Honda HR-V 1999 Manual
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Honda HR-V 1999 Manual

Honda HR-V 1999 Manual

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Summary of Contents for Honda HR-V 1999

  • Page 7 General Information Index General Information Chassis and Engine Numbers Identification Number Locations Warning/Caution Label Locations Lift and Support Points Lift and Safety Stands Floor Jack Towing Service Precautions 1-10 Preparation of Work 1-11 Abbreviations 1-18 Wiring Diagrams...

  • Page 8: Specifications Index

    Specifications Index Specifications Standards and Service Limits Design Specifications 2-13 Body Specifications 2-19 Wiring Diagrams...

  • Page 9: Maintenance Index

    Maintenance Index Maintenance Lubrication Maintenance Schedule Wiring Diagrams...
  • Page 10 Engine Electrical Index Engine Electrical Special Tools Starting System Component Location Index Circuit Diagram Starter Test Starter Solenoid Test Starter Replacement Starter Overhaul Brush Inspection 4-10 Overrunning Clutch Inspection 4-10 Armature Inspection and Test 4-11 Brush Holder Test 4-13 Starter Reassembly 4-13 Performance Test 4-14...
  • Page 11 Engine Index Engine Removal/Installation Cylinder Head/Valve Train Engine Block Engine Lubrication Intake Manifold/Exhaust System Wiring Diagrams...
  • Page 12 Engine Index Engine Removal/Installation Special Tools Engine Removal/Installation Removal Installation 5-11 Cylinder Head/Valve Train Engine Block Engine Lubrication Intake Manifold/Exhaust System...
  • Page 13 Engine Index Engine Removal/Installation Cylinder Header/Valve Train Special Tools Valve Clearance Adjustment Crankshaft Pulley and Pulley Bolt Replacement Timing Belt Illustrated Index Inspection Tension Adjustment Removal Installation 6-10 Cylinder Head Illustrated Index 6-12 Removal 6-14 Warpage 6-24 Installation 6-29 Rocker Arms Removal 6-18 Disassembly/Reassembly...
  • Page 14 Engine Index Engine Removal/Installation Cylinder Head/Valve Train Engine Block Special Tools Illustrated Index Flywheel and Drive Plate Replacement Connecting Rod and Crankshaft End Play Main Bearings Clearance Selection Connecting Rod Bearings Clearance 7-10 Selection 7-10 Pistons and Crankshaft Removal 7-11 Crankshaft Inspection 7-13...
  • Page 15 Engine Index Engine Removal/Installation Cylinder Head/Valve Train Engine Block Engine Lubrication Special Tools Illustrated Index Engine Oil Inspection Replacement Oil Filter Replacement Oil Pressure Switch Testing Oil Pressure Testing Oil Pump Overhaul Removal/Inspection/Installation 8-10 Intake Manifold/Exhaust System...
  • Page 16 Engine Index Engine Removal/Installation Cylinder Head/Valve Train Engine Block Engine Lubrication Intake Manifold/Exhaust System Intake Manifold Replacement Exhaust Manifold Replacement Exhaust Pipe and Muffler Replacement...
  • Page 18 Cooling Index Cooling 10-1 Radiator Illustrated Index 10-2 Replacement 10-4 Engine Coolant Refilling and Bleeding 10-5 Cap Testing 10-7 Testing 10-7 Thermostat Replacement 10-8 Testing 10-9 Water Pump Illustrated Index 10-10 Inspection 10-11 Replacement 10-11 Fan Controls Component Location Index 10-12 Circuit Diagram 10-13...
  • Page 20 Fuel and Emissions Index Fuel and Emissions 11-1 Special Tools 11-2 Component Locations Index 11-3 System Description Vacuum Connections 11-7 Electrical Connections 11-10 Troubleshooting Troubleshooting Procedures 11-13 Troubleshooting Guide 11-17 Engine Control Module/Powertrain Control Module Terminal Arrangement 11-19 Diagnostic Trouble Code Chart 11-23 PGM-FI System System Description...

  • Page 21: Wiring Diagrams

    Fuel Injected System Connectors - RH 11-115 Wiring Diagrams...
  • Page 23 Transaxle Index Clutch 12-1 Manual Transmission 13-1 Continuously Variable Transmission (CVT) Honda Multi Matic 14-1 Differential (Rear Differential) 15-1 Driveshafts 16-1 Wiring Diagrams...
  • Page 24 Pressure Plate Removal/Installation 12-10 Clutch Disc Removal/Inspection 12-11 Flywheel Inspection/Replacement 12-12 Clutch Disc, Pressure Plate Installation 12-13 Release Bearing Removal/Inspection 12-14 Installation 12-14 Manual Transmission 13-1 Continuously Variable Transmission (CVT) Honda Multi Matic 14-1 Differential (Rear Differential) 15-1 Driveshafts 16-1...
  • Page 25 Transfer Housing Bearing Outer Race Replacement 13-55 Reassembly 13-56 Mainshaft Bearing/Oil Seal Replacement 13-66 Countershaft Bearing Replacement 13-67 Mainshaft Thrust Clearance Adjustment 13-68 Transmission Assembly Reassembly 13-71 Installation 13-76 Continuously Variable Transmission (CVT) Honda Multi Matic 14-1 Differential (Rear Differential) 15-1 Driveshafts 16-1...
  • Page 27 Transaxle Index Clutch 12-1 Manual Transmission 13-1 Continuously Variable Transmission (CVT) Honda Multi Matic 14-1 Service Precaution 4W (Four-wheel Drive Model Precaution 14-2 Special Tools 14-3 Description 14-4 Clutches/Reverse Brake/Planetary Gear/Pulleys 14-6 Power Flow 14-8 Electronic Control System 14-11 Hydraulic Control...
  • Page 28 Forward Clutch Illustrated Index 14-115 Disassembly 14-116 Reassembly 14-118 Secondary Gear Shaft 25 x 35 mm Thrust Shim Selection 14-122 Differential Illustrated Index 14-123 Backlash Inspection 14-124 Bearing Replacement 14-124 Differential Carrier Replacement 14-125 Oil Seal Removal 14-126 Oil Seal Installation 14-126 Side Clearance Inspection 14-127...
  • Page 29 Transaxle Index Clutch 12-1 Manual Transmission 13-1 Continuously Variable Transmission (CVT) Honda Multi Matic 14-1 Differential (Rear Differential) 15-1 Service Precautions 4WD (Four-wheel Drive) Model Precautions 15-2 Special Tools 15-3 Description Rear Differential 15-4 Hydraulic Flow 15-6 Real-time 4WD-Dual Pump System...
  • Page 30 Transaxle Index Clutch 12-1 Manual Transmission 13-1 Continuously Variable Transmission (CVT) Honda Multi Matic 14-1 Differential (Rear Differential) 15-1 Driveshafts 16-1 Special Tools 16-2 Driveshafts Inspection 16-3 Front Driveshafts Removal 16-3 Disassembly 16-5 Reassembly 16-8 Installation 16-15 Rear Driveshafts Removal...

  • Page 32: Supplemental Restraint System (Srs)

    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 therefore be done by an authorized Honda dealer. To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer.
  • Page 34 Suspension Index Suspension 18-1 Special Tools 18-2 Component Locations Index 18-3 Wheel Alignment Service Information 18-4 Camber 18-4 Caster 18-5 Toe Inspection/Adjustment 18-5 Turning Angle Inspection 18-6 Wheel/Hub Inspection Bearing End Play 18-6 Wheel Runout 18-7 Front Suspension Suspension/Arms Replacement 18-8 Knuckle/Hub Replacement 18-9...
  • Page 36 Brakes Index Conventional Brakes 19-A-1 Anti-lock Brake System (ABS) 19-B-1 Wiring Diagrams...
  • Page 37 Brakes Index Conventional Brakes 19-A-1 Special Tools 19-A-2 Component Locations Index 19-A-3 Inspection and Adjustment Brake System Rubber Parts and Brake Booster 19-A-4 Brake Pedal 19-A-5 Parking Brake 19-A-6 Bleeding 19-A-7 Brake System Indicator Circuit Diagram 19-A-8 Parking Brake Switch Test 19-A-8 Brake Fluid Level Switch Test 19-A-8...
  • Page 38 Brakes Index Conventional Brakes 19-A-1 Anti-lock Brake System (ABS) 19-B-1 Special Tools 19-B-2 Component Locations 19-B-3 Anti-lock Brake System (ABS) Features/Construction 19-B-4 Circuit Diagram 19-B-10 ABS Control Unit Terminal Arrangement 19-B-12 Troubleshooting Precautions 19-B-14 Diagnostic Trouble Code (DTC) Indication 19-B-16 DTC Clearing 19-B-17 Troubleshooting Index...
  • Page 40 Body Index Body 20-1 Door Component Location Index 20-2 Door Panel Removal and Installation 20-4 Door Outer Handle Replacement 20-5 Door Latch Replacement 20-7 Door Glass and Regulator Replacement 20-9 Door Channel Tape Replacement 20-11 Door Position Adjustment 20-13 Mirrors Component Location Index 20-14 Mirror Replacement...
  • Page 41 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 therefore be done by an authorized Honda dealer. To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer.

  • Page 43: Heater & Air Conditioning

    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 therefore be done by an authorized Honda dealer. To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer.
  • Page 44 Heater & Air Conditioning Heater 21-1 Component Location Index 21-2 Circuit Diagram 21-3 Troubleshooting Symptom Chart 21-4 Flowcharts Blower Motor Speed 21-5 Blower Motor 21-6 Recirculation Control Motor 21-9 Relay Test 21-11 Heater Fan Switch Test 21-11 Recirculation Control/A/C Switch Replacement 21-12 Test...
  • Page 45 Heater & Air Conditioning Heater 21-1 Air Conditioning 22-1 Special Tools 22-2 Component Location Index 22-3 Description 22-5 Circuit Diagram 22-6 Troubleshooting Symptom Chart 22-7 Flowcharts Radiator Fan 22-8 Condenser Fan 22-11 Both Fans 22-14 Radiator Fan Switch 22-15 Compressor 22-16 A/C System 22-19...
  • Page 47 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 therefore be done by an authorised Honda dealer. To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorised Honda dealer.
  • Page 48 Electrical Index Locations 23-A-1 Relay and Control Unit Locations Engine Compartment 23-A-2 Dashboard 23-A-3 Door 23-A-5 Wire Harness and Ground Locations Engine Compartment 23-A-6 Dashboard 23-A-10 Floor/Rear 23-A-14 Tailgate 23-A-15 Roof 23-A-16 Door 23-A-17 Power and Ground Distributions 23-B-1 Gauges 23-C-1 Lighting System 23-D-1...
  • Page 49 Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Battery Test 23-B-2 Power Relays Relay Test 23-B-3 * Ignition Switch Test 23-B-4 Fuses Under-hood Fuse/Relay Box 23-B-5 Under-dash Fuse/Relay Box 23-B-8 Power Distribution Circuit Identification 23-B-10 Ground Distribution Circuit Identification 23-B-26 Gauges 23-C-1...
  • Page 50 Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Gauges 23-C-1 Special Tools 23-C-2 Gauge Assembly Component Location Index 23-C-3 Circuit Diagram 23-C-4 Gauge/Terminal Location Index 23-C-8 Bulb Locations 23-C-9 Replacement 23-C-10 Vehicle Speed Sensor (VSS) Replacement 23-C-10 Troubleshooting 23-C-11 Vehicle Speed Alarm System (KY model) Circuit Diagram 23-C-13...
  • Page 51 Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Gauges 23-C-1 Lighting System 23-D-1 Component Location Index 23-D-2 Circuit Diagram 23-D-4 Combination Light Switch Test/Replacement 23-D-5 Headlights Replacement 23-D-6 Adjustment 23-D-7 Side Turn Signal Lights Replacement 23-D-7 Taillights Replacement 23-D-8 License Plate Lights Replacement 23-D-8...
  • Page 52 Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Gauges 23-C-1 Lighting System 23-D-1 Controls 23-E-1 Special Tools 23-E-2 Integrated Control Unit Circuit Diagram 23-E-3 Input Test 23-E-4 Power Windows Component Location Index 23-E-6 Circuit Diagram 23-E-7 Troubleshooting 23-E-8 Master Switch Test 23-E-9 Master Switch Input Test 23-E-10...
  • Page 53 Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Gauges 23-C-1 Lighting System 23-D-1 Controls 23-E-1 Instruments 23-F-1 Rear Window Defogger Component Location Index 23-F-2 Circuit Diagram 23-F-3 Switch Test 23-F-3 Function Test 23-F-4 Defogger Wire Repair 23-F-4 Power Mirrors Component Location Index 23-F-5 Circuit Diagram...
  • Page 54 Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Gauges 23-C-1 Lighting System 23-D-1 Controls 23-E-1 Instruments 23-F-1 Security 23-G-1 Immobiliser System Component Location Index 23-G-2 System Description 23-G-3 Circuit Diagram 23-G-4 Troubleshooting 23-G-5 Immobiliser Receiver Unit Replacement 23-G-7...
  • Page 56 Restraints Index Seat Belts 24-1 Supplemental Restraint System (SRS) 24-11 Wiring Diagrams...
  • Page 57 Restraints Index 24-1 Seat Belts Component Location Index 24-2 Front Seat Belt Replacement 24-3 Rear Seat Belt Replacement 24-6 Inspection 24-9 Supplemental Restraint System (SRS) 24-11...
  • Page 58 Restraints Index Supplemental Restraint System (SRS) 24-11 Special Tools 24-12 Component/Wiring Locations Index 24-13 Circuit Diagram 24-14 Wiring Harness and Connectors 24-15 Description 24-16 Precautions/Procedures General Procedures 24-17 Airbag/Seat Belt Tensioner Handling and Storage 24-18 SRS Unit Precautions 24-19 Steering-related Precautions 24-19 Wiring Precautions 24-20...
  • Page 60 Wiring Diagrams Wiring Diagrams Air Conditioning Anti-lock Brake System (ABS) Battery Charging System Cigarette Lighter Clock Dash Lights Brightness Controller Fan Controls Gauges Gauges Gauges Headlight Adjuster Horn Ignition Switch Ignition System Immobilizer System Indicators ABS Indicator A/T Gear Position Indicator Door Indicator High Beam Indicator Immobilizer Indicator...
  • Page 62 Preparation of Work Index Preparation of Work Description Checkpoints Correction of the Damaged Area Measurement (Excluding small damage) Positioning Jigs...
  • Page 64 Welding Methods/Repair Tools Welding Methods/Repair Tools Spot Welding Gas Welding Carbon Dioxide Arc Welder (MIG Arc Weld) Examples of Repair Tools...

  • Page 66: General Information

    General Information General Information Zinc-plated Steel Plate Repair Door and Bumper Reinforcement Beams...

  • Page 68: Supplemental Restraint System (Srs)

    SRS components. Servicing, disassembling or replacing these items will require special precautions and tools, and should therefore be done by an authorized Honda dealer. To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer.
  • Page 70 Cross Section of Body and Sealants Cross Section of Body and Sealants Engine Compartment, Front Wheelhouse/ Damper Housing Dashboard, Floors, Roof Panel/Outer Panel Rear Side Outer Panel/Rear Panel Rear Wheelhouse, Under Floor Rear Side Outer Panel/Rear Pillar Gutter Rear Wheelhouse NOTE: Seal the following areas to prevent air leaks, water leaks and rust.
  • Page 72 Body Dimensional Drawings Body Dimensional Drawings Upper Body Measuring Dimensions Engine Compartment Passenger Compartment Rear Pillar Gutter Positions Under Body Measuring Dimensions Opening Repair Chart Frame Repair Chart Top View Side View...
  • Page 74 Rust-preventative Treatments Rust-preventative Treatments General Area to be Covered by Anti-rust Treatment Undercoating Diagram...
  • Page 76 Body Paint Repair Body Paint Repair Colour Chart Painting Specifications Paint General Paint Refinishing Refinishing Processes Refinishing Procedures Soft Chipping Guard Primer Coat General 8-10 Coating Diagram 8-11 Repair Materials and Tools 8-12 Coating Procedures 8-13...
  • Page 78 Resin Parts Paint Repair (Exterior) Resin Parts Paint Repair (Exterior) Types and Materials of Exterior Resin Parts Polypropylene (PP) Resin Parts General Information Repair Materials and Tools Refinishing Processes Repair Procedures Refinishing Procedures ABS/PC Resin Parts General Information 9-12 Repair Materials 9-12 Repair Procedures 9-13...
  • Page 80 General Information Index General Information Chassis and Engine Numbers Identification Number Locations Abbreviations...
  • Page 82 Specifications Index Specifications Standards and Service Limits Design Specifications 2-13 Body Specifications 2-26...

  • Page 84: Maintenance Index

    Maintenance Index Maintenance Lubrication Points Maintenance Schedule...
  • Page 86 Engine Index Cylinder Head/Valve Train Intake Manifold/Exhaust System NOTE: D16W5 engine has been added. For related information, refer to the D16W1, D16W2 engines information in 1999 HR-V Shop Manual (P/N, 62S2H00) and changed above items.
  • Page 87 Engine Index Cylinder Header/Valve Train Special Tools VTEC System Troubleshooting Flowchart (KQ, KU models) Troubleshooting Flowchart (KE, KG models) VTEC Solenoid Valve Inspection VTEC Rocker Arms Manual Inspection Inspection Using Special Tools Rocker Arms Disassembly/Reassembly 6-12 Inspection 6-13 Rocker Arms and Shafts Clearance Inspection 6-14 Camshaft...
  • Page 88 Engine Index Intake Manifold/Exhaust System Intake Manifold Replacement...
  • Page 90 Cooling Index Cooling 10-1 Radiator Component Location 10-2 NOTE: D16W5 engine has been added. For related information, refer to the D16W1, D16W2 engines information in 1999 HR-V Shop Manual (P/N, 62S2H00) and changed above items.
  • Page 92 Fuel and Emissions Index Fuel and Emissions 11-1 KG, KE model 11-1 Special Tools 11-2 Fuel and Emissions System Component Locations Index 11-3 Vacuum Hose Routing 11-8 Vacuum Distribution 11-9 ECM/PCM Circuit Diagram 11-11 General Troubleshooting Information How to use the PGM Tester or a Scan Tool 11-36 How to Reset the ECM/PCM 11-37...
  • Page 93 Intake Air System Throttle Cable 11-148 Throttle Body 11-149 Emission Control System Positive Crankcase Ventilation System 11-151 Evaporative Emission Controls 11-152 Outline of Model Changes D16W5 engine has been added and changed the following Vacuum Connections Electrical Connections The Knock Sensor has been added (KQ model) Idle Speed Setting Fuel Pressure Relieving/Inspection Fuel Filter...
  • Page 95 Transaxle Index Continuously Variable Transmission (CVT)/ Honda Multi Matic 14-1...
  • Page 96 14-17 Outline of Model Changes For KE and KG models: Electrical troubleshooting procedures has been changed; checking DTC procedure with OBD scan tool and HONDA PGM tester on electrical troubleshooting procedures has been adopted. Electrical symptom-to-component chart has been modified.
  • Page 98 Body Index Body 20-1 Door Component Location Index 5D Front Door 20-2 Component Location Index 5D Rear Door 20-4 Glass Component Location Index 20-22 Interior Trim Trim Removal and Installation 20-28 Roof Side Pad and Roof Side Absorber Replacement 20-31 Console Rear Console Disassembly/Reassembly 20-32...
  • Page 100 Body Electrical Index Locations 23-A-1 Power and Ground Distribution 23-B-1 Lighting System 23-D-1 Controls 23-E-1 Instruments 23-F-1 Outline of Model Changes 4-door hatchback model has been added; following information was entered. Power and ground distributions have been changed. Rear fog light switch on KG and KE models has been changed. Headlight adjuster switch on KG and KE modes has been changed.
  • Page 101 Body Electrical Index Locations 23-A-1 Relay and Control Unit Locations Dashboard 23-A-2 Wire Harness and Ground Locations Dashboard 23-A-3 Roof 23-A-4 Door 23-A-5 Power and Ground Distribution 23-B-1 Lighting System 23-D-1 Controls 23-E-1 Instruments 23-F-1...
  • Page 102 Body Electrical Index Locations 23-A-1 Power and Ground Distribution 23-B-1 Fuses Under-hood Fuse/Relay Box 23-B-2 Under-dash Fuse/Relay Box 23-B-4 Power Distribution Circuit Identification 23-B-6 Ground Distribution Circuit Identification 23-B-16 Lighting System 23-D-1 Controls 23-E-1 Instruments 23-F-1...
  • Page 103 Body Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Lighting System 23-D-1 Lighting System Component Location Index 23-D-2 Rear Fog Light (KG and KE models) Switch Test 23-D-4 Headlight Adjuster (KG and KE models) Headlight Adjuster Switch Test 23-D-5 Dash Lights Brightness Controller (KQ model) Circuit Diagram 23-D-6...
  • Page 104 Body Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Lighting System 23-D-1 Controls 23-E-1 Power Windows Component Location Index 23-E-2 Circuit Diagram 23-E-3 Master Switch Input Test 23-E-6 Master Switch Test 23-E-9 Rear Window Switch Test 23-E-11 Rear Window Motor Test 23-E-11 Power Door Locks Component Location Index...
  • Page 105 Body Electrical Index Locations 23-A-1 Power and Ground Distributions 23-B-1 Lighting System 23-D-1 Controls 23-E-1 Instruments 23-F-1 Power Mirrors Component Location Index 23-F-2 Circuit Diagram (KG model: With Defogger) 23-F-3 (With Retractable Power Mirror) 23-F-4 (Without Retractable Power Mirror) 23-F-5 Function Test 23-F-6 Stereo Sound System...
  • Page 107 Restraints Index Seat Belts 24-1 Supplemental Restraint System (SRS) 24-7 NOTE: Refer to the 1999 HR-V Shop Manual, P/N. 62S2H00, for the items not shown in this section. Outline of Model Change 5-door model has been added. The work of the following items are different against the 3-door model. Front seat belt Front seat belt shoulder anchor adjuster (added) Rear seat belt...
  • Page 108 Restraints Index 24-1 Seat Belts Front Seat Belt Replacement 24-2 Rear Seat Belt Replacement 24-4 Inspection 24-6 Supplemental Restraint System (SRS) 24-11 NOTE: Refer to the 1999 HR-V Shop Manual, P/N. 62S2H00, for the items not shown in this section. Outline of Model Change 5-door model has been added.
  • Page 109 Restraints Index Supplemental Restraint System (SRS) 24-7 Replacement 24-8 NOTE: Refer to the 1999 HR-V Shop Manual, P/N. 62S2H00, for the items not shown in this section. Outline of Model Change The installation of the front seat belt has changed.
  • Page 111 Preparation of Work Index Preparation of Work Description...

  • Page 113: Supplemental Restraint System (Srs)

    Information necessary to safely service the SRS is included in the HR-V Shop Manual, P/N 62S2H00. 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 therefore be done by an authorized Honda dealer.
  • Page 115 Cross Section of Body and Sealants Cross Section of Body and Sealants Middle Floor/Rear Floor Rear Wheelhouse...
  • Page 117 Body Dimensional Drawings Body Dimensional Drawings Upper Body Measuring Dimensions Opening Repair Chart Under Body Measuring Dimensions Frame Repair Chart...
  • Page 119 Body Paint Repair Body Paint Repair Colour Chart Paint Specifications...
  • Page 121 To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer. Improper service procedures, including incorrect removal and...

  • Page 126: Under-Dash Fuse/Relay Box

    PERSONAL INJURY, or could damage a vehicle or make it unsafe. Please understand that these warnings and cautions cannot cover all conceivable ways in which service, whether or not recommend by HONDA, might be done, or of the possible hazardous consequences of each conceivable way, nor could HONDA investigate all such ways.
  • Page 128 Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommend by HONDA, might be done, or of the possible hazardous consequences of every conceivable way, nor could HONDA investigate all such ways. Anyone...
  • Page 129 DRIVER’S AIRBAG ASSEMBLY FRONT PASSENGER’S AIRBAG ASSEMBLY FRONT PASSENGER’S SEAT BELT RETRACTOR (With tensioner) DRIVER’S SEAT BELT RETRACTOR (With tensioner) SRS UNIT (With built- in sensor) SRS MAIN HARNESS (Indicated by yellow color coding) UNDER- DASH FUSE/RELAY BOX ITEM DESCRIPTION REFERENCE MODEL SECTION...

  • Page 131: General Safety Precautions

    PERSONAL INJURY, or could damage a vehicle or make it unsafe. Please understand that these warnings and cautions cannot cover all conceivable ways in which service, whether or not recommend by HONDA, might be done, or of the possible hazardous consequences of each conceivable way, nor could HONDA investigate all such ways.
  • Page 132 Before beginning work: Disconnect the battery to reduce the possibility of fire caused by electrical shorts. Check for fuel leaks and repair as necessary. Remove the fuel tank and/or fuel lines if welding equipment is to be used near the fuel system. Before welding, sanding or cutting, protect carpets and seats with fire-proof covers.
  • Page 134 Chassis and Engine Numbers Vehicle Identification Number (VIN) Engine Number/Transmission Number...
  • Page 135 Chassis and Engine Numbers Applicable Area Code/VIN/Engine Number/Transmission Number APPLICABLE DRIVE- TRANSMISSION VEHICLE ENGINE TRANSMISSION AREA CODE TRAIN TYPE IDENTIFICATION NUMBER NUMBER NUMBER | JHMGH2340XS200001~ | D16W1-1000001~ | SEP-1000001~ | JHMGH2440XS200001~ | D16W1-1000001~ | META-1000001~ | JHMGH2350XS200001~ | D16W1-1000001~ | SEP-1000001~ | JHMGH2450XS200001~ | D16W1-1000001~ | META-1000001~ | JHMGH1340XS200001~ | D16W1-1000001~ | SEV-1000001~ | JHMGH1440XS200001~ | D16W1-1000001~ | MENA-1000001~...

  • Page 136: Identification Number Locations

    Identification Number Locations 1. VEHICLE IDENTIFICATION NUMBER 2. CERTIFICATION PLATE (KG, KE, KN, KQ, KU, KT) 3. TRANSMISSION NUMBER (MANUAL) 4. TRANSMISSION NUMBER (CVT/MULTI MATIC) 5. ENGINE NUMBER 6. CERTIFICATION PLATE (KY)

  • Page 137: Warning/Caution Label Locations

    Warning/Caution Label Locations NOTE: LHD model is shown; RHD model is similar. 1. DRIVER SRS AIRBAG INFORMATION 2. FRONT SEAT PASSENGER AIRBAG CHILD SEAT CAUTION 3. FRONT SEAT PASSENGER AIRBAG MODULE DANGER/WARNING 4. FRONT SEATBELT TENSIONER DANGER/WARNING 5. MONITOR NOTICE 6.
  • Page 138 Warning/Caution Label Locations (cont'd) 1. SRS AIRBAG WARNING 2. COOLANT INFORMATION (KN, KT, KU, KY) SERVICE INFORMATION (KQ) 3. AIR CONDITIONING INFORMATION 4. RADIATOR CAP CAUTION 5. BATTERY CAUTION 6. TYRE INFORMATION (LOCATED ON DRIVER SIDE DOORJAMB) NOTE: LHD model is shown, RHD model is symmetrical...
  • Page 139 Lift and Support Points Lift and Safety Stands Place the lift blocks as shown. Raise the hoist a few inches (centimeters), and rock the vehicle to be sure it is firmly supported. Raise the hoist to full height, and inspect the lift points for solid support. NOTE: Use the same support points to support the vehicle on safety stands.
  • Page 140 Floor Jack Set the parking brake and block the wheels that are not being lifted. When lifting the rear of the vehicle, put the gearshift lever in reverse (CVT/Honda Multi Matic in position). Raise the vehicle high enough to insert the safety stands.
  • Page 141 Towing If the vehicle needs to be towed, call a professional towing Towing Hook and Tie Down Bracket Locations: service. Never tow the vehicle behind another vehicle with Towing Hook: just a rope or chain. It is very dangerous. Remove the cover from the front bumper. Emergency Towing Install the front towing hook securely into the bolt There are three popular methods of towing a vehicle.
  • Page 143 Start the engine, shift the transmission to 3rd gear (manual transmission) and or to position (CVT/Honda Multi Matic), accelerate the vehicle gradually, and measure the vehicle speed. After measurement, use the brake pedal to gradually decelerate and stop the vehicle.
  • Page 144 Preparation of Work 1-11 Mark or place all removed parts in order in a parts rack so they can be reassembled in their original places. 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 145 After disconnecting brake hoses or pipes, be sure to plug the openings to prevent loss of Use genuine HONDA parts and lubricants or those brake fluid. equivalent. When parts are to be reused, they must be...

