cable (B)  Install the shift cable end (A) in the shift cable end to face the tab (C) on the holder opposite to the holder (B).
  • Page 807 $7 ,QWHUORFN 6\VWHP 3DUN 3LQ 6ZLWFK 7HVW5HSODFHPHQW  Remove the ash tray, front console box, heater  Shift the shift lever to [R] position. control panel (see page 20-91), driver’s dashboard  Slide the lock tab (A) down on the shift cable end lower cover (see page 20-88), and dashboard...
  • Page 808 $7 ,QWHUORFN 6\VWHP 3DUN 3LQ 6ZLWFK 7HVW5HSODFHPHQW FRQW¶G  Rotate the socket holder (A) on the shift cable (B) a  Remove the shift lever assembly. quarter turn; the tab (C) on the socket holder will be NOTE: The illustration shows LHD model; RHD is in the opening (D) of the socket holder bracket (E).
  • Page 809 $7 ,QWHUORFN 6\VWHP  Remove the shift lever cover.  Route the harnesses, and clamp them as shown.  Remove the control checker (A) from the shift lever, and remove the park pin switch from the control checker.  Install the O/D switch harness terminals (A) in the No.
  • Page 810 $7 ,QWHUORFN 6\VWHP 3DUN 3LQ 6ZLWFK 7HVW5HSODFHPHQW FRQW¶G  Align the marks (A) on the harnesses, and tie the  Turn the ignition switch ON (II), and verify that the harness band (B) over the marks. Clamp the O/D [R] position indicator comes on. switch harness (C) at 15 mm (0.6 in.) (D) from the  If necessary, push the shift cable until it stops, then harness band.
  • Page 811 $7 ,QWHUORFN 6\VWHP  Rotate the socket holder (A) on the shift cable (B)  Install the shift cable end (A) in the shift cable end to face the tab (C) on the holder opposite to the holder (B). Keep the shift cable end and end holder opening (D) in the socket holder bracket (E).
  • Page 812 7UDQVPLVVLRQ (QG &RYHU 7UDQVPLVVLRQ (QG &RYHU (QG &RYHU 5HPRYDO ([SORGHG 9LHZ :' %Ñà À€ US6ITHDTTDPIÃS6IB@ÃTXDU8Cà 8PW@S US6ITHDTTDPIà 6UAÃ8PPG@SÃGDI@Ã7PGU S6IB@ÃTXDU8C %Ñà À€ T@6GDIBÃX6TC@S @I9Ã8PW@S Replace. 6UAÃ8PPG@SÃGDI@ %Ñà À€ 8PVIU@STC6AUà GP8FIVU H6DITC6AUà Replace. GP8FIVU Replace. 8PID86GÃTQSDIBà 8PID86GÃTQSDIBÃX6TC@S 'Ñà À€ Replace. X6TC@S Replace. H6DITC6AUÃD9G@SÃB@6S Q6SFÃB@6S Replace.
  • Page 813 7UDQVPLVVLRQ (QG &RYHU ([SORGHG 9LHZ :' %Ñà À€ US6ITHDTTDPIÃS6IB@à TXDU8CÃ8PW@S US6ITHDTTDPIà S6IB@ÃTXDU8C 6UAÃ8PPG@SÃGDI@Ã7PGU %Ñà À€ @I9Ã8PW@S T@6GDIBÃX6TC@ST Replace. 6UAÃ8PPG@SÃGDI@ %Ñà À€ H6DITC6AUÃGP8FIVU 8PVIU@STC6AUÃGP8FIVU Replace. Replace. 8PID86GÃTQSDIBÃX6TC@S 'Ñà À€ Replace. H6DITC6AUÃD9G@SÃB@6S Replace. @I9Ã8PW@SÃB6TF@U Replace. 8PID86GÃTQSDIBÃX6TC@S Replace. 6UAÃEPDIUÃQDQ@ Q6SFÃB@6S X6TC@S %Ñà À€ Q6SFÃG@W@S Replace.
  • Page 814 7UDQVPLVVLRQ (QG &RYHU (QG &RYHU 5HPRYDO FRQW¶G 6SHFLDO 7RROV 5HTXLUHG  Cut the lock tab (A) of the each shaft locknut (B) using a chisel (C). Then remove the locknuts and Mainshaft holder set 07PAB-0010000 conical spring washers from each shaft. NOTE: Refer to the Exploded View as needed during the NOTE: following procedure.
  • Page 815 7UDQVPLVVLRQ (QG &RYHU 3DUN /HYHU 6WRS ,QVSHFWLRQ DQG $GMXVWPHQW  Set a two-jaw (or three-jaw) puller (A) on the  Set the park lever in the [P] position. countershaft (B) with putting a collar (C) between  Measure the distance (A) between the park pawl the puller and countershaft, then remove the park shaft (B) and the park lever roller pin (C).
  • Page 816 7UDQVPLVVLRQ (QG &RYHU ,GOHU *HDU 6KDIW %HDULQJ 5HSODFHPHQW &RQWURO 6KDIW 2LO 6HDO 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG 6SHFLDO 7RROV 5HTXLUHG ‡ Adjustable bearing remover set 07JAC-PH80000 ‡ Handle driver 07749-0010000 ‡ Handle driver 07749-0010000 ‡ Driver attachment, 22 x 24 mm 07746-0010800 ‡...
  • Page 817 7UDQVPLVVLRQ (QG &RYHU &RQWURO 6KDIW %HDULQJ 5HSODFHPHQW $7) )HHG 3LSHV 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Remove the snap rings (A), ATF feed pipes (B) and ‡ Handle driver 07749-0010000 feed pipe flanges (C) from the end cover (D). ‡ Driver attachment, 22 x 24 mm 07746-0010800  Remove the oil seal from the end cover, then remove the bearing.
  • Page 818 7UDQVPLVVLRQ +RXVLQJ 7UDQVPLVVLRQ +RXVLQJ +RXVLQJ DQG 6KDIW $VVHPEOLHV 5HPRYDO ([SORGHG 9LHZ :' 6UAÃA@@9ÃQDQ@ US6ITHDTTDPIÃCPVTDIBÃ HPVIUDIBÃ7PGUT 6UAÃGV7SD86UDPIÃQDQ@ 20 Bolts 8PVIU@STC6AUÃS@W@ST@ÃB@6S TCDAUÃTPG@IPD9Ã 8PW@S H6DITC6AUÃ TQ@@9ÃT@ITPS GP8FÃX6TC@S Replace. B6TF@U Replace. S@W@ST@Ã 9PX@GÃQDITÃ! S@W@ST@ÃTCDAUÃAPSF T@G@8UPS US6ITHDTTDPIÃ C6IB@S I@@9G@Ã C6SI@TTÃ8G6HQÃ 7@6SDIB 7S68F@U 9PX@GÃQDITÃ" 8PVIU@STC6AUÃ TV76TT@H7G` 8PVIU@STC6AUÃ...
  • Page 819 7UDQVPLVVLRQ +RXVLQJ ([SORGHG 9LHZ :' US6ITHDTTDPIÃCPVTDIBà 6UAÃA@@9ÃQDQ@ HPVIUDIBÃ7PGUTà 6UAÃGV7SD86UDPIÃQDQ@ Ñà !$À€ 8PVIU@STC6AUÃS@W@ST@ÃB@6S 19 Bolts TCDAUÃTPG@IPD9ÃW6GW@à 8PW@S GP8FÃX6TC@S H6DITC6AUà Replace. TQ@@9ÃT@ITPS B6TF@U Replace. S@W@ST@ TCDAU APSF S@W@ST@à 9PX@GÃQDITÃ! T@G@8UPS US6ITHDTTDPIà I@@9G@à C6IB@S 7@6SDIB 8PVIU@STC6AU TV76TT@H7G` C6SI@TTÃ8G6HQà 7S68F@U 9PX@GÃQDITÃ" 8PVIU@STC6AU TQ@@9ÃT@ITPS T@8PI96S`ÃTC6AUà TV76TT@H7G` PSDIBT Replace.
  • Page 820 7UDQVPLVVLRQ +RXVLQJ +RXVLQJ DQG 6KDIW $VVHPEOLHV 5HPRYDO FRQW¶G 6SHFLDO 7RROV 5HTXLUHG  Disconnect the connectors from the shift solenoid ‡ Housing puller 07HAC-PK40102 valves. ‡ Snap ring pliers 07LGC-0010100  Remove the mainshaft and countershaft speed sensors. NOTE: Refer to the Exploded View as needed during the following procedure.
  • Page 821 7UDQVPLVVLRQ +RXVLQJ  Unhook the detent spring (A) from the detent arm  Remove the mainshaft sub-assembly (A), (B). countershaft sub-assembly (B), and secondary shaft sub-assembly (C) together.  Remove the control shaft (A).  Remove the differential assembly.  Remove the transfer assembly for 4WD model. ...
  • Page 822 7UDQVPLVVLRQ +RXVLQJ %HDULQJ 5HPRYDO 6SHFLDO 7RROV 5HTXLUHG  Expand the snap ring of the idler gear shaft bearing ‡ Snap ring pliers 07LGC-0010100 with the snap ring pliers, then push the bearing out. ‡ Driver attachment, 78 x 90 mm 07GAD-SD40101 ‡...
  • Page 823 7UDQVPLVVLRQ +RXVLQJ %HDULQJ ,QVWDOODWLRQ 6SHFLDO 7RROV 5HTXLUHG  Expand the snap ring of the idler gear shaft (A) with ‡ Snap ring pliers 07LGC-0010100 the snap ring pliers, and install the bearing part- ‡ Driver attachment, 78 x 90 mm 07GAD-SD40101 way into the housing.
  • Page 824 7UDQVPLVVLRQ +RXVLQJ 5HYHUVH ,GOHU *HDU 5HPRYDO DQG ,QVWDOODWLRQ 5HPRYDO ,QVWDOODWLRQ  Remove the bolt (A) securing the reverse idler gear  Install the reverse idler gear in the transmission shaft holder. housing.  Coat the reverse idler gear shaft (A), needle bearing (B), and new O-rings (C) with lithium grease lightly.
  • Page 825 9DOYH %RG\ 9DOYH %RG\ 9DOYH %RGLHV DQG $7) 6WUDLQHU 5HPRYDO ([SORGHG 9LHZ NOTE: The illustration shows the 4WD transmission; the 2WD is similar. %Ñà À€ %Ñà À€ !Ã7‚y‡† &Ã7‚y‡† S@BVG6UPSÃW6GW@Ã7P9` %Ñà À€ 6UAÃA@@9ÃQDQ@ 6UAÃTUS6DI@S Ã7‚y‡ 'Ñà ('À€ 6UAÃA@@9ÃQDQ@ 'ÑÃ!!À€ PSDIB Replace.
  • Page 826 9DOYH %RG\ 9DOYH %RGLHV DQG $7) 6WUDLQHU 5HPRYDO FRQW¶G  Clean the inlet opening (A) of the ATF strainer (B) NOTE: Refer to the Exploded View as needed during the following procedure. thoroughly with compressed air, then check that it is in good condition and that the inlet opening is not  Remove the ATF feed pipes from the regulator clogged.
  • Page 827 9DOYH %RG\ 9DOYH %RG\ 5HSDLU  Remove the #600 paper. Thoroughly wash the NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores. entire valve body in solvent, then dry it with Use this procedure to free the valves.
  • Page 828 9DOYH %RG\ 9DOYH %RG\ 9DOYH ,QVWDOODWLRQ  Coat all parts with ATF before assembly.  Install the valves and springs in the sequence shown for the main valve body (see page 14-209), regulator valve body (see page 14-211), and servo body (see page 14-212).