  • Page 146: Locking Tab

    Preparation of Work 1-13 Electrical Troubleshooting Before Troubleshooting Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead. Check applicable fuses in the appropriate fuse/relay box. Always reinstall plastic covers. Check the battery for damage, state of charge, and clean and tighten connections.

  • Page 147: Snap Ring Pliers

    Preparation of Work 1-14 Electrical Troubleshooting (cont’d) Insert the connector all the way and make sure it is Seat grommets in their grooves properly. securely locked. Position wires so that the open end of the cover faces down. NOT GOOD Testing and Repairs Do not use wires or harnesses with broken Face open end down...
  • Page 148 Preparation of Work 1-15 Electrical Troubleshooting (cont’d) How to Read Flowcharts Except SRS: A flowchart is designed to be used from start to final repair. It’s like a map showing you the shortest distance. But beware: if you go off the “map” anywhere but a “stop” symbol, you can easily get lost.
  • Page 149 Preparation of Work 1-16 Electrical Troubleshooting (cont’d) Five-step Troubleshooting Wire Colour Codes Verify The Complaint The following abbreviations are used to identify wire Turn on all the components in the problem circuit to colours in the circuit schematics: verify the customer complaint. Note the symptoms. Do White not begin disassembly or testing until you have narrowed Yellow...

  • Page 150: Digital Circuit Tester

    Preparation of Work 1-17 Electrical Troubleshooting (cont’d) When checking any control module(s) or units(s) connector terminals, gently slide the sharp tester probe from the wire side into the connector until it comes in contact with the terminal end of the wire. 1.
  • Page 151 Abbreviations 1-18 List of automotive abbreviations, which may be used in shop EVAP Evaporative manual. Exhaust Anti-lock Brake System Air Conditioning, Air Conditioner Front Air Cleaner Fuel Injection Air Air Fuel Ratio Front Left Alternator Fuel Pump Ampere (s) Front Right Antenna Fail Safe Relay American Petroleum Institute...
  • Page 152 Abbreviations 1-19 (cont’d) Manifold Absolute Pressure Standard MAX. Maximum Switch Mainshaft Brake System Motor Check Torque Moment Control Unit Throttle Body Malfunction Indicator Light Timing Belt MIN. Minimum Torque Converter Multi Point Injection Transmission Control Module Manual Steering Traction Control System Manual Transmission Top Dead Centre Thin Film Transistor...
  • Page 154 Standards and Service Limits Engine Electrical - Section 4 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) | Ignition coil | Rated voltage V | 12 | Primary winding resistance at 20°C (68°F) ohms: | 0.63 - 0.77 Secondary winding resistance at 20°C (68°F) k 12.8 - 19.2 ohms | Spark plug...
  • Page 155 Standards and Service Limits Cylinder Head/Valve Train – Section 6 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) SERVICE LIMIT | Compression | 250 rpm (min- ) and Nominal | 1,520 (15.5, 220) | wide open throttle Minimum | 930 (9.5, 135) | kPa (kgf/cm , psi) Max.
  • Page 156 | (including engine, heater, cooling line and | 2.8 (3.0, 2.5) for coolant change | reservoir) | Reservoir capacity | CVT: Honda Multi Matic | 0.4 l (0.42 US qt. 0.35 Imp qt.) 4.1 (4.3, 3.6) for overhaul 3.0 (3.2, 2.6) for coolant change...
  • Page 157 Standards and Service Limits Clutch - Section 12 Clutch - Section 12 Unit of length: mm (in) | STANDARD (NEW) MEASUREMENT SERVICE LIMIT | Clutch pedal | Pedal height to floor | 179 (7.05) | 183 (7.20) | Stroke | 130-140 (5.12-5.51) | Free play | 8-18 (0.31-0.71) | Disengagement height...

  • Page 158: Service Limit

    Standards and Service Limits Manual Transmission – Section 13 (cont’d) Unit of length: mm (in) MEASUREMENT | STANDARD (NEW) SERVICE LIMIT | Reverse Shift | Pawl groove width | 13.0-13.3 (0.51-0.52) | Fork | Fork-to-reverse idle gear clearance | 0.5-1.1 (0.02-0.04) 1.8 (0.07) | Groove width * at A...
  • Page 159 Standards and Service Limits CVT/Honda Multi Matic – Section 14 Unit of length: mm (in) MEASUREMENT | STANDARD (NEW) SERVICE LIMIT | Transmission fluid | Capacity l (US qt, lmp qt) | KE, KG models | 6.7 (7.1, 5.9) for overhaul | 4.0 (4.2, 3.5) for fluid change...
  • Page 160 Standards and Service Limits CVT/Honda Multi Matic – Section 14 (cont’d) Unit of length: mm (in) MEASUREMENT | STANDARD (NEW) SERVICE LIMIT | Clutch (cont’d) | Forward clutch end plate thickness Mark 1 or 15 | 3.4-3.5 (0.134-0.138) Discolouration Mark 2 or 16 | 3.5-3.6 (0.138-0.142)
  • Page 161 Standards and Service Limits CVT/Honda Multi Matic (cont’d) Section 14 Unit of length: mm (in) | STANDARD (NEW) MEASUREMENT SERVICE LIMIT | Transmission | Thrust shim, 25 x 31 mm thickness | 1.02-1.05 (0.040-0.041) Wear or damage | (cont’d) | 1.09-1.12 (0.043-0.044) Wear or damage | 1.16-1.19 (0.046-0.047)
  • Page 162 Standards and Service Limits 2-10 CVT/Honda Multi Matic (cont’d) - Section 14 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) | Differential | Pinion shaft contact area I.D. | 18.010-18.028 (0.7091-0.7098) | carrier | Carrier-to-pinion clearance | 0.023-0.057 (0.0009-0.0022) 0.1 (0.004) | Drive shaft contact area I.D.
  • Page 163 Pump pressure with shut-off valve closed 7,200-7,800 (73-80, 1,040-1,140) kPa (kgf/cm2, psi) | Power steering | Recommended fluid | Honda power steering fluid (V, II or S) | fluid | Fluid capacity For overhaul RHD | 0.65 (0.70, 0.57) | l (US qt. lmp qt) | 0.61 (0.64, 0.54)
  • Page 164 Standards and Service Limits 2-12 Brakes - Section 19 Unit of length: mm (in) MEASUREMENT STANDARD (NEW) Parking brake Play on stroke at 196 N (20 kgf, 44 lbf) To be locked when pulled 7-10 notches lever lever force Foot brake pedal | Pedal height (With floor mat removed) Free play 1-5 (0.04-0.20)

  • Page 165: Design Specifications

    Design Specifications 2-13 ITEM METRIC ENGLISH NOTES | Dimensions | Overall Length Except KQ models | 3,995 mm 157.3 in KQ model 4,005 mm 157.7 in | Overall Width 1,695 mm 66.7 in | Overall Height 1,590 mm 62.6 in KQ model with rear spoiler 1,700 mm 66.9 in...
  • Page 166 Design Specifications 2-14 (cont’d) ITEM METRIC ENGLISH NOTES | Weight | Curb Weight | KQ Models 2WD 5MT 1,140 kgs 2,513 lbs | KQ model are | 5MT with ABS 1,145 kgs 2,524 lbs | equipped with | 5MT with sunroof 1,150 kgs 2,535 lbs | power steering, |...
  • Page 167 | system Honda Multi Matic with ABS 1,170 kgs 2,579 lbs Honda Multi Matic with sunroof 1,175 kgs 2,590 lbs Honda Multi Matic with ABS and 1,180 kgs 2,601 lbs sunroof 4WD 5MT 1,195 kgs 2,634 lbs 5MT with ABS...
  • Page 168 0.870 Reverse 3.000 Final Reduction Gear type Single helical gear Gear ratio 4.562 Transfer 0.434 Rear Differential 2.533 | CVT/Honda Multi Matic Gear Ratio Low-High 2.466-0.449 Reverse 2.466 Final Reduction Gear type Single helical gear Gear ratio 4.714 Transfer 0.433 Rear Differential 2.533...
  • Page 169 Design Specifications 2-17 (cont’d) ITEM DESCRIPTION NOTES Air Conditioning| Cooling Capacity Except KY models 3,172 Kcal/h 12,580 BTU/h KY model 3,529 Kcal/h 14,000 BTU/h | Air | Compressor | Conditioning Type/Manufacturer Scroll/KEIHIN Capacity 85.7 cm /rev 5.23 cu-in/rev Max. Speed 10,000 rpm (min- Lubricant Capacity 130 cm...
  • Page 170 Design Specifications 2-18 (cont’d) ITEM DESCRIPTION NOTES | Electrical | Battery 12 V, 36 AH, 5 HR | Starter 12V - 1.0 kW | Alternator 12V - 75A | Fuses In the Under-dash Fuse Box 7.5A, 10A, 15A, 20A In the Under-hood Fuse/Relay box 7.5A, 10A, 15A, 20A, 30A, 40A, 50A, | Headlights High/Low...
  • Page 171 Body Specifications 2-19 Unit: mm (in) *1: KQ model with rear spoiler *2: KY model with rear spoiler...
  • Page 173 *1: If Honda MTF is not available, you may use an AP1 service SG, SH or SJ-rated motor oil with viscosity of SAE 10W-30 or 10W-40 temporarily. Motor oil can cause increased transmission wear and higher shifting effort.
  • Page 174 Lubrication Points (cont’d)
  • Page 175 Replace engine coolant Check specific gravity for freezing 10-5 point. | Replace transmission fluid | (X: Inspect) | Genuine Honda MTF 13-4 | Genuine Honda CVT Fluid 14-84 Replace rear differential fluid *1 | Genuine Honda ATF PREMIUM 15-14 (Automatic Transmission Fluid-PREMIUM)
  • Page 176 Maintenance Schedule European Model - Normal Conditions (cont’d) Service at the km x 1,000 NOTES SECTION indicated distance or miles x 1,000 and PAGE time whichever months comes first Visually inspect the following items Check for correct installation and position, check for cracks, deterioration, rust and leaks.
  • Page 177 Check specific gravity for freezing 10-5 point Replace transmission fluid MT | Genuine Honda MTF 13-4 Replace transmission fluid CVT | Genuine Honda CVT Fluid 14-84 Replace rear differential fluid Genuine Honda ATF PREMIUM 15-14 (Automatic Transmission Fluid-PREMIUM) Check the brake pad and disc 19-A-4, thickness.
  • Page 178 Maintenance Schedule European Models - Severe Conditions (cont’d) Service at the km x 1,000 22.5 37.5 52.5 67.5 NOTES SECTION 82.5 97.5 13.5 22.5 31.5 40.5 indicated distance or miles x 1,000 and PAGE 49.5 58.5 67.5 time whichever months comes first Visually inspect the following items: Check for correct installation...
  • Page 179 19-A-25 Replace brake fluid Use only DOT3 or DOT4 fluid (We 19-A-7 recommend Genuine Honda Brake Fluid). Check that brake fluid level is between the upper and lower marks on the reservoir. | Check parking brake adjustment | Check the parking brake operation...
  • Page 180 Maintenance Schedule Australian Model - Normal Conditions (cont’d) Service at the km x 1,000 NOTES SECTION indicated distance or miles x 1,000 and PAGE time whichever months comes first Visually inspect the following items: Check for correct installation and position. Check for cracks, deterioration, rust and leaks.
  • Page 181 19-A-25 Replace brake fluid Use only DOT3 or DOT4 fluid (We 19-A-7 recommend Genuine Honda Brake Fluid). Check that brake fluid level is between the upper and lower marks on the reservoir. | Check parking brake adjustment | Check the parking brake operation...
  • Page 182 Maintenance Schedule 3-11 Australian Model - Severe Conditions (cont’d) Service at the km x 1,000 NOTES SECTION indicated distance or miles x 1,000 and PAGE time whichever months comes first Visually inspect the following items: Check for correct installation and position. Check for cracks, deterioration, rust and leaks.

  • Page 183: Maintenance Schedule

    Check the hose for blockage, cracks or disconnected. Replace Genuine Honda MTF 13-4 transmission fluid CVT/Honda Genuine Honda ATF PREMIUM 14-84 Multi Matic (Automatic Transmission Fluid-PREMIUM) Replace rear differential fluid *1 | Genuine Honda ATF PREMIUM 15-14 (Automatic Transmission Fluid-PREMIUM)
  • Page 184 Replace brake fluid (including ABS) | Use only DOT3 or DOT4 fluid (We 19-A-7 recommend Genuine Honda Brake Fluid). Check that brake fluid level is between the upper and lower marks on the reservoir. | Check parking brake adjustment...

  • Page 186: Special Tools

    Special Tools | Ref No. Tool Number Description | Qty Remark | 07JGG - 0010100 | Belt Tension Gauge...

  • Page 187: Starting System Component Location Index

    Starting System Component Location Index NOTE: LHD type is shown, RHD type is similar. 1. BATTERY, Test, section 23 2. A/T GEAR POSITION SWITCH Test, section 23 Replacement, section 23 3. STARTER Test, (See page 4-6) Solenoid Test, ( See page 4-7) Replacement, (See page...
  • Page 188 Starting System Circuit Diagram (M/T, CVT with RHD)
  • Page 189 Starting System Circuit Diagram (CVT with LHD)
  • Page 190 Starting System Starter Test NOTE:The air temperature must be between 15 and 38° C Check the battery, battery positive cable, ground, (59 and 100°F) before testing. starter cut relay, and the wire connections for looseness and corrosion. Test again. Recommended Procedure: If the starter still does not crank the engine, go to Use starter system tester.
  • Page 191 Starting System Starter Test (cont’d) Starter Solenoid Test Check for Wear and Damage Check the hold-in coil for continuity between the S terminal and the armature housing (ground). The The starter should crank the engine smoothly and steadily. If coil is OK if there is continuity. the starter engages, but cranks the engine erratically, remove it, and inspect the starter drive gear and torque converter ring gear for damage.
  • Page 192 Starting System Starter Replacement Disconnect the battery negative cable. Disconnect the starter cable form the B terminal on the solenoid, then disconnect the BLK/WHT wire from the S terminal. 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) BLK/WHT WIRE B TERMINAL MOUNTING NUT, 9 Nm (0.9 kgf/m, 7 lbf/ft) STARTER CABLE...

  • Page 193: Brush Holder

    Starting System Starter Overhaul 1. END COVER 2. BRUSH Inspection, (See page 4-10) 3. ARMATURE HOUSING 4. ARMATURE 5. BRUSH HOLDER 6. STARTER SOLENOID 7. SOLENOID LEVER 8. OVERRUNNING CLUTCH 9. ARMATURE Inspection and Test, ( See page 4-10) 10. MOLYBDENUM DISULFIDE 11.
  • Page 194 Starting System 4-10 Brush Inspection Overrunning Clutch Inspection Measure the brush length. If it is not within the service limit, Slide the overrunning clutch along the shaft. Does replace the brush (or brush holder assembly). it move freely? If not, replace it. Brush Length Rotate the overrunning clutch both ways.
  • Page 195 Starting System 4-11 Armature Inspection and Test Inspect the armature for wear or damage due to contact If commutator diameter is below the service with the field winding. If there is wear or damage, limit, replace the armature. replace the armature. Commutator Diameter Check commutator surface and diameter.
  • Page 196 Starting System 4-12 Armature Inspection and Test (cont’d) Check the mica depth. If necessary, undercut the mica Place the armature on an armature tester. Hold a with a hacksaw blade to achieve proper depth. If the hacksaw blade on the armature core. service limit cannot be maintained, replace the armature.
  • Page 197 Starting System 4-13 Brush Holder Test Starter Reassembly Check that there is no continuity between the + and - NOTE: Use the illustration on page (See page 4-8) as brush holders. If there is continuity, replace the brush reference for reassembly. holder assembly.
  • Page 198 Starting System 4-14 Performance Test Disconnect the wire from the terminal M. Disconnect the battery also from the body. If the Make a connection as described below using as heavy a pinion retracts immediately, it is working properly. wire as possible (preferably equivalent to the wire used To avoid damaging the starter, do not leave the for the vehicle).

  • Page 199: Ignition Timing Control System

    Ignition System 4-15 Component Location Index NOTE: LHD type is shown, RHD type is similar. IGNITION TIMING CONTROL SYSTEM Troubleshooting, section 11 Idle speed Inspection/Adjustment, section 11 Inspection and Setting (See Page 4-19) 1. IGNITION WIRES Inspection and Test, See page 4-21) 2.

  • Page 200: Ignition System Circuit Diagram

    Ignition System 4-16 Circuit Diagram...
  • Page 201 Ignition System 4-17 Ignition Timing Inspection and Setting Check the idle speed, and adjust it if necessary (see If necessary, adjust the ignition timing as follows. section 11). Loosen the distributor mounting bolts, and turn the Pull out the service check connector 2P (BRN and BLK distributor (DI) housing counterclockwise to wires), then connect the SCS short connector (P/N advance the timing or clockwise to retard the...
  • Page 202 Ignition System 4-18 Distributor Replacement Removal: Connect the ignition wires to the distributor ignition (DI) cap as shown. Disconnect the connector from the distributor. Disconnect the ignition wires from the distributor ignition (DI) cap. Remove the mounting bolts from the distributor, then remove the distributor from the cylinder head.

  • Page 203: Ignition Control Module (Icm)

    Ignition System 4-19 Distributor Overhaul 1. LEAK COVER 2. DISTRIBUTOR IGNITION (DI) ROTOR 3. CAP SEAL. Check for damage. 4. DISTRIBUTOR IGNITION (DI) CAP Check for cracks, wear, damage and fouling. Clean or replace. 5. MAGNETIC SHIELD 6. IGNITION COIL Test, (See page 4-20)
  • Page 204 Ignition System 4-20 Ignition Coil Test Ignition Control Module (ICM) Input Test Using an ohmmeter, measure the resistance between the Remove the distributor ignition (DI) cap, the terminals. If the resistance is not within specifications, distributor ignition (DI) rotor and the leak cover. replace the ignition coil.
  • Page 205 Ignition System 4-21 Ignition Wire Inspection and Test Spark Plug Inspection Carefully remove the ignition wires by pulling on the Inspect the electrodes and ceramic insulator for: rubber boots. Do not bend the wires; you might break them inside. Check the condition of the ignition wire terminals. If any terminal is corroded, clean it, and if it is broken or distorted, replace the ignition wire.
  • Page 206 Ignition System 4-22 Spark Plug Inspection (cont’d) Check the electrode gap. Adjust the gap with suitable gapping tool. Electrode Gap Standard 1.1 - 8.1 mm (0.043 - 8.004 in) 1.1 mm (0.043 in) Replace the plug if the centre electrode is rounded as shown below: ROUNDED ELECTRODE Spark Plugs...

  • Page 207: Charging System Component Location Index

    Charging System 4-23 Component Location Index NOTE: LHD type is shown, RHD type is similar. 1. BATTERY Test, section 23 2. UNDER-HOOD FUSE/RELAY BOX (* Has a built-in ELECTRICAL LOAD DETECTOR (ELD) UNIT) 3. CHARGING SYSTEM LIGHT (In the gauge assembly) Test, (See page 4-25)

  • Page 208: Charging System Circuit Diagram

    Charging System 4-24 Circuit Diagram...
  • Page 209 Charging System 4-25 Troubleshooting If the charging system light does not come on or does not go off, or the battery is dead or low, test the following items in the order listed below: Battery (See page 23-B-2). Charging system light. Voltage.
  • Page 210 Charging System 4-26 Troubleshooting (cont’d) [ ] Except KG, KE, KQ and KU models...
  • Page 211 Charging System 4-27 Troubleshooting (cont’d) Alternator Control System Test (KG, KE, KQ, KU models) NOTE: Before testing, check proper operation of the ELD by confirming with the MIL (see section 11).
  • Page 212 Charging System 4-28 Troubleshooting (cont’d)
  • Page 213 Charging System 4-29 Troubleshooting (cont’d) Alternator/Regulator Test Be careful during testing as the radiator and condenser fans come on suddenly while the engine is running. Be sure to use an ammeter capable of measuring amperages higher than 120 A.
  • Page 214 Charging System 4-30 Alternator Replacement Disconnect the battery negative terminal first, then the Remove the adjusting bolt, mounting nut and positive terminal. mounting bolts, then remove the alternator bracket Remove the harness stay from the upper bracket. and engine mount bracket A. Disconnect the 4P (or 3P) connector and B terminal wire from the alternator.
  • Page 215 Charging System 4-31 Alternator Overhaul (DENSO) NOTE: It is necessary to separate the pulley, drive end housing and rotor only when the front bearing needs replacement. To loosen the pulley use tools as shown. If necessary, use an impact wrench. 1.
  • Page 216 Charging System 4-32 Alternator Overhaul (MITSUBISHI) NOTE: Do not remove the pulley unless the front bearing needs replacement. To loosen the pulley locknut, use 10 mm and 22 mm wrenches. If necessary, use an impact wrench. 1. CAUTION: Do not get grease or oil on the slip rings.
  • Page 217 Charging System 4-33 Rectifier Test (DENSO) Rectifier Test (MITSUBISHI) NOTE: The diodes are designed to allow current to pass in NOTE: The diodes are designed to allow current to one direction while blocking it in the opposite direction. Since pass in one direction while blocking it in the opposite the alternator rectifier is made up of eight diodes (four pairs), direction.
  • Page 218 Charging System 4-34 Rectifier Removal (MITSUBISHI) Remove the four through bolts Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them apart. NOTE: Be careful not to damage the stator with the tip of the screwdriver.
  • Page 219 Charging System 4-35 Rectifier Removal (MITSUBISHI) (cont’d) Separate the rear housing from the stator/rectifier Install the new rectifier in the reverse order of assembly by removing the four screws and the terminal removal. nut. Apply the soldering iron only long enough to ensure a good connection so that the heat will not damage the diodes.

  • Page 220: Soldering Iron

    Charging System 4-36 Alternator Brush Inspection (DENSO) Alternator Brush Inspection (MITSUBISHI) Remove the end cover, then take out the brush holder Separate the drive-end housing from the rear by removing its two screws. housing as described on page 4-34. Measure the length of the brushes with a vernier caliper. Separate the rear housing from the stator/rectifier assembly by removing the four screws and the Alternator Brush Length:...
  • Page 221 Charging System 4-37 Rotor Slip Ring Test Stator Test Check the resistance between the slip rings Check that there is continuity between each pair of There should be 1.8 - 3.0 ohms. leads. If resistance meets the specification, go to step 2. Nippondenso: If resistance does not meet the specification, replace the alternator.
  • Page 222 Charging System 4-38 Rear Bearing Replacement (MITSUBISHI) Alternator Reassembly (MITSUBISHI) Pull off the rear bearing. Push the brushes in, then insert a pin or drill bit Make sure the tips of the bearing puller jaws are (about 1.8 mm diameter) to hold them there. thin enough to fit between the bearing and the slip rings.

  • Page 223: Charging System

    Charging System 4-39 Alternator Belt Inspection and Adjustment NOTE: When using a new belt, first adjust the deflection or Belt tension gauge method: tension to the values for the new belt, then readjust the Attach the belt tension gauge to the belt and measure deflection or tension to the values for the used belt after the tension.
  • Page 224 Charging System 4-40 Alternator Belt Inspection and Adjustment (cont’d) If adjustment is necessary: Loosen the mounting nut and the locknut. Move the alternator to obtain the proper belt tension, then retighten the nuts. LOCKNUT, 8 x 1.25 mm, 24 Nm (2.4 kgf/m, 17 lbf/ft) MOUNTING NUT, 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) Recheck the deflection or tension of the belt.

  • Page 226: Special Tools

    Special Tools | Ref No. Tool Number Description | Qty Remark | 07KAK - SJ40101 | Engine Tilt Hanger Set | Except EU | 07MAK - PY30100 | Engine Sub Hanger Stay | Except EU...
  • Page 227 Engine Removal/Installation Removal NOTE: Disconnect the engine wire harness connector on Use fender covers to avoid damaging painted surfaces. the right side of the engine compartment. To avoid damage, unplug the wiring connectors carefully Remove the harness clamps. while holding the connector portion. Mark all wiring and hoses to avoid misconnection.
  • Page 228 Engine Removal/Installation Removal (cont’d) Remove the breather hose, then disconnect the intake 11. Remove the P/S pump bracket. air temperature (IAT) sensor connector. Remove the air cleaner housing and the intake air duct. P/S PUMP BRACKET 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) 12.
  • Page 229 Engine Removal/Installation Removal (cont’d) 13. Remove the A/C compressor without disconnecting the 15. Relieve fuel pressure (see section 11). A/C hoses. 16. Remove the fuel feed hose, fuel return hose and evaporative emission (EVAP) control canister hose. A/C COMPRESSOR 8 x 1.25 mm, 24 Nm (2.4 kgf/m, 17 lbf/ft) 14.

  • Page 230: Spring Pin

    Engine Removal/Installation Removal (cont’d) 18. Disconnect the engine control module (ECM)/ 20. Remove the shift cable. Take care not to bend the powertrain control module (PCM) connectors from the cable when removing them. Always replace any ECM/PCM, then disconnect the engine wire harness kinked cable with a new one (CVT).

  • Page 231: Splash Shield

    Engine Removal/Installation Removal (cont’d) 22. Remove the clutch slave cylinder and line/hose 26. Remove the splash shield. assembly (M/T). NOTE: Do not disconnect the line/hose assembly. Do not operate the clutch pedal once the slave cylinder has been removed. Take care not to bend the line. SPLASH SHIELD 27.

  • Page 232: Ground Cable

    Engine Removal/Installation Removal (cont’d) 33. Remove exhaust pipe A. 34. Lower the hoist, then remove the upper radiator hose, lower radiator hose and the heater hoses. GASKET, Replace 8 x 1.25 mm, 22 Nm (2.2 kgf/m, 16 lbf/ft). Replace HEATER HOSES GASKET, Replace UPPER RADIATOR HOSE SELF-LOCKING NUT 8 x 1.25 mm, 16 Nm (1.6 kgf/m, 12 lbf/ft),...

  • Page 233: Propeller Shaft

    Engine Removal/Installation Removal (cont’d) 37. Attach the chain hoist to the engine as shown. 40. Remove the shift cable bracket from the rear mount bracket (CVT). SHIFT CABLE BRACKET 41. When removing the propeller shaft, marks on the transfer companion flange and propeller shaft as shown.

  • Page 234: Mounting Bolts

    Engine Removal/Installation 5-10 Removal (cont’d) 43. Remove the left front mount bracket mounting bolts. 45. Remove the side engine mount support nuts. MOUNTING BOLTS 44. Remove the right front mount mounting bolts. SUPPORT BOLTS 46. Remove the transmission mount bracket support bolt/nuts.
  • Page 235 Engine Removal/Installation 5-11 Installation Bracket Bolts/Nuts Torque Specification: 1. REAR STIFFENER 2. 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) 3. 8 x 1.25 mm, 24 Nm (2.4 kgf/m, 17 lbf/ft) 4. REAR STIFFENER 5. 8 x 1.25 mm, 24 Nm (2.4 kgf/m, 17 lbf/ft) 6.

  • Page 236: Mounting Bolt

    Engine Removal/Installation 5-12 Installation (cont’d) Engine Installation: Tighten the transmission mount bracket support bolt/nuts, then loosen the mounting bolt. Install the engine in the reverse order of removal. Reinstall the mount bolts/nuts in the following sequence. CVT: Failure to follow this procedure may cause excessive noise and vibration, and reduce bushing life.
  • Page 237 Engine Removal/Installation 5-13 Installation (cont’d) Install the shift cable bracket on the rear mount bracket Tighten the side engine mount mounting bolt. (CVT). 12 x 1.25 mm, 74 Nm (7.5 kgf/m, 54 lbf/ft) 6 x 1.0 mm, 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft) SHIFT CABLE BRACKET Tighten the transmission mount bracket mounting bolt.
  • Page 238 Engine Removal/Installation 5-14 Installation (cont’d) Tighten the left front mount bracket support bolts. 10. Adjust and make sure as follows: Check that the set ring on the ends of the driveshaft and intermediate shaft set rings into place. Adjust the throttle cable (see section 11). Refill the engine with engine oil (See Page 8-5).
  • Page 239 Engine Removal/Installation 5-15 Installation (cont’d) Mount and Bracket Bolts/Nuts Torque Specification: 1. TRANSMISSION MOUNT (M/T) 2. 12 x 1.25 mm, 64 Nm (6.5 kgf/m, 47 lbf/ft) 3. REAR MOUNT (CVT) 4. 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) 5.

  • Page 241: Special Tools

    Special Tools | Ref No. Tool Number Description | Qty | Remark | 07HAH - PJ70100 | Valve Guide Reamer, 5.525 mm | 07JAA - 0010100 | Socket Wrench, 17 mm | 07JAB - 0010200 | Handle | 07JAB - 0010400 | Pulley Holder Attachment, HEX 50 mm | 07PAD - 0010000 | Stem Seal Driver...
  • Page 242 Valve Clearance Adjustment NOTE: Loosen locknut and turn adjustment screw until Valves should be adjusted only when the cylinder head feeler gauge slides back and forth with slight temperature is less than 38°C (100°F). amount of drag. After adjusting, loosen the crankshaft pulley bolt, then NOTE: Do not overtighten the locknuts, for the retorque the crankshaft pulley bolt to 20 Nm (2.0 kgf/m, rocker arms are made of aluminium.

  • Page 243: Feeler Gauge

    Valve Clearance Adjustment (cont’d) Tighten the locknut, and check clearance again. Repeat Rotate the crankshaft 180° counterclockwise to the adjustment if necessary. bring No. 4 piston to TDC. Both TDC grooves are once again visible. Adjust valves on No. 4 cylinder. FEELER GAUGE Rotate the crankshaft 180°...

  • Page 244: Crankshaft Pulley And Pulley Bolt Replacement

    Crankshaft Pulley and Pulley Bolt Replacement Remove any oil from the pulleys, crankshaft, bolt and Use a felt tip pen to mark the pulley bolt head and washer. Clean and lubricate as shown below. washer. O: Clean X: Remove any oil : Lubricate PULLEY BOLT MARKING...

  • Page 245: Cylinder Head Cover

    Timing Belt Illustrated Index NOTE: For how to position the crankshaft and pulley before installing the belt (see page 6-10). Mark the direction of rotation on the belt before removing. Do not use the upper cover and lower cover for storing removed items. Clean the upper cover and lower cover before installing.
  • Page 246 Tension Adjustment Timing Belt Inspection Remove the breather hose, then remove the air cleaner NOTE: Always adjust the timing belt tension with the housing (see page 5-4). engine cold. Remove the cylinder head cover. The tensioner is spring-loaded to apply tension to When installing (see page 6-30).
  • Page 247 Timing Belt Removal NOTE: Loosen the mounting nut and lock bolt, then Turn the crankshaft pulley so the No. 1 piston is at top remove the alternator belt. dead centre (TDC) before removing the belt (see page 6-11). Inspect the water pump before installing the timing belt (see page 10-11) Remove the splash shield...
  • Page 248 Timing Belt Removal (cont’d) Support the engine with the jack and wood block under 12. Remove the dipstick tube and lower cover. the oil pan. NOTE: Do not use the upper cover for storing 10. Remove the side engine mount. removed items.
  • Page 249 Timing Belt 6-10 Installation Install the timing belt in the reverse order of removal; Install the timing belt tightly in the sequence Only key points are described here. shown. 1 - Timing belt pulley (crankshaft). 2 - Set the timing belt drive pulley so that the No. 1 piston is Adjusting pulley.

  • Page 250: Crankshaft Pulley

    Timing Belt 6-11 Installation (cont’d) Check that the crankshaft pulley and camshaft pulley are both at TDC. CRANKSHAFT PULLEY: TDC MARK (WHITE) CAMSHAFT PULLEY: UP MARK TDC MARK 10. If the camshaft and crankshaft pulleys are not positioned at TDC remove the timing belt, and adjust the position following the procedure (see page 6-9), then reinstall...

  • Page 251: Cylinder Head Bolt

    Cylinder Head 6-12 Illustrated Index (cont’d) NOTE: To avoid damage, wait until the engine coolant temperature drops below 38 °C (100°F) before removing the cylinder head. When handling a metal gasket, take care not to fold it or damage the contact surface. Use new O-rings and gaskets when reassembling.

  • Page 252: Rocker Arm Assembly

    Cylinder Head 6-13 Illustrated Index (cont’d) Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. 1. ROCKER ARM ASSEMBLY Removal (See Page 6-18) Inspection (See Page 6-19). 2. 8 x 1.25 mm, 20 Nm (2.0 kgf/m, 14 lbf/ft).

  • Page 253: Cylinder Head Removal

    Cylinder Head 6-14 Removal Engine Removal is not required in this procedure. Remove the breather hose then disconnect the NOTE: intake air temperature (IAT) sensor connector. Use fender covers to avoid damaging painted surfaces. Remove the air cleaner housing and the intake air To avoid damage, carefully unplug the wiring connectors duct.

  • Page 254: A/C Compressor Belt

    Cylinder Head 6-15 Removal (cont’d) Remove the P/S pump bracket. 10. Loosen the mounting nut and lock bolt, then remove the alternator belt. P/S PUMP BRACKET 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) LOCK BOLT, 8 x 1.25 mm, 24 Nm (2.4 kgf/m, 17 lbf/ft) ALTERNATOR BELT Loosen the idler pulley centre nut and adjusting bolt, MOUNTING NUT, 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft)
  • Page 255 Cylinder Head 6-16 Removal (cont’d) 12. Remove the throttle cable by loosen the locknut, then 15. Remove the brake booster vacuum hose, positive slip the cable end out of the accelerator linkage. crankcase ventilation (PCV) hose and vacuum NOTE: hose.. Take care not to bend the cable when removing it.

  • Page 256: Back Cover

    Cylinder Head 6-17 Removal (cont’d) 17. Remove the engine wire harness connectors and wire 21. Remove air cleaner housing bracket, then remove harness clamps from the cylinder head and the intake the cylinder head cover manifold. Four injector connectors Idler air control (IAC) valve connector Throttle position sensor connector Manifold absolute pressure (MAP) sensor connector Engine coolant temperature (ECT) sensor connector...
  • Page 257 Cylinder Head Rocker Arms 6-18 Removal (cont’d) Removal 24. Remove the exhaust manifold (see page 9-3). Loosen the adjusting screws. 25. Remove the intake manifold (see page 9-2). 26. Remove the cylinder head bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
  • Page 258 Rocker Arms 6-19 Disassembly/Reassembly NOTE: Identify parts as they are removed to ensure reinstallation in original locations. Inspect rocker shafts and rocker arms (see page 6-20). Rocker arms must be installed in the same position if reused. When removing or installing rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the holders, springs and rocker arms on the shaft. 1.
  • Page 259 Rocker Arms and Shafts 6-20 Clearance Inspection Measure both the intake rocker shaft and exhaust rocker Measure inside diameter of rocker arm and check shaft. for out-of-round condition. Measure the diameter of shaft at the first rocker location. Rocker Arm-to-Shaft Clearance: Standard (New): Intake: 0.017 - 0.050 mm...
  • Page 260 Camshaft 6-21 Inspection NOTE: Seat the camshaft by pushing it toward the rear of Do not rotate the camshaft during inspection. the cylinder head. Remove the rocker arms and rocker shafts. Zero the dial indicator against the end of the Put the camshaft and the camshaft holders on the camshaft.
  • Page 261 Camshaft 6-22 Inspection (cont’d) Remove the camshaft holders, then measure the widest Check the cam lobe height wear. portion of the plastigage on each journal. Cam Lobe Height Standard (New): Camshaft-to-Holder Oil Clearance: Intake A: 35.299 mm (1.3897 in) Standard (New): 0.060 - 0.089 mm Exhaust: 37.281 mm (1.4678 in) (0.002 - 0.004 in) Service Limit:...

  • Page 262: Valves, Valve Springs And Valve Seals Removal

    Valves, Valve Springs and Valve Seals 6-23 Removal NOTE: Identify valves and valve springs as they are removed so that each item can be reinstalled in its original position. Using an appropriate-sized socket and plastic mallet, lightly tap the valve retainer to loosen the valve keepers before installing the valve spring compressor.
  • Page 263 Valve Guides Cylinder Head 6-24 Valve Movement Warpage Measure the guide-to-stem clearance with a dial indicator NOTE: If the camshaft-to-holder oil clearances (see while rocking the stem in the direction of normal thrust page 6-21) are not within specification, the cylinder (wobble method).
  • Page 264 Valve Seats 6-25 Reconditioning Renew the valve seats in the cylinder head using a valve After resurfacing the seat, inspect for even valve seat cutter. seating: Apply Prussian Blue compound to the valve face, and insert the valve in its original NOTE: If the guides are worn (see page 6-24) replace...

  • Page 265: Valve Guide

    Valve Guides 6-26 Replacement Reaming NOTE: NOTE: For new valve guides only. For best results, heat cylinder head to 150°C (300°F) Coat both the reamer and valve guide with cutting before removing or installing guides. oil. It may be necessary to use an air hammer to remove Rotate the reamer clockwise the full length of the some valve guides.
  • Page 266 Valves, Valve Springs and Valve Seats 6-27 Installation Insert the valves into the valve guides coat the valve Install the valve spring and valve retainer, then stems with engine oil before inserting the valves. install the valve spring compressor. Compress the NOTE: Check the valves move up and down smoothly.
  • Page 267 Camshaft/Rocker Arms and Camshaft 6-28 Seal/Pulley Installation NOTE: Apply liquid gasket (P/N 08C70 - K0234M, 08C70 - Make sure that all rockers are in alignment with valves K0334M, or 08C70 - X0331S) to the head mating when torquing rocker assembly bolts. surfaces of the No.
  • Page 268 Camshaft/Rocker Arms and Camshaft Cylinder Head 6-29 Installation Seal/Pulley Installation (cont’d) Install the back cover, then install the camshaft pulley. Install the cylinder head in the reverse order of removal: NOTE: Always use a new head gasket. Cylinder head and cylinder block surface must be clean.

  • Page 269: Cylinder Head Bolt Torque Sequence

    Cylinder Head 6-30 Installation (cont’d) Position the camshaft correctly (see page 6-10). Install the timing belt (see page 6-10). Tighten the cylinder head bolts sequentially in four steps. Adjust the valve clearance (see page 6-3). 1st step: (1) - (10) 20 Nm (2.0 kgf/m, 14 Ibf/ft) Install the head cover gasket in the groove of the cylinder head cover.
  • Page 270 Cylinder Head 6-31 Installation (cont’d) 11. When installing the cylinder head cover, hold the head 12. Tighten the nuts in two or three steps. In the final cover gasket in the groove by placing your fingers on the step, tighten all bolts, in sequence, to 9.8 Nm (1.0 camshaft holder contacting surfaces (top of the kgf/m, 7.2 lbf/ft).

  • Page 272: Special Tools

    Special Tools | Ref No. Tool Number Description | Qty | Remark | 07LAB - PV00100 | Ring Gear Holder | 07PAF - 0010000 | Piston Pin Assembly Tool Set | 07PAF - 0010650 | Piston Collar, O.D. 19 mm | 07749 - 0010000 | Handle Driver | 07948 - SB00101...

  • Page 273: Illustrated Index

    Illustrated Index NOTE: Apply liquid gasket to the mating surfaces of the right side cover and oil pump housing before installing them. Use liquid gasket part No. 08C70-K0234M, 08C70-K0334M or, 08C70-X0331S. Clean the oil pan gasket mating surfaces before installing it. Lubricate all internal parts with engine oil during reassembly.
  • Page 274 Illustrated Index (cont’d) Except Europe, Australia and South Africa models: 1. OIL PAN. Installation (see page 7-26). 2. 6 x 1.0 mm, 12 Nm ( 1.2 kgf/m, 8.7 lbf/ft) 3. DRAIN BOLT, 44 Nm (4.5 kgf/m, 33 lbf/ft) 4. WASHER. Replace. 5.
  • Page 275 Illustrated Index (cont’d) NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft identification markings (see page 7-10). Lubricate all internal parts with engine oil during reassembly. 1. PISTON INSTALLATION DIRECTION 2. EXHAUST 3. INTAKE 4. PISTON RINGS Replacement (see page 7-19).

  • Page 276: Flywheel And Drive Plate Replacement

    Flywheel and Drive Plate Replacement Manual Transmission Automatic Transmission Remove the six flywheel bolts, then separate the flywheel Remove the six drive plate bolts, then separate the from the crankshaft flange. After installation, tighten the bolts drive plate from the crankshaft flange. After installation, in a criss-cross pattern.
  • Page 277 Connecting Rod and Crankshaft End Play Connecting Rod End Play: Push the crankshaft firmly away from the dial indicator and zero the dial against the end of the crankshaft. Standard (New): 0.15 - 0.30 mm Then pull the crankshaft firmly back towards the (0.006 - 0.012 in) indicator;...
  • Page 278 Main Bearings Clearance To check main bearing-to-journal oil clearance, remove Main Bearing-to-Journal Oil Clearance: the main caps and bearing halves. Standard (New): Clean each main journal and bearing half with a clean No. 1, 5 Journals: shop towel. 0.018 - 0.036 mm (0.0007 - 0.0014 in) Place one strip of plastigage across each main journal.
  • Page 279 Main Bearings Selection NOTE: If the codes are indecipherable because of an Main Journal Code Location (Numbers) accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Crankshaft Bore Code Location Letters have been stamped on the end of the block as a code for the size of each of the 5 main journal bores.
  • Page 280 Selection Connecting Rod Bearings 7-10 Clearance Remove the connecting rod cap and bearing half. NOTE: If the codes are indecipherable because of an Clean the crankshaft rod journal and bearing half with a accumulation of dirt and dust, do not scrub them with a clean shop towel.
  • Page 281 Pistons and Crankshaft 7-11 Removal Removal the oil pan assembly. Remove the bolts. To prevent warpage, unscrew Remove the right side cover. the bolt in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened, then remove the bearing cap.
  • Page 282 Pistons and Crankshaft 7-12 Removal (cont’d) Remove the upper bearing halves from the connecting rods and set them aside with their respective caps. Reinstall the main caps and bearings on the engine in the proper order. 10. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer.
  • Page 283 Crankshaft 7-13 Inspection Clean the crankshaft oil passages with pipe cleaners or Out-of-Round and Taper a suitable brush. Measure out-of-round at the middle of each rod Check the keyway and threads. and main journal in two places. Alignment The difference between measurements on each Measure runout on all main journals to make sure the journal must not be more than the service limit.
  • Page 284 Pistons 7-14 Inspection Check the pistons for distortion or cracks. Calculate difference between cylinder bore NOTE: If cylinder is bored, an oversized piston must be diameter (See Page 7-15) and piston diameter. used. Piston-to-Cylinder Clearance Measure piston diameter at a point A from bottom of Standard (New): 0.010 - 0.040 mm skirt.
  • Page 285 Cylinder Block 7-15 Inspection Measure wear and taper in directions X and Y at three Measurements in any cylinder are beyond levels in each cylinder as shown. Oversize Bore Service Limit, replace the block. If block is to be rebored, refer to Piston Clearance Inspection (See Page 7-14) after reboring.
  • Page 286 Cylinder Block Piston Pins 7-16 Bore Honing Removal Measure cylinder bores as shown (See Page 7-15). If NOTE: Use the piston pin assembly tool set (No. the block is to be reused, hone the cylinders and 07PAF-0010000) for removal of piston pins. remeasure the bores.

  • Page 287: Connecting Rods Selection

    Connecting Rods Piston Pins 7-17 Selection Installation Each rod falls into one of four tolerance ranges (from 0 to + NOTE: 0.024 mm (0 to + 0.0009 in) in 0.006 mm (0.0002 in) Use the piston pin assembly tool set (No. increments) depending on the size of its big end bore.
  • Page 288 Piston Pins 7-18 Inspection Measure the diameter of the piston pin. Measure the piston pin-to-piston clearance. NOTE: Check the piston for distortion or cracks. Piston Pin Diameter: If the piston pin clearance is greater than 0.024 Standard (New): 18.994 - 19.000 mm mm (0.0009 in), remeasure using an oversize (0.7478 - 0.7480 in) piston pin.

  • Page 289: Piston Ring

    Replacement Piston Rings 7-19 End Gap Using a piston, push a new ring into the cylinder bore 15 Using a ring expander, remove the old piston rings. - 20 mm (0.6 - 0.8 in) from the bottom. Clean all ring grooves thoroughly. NOTE: Use a squared-off broken ring or ring groove cleaner with blade to fit piston grooves.

  • Page 290: Feeler Gauge

    Alignment Piston Rings 7-20 Ring-to-Groove Clearance After installing a new set of rings, measure ring-to-groove Install the rings as shown. clearances: NOTE: The manufacturing marks must be facing upwards. Top Ring Clearance D16W1 engine: Standard (New): 0.035 - 0.060 mm (0.0014 - 0.0024 in) Service limit: 0.13 mm (0.005 in) D16W2 engine:...
  • Page 291 Piston Rings Crankshaft Oil Seal 7-21 Alignment (cont’d) Installation Rotate the rings in their grooves to make sure they do not bind. The seal surface on the block should be dry. Apply a light coat of oil to the crankshaft and to the tip of the seal.
  • Page 292 Pistons Crankshaft 7-22 Installation Installation Before installing the piston, apply a coat of engine oil Before installing the crankshaft, apply a coat of to the ring grooves and cylinder bores. engine oil the main bearings and rod bearings. If the crankshaft is already installed: Insert the thrust washers in the No.
  • Page 293 Crankshaft 7-23 Installation (cont’d) Check rod bearing clearance with plastigage (See page Install the main bearing caps. 7-10), then torque the cap nuts. Check clearance with plastigage (See page 7-8), 31 Nm (3.2 kgf/m, 23 lbf/ft) then tighten the bearing cap bolts in two steps. Apply engine oil to the bolt threads.

  • Page 294: Dowel Pin

    Crankshaft 7-24 Installation (cont’d) NOTE: 11. Apply liquid gasket to the oil pump mating surface Use liquid gasket, part No. 08C70-K0234M, of the block, then install the oil pump on the 08C70-K0334M or 08C70-X0331S. cylinder block. Check that the mating surfaces are clean and dry Apply grease to the lips of the oil seals.
  • Page 295 Oil Pan 7-25 Installation Europe, Australia and South Africa models: Apply liquid gasket to the block mating surfaces of the oil pan, then install it. NOTE: Apply liquid gasket to the shaded areas. Use liquid gasket, part No. 08C70-K0234M, 08C70-K0334M or 08C70-X0331S. Check that the mating surfaces are clean and dry before applying liquid gasket.

  • Page 296: Right Side Cover

    Oil Pan 7-26 Installation (cont’d) Except Europe, Australia and South Africa models: Install the oil pan gasket and oil pan. NOTE: NOTE: Use a new oil pan gasket. Use liquid gasket, part No. 08C70-K0234M, Install oil pan no more than five minutes after 08C70-K0334M or 08C70-X0331S.

  • Page 298: Special Tools

    Special Tools | Ref No. Tool Number Description | Qty Remark | 07406 - 0030000 | Oil Pressure Gauge Attachment | 07506 - 3000000 | Oil Pressure Gauge | 07746 - 0010400 | Driver Attachment, 52 x 55 mm | 07749 - 0010000 | Handle Driver | 07912 - 6110001 | Oil Filter Wrench...

  • Page 299: Illustrated Index

    Illustrated Index NOTE: Use new O-rings when reassembling. Apply oil to O-rings before installation. Use liquid gasket, Part No. 08C70-K0234M, 08C70-K0334M or 08C70-X0331S. Clean the oil pan gasket mating surfaces before installing. Europe, Australia and South Africa models: 1. OIL PUMP Overhaul, (See Page 8-9)

  • Page 300: Oil Pump

    Illustrated Index (cont’d) NOTE: Use new O-rings when reassembling. Apply oil to O-rings before installation. Use liquid gasket, Part No. 08C70-K0234M, 08C70-K0334M or 08C70-X0331S. Clean the oil pan gasket mating surfaces before installing. Except Europe, Australia and South Africa models: 1.
  • Page 301 Engine Oil Replacement Inspection Park the vehicle on level ground, and turn off the engine. Warm up the engine. Allow the oil a few minutes to drain back into the oil pan Drain the engine oil. so that the dipstick will show the actual level. Europe, Australia and South Africa models: Make certain that the oil level indicated on the dipstick is between the upper and lower marks.

  • Page 302: Oil Filter

    Engine Oil Oil Filter Replacement (cont’d) Replacement Reinstall the drain plug with new washer, and refill with Remove the oil filter with the special oil filter the recommended oil. wrench. Inspect the threads and rubber seal on the new Requirement filter.
  • Page 303 Oil Filter Replacement (cont’d) Install the oil filter by hand. Eight numbers (1 to 8) are printed on the surface of the filter. After the rubber seal seats, tighten the oil filter clockwise The following explains the procedure for tightening with the special tool.
  • Page 304 Oil Pressure Switch Oil Pressure Testing Testing Remove the YEL/RED wire from the engine oil pressure If the oil pressure warning light stays on with the engine switch. running, check the engine oil level. If the oil level is Check for continuity between the positive terminal and correct: the engine (ground).
  • Page 305 Oil Pump Overhaul NOTE: Use new O-rings when reassembling. Apply oil to O-rings before installation. Use liquid gasket, Part No. 08C70-K0234M, 08C70-K0334M or 08C70 -X0331S The rotors must be installed to the same direction. After reassembly, check that the rotors move without binding. 1.
  • Page 306 Oil Pump 8-10 Removal/Inspection/Installation Drain the engine oil. 10. Remove the screws from the pump housing, then Turn the crankshaft and align the white groove on the separate the housing and cover. crankshaft pulley with the pointer on the lower cover. 11.

  • Page 307: Pump Housing

    Oil Pump 8-11 Removal/Inspection/Installation (cont’d) 13. Check the housing-to-outer rotor radial clearance. If the 17. Reassemble the oil pump, applying thread lock to housing-to-outer rotor radial clearance exceeds the the pump housing screws. service limit, replace the set of inner and outer rotors 18.

  • Page 308: Oil Screen

    Oil Pump 8-12 Removal/Inspection/Installation (cont’d) 22. Install the oil pump on the cylinder block. Apply grease to the lip of the pump seal. Then, install the oil pump onto the crankshaft. When the pump is in place, clean any excess grease off the crankshaft and check that the oil seal lip is not distorted.

  • Page 310: Intake Manifold Replacement

    Intake Manifold Replacement NOTE: Use new gaskets when reassembling. Check for folds or scratches on the surface of the gaskets. Replace with a new gasket if damaged. 1. 6 x 1.0 mm, 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft) 2. 8 x 1.25 mm, 22 Nm (2.2 kgf/m, 16 lbf/ft) 3.
  • Page 311 Exhaust Manifold Replacement (cont’d) NOTE: Use new gaskets and self-locking nuts when reassembling. 1. 8 x 1.25 mm, 22 Nm (2.2 kgf/m, 16 lbf/ft) 2. COVER 3. EXHAUST MANIFOLD 4. GASKET. Replace. 5. SELF-LOCKING NUT, 8 x 1.25 mm, 31 Nm (3.2 kgf/m, 23 lbf/ft). Replace. 6.
  • Page 312 Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. 1. 6 x 1.0 mm, 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft) 2. HEAT SHIELD 3. EXHAUST PIPE B 4. MUFFLER 5. GASKET. Replace. 6. SELF-LOCKING NUT, 10 x 1.25 mm, 54 Nm (5.5 kgf/m, 40 lbf/ft).
  • Page 314 Radiator 10-2 Illustrated Index Total Cooling System Capacity [Including heater and NOTE: Check all cooling system hoes for damage, leaks reservoir] or deterioration and replace if necessary. M/T: 3.9 l (4.1 US qt, 3.4 Imp qt) Check all hose clamps and retighten if necessary. CVT: 4.1 I (4.3 US qt, 3,6 Imp qt) Use new O-rings when reassembling.
  • Page 315 Radiator 10-3 Illustrated Index (cont’d) Engine Hose Connections: 1. WATER BYPASS HOSE 2. IDLE AIR CONTROL (IAC) VALVE 3. THERMOSTAT HOUSING 4. HEATER VALVE 5. HEATER HOSES 6. O-RING. Replace 7. CONNECTING PIPE 8. O-RING. Replace...

  • Page 316: Radiator Cap

    Radiator 10-4 Replacement Drain the engine coolant. Remove the fan shroud assembly and other parts Remove the upper and lower radiator hoses, and ATF from the radiator. cooler hoses. Install the radiator in the reverse order of removal. Disconnect the fan motor connector. make sure the upper and lower cushions are set Remove the radiator upper bracket, then pull up the securely.

  • Page 317: Drain Plug

    MAX MARK Mix the recommended antifreeze with an equal amount of water in a clean container. NOTE: Use only genuine Honda antifreeze/coolant. For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum. Coolant concentrations less then 50% may not provide sufficient protection against corrosion or freezing.
  • Page 318 Radiator 10-6 Engine Coolant Refilling and Bleeding (cont’d) Pour coolant into the radiator up to the base of the filler neck. 10. Start the engine and let it run until it warms up (the radiator fan comes on at least twice). 11.
  • Page 319 Radiator 10-7 Testing Cap Testing Remove the radiator cap, wet its seal with engine Wait until the engine is cool, then carefully remove coolant, then install it on the pressure tester. the radiator cap and fill the radiator with engine coolant to the top of the filler neck.

  • Page 320: Thermostat Housing

    Thermostat 10-8 Replacement NOTE: Use new 0-rings when reassembling. 1. THERMOSTAT. Install with pin up. 2. PIN 3. RUBBER SEAL. Replace 4. THERMOSTAT COVER 5. 6 x 1.0 mm, 11 Nm (1.1 kgf/m, 8.0 lbf/ft) 6. O-RING. Replace 7. RADIATOR FAN SWITCH, 24 Nm (2.4 kgf/m, 17 lbf/ft) 8.

  • Page 321: Standard Thermostat

    Thermostat 10-9 Testing Replace the thermostat if it is open at room temperature. To test a close thermostat: Suspend the thermostat in a container of water as shown. THERMOMETER THERMOSTAT Heat the water and check the temperature with a thermometer. Check the temperature at which the thermostat first opens, and at which it is fully open, Measure the lift height of the thermostat when it is fully open...
  • Page 322 Water Pump 10-10 Illustrated Index NOTE: Use new O-rings when reassembling 1. COOLANT TEMPERATURE GAUGE SENDING UNIT, 9 Nm (0.9 kgf/m, 7 lbf/ft) Apply liquid gasket to the threads. 2. 6 x 1.0 mm, 11 Nm (1.1 kgf/m, 8.0 lbf/ft) 3.
  • Page 323 Replacement Water Pump 10-11 Inspection Remove the timing belt, (See Page 6-8). Remove the timing belt, (See Page 6-8). Check that the water pump turns counterclockwise. Remove the water pump by removing five bolts. Check for signs of seal leakage. NOTE: Inspect, repair and clean the O-ring groove NOTE: A small amount of “weeping”...
  • Page 324 Fan Controls 10-12 Component Location Index 1. UNDER-HOOD FUSE/RELAY BOX 2. RADIATOR FAN RELAY. Test, section 3. RADIATOR FAN SWITCH. Test, (See Page 10-14) 4. RADIATOR FAN MOTOR. Test (See Page 10-14)
  • Page 325 Fan Controls 10-13 Circuit Diagram...
  • Page 326 Radiator Fan Switch Testing Fan Control 10-14 Fan Motor Testing Disconnect the 2P connectors from the radiator fan NOTE: Bleed air from the cooling system after installing motor. the radiator fan switch, (See Page 10-5) Remove the radiator fan switch from the thermostat cover, (See Page 10-8).
  • Page 327 Sending Unit Testing Engine Coolant Temperature Gauge 10-15 Gauge Testing Check the No. 6 (7.5 A) fuse in the driver’s under-dash Disconnect the YEL/GRN wire from the coolant fuse/relay box before testing. temperature gauge sending unit. Make sure the ignition switch is OFF, then disconnect the YEL/GRN wire from the coolant temperature gauge sending unit, and ground with a jumper wire.