  • Page 829 9DOYH %RG\ 0DLQ 9DOYH %RG\ 'LVDVVHPEO\ ,QVSHFWLRQ DQG 5HDVVHPEO\  Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blow out all passages.  Do not use a magnet to remove the check balls, it may magnetize the balls.  Inspect the valbe body for scoring and damage.
  • Page 830 9DOYH %RG\ $7) 3XPS ,QVSHFWLRQ  Install the ATF pump drive gear (A), driven gear (B)  Measure the side clearance of the ATF pump drive and ATF pump driven gear shaft (C) in the main gear (A) and driven gear (B). valve body (D).
  • Page 831 9DOYH %RG\ 5HJXODWRU 9DOYH %RG\ 'LVDVVHPEO\ ,QVSHFWLRQ DQG 5HDVVHPEO\  Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blow out all passages.  Inspect the valve body for scoring and damage.  Check all valves for free movement. If any fail to slide freely, refer to Valve Body Repair (see page 14-207).
  • Page 832 9DOYH %RG\ 6HUYR %RG\ 'LVDVVHPEO\ ,QVSHFWLRQ DQG 5HDVVHPEO\  Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blow out all passages.  Inspect the valve body for scoring and damage.  Check CPB valve for free movement. If any fail to slide freely, refer to Valve Body Repair (see page 14-207).
  • Page 833 9DOYH %RG\ 6KLIW 6ROHQRLG 9DOYHV ,QVWDOODWLRQ NOTE: ‡ Do not install the shift solenoid valve B before installing the shift solenoid valve E. If solenoid valve B is installed before solenoid valves E, it may damage to hydraulic control system. ‡...
  • Page 834 7RUTXH &RQYHUWHU +RXVLQJ 7RUTXH &RQYHUWHU +RXVLQJ 0DLQVKDIW %HDULQJ DQG 2LO 6HDO 5HSODFHPHQW  Install the new oil seal flush with the housing with the special tools. 6SHFLDO 7RROV 5HTXLUHG ‡ Adjustable bearing remover set 07JAC-PH80000 ‡ Handle driver 07749-0010000 ‡ Driver attachment, 62 x 68 mm 07746-0010500 ‡...
  • Page 835 7RUTXH &RQYHUWHU +RXVLQJ &RXQWHUVKDIW %HDULQJ 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Install the ATF guide plate (A). ‡ Adjustable bearing remover set 07JAC-PH80000 ‡ Handle driver 07749-0010000 ‡ Driver attachment, 62 x 68 mm 07746-0010500  Remove the countershaft bearing with the special tool.
  • Page 836 7RUTXH &RQYHUWHU +RXVLQJ 6HFRQGDU\ 6KDIW %HDULQJ 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Install the new O-rings (A) on the ATF guide collar ‡ Handle driver 07749-0010000 (B), then install the ATF guide collar in the housing. ‡ Driver attachment, 62 x 68 mm 07746-0010500  Remove the bolt, then remove the lock washer (A) and bearing set plate (B).
  • Page 837 7RUTXH &RQYHUWHU +RXVLQJ &RQWURO 6KDIW 2LO 6HDO 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG ‡ Handle driver 07749-0010000 ‡ Driver attachment, 22 x 24 mm 07746-0010800  Remove the oil seal (A) from the torque converter housing (B).  Install the new oil seal flush to the torque converter housing with the special tools.
  • Page 838 6KDIWV DQG &OXWFKHV 6KDIWV DQG &OXWFKHV 0DLQVKDIW 'LVDVVHPEO\ ,QVSHFWLRQ DQG 5HDVVHPEO\  Inspect the thrust needle bearing and the needle bearing for galling and rough movement. GP8FIVUÃAG6IB@ÃIVUà !#Ñà !$À€ → → !!%ÃIÀÃ!"ÃxtsÀà %%ÃyisÃs‡à à %&ÃIÀà &ÃxtsÀà !"ÃyisÃs‡ Replace. 8PID86GÃTQSDIBà UCSVTUÃI@@9G@Ã7@6SDIB X6TC@S Replace.
  • Page 839 6KDIWV DQG &OXWFKHV 0DLQVKDIW UG *HDU &OHDUDQFH ,QVSHFWLRQ  Remove the mainshaft transmission housing  Measure the clearance between the mainshaft bearing (see page 14-202). flange (A) and 41 x 68 mm thrust washer (B) with a feeler gauge (C), in at least three places. Use the  Assemble 41 x 68 mm thrust washer (A), 3rd/4th average as the actual clearance.
  • Page 840 6KDIWV DQG &OXWFKHV 0DLQVKDIW UG *HDU &OHDUDQFH ,QVSHFWLRQ FRQW¶G  If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness.  Select and install a new thrust washer, then recheck. 7+5867 :$6+(5  [  PP I‚ Qh…‡ÃIˆ€ir…...
  • Page 841 6KDIWV DQG &OXWFKHV &RXQWHUVKDIW 'LVDVVHPEO\ ,QVSHFWLRQ DQG 5HDVVHPEO\ .$ DQG .$ (QJLQH 0RGHOV  Inspect the thrust needle bearing and the needle bearing for galling and rough movement. GP8FIVUÃAG6IB@ÃIVUà !#Ñà !$À€ → → !!%ÃIÀÃ!"ÃxtsÀà %%ÃyisÃs‡à à %&ÃIÀà &ÃxtsÀà !"ÃyisÃs‡ Replace. Left-hand threads S@W@ST@ÃB@6S 8PID86GÃTQSDIBÃ...
  • Page 842 6KDIWV DQG &OXWFKHV &RXQWHUVKDIW 'LVDVVHPEO\ ,QVSHFWLRQ DQG 5HDVVHPEO\ FRQW¶G .$ (QJLQH 0RGHO  Inspect the thrust needle bearing and the needle bearing for galling and rough movement. GP8FIVUÃAG6IB@ÃIVUà !#Ñà !$À€ → → !!%ÃIÀÃ!"ÃxtsÀà %%ÃyisÃs‡à à %&ÃIÀà &ÃxtsÀà !"ÃyisÃs‡ Replace. S@W@ST@ÃB@6S Left-hand threads 8PID86GÃTQSDIBÃ...
  • Page 843 6KDIWV DQG &OXWFKHV 6HOHFWRU +XE DQG WK *HDU &ROODU 5HPRYDO 6SHFLDO 7RROV 5HTXLUHG  Install the special tool with inserting it to the opening between 31 x 50 x 18.5 mm collar (A) and Bearing separator 07KAF-PS30200 4th gear collar (B). Set the puller (C) to the special .$ DQG .$ (QJLQH 0RGHOV tool, then remove the 4th gear collar.
  • Page 844 6KDIWV DQG &OXWFKHV 6HOHFWRU +XE DQG WK *HDU &ROODU ,QVWDOODWLRQ 6SHFLDO 7RROV 5HTXLUHG  Install the needle bearing and 4th gear. ‡ Driver 40 mm I.D. 07746-0030100  Install the reverse selector hub (A) with the special ‡ Driver attachment, 35 mm I.D. 07746-0030400 tool and a press.
  • Page 845 6KDIWV DQG &OXWFKHV 5HYHUVH 6HOHFWRU +XE DQG VW *HDU 5HPRYDO .$ (QJLQH 0RGHO  Remove the 1st gear (A) and 3rd gear (B) from the countershaft with a press. Place a shaft protector  Remove the reverse selector hub (A) and the 4th (C) between the countershaft and press to prevent gear (B) from the countershaft with a press.
  • Page 846 6KDIWV DQG &OXWFKHV 5HYHUVH 6HOHFWRU +XE DQG VW *HDU ,QVWDOODWLRQ 6SHFLDO 7RROV 5HTXLUHG  Slide the reverse selector hub (A) over the countershaft (B), then press it in place with the Driver 40 mm I.D. 07746-0030100 special tool and a press. .$ (QJLQH 0RGHO NOTE: Some reverse selector hubs are not press- fitted, and can be installed without using the special...
  • Page 847 6KDIWV DQG &OXWFKHV 6HFRQGDU\ 6KDIW 'LVDVVHPEO\ ,QVSHFWLRQ DQG 5HDVVHPEO\ NOTE: The illustration shows the K20A4 and K20A5 engine models; the K24A1 engine model is similar.  Inspect the thrust needle bearing and the needle bearing for galling and rough movement. GP8FIVUÃAG6IB@ÃIVUÃ...
  • Page 848 6KDIWV DQG &OXWFKHV 6HFRQGDU\ 6KDIW %DOO %HDULQJ ,GOHU *HDU 5HPRYDO DQG ,QVWDOODWLRQ 6SHFLDO 7RROV 5HTXLUHG ,QVWDOODWLRQ Driver attachment, 42 mm I.D. 07QAD-P0A0100  Install the idler gear (A) on the secondary shaft (B), NOTE: The illustration shows the K20A4 and K20A5 and install the ball bearing (C) over the idler gear engine models;...
  • Page 849 6KDIWV DQG &OXWFKHV 6HFRQGDU\ 6KDIW QG *HDU &OHDUDQFH ,QVSHFWLRQ  Measure the clearance between the snap ring (A) NOTE: The illustration shows the K20A4 and K20A5 engine models; the K24A1 engine model is similar. and the 2nd clutch guide (B) with a feeler gauge (C), in at least three places.
  • Page 850 6KDIWV DQG &OXWFKHV 6HFRQGDU\ 6KDIW QG *HDU &OHDUDQFH ,QVSHFWLRQ FRQW¶G  If the clearance is out of standard, remove the 37 x 58 mm thrust washer and measure its thickness.  Select and install a new thrust washer, then recheck. 7+5867 :$6+(5  [  PP I‚ Qh…‡ÃIˆ€ir…...
  • Page 851 6KDIWV DQG &OXWFKHV 6HFRQGDU\ 6KDIW VW *HDU &OHDUDQFH ,QVSHFWLRQ 6SHFLDO 7RROV 5HTXLUHG  Install the idler gear (I), then install the ball bearing (J) on the idler gear with the special tool and a Driver attachment, 42 mm I.D. 07QAD-P0A0100 press.
  • Page 852 6KDIWV DQG &OXWFKHV 6HFRQGDU\ 6KDIW VW *HDU &OHDUDQFH ,QVSHFWLRQ FRQW¶G  Hold the secondary shaft, and measure the 1st  Select and install a new thrust washer, then gear axial clearance in at least three places while recheck. moving the 1st gear (A). Use the average as the 7+5867 :$6+(5  [  PP actual clearance.
  • Page 853 6KDIWV DQG &OXWFKHV ,GOHU *HDU 6KDIW 5HPRYDO DQG ,QVWDOODWLRQ  Remove the snap ring (A), cotter retainer (B), and cotter keys (C). Do not distort the snap ring.  Remove the idler gear shaft/idler gear assembly (D) from the transmission housing.  Check the snap rings and cotter retainer for wear and damage.
  • Page 854 6KDIWV DQG &OXWFKHV ,GOHU *HDU,GOHU *HDU 6KDIW 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Replace the idler gear or idler gear shaft, and ‡ Handle driver 07749-0010000 attach the idler gear shaft to the idler gear. ‡ Driver attachment, 32 x 35 mm 07746-0010100  Remove the snap ring from the idler gear/idler shaft assembly.
  • Page 855 6KDIWV DQG &OXWFKHV &OXWFK 'LVDVVHPEO\ 6SHFLDO 7RROV 5HTXLUHG  Disassemble the 1st clutch of K20A4 and K20A5 ‡ Clutch spring compressor set 07LAE-PX40000 engine models: Remove the clutch end plate (A), ‡ Clutch spring compressor attachment clutch discs (4) (B), clutch waved-plates (4) (C), and waved spring (D) from the 1st clutch drum (E).
  • Page 856 6KDIWV DQG &OXWFKHV &OXWFK 'LVDVVHPEO\ FRQW¶G  Disassemble the 3rd clutch of K20A4 and K20A5  Disassemble the 1st clutch of K24A1 engine engine models: Remove the clutch end plate (A), model: Remove the clutch end plate (A), clutch clutch discs (3) (B), clutch waved-plates (3) (C), discs (5) (B), clutch waved-pates (5) (C), and and waved spring (D) from the 3rd clutch drum (E).
  • Page 857 6KDIWV DQG &OXWFKHV  Disassemble the 3rd clutch of K24A1 engine  Install the special tools. model: Remove the clutch end plate (A), clutch discs (3) (B), clutch waved-plates (3) (C), and waved spring (D) from the 3rd clutch drum (E).  Disassemble the 4th clutch of K24A1 engine model: Remove the clutch end plate (A), clutch  Be sure the special tool (A) is adjusted to have full...
  • Page 858 6KDIWV DQG &OXWFKHV &OXWFK 'LVDVVHPEO\ FRQW¶G  Set the special tool (A) on the spring retainer (B) of  Compress the return spring until the snap ring can the 1st and 2nd clutches in such a way that the be removed. special tool works on the clutch return spring (C).
  • Page 859 6KDIWV DQG &OXWFKHV  Remove the snap ring (A), spring retainer (B), and  Remove the piston, then remove the O-rings from return spring (C). the 3rd and 4th clutch pistons.  Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove  Remove the piston, then remove the O-ring from the piston (B).
  • Page 860 6KDIWV DQG &OXWFKHV &OXWFK ,QVSHFWLRQ  Inspect the 3rd and 4th clutch pistons and clutch  Inspect the clutch discs, clutch plates, and clutch piston check valves. end plate for wear, damage, and discoloration. T‡hqh…qÃUuvpxr†† 8yˆ‡puÃ9v†p†) (#À€Ã&%Ãv 8yˆ‡puÃQyh‡r†) F!6#ÃhqÃF!6$Ãrtvr† 6yyÃyh‡r†) !À€Ã&(Ãv F!#6 Ãrtvr...
  • Page 861 6KDIWV DQG &OXWFKHV &OXWFK :DYHGSODWH 3KDVH 'LIIHUHQFH ,QVSHFWLRQ  Place the clutch waved-plate (A) on a surface plate,  Measure the phase difference at the other two tops and set a dial indicator (B) on the waved-plate. (G and I) of the waved-plate by following steps 3 thru 5.
  • Page 862 6KDIWV DQG &OXWFKHV &OXWFK &OHDUDQFH ,QVSHFWLRQ 6SHFLDO 7RROV 5HTXLUHG  Assemble the 1st clutch of K20A4 and K20A5 engine models: Install the waved spring (A) in the Clutch compressor attachment 07ZAE-PRP0100 1st clutch drum (B). Starting with the clutch waved-  Inspect the clutch piston, discs, plates, and end plate, alternately install the clutch plates (4) (C) and plate for wear and damage...
  • Page 863 6KDIWV DQG &OXWFKHV  Assemble the 3rd clutch of K20A4 and K20A5  Assemble the 1st clutch of K24A1 engine model: engine models: Install the waved spring (A) in the Install the waved spring (A) in the 1st clutch drum 3rd clutch drum (B).
  • Page 864 6KDIWV DQG &OXWFKHV &OXWFK &OHDUDQFH ,QVSHFWLRQ FRQW¶G  Assemble the 3rd clutch of K24A1 engine model:  Install the snap ring with a screwdriver. Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end plate (E) with the flat side toward the disc.
  • Page 865 6KDIWV DQG &OXWFKHV  Release the clutch end plate to lower the clutch &/87&+ (1' 3/$7(6 end plate, then put the special tool on the end plate .$ DQG .$ (QJLQH 0RGHOV (A). )RU VW FOXWFK Qyh‡rà Qh…‡ÃIˆ€ir… Uuvpxr†† I‚ 22551-PRP-003 2.3 mm (0.091 in.) 22552-PRP-003...
  • Page 866 6KDIWV DQG &OXWFKHV &OXWFK &OHDUDQFH ,QVSHFWLRQ FRQW¶G &/87&+ (1' 3/$7(6 .$ (QJLQH 0RGHO )RU VW FOXWFK Qyh‡rà Qh…‡ÃIˆ€ir… Uuvpxr†† I‚ 22551-PPV-003 2.6 mm (0.102 in.) 22552-PPV-003 2.7 mm (0.106 in.) 22553-PPV-003 2.8 mm (0.110 in.) 22554-PPV-003 2.9 mm (0.114 in.) 22555-PPV-003 3.0 mm (0.118 in.) 22556-PPV-003...
  • Page 867 6KDIWV DQG &OXWFKHV &OXWFK 5HDVVHPEO\ 6SHFLDO 7RROV 5HTXLUHG  Install the new O-ring (A) in the 1st, 2nd clutch ‡ Clutch spring compressor set 07LAE-PX40000 pistons (B), and install the new O-ring (C) on the ‡ Clutch spring compressor attachment clutch drums (D).
  • Page 868 6KDIWV DQG &OXWFKHV &OXWFK 5HDVVHPEO\ FRQW¶G  Install the return spring (A) and spring retainer (B),  Be sure the special tool (A) is adjusted to have full and position the snap ring (C) on the retainer. contact with the spring retainer (B) on the 3rd and 4th clutches.
  • Page 869 6KDIWV DQG &OXWFKHV  If either end of the special tool is set over an area of  Install the snap ring with snap ring pliers. the spring retainer which is unsupported by the return spring, the retainer may be damaged.  Remove the special tools.
  • Page 870 6KDIWV DQG &OXWFKHV &OXWFK 5HDVVHPEO\ FRQW¶G  Assemble the 2nd clutch of K20A4 and K20A5  Assemble the 4th clutch of K20A4 and K20A5 engine models: Install the waved spring (A) in the engine models: Install the waved spring (A) in the 2nd clutch drum (B).
  • Page 871 6KDIWV DQG &OXWFKHV  Assemble the 2nd clutch of K24A1 engine model:  Assemble the 4th clutch of K24A1 engine model: Install the waved spring (A) in the 2nd clutch drum Install the waved spring (A) in the 4th clutch drum (B).
  • Page 872 9DOYH %RG\ 9DOYH %RG\ 9DOYH %RGLHV DQG $7) 6WUDLQHU ,QVWDOODWLRQ ([SORGHG 9LHZ NOTE: The illustration shows the 4WD transmission; the 2WD is similar. %Ñà À€ U‚…„ˆrÃTƒrpvsvph‡v‚†) &Ã7‚y‡† %Ñà À€)à !ÃIÀà !ÃxtsÀÃ'&ÃyisÃs‡ 6UAÃA@@9ÃQDQ@4 'Ñà !$À€)à 'ÃIÀà 'ÃxtsÀà "ÃyisÃs‡ S@BVG6UPSà 'Ñà ('À€ W6GW@Ã7P9` %ÑÃ...
  • Page 873 9DOYH %RG\  If the ATF pump drive gear and ATF pump driven NOTE: Refer to the Exploded View as needed during the following procedure. gear shaft do not move smoothly, loosen the main valve body bolts. Realign the ATF pump driven  Install the main separator plate (A) and two dowel gear shaft, and retighten the bolts to the specified pins on the torque converter housing.
  • Page 874 7UDQVPLVVLRQ +RXVLQJ 7UDQVPLVVLRQ +RXVLQJ 6KDIW $VVHPEOLHV DQG +RXVLQJ ,QVWDOODWLRQ ([SORGHG 9LHZ US6ITHDTTDPIÃCPVTDIBà HPVIUDIBÃ7PGUT 8PVIU@STC6AUÃS@W@ST@ÃB@6S Ñà !$À€ ##ÃIÀÃ#$ÃxtsÀÃ""ÃyisÃs‡ 6UAÃA@@9ÃQDQ@ 4WD: 20 Bolts %Ñà À€ 2WD: 19 Bolts 6UAÃGV7SD86UDPIÃQDQ@ #ÃIÀà H6DITC6AUà TCDAUÃTPG@IPD9Ã8PW@S  #ÃxtsÀà ÃyisÃs‡ TQ@@9ÃT@ITPS B6TF@U Replace. S@W@ST@à GP8FÃX6TC@S 9PX@GÃQDITÃ! Replace. T@G@8UPS US6ITHDTTDPIÃC6IB@S S@W@ST@ÃTCDAUÃAPSF...
  • Page 875 7UDQVPLVVLRQ +RXVLQJ 6SHFLDO 7RROV 5HTXLUHG  If the detent arm was removed, install the detent arm (A) with arm collar (B) on the servo body (C), Snap ring pliers 07LGC-0010100 and install the new lock washer (D) with aligning its NOTE: Refer to the Exploded View as needed during the cutout (E) with the projection (F) of the servo body.
  • Page 876 7UDQVPLVVLRQ +RXVLQJ 6KDIW $VVHPEOLHV DQG +RXVLQJ ,QVWDOODWLRQ FRQW¶G  Install the control shaft (A) in the torque converter  Turn the shift fork shaft (A) so the large chamfered housing aligning the manual valve lever pin (B) on hole (B) is facing the fork bolt hole (C) of the shift the control shaft with the guide of the manual valve fork (D).
  • Page 877 7UDQVPLVVLRQ +RXVLQJ  Align the spring pin (A) on the control shaft (B) with  Verify that the secondary shaft bearing snap ring the transmission housing groove (C) by turning the (A) is seated in the bearing and housing groove, control shaft.
  • Page 878 7UDQVPLVVLRQ +RXVLQJ 6KDIW $VVHPEOLHV DQG +RXVLQJ ,QVWDOODWLRQ FRQW¶G  Install the mainshaft speed sensor (A) and  Install the shift solenoid valve cover (A) with the countershaft speed sensor (B) with new O-rings two dowel pins (B) and the new gasket (C), and (C).
  • Page 879 7UDQVPLVVLRQ (QG &RYHU 7UDQVPLVVLRQ (QG &RYHU (QG &RYHU ,QVWDOODWLRQ  Install the park lever (A) and park lever stop (B) on the control shaft (C), then install the lock bolt with the new lock washer (D). Do not bend the lock tab 6SHFLDO 7RROV 5HTXLUHG of the lock washer until step 18.
  • Page 880 7UDQVPLVVLRQ (QG &RYHU (QG &RYHU ,QVWDOODWLRQ FRQW¶G  Lubricate the threads of the shafts, the new  Install the control level (A) on the control shaft (B), locknuts and the new conical spring washers with and install the bolt with the new lock washer (C), ATF.
  • Page 881 7UDQVPLVVLRQ (QG &RYHU  Install the ATF feed pipe (A) into the idler gear  Set the control shaft (A) to [N] position by turning shaft, and install the ATF lubrication pipe (B) into the control lever on the torque converter side. the transmission housing.
  • Page 882 7UDQVPLVVLRQ (QG &RYHU (QG &RYHU ,QVWDOODWLRQ FRQW¶G  Install the transmission range switch (A) gently on  Connect the transmission range switch connector the control shaft (B) with holding the [N] position (A) securely, then install the harness clamps (B) on with the 2.0 mm (0.08 in.) blade (C).