  • Page 329: Special Tools

    Special Tools 11-2 | Ref No. Tool Number Description | Qty Remark | 07LAA - PT50101 | O2 Sensor Socket Wrench | 07PAZ - 0010100 | SCS Short Connector | 07406 - 0040002 | Fuel Pressure Gauge Set | 07406 - 0040202 | Fuel Pressure Hose Assembly | (1) | Component Tools...
  • Page 330 Component Locations 11-3 Index 1. EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE (With TWC models) Troubleshooting, (See Page 11-108) 2. THROTTLE POSITION (TP) SENSOR Troubleshooting, (See Page 11-41) 3. INTAKE AIR TEMPERATURE (IAT) SENSOR Troubleshooting, (See Page 11-44) 4. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Troubleshooting, (See Page...

  • Page 331: Throttle Body (Tb)

    Component Locations 11-4 Index (cont’d) 1. AIR CLEANER (ACL) Replacement, (See Page 11-99) 2. THROTTLE CABLE Inspection/Adjustment, (See Page 11-100) Installation, (See Page 11-100) 3. RESONATOR 4. POSITIVE CRANKCASE VENTILATION (PCV) VALVE Inspection, (See Page 11-105) 5. THROTTLE BODY (TB) Inspection(See Page 11-101) Disassembly,...
  • Page 332 Component Locations 11-5 Index (cont’d) LHD: 1. PGM-FI MAIN RELAY Relay testing, (See Page 11-92) Troubleshooting, (See Page 11-93) 2. INERTIA SWITCH Description, (See Page 11-91) 3. IDLE MIXTURE ADJUSTER (IMA) (Without TWC models) Troubleshooting, (See Page 11-46) 4. ENGINE CONTROL MODULE (ECM/POWERTRAIN CONTROL MODULE (PCM) Removal,...
  • Page 333 Component Locations 11-6 Index (cont’d) 1. FUEL PULSATION DAMPER 2. FUEL VAPOUR PIPE 3. FUEL FILTER Replacement (See Page 11-86) 4. FUEL FEED PIPE 5. FUEL TANK Replacement (See Page 11-96) 6. FUEL PUMP Testing ( See Page 11-87) Replacement (See Page 11-87) FUEL GAUGE SENDING UNIT...

  • Page 334: System Description Vacuum Connections

    System Description 11-7 Vacuum Connections 1. To EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE 2. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 3. FRONT OF VEHICLE 4. EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE (With TWC models) 5. FUEL PRESSURE REGULATOR 6. EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER...

  • Page 335: Engine Coolant

    System Description 11-8 Vacuum Connections (cont’d) With TWC models: 1. ENGINE COOLANT 1 Primary heated oxygen sensor (Primary HO2S) 13 Fuel tank 2 Secondary heated oxygen sensor (Secondary HO2S) 14 Fuel tank evaporative emission (EVAP) valve 3 Exhaust gas temperature (EGT) sensor 15 Throttle body (TB) 4 Manifold absolute pressure (MAP) sensor 16 Air cleaner...
  • Page 336 System Description 11-9 Vacuum Connections (cont’d) Without TWC models: 1. ENGINE COOLANT 2. without PCV 3. with PCV 1 Manifold absolute pressure (MAP) sensor 10 Fuel tank 2 Engine coolant temperature (ECT) sensor 11 Fuel tank evaporative emission (EVAP) valve 3 Intake air temperature (IAT) sensor 12 Throttle body (TB) 4 Idle air control (IAC) valve...
  • Page 337 System Description 11-10 Electrical Connections...
  • Page 338 System Description 11-11 Electrical Connections (cont’d)
  • Page 339 System Description 11-12 Electrical Connections (cont’d)

  • Page 340: Malfunction Indicator Lamp (Mil)

    When the Malfunction indicator Lamp (MIL) has been reported on, check the Diagnostic Trouble Code (DTC) as follows: NOTE: This operation can also be carried out with Honda PGM Tester connected to data link connector (5P)). Connect the SCS short connector to Service Check Connector as shown (The 2P Service Check Connector is located under the dash on the passenger side of the car). Turn the ignition switch ON (II).
  • Page 341 Troubleshooting Procedures (cont’d) Engine/Powertrain Control Module (ECM/PCM) Reset Procedure NOTE: This operation can also be carried out with Honda PGM Tester. Turn the ignition switch off. Remove the BACK UP (7.5 A) fuse from the under-dash fuse/relay box for 10 seconds to reset the ECM/PCM.
  • Page 342 Troubleshooting 11-15 Troubleshooting Procedures (cont’d) Known-Good ECM/PCM Substitution (KG, KE, KQ, KU, KN models) Use the following procedure if you need a known-good ECM/PCM to test a vehicle. It allows you to swap an ECM/PCM from a “donor” vehicle without having to program it to the test vehicle’s ignition key.
  • Page 343 Troubleshooting 11-16 Troubleshooting Procedures (cont’d) Checking The ECM/PCM Connector Terminals When checking the ECM/PCM connector terminals, gently slide the sharp tester probe from the wire side into the connector until it comes in contact with the terminal end of the wire. 1.
  • Page 344 Troubleshooting 11-17 Troubleshooting Guide NOTE: Across each row in the chart, the systems that could be sources of a symptom are ranked in the order they should be inspected starting with 1. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the tope of that column. If inspection shows the system is OK, try the next most likely system 2. etc. To go to the pages referenced on the diagram above, click on the following: (See Page 11-27)
  • Page 345 Troubleshooting 11-18 Troubleshooting Guide (cont’d) To go to the pages referenced on the diagram above, click on the following: (See Page 11-49) (See Page 11-56) (See Page 11-63) (See Page 11-61) (See Page 11-81) (See Page 11-74) (See Page 11-97) (See Page 11-103)

  • Page 346: Troubleshooting

    With radiator fan stopped: Battery voltage LT BLU TXD/RXD (DLC) Sends and receives With ignition switch ON (II): 5V Honda PGM Tester signal ATPL (At gear position Detects A/T gear position: 0V switch) position switch signal In any other position: Battery voltage...
  • Page 347 signal With brake pedal depressed: Battery voltage *1 : with TWC models *4 : A/T *2 : without TWC models *5 : KG, KE, KQ, KU models *3 : with TWC models except KU model *6 : KG, KE, KQ, KN, KU models...
  • Page 348 Troubleshooting 11-20 Engine/Powertrain Control Module Terminal Arrangement (cont’d) ECM/PCM CONNECTOR B (25P) NOTE: Standard battery voltage is 12V. Terminal Wire Colour | Terminal Name Description Signal YEL/BLK IGP1 (Power source) Power source for the With ignition switch ON (II): Battery ECM/PCM control circuit voltage With ignition switch OFF: 0V...
  • Page 349 Troubleshooting 11-21 Engine/Powertrain Control Module Terminal Arrangement (cont’d) ECM/PCM CONNECTOR C (31P) NOTE: Standard battery voltage is 12V. Terminal Wire Colour | Terminal Name Description Signal BLK/WHT PO2SHTC (Primary Drives primary heated With ignition switch ON (II): Battery heated oxygen sensor oxygen sensor heater voltage heater control)
  • Page 350 Troubleshooting 11-22 Engine/Powertrain Control Module Terminal Arrangement (cont’d) PCM CONNECTOR D (16P) *4 NOTE: Standard battery voltage is 12V. Terminal Wire Colour | Terminal Name Description Signal WHT/RED VEL (Secondary gear Secondary gear shaft Depending on vehicle speed: Pulses shaft speed sensor) speed sensor When vehicle is stopped: 0V GRN/BLK...
  • Page 351 Troubleshooting 11-23 Diagnostic Trouble Code (DTC) Chart DIAGNOSTIC SYSTEM INDICATED Page TROUBLE CODE (DTC) Engine/Powertrain control module (ECM/PCM) (see page11-27) Primary heated oxygen sensor (Primary HO2S) (see page11-32) Manifold absolute pressure (MAP) sensor (see page11-34) Crankshaft position (CKP) sensor (see page11-37) Engine coolant temperature (ECT) sensor (see...

  • Page 352: Pgm-Fi System

    PGM-FI System 11-24 System Description *1 : with TWC models *2 : without TWC models *3 : with TWC models except KU model *4 : A/T *5 : KG, KE, KQ, KU models PGM-FI System The PGM-FI system on this model is a sequential multiport fuel injection system. Fuel Injector Timing and Duration The ECM/PCM contains memories for the basic discharge durations at various engine speeds and manifold pressures.
  • Page 353 PGM-FI System 11-25 System Description (cont’d) Other Control Functions Starting Control When the engine is started, the ECM/PCM provides a rich mixture by increasing fuel injector duration. Fuel Pump Control When the ignition switch is initially turned ON (II), the ECM/PCM supplies ground to the PGM-FI main relay that supplies current to the fuel pump for two seconds to pressurise the fuel system.
  • Page 354 PGM-FI System 11-26 How to Read Flowcharts A flowchart is designed to be used from start to final repair. It’s like a map showing you the shortest distance. But beware: if you go off the “map” anywhere but a “stop” symbol, you can easily get lost.
  • Page 355 PGM-FI System 11-27 Engine/Powertrain Control Module (ECM/PCM) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 356 PGM-FI System 11-28 Engine/Powertrain Control Module (ECM/PCM) (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-93)
  • Page 357 PGM-FI System 11-29 Engine/Powertrain Control Module (ECM/PCM) (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 358 PGM-FI System 11-30 Engine/Powertrain Control Module (ECM/PCM) (cont’d) To go to the pages referenced on the diagram above, click on the following: (See Page 11-13) (See Page 11-15)
  • Page 359 PGM-FI System 11-31 Engine/Powertrain Control Module (ECM/PCM) (cont’d)
  • Page 360 PGM-FI System 11-32 Primary Heated Oxygen Sensor (Primary HO2S) (with TWC models The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 1: A problem in the Primary Heated Oxygen Sensor (HO2S) circuit. The Primary Heated Oxygen Sensor (HO2S) detects the oxygen content in the exhaust gas and signals the ECM/PCM in operation, the ECM/PCM receives the signals from the sensor and varies the duration during which fuel is injected.
  • Page 361 PGM-FI System 11-33 Primary Heated Oxygen Sensor (Primary HO2S) (with TWC models (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 362 PGM-FI System 11-34 Manifold Absolute Pressure (MAP) Sensor The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 3: An electrical problem in the Manifold Absolute Pressure (MAP) Sensor circuit. The MAP sensor converts manifold absolute pressure into electrical signals and inputs the ECM/PCM. 1.
  • Page 363 To go to the pages referenced on the diagram above, click on the following: (See Page 11-13) (See Page 11-14) (See Page 11-15)
  • Page 364 PGM-FI System 11-35 Manifold Absolute Pressure (MAP) Sensor (cont’d)
  • Page 365 PGM-FI System 11-36 Manifold Absolute Pressure (MAP) Sensor (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 366 PGM-FI System 11-37 CKP/TDC/CYP Sensor The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 8: A problem in the Top Dead Centre (TDC) sensor circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 9: A problem in the Cylinder Position (CYP) sensor circuit.
  • Page 367 PGM-FI System 11-38 CKP/TDC/CTP Sensor (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 368 PGM-FI System 11-39 Engine Coolant Temperature (ECT) Sensor The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 6: A problem in the Engine Coolant Temperature (ECT) sensor circuit. The ECT Sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the engine coolant temperature increases as shown below: 1.
  • Page 369 PGM-FI System 11-40 Engine Coolant Temperature (ECT) Sensor (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 370 PGM-FI System 11-41 Throttle Position (TP) Sensor The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 7: A problem in the Throttle Position (TP) sensor circuit. The TP Sensor is a potentiometer. It is connected to the throttle valve shaft. As the throttle position changes, the throttle position sensor varies the voltage signal to the ECM/PCM. 1.
  • Page 371 PGM-FI System 11-42 Throttle Position (TP) Sensor (cont’d( To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 372 PGM-FI System 11-43 Throttle Position (TP) Sensor (cont’d)
  • Page 373 PGM-FI System 11-44 Intake Air Temperature (IAT) Sensor The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 10: A problem in the Intake Air Temperature (IAT) sensor circuit. The IAT sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the intake air temperature increases as shown below: 1.
  • Page 374 PGM-FI System 11-45 Intake Air Temperature (IAT) Sensor (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 375 PGM-FI System 11-46 Idle Mixture Adjuster (IMA) (without TWC models) The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 11: A problem in the Idle Mixture Adjuster (IMA) circuit. The idle Mixture Adjuster (IMA) is selected resistance device used to control idle mixture.
  • Page 376 To go to the pages referenced on the diagram above, click on the following: (See Page 11-13) (See Page 11-14) (See Page 11-15)
  • Page 377 PGM-FI System 11-47 Idle Mixture Adjuster (IMA) (without TWC models) (cont’d)
  • Page 378 PGM-FI System 11-48 Idle Mixture Adjuster (IMA) (without TWC models) (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 379 PGM-FI System 11-49 Vehicle Speed Sensor (VSS) The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 17: A problem in the Vehicle Speed Sensor (VSS) circuit. The VSS generates a pulsing signal when the front wheels turn. To go to the pages referenced on the diagram above, click on the following: (See Page 11-13) (See Page...
  • Page 380 PGM-FI System 11-50 Vehicle Speed Sensor (VSS) (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 381 PGM-FI System 11-51 Electrical Load Detector (ELD) (KG, KE, KU, KQ models) The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 20: A problem in the Electrical Load Detector (ELD) circuit. To go to the pages referenced on the diagram above, click on the following: (See Page 11-13) (See Page...
  • Page 382 PGM-FI System 11-52 Electrical Load Detector (ELD) (KG, KE, KU, KQ models) (cont’d)
  • Page 383 PGM-FI System 11-53 Heated Oxygen Sensor (HO2S) Heater (with TWC models) The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 41: A problem in the Primary Heated Oxygen Sensor (HO2S) heater circuit. The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 65: A problem in the Secondary Heated Oxygen Sensor (HO2S) heater circuit (with TWC models except KU model.
  • Page 384 PGM-FI System 11-54 Heated Oxygen Sensor (HO2S) Heater (with TWC model) (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 385 PGM-FI System 11-55 Heated Oxygen Sensor (HO2S) Heater (With TWC model (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 386 PGM-FI System 11-56 Exhaust Gas Temperature (EGT) Sensor (with TWC model (except KU model) The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 55: A problem in the Exhaust Gas Temperature (EGT) Sensor circuit. The EGT sensor is a temperature dependant resistor (thermistor). The resistance of the thermistor decreases as the exhaust gas temperature increases. To go to the pages referenced on the diagram above, click on the following: (See Page 11-13)
  • Page 387 PGM-FI System 11-57 Exhaust Gas Temperature (EGT) Sensor (with TWC model (except KU model) (cont’d)
  • Page 388 PGM-FI System 11-58 Heated Oxygen Sensor (HO2S) Heater (with TWC model) (except KU model) The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 63: A problem in the Secondary Heated Oxygen Sensor (HO2S) heater circuit. To go to the pages referenced on the diagram above, click on the following: (See Page 11-13) (See Page...
  • Page 389 PGM-FI System 11-59 Heated Oxygen Sensor (HO2S) Heater (With TWC model) (except KU model) (cont’d)
  • Page 390 Heated Oxygen Sensor 11-60 Replacement Disconnect the HO2S 4P connector, then remove the HO2S. Primary HO2S: PRIMARY HO2S, 44 Nm (4.5 kgf/m, 33 lbf/ft) O2 SENSOR SOCKET WRENCH, 07LAA-PT50101 HO2S 4P CONNECTOR Secondary HO2S HO2S 4P CONNECTOR O2 SENSOR WRENCH, Snap-on YA 8875 or equivalent SECONDARY HO2S, 44 Nm (4.5 kgf/m.
  • Page 391 Idle Control System 11-61 System Troubleshooting Guide NOTE: Across each row in the chart, the sub-systems that could be sources of a symptom are ranked in the order they should be inspected, starting with 1. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column.

  • Page 392: Various Sensors

    Idle Control System 11-62 System Description The idle speed of the engine is controlled by the Idle Air Control (IAC) Valve. The valve changes the amount of air bypassing into the intake manifold in response to electric current controlled by the ECM/PCM. When the IAC Valve is activated, the valve opens to maintain the proper idle speed. 1.
  • Page 393 Idle Control System 11-63 Idle Air Control (IAC) Valve The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 14: A problem in the Idle Air Control (IAC) valve. The IAC valve changes the amount of air bypassing the throttle body in response to a curretn signal from the ECM/PCM in order to maintain the proper idle speed. 1.
  • Page 394 Idle Control System 11-64 Idle Air Control (IAC) Valve (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 395 Idle Control System 11-65 Air Conditioning Signal The signals the ECM/PCM when there is a demand for cooling from the air condition system. To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 396 Idle Control System 11-66 Air Conditioning Signal (cont’d)
  • Page 397 Idle Control System 11-67 Alternator (ALT) FR Signal This signals the ECM/PCM when the Alternator (ALT) is charging. To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 398 Idle Control System 11-68 Alternator (ALT) FR Signal (cont’d)
  • Page 399 Idle Control System 11-69 Brake Switch Signal This signals the ECM/PCM when the brake pedal is depressed.
  • Page 400 Idle Control System 11-70 Starter Switch Signal This signals the ECM/PCM when the engine is cranking...
  • Page 401 Idle Control System 11-71 Power Steering Pressure (PSP) Switch Signal This signals the ECM/PCM when the power steering load is high.
  • Page 402 Idle Control System 11-72 Power Steering Pressure (PSP) Switch Signal (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 403 Inspection/Adjustment Adjust the idle speed, if necessary, by turning the idle adjusting screw 1/2-turn clockwise or Adjust the idle speed by means of a Honda PGM TESTER. If counter-clockwise. not, check the following: NOTE: Before setting the idle speed, check the following items: The MIL has not been reported on.
  • Page 404 Fuel Supply System 11-74 System Troubleshooting Guide NOTE: Across each row in the chart, the sub-systems that could be sources of a symptom are ranked in the order they should be inspected starting with 1. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column, If inspection shows the system is OK, try the next most likely system 2.
  • Page 405 Fuel Supply System 11-75 Fuel Lines NOTE: Check fuel system lines, hoses and fuel filter for damage, leaks or deterioration and replace if necessary...
  • Page 406 Fuel Supply System 11-76 Fuel Lines (cont’d) NOTE: Check all hose clamps and retighten if necessary. 1. BASE PACKING, Replace 2. FUEL PUMP/FUEL GAUGE SENDING UNIT 3. FUEL TANK 4. FUEL TUBE/QUICK-CONNECT FITTINGS 5. To FUEL PRESSURE REGULATOR 6. FUEL FILTER 7.
  • Page 407 Fuel Supply System 11-77 Fuel Tube/Quick-Connect Fittings Precautions Disconnections Do not smoke while working on the fuel system. Keep open Do not smoke while working on the fuel system. Keep flame or sparks away from the work area. open flame or sparks away from the work area. The fuel tube/quick-connect fittings assembly connects the Disconnect the battery negative cable.
  • Page 408 Fuel Supply System 11-78 Fuel Tube/Quick-Connect Fittings (cont’d) To prevent damage and keep out foreign matter cover Connection the disconnected connector and pipe end with plastic bags. Do not smoke while working on the fuel system. Keep open flame or sparks away from the work area. Check the pipe contact area for dirt and damage and clean it necessary.
  • Page 409 Fuel Supply System 11-79 Fuel Tube/Quick-Connect Fittings (cont’d) Before connecting a new fuel tube/quick-connect fitting Make sure the connection is secure and that the assembly, remove the old retainer from the mating pipe. pawls are firmly locked into place; check visually and by pulling the connector.
  • Page 410 Fuel Pressure Fuel Supply System 11-80 System Description The fuel supply system consists of a fuel tank, in-tank Relieving high-pressure fuel pump, PGM-FI main relay, fuel filter, fuel Before disconnecting fuel pipes or hoses, release pressure regulator, fuel injectors and fuel delivery and return pressure from the system by loosening the 12 mm lines.
  • Page 411 Fuel Injectors Fuel Supply System 11-81 Fuel Pressure (cont’d) Inspection Description The fuel injectors are a solenoid-actuated Relieve fuel pressure (see page 11-80). constant-stroke, pintle-type consisting of a solenoid, Remove the 12 mm banjo bolt on the fuel filter while plunger needle valve and housing.

  • Page 412: Fuel Injector

    Fuel Supply System 11-82 Fuel Injectors (cont’d) Testing Testing NOTE: Check the following times before testing: idle speed, Remove the connector of the fuel injector and ignition timing and idle CO%. measure the resistance between the 2 terminals of the fuel injector. If the engine runs: Resistance should be: 12-15 ohm With the engine idling, disconnect each fuel injector...
  • Page 413 Fuel Supply System 11-83 Fuel Injectors (cont’d) Replacement Do not smoke while working on the fuel system. Keep open flame or sparks away from the work area. Relieve the fuel pressure (See Page 11-80). Remove the air cleaner housing. Disconnect the connectors from the fuel injectors. Disconnect the vacuum hoses and fuel return hose from the fuel pressure regulator.
  • Page 414 Fuel Supply System 11-84 Fuel Injectors (cont’d) 13.. To prevent damage to the O-rings, install the fuel injectors in the fuel rail first, then install them in the intake manifold. 1. FUEL RAIL 2. FUEL INJECTOR 3. INTAKE MANIFOLD 14. Install and tighten the retainer nuts. 15.
  • Page 415 Fuel Supply System 11-85 Fuel Pressure Regulator Description Testing The fuel pressure regulator maintains a constant fuel pressure to the fuel injectors. When the difference between the fuel pressure and manifold pressure exceeds 290 kPa Do not smoke while working on the fuel system. Keep (3.0 kgf/m, 43 psi), the diaphragm is pushed upward, and the open flame or sparks away from the work area.
  • Page 416 Fuel Filter Fuel Supply System 11-86 Fuel Pressure Regulator (cont’d) Replacement Replacement Do not smoke while working on the fuel system. Keep open Do not smoke while working on the fuel system. Keep flame or sparks away from the work area. open flame or sparks away from the work area.
  • Page 417 Fuel Supply System 11-87 Fuel Pump Testing Replacement Do not smoke while working on the fuel system. Keep open Do not smoke while working on the fuel system. Keep flame or sparks away from the work area. open flame or sparks away from the work area. If you suspect a problem with the fuel pump, check that the Relieve fuel pressure (See Page...

  • Page 418: Jumper Wire

    Fuel Gauge Fuel Supply System 11-88 Fuel Pump (cont’d) Remove the bracket, the fuel gauge sending unit, the Testing hose and the wire harness. NOTE: See section 23 for the fuel gauge system circuit diagram. Check the INSTRUMENT LIGHT (7.5A) fuse in the under-dash fuse/relay box before testing.
  • Page 419 Fuel Gauge Sending Unit Fuel Supply System 11-89 Fuel Gauge(cont’d) Check that the pointer of the fuel gauge starts moving Testing toward the “F” mark. Relieve fuel pressure (See Page 11-80). If the pointer of the fuel gauge does not move at all, Remove the access panel from the floor.

  • Page 420: Low Fuel Indicator Light

    Low Fuel Indicator Light System Fuel Supply System 11-90 Fuel Gauge Sending Unit (cont’d) Measure the resistance between the No. 1 and No.2 Indicator Light Testing terminals at E (EMPTY), 1/2 (HALF FULL) and F (FULL) NOTE: See section 23 for the low fuel indicator circuit by moving the float.

  • Page 421: Reset Button

    Inertia Switch (KG, KE, models) Fuel Supply System 11-91 Low Fuel Indicator Light System (cont’d) Description The inertia switch is a safety device which automatically cuts off he fuel supply in the event of a collision or sudden impact. The switch is located behind the glove box. After an impact, the switch must be reset by pressing the button before the engine can be restarted.
  • Page 422 Fuel Supply System 11-92 PGM-FI Main Relay Description Relay Testing The PGM-FI main relay actually contains two individual NOTE: If the engine starts and continues to run, the relays. This relay is located at the driver side of the cowl. One PGM-FI main relay is OK.
  • Page 423 Fuel Supply System 11-93 PGM-FI Main Relay (cont’d) Troubleshooting...
  • Page 424 Fuel Supply System 11-94 PGM-FI Main Relay (cont’d)
  • Page 425 Fuel Supply System 11-95 PGM-FI Main Relay (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 11-15)
  • Page 426 Fuel Supply System 11-96 Fuel Tank Replacement Do not smoke while working on the fuel system. Keep open flame or sparks away from the work area. Relieve the fuel pressure (See Page 11-80). Drain the fuel into an approved container with hand pump. Jack up the vehicle and support it with jackstands.

  • Page 427: Throttle Cable

    Intake Air System 11-97 System Troubleshooting Guide NOTE: Across each row in the chart, the sub-systems that could be sources of a symptom are ranked in the order they should be inspected starting with 1. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column.
  • Page 428 Intake Air System 11-98 System Description The system supplies air for all engine needs. It consists of the intake air pipe, Air Cleaner (ACL), Intake air duct, Throttle Body (TB), Idle Air Control (IAC) Valve and Intake manifold. A resonator in the intake air pipe provides additional silencing as air is drawn into the system. 1.
  • Page 429 Intake Air System 11-99 Air Cleaner (ACL) ACL Element Replacement NOTE: Do not clean the ACL element by blowing it off with compressed air. 1. ACL HOUSING 2. ACL ELEMENT Maintenance Schedule, see section 3.
  • Page 430 Intake Air System 11-100 Throttle Cable Inspection/Adjustment Installation Start the engine. Hold the engine at 3,000 rpm (min-1) Open the throttle valve fully, then install the throttle with no load (in Park or neutral) until the radiator fan cable in the throttle link and install the cable comes on, then let it idle.
  • Page 431 Intake Air System 11-101 Throttle Body Description Allow the engine to idle and check that the gauge indicates no vacuum. The throttle body is of a single-barrel side-draft type. The lower portion of the throttle valve is heated by engine coolant If there is vacuum, check the throttle cable (See from the cylinder head.
  • Page 432 Intake Air System 11-102 Throttle Body (cont’d) Removal 1. 22 Nm (2.2 kgf/m, 16 lbf/ft) 2. MAP SENSOR 3. THROTTLE CABLE 4. GASKET, Replace. 5. IAC VALVE 6. TP SENSOR NOTE: Do not adjust the throttle stop screw. After reassembly, adjust the throttle cable (See Page 11-100).
  • Page 433 Emission Control System 11-103 System Troubleshooting Guide NOTE: Across each row in the chart, the sub-systems that could be sources of a symptom are ranked in the order they should be inspected starting with 1. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column.
  • Page 434 Three Way Catalytic Converter Emission Control System 11-104 (TWC) System Description The emission control system includes a Three Way Catalytic Description Converter (TWC), Positive Crankcase Ventilation (PCV) The Three Way Catalytic Converter (TWC) is used to system and Evaporative Emission (EVAP) Control system. convert hydrocarbons (HC), carbon monoxide (CO) and Tailpipe Emission oxides of nitrogen (Nox) in the exhaust gas, to carbon...
  • Page 435 Emission Control System 11-105 Positive Crankcase Ventilation (PCV) System Description Inspection The Positive Crankcase Ventilation (PCV) system is Check the PCV hoses and connections for leaks designed to prevent blow-by gas from escaping to the and clogging. atmosphere. The PCV valve contains a spring-loaded plunger.
  • Page 436 Emission Control System 11-106 Evaporative Emission (EVAP) Controls Description The evaporative emission controls are designed to minimise the amount of fuel vapour escaping to the atmosphere. The system consists of the following components. Evaporative Emission (EVAP) Control Canister An EVAP control canister is used for the temporary storage of fuel vapour until the fuel vapour can be purged from the EVAP control canister into the engine and burned. Vapour Purge Control System EVAP control canister purging is accomplished by drawing fresh air through the EVAN control canister and into a port on the throttle body.
  • Page 437 Emission Control System 11-107 Evaporative Emission (EVAP) Controls (cont’d) without TWC models: 1. FUEL TANK EVAP VALVE 2. EVAP TWO WAY VALVE 3. (without PCV) 4. EVAP CONTROL CANISTER 5. FRESH AIR 6. EVAP PURGE CONTROL DIAPHRAGM VALVE 7. EVAP CONTROL CANISTER 8.
  • Page 438 Emission Control System 11-108 Evaporative Emission (EVAP) Controls (cont’d) Troubleshooting (with TWC models)
  • Page 439 Emission Control System 11-109 Evaporative Emission (EVAP) Controls (cont’d)
  • Page 440 Emission Control System 11-110 Evaporative Emission (EVAP) Controls (cont’d) Testing (without TWC models) Raise engine speed to 3,500 rpm (min-1). Vacuum should appear on gauge within 1 minute. Remove the fuel fill cap. If vacuum appears on gauge in 1 minute, Start the engine and allow to idle.
  • Page 441 Emission Control System 11-111 Evaporative Emission (EVAP) Controls (cont’d) Evaporative Emission (EVAP) Two Way Valve Testing Remove the fuel fill cap. Remove the vapour line from the two way valve on the fuel tank and connect it to a T-fitting from vacuum gauge and vacuum pump as shown T-FITTING Apply vacuum slowly and continuously while watching...
  • Page 442 Fuel Injected System Diagram 11-112...
  • Page 446 Fuel Injected System Diagram 11-113...
  • Page 450 Fuel Injected System Connectors 11-114...
  • Page 454 Fuel Injected System Connectors 11-115...