  • Page 883 7UDQVPLVVLRQ (QG &RYHU  Install the new gasket (A) on the transmission  Install the breather tube (A) with facing the dot (B) housing, and install the ATF joint pipes (B). on the tube in a rearward position (differential side), then install the other end (C) in the slot (D) of the transmission hanger (E).
  • Page 884 $7 'LIIHUHQWLDO $7 'LIIHUHQWLDO &RPSRQHQW /RFDWLRQ ,QGH[ :' :' " " & & Preload Inspection, page 14-270 UCSVTUÃTCDH Ã&%À€ UCSVTUÃX6TC@SÃ&%!À€Ã Replacement, page 14-268 " 7@6SDIBÃPVU@SÃS68@ Replacement, page 14-265 86SSD@SÃ7@6SDIB Replacement, page 14-266 ADI6GÃ9SDW@IÃB@6S Backlash Inspection, page 14-265 9DAA@S@IUD6GÃ86SSD@S Preload Inspection, page 14-270 Replacement, page 14-266...
  • Page 885 $7 'LIIHUHQWLDO %DFNODVK ,QVSHFWLRQ &DUULHU %HDULQJ 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG NOTE: The illustration shows the 4WD model; 2WD is similar. Attachment, 40 x 50 mm 07LAD-PW50601  Install the driveshaft and intermediate shaft on the NOTE: ‡ The bearing and bearing outer race should be replaced differential, then place the axles on V-blocks.
  • Page 886 $7 'LIIHUHQWLDO 'LIIHUHQWLDO &DUULHU)LQDO 'ULYHQ *HDU 5HSODFHPHQW :' :'  Remove the final driven gear (A) and transfer drive  Remove the final driven gear from the differential gear (B) from the differential carrier (C). carrier, and replace the differential carrier or final driven gear.
  • Page 887 $7 'LIIHUHQWLDO 2LO 6HDO 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Install the new oil seal (A) in the transmission ‡ Handle driver 07749-0010000 housing with the special tools. ‡ Oil seal driver attachment 07947-SD90101 ‡ Oil seal driver attachment 07JAD-PH80101 NOTE: The illustration shows the 4WD model; 2WD is similar.
  • Page 888 $7 'LIIHUHQWLDO &DUULHU %HDULQJ 2XWHU 5DFH 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Remove the bearing outer race (A) and 80 mm ‡ Handle driver 07749-0010000 thrust washer (B) from the torque converter ‡ Driver attachment, 78 x 90 mm 07GAD-SD40101 housing (C). ‡...
  • Page 889 $7 'LIIHUHQWLDO  Install the 76 mm thrust shim (A), 76.2 mm thrust washer (B), and the new bearing outer race (C) in the transmission housing (D).  Drive the bearing outer race to install securely so there is no clearance between the outer race, thrust washer, shim and housing with the special tools.
  • Page 890 $7 'LIIHUHQWLDO &DUULHU %HDULQJ 3UHORDG ,QVSHFWLRQ 6SHFLDO 7RROV 5HTXLUHG  Install the 76 mm thrust shim (A) in the ‡ Handle driver 07749-0010000 transmission housing (B). ‡ Driver attachment, 72 x 75 mm 07746-0010600 If you replace the 76 mm thrust shim with new one, ‡...
  • Page 891 $7 'LIIHUHQWLDO  Install the differential assembly (A) in the torque  Rotate the differential assembly in both directions converter housing (B), and install the gasket (C) to seat the bearings. and dowel pins (D) on the housing.  Measure the starting torque of the differential assembly with the special tool, a torque wrench (A) ÑÃ...
  • Page 892 $7 'LIIHUHQWLDO &DUULHU %HDULQJ 3UHORDG ,QVSHFWLRQ FRQW¶G  If the measurement is out of standard, remove the 7+5867 6+,0  PP FRQW¶G thrust shim and select the thrust shim from table below. Install the new thrust shim and recheck. To I‚ Qh…‡ÃIˆ€ir…...
  • Page 893 7UDQVIHU $VVHPEO\ 7UDQVIHU $VVHPEO\ ,QVSHFWLRQ  Remove the transfer holder (A) from the transfer housing (B), then remove the O-ring (C) from the transfer holder.  Set a dial indicator (A) on the companion flange (B).  Measure the transfer gear backlash. TU6I96S9)Ã...
  • Page 894 7UDQVIHU $VVHPEO\ 'LVDVVHPEO\ ([SORGHG 9LHZ US6ITA@SÃTC6AU SPGG@SÃ7@6SDIB %Ñà À€ US6ITA@SÃCPG9@S  !ÃIÀà !ÃxtsÀÃ'&ÃyisÃs‡ PSDIB Replace. 9PX@GÃQDI UCSVTUÃTCDH Ã%'À€ Selective part U6Q@S@9ÃSPGG@SÃ7@6SDIBà PVU@SÃS68@ U6Q@S@9ÃSPGG@SÃ7@6SDIB US6ITA@SÃ9SDW@ÃB@6Sà UCSVTUÃTCDHÃ!$À€ C`QPD9ÃB@6S Selective part U6Q@S@9ÃSPGG@SÃ7@6SDIB US6ITA@SÃ8PGG6S US6ITA@Sà 9SDW@IÃB@6Sà C`QPD9ÃB@6S 8PID86GÃTQSDIBà UCSVTUÃTCDH Ã"$À€ Selective part X6TC@S Replace. U6Q@S@9ÃSPGG@SÃ7@6SDIB U6Q@S@9ÃSPGG@SÃ7@6SDIBÃ...
  • Page 895 7UDQVIHU $VVHPEO\ 6SHFLDO 7RROV 5HTXLUHG  Secure the transfer housing (A) in a bench vise (B) with soft jaws. To prevent damage to the transfer Companion flange holder 07PAB-0020000 housing, always use soft jaws or equivalent NOTE: Refer to the Exploded View as needed during the materials between the transfer housing and the following procedure.
  • Page 896 7UDQVIHU $VVHPEO\ 'LVDVVHPEO\ FRQW¶G  Remove the transfer driven gear (A) from the transfer housing (B), then remove the transfer spacer (C) from the transfer driven gear.  Remove the oil seal (A) and tapered roller bearing (B) from the transfer housing (C). ...
  • Page 897 7UDQVIHU $VVHPEO\ 7UDQVIHU +ROGHU 'LVDVVHPEO\  Cut the lock tab on the locknut of the transfer shaft  Remove the locknut (A) and conical spring washer using a chisel. (B).  Put a 14 mm Allen wrench (A) in the transfer shaft (B), then secure the Allen wrench in a bench vise.
  • Page 898 7UDQVIHU $VVHPEO\ 7UDQVIHU +ROGHU 5ROOHU %HDULQJ 5HSODFHPHQW 7UDQVIHU +ROGHU 7DSHUHG 5ROOHU %HDULQJ 2XWHU 5DFH 5HPRYDO,QVWDOODWLRQ 6SHFLDO 7RROV 5HTXLUHG ‡ Handle driver 07749-0010000 6SHFLDO 7RROV 5HTXLUHG ‡ Driver attachment, 62 x 68 mm 07746-0010500 ‡ Handle driver 07749-0010000 ‡ Driver attachment, 62 x 68 mm 07746-0010500  Remove the roller bearing from the transfer holder.
  • Page 899 7UDQVIHU $VVHPEO\ 7UDQVIHU 'ULYH *HDU %HDULQJ 5HSODFHPHQW 7UDQVIHU 'ULYHQ *HDU %HDULQJ 5HPRYDO ,QVWDOODWLRQ 6SHFLDO 7RROV 5HTXLUHG ‡ Handle driver 07749-0010000 6SHFLDO 7RROV 5HTXLUHG ‡ Driver attachment, 37 x 40 mm 07746-0010200 ‡ Driver 40 mm I.D. 07746-0030100 ‡ Driver attachment, 42 x 47 mm 07746-0010300 ‡...
  • Page 900 7UDQVIHU $VVHPEO\ 7UDQVIHU +RXVLQJ 7DSHUHG 5ROOHU %HDULQJ 2XWHU 5DFH 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Install the 57 mm bearing outer race (A) in the ‡ Handle driver 07749-0010000 housing (B) with the special tools. ‡ Oil seal driver attachment 07947-SD90101 ‡...
  • Page 901 7UDQVIHU $VVHPEO\ 5HDVVHPEO\ 6SHFLDO 7RROV 5HTXLUHG ([DPSOH ‡ Driver 40 mm I.D. 07746-0030100 ‡ Driver attachment, 35 mm I.D. 07746-0030400 8) @YDTUDIBÃ"$À€ Y) S@QG68@H@IUÃ"$À€ ‡ Handle driver 07749-0010000 UCSVTUÃTCDH UCSVTUÃTCDH ‡ Oil seal driver attachment 07JAD-PH80101 Uuvpxr††)Ã8Ã2à $À€ Uuvpxr††)ÃYÃ2Ã4Ã4À€ ‡ Companion flange holder 07PAB-002000 ‡...
  • Page 902 7UDQVIHU $VVHPEO\ 5HDVVHPEO\ FRQW¶G  Install the 35 mm thrust shim (A) on the transfer  Install the transfer driven gear (A) in the transfer driven gear (B), then install the tapered roller housing (B). Do not install the transfer spacer on bearing (C) with the special tools and a press.
  • Page 903 7UDQVIHU $VVHPEO\  Secure the transfer housing (A) in a bench vise (B)  Install the transfer shaft (A) in the transfer holder with soft jaws. To prevent damage to the transfer (B), and install the transfer drive gear (C), transfer housing, always use soft jaws or equivalent collar (D), 25 mm thrust shim (E), tapered roller materials between the transfer housing and the...
  • Page 904 7UDQVIHU $VVHPEO\ 5HDVVHPEO\ FRQW¶G  Apply Prussian Blue to both sides of the transfer  Remove the transfer holder, and check the transfer drive gear teeth lightly and evenly. drive gear tooth contact pattern.  Temporarily install the transfer holder (A) and 8PSS@8UÃUPPUCÃ8PIU68UÃQ6UU@SI dowel pin (B) without O-ring, and tighten the bolts.
  • Page 905 7UDQVIHU $VVHPEO\  If the measurement of the backlash is out of 7+5867 6+,0  PP standard, adjust the transfer gear backlash with the 35 mm thrust shim and recheck. Do not use more Tuv€ Qh…‡ÃIˆ€ir… Uuvpxr†† I‚ than two 35 mm thrust shims to adjust the transfer 1.70 29411-P1C-000 1.70 mm (0.067 in.)
  • Page 906 7UDQVIHU $VVHPEO\ 5HDVVHPEO\ FRQW¶G  Secure the transfer housing (A) in a bench vise (B)  Remove the transfer driven gear (A) from the with soft jaws. To prevent damage to the transfer transfer housing (B). housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
  • Page 907 7UDQVIHU $VVHPEO\  Secure the transfer housing (A) in a bench vise (B)  Stake the locknut using a 3.5 mm punch. with soft jaws. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
  • Page 908 7UDQVIHU $VVHPEO\ 5HDVVHPEO\ FRQW¶G  Secure the transfer housing (A) in a bench vise (B)  If the measurement is out of standard, put a 14 mm with soft jaws. To prevent damage to the transfer Allen wrench (A) in the transfer shaft (B), then housing, always use soft jaws or equivalent secure the Allen wrench in a bench vise.