  • Page 459: Special Tools

    Special Tools 12-2 | Ref No. Tool Number Description | Qty Remark | 07LAB - PV00100 or | Ring Gear Holder | 07924 - PD20003 | 07PAF - 0020000 | Clutch Alignment Tool Set...

  • Page 460: Table Of Contents

    Illustrated Index 12-3 NOTE: Whenever the transmission is removed, clean and grease the release bearing sliding surface. If the parts marked * are removed, the clutch hydraulic system must be bled (See page 12-9). Inspect the hoses for damage, leaks, interference and twisting. LHD type as shown, RHD type is symmetrical.
  • Page 461 Clutch Pedal 12-4 Adjustment NOTE: Loosen locknut B, and turn the push rod in or out To check the clutch switch, see section 23. to get the specified stroke (A) and height (C) at the The clutch is self adjusting to compensate for wear. clutch pedal.

  • Page 462: Reservoir Hose

    Do not mix different brands of brake fluid as they may not be compatible. Do not reuse the drained fluid. Use only Genuine Honda Brake Fluid or an equivalent DOT 3 or DOT 4 brake fluid. NOTE: LHD type is shown. RHD type is similar.

  • Page 463: Clutch Master Cylinder Replacement

    Clutch Master Cylinder 12-6 Replacement Pry out the cotter pin and pull the pedal pin out of the yoke. Remove the nuts. Do not spill brake fluid on the vehicle may damage the paint; if brake fluid does contact the paint, wash it off immediately with water Plug the end of the clutch line reservoir hose with a shop towel to prevent brake fluid from coming out.
  • Page 464 Do not mix different brands of brake fluid as they may not be compatible. Do not reuse the drained fluid. Use only Genuine Honda Brake Fluid or an equivalent DOT 3 or DOT 4 brake fluid. Pry the circlip off the clutch master cylinder.
  • Page 465 Do not mix different brands of brake fluid as they may not be compatible. Do not reuse the drained fluid. Use only Genuine Honda Brake Fluid or an equivalent DOT 3 or DOT 4 brake fluid. HONDA Genuine Urea Grease UM264 (P/N41211-PY5-305).

  • Page 466: Slave Cylinder Replacement

    Refill the clutch master cylinder with fluid when done. Use only genuine Honda Super Duty DOT 3 brake fluid or an equivalent DOT 3 or DOT 4 brake fluid. Confirm clutch operation and check for leaking fluid.

  • Page 467: Dial Indicator

    Pressure Plate 12-10 Removal/Inspection Check the diaphragm spring fingers for height using the Inspect the fingers of the diaphragm spring for dial indicator. wear at the release bearing contact area. Standard (New): 0.6 mm (0.02 in) max Service Limit: 0.8 mm (0.03 in) DIAPHRAGM SPRING PRESSURE PLATE Inspect the pressure plate surface for wear, cracks...

  • Page 469: Clutch Disc

    Clutch Disc 12-11 Removal/Inspection Remove the clutch disc and special tools. Measure the rivet depth from the lining surface to the rivets, on both sides. Standard (New): 1.65 - 2.25 mm (0.065 - 0.089 in) Service Limit: 0.2 mm (0.008 in) CLUTCH DISC Inspect the lining of the clutch disc for signs of slippage or oil.
  • Page 470 Replacement Flywheel 12-12 Inspection Inspect the ring gear teeth for wear and damage. Install the special tool as shown. Inspect the clutch disc mating surface on the flywheel for Remove the flywheel mounting bolts in a crisscross wear, cracks and burning. pattern in several steps, and remove the flywheel.

  • Page 471: Clutch Disc Pressure Plate Installation

    Tighten the bolts in several steps to grease. prevent warping the diaphragm spring. NOTE: Use only HONDA Genuine Urea Grease UM264 8 x 1.28 mm, 25 Nm (2.6 kgf/m, 19 lbf/ft) (P/N 41211-PY5-305). Install the ring gear holder.

  • Page 472: Release Bearing

    12-14 Removal/Inspection Installation Remove the release fork boot from the clutch housing. NOTE: Use only HONDA Genuine Urea Grease UM264 Remove the release fork and release bearing from the (P/N 41211-PY5-305) clutch housing. With the release fork slid between the release...
  • Page 473 Release Bearing 12-15 Installation (cont’d) Move the release fork right and left to make sure that it fits properly against the release bearing, and that the release bearing slides smoothly. RELEASE FORK RELEASE BEARING Install the release fork boot; make sure the boot seals around the release fork and clutch housing.
  • Page 475 Start the engine, shift the transmission to 3rd gear (manual transmission) or to position (CVT/Honda Multi Matic), accelerate the vehicle gradually and measure the vehicle speed. After measurement, use the brake pedal to gradually decelerate and stop the vehicle.

  • Page 476: Special Tools

    Special Tools 13-3 | Ref No. Tool Number Description | Qty Remark | 07GAD - PG20100 | Pin Driver, 5.0 mm | 07GAJ - PG40100 | Driver Attachment | 07GAJ - PG20102 | Mainshaft Clearance Inspection Tool Set | 07GAJ - PG20110 | Mainshaft Holder | (1) | 07GAJ - PG20130...
  • Page 477 1.65 l (1.74 US qt, 1.45 Imp qt) at fluid change 2.1 l (2.2 US qt, 1.8 Imp qt) at overhaul Always use Genuine Honda Manual Transmission Fluid (MTF). If it is not available, you may use an API service SG, SH or SJ grade motor oil with a viscosity of SAE 10 W-30 or 10 W-40 as a temporary replacement.
  • Page 478 Back-up Light Switch Transfer Assembly 13-5 Test Replacement Inspection Disconnect the back-up light switch 2P connector. Make sure jacks and safety stands are placed properly (see section 1). Raise the front of the vehicle and support it with safety stands (see section 1). Set the parking brake and block both rear wheels securely.
  • Page 479 Transfer Assembly 13-6 Removal Inspection (cont’d) Set a dial indication on the transfer assembly flange, then measure the transfer gear backlash. STANDARD: 0.06 - 0.16 MM (0.002 - 0.006 in) Make sure jacks and safety stands are placed properly (see section 1). Raise the front of the vehicle and support it with safety stands (see section 1).

  • Page 480: Dowel Pin

    Transfer Assembly 13-7 Installation Removal (cont’d) Make reference marks across the propeller shaft and Install the new O-ring on the transfer assembly. the transfer assembly flanges. Clean the areas where the transfer assembly Separate the propeller shaft from the transfer assembly contacts the transmission with solvent or flanges.
  • Page 481 Transfer Assembly 13-8 Installation (cont’d) Install the propeller shaft to the transfer assembly by Refill the MTF (See page 13-4). aligning the reference marks. Start the engine and run it to normal operation temperature (the radiator fan comes on). Turn the engine OFF and check the fluid level.

  • Page 482: Gearshift Mechanism Overhaul

    Gearshift Mechanism 13-9 Overhaul NOTE: Inspect rubber parts for wear and damage when disassembling. Check that the new cotter pin is seated firmly. Be careful not to damage the guide pipe when removing the cables. 1. CHANGE LEVER KNOB, 8 Nm (0.8 kgf/m, 5.8 lbf/ft) 2.
  • Page 483 Transmission Assembly 13-10 Removal Disconnect the starter motor cable and transmission ground cable. Make sure jacks and safety stands are placed properly (see section 1). Apply parking brake and block rear wheels so vehicle will not roll off stands and fall on you while working under it. Use fender covers to avoid damaging painted surfaces Disconnect the negative (-) cable first, then the positive (+) cable from the battery.

  • Page 484: Splash Shield

    Transmission Assembly 13-11 Removal (cont’d) Remove the cotter pins, then remove the steel washers, Remove the three upper transmission mounting plastic washers, shift cables and select cable from the bolts. levers. Remove the cable bracket from the clutch housing. TRANSMISSION MOUNTING BOLTS 10.
  • Page 485 Transmission Assembly 13-12 Removal (cont’d) 12. Hold the stabiliser link ball joint pin with a hexagonal 14. Pull the driveshafts out of the intermediate shaft wrench and remove the flange nut, then separate the and differential. Coat all the precision finished front stabiliser link and front stabiliser.
  • Page 486 Transmission Assembly 13-13 Removal (cont’d) 16. Remove the exhaust pipe A. 18. Remove the rear engine mount bracket/rubber assembly. REAR ENGINE MOUNT BRACKET/RUBBER 19. Make reference marks across the propeller shaft GASKET, Replace and the transfer assembly flanges (only SEPM SELF-LOCKING NUT, Replace model manual transmission).

  • Page 487: Clutch Cover

    Transmission Assembly 13-14 Removal (cont’d) 21. Remove the engine stiffener(s). 22. Remove the clutch cover. CLUTCH COVER 23. Remove the right front stopper rubber/bracket. RIGHT FRONT STOPPER RUBBER/BRACKET ENGINE STIFFENERS ENGINE STIFFENERS ENGINE STIFFENER...
  • Page 488 Transmission Assembly 13-15 Removal (cont’d) 24. Place a floor jack under the transmission and raise the 28. Remove the starter motor and hose clamp from transmission just enough to take the weight off the the transmission housing. mounts. 25. Remove the transmission mount bracket and transmission mount rubber.
  • Page 489 Transmission Assembly 13-16 Illustrated Index Refer to the drawing below for the transmission disassembly/reassembly. Clean all parts thoroughly in solvent and dry with compressed air. Lubricate all the parts with MTF before reassembly. NOTE: This transmission uses no gaskets between the major housings; use liquid gasket (08C70-K0234M) (See page 13-73) and (See page...
  • Page 490 Transmission Assembly 13-17 Illustrated Index (cont’d) 1. TRANSMISSION HANGER 2. INTERLOCK BOLT 3. 32 mm SEALING BOLT 4. STEEL BALL (5/16 in) 5. SPRING 26.1 mm (1.03 in) 6. WASHER, Replace 7. SET BALL SCREW 8. WASHER, Replace 9. FLANGE BOLT 10.
  • Page 491 Transmission Housing 13-18 Disassembly Remove the transfer assembly or left side cover. Remove the interlock bolt. 2WD Model: LEFT SIDE COVER O-RING, Replace 4WD Model: SELECT LEVER INTERLOCK BOLT SELECT ARM SHIFT ARM SHAFT SHIFT ARM A Turn the select lever counterclockwise, then remove the shift arm A finger from the groove of the shift forks.
  • Page 492 Transmission Housing 13-19 Disassembly (cont’d) Remove the set ball screws, washers, springs, steel Remove the transmission housing mounting bolts balls and back-up light switch. in a crisscross pattern in several steps. WASHER, Replace STEEL BALL 5/16 in D. WASHER, Replace SET BALL SCREW TRANSMISSION HANGER SPRING, 26.1 mm (1.03 in) L...

  • Page 493: Select Lever

    Transmission Housing 13-20 Disassembly (cont’d) 14. Remove the oil gutter plate, 78 mm shim and oil guide M 16. Remove the spring pin using the pin driver to push plate. it half way out, then pull out the spring pin using a nipper.

  • Page 494: Differential Assembly

    Transmission Housing 13-21 Disassembly (cont’d) 19. Remove the reverse lock cam. 23. Remove the mainshaft and countershaft assemblies with the shift forks, from the clutch housing NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft spline to protect it. REVERSE LOCK CAM 20.

  • Page 495: Disassembly/Reassembly

    Shift Arm Cover/Shift Arm Shaft Assembly 13-22 Disassembly/Reassembly Shift Arm Cover Assembly Install in the reverse order of removal. Remove the breather cap and set ball screw, washer, spring and steel ball. HANDLE DRIVER, 07749-0010000 DRIVER ATTACHMENT, 32 x 35 mm, 07746-0010100 OIL SEAL, Replace Shift Arm Shaft Assembly Remove the special bolts and conical spring...
  • Page 496 Shift Arm Cover/Shift Arm Shaft Assembly 13-23 Clearance Inspection Measure the clearance between the shift arm A and Measure the clearance between the shift arm B select arm. and shift arm C. Standard: 0.05 - 0.25 mm (0.002 - 0.01 in) Standard: 0.05 - 0.25 mm (0.002 - 0.01 in) Service Limit: 0.5 mm (0.02 in)
  • Page 497 Reverse Shift Holder 13-24 Clearance Inspection Measure the clearances between the reverse shift Measure the clearance between the reverse idler holder and 5th/reverse shift piece pin. gear and reverse shift holder. Standard: A: 0.05 - 0.35 mm (0.002 - 0.014 in) Standard: 0.5 - 1.1 mm (0.02 - 0.04 in) B: 0.4 - 0.8 mm (0.02 - 0.03 in)

  • Page 499: Shift Fork Assembly Disassembly/Reassembly

    Shift Fork Assembly 13-25 Disassembly/Reassembly Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. 1. 3RD/4TH SHIFT FORK 2. 1ST/2ND SHIFT FORK 3. PIN DRIVER 5.0 mm, 07GAD-PG20100 4. 5 x 22 mm SPRING PIN, Replace 5.

  • Page 500: Shift Fork

    Shift Fork Assembly 13-26 Clearance Inspection NOTE: The synchro sleeve and synchro hub should be Measure the clearance between the shift fork and replaced as a set. the shift arm A. Measure the clearance between each shift fork and its Standard: 0.2 - 0.5 mm (0.008 - 0.019 in) matching synchro sleeve.
  • Page 501 Mainshaft Assembly 13-27 Index NOTE: The 3rd/4th and 5th synchro hubs and the ball bearing are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 3rd/4th and 5th synchro hubs, however, should be installed with a press before lubricating them.
  • Page 502 Mainshaft Assembly 13-28 Clearance Inspection NOTE: If replacement is required, always replace the synchro Measure the clearance between 4th gear and the sleeve and hub as a set. spacer collar. Support the bearing inner race with a socket and push Standard: 0.06 - 0.21 mm (0.002 - 0.008 in) down on the mainshaft.
  • Page 503 Disassembly Mainshaft Assembly 13-29 Clearance Inspection (cont’d) Measure the clearance between the spacer collar and 5th gear. Standard: 0.06 - 0.21 mm (0.002 - 0.008 in) Remove the synchro hubs using a press and steel blocks Service Limit: 0.3 mm (0.01 in) as shown.
  • Page 504 Mainshaft Assembly 13-30 Inspection Inspect the gear surface and bearing surface for wear Inspect for runout. and damage, then measure the mainshaft at points A, B Standard: 0.02 mm (0.0008 in) max. and C. Service Limit: 0.05 mm (0.002 in) Standard: NOTE: Support the mainshaft at both ends as A (Ball bearing surface):...
  • Page 505 Mainshaft Assembly 13-31 Reassembly NOTE: For reassembly sequence (See page 13-27). Install the ball bearing using the special tools and a press as shown. Support 2nd gear on steel blocks as shown, then install the 3rd/4th synchro hub using the special tools and a press as shown.
  • Page 506 Countershaft Assembly 13-32 Index Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. 1. REVERSE GEAR Inspection, (See page 13-40) 2. 1ST/2ND SYNCHRO HUB Inspection, (See page 13-40) 3. FRICTION DAMPER Check for wear and damage 4.
  • Page 507 Countershaft Assembly 13-33 Clearance Inspection NOTE: If replacement is required, always replace the synchro If the thickness is less than the standard, replace sleeve and hub as a set. the thrust washer with a new one. Measure the clearance between the 1st gear and thrust If the thickness is within the service limit, measure washer.
  • Page 508 Countershaft Assembly 13-34 Clearance Inspection (cont’d) Measure the clearance between the 2nd gear and 3rd If the thickness is less than the standard, replace gear. the spacer with a new one. If the thickness is within the standard, measure the Standard: 0.07 - 0.14 mm (0.003 - 0.006 in) thickness of the 2nd gear.
  • Page 509 Countershaft Assembly 13-35 Disassembly Securely clamp the countershaft assembly in a bench Remove the friction damper from the spacer using vice with wood blocks. a press and a socket as shown. Raise the locknut tab from the groove in the countershaft, then remove the locknut and the spring washer.
  • Page 510 Countershaft Assembly 13-36 Inspection Inspect the gear surface and bearing surface for wear Inspect for runout. and damage, then measure the countershaft at points A, Standard: 0.02 mm (0.0008 in) max. B and C. Service Limit: 0.05 mm (0.002 in) Standard: A: 36.000 - 36.015 mm NOTE: Support the countershaft at both ends as...
  • Page 511 Countershaft Assembly 13-37 Reassembly Install the double cone synchro. Press the 3rd, 4th and 5th gear on the countershaft without lubrication. When installing the 3rd, 4th and 5th gears, support the shaft on steel blocks and install the gears using a press. Press the 3rd, 4th and 5th gear on the countershaft with press fit load 9,800 N (1,000 kgf, 2,205 lbf).
  • Page 512 Countershaft Assembly 13-38 Reassembly (cont’d) Reassemble the friction damper on the spacer using the Support the countershaft on a steel block as special tools and a press as shown. shown and install 3rd gear using the special tools and a press as shown. HANDLE DRIVER, 07749-0010000 PRESS DRIVER ATTACHMENT, 42 x 47 mm, 07746-0010300...
  • Page 513 Countershaft Assembly 13-39 Reassembly (cont’d) Install 5th gear using the special tools and a press as 10. Install the ball bearing using the special tools and a shown. press as shown. PRESS PRESS 5TH GEAR BALL BEARING ATTACHMENT, 30 mm I.D. 07746-0030300 ATTACHMENT, 30 mm I.D., 07746-0030300 DRIVER, 40 mm I.D., 07746-030300 DRIVER, 40 mm I.D., 07746-0030010...

  • Page 514: Synchro Sleeve Synchro Hub

    Synchro Sleeve, Synchro Hub 13-40 Installation Inspection Inspect gear teeth on all synchro hubs and synchro When assembling the synchro sleeve and synchro hub, sleeves for rounded off corners, which indicate wear. be sure to match the three sets of longer teeth (120 Install each synchro hub in its mating synchro sleeve degrees apart) on the synchro sleeve with the three and check for freedom of movement.
  • Page 515 Synchro Ring, Gear 13-41 Inspection Inspect the synchro ring and gear. Inspect the inside of the synchro ring for wear. Inspect the synchro sleeve teeth and matching teeth on the synchro ring for wear (rounded off). GOOD WORN Inspect the synchro sleeve teeth and matching teeth on the gear for wear (rounded off).

  • Page 516: 1.0 Mm, 103 Nm

    Differential 13-42 Index NOTE: If the * marked parts are replaced, the tapered roller bearing preload must be adjusted (See page 13-45). SEPM Model Manual 1. * THRUST SHIM SEVM Model Manual 11. * THRUST SHIM Adjustment, (See page 13-45) Adjustment, (See page 13-45)
  • Page 517 Differential 13-43 Inspection/Replacement Place the differential assembly on V-blocks and install Remove the bolts in a crisscross pattern in several both axles. steps, remove the final driven gear and transfer Measure the backlash of both pinion gears. If the driven gear from the differential carrier. backlash is not within the standard, replace the NOTE: The final driven gear bolts have left-hand differential carrier.

  • Page 518: Transmission Housing

    Differential 13-44 Bearing Outer Race Replacement NOTE: Install the thrust shim or 75 mm shim and the The bearing outer race and tapered roller bearing should bearing outer race in the transmission housing and be replaced as a set. clutch housing using the special tools as shown. Inspect and adjust the tapered roller bearing preload NOTE: whenever the tapered roller bearing is replaced.
  • Page 519 Differential 13-45 Tapered Roller Bearing Preload Adjustment NOTE: If any of the items listed below are replaced, the After installing the thrust shim, install the bearing tapered roller bearing preload must be adjusted. outer race in the transmission housing (See page Transmission housing 13-40).
  • Page 520 Differential 13-46 Tapered Roller Bearing Preload Adjustment (cont’d) If the tapered roller bearing preload is not within the Recheck the tapered roller bearing preload. standard, select the thrust shim which will give the How to select the correct thrust shim: correct tapered roller bearing preload from the following -1) Compare the tapered roller bearing preload table.
  • Page 521 Differential 13-47 Oil Seal Replacement Transmission Housing: Clutch Housing: Remove the oil seal from the transmission housing. Remove the oil seal from the clutch housing. CLUTCH HOUSING OIL SEAL, Replace Install the new oil seal into the clutch housing using the special tools as shown.
  • Page 522 Transfer Assembly 13-48 Illustrated Index...

  • Page 523: Torque Specifications

    Transfer Assembly 13-49 Illustrated Index (cont’d) TRANSFER HOUSING O-RING, Replace DAMPER HUB NEEDLE BEARING TRANSFER DRIVEN GEAR TRANSFER SHAFT TAPERED ROLLER BEARING OUTER RACE TAPERED ROLLER BEARING TRANSFER SHAFT COLLAR 10. THRUST SHIM, 25 mm, Selective part 11. TRANSFER DRIVE GEAR (HYPOID GEAR) 12.

  • Page 524: Transfer Drive Gear

    Transfer Assembly 13-50 Inspection NOTE: To prevent damage to the transfer housing, always Transfer Gear (Hypoid gear) Tooth Contact use soft jaws or equivalent materials between the transfer Inspection housing and the vice. Remove transfer cover B, then apply Prussian Blue Transfer Gear (Hypoid gear) Backlash Measurement to both sides of the transfer gear teeth lightly and Set a dial indicator on the companion flange as shown.
  • Page 525 Transfer Assembly 13-51 Adjustment Remove the transfer covers A and B. Put a 14 mm Allen wrench in the gear side of the transfer shaft, then secure the Allen wrench in a bench vice. Loosen the transfer shaft locknut. The transfer shaft locknut has left hand threads.
  • Page 526 Transfer Assembly 13-52 Disassembly Secure the transfer housing in a bench vice with soft Remove the transfer driven gear shaft, then jaws. To prevent damage to the transfer housing, always remove the transfer space from the transfer driven use soft jaws or equivalent materials between the gear shaft.
  • Page 527 Transfer Driven Gear Shaft Transfer Assembly 13-53 Bearing Replacement Transfer Drive Gear Bearing Replacement NOTE: Coat all parts with oil during reassembly. NOTE: Coat all parts with oil during reassembly. Remove the tapered roller bearing from the transfer Remove the tapered roller bearing from the drive gear using the special tools and a press.
  • Page 528 Transfer Cover A Bearing Outer Transfer Assembly 13-54 Race Replacement Transfer Shaft Disassembly/Reassembly Support the transfer driven gear on steel blocks, then NOTE: Coat all parts with oil during reassembly. press the transfer shaft out of damper hub as shown. Remove the tapered roller bearing outer race from transfer cover A by heating the cover to almost 212°F (100°C) using a heat gun.

  • Page 529: Transfer Assembly

    Transfer Assembly 13-55 Transfer Housing Bearing Outer Race Replacement NOTE: Coat all parts with oil during reassembly. Bearing Outer Race Locations and Special Tool Remove the tapered roller bearing outer race from the Applications transfer housing. TRANSFER HOUSING Sectional View TRANSFER HOUSING ATTACHMENT, 62 x 68 mm, 07746-0010500 BEARING OUTER RACE...
  • Page 530 Transfer Assembly 13-56 Reassembly NOTE: EXAMPLE: While reassembling the transfer assembly: C: EXISTING 35 mm X: REPLACEMENT 35 mm THRUST SHIM THRUST SHIM Check and adjust the transfer gear tooth contact. Thickness: C= 1.05 mm Thickness: X = ?? mm Measure and adjust the transfer gear backlash.
  • Page 531 Transfer Assembly 13-57 Reassembly (cont’d) Transfer Gear Backlash Inspection and Transfer Gear Install the transfer driven gear shaft in the transfer housing. Do not install the transfer spacer on the Tooth Contact Inspection transfer driven gear shaft in this step. Install the 35 mm thrust shim on the transfer driven gear shaft, then install the tapered roller bearing using the special tools and a press as shown.

  • Page 532: Starting Torque

    Transfer Assembly 13-58 Reassembly (cont’d) Secure the transfer housing in a bench vice with soft Install the transfer shaft assembly in the transfer jaws, then install the special tool on the companion housing, then install the tapered roller bearing, flange. To prevent damage to the transfer housing, transfer shaft collar, 25 mm thrust shim, transfer always use soft jaws or equivalent materials between drive gear, conical spring washer and locknut on...
  • Page 533 Transfer Assembly 13-59 Reassembly (cont’d) 10. Put a 14 mm Allen wrench in the gear side of the 13. Rotate the companion flange several times to seat transfer shaft, then secure the Allen wrench in a bench the tapered roller bearing. vice.
  • Page 534 Transfer Assembly 13-60 Reassembly (cont’d) 16. Apply Prussian Blue to both sides of the transfer gear 19. If the transfer gear tooth contact is incorrect, adjust teeth lightly and evenly. the transfer gear tooth contact with a 35 mm or 25 mm thrust shim.
  • Page 535 Transfer Assembly 13-61 Reassembly (cont’d) 20. Remove the parts on the transfer shaft and remove the 23. Remove the transfer driven gear shaft and the transfer shaft from the transfer housing. companion flange. 24. Install the new transfer spacer on the transfer driven gear shaft, then install them in the transfer housing.

  • Page 536: Tightening Torque

    Transfer Assembly 13-62 Reassembly (cont’d) 26. Secure the transfer housing in a bench vice with soft 28. Stake the locknut into the transfer driven gear shaft jaws. To prevent damage, always use soft jaws or using a 3.5 mm punch as shown. equivalent materials between the transfer housing and the vice.

  • Page 537: Torque Wrench

    Transfer Assembly 13-63 Reassembly (cont’d) 30. Put a 14 mm Allen wrench in the gear side of the Total Starting Torque Inspection and Adjustment transfer shaft, then secure the Allen wrench in a bench 32. Temporarily install transfer cover A without the vice.
  • Page 538 Transfer Assembly 13-64 Reassembly (cont’d) 35. Remove transfer cover A. 37. Select the 68n mm thrust shim. 36. If the measurement is out of specification, remove the THRUST SHIM, 68 mm 68 mm thrust shim from transfer cover A by heating the cover to almost 212°F (100°C) using a heat gun.
  • Page 539 Transfer Assembly 13-65 Reassembly (cont’d) 38. Install the 68 mm thrust shim using the special tools. 40. Install the new O-rings on transfer covers A and B, then install the covers on the transfer housing. PRESS DRIVER, 07749-0010000 THRUST SHIM, 68 mm, Selective part BEARING OUTER RACE ATTACHMENT, 62 x 68 mm, 07746-0010500 TRANSFER COVER A...

  • Page 540: Ball Bearing

    Main Bearing/Oil Seal 13-66 Replacement Remove the ball bearing using the special tool as shown. Drive the new oil seal in from the transmission side using the special tools as shown. ADJUSTABLE BEARING REMOVER SET, 07JAC-PH80000 CLUTCH HOUSING Remove the oil seal from the clutch housing. CLUTCH HOUSING HANDLE DRIVER, 07749-0010000 OIL SEAL, Replace...

  • Page 541: Countershaft Bearing Replacement

    Countershaft Bearing 13-67 Replacement Remove the retaining plate from the clutch housing. Position the oil guide plate. Drive the needle bearing using the special tools as shown. CLUTCH HOUSING Replace RETAINING PLATE Remove the needle bearing using the special tool, then remove the oil guide plate.
  • Page 542 Mainshaft Thrust Clearance 13-68 Adjustment Remove the 78 mm shim and oil guide plate from the Measure distance (B) between the end of the transmission housing. clutch housing and bearing inner race. NOTE: Use a straight edge and vernier caliper. Measure at three locations and average the reading.
  • Page 543 Mainshaft Thrust Clearance 13-69 Adjustment (cont’d) 78 mm SHIM Check the thrust clearance in the manner described below: Part Number Thickness NOTE: Measurement should be made at normal 23941-P16-000 1.20 mm (0.0472 in) room temperature. 23942-P16-000 1.23 mm (0.0484 in) -1.
  • Page 544 Mainshaft Thrust Clearance 13-70 Adjustment (cont’d) -7. Slide the mainshaft base over the mainshaft. -12. Turn the mainshaft holder bolt clockwise; stop turning when the dial gauge has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft end play. Turning the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge stops moving may damage the transmission.
  • Page 545 Transmission Assembly 13-71 Reassembly Install the differential assembly in the clutch housing. Install the reverse idle gear and reverse gear shaft in the clutch housing. REVERSE GEAR SHAFT REVERSE IDLE GEAR Install the reverse shift holder in the clutch housing with the 5th/reverse shift piece pin positioned in the DIFFERENTIAL ASSEMBLY slot of the reverse shift fork.
  • Page 546 Transmission Assembly 13-72 Reassembly (cont’d) Install the reverse lock cam on the clutch housing. 10. Install the select spring bolt. 6 x 1.0 mm, 15 Nm (1.5 kgf/m, 11 lbf/ft) REVERSE LOCK CAM SELECT SPRING BOLT, 39 Nm (4.0 kgf/m, 29 lbf/ft) Install the oil seal.
  • Page 547 Transmission Assembly 13-73 Reassembly (cont’d) 12. Apply liquid gasket to the surface of the transmission 15. Lower the transmission housing with the snap ring housing as shown. pliers, and set the snap ring into the groove of the NOTE: countershaft bearing. Use liquid gasket (P/N 08C70-K00234M).

  • Page 548: Vehicle Speed Sensor

    Transmission Assembly 13-74 Reassembly (cont’d) 17. Install the 32 mm sealing bolt. 20. Install the steel balls, springs, washers, set ball NOTE: Apply liquid gasket (P/N 0Y740-99986 or screws and back-up light switch. 08C70-X0134S) to the threads. 18. Install transmission hanger, then tighten the bolts in a crisscross pattern in several steps as shown.

  • Page 549: Left Side Cover

    Transmission 13-75 Reassembly (cont’d) 22. Turn the select lever and shift arm shaft 26. Install the shift arm cover assembly. counterclockwise, then insert the shift arm shaft. 23. Align the shift arm A groove and select arm finger by turning the shift arm shaft and select lever clockwise, then install the shift arm shaft assembly.

  • Page 550: Transmission Installation

    Place the transmission on the transmission jack housing. and raise it to the engine level. Apply HONDA Genuine Urea Grease UM264 (P/N Install the two lower transmission mounting bolts. 41211-PY-305) to the release fork, the release fork bolt, the release bearing and the release bearing guide.

  • Page 551: Installation

    Transmission 13-77 Installation (cont’d) Install the right front stopper rubber/bracket. 10. Install the engine stiffener. 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) 8 x 1.25 mm, 24 Nm (2.4 kgf/m, 17 lbf/ft) 12 x 1.25 mm, 64 Nm (6.5 kgf/m, 47 lbf/ft) Replace RIGHT FRONT STOPPER RUBBER/BRACKET 10 x 1.25 mm, 44 Nm (4.5 kgf/m, 33 lbf/ft) Install the clutch cover.

  • Page 552: Installation

    Transmission 13-78 Installation (cont’d) 11. Install the propeller shaft to the transfer assembly by 13. Install the rear beam. aligning the reference marks (only SEPM model manual transmission). REAR BEAM 10 x 1.25 mm, 38 Nm (3.9 kgf/m, 28 lbf/ft) 12 x 1.25 mm, 64 Nm (6.5 kgf/m, 47 lbf/ft) REFERENCE MARKS 8 x 1.25 mm, 32 Nm (3.3 kgf/m, 24lbf/ft)
  • Page 553 Transmission 13-79 Installation (cont’d) 15. Install the intermediate shaft (see section 16). 17. Install the knuckle onto the lower arms and install the castle nuts and lock pins (see section 18). 10 x 1.25 mm, 39 Nm (4.0 kgf/m, 29 lbf/ft) INTERMEDIATE SHAFT SE RING, Replace 16.

  • Page 554: Splash Shield

    Transmission 13-80 Installation (cont’d) 19. Install the splash shield. 21. Connect the vehicle speed sensor (VSS) connector. VSS CONNECTOR 22. Install the cable bracket and cables. turn the shift lever boot so the hole is facing down. SPLASH SHIELD 20. Install the three upper transmission mounting bolts. COTTER PIN, Replace 12 x 1.25 mm, 64 Nm (6.5 kgf/m, 47 lbf/ft) 8 x 1.25 mm, 27 Nm (2.8 kgf/m, 20 lbf/ft)

  • Page 555: Breather Cap

    13-81 Installation (cont’d) 23. Connect the back-up light switch connector. 26. Apply HONDA Genuine Urea Grease UM264 (P/N 24. Install the wire harness clamp. 41211-PY5-305) to the end of the slave cylinder rod. Install the slave cylinder and clutch line clamp.
  • Page 557 50 km/h (31 mph) or for more than three minutes. the vehicle from rolling off or over the free rollers. Start the engine, shift the transmission to position (CVT/Honda Multi Matic), accelerate the vehicle gradually and measure the vehicle speed. After measurement, use the brake pedal to...

  • Page 558: Special Tools

    Special Tools 14-3 | Ref No. | Tool Number Description | Qty Remark | 07JAC-PH80000 | Adjustable Bearing Remover Set | 07JAC-PH80100 | Bearing Remover Attachment | 07JAC-PH80200 | Remover Handle Assembly | 07741-0010201 | Remover Weight | 07JAD-PH80101 | Driver Attachment, 58 mm | 07JAD-PH80200 | Pilot, 26 x 30 mm | 07LAD-PW50601...
  • Page 559 14-4 The Continuously Variable Transmission (CVT/Honda Multi Matic) is an electronically controlled automatic transmission with drive and driven pulleys and a steel belt. The CVT/Honda Multi Matic provides non-stage speeds forward and one reverse. The entire unit is positioned in line with the engine.
  • Page 560 Description 14-5 (cont’d) Gear Selection The shift lever has five positions: , PARK, REVERSE, NEUTRAL, DRIVE and LOW. Position Description Front wheels locked; parking brake pawl engaged with the PARK parking gear on the driven pulley shaft. The start clutch and the forward clutch released.
  • Page 561 Description 14-6 Clutches/Reverse Brake/Planetary Gear/Pulleys Clutches/Reverse Brake The CVT uses the hydraulically-actuated clutches and brake to engage or disengage the transmission gears. When hydraulic pressure is introduced into the clutch drum and the reverse brake piston cavity, the clutch piston and the reverse brake piston move. This presses the friction discs and the steel plates together, locking them so they don’t slip. Power is then transmitted through the engaged clutch pack to its hub-mounted gear and through engaged ring gear to pinion gears.
  • Page 562 Description 14-7 Clutches/Reverse Brake/Planetary Gear/Pulleys (cont’d) 1. ATF PUMP DRIVEN SPROCKET 2. ATF PUMP 3. DRIVE PULLEY 4. REVERSE BRAKE PISTON 5. FORWARD CLUTCH 6. REVERSE BRAKE 7. CARRIER 8. RING GEAR 9. PLANETARY PINION GEAR 10. INPUT SHAFT 11. DRIVE PULLEY SHAFT 12.
  • Page 563 Description 14-8 Power Flow Position Start Clutch: released Forward Clutch: released Reverse Brake: released Hydraulic pressure is not applied to the start clutch, forward clutch and the reverse brake. Power is not transmitted to the secondary drive gear. Position Start Clutch: released Forward Clutch: released Reverse Brake: released Hydraulic pressure is not applied to the start clutch, forward clutch and the reverse brake.
  • Page 564 Description 14-9 Power Flow (cont’d) Positions (Forward Range) Start Clutch: engaged Forward Clutch: engaged Reverse Brake: released The hydraulic pressure is applied to the forward clutch and the start clutch and the sun gear drives the forward clutch. The forward clutch drives the drive pulley shaft, which drives the driven pulley shaft linked by the steel belt. The driven pulley shaft drives the secondary drive gear, via the start clutch.
  • Page 565 Description 14-10 Power Flow (cont’d) Position Start Clutch: engaged Forward Clutch: engaged Reverse Brake: released The hydraulic pressure is applied to the reverse brake and the start clutch. The sun gear drives gears and the pinion gears revolve around the sun gear. The carrier assembly rotates in the opposite direction from the rotation direction of the sun gear.
  • Page 566 Description 14-11 Electronic Control System The electronic control system consists of a Powertrain Control Module (PCM), sensors, three linear solenoids and an inhibitor solenoid. Shifting is electronically controlled for comfort under all conditions. Also a Grade Logic Control System has been adopted to control shifting in position while the vehicle is ascending or descending a slope.
  • Page 567 Description 14-12 Electronic Control System (cont’d) Start Clutch Function The start clutch generates two types of creep, that is weak creep and strong creep, under the following conditions. Conditions of weak creep: position (includes Sport mode), Brake ON and stopped, Throttle OFF, Engine Coolant Temperature above 75°C (167°F). Conditions of strong creep: Other conditions than those of weak creep in position.
  • Page 568 Description 14-13 Electronic Control System (cont’d) Circuit Diagram and Terminal Locations...
  • Page 569 Description 14-14 Hydraulic Control The hydraulic control system is controlled by the ATF pump, the valves and the solenoids. The ATF pump is driven by the input shaft. The ATF pump and the input shaft are linked by the ATF pump drive chain and the sprockets. The inhibitor solenoid valve and the linear solenoids, which are located on their valve body, are controlled by the PCM. Fluid from the ATF pump flows through the PH regulator valve to maintain specified pressure to the drive pulley, the driven pulley and the manual valve.
  • Page 570 Description 14-15 Hydraulic Control (cont’d) Secondary Valve Body The secondary valve body contains the PH regulator valve, the clutch reducing valve, the start clutch valve accumulator and the shift inhibitor valve. PH Regulator Valve The PH regulator valve maintains hydraulic pressure supplied from the ATF pump and supplies PH pressure to the hydraulic control circuit and the lubrication circuit. PH pressure is regulated at the PH regulator valve by the PH control pressure (PHC) from the PH control valve.
  • Page 571 Description 14-16 Hydraulic Control (cont’d) PL Regulator Valve Body The PL regulator valve body contains the PL regulator valve and the PH-PL control valve, which is joined with the PH-PL control linear solenoid. The inhibitor solenoid is bolted on the PL regulator valve body.
  • Page 572 Description 14-17 Hydraulic Control (cont’d) Shift Valve Body The shift valve body contains the shift valve and the shift control valve. Both are joined to the shift control linear solenoid. Shift Valve The shift valve is controlled by shift valve pressure (SV) from the shift control valve. The shift valve distributes PH pressure and PL pressure to drive pulley and the driven pulley, to shift the transmission.
  • Page 573 Description 14-18 Hydraulic Control (cont’d) General Chart of Hydraulic Pressure DESCRIPTION OF PRESSURE DESCRIPTION OF PRESSURE | CLUTCH CONTROL | PITOT PIPE | ATF COOLER | PITOT REGULATOR | CLUTCH REDUCING | RECIRCULATION | DRIVEN PULLEY | REVERSE INHIBITOR | DRIVE PULLEY | REVERSE BRAKE | FORWARD CLUTCH | START CLUTCH...
  • Page 574 Description 14-19 Hydraulic Flow (cont’d) Position As the engine turns, the ATF pump also starts to operate. Fluid from the ATF pump flows to the PH regulator valve and the clutch reducing valve. The PH regulator valve regulates high pressure (PH) and sends it to the shift valve and the PL regulator valve. The high pressure (PH) flows to the movable face of the driven pulley via the shift valve and turns into low pressure (PL) at the PL regulator valve.
  • Page 575 Description 14-20 Hydraulic Flow (cont’d) position, at low speed range The flow of fluid up to the drive pulley, the driven pulley and the clutch reducing valve is the same as in position. The pulley ratio is low because the driven pulley receives high pressure (PH) and the drive pulley receives low pressure (PL).
  • Page 576 Description 14-21 Hydraulic Flow (cont’d) position, at middle speed range. As the speed of the vehicle reaches the prescribed value, the shift control linear solenoid is activated by the PCM. The shift control linear solenoid controls the shift control valve to activate shift valve pressure (SV).
  • Page 577 Description 14-22 Hydraulic Flow (cont’d) position, at high speed range As the speed of the vehicle reaches the prescribed value, the shift control linear solenoid moves the shift control valve to increase shift valve pressure (SV) at the left end of the shift valve.
  • Page 578 Description 14-23 Hydraulic Flow (cont’d) position The flow of fluid up to the drive pulley, the driven pulley and the clutch reducing valve is the same as in position. The pulley ratio is low because the driven pulley receives high pressure (PH) and the drive pulley receives low pressure (PL).
  • Page 579 Description 14-24 Hydraulic Flow (cont’d) position Reverse Inhibitor Control If the position is selected while the vehicle is moving forward at speeds over 6 mph (10 km/h), the inhibitor solenoid does not turn off by means of the PCM. Reverse inhibitor pressure (RI) is not applied to the reverse inhibitor valve as the reverse inhibitor solenoid turns on.
  • Page 580 Description 14-25 Hydraulic Flow (cont’d) position The flow of fluid up to the drive pulley, the driven pulley and the clutch reducing valve is the same as in position. Clutch reducing pressure (CR) flows to the start clutch control valve, the manual valve and the shift control valve and is intercepted by those valves. Under this condition, hydraulic pressure is not applied to the clutches and reverse brake.
  • Page 581 Description 14-26 Hydraulic Flow (cont’d) position, when the electronic control system is faulty. When the electronic control system (linear solenoids and sensors) is faulty, the transmission uses the pitot pipe pressure (PP) to allow the vehicle to drive. When all linear solenoids and sensors are off because of a faulty electronic control system, clutch reducing pressure (CR) flows to the start clutch control valve, the manual valve, the PH-PL control valve and the shift control valve.
  • Page 582 Description 14-27 Hydraulic Flow (cont’d) position, when the electronic control system is faulty The flow of fluid up to the drive pulley, the driven pulley and the start clutch is the same as in position. The manual valve is shifted into the position and it uncovers the port that leads reverse brake pressure (RVS) to the reverse inhibitor valve.
  • Page 583 Description 14-28 Parking Brake Mechanism The parking brake mechanism locks the transmission by engaging the parking brake pawl with the parking gear which is integral with the secondary drive gear. The secondary drive gear engages with the secondary driven gear which engages with the final driven gear. Shifting to position causes the parking cone (installed at the end of the parking brake rod) to press the parking brake pawl onto the parking gear.
  • Page 584 Description 14-30 Component Locations LHD: 1. MODE SWITCH 2. POWERTRAIN CONTROL MODULE (PCM) 3. AUTOMATIC TRANSAXLE (A/T) GEAR POSITION SWITCH 4. BRAKE SWITCH RHD: 1. POWERTRAIN CONTROL MODULE (PCM) 2. SHIFT LOCK SOLENOID (KQ, KU models) 3. PARKING PIN SWITCH (KQ, KU models) 4.
  • Page 585 Description 14-31 Component Locations (cont’d) Engine compartment: NOTE: LHD model is shown; RHD is similar 1. DRIVEN PULLEY SPEED SENSOR 2. SECONDARY GEAR SHAFT SPEED SENSOR 3. THROTTLE POSITION (TP) SENSOR 4. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 5. PH-PL CONTROL LINEAR SOLENOID 6.
  • Page 586 PCM Circuit Diagram (A/T Control System) 14-32...
  • Page 587 PCM Circuit Diagram (A/T Control System) 14-33 (cont’d)
  • Page 588 PCM Terminal Voltage/Measuring 14-34 Conditions A/T Control System 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. PCM CONNECTOR A(32P) Terminal No.
  • Page 589 PCM Terminal Voltage/Measuring 14-35 Conditions A/T Control System (cont’d) PCM CONNECTOR D (16P) Terminal No. Signal Description Measuring Conditions/Terminal Voltage Secondary gear shaft speed Depending on vehicle speed: Pulsing signal sensor signal input When vehicle is stopped: Approx. 0V SOL INH | Inhibitor solenoid control With inhibitor solenoid ON: Battery voltage With inhibitor solenoid OFF: 0V...

  • Page 590: Troubleshooting Procedures

    Troubleshooting Procedures 14-36 When the PCM senses an abnormality in the input or output systems, the indicator light in the gauge assembly will blink. What the Service Check Connector (located under the dash on the passenger side) is connected with the special tool as shown, the indicator light will blink the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (II).
  • Page 591 Troubleshooting Procedures 14-37 (cont’d) Remove the glove box (see section 20). PCM Reset Procedure Remove the PCM. Turn the ignition switch off. NOTE: RHD is shown: LHD is symmetrical. Remove the BACK-UP fuse (7.5 A) from the under-dash fuse/relay box for 10 seconds to reset the PCM.
  • Page 593 Symptom-to-Component Chart 14-38 Electrical System Diagnostic Symptom Possible Cause Refer to Indicator Trouble Code* Page Light Blinks Transmission shifts Short in A/T gear position switch (See page wire 14-40) same as position Faulty A/T gear position switch in any of the positions. Transmission shifts Disconnected A/T gear position (See page...
  • Page 594 Symptom-to-Component Chart 14-39 Electrical System (cont’d) If the self-diagnostic indicator light does not blink, perform an inspection according to the table below. Symptom Inspection Ref. Page (see page indicator light is on constantly (not blinking) whenever the 14-61) ignition switch is ON (II) (see page indicator light does not come on for two seconds after ignition 14-62)
  • Page 595 Electrical Troubleshooting 14-40 Troubleshooting Flowchart - A/T Gear Position Switch (Short)
  • Page 596 Electrical Troubleshooting 14-41 Troubleshooting Flowchart - A/T Gear Position Switch (Short) (cont’d)
  • Page 597 Electrical Troubleshooting 14-42 Troubleshooting Flowchart - A/T Gear Position Switch (Open) To go to the pages referenced on the diagram above, click on the following: (See Page 14-72)
  • Page 598 Electrical Troubleshooting 14-43 Troubleshooting Flowchart - A/T Gear Position Switch (Open) (cont’d)
  • Page 599 Electrical Troubleshooting 14-44 Troubleshooting Flowchart - Shift Control Linear Solenoid...
  • Page 600 Electrical Troubleshooting 14-45 Troubleshooting Flowchart - Shift Control Linear Solenoid (cont’d)
  • Page 601 Electrical Troubleshooting 14-46 Troubleshooting Flowchart - PH-PL Control Linear Solenoid...
  • Page 602 Electrical Troubleshooting 14-47 Troubleshooting Flowchart - PH-PL Control Linear Solenoid (cont’d)
  • Page 603 Electrical Troubleshooting 14-48 Troubleshooting Flowchart - Start Clutch Control Linear Solenoid...
  • Page 604 Electrical Troubleshooting 14-49 Troubleshooting Flowchart - Start Clutch Control Linear Solenoid (cont’d)
  • Page 605 Electrical Troubleshooting 14-50 Troubleshooting Flowchart - Inhibitor Solenoid...
  • Page 606 Electrical Troubleshooting 14-51 Troubleshooting Flowchart - Inhibitor Solenoid Cont’d)
  • Page 607 Electrical Troubleshooting 14-52 Troubleshooting Flowchart - Drive Pulley Speed Sensor...
  • Page 608 Electrical Troubleshooting 14-53 Troubleshooting Flowchart - Drive Pulley Speed Sensor (cont’d)
  • Page 609 Electrical Troubleshooting 14-54 Troubleshooting Flowchart - Driven Pulley Speed Sensor...
  • Page 610 Electrical Troubleshooting 14-55 Troubleshooting Flowchart - Driven Pulley Speed Sensor (cont’d)
  • Page 611 Electrical Troubleshooting 14-56 Troubleshooting Flowchart - Secondary Gear Shaft Speed Sensor...
  • Page 612 Electrical Troubleshooting 14-57 Troubleshooting Flowchart - Secondary Gear Shaft Speed Sensor (cont’d)
  • Page 613 Electrical Troubleshooting 14-58 Troubleshooting Flowchart - Shift Control System To go to the pages referenced on the diagram above, click on the following: (See Page 14-82) (See Page 14-80) (See Page 14-81)
  • Page 614 Electrical Troubleshooting 14-59 Troubleshooting Flowchart - Start Clutch Control System...
  • Page 615 Electrical Troubleshooting 14-60 Troubleshooting Flowchart - Start Clutch Control System (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 14-82)
  • Page 616 Electrical Troubleshooting 14-61 Troubleshooting Flowchart - D Indicator Light On Constantly To go to the page referenced on the diagram above, click on the following: (See Page 14-72)
  • Page 617 Electrical Troubleshooting 14-62 Troubleshooting Flowchart - D Indicator Light Does Not Come On...
  • Page 618 Electrical Troubleshooting 14-63 Troubleshooting Flowchart - D Indicator Light Does Not Come On (cont’d)
  • Page 619 Electrical Troubleshooting 14-64 Troubleshooting Flowchart - Mode Switch Does Not Operate...
  • Page 620 Electrical Troubleshooting 14-65 Troubleshooting Flowchart - Mode Switch Does Not Operate (cont’d)
  • Page 621 Electrical Troubleshooting 14-66 Troubleshooting Flowchart - S Mode Indicator Light Does Not Come On...
  • Page 622 Electrical Troubleshooting 14-67 Troubleshooting Flowchart - Interlock System - Shift Lock System KQ and KU Models...
  • Page 623 Electrical Troubleshooting 14-68 Troubleshooting Flowchart - Interlock System - Key Interlock System KQ and KU Models...
  • Page 624 Linear Solenoids/Inhibitor Solenoid 14-69 Test) Disconnect the 8P connector from the solenoid harness If all of the resistances are within the standard, a connector. clicking sound should be heard when connecting Measure the resistance of the shift control linear the battery terminals to the solenoid harness solenoid between the No.
  • Page 625 Drive Pulley/Driven Pulley/Secondary Gear 14-70 Shaft Speed Sensors Replacement While replacing the speed sensor, be sure not to allow dust and other foreign particles to enter into the transmission. Disconnect the drive pulley, the driven pulley, or the secondary gear shaft speed sensor connector. Remove the 6 mm bolt from the transmission housing and remove the drive pulley, the driven pulley, or the secondary gear shaft speed sensor.
  • Page 626 Start Clutch Control 14-71 Start Clutch Calibration Procedure When the following the parts are replaced, the PCM must memorise the feedback signal for the start clutch control. Transmission assembly Start clutch assembly Lower valve body assembly Engine assembly or overhaul Start the engine and warm up to normal operating temperature (the radiator fan comes on).

  • Page 627: A/T Gear Position Switch Test

    A/T Gear Position Switch 14-72 Test Remove the front console (see section 20), then disconnect the A/T gear position switch connector (14P). Check for continuity between the terminals in each position according to the following table. Move the shift lever back and forth at each position without pushing the push button and check for continuity within the range of free play. If there is no continuity within the range of free play, adjust the installing position of the A/T gear position switch as described on the next page.
  • Page 628 Replacement A/T Gear Position Switch 14-73 Adjustment Remove the front console, then disconnect the A/T Shift to the position and loosen the nuts. gear position switch connector (14P). Slide the switch in the direction of the arrow within 2.0 Remove the two mounting nuts. mm (0.79 in.) so that there is continuity between the No.
  • Page 629 A/T Gear Position Indicator 14-74 Indicator Input Test SRS components are located in this area. Review the SRS component locations, precautions and procedures in the SRS (section 23) before performing repairs or service. Remove the gauge assembly from the dashboard (see section 20), then disconnect the A (22P) and B (16P) connectors from the gauge assembly. Inspect the connectors and connector terminals to be sure they are making good contact.
  • Page 630 Parking Pin Switch Test Interlock System (KQ and KU Models) 14-75 Key Interlock Solenoid Test SRS components are located in this area. Review the SRS Remove the front console (see section 20) component locations, precautions and procedures in the SRS Disconnect the parking pin switch connector (section 23) before performing repairs or service.
  • Page 631 Shift Lock Solenoid Interlock System (KQ and KU Models) 14-76 Replacement Shift Lock Solenoid Test Remove the front console (see section 20). Remove the front console (see section 20). Disconnect the shift lock solenoid connector. Disconnect the shift lock solenoid connector. Connect the No.
  • Page 632 Symptom-to-Component Chart 14-78 Hydraulic System SYMPTOM | Check these items on the PROBABLE CAUSE List | | Engine runs, but vehicle does move in any position. | 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 20, 34, 35, 36, 38, 41 | Vehicle does not move in D, L positions.
  • Page 633 Symptom-to-Component Chart 14-79 Hydraulic System PROBABLE CAUSE LIST | Low CVT fluid level. | ATF pump worn. AT gears worn or damaged. Foreign material in ATF pump. | ATF pump chain/ATF pump sprocket worn or damaged. | Input shaft worn or damaged. | Sun gear worn or damaged.
  • Page 634 Road Test 14-80 NOTE: Warm up the engine to normal operating temperature (the radiator fan comes on). Apply the parking brake and block the wheels. Start the engine, then shift to the position while depressing the brake pedal. Depress the accelerator pedal and release it suddenly.
  • Page 635 Road Test 14-81 (cont’d) position: Engine Speed rpm (min-1) Throttle Opening Vehicle Speed) 25 mph (40 km/h) 37 mph (60 km/h 62 mph (100 km/h) | Throttle position sensor voltage: 0.75 V 1,150 - 1,550 | Throttle position sensor voltage: 2.0 V 2.300 - 2,900 2,500 - 3,100 2,700 - 3,300...
  • Page 636 Stall Speed 14-82 Test To prevent transmission damage, do not test stall speed for more than 10 seconds at a time. Do not shift the lever while raising the engine speed. Be sure to remove the pressure gauge before testing stall speed. NOTE: Stall speed test should be used for diagnostic purposes only.
  • Page 637 If the level is below the lower mark, add fluid into the filter hole to bring it to the upper mark. Use the following recommended fluid only. DIPSTICK (YELLOW LOOP) European models: Genuine Honda CVT Fluid. Except European models: Genuine Honda ATF PREMIUM (Automatic Transmission Fluid-PREMIUM).
  • Page 638 Always use the recommended fluid as While changing, be sure not to allow dust and other foreign follows: particles to enter into the transmission. European models: Genuine Honda CVT Fluid. Change Intervals: Except European models: Genuine Honda European Models:...

  • Page 639: Pressure Testing

    Pressure Testing 14-85 While testing, be careful of the rotation wheels. Make sure lifts, jacks and safety stands are placed properly (see section 1). Before testing, be sure the transmission is filled to the proper level. Warm up the engine to normal operating temperature before testing.
  • Page 640 Pressure Testing 14-86 (cont’d) Start the engine. Shift the respective shift lever position as in the table and measure the following pressures at 1,500 rpm. Forward Clutch Pressure Reverse Brake Pressure Drive Pulley Pressure Driven Pulley Pressure Shift to position and measure the lubrication pressure at 3,000 rpm. Pressure Shift lever Symptom...
  • Page 641 Lower Valve Body Assembly 14-87 Replacement Remove the ATF cooler inlet line bracket bolt. Remove the ATF pan (14 bolts). Remove the ATF strainer, then remove the bolt Make sure lifts, jacks and safety stands are placed securing the solenoid harness connector. properly (see section 1).

  • Page 642: Atf Filter

    ATF Filter 14-88 Removal/Installation Remove the ATF cooler inlet line bracket bolt. Remove the ATF pan (14 bolts). Remove the ATF cooler inlet line from the ATF pan. Make sure lifts, jacks and safety stands are placed Remove the ATF filter and clean it. properly (see section 1).
  • Page 643 Transfer 14-89 Inspection Set a dial indicator on the transfer companion flange, then measure the transfer gear backlash. Make sure lifts, jacks and safety stands are placed STANDARD: 0.06 - 0.16 mm (0.002 - 0.0006 in) properly (see section 1). Apply parking brake and block rear wheels so vehicle will not roll off stands and fall on you while working under it.