  • Page 909 7UDQVIHU $VVHPEO\  Remove the locknut (A) and conical spring washer  Measure the thickness of the 68 mm thrust shim, (B). and select the new 68 mm thrust shim. 7+5867 6+,0  PP Tuv€ Qh…‡ÃIˆ€ir… Uuvpxr†† I‚ 23974-P1C-020 1.41 mm (0.056 in.) 23975-P1C-020 1.44 mm (0.057 in.) 23976-P1C-020...
  • Page 910 7UDQVIHU $VVHPEO\ 5HDVVHPEO\ FRQW¶G  Install the new 68 mm thrust shim (A) in the transfer  Put a 14 mm Allen wrench (A) in the transfer shaft holder, then install the tapered roller bearing outer (B), then secure the Allen wrench in a bench vise. race (B) with the special tools.
  • Page 911 7UDQVIHU $VVHPEO\  Stake the locknut of the transfer shaft using a 3.5 mm punch.  Install the new O-ring (A) on the transfer holder (B), then install the transfer holder with the dowel pin (C) on the transfer housing (D). ...
  • Page 913 5HDU 'LIIHUHQWLDO TƒrpvhyÃU‚‚y†  T’†‡r€Ã9r†p…vƒ‡v‚   $" 9ˆhyÃQˆ€ƒÃT’†‡r€ÃAˆp‡v‚ÃUr†‡   T’€ƒ‡‚€ÃU…‚ˆiyr†u‚‚‡vtÃDqr‘  $ ! 9vssr…r‡vhyÃAyˆvqÃD†ƒrp‡v‚ÃhqÃSrƒyhpr€r‡   $ " 9vssr…r‡vhyÃSr€‚‰hy   $ # 9vssr…r‡vhyÃC‚ˆ†vtÃ6††r€iy’ÃSr€‚‰hyÃhqÃD†‡hyyh‡v‚   $ $ PvyÃTrhyÃSrƒyhpr€r‡   $ % 9vssr…r‡vhyÃ9v†h††r€iy’   $ ' 9vssr…r‡vhyÃSrh††r€iy’...
  • Page 914 5HDU 'LIIHUHQWLDO 6SHFLDO 7RROV 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07GAD-PH70201 Oil Seal Driver 64 07JAD-PL90100 Oil Seal Driver 65 07NAD-PX40100 Attachment, 78 x 80 mm " 07PAB-0020000 Companion Flange Holder 07749-0010000 Driver 15 x 135L " ...
  • Page 915 The oil pumps are designed so the fluid intake works as a fluid discharge when the oil pumps rotate in reverse. Honda DPSF (Dual Pump System Fluid) is used instead of differential fluid.
  • Page 916 5HDU 'LIIHUHQWLDO 6\VWHP 'HVFULSWLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G 5($5 ',))(5(17,$/ $66(0%/< UPSRV@Ã8PIUSPGÃ Ã9DAA@S@IUD6GÃ86SSD@S ÃPDGÃQVHQÃ7P9` 9DAA@S@IUD6GÃ86T@ C`QPD9Ã9SDW@Ã QDIDPIÃB@6S 9DAA@S@IUD6GÃ8GVU8CÃ Ã9DAA@S@IUD6GÃ 6TT@H7G` C`QPD9ÃSDIBÃB@6S 8GVU8CÃBVD9@ 8PHQ6IDPIÃ AG6IB@ 8GVU8CÃCV7 S@6SÃPDGÃQVHQ 8GVU8CÃ ASPIUÃPDGÃQVHQ QG6U@ Ã9DAA@S@IUD6GÃCPVTDIB 8GVU8CÃ9DT8 +<'5$8/,& &21752/ 6<67(0 9DT8ÃTQSDIB ASPIUÃPDGÃQVHQ S@6SÃPDGÃQVHQ 8GVU8CÃQDTUPI PSDAD8@T 9DAA@S@IUD6GÃ 8GVU8CÃ 6TT@H7G` UC@SH6GÃTXDU8C S@GD@AÃW6GW@...
  • Page 917 6\VWHP 'HVFULSWLRQ )RUZDUG 6WDUW DQG $FFHOHUDWLRQ :' During a forward start and forward acceleration, the dual pump system can engage four wheel drive. If the front wheels spin faster than the rear wheels, the front oil pump spins faster than the rear oil pump. The front pump draws fluid through check valve B and discharges it.
  • Page 918 5HDU 'LIIHUHQWLDO 6\VWHP 'HVFULSWLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G )RUZDUG 'HFHOHUDWLRQ :' During forward deceleration, the dual pump system functions in two wheel drive mode. Because of braking characteristics, the speed of the rear wheels may exceed the speed of the front wheels during deceleration.
  • Page 919 6\VWHP 'HVFULSWLRQ 5HYHUVH 'ULYLQJ DW &RQVWDQW 6SHHG :' When driving in reverse at a constant speed, the dual pump system functions in two wheels drive mode. The rotation speed of the front and rear wheels is the same, so the speed of the front and rear pumps is also the same. Fluid discharged by the front oil pump is drawn in by the rear oil pump and is circulated through the system.
  • Page 920 5HDU 'LIIHUHQWLDO 6\VWHP 'HVFULSWLRQ 6\VWHP 'HVFULSWLRQ FRQW¶G 7KHUPDO 6ZLWFK 2SHUDWLRQ :' During 4WD operation, pressure-regulated fluid is in contact with the clutch piston and the thermal switch. If the temperature of the fluid in the differential goes too high, the thermal switch pushes open the relief valve R. This causes the pressure in the clutch piston to drop, and 4WD mode is disengaged.
  • Page 921 'XDO 3XPS 6\VWHP )XQFWLRQ 7HVW 'XDO 3XPS 6\VWHP )XQFWLRQ 7HVW $XWRPDWLF 7UDQVPLVVLRQ :KHQ VWDUWLQJ DQG DFFHOHUDWLQJ LQ UHYHUVH JHDU :' PRGH :KHQ VWDUWLQJ DQG DFFHOHUDWLQJ LQ IRUZDUG JHDUV  Lift up the vehicle so all four wheels are off the :' PRGH ground (see page...
  • Page 922 5HDU 'LIIHUHQWLDO 'XDO 3XPS 6\VWHP )XQFWLRQ 7HVW 7URXEOHVKRRWLQJ FRQW¶G 0DQXDO 7UDQVPLVVLRQ :KHQ VWDUWLQJ DQG DFFHOHUDWLQJ LQ UHYHUVH JHDUV :' PRGH :KHQ VWDUWLQJ DQG DFFHOHUDWLQJ LQ IRUZDUG JHDUV  Lift up the vehicle so all four wheels are off the :' PRGH ground (see page 01-7).
  • Page 923 'XDO 3XPS 6\VWHP )XQFWLRQ 7HVW $XWRPDWLF 7UDQVPLVVLRQ0DQXDO :KHQ GHFHOHUDWLQJ LQ UHYHUVH JHDUV :' PRGH 7UDQVPLVVLRQ  Block the front wheels (A), raise the left rear wheel, and support it with a safety stand (B) as shown. :KHQ GHFHOHUDWLQJ LQ D IRUZDUG JHDUV :' PRGH  Block the front wheels (A) raise the left rear wheel, and support it with a safety stand (B) as shown.
  • Page 924 5HDU 'LIIHUHQWLDO 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ Most problems in the unit are to be diagnosed by identifying noises from the gears or bearings. Care should be taken during diagnosis not to confuse differential noises with those from other drivetrain components. T’€ƒ‡‚€...
  • Page 925 'LIIHUHQWLDO )OXLG ,QVSHFWLRQ DQG 5HSODFHPHQW 'LIIHUHQWLDO )OXLG ,QVSHFWLRQ DQG 5HSODFHPHQW  With the vehicle on level ground, inspect the  Clean the drain plug, then reinstall it with a new differential fluid with engine OFF. sealing washer, and refill the differential with the recommended fluid to the proper level.
  • Page 926 5HDU 'LIIHUHQWLDO 'LIIHUHQWLDO 5HPRYDO 'LIIHUHQWLDO 5HPRYDO  Drain the differential fluid  Remove the mounting bolts and the plate. (see page 15-13).  Mark the propeller shaft (A) and companion flange of the rear differential assembly (B) so they can be reinstalled in their original positions (C).
  • Page 927 'LIIHUHQWLDO +RXVLQJ $VVHPEO\ 5HPRYDO DQG ,QVWDOODWLRQ 'LIIHUHQWLDO +RXVLQJ $VVHPEO\ 5HPRYDO DQG ,QVWDOODWLRQ  Remove the six mounting bolts in a crisscross  Install the differential housing assembly (A), then pattern in several steps, then remove the torque the six mounting bolts (B) in a crisscross differential housing assembly (A) and oil seals (B).
  • Page 928 5HDU 'LIIHUHQWLDO 2LO 6HDO 5HSODFHPHQW 2LO 6HDO 5HSODFHPHQW 6SHFLDO 7RROV 5HTXLUHG  Install the oil seals (A) squarely using the special ‡ Driver 07749-0010000 tools. Be careful not to damage the lip of the oil ‡ Attachment, 78 x 80 mm 07NAD-PX40100 seals.
  • Page 929 2LO 6HDO 5HSODFHPHQW  Remove the oil seal (A) from the torque control differential case (B). NOTE: Be careful not to damage the shaft or case while prying out the seal.  Install the oil seal (A) squarely using the special tool.
  • Page 930 5HDU 'LIIHUHQWLDO 'LIIHUHQWLDO 'LVDVVHPEO\ 'LIIHUHQWLDO 'LVDVVHPEO\ 6SHFLDO 7RROV 5HTXLUHG  Install the special tools on the companion flange. Companion Flange Holder 07PAB-0020000  Remove the drain plug (A) and the oil filler plug (B) with sealing washers (C).  Loosen the locknut (A) counterclockwise so that its tab (B) comes out from the groove (C) in the clutch guide.
  • Page 931 'LIIHUHQWLDO 'LVDVVHPEO\  Tighten the locknut (A) until its tab (B) aligns with  Remove the eight mounting bolts (A) in a crisscross the groove (C). pattern in several steps, then remove the torque control differential case (B) and the dowel pin (C).  Remove any dirt from inside of the groove in the clutch guide, then loosen the locknut.
  • Page 932 5HDU 'LIIHUHQWLDO 'LIIHUHQWLDO 'LVDVVHPEO\ 'LIIHUHQWLDO 'LVDVVHPEO\ FRQW¶G  Remove the clutch hub/plates/discs (A) and the  Remove the oil pump body assembly (A), the oil pressure plate (B). pump pin (B), the collar (C), the magnet (D), and the ATF strainer (E).  Remove the thrust needle bearing (A) and the oil pump driveshaft (B).
  • Page 933 'LIIHUHQWLDO 5HDVVHPEO\ 'LIIHUHQWLDO 5HDVVHPEO\ ([SORGHG 9LHZ UPSRV@Ã8PIUSPGà 9DAA@S@IUD6GÃ86T@ 9PX@GÃQDIT 8PHQ6IDPIÃAG6IB@ 768FVQÃSDIB 9DT8ÃTQSDIBÃX6TC@Sà !#À€ PDGÃT@6G Replace. PSDIB Replace. PDGÃQVHQà 7P9`à UCSVTUÃI@@9G@à GP8FIVUÃ!#À€ 6TT@H7G` 7@6SDIB Replace. 'ÃIÀ  !ÃxtsÀÃ'&ÃyisÃs‡ QS@TTVS@ÃQG6U@ 8GVU8CÃCV7 ÃÃQG6U@TÃÃ9DT8T PDGÃQVHQÃ9SDW@TC6AU 8GVU8CÃBVD9@ 9DAA@S@IUD6Gà 8GVU8CÃ6TT@H7G` 7S@6UC@SÃUV7@Ã7 7S@6UC@Sà 7S@6UC@Sà TCDHÃ"À€ UV7@Ã6 UV7@Ã8 PDGÃT@6G Replace.
  • Page 934 5HDU 'LIIHUHQWLDO 'LIIHUHQWLDO 5HDVVHPEO\ 'LIIHUHQWLDO 5HDVVHPEO\ FRQW¶G 6SHFLDO 7RROV 5HTXLUHG  Tighten the oil pump body assembly mounting bolts. Companion Flange Holder 07PAB-0020000  Apply DPSF to the rubber of the ATF strainer (A),  Install the oil pump driveshaft (A) by aligning the then install the ATF strainer, the magnet (B), and projection (B) of the oil pump driveshaft with the the oil pump pin (C), and the collar (D) to the...
  • Page 935 'LIIHUHQWLDO 5HDVVHPEO\  Install the differential clutch assembly (A) by  Install the 30 mm shim (A), the 6 x 1.0 mm dowel aligning the tabs of the pressure plate (B) with the pins (B), and the torque control differential case grooves in the oil pump driveshaft (C).
  • Page 936 5HDU 'LIIHUHQWLDO 'LIIHUHQWLDO 5HDVVHPEO\ 'LIIHUHQWLDO 5HDVVHPEO\ FRQW¶G  Install the special tools to the companion flange,  Install the drain plug (A) and the oil filler plug (B) then tighten the new locknut to specified torque. with new washers (C). UPSRV@) 'ÃI€Ã !Ãxts€Ã'&ÃyisÂs‡...
  • Page 937 'LIIHUHQWLDO ,QVWDOODWLRQ 'LIIHUHQWLDO ,QVWDOODWLRQ  Install the rear differential mount assembly A (A) to  Install the plates (A) and torque the rear differential the rear differential assembly (B). mount assembly mounting bolts (B).  Install the right and left rear differential mount  Jack up the rear differential.
  • Page 938 5HDU 'LIIHUHQWLDO 'LIIHUHQWLDO ,QVWDOODWLRQ 'LIIHUHQWLDO ,QVWDOODWLRQ FRQW¶G  Install the No. 2 propeller shaft (A) onto the rear differential (B) by aligning the reference mark (C). Be sure to use new mounting bolts (D).  Fill the rear differential with the specified amount of DPSF (see page 15-13).
  • Page 939 'LIIHUHQWLDO 0RXQW 5HSODFHPHQW 'LIIHUHQWLDO 0RXQW 5HSODFHPHQW ([SORGHG 9LHZ S@6SÃ9DAA@S@IUD6GÃ HPVIUÃ6TT@H7G`Ã6 QG6U@ S@6SÃ9DAA@S@IUD6GÃ DITVG6UPSÃSV77@S 96HQ@S SGÃS@6SÃ9DAA@S@IUD6GÃ S@6SÃ9DAA@S@IUD6GÃ6TT@H7G` HPVIUÃ7S68F@UÃ7 ...
  • Page 941 'ULYHOLQH$[OH TƒrpvhyÃU‚‚y†  9…v‰r†uhs‡ÃD†ƒrp‡v‚   %" A…‚‡Ã9…v‰r†uhs‡†ÃSr€‚‰hy   %" A…‚‡Ã9…v‰r†uhs‡†Ã9v†h††r€iy’   9’h€vpÃ9h€ƒr…ÃSrƒyhpr€r‡   A…‚‡Ã9…v‰r†uhs‡†ÃSrh††r€iy’   A…‚‡Ã9…v‰r†uhs‡†ÃD†‡hyyh‡v‚   % & D‡r…€rqvh‡rÃTuhs‡ÃSr€‚‰hy   % ( D‡r…€rqvh‡rÃTuhs‡Ã9v†h††r€iy’   %! D‡r…€rqvh‡rÃTuhs‡ÃSrh††r€iy’   D‡r…€rqvh‡rÃTuhs‡ÃD†‡hyyh‡v‚   %!"...
  • Page 942 'ULYHOLQH$[OH 6SHFLDO 7RROV 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07GAD-PH70201 Oil Seal Driver 07MAC-SL00200 Ball Joint Remover, 28 mm 07NAF-SR30101 Half Shaft Base " 07XAC-0010200 Threaded Adapter, 24 x 1.5 mm 07746-0010400 Attachment, 52 x 55 mm 07746-0030400 Attachment, 35 mm I.D. 07749-0010000 Driver &...
  • Page 943 'ULYHVKDIW ,QVSHFWLRQ 'ULYHVKDIW ,QVSHFWLRQ )URQW 'ULYHVKDIWV 5HPRYDO  Check the inboard boot (A) and the outboard boot 6SHFLDO 7RRO 5HTXLUHG (B) on the driveshaft (C) for cracks, damage, Ball joint remover, 28 mm 07MAC-SL00200 leaking grease, and loose boot bands (D). If any  Loosen the wheel nuts slightly.
  • Page 944 'ULYHOLQH$[OH )URQW 'ULYHVKDIWV 5HPRYDO )URQW 'ULYHVKDIWV 5HPRYDO FRQW¶G  Remove the cotter pin (A) from the lower arm ball  Pry (left driveshaft)/tap (right driveshaft), the joint castle nut (B), and remove the nut. inboard joint (A) with a prybar, and remove the driveshaft from the differential case or bearing support as an assembly.
  • Page 945 )URQW 'ULYHVKDIWV 'LVDVVHPEO\ )URQW 'ULYHVKDIWV 'LVDVVHPEO\ 6SHFLDO 7RROV 5HTXLUHG 9‚ˆiyrÃG‚‚ƒÃU’ƒr ‡ Threaded adapter, 24 x 1.5 mm 07XAC-0010200 ‡ Sliding hammer set 07936-5790001 ‡ Boot band pincers, commercially available ,QERDUG -RLQW 6LGH  Remove the set ring from the inboard joint. G‚ÃQ…‚svyrÃU’ƒr  Remove the boot bands.
  • Page 946 'ULYHOLQH$[OH )URQW 'ULYHVKDIWV 'LVDVVHPEO\ )URQW 'ULYHVKDIWV 'LVDVVHPEO\ FRQW¶G ,QERDUG -RLQW 6LGH FRQW¶G  Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.  Make a mark (A) on each roller (B) and inboard joint (C) to identify the locations of rollers and grooves in the inboard joint.
  • Page 947 )URQW 'ULYHVKDIWV 'LVDVVHPEO\ 2XWERDUG -RLQW 6LGH  Wipe off the grease to expose the driveshaft and the outboard joint inner race.  Remove the boot bands. Be careful not to damage  Make a mark (A) on the driveshaft (B) at the same the boot and dynamic damper.
  • Page 948 'ULYHOLQH$[OH '\QDPLF 'DPSHU 5HSODFHPHQW )URQW 'ULYHVKDIWV 'LVDVVHPEO\ '\QDPLF 'DPSHU 5HSODFHPHQW FRQW¶G  Remove the inboard joint (see page 16-5). 2XWERDUG -RLQW 6LGH FRQW¶G  Remove the dynamic damper bands. Be careful not to damage the dynamic damper (see page 16-5).  Remove the stop ring from the driveshaft.
  • Page 949 )URQW 'ULYHVKDIWV 5HDVVHPEO\ )URQW 'ULYHVKDIWV 5HDVVHPEO\ ([SORGHG 9LHZ T@UÃSDIB GPXÃQSPADG@à SPGG@S Replace. DI7P6S9ÃEPDIU 76I9 Replace. (U.K. Product only) 8DS8GDQ Pack cavity with specified TQD9@S amount of grease. DI7P6S9Ã7PPU Pack cavity with Svtu‡Ãq…v‰r…†uhs‡ specified amount of grease. Pack cavity with specified amount of grease.
  • Page 950 'ULYHOLQH$[OH )URQW 'ULYHVKDIWV 5HDVVHPEO\ )URQW 'ULYHVKDIWV 5HDVVHPEO\ FRQW¶G 6SHFLDO 7RROV 5HTXLUHG  Install the spider (A) onto the driveshaft by aligning ‡ Boot band tool, KD-3191 or equivalent, commercially the marks (B) on the spider and the end of the available driveshaft.
  • Page 951 )URQW 'ULYHVKDIWV 5HDVVHPEO\  Pack the inboard joint with the joint grease included  Make sure the ends of the boot are seated in the in the new driveshaft set. grooves in the driveshaft and joint, then install the boot bands. B…rh†rĈh‡v‡’...
  • Page 952 'ULYHOLQH$[OH )URQW 'ULYHVKDIWV 5HDVVHPEO\ )URQW 'ULYHVKDIWV 5HDVVHPEO\ FRQW¶G ,QERDUG -RLQW 6LGH FRQW¶G  Thread the free end of the band through the nose section of the commercially available boot band  Set the new double loop band (A) onto the boot tool KD-3191 or equivalent (A), and into the slot on with the band end toward the front of the vehicle.
  • Page 953 )URQW 'ULYHVKDIWV 5HDVVHPEO\  Unwind the boot band tool, and cut off the excess  Install the new set ring. free end of the band to leave a 5 - 10 mm (0.2 - 0.5 in.) tail protruding from the clip. (cont’d)  Bend the band end (A) by tapping it down with a hammer.
  • Page 954 'ULYHOLQH$[OH )URQW 'ULYHVKDIWV 5HDVVHPEO\ )URQW 'ULYHVKDIWV 5HDVVHPEO\ FRQW¶G 2XWERDUG -RLQW 6LGH  Insert the driveshaft (A) into the outboard joint (B) until the stop ring (C) is close to the joint.  Wrap the splines with vinyl tape (A) to prevent damage to the outboard boot.
  • Page 955 )URQW 'ULYHVKDIWV 5HDVVHPEO\  Check the alignment of the paint mark (A) with the  Adjust the length of the driveshafts to the figure outboard joint end (B). below, then adjust the boots to halfway between full compression and full extension. Make sure the ends of the boots seat in the groove of the driveshaft and joint.
  • Page 956 'ULYHOLQH$[OH )URQW 'ULYHVKDIWV 5HDVVHPEO\ )URQW 'ULYHVKDIWV 5HDVVHPEO\ FRQW¶G 2XWERDUG -RLQW 6LGH FRQW¶G  Check the clearance between the closed ear portion of the band. If the clearance is not within the  Fit the boot (A) ends onto the driveshaft (B) and standard, close the ear portion of the band further.
  • Page 957 )URQW 'ULYHVKDIWV ,QVWDOODWLRQ )URQW 'ULYHVKDIWV ,QVWDOODWLRQ  Install a new set ring onto the set ring groove of the  Clean the areas where the driveshaft contacts the driveshaft (left driveshaft). differential thoroughly with solvent or carburetor cleaner, and dry with compressed air. Insert the inboard end (A) of the driveshaft into the differential (B) or intermediate shaft (C) until the set ring (D) locks in the groove (E).
  • Page 958 'ULYHOLQH$[OH )URQW 'ULYHVKDIWV ,QVWDOODWLRQ )URQW 'ULYHVKDIWV ,QVWDOODWLRQ FRQW¶G  Install the knuckle (A) onto the lower arm (B). Wipe  Install a new spindle nut (A), then tighten the nut. off the grease before tightening the nut at the ball After tightening, use a drift to stake the spindle nut joint.