  • Page 644: Splash Shield

    Transfer 14-90 Removal Remove the rear beam Make sure lifts, jacks and safety stands are placed properly (see section 1). Apply parking brake and block rear wheels so vehicle will not roll off stands and fall on you while working under it. Raise the front of the vehicle and make sure it is securely supported.
  • Page 645 Transfer 14-91 Removal (cont’d) Make a reference mark across the propeller shaft and the transfer assembly flange. Separate the propeller shaft from the transfer assembly. 8 x 1.25 mm, Replace REFERENCE MARK TRANSFER ASSEMBLY TRANSFER FLANGE PROPELLER SHAFT Remove the rear stiffener, then remove the transfer assembly from the transmission.
  • Page 646 Transfer 14-92 Installation Install the propeller shaft to the transfer assembly by aligning the reference mark. While installing the transfer assembly, be sure not to allow dust and other foreign particles to enter into the transmission. Install the new O-ring on the transfer assembly. Clean the areas where the transfer assembly contacts the transmission with solvent or carburettor cleaner and dry with compressed air.
  • Page 647 Transfer 14-93 Installation (cont’d) Install the rear beam Refill the transmission with transmission fluid (See Page 14-84). 10. Start the engine and run it to normal operating temperature (the radiator fan comes on). Turn the engine OFF and check the fluid level. REAR BEAM 12 x 1.25 mm, 64 Nm (6.5 kgf/m, 47 lbf/ft) 10 x 1.25 mm, 38 Nm (3.9 kgf/m, 28 lbf/ft)

  • Page 648: Transmission Removal

    Transmission 14-94 Removal Remove the harness clamp from the clamp bracket, then disconnect the starter cables. Make sure lifts, jacks and safety stands are placed properly and hoist brackets are attached to the correct position on the engine (see section 1). Apply parking brake and block rear wheels so vehicle will not roll off stands and fall on you while working under it.
  • Page 649 Transmission 14-95 Removal (cont’d)) Remove the clip from the shift cable end, then separate 12. Remove the distributor. the cable end from the control lever.. 13. Remove the transmission housing mounting bolts. 10. Remove the shift cable bracket with shift cable. Do not bend the shift cable excessively.
  • Page 650 Transmission 14-96 Removal (cont’d) 15. Install a 5 mm Allen wrench into the tip of the ball joint 18. Pry the driveshaft out of the differential and the pins, then remove the flange nuts from the ball joint pins intermediate shaft, then pull on the inboard joints to on the front stabiliser link.
  • Page 651 Transmission 14-97 Removal (cont’d) 22. Make a reference mark across the propeller shaft and 26. Remove the ATF cooler hoses from the ATF the transfer assembly flange, then separate the propeller cooler lines. Turn the ends of the ATF cooler shaft from the transfer assembly for 4WD model.
  • Page 652 Transmission 14-98 Removal (cont’d) 30. Remove the rear mount/bracket. 32. Place a jack under the transmission and raise the transmission just enough to take weight off mounts. 33. Remove the transmission mount bracket. REAR MOUNT BRACKET 31. Attach a hoist bracket to the engine, then lift the engine slightly.

  • Page 653: Drive Plate

    Transmission 14-99 Removal (cont’d) 35. Pull the transmission away from the engine until it clears the dowel pin. 36. Remove the starter from the transmission. 37. Remove the flywheel from the transmission. 38. Inspect the drive plate and replace it if damaged. DRIVE PLATE WASHER Install in this direction.
  • Page 654 Illustrated Index 14-100 Transmission/Lower Valve Body...

  • Page 655: Torque Specifications

    Illustrated Index 14-101 Transmission/Lower Valve Body (cont’d) ATF Dipstick 12 ATF filter O-ring. Replace. 13 O-ring Replace. Solenoid harness connector 14 ATF pan Lower valve body assembly 15 Dowel pin Dowel pin 16 O-ring Replace. ATF cooler outlet line 17 ATF strainer Sealing washer Replace.
  • Page 656 Illustrated Index 14-102 Transmission Housing/Flywheel Housing (2WD)
  • Page 657 Illustrated Index 14-103 Transmission Housing/Flywheel Housing (2WD) (cont’d) Oil seal Replace. 27 Start clutch ATF feed pipe Oil seal Replace. 28 O-ring Replace. Flywheel housing 29 Feed pipe flange Dowel pin 12 x 20 mm 30 Snap ring Differential assembly 31 Connector bracket Flywheel housing gasket Replace.
  • Page 658 Illustrated Index 14-104 Transmission Housing/Flywheel Housing (4WD)
  • Page 659 Illustrated Index 14-105 Transmission Housing/Flywheel Housing (4WD) (cont’d) Oil seal Replace. 29 Feed pipe flange Oil seal Replace. 30 Snap ring Flywheel housing 31 Connector bracket Dowel pin 12 x 20 mm 32 O-ring Replace. Differential assembly 33 Ball bearing Flywheel housing gasket Replace.
  • Page 660 Illustrated Index 14-106 Right Side Cover/Intermediate Housing...
  • Page 661 Illustrated Index 14-107 Right Side Cover/Intermediate Housing (cont’d) Right side cover. 38 Snap ring ATF feed pipe. 39 Forward clutch assembly Dowel pin 40 O-ring Replace. O-ring Replace. 41 Snap ring Feed pipe flange 42 Spring retainer/return spring assembly Feed pipe flange plate. 43 Reverse brake piston Right side cover gasket Replace.

  • Page 662: Dowel Pin

    Transmission Housing/Lower Valve Body 14-108 Assembly Removal NOTE: Clean all parts thoroughly in solvent or carburettor cleaner and dry them with compressed air. Blow out all passages. When removing the lower valve body assembly, replace the following: O-rings ATF pan gasket 1.
  • Page 663 Transmission Housing/Lower Valve Body 14-109 Assembly Removal (cont’d) Remove the ATF cooler inlet line bracket bolt. Remove the ATF pan (fourteen bolts). Remove the ATF strainer (two bolts). Remove the one bolt securing the solenoid harness connector, then push the connector. Remove the lower valve body (eight bolts).
  • Page 664 Transmission Housing/Flywheel Housing 14-110 Removal NOTE: The illustration shows the 4WD transmission; the 2WD transmission does not have the transfer assembly and related parts to the transfer. Clean all parts thoroughly in solvent or carburettor cleaner and dry them with compressed air. Blow out all passages.
  • Page 665 Transmission Housing/Flywheel Housing 14-111 Removal (cont’d) Remove the transfer assembly from the transmission for 12. Set the special tool on the start clutch and attach 4WD transmission. the pawl of the special tool to the parking gear Remove the ATF passage pipe holder assembly. securely as shown.
  • Page 666 Right Side Cover/Intermediate Housing 14-112 Removal NOTE: Clean all parts in solvent or carburettor cleaner and dry them with compressed air. Blow out all passages. When removing the right side cover/intermediate housing, replace the following parts. O-rings Right side cover gasket Transmission housing gasket Sealing washers 1.
  • Page 667 Right Side Cover/Intermediate Housing 14-113 Removal Remove the right side cover (three 6 mm bolts, eleven 8 11. Compress the return springs, then remove the mm bolts). snap ring. Remove the manual valve body lines A and B. NOTE: If the spring retainer tab is on the reverse Remove the snap ring securing the ring gear, then brake piston, the spring retainer may be damaged.
  • Page 668 Manual Valve Body 14-114 Disassembly/Inspection/Reassembly NOTE: Clean all parts thoroughly in solvent or carburettor cleaner and dry them with compressed air. Blow out all passages. Coat all parts with transmission fluid during assembly. 1. REVERSE INHIBITOR VALVE 2. REVERSE INHIBITOR VALVE SPRING 3.

  • Page 669: Clutch Drum

    Forward Clutch 14-115 Illustrated Index 1. CLUTCH DRUM 2. O-RINGS Replace. 3. DISC SPRING 4. RETURN SPRING 5. SPRING RETAINER 6. SNAP RING 7. CLUTCH PLATES Standard thickness: 2.00 mm, (0.079 in). 8. CLUTCH END PLATE 9. SNAP RING 10. CLUTCH DISCS Standard thickness: 1.94 mm, (0.076 in).
  • Page 670 Forward Clutch 14-116 Disassembly Remove the snap ring, then remove the clutch end Install the special tools as shown. plate, clutch discs and plates SCREWDRIVER SNAP RING Remove the disc spring. CLUTCH SPRING COMPRESSOR SET, 07LAE-PX40000 CLUTCH SPRING COMPRESSOR ATTACHMENT, 07LAE-PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT, 07HAE-PL50100...
  • Page 671 Forward Clutch 14-117 Disassembly (cont’d) Compress the return spring. Wrap a shop rag around the clutch drum and apply air pressure to the fluid passage to remove the piston. Place a finger tip on the other end while applying air pressure. Remove the snap ring.
  • Page 672 Forward Clutch 14-118 Reassembly NOTE: Install the piston in the clutch drum. Apply pressure Clean all parts thoroughly in solvent or carburetor and rotate to ensure proper seating. cleaner and dry them with compressed air. NOTE: Do not pinch the O-ring by installing the Blow out all passages.
  • Page 673 Forward Clutch 14-119 Reassembly (cont’d) Install the special tools as shown. Compress the return spring Install the snap ring CLUTCH SPRING COMPRESSOR SET 07LAE-PX40000 CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100 CLUTCH SPRING COMPRESSOR ATTACHMENT 07HAE-PL50100 CLUTCH SPRING COMPRESSOR BOLT ASSEMBLY 07GAE-PG40200 NOTE: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.
  • Page 674 Forward Clutch 14-120 Reassembly (cont’d) Install the disc spring in the direction shown. 13. Install the snap ring. DISC SPRING CLUTCH DRUM 10. Soak the clutch discs thoroughly in recommended transmission fluid for a minimum of 30 minutes. 11. Make sure the inside of the clutch drum is free of dirt or SCREWDRIVER SNAP RING other foreign matter.

  • Page 675: Plate Number

    Forward Clutch 14-121 Reassembly (cont’d) 15. Measure the clearance between the clutch end plate and 16. If the clearance is out of tolerance, select a new top disc with a dial indicator. Zero the dial indicator with clutch end plate from the following table, then the clutch end plate lowered and lift it up to the snap recheck.
  • Page 676 Secondary Gear Shaft 14-122 25 x 35 mm Thrust Shim Selection Measure the distance between the flywheel housing Calculate 25 x 35 mm thrust shim thickness by surface and the ball bearing as shown, then note the following formula. measurement (Measurement A) FORMULA: 25 x 35 mm Thrust Shim Thickness = Measure A - Measure B + Flywheel...

  • Page 677: Ball Bearing

    Differential 14-123 Illustrated Index 10 x 1.5 mm, BOLT, 98.0 Nm (10.0 kgf/m, 72.3 lbf/ft) Left-hand threads FINAL DRIVEN GEAR, Inspect for excessive wear. BALL BEARING DIFFERENTIAL CARRIER, Inspect for cracks BALL BEARING SET RING, 80 mm, Selective part. TRANSFER DRIVE GEAR, Inspect for excessive wear. FINAL DRIVEN GEAR, Inspect for excessive wear.
  • Page 679 Bearing Replacement Differential 14-124 Backlash Inspection Place the differential assembly on V-blocks and install NOTE: Check the bearings for wear and rough rotation, both axles. if the bearing is OK, removal is not necessary. Set a dial indicator to the pinion gear. Remove the bearings using the bearing puller Check the backlash of the pinion gears.

  • Page 680: Differential Carrier

    Differential 14-125 Differential Carrier Replacement 4WD: Remove the final driven gear from the differential carrier. Remove the transfer drive gear and the final driven NOTE: The final driven gear bolts have left-hand threads. gear from the differential carrier. Install the final driven gear with its chamfered side on NOTE: The final driven gear bolts have left-hand the inner bore facing the differential carrier.

  • Page 682: Flywheel Housing

    Oil Seal Installation Differential 14-126 Oil Seal Removal Remove the differential assembly. Install the oil seal in the transmission housing Remove the oil seal from the transmission housing. using the special tools. OIL SEAL, Replace. TRANSMISSION HOUSING Remove the oil seal from the flywheel housing. HANDLE DRIVER, 07749-0010000 DRIVER ATTACHMENT, 78 x 80 mm, 07NAD-PX40100 PITOT, 26 x 30 mm, 07JAD-PH80200...
  • Page 684 Differential 14-127 Side Clearance Inspection Install the 2.50 mm (0.098 in) thick 80 mm set ring in the Install the flywheel housing with new gasket, dowel transmission housing. pins an connector bracket. NOTE: Do not install the oil seal. Tighten the bolts to the specified torque. SET RING, 80 mm, Selective part.
  • Page 685 Differential Flywheel Housing Input 14-128 Side Clearance Inspection (cont’d) Shaft Oil Seal Replacement Measure the side clearance between the 80 mm set ring Remove the input shaft oil seal from the flywheel and outer race of the ball bearing in the transmission housing.
  • Page 686 Transmission Housing Bearings 14-129 Driven Pulley Shaft Bearing Replacement To remove the driven pulley shaft bearing from the Expand the snap ring with snap ring pliers, insert transmission housing, expand the snap ring with snap the new bearing part-way into the housing using ring pliers, then push the bearing out using the special the special tools and a press as shown.
  • Page 687 Transmission Housing Bearings Flywheel Housing Bearing 14-130 Secondary Gear Shaft Bearing Replacement Secondary Gear Shaft Bearing Replacement Remove the secondary gear shaft bearing using the Remove the secondary gear shaft bearing using special tool as shown. the special tool as shown. ADJUSTABLE BEARING REMOVER SET, 07JAC-PH80000 SECONDARY GEAR SHAFT BEARING FLYWHEEL HOUSING...
  • Page 688 Ring Gear Bearing Control Shaft Assembly 14-131 Replacement Removal/Installation Remove the ring gear bearing. Remove the bolt and lock washer, then remove the roller. Remove the control lever from the control shaft. Remove the control shaft assembly. Install the control shaft assembly in the transmission housing.
  • Page 689 Transfer Assembly 14-132 Illustrated Index...
  • Page 690 Pressure Testing 14-133 (cont’d) Transfer housing. 17 Transfer cover B O-ring Replace. 18 O-ring Replace. Transfer housing roller bearing 19 Transfer driven gear shaft (Hypoid gear) Transfer shaft 20 Thrust shim, 35 mm Selective part. Tapered roller bearing out race 21 Tapered roller bearing.
  • Page 691 Transfer Assembly 14-134 Inspection NOTE: To prevent damage to the transfer housing, always Transfer Gear (Hypoid gear) Tooth Contract use soft jaws or equivalent materials between the transfer Inspection housing and the vice. Remove transfer cover B, then apply Prussian Blue Transfer Gear (Hypoid gear) Backlash Measurement to both sides of the transfer gear teeth lightly and Set a dial indicator on the companion flange as shown.
  • Page 692 Transfer Assembly 14-135 Disassembly Remove the transfer covers A and B. Put a 14 mm Allen wrench in the gear side of the transfer shaft, then secure the Allen wrench in a bench vice. Remove the transfer shaft locknut and the conical spring washer.
  • Page 693 Transfer Assembly 14-136 Disassembly (cont’d) Secure the transfer housing in a bench vice with soft Remove the transfer driven gear shaft, then jaws. To prevent damage to the transfer housing, always remove the transfer spacer from the transfer driven use soft jaws or equivalent materials between the gear shaft.
  • Page 694 Transfer Driven Gear Shaft Transfer Assembly 14-137 Bearing Replacement Transfer Drive Gear Bearing Replacement NOTE: Coat all parts with transmission fluid during NOTE: Coat all parts with transmission fluid during reassembly. reassembly. Remove the tapered roller bearing from the transfer Remove the tapered droller bearing from the drive gear using the special tools and a press.
  • Page 695 Transfer Cover A Bearing Outer Transfer Assembly 14-138 Race Replacement Transfer Housing Roller Bearing Replacement NOTE: Coat all parts with transmission fluid during NOTE: Coat all parts with transmission fluid during reassembly. reassembly. Remove the roller bearing from the transfer housing. Remove the tapered roller bearing outer race from transfer cover A by heating the cover to almost 100°C (212°F) using a heat gun.

  • Page 696: Transfer Assembly

    Transfer Assembly 14-139 Transfer Housing Bearing Outer Race Replacement NOTE: Coat all parts with transmission fluid during Bearing Outer Race Locations and Special Tool reassembly. Applications. Remove the tapered roller bearing outer race from the transfer housing. TRANSFER HOUSING BEARING OUTER RACE TRANSFER HOUSING, Sectional view DRIVER ATTACHMENT, 62 x 68 mm, 07746-0010500 Install the new tapered roller bearing outer race using...
  • Page 697 Transfer Assembly 14-140 Reassembly NOTE: EXAMPLE: While reassembly the transfer assembly: Check and adjust the transfer gear tooth contact. Measure and adjust the transfer gear backlash Check and adjust the tapered roller bearing starting torque. Coat all parts with transmission fluid during reassembly. Replace the tapered roller bearing and the bearing outer race a set if either part is replaced.
  • Page 698 Transfer Assembly 14-141 Reassembly (cont’d) Transfer Gear Backlash Inspection and Transfer Gear Install the transfer driven gear shaft in the transfer housing. Do not install the transfer spacer on the Tooth Contact Inspection transfer driven gear shaft in this step. Install the 35 mm thrust shim on the transfer driven gear shaft, then install the tapered roller bearing using the special tools and a press.

  • Page 699: Starting Torque

    Transfer Assembly 14-142 Reassembly (cont’d) Secure the transfer housing in a bench vice with soft Install the transfer shaft in the transfer housing, jaws, then install the special tool on the companion then install the tapered roller bearing, transfer shaft flange.
  • Page 700 Transfer Assembly 14-143 Reassembly (cont’d) 10. Put a 14 mm Allen wrench in the gear side of the 13. Rotate the companion flange several times to seat transfer shaft, then secure the Allen wrench in a bench the tapered roller bearing. vice.
  • Page 701 Transfer Assembly 14-144 Reassembly (cont’d) 16 Apply Prussian Blue to both sides of the transfer gear 19. If the transfer gear tooth contact is incorrect, adjust teeth lightly and evenly. the transfer gear tooth contact with a 35 mm or 25 mm thrust shim.
  • Page 702 Transfer Assembly 14-145 Reassembly (cont’d) 20. Remove the parts on the transfer shaft and remove the 23. Remove the transfer driven gear shaft and the transfer shaft from the transfer housing. companion flange. 24. Install the new transfer spacer on the transfer driven gear shaft, then install them in the transfer housing.
  • Page 703 Transfer Assembly 14-146 Reassembly (cont’d) 26. Secure the transfer housing in a bench vice with soft 28. Stake the locknut into the transfer driven gear shaft jaws. To prevent damage, always use soft jaws or using a 3.5 mm punch as shown. equivalent materials between the transfer housing and the vice.
  • Page 704 Transfer Assembly 14-147 Reassembly (cont’d) 30. Put a 14 mm Allen wrench in the gear side of the Total Starting Torque Inspection and Adjustment transfer shaft, then secure the Allen wrench in a bench 32. Temporarily install transfer cover A without the vice.
  • Page 705 Transfer Assembly 14-148 Reassembly (cont’d) 35. Remove transfer cover A. 37. Select the 68 mm thrust shim. 36. If the measurement is out of specification, remove the Shim No. Part Number Thickness 68 mm thrust shim from transfer cover A by heating the 23974-P1C 020 1.41 mm (0.056 in) cover to almost 100°C (212°F) using a heat gun, Do not...
  • Page 706 Transfer Assembly 14-149 Reassembly (cont’d) 38. Install the 68 mm thrust shim using the special tools. 40. Install the new O-rings on transfer covers A and B, then install the covers on the transfer housing. PRESS HANDLE DRIVER, 07749-0010000 THRUST SHIM, 68 mm, Selective part BEARING OUTER RACE DRIVER ATTACHMENT, 62 x 68 mm, 07746-0010500 TRANSFER COVER A...

  • Page 707: Transmission Reassembly

    Transmission 14-150 Reassembly While reassembling, be sure not to allow dust and other foreign particles to enter into the transmission. NOTE: Coat all parts with transmission fluid. Replace the following parts: O-rings Sealing rings Sealing washers Gaskets Start clutch assembly and Secondary drive gear assembly 1.
  • Page 708 Transmission 14-151 Reassembly (cont’d) Install the ATF feed pip in the transmission housing and Compress the return springs, then install the snap install the three ATF feed pipes with new O-rings in the ring in the intermediate housing above the spring transmission housing.
  • Page 709 Transmission 14-152 Reassembly (cont’d) 15. If the clearance is not within the standard, remove the 22. Verify that the outside diameter of the snap ring is reverse brake end plate and measure its thickness. correct. 16. Select and install a new reverse brake end plate, then recheck.
  • Page 710 Transmission 14-153 Reassembly (cont’d) 26. Install the thrust washer, the thrust needle bearing. and 30. If the clearance is out of tolerance, remove the 25 the thrust washer on the carrier assembly. x 31 mm thrust shim and measure its thickness. 31.
  • Page 711 Transmission 14-154 Reassembly (cont’d) 32. After replacing the 25 x 31 mm thrust shim, make sure 36. Install the manual valve body lines A and B with that the clearance is within the tolerance and the snap new O-rings on the manual valve body and the ring outside diameter is correct as described in the step intermediate housing.
  • Page 712 Transmission 14-155 Reassembly (cont’d) Install the parking brake pawl, pawl spring and pawl 41. Wrap the driven pulley shaft splines with tape to shaft on the transmission housing, then move the control prevent damage to the O-rings, then install the new O-rings.
  • Page 713 Transmission 14-156 Reassembly (cont’d) 44. Push the handle of the special tool, then tighten the nut 47. If the clearance is not within the standard, remove to seat the secondary drive gear assembly on the drive the cotters and measure their thickness. pulley shaft securely.
  • Page 714 Transmission 14-157 Reassembly (cont’d) 53. Verify that the outside diameter of the snap ring is 57. After replacing the 22 x 28 mm thrust shim, make correct. sure that the clearance is within tolerance and the snap ring outside diameter is correct. 58.

  • Page 715: Connector Bracket

    Transmission 14-158 Reassembly (cont’d) 60. Install the differential assembly. 61. Install the ATF passage pipe assembly with new O-rings. 62. Install the three dowel pins and new flywheel gasket on the transmission housing. 63. Install the flywheel housing on the transmission housing. 64.
  • Page 716 Transmission 14-159 Reassembly (cont’d) 66. Install the solenoid harness connector with new O-ring and install the lower valve body assembly with three dowel pins and eight bolts. 67. Install the ATF strainer with new O-ring and two bolts. 68. If necessary, assemble the ATF pan, ATF filter and the ATF cooler inlet line ( See Page 14-88).
  • Page 717 Transmission 14-160 Reassembly (cont’d) 71. Install the breather cap on the breather pipe so its arrow NOTE: Steps 72 and 73 are applied to 4WD points to the flywheel housing transmission. 72. Clean the areas where the transfer assembly contacts the transmission with solvent or carburetor cleaner and dry them with compressed air, then apply to contact areas with transmission fluid.
  • Page 718 Flywheel Drive Plate 14-161 1. DRIVE PLATE 2. WASHER Install in this direction. 3. FLYWHEEL Inspect the teeth of the ring gear for excessive wear. 4. 12 x 1.0 mm, 74 Nm (7.5 kgf/m, 54 lbf/ft) Torque in a criss-cross pattern.
  • Page 719 Transmission 14-162 Installation Remove the used grease in the flywheel hub cap and Place the transmission on a jack and raise it to the flywheel splines. engine assembly level. Fill the inside of the flywheel hub cap and coat the Attach the transmission on the engine, then install flywheel hub splines with Super Urea Grease (P/N the transmission housing mounting bolt.
  • Page 720 Transmission 14-163 Installation (cont’d) Install the right front mount/bracket. 11. Remove the transmission jack and the hoist, then Connect the ATF cooler hoses to the ATF cooler lines remove the hoist bracket from the engine. 12. Attach the flywheel to the drive plate with eight (See Page 14-173).

  • Page 721: Intermediate Shaft

    Transmission 14-164 Installation (cont’d) 15. Install new set rings on the ends of the intermediate 19. Install the propeller shaft to the transfer assembly shaft and the right driveshaft (see section 18). by aligning the reference mark. 16. Install the intermediate shaft. NOTE: While installing the intermediate shaft in the differential, be sure not to allow dust and other...
  • Page 723 Transmission 14-165 Installation (cont’d) 21. Install the rear beam 25. Install the splash shield. CLIP SPLASH SHIELD 6 x 10 mm, 12 Nm (1.2 kgf/m, 8.7 lbf/ft) REAR BEAM 26. Install the shift cable bracket on the transmission. 12 x 1.25 mm, 64 Nm (6.5 kgf/m, 47 lbf/ft) 27.
  • Page 724 Transmission 14-166 Installation (cont’d) 28. Connect the secondary gear shaft speed sensor, driven 30. Connect the starter cables on the starter with ring pulley speed sensor, ECT sensor and VSS connectors, terminal crimped side facing out. then install the harness clamp bracket. CLAMP BRACKET VSS CONNECTOR STARTER...
  • Page 725 Shift Cable 14-167 Adjustment Check that the hole in the adjuster is perfectly aligned with the hole in the shift cable. There are two holes in the adjuster. They are positioned 90° Make sure lifts, jacks and safety stands are placed properly apart to allow cable adjustment in 1/4 turn (see section 1).
  • Page 726 Shift Cable 14-168 Replacement Remove the clip from the shift cable end, then separate the able end from the control lever. Remove the shift cable bracket with shift cable. Do Make sure lifts, jacks and safety stands are placed properly not bend the shift cable excessively.

  • Page 727: Shift Lever

    Shift Cable Shift Lever 14-169 Replacement (cont’d) Removal/Installation Remove the bolts securing the shift cable brackets. Make sure lifts, jacks and safety stands are placed properly (see section 1). Raise the front of the vehicle and make sure it is securely supported.
  • Page 728 Shift Lever 14-170 Disassembly - KG Model 1. PUSH KNOB 2. SPRING 3. SHIFT LEVER KNOB 4. SCREW 3 Nm (0.3 kgf/m, 2 lbf/ft) Apply non-hardening thread lock sealant. 5. A/T GEAR POSITION INDICATOR PANEL 6. LEVER COVER 7. BUSHING SILICONE GREASE 8.
  • Page 729 Shift Lever 14-171 Disassembly - KE Model 1. SCREW 3 Nm (0.3 kgf/m, 2 lbf/ft) Apply non-hardening thread lock sealant. 2. SHIFT LEVER KNOB 3. SPRING 4. SILICONE GREASE 5. PUSH KNOB 6. A/T GEAR POSITION INDICATOR PANEL 7. LEVER COVER 8.
  • Page 730 Shift Lever 14-172 Disassembly - KG and KU Models 1. SCREW 3 Nm (0.3 kgf/m, 2 lbf/ft) Apply non-hardening thread lock sealant. 2. SHIFT LEVER KNOB 3. SPRING 4. SILICONE GREASE 5. PUSH KNOB 6. PARKING PIN SWITCH CONNECTOR 7. A/T GEAR POSITION INDICATOR PANEL 8.
  • Page 731 Shift Indicator Panel ATF Cooler Hoses 14-173 Adjustment Installation Check that the index mark on the shift lever aligns with Apply transmission fluid to the junction between the ATF cooler line and ATF cooler hose inner. index mark on the shift indicator panel when the Connect the ATF cooler hoses to the ATF cooler transmission is in position.
  • Page 733 Start the engine, shift the transmission to 3rd gear (manual transmission) or to position (CVT/Honda Multi Matic), accelerate the vehicle gradually and measure the vehicle speed. After measurement, use the brake pedal to gradually decelerate and stop the vehicle.

  • Page 734: Special Tools

    Special Tools 15-3 | Ref No. Tool Number Description | Qty Remark | 07GAD - PH70201 | Oil Seal Driver | 07JAD - PL90100 | Oil Seal Driver | 07NAD - PX40100 | Driver Attachment, 78 x 80 mm | 07PAB - 0020000 | Companion Flange Holder | 07749 - 0010000 | Handle Driver...
  • Page 735 The oil pumps are designed so that the fluid intake works as an fluid discharge when the oil pumps rotate in reverse. Genuine Honda ATR PREMIUM (Automatic Transmission Fluid PREMIUM) is used instead of differential fluid.