  • Page 959 ,QWHUPHGLDWH 6KDIW 5HPRYDO ,QWHUPHGLDWH 6KDIW 5HPRYDO  Remove the right driveshaft  Remove the intermediate shaft (A) from the (see page 16-3) differential. Hold the intermediate shaft horizontal  Remove the heat cover. until it is clear of the differential to prevent damage to the differential oil seal (B).
  • Page 960 'ULYHOLQH$[OH ,QWHUPHGLDWH 6KDIW 'LVDVVHPEO\ ,QWHUPHGLDWH 6KDIW 'LVDVVHPEO\ 6SHFLDO 7RROV 5HTXLUHG  Remove the internal snap ring. ‡ Oil seal driver 07947-SB00100 ‡ Half shaft base 07NAF-SR30101  Remove the set ring (A), outer seal (B), and external snap ring (C).  Press the intermediate shaft bearing (A) out of the bearing support (B) using the special tools and a press.
  • Page 961 ,QWHUPHGLDWH 6KDIW 5HDVVHPEO\ ,QWHUPHGLDWH 6KDIW 5HDVVHPEO\ ([SORGHG 9LHZ AG6IB@Ã7PGU Ñà !$À€ 9PX@GÃ7PGU DIU@SH@9D6U@ÃTC6AUÃSDIB "(ÃIÀ Ñà !$À€ #ÃxtsÀÃ!(ÃyisÃs‡ "(ÃIÀ #ÃxtsÀÃ!(ÃyisÃs‡ 7@6SDIBÃTVQQPSUÃSDIB @YU@SI6GÃTI6QÃSDIB DIU@SH@9D6U@ÃTC6AU PVU@SÃT@6G Replace. DIU@SI6GÃTI6QÃSDIB DIU@SH@9D6U@ÃTC6AUà 7@6SDIB Replace. T@UÃSDIB Replace. 7@6SDIBÃTVQQPSU Pack the interior of the outer seal. (cont’d) ...
  • Page 962 'ULYHOLQH$[OH ,QWHUPHGLDWH 6KDIW 5HDVVHPEO\ ,QWHUPHGLDWH 6KDIW 5HDVVHPEO\ FRQW¶G 6SHFLDO 7RROV 5HTXLUHG  Press the intermediate shaft (A) into the shaft ‡ Driver 07749-0010000 bearing (B) using the special tool and a press. ‡ Attachment, 52 x 55 mm 07746-0010400 ‡ Attachment, 35 mm I.D. 07746-0030400 QS@TT ‡...
  • Page 963 ,QWHUPHGLDWH 6KDIW ,QVWDOODWLRQ ,QWHUPHGLDWH 6KDIW ,QVWDOODWLRQ  Install the outer seal (A) into the bearing support  Use solvent or carburetor cleaner to thoroughly (B) using the special tool and a press. clean the areas where the intermediate shaft (A) contacts the transmission (differential), and dry with QS@TT compressed air.
  • Page 964 'ULYHOLQH$[OH 5HDU 'ULYHVKDIWV 5HPRYDO ,QWHUPHGLDWH 6KDIW ,QVWDOODWLRQ 5HDU 'ULYHVKDIWV 5HPRYDO FRQW¶G  Loosen the wheel nuts slightly.  Install the heat cover, and tighten the three bolts.  Raise the front of the vehicle, and support it with safety stands in the proper locations (see page 01-  Remove the wheel nuts and front wheels.
  • Page 965 5HDU 'ULYHVKDIWV 'LVDVVHPEO\ 5HDU 'ULYHVKDIWV 'LVDVVHPEO\  Remove the rear driveshaft (A). NOTE: NOTE: ‡ Due to the amount of work required to replace one ‡ Be careful not to damage the ABS wheel sensor (B). damaged boot, it is best to replace both boots at the ‡...
  • Page 966 'ULYHOLQH$[OH 5HDU 'ULYHVKDIWV 'LVDVVHPEO\ 5HDU 'ULYHVKDIWV 'LVDVVHPEO\ FRQW¶G  Make a mark (A) on the rollers (B) and spider (C) to 9‚ˆiyrÃG‚‚ƒÃU’ƒr identify the locations of the rollers on the spider, them remove the rollers. G‚ÃQ…‚svyrÃU’ƒr  Remove the circlip (D).  Mark the spider (C) and driveshaft (E) to identify the position of the spider on the shaft.
  • Page 967 5HDU 'ULYHVKDIWV 5HDVVHPEO\ 5HDU 'ULYHVKDIWV 5HDVVHPEO\ ([SORGHG 9LHZ DI7P6S9ÃEPDIU GPXÃQSPADG@Ã 76I9 8DS8GDQ Replace. SPGG@S (U.K. product only) TQD9@S T@UÃSDIB Replace. 9PV7G@ÃGPPQÃ 76I9 Replace. (Replacement parts only) 9SDW@TC6AUÃSDIBT DI7P6S9Ã7PPU Pack cavity with grease. 9SDW@TC6AU 9PV7G@ÃGPPQÃ76I9 Replace. (Replacement parts only) SPGG@S TQD9@S 8DS8GDQ PVU7P6S9Ã7PPU PVU7P6S9ÃEPDIU...
  • Page 968 'ULYHOLQH$[OH 5HDU 'ULYHVKDIWV 5HDVVHPEO\ 5HDU 'ULYHVKDIWV 5HDVVHPEO\ FRQW¶G 6SHFLDO 7RROV 5HTXLUHG  Fit the rollers (A) onto the spider (B) with their high ‡ Boot band tool, KD-3191 or equivalent, commercially shoulders facing outward, and note these items: available ‡ Reinstall the rollers in their original positions on the ‡...
  • Page 969 5HDU 'ULYHVKDIWV 5HDVVHPEO\  Fit the inboard joint onto the driveshaft, and note  Make sure the ends of the boot are seated in the these items: grooves in the driveshaft and joint, then install the boot bands. ‡ Reinstall the inboard joint onto the driveshaft by aligning the marks (A) on the inboard joint and the ‡...
  • Page 970 'ULYHOLQH$[OH 5HDU 'ULYHVKDIWV 5HDVVHPEO\ 5HDU 'ULYHVKDIWV 5HDVVHPEO\ FRQW¶G  Fit the boot ends onto the driveshaft and the  Place a wrench on the winding mandrel of the boot inboard joint, then install the new double loop band band tool, and tighten the band until the marked (A) onto the boot.
  • Page 971 5HDU 'ULYHVKDIWV ,QVWDOODWLRQ 5HDU 'ULYHVKDIWV ,QVWDOODWLRQ  Bend the band end (A) by tapping it down with a NOTE: Before starting installation, make sure the wating hammer. surfaces of the joint and the spline section are free from NOTE: dirt or dust. ‡...
  • Page 972 'ULYHOLQH$[OH 3URSHOOHU 6KDIW ,QVSHFWLRQ 3URSHOOHU 6KDIW ,QVSHFWLRQ 8QLYHUVDO -RLQW DQG %RRWV 3URSHOOHU 6KDIW 5XQRXW  Shift the transmission to Neutral.  Install a dial indicator with its needle on the center of the No. 1 or No. 2 propeller shaft.  Raise the vehicle off the ground, and support it with  Turn the other propeller shaft slowly, and check the safety stands in the proper locations...
  • Page 973 3URSHOOHU 6KDIW 5HPRYDO 3URSHOOHU 6KDIW 5HPRYDO  Raise the vehicle off the ground, and support it with  Separate the propeller shaft from the transfer safety stands in the proper location (see page 01- assembly.  Remove the center support bearing mounting bolts.  Remove the No.
  • Page 974 'ULYHOLQH$[OH 3URSHOOHU 6KDIW ,QVWDOODWLRQ 3URSHOOHU 6KDIW ,QVWDOODWLRQ  Install the propeller shaft (A) onto the rear  Install the propeller shaft (A) onto the transfer (B) differential (B) by aligning the reference mark (C). by aligning the reference mark (C).  Install the center support bearing mounting bolt.
  • Page 975 6WHHULQJ Q‚r…ÃT‡rr…vt   &! Special Tools ................................17-2 Component Location Index ............................17-3 Symptom Troubleshooting Index..........................17-4 Hard Steering Troubleshooting........................... 17-6 Steering Wheel Rotational Play Check ........................17-7 Power Assist Check ..............................17-7 Steering Linkage and Gearbox Inspection ......................... 17-8 Pump Pressure Test..............................
  • Page 976 6WHHULQJ 3RZHU 6WHHULQJ 3RZHU 6WHHULQJ 6SHFLDO 7RROV SrsÃI‚ U‚‚yÃIˆ€ir… 9r†p…vƒ‡v‚ R‡’ 07MAA-SL00100 Locknut Wrench, 40 mm 07MAC-SL00200 Ball Joint Remover, 28 mm 07NAD-SR30101 Driver Handle " 07NAD-SR30200 Cylinder End Seal Remover Attachment 07NAG-SR30900 Valve Seal Ring Sizing Tool 07QAD-P0A0100 Attachment, 42 mm 07YAG-S2X0100 Sleeve Seal Ring Guide &...
  • Page 977 3RZHU 6WHHULQJ &RPSRQHQW /RFDWLRQ ,QGH[ " Removal / Installation, page 23-135 9SDW@S·TÃ6DS76B Steering Wheel Removal, page 17-21; Steering Wheel Disassembly / Reassembly, page 17-22; Steering Wheel TU@@SDIBÃXC@@G Installation, page 17-23 Steering Column Tilt Operation Check, page 17-25; Steering Column Removal and Installation, page 17-24;...
  • Page 978 6WHHULQJ 3RZHU 6WHHULQJ 6\PSWRP 7URXEOHVKRRWLQJ ,QGH[ Find the symptom in the chart below, and do the related procedures in the order listed until you find the cause. T’€ƒ‡‚€ Q…‚prqˆ…r† 6y†‚ÃpurpxÃs‚…) Hard steering Troubleshoot the system (see page 17-6). Modified ‡ suspension Damaged ‡...
  • Page 979 3RZHU 6WHHULQJ Rattle or chattering Check for loose steering components (tie-rod and ball joints). Tighten or replace (Rack rattle) as necessary. Check the steering column shaft for wobbling. If the steering column wobbles, replace the steering column assembly (see page 17-24).
  • Page 980 6WHHULQJ 3RZHU 6WHHULQJ +DUG 6WHHULQJ 7URXEOHVKRRWLQJ +DUG 6WHHULQJ  Measure the fluid pressure with shut-off valve and pressure gauge valve open, while turning the  Check the power assist (see page 17-7). steering wheel fully to the left and fully to the right. ,V WKH VWDUWLQJ ORDG PRUH WKDQ  1  NJI  OEI "...
  • Page 981 3RZHU 6WHHULQJ 6WHHULQJ :KHHO 5RWDWLRQDO 3OD\ &KHFN 3RZHU $VVLVW &KHFN  Turn the front wheels to the straight ahead position.  Check the power steering fluid level (see page 17-11).  Measure how far you can turn the steering wheel  Start the engine, let it idle, and turn the steering left and light without moving the front wheels.
  • Page 982 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ /LQNDJH DQG *HDUER[ ,QVSHFWLRQ 7PPUT Inspect for damage and deterioration. TU@@SDIBÃ8PGPVHI Inspect for loose coloumn mounting nuts. TU@@SDIBÃEPDIUT Check for loose joint bolts. 76GÃEPDIUÃ7PPU TU@@SDIBÃB@6S7PY Inspect for damage and Inspect for loose mounting hardware. deterioration. B@6S7PYÃHPVIUDIBÃ8VTCDPIT Inspect for deterioration.
  • Page 983 3RZHU 6WHHULQJ 3XPS 3UHVVXUH 7HVW 6SHFLDO 7RROV 5HTXLUHG  Fully open the shut-off valve (A). ‡ P/S joint adapter (pump) 07ZAK-S7C0101 ‡ P/S joint adapter (hose) 07ZAK-S7C0200 ‡ P/S pressure gauge 07406-0010001 Check the fluid pressure as follows to determine whether the trouble is in the pump or gearbox.
  • Page 984 6WHHULQJ 3RZHU 6WHHULQJ )OXLG /HDNDJH ,QVSHFWLRQ QVHQÃ6TT@H7G` Check for leaks at the pump seal and inlet and outlet fittings. B@6S7PYÃhqÃW6GW@Ã7P9`ÃVIDU Check for leaks at the mating surface and flare nut connections. CPT@TÃhqÃGDI@T Inspect hoses for damage, leaks, interference, and twisting. Inspect fluid lines for damage, rusting, and leakage.
  • Page 985 Always use Genuine hose (A) to drain the reservoir. Take care not to spill Honda Power Steering Fluid. Using any other type of the fluid on the body and parts. Wipe off any spilled power steering fluid or automatic transmission fluid can fluid at once.
  • Page 986 6WHHULQJ 3RZHU 6WHHULQJ +RVHV DQG /LQHV 5HSODFHPHQW Note these items during installation: ‡ Connect each hose to the corresponding line securely until it contacts the stop on the line. Install the clamp or adjustable clamp at the specified distance from the hose end as shown. ‡...
  • Page 987 3RZHU 6WHHULQJ 3XPS 5HSODFHPHQW  Place a suitable container under the vehicle.  Connect the pump inlet hose and pump outlet hose.  Drain the power steering fluid from the reservoir.  Loosely install the pump in the pump bracket with  Remove the drive belt (A) from the pump pulley the mounting bolts, then tighten the pump fittings (see page...
  • Page 988 6WHHULQJ 3RZHU 6WHHULQJ 3XPS 2YHUKDXO ([SORGHG 9LHZ Replace the pump as an assembly if the parts indicated with asterisk (*) are worn or damaged. DIG@UÃEPDIU %Ñà À€ ÃIÀà   ÃxtsÀÃ'ÃyisÃs‡ "Ñà (À€ÃPSDIB 'Ñà !$À€ Replace. !ÃIÀà !ÃxtsÀà #ÃyisÃs‡ QVHQÃ8PW@SÃT@6GT Replace.
  • Page 989 3RZHU 6WHHULQJ 6SHFLDO 7RROV 5HTXLUHG ,QVSHFWLRQ ‡ Attachment, 32 x 35 mm 07746-0010100  Check the pressure control valve for wear, burrs, ‡ Driver 07749-0010000 and other damage to the edges of the grooves in ‡ Pulley holder 07ZAB-S5A0100 the valve. 'LVDVVHPEO\ NOTE: Refer to the Exploded View as needed during the following procedure.
  • Page 990 6WHHULQJ 3RZHU 6WHHULQJ 3XPS 2YHUKDXO FRQW¶G ,QVSHFWLRQ FRQW¶G 5HDVVHPEO\  Attach a hose (A) to the end of the pressure control  Install the new pump seal (A) (with its grooved side valve (B) as shown. Then submerge the pressure facing in) into the pump housing (B) by hand first, control valve in a container of power steering fluid then drive it in using the special tools with until...
  • Page 991 3RZHU 6WHHULQJ  Coat the new 23.8 mm O-ring (A) with the power  Install the outer case (A) by aligning the slot (B) steering fluid, then position it on the bottom (B) of inside the outer case with the cover roll pin hole the pump housing.
  • Page 992 6WHHULQJ 3RZHU 6WHHULQJ 3XPS 2YHUKDXO FRQW¶G 5HDVVHPEO\ FRQW¶G  Place the side plate (A) on the cam ring, and aligning the roll pin set hole (B) in the side plate  Install the cam ring (A) with the “•” mark on it up with the roll pin end (C).
  • Page 993 3RZHU 6WHHULQJ  Align the bolt holes in the cover (A) with the  Install the pump preload spring (A) in the pump threaded holes in the pump housing. Install the housing. flange bolts loosely first, then torque the flange bolts in a criss cross pattern in two or more steps.
  • Page 994 6WHHULQJ 3RZHU 6WHHULQJ 3XPS 2YHUKDXO FRQW¶G 5HDVVHPEO\ FRQW¶G  Coat the new O-ring (A) with power steering fluid, and install it on the inlet joint (B).  Install the inlet joint on the pump housing.  Install the pulley (A), then loosely install the pulley nut (B).
  • Page 995 3RZHU 6WHHULQJ 6WHHULQJ :KHHO 5HPRYDO  Install a commercially available steering wheel SRS components are located in this area. Review the SRS component locations (see page 23-14) and precautions puller (A) on the steering wheel (B). Free the and procedures (see page 23-16) in the SRS section steering wheel from the steering column shaft by...
  • Page 996 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ :KHHO 'LVDVVHPEO\5HDVVHPEO\ TU@@SDIBÃXC@@G 96HQ@S TU@@SDIBÃXC@@GÃ CPSIÃQG6U@ S@6SÃ8PW@S TQSDIB TQ68@S TGD9@ÃT8S@X 688@TTÃQ6I@G CPSIÃQG6U@Ã8PW@S 8SVDT@Ã8PIUSPGÃ T@UÃÃS@TVH@ÃTXDU8C ...
  • Page 997 3RZHU 6WHHULQJ 6WHHULQJ :KHHO ,QVWDOODWLRQ  Before installing the steering wheel, make sure the  Install the steering wheel bolt (A) and tighten it to front wheels are aligned straight ahead, then center the specified torque. Connect the horn and cruise the cable reel (A).
  • Page 998 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ &ROXPQ 5HPRYDO DQG ,QVWDOODWLRQ SRS components are located in this area. Review the SRS component locations (see page 23-14) and precautions and procedures (see page 23-16) in the SRS section before performing repairs or service. 5HPRYDO  Record the radio station presets, and disconnect the battery.
  • Page 999 3RZHU 6WHHULQJ 6WHHULQJ &ROXPQ 7LOW 2SHUDWLRQ &KHFN ,QVWDOODWLRQ  Set the steering wheel in the straight driving position, and loosen the tilt lever fully.  Install the steering column in the reverse order of removal, and note these items:  Attach the spring scale to the highest point of the steering wheel, and set the tilting position at the ‡...
  • Page 1000 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ &ROXPQ7LOW /HYHU ,QVSHFWLRQ$GMXVWPHQW ‡ Check the steering column ball bearing (A) and the steering joint bearings (B) for play and proper movement. If any bearing is noisy or has excessive play, replace the steering column as an assembly. ‡...
  • Page 1001 3RZHU 6WHHULQJ 6WHHULQJ /RFN 5HSODFHPHQW 7LOW /HYHU 3UHORDG ,QVSHFWLRQ  Remove the steering column (see page 17-24).  Move the tilt lever (A) from the loose position to the  Center punch each of the two shear bolts, and drill lock position three to 5 times;...
  • Page 1002 6WHHULQJ 3RZHU 6WHHULQJ 5DFN *XLGH $GMXVWPHQW 6SHFLDO 7RROV 5HTXLUHG  Remove the old sealant from rack guide screw, and Locknut wrench, 40 mm 07MAA-SL00100 apply new sealant to the middle of the threads (C). Loosely install the rack guide screw on the steering  Set the wheels in the straight ahead position.
  • Page 1003 3RZHU 6WHHULQJ 6WHHULQJ *HDUER[ 5HPRYDO 6SHFLDO 7RROV 5HTXLUHG  Remove the air cleaner (A). Ball joint remover, 28 mm 07MAC-SL00200 Note these items during removal: ‡ Using solvent and a brush, wash any oil and dirt off the valve body unit, its lines, and the end of the gearbox. Blow dry with compressed air.
  • Page 1004 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ *HDUER[ 5HPRYDO FRQW¶G  Loosen the adjustable hose clamp (A) and  On the driver’s side, loosen the 14 mm flare nut (A) disconnect the return hose (B), and return line and disconnect the feed line (B), and feed line clamp (RHD model) (C).
  • Page 1005 3RZHU 6WHHULQJ  On the passenger’s side, remove the P/S return  Remove the 10 mm flange bolt and nut from the line bracket (A) and return line clamp (B). right side (RHD: left side) of the gearbox, then remove the mounting bracket (A).  Lower the steering gearbox, and rotate it so the pinion shaft points upward.
  • Page 1006 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ *HDUER[ 5HPRYDO FRQW¶G  Carefully move the steering gearbox (A) and tie- rods (B) as an assembly toward the driver’s side until the pinion shaft clears the wheelwell opening (C) on the frame.  Remove the steering gearbox through the wheelwell opening on the driver’s side.
  • Page 1007 3RZHU 6WHHULQJ 6WHHULQJ *HDUER[ 2YHUKDXO ([SORGHG 9LHZ AG6IB@Ã7PGUT !ÃIÀÃ!ÃxtsÀà #ÃyisÃs‡ W6GW@ÃCPVTDIB W6GW@ÃPDGÃT@6G Replace. SPGG@SÃ7@6SDIB TI6QÃSDIB Replace. 8`GDI9@SÃGDI@T TG@@W@ TG@@W@ÃT@6GÃSDIBT Replace. W6GW@ÃT@6GÃSDIBT Replace. PSDIB Replace. 768FVQÃSDIB W6GW@ÃPDGÃT@6G 8`GDI9@SÃCPVTDIB GP8FÃT8S@X Replace. Replace. X6W@ÃX6TC@S QDIDPIÃTC6AU PSDIB Replace. B@6S7PYÃCPVTDIB 7VTCDIB 8`GDI9@SÃ@I9ÃT@6G 7PPUÃ6 S68FÃBVD9@ Replace. Replace.
  • Page 1008 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ *HDUER[ 2YHUKDXO FRQW¶G 6SHFLDO 7RROV 5HTXLUHG  Unbend the lock washer (A). ‡ Cylinder end seal remover attachment 07NAD-SR30200 ‡ Driver, 27 mm 07ZAF-S5A0100 ‡ Valve seal ring sizing tool 07NAG-SR30900 ‡ Sleeve seal ring guide 07YAG-S2X0100 ‡...
  • Page 1009 3RZHU 6WHHULQJ  Remove the stop washer (A), the 12 mm flange  Loosen the locknut (A), then remove the rack guide bolts (B), O-rings (C), and bracket (D) from the screw (B), spring (C), and rack guide (D) from the steering gearbox.
  • Page 1010 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ *HDUER[ 2YHUKDXO FRQW¶G 'LVDVVHPEO\ FRQW¶G  Hold the gearbox housing using a C-clamp (commercially available) (A) and the wooden  Remove the valve body unit (A) from the steering blocks (B) as shown. Do not clamp the cylinder gearbox.
  • Page 1011 3RZHU 6WHHULQJ  Remove the special tool.  Remove and discard the stop ring (A) on the cylinder by expanding it with snap ring pliers.  Pull on the cylinder to remove it from the gearbox Remove and discard the lock screw (B). housing.
  • Page 1012 6WHHULQJ 3RZHU 6WHHULQJ 6WHHULQJ *HDUER[ 2YHUKDXO FRQW¶G 'LVDVVHPEO\ FRQW¶G  Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston. Be careful not to damage the  Insert the special tools into the cylinder. inside of the seal ring groove and piston edges Make sure the attachment (A) of the special tools is when removing the seal ring.