  • Page 736: Rear Differential Assembly

    Description 15-5 Rear Differential (cont’d) REAR DIFFERENTIAL ASSEMBLY 1. CLUTCH GUIDE 2. DIFFERENTIAL CLUTCH ASSEMBLY 3. OIL PUMP BODY 4. TORQUE CONTROL DIFFERENTIAL CASE 5. HYPOID DRIVE PINION GEAR 6. DIFFERENTIAL CARRIER 7. DIFFERENTIAL 8. HYPOID RING GEAR 9. DIFFERENTIAL HOUSING 10.
  • Page 737 Description 15-6 Hydraulic Flow Forward Start and Acceleration (4WD) 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. Some of the discharged fluid is drawn in by the rear oil pump.

  • Page 738: Rear Oil Pump

    Description 15-7 Hydraulic Flow (cont’d) Forward Deceleration (2WD) During a forward deceleration, the dual pump system functions in two wheel drive mode. Because of the braking characteristics, the speed of the rear wheels may exceed the speed of the front wheels during deceleration. If so , the rear oil pump spins faster than the front oil pump.
  • Page 739 Description 15-8 Hydraulic Flow (cont’d) Reverse Driving at Constant Speed (2WD) When driving in reverse at a constant speed, the dual pump system functions in two wheel 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, but, because there is a difference in the capacity between the two pumps, fluid flows through check valve E and then through orifices.

  • Page 740: Relief Valve

    Description 15-9 Hydraulic Flow (cont’d) Thermal Switch Operation (2WD) 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 to 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 741: Propeller Shaft

    Real-time 4WD-Dual Pump System 15-10 Troubleshooting When starting and accelerating in forward gears (4WD Automatic Transmission: mode) Lift up the vehicle so all four wheels are off the ground (see section 1). Manual Transmission: Lift up the vehicle so all four wheels are off the ground (see section 1).
  • Page 742 Real-time 4WD-Dual Pump System 15-11 Troubleshooting (cont’d) When starting and accelerating in reverse gear (4WD Automatic Transmission: mode) Lift up the vehicle so all four wheels are off the ground (see section 1). Manual Transmission: Lift up the vehicle so all four wheels are off the ground (see section 1).
  • Page 743 Real-time 4WD-Dual Pump System 15-12 Troubleshooting (cont’d) When decelerating in a forward gear (2WD mode) When decelerating in reverse gear (4WD mode) Block the front wheels, raise the left rear wheel and Block the front wheels, raise the left rear wheel and support it with a safety stand as shown.
  • Page 744 Rear Differential Assembly 15-13 Troubleshooting 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. Symptom Probable Cause Remedy | Will not go into 4WD mode...
  • Page 745 Fluid Capacity 1.0 L (1.1 US qt, 0.9 Imp qt) at fluid change 1.2 L (1.3 US qt, 1.1 Imp qt) at overhaul Recommended fluid: Genuine Honda ATF PREMIUM (Automatic Transmission Fluid-PREMIUM) WASHER, Replace Proper level OIL FILLER PLUG, 47Nm (4.8 kgf/m, 35 lbf/ft) The fluid level must be up to the fill hole.
  • Page 746 Rear Differential Assembly 15-15 Removal Raise the front of the vehicle and support it with safety Disconnect the breather tube from the rear stands in the proper locations (see section 1). differential. Drain the rear differential oil (See page 15-14). Make a reference mark across the propeller shaft and the rear differential flanges.

  • Page 747: Differential Housing

    Rear Differential Assembly 15-16 Removal (cont’d) Leak Repair Remove the two rear differential mount B mounting bolts. Remove the bolts in a crisscross pattern, then remove the differential housing. MOUNTING BOLTS Pry the driveshaft assembly with a screwdriver, as shown, to force the set ring at the driveshaft end past the groove.
  • Page 748 Rear Differential Assembly 15-17 Illustrated Index 1. LOCKNUT, 24 mm Replace 118 Nm, (12.0 kgf/m, 87 lbf/ft) 2. BACK-UP RING 3. O-RING, Replace 4. COMPANION FLANGE 5. 6 x 1.0 mm, 12 Nm (1.2 kgf/m, 8.7 lbf/ft) 6. TORQUE CONTROL DIFFERENTIAL 7.
  • Page 749 Rear Differential Assembly 15-18 Oil Seals Replacement Remove the oil seals from the differential housing. Install the oil seals squarely using the special tools. Be careful no to damage the lip of the oil seals. Right side: Right side: Installation depth of the oil seal is 9 mm (0.35 in) below the edge of the differential housing.
  • Page 750 Disassembly Rear Differential Assembly 15-19 Oil Seals Replacement (cont’d) Remove the oil seal from the torque control differential Remove the drain plug and the oil filler plug. case. OIL FILLER PLUG DRAIN PLUG OIL SEAL, Replace WASHERS, Replace TORQUE CONTROL DIFFERENTIAL CASE Raise the locknut from the groove of the clutch Install the oil seal squarely using the special tool.
  • Page 751 Rear Differential Assembly 15-20 Disassembly (cont’d) Install the special tool on the companion flange. Remove the locknut, the disc spring washer, the back-up ring, the O-ring and the companion flange. COMPANION FLANGE HOLDER, 07PAB-0020000 8 x 1.25 mm, 32 Nm (3.3 kgf/m, 24 lbf/ft) Loosen the locknut counterclockwise so that its tab comes out from the groove in the clutch guide.
  • Page 752 Rear Differential Assembly 15-21 Disassembly (cont’d) Remove the shim and the clutch guide. 11. Remove the thrust needle bearing and the oil pump driveshaft. SHIM, 30 mm CLUTCH GUIDE 10. Remove the clutch hub/plates/discs and the pressure plate. THRUST NEEDLE BEARING OIL PUMP DRIVESHAFT 12.
  • Page 753 Rear Differential Assembly 15-22 Reassembly Apply CVT fluid to the rubber of the oil strainer, then Tighten the oil pump body assembly mounting install the oil strainer, the magnet and the oil pump pin to bolts. the differential carrier. Install the oil pump driveshaft by aligning the projection of the oil pump driveshaft with the groove of the front oil pump in the oil pump body assembly.
  • Page 754 Rear Differential Assembly 15-23 Reassembly (cont’d) Install the clutch hub/plates/discs then align the 10. Install the dowel pins and torque control differential. projection of the plates with the discs. SHIM, 30 mm 6 x 1.0 mm, 12 Nm (1.2 kgf/m, 8.7lbf/ft) CLUTCH GUIDE TORQUE CONTROL DIFFERENTIAL CASE CLUTCH HUB/PLATES/DISCS...
  • Page 755 Rear Differential Assembly 15-24 Reassembly (cont’d) 12. Install the special tool to the companion flange, then 14. Install the drain plug and the oil filler plug with new tighten the locknut to specified torque. washers. TORQUE: 118 Nm (12.0 kgf/m, 87 lbf/ft) COMPANION FLANGE HOLDER, 07PAB-0020000 OIL FILLER PLUG, 47 Nm (4.8 kgf/m, 35 lbf/ft) 8 x 1.25 mm, 32 Nm (3.3 kgf/m, 24 lbf/ft)
  • Page 756 Rear Differential Assembly 15-25 Illustrated Index NOTE: When installing the rear differential and mount assemblies, tighten the rear differential mount B mounting bolts (A) first, then the rear differential mount rubber A mounting bolts (B). 1. REAR DIFFERENTIAL MOUNT B 2.
  • Page 757 Rear Differential Assembly 15-26 Installation Place the rear differential on the transmission jack and Install the four rear differential mount A mounting raise it to the mounting level. bolts. Clean the areas where the driveshaft contacts the differential thoroughly with solvent or carburettor cleaner and dry with compressed air.
  • Page 758 Rear Differential Assembly 15-27 Installation (cont’d) Hold the stabiliser link ball joint pin with a hexagonal wrench and install the flange nut. STABILISER LINK HEXAGONAL WRENCH 10 x 1.25 mm, 29 Nm (3.0 kgf/m, 22 lbf/ft) REAR STABILISER Install the propeller shaft to the rear differential by aligning the reference marks.

  • Page 760: Special Tools

    Special Tools 16-2 | Ref No. Tool Number Description | Qty Remark | 07JAC - SJ60200 | Hub Puller Attachment | 07LAD - PW50601 | Inner Race Driver, 40 x 45 mm | 07MAC - SL00200 | Ball Joint Remover, 28 mm | 07NAF - SR30101 | Half Shaft Base | 07XAC - 0010100...
  • Page 761 Driveshafts 16-3 Inspection Removal Check the inboard boot and outboard boot on the Loosen the wheel nuts slightly. driveshaft for cracks, damage, leaking grease and loose Raise the front of the vehicle and support it with boot bands. If any damage is found, replace the boot safety stands in the proper location (see section 1).
  • Page 762 Driveshafts 16-4 Removal (cont’d) Remove the cotter pin from the lower arm ball joint 11. Prey the driveshaft assembly with a screwdriver as castle nut and remove the nut. shown, to force the set ring at the driveshaft end Separate the ball joint from the lower arm with the past the groove.
  • Page 763 Driveshafts 16-5 Disassembly Inboard Joint Side: Make a mark on each roller and inboard joint to identify the locations of rollers and grooves in the Remove the set ring from the inboard joint. inboard joint. The remove the inboard joint and place on the shop towel.
  • Page 764 Driveshafts 16-6 Disassembly (cont’d) Wrap the splines on the driveshaft with vinyl tape to Outboard Joint Side: prevent damage to the inboard boot and dynamic Lift up the three tabs with a screwdriver, then damper. remove the boot bands. Take care not to damage Remove the inboard boot and dynamic damper.
  • Page 765 Driveshafts 16-7 Disassembly (cont’d) Wipe off the grease to expose the driveshaft and the Remove the stop ring from the driveshaft. outboard joint inner race. Make a mark on the driveshaft at the same position of the outboard joint end with paint. DRIVESHAFT STOP RING, Replace Wrap the splines on the driveshaft with vinyl tape...
  • Page 766 Driveshafts 16-8 Reassembly NOTE: Clean the disassembled parts with solvent and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent. Thoroughly pack both joints and both joint boots with the joint grease included in the new driveshaft set. The driveshaft uses a TPE (Thermoplastic Polyester Elastomer) outboard joint boot.
  • Page 767 Driveshafts 16-9 Reassembly (cont’d) Inboard Joint Side: Fit the rollers to the spider with their high shoulders facing outward and note the following items: Wrap the splines with vinyl tape to prevent damage to Reinstall the rollers in their original positions the inboard boot and dynamic damper.
  • Page 768 Driveshafts 16-10 Reassembly (cont’d) Fit the inboard joint onto the driveshaft and note the Position the dynamic damper as shown below. following items: Standard: Reinstall the inboard joint onto the driveshaft by Left driveshaft: 251 - 255 mm (9.9 - 10.0 in) aligning the marks on the inboard joint and the Right driveshaft: 242 - 246 mm (9.5 - 9.7 in) rollers.
  • Page 769 Driveshafts 16-11 Reassembly (cont’d) 11. Pull up the slack in the band by hand. 15. Lift up the band tightening tool to bend the free end 12. Mark a position on the band 10 -14 mm (0.4 - 0.6 in) of the band 90°...
  • Page 770 Driveshafts 16-12 Reassembly (cont’d) 17. Bend the band end by tapping it down with a hammer. Outboard Joint Side: NOTE: Wrap the splines with vinyl tape to prevent damage Make sure the band and clip do not interfere with to the outboard boot. anything and the band does not move.
  • Page 771 Driveshafts 16-13 Reassembly (cont’d) Insert the driveshaft into the outboard joint until the stop Check the alignment of the paint mark with the ring is close to the joint. outboard joint end. PAINT MARK DRIVESHAFT OUTBOARD JOINT END Pack the outboard joint with the joint grease STOP RING, Replace included in the new joint boot set.
  • Page 773 Driveshafts 16-14 Reassembly (cont’d) Fit the boot ends onto the driveshaft and outboard joint. 11. Close the ear portion of the band with (commercially available) boot band pincers. OUTBOARD JOINT BOOT BAND PINCERS OUTBOARD BOOT (Commercially available) KENT-MOORE J-35910 or equivalent OUTBOARD BOOT EAR PORTION DRIVESHAFT...
  • Page 774 Driveshafts 16-15 Installation Install a new set ring onto the set ring groove of the Install the outboard joint into the front hub. driveshaft. SET RING, Replace Clean the areas where the driveshaft contacts the differential thoroughly with solvent or carburettor cleaner and dry with compressed air.

  • Page 775: Front Wheel

    Driveshafts 16-16 Installation (cont’d) Connect the front stabiliser link and front stabiliser, then Clean the mating surfaces of the brake disc and hold the stabiliser link ball joint pin with a hexagonal the front wheel, then install the front wheel with the wrench and tighten the flange nut.

  • Page 776: Rear Driveshaft Removal

    Rear Driveshaft 16-17 Removal Disassembly Loosen the wheel nuts slightly. Inboard Joint Side: Raise the rear of the vehicle and support it with safety Remove the set ring from the inboard joint. stands in the proper location (see section 1). Remove the wheel nuts and rear wheels.
  • Page 777 Rear Driveshaft 16-18 Disassembly (cont’d) Remove the snap ring from the inboard joint. Remove the bearing race from the driveshaft using Place reference marks on the inboard joint and the a commercially available bearing remover. bearing retainer as shown. Wrap the inboard joint with Remove the bearing retainer.
  • Page 778 Rear Driveshaft 16-19 Disassembly (cont’d) Outboard Joint Side: Wipe off the grease to expose the driveshaft and the outboard joint inner race. Remove the boot bands. Take care not to damage the Make a mark on the driveshaft at the same boot and dynamic damper.
  • Page 779 Rear Driveshaft 16-20 Disassembly (cont’d) Remove the stop ring from the driveshaft. DRIVESHAFT STOP RING, Replace Wrap the splines on the driveshaft with vinyl tape to prevent damage to the outboard boot and dynamic damper. Remove the outboard boot. Take care not to damage the boot.
  • Page 780 Rear Driveshaft 16-21 Reassembly Note the following items during reassembly: Clean the disassembled parts with solvent and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent. Thoroughly pack both joints and both joint boots with the joint grease included in the new driveshaft set. Grease quantity Inboard joint: 45 - 65 g (1.6 - 2.3 oz) Outboard joint: 30 -40 g (1.1 - 1.4 oz)
  • Page 781 Rear Driveshaft 16-22 Reassembly (cont’d) Inboard Joint Side: Fit the circlip into the driveshaft groove. Always rotate the circlip in its groove to be sure it is fully Wrap the splines with vinyl tape to prevent damage to seated. the inboard boot. Position the bearing retainer on the bearing race Install the inboard boot to the driveshaft, then remove the vinyl tape.
  • Page 782 Rear Driveshaft 16-23 Reassembly (cont’d) Install the inboard joint onto the driveshaft by aligning 12. Fit the boot ends onto the driveshaft and the the marks on the inboard joint with the marks on the inboard joint, then install the boot bands with the bearing retainer.
  • Page 783 Rear Driveshaft 16-24 Reassembly (cont’d) 15. Thread the free end of the band through the nose 18. Unwind the band tightening tool and cut off the section of the commercially available boot band tool excess free end of the band to leave a 5 - 10 mm KD-3191 or equivalent and into the slot on the winding (0.2 - 0.5 in) tail protruding from the clip.
  • Page 784 Rear Driveshaft 16-25 Reassembly (cont’d) 20. Install the new set ring. Outboard Joint Side: Wrap the splines with vinyl tape to prevent damage to the outboard boot. Install the outboard boot. Take care not to damage the outboard boot. Remove the vinyl tape. SET RING, Replace DRIVESHAFT VINYL TAPE...
  • Page 785 Rear Driveshaft 16-26 Reassembly (cont’d) Insert the driveshaft into the outboard joint until the stop Check the alignment of the paint mark with the ring is close to the joint. outboard joint end. PAINT MARK DRIVESHAFT OUTBOARD JOINT END Pack the outboard joint with the joint grease included in the new joint boot set.
  • Page 786 Rear Driveshaft 16-27 Reassembly (cont’d) Fit the boot ends onto the driveshaft and outboard joint. 11. Pull up the slack in the band by hand. 12. Mark a position on the band 10 -14 mm (0.4 - 0.6 in) from the clip. OUTBOARD JOINT OUTBOARD BOOT CLIP...
  • Page 787 Rear Driveshaft 16-28 Reassembly (cont’d) 15. Lift up the band tightening tool to bend the free end of 17. Bend the band end by tapping it down with a the band 90° to the clip. Centre punch the clip then fold hammer.

  • Page 788: Rear Driveshaft Installation

    Rear Driveshaft 16-29 Installation Install the set ring on the outboard joint. Install the two backing plate mounting bolts. SET RING, Replace INBOARD JOINT Install the rear driveshaft using the special tool as shown. 10 x 1.25 mm, 64 Nm (6.5 kgf/m, 47 lbf/ft) Install the rear hub bearing unit (see section 18).
  • Page 789 Intermediate Shaft 16-30 Removal Installation Drain the MTF (see section 13) or ATF (see section 14). Clean the areas where the intermediate shaft contacts the transmission (differential) thoroughly Remove the left driveshaft (See page 16-3). with solvent or carburettor cleaner and dry with Remove the three dowel bolts.

  • Page 790: Intermediate Shaft Disassembly

    Intermediate Shaft 16-31 Disassembly NOTE: Be careful not to damage the metal rings on the Press the intermediate shaft bearing out of the intermediate shaft during disassembly. bearing support using the special tools and a press Remove the set ring. as shown.

  • Page 791: Intermediate Shaft Reassembly

    Intermediate Shaft 16-32 Reassembly NOTE: Clean the disassembled parts with solvent and dry them thoroughly with compressed air. Do not wash the rubber parts with solvent. Be careful not to damage the metal rings on the intermediate shaft during reassembly. 1.
  • Page 792 Intermediate Shaft 16-33 Reassembly (cont’d) Press the intermediate shaft bearing into the bearing Seat the external circlip in the groove of the support using the special tools and a press as shown. intermediate shaft. Install the outer seal into the bearing support using the special tools as shown.
  • Page 793 Propeller Shaft 16-34 Inspection Rear Propeller Shaft: Shift into the neutral position (M/T or position (A/T). Raise the vehicle off the ground and support it with safety sands in the proper locations (see section 1). Check the centre support bearing for excessive play or rattle.
  • Page 794 Propeller Shaft 16-35 Removal Raise the vehicle off the ground and support it with Remove the two centre bearing support mounting safety stand in the proper locations (see section 1). bolts, then remove the propeller shaft. Make a reference mark across the propeller shaft and the transfer flanges.

  • Page 795: Propeller Shaft Installation

    Propeller Shaft 16-36 Installation Install the centre bearing support. Install the propeller shaft to the transfer by aligning the reference marks. CENTRE BEARING SUPPORT 10 x 1.25 mm, 39 Nm (4.0 kgf/m, 29 lbf/ft) Install the propeller shaft to the rear differential by aligning the reference marks.

  • Page 797: Special Tools

    Special Tools 17-2 | Ref No. Tool Number Description | Qty Remark | 07JGG - 0010100 | Belt Tension Gauge | 07MAA - SL00100 | Locknut wrench, 40 mm | 07MAC - SL00200 | Ball Joint Remove, 28 mm | 07NAD - SR30101 | Driver Handle | 07NAD - SR30200 | End Packing Remover...
  • Page 798 Component Locations 17-3 Index Note these items during disassembly: If an intact airbag assembly has been removed from a scrapped car or has been found defective or damaged during transit, storage or service, it should be deployed (see section 24). Before removing the gearbox, remove the driver's airbag assembly and steering wheel.
  • Page 799 Component Locations 17-4 Index (cont’d) Note these items during disassembly: If an intact airbag assembly has been removed from a scrapped car or has been found defective or damaged during transit, storage or service, it should be deployed (see section 24).
  • Page 800 Troubleshooting 17-5 General Troubleshooting Check the following before you begin: Has the suspension been modified in a way that would affect steering? Are tyre sizes, tyre variety and air pressure correct? Is the steering wheel original equipment? Is the power steering pump belt properly adjusted? Is steering fluid reservoir filled to proper level? Is the engine idle speed correct and steady? To go to the pages referenced on the diagram above, click on the following:...
  • Page 801 Troubleshooting 17-6 General Troubleshooting (cont’d) To go to the pages referenced on the diagram above, click on the following: (See Page 17-14) (See Page 17-17) (See Page 17-19)
  • Page 802 Troubleshooting 17-7 General Troubleshooting (cont’d) To go to the pages referenced on the diagram above, click on the following: (See Page 17-16) (See Page 17-17)
  • Page 803 Troubleshooting 17-8 General Troubleshooting (cont’d)
  • Page 804 Troubleshooting 17-9 General Troubleshooting (cont’d) To go to the pages referenced on the diagram above, click on the following: (See Page 17-16) (See Page 17-17) (See Page 17-19)
  • Page 805 Troubleshooting 17-10 Noise and Vibration NOTE: Pump noise in first 2 - 3 minutes after starting in cold weather is normal. To go to the pages referenced on the diagram above, click on the following: (See page 17-17)
  • Page 806 Troubleshooting 17-11 Noise and Vibration (cont’d)
  • Page 807 Troubleshooting 17-12 Fluid Leaks Check the gearbox assembly for oil leaks carefully. Oil can leak out of various points, depending on location of the faulty oil seals/seal rings. Check the following before removing the gearbox from the frame.
  • Page 808 Troubleshooting 17-13 Fluid Leaks (cont’d)
  • Page 809 Inspection and Adjustment 17-14 Steering Operation Power Assist Check with Vehicle Parked Place the front wheels in the straight ahead position and Check the power steering fluid level (See page measure the distance the steering wheel can be turned 17-18) and pump belt tension (See page 17-16).
  • Page 810 Inspection and Adjustment 17-15 Steering Linkage and Gearbox NOTE: LHD type is shown, RHD type is symmetrical. 1. TIE-ROD END BALL JOINT Inspect for faulty movement and damage. 2. STEERING COLUMN Inspect for loose column mounting bolts and nuts. 3. STEERING JOINTS Check for loose joint bolts.

  • Page 811: Inspection

    Inspection and Adjustment 17-16 Pump Belt When using a new belt, first adjust the deflection or tensions Measurement without Belt Tension Gauge: to the values for the new belt, then readjust the deflection or Apply a force of 98 N (10 kgf, 22 lbf) and measure the tension to the values for the used belt after running engine for deflection between the power steering pump and the five minutes.

  • Page 812: Rear Mounting Bracket

    Inspection and Adjustment 17-17 Rack Guide Adjustment 1. Remove the rear beam. For vehicles with RHD; remove the shift cable clamp (CVT only). Remove the rear mounting bracket from the transmission housing. SHIFT CABLE (CVT) 1. REAR BEAM 9.8 Nm (1.0 kgf/m 7.2 lbf/ft) 2.

  • Page 813: System Capacity

    Take care not to spill the fluid on the body and parts. Wipe off spilled fluid at once. Use only Genuine Honda Power Steering Fluid (V, II or S). Using other fluids such as ATF or other manufacturer’s power steering fluid will damage the system.

  • Page 814: Shut-Off Valve

    Inspection and Adjustment 17-19 Pump Pressure Check Check the fluid pressure as follows to determine whether the Fully open the shut-off valve. trouble is in the pump or gearbox. Check the power steering fluid level (See Page 17-18) and pump belt tension (See Page 17-16).

  • Page 815: Steering Wheel

    Steering Wheel 17-20 Removal SRS components are located in this area. Review the SRS Loosen the steering wheel bolt, then install a component locations, precautions, and procedures in the steering wheel puller on the steering wheel and SRS section (24) before performing repairs or service. remove it.

  • Page 816: Steering Wheel Disassembly/Reassembly

    Steering Wheel 17-21 Disassembly/Reassembly 1. BOSS COVER PLATE 2. STEERING WHEEL 3. WHEEL LOWER COVER 4. BODY COVER CAP 5. ACCESS PANEL 6. MODE SELECT SWITCH (CVT only) 7. SWITCH PLATE...

  • Page 817: Installation

    Steering Wheel 17-22 Installation Before installing the steering wheel, make sure the front Install the steering wheel nut and tighten it to 49 wheels are aligned straight ahead, then centre the cable Nm (5.0 kgf/m, 36 lbf/ft). reel. Do this by first rotating the cable reel clockwise until Connect the horn connector and mode select it stops.
  • Page 818 Steering Column 17-23 Removal/Installation SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section (24) before performing repairs or service. Remove the driver’s airbag assembly and cable reel (see section 24). Remove the steering wheel (See page 17-20).

  • Page 819: Steering Column

    Steering Column 17-24 Removal/Installation (cont’d) 10. Install the steering column in the reverse of removal, and note these items: Be sure the wires are not caught or pinched by any parts when installing the column. Make sure the wire harness is routed and fastened properly.

  • Page 820: Inspection

    Steering Column 17-25 Inspection Check the steering column ball bearing and the steering joint bearings for play and proper movement. If there is noise or if there is excessive play, replace the steering column as an assembly. Check the retaining collar for damage, if it is damaged, replace the steering column as an assembly. Check the absorbing plates for distortion breakage.
  • Page 821 Steering Column 17-26 Inspection (cont’d) Steering Lock Replacement Move the tilt lever from the loose position to the lock Remove the steering column (See page 17-23). position 3 to 5 times; then measure the tilt lever preload Centre punch each of the two shear bolts, and drill 10 mm (0.4 in) from the end of the tilt lever.

  • Page 822: Power Steering Hoses, Lines Fluid Leakage Inspection

    Power Steering Hoses, Lines 17-27 Fluid Leakage Inspection 1. HOSES and LINES Inspect hoses for damage, leaks, interference and twisting. Inspect fluid lines for damage, rusting and leakage. Check for leaks at hose and line joints and connections. 2. PUMP ASSEMBLY Check for leaks at the pump seal, inlet and outlet fittings.

  • Page 823: Replacement

    Power Steering Hoses, Lines 17-28 Replacement Note these times 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 824: Replacement

    Power Steering Pump 17-29 Replacement Place a suitable container under the vehicle. Remove the pump mounting bolts and lock bolt, Drain the power steering fluid from the reservoir. then remove the pump. Do not turn the steering Remove the belt by loosening the pump mounting bolt wheel with the pump removed.

  • Page 825: Disassembly

    Power Steering Pump 17-30 Disassembly Note these items during disassembly: The power steering components are made of aluminium. Avoid damaging the components during assembly. Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a solvent. Always replace the O-rings and rubber seals with new ones before assembly.

  • Page 826: Inspection

    Power Steering Pump 17-31 Disassembly (cont’d) Inspection Drain the fluid from the pump. Flow Control Valve Hold the steering pump in a vice with soft jaws, hold the Check the flow control valve for wear, burrs, and pulley with the extension bar, and remove the pulley nut other damage to the edges of the grooves in the and pulley.

  • Page 827: Ball Bearing

    Power Steering Pump 17-32 Inspection (cont’d) Attach a hose to the end of the valve. Submerge the Ball Bearing valve in a container of power steering fluid or solvent, Inspect the ball bearing by rotating the out race and blow in the hose. If air bubbles leak through the slowly, if any play or roughness is felt, replace the valve at less than 98 kPa (1.0 kgf/cm , 14.2 psi), replace...

  • Page 828: Reassembly

    Power Steering Pump 17-33 Reassembly Align the pin of the sub-valve with the oil passage in Coat the pump cover seal with power steering fluid, pump housing, and push down the sub-valve. Install the and install it into the groove in the pump cover. snap ring properly.
  • Page 829 Power Steering Pump 17-34 Reassembly (cont’d) Assemble pump rotor to the pump cover. 12. Coat the O-ring with power steering fluid, and Set the 10 vanes in the grooves in the rotor. Make sure position it into the pump housing. that the round ends of the vanes are in contact with the 13.
  • Page 830 Power Steering Pump 17-35 Reassembly (cont’d) 18. Coat the O-ring with power steering fluid, and install it 21. Hold the pulley with the extension bar, and tighten into the grooves in the inlet joint. the pulley nut. INLET JOINT PULLEY NUT, 64 Nm (6.5 kgf/m, 47 lbf/ft) 15.2 x 2.4 mm O-RING ,Replace EXTENSION BAR: (Commercially available) FLANGE BOLTS, 11 Nm (1.1 kgf/m, 8 lbf/ft)
  • Page 831 Power Steering Gearbox 17-36 Removal Note these items during removal: Remove the cotter pin from the 12 mm nut and Using solvent and a brush, wash any oil and dirt off of loosen the nut. the valve body unit its lines, and the end if the gearbox. Blow dry with compressed air.

  • Page 832: Power Steering Gearbox Removal

    Power Steering Gearbox 17-37 Removal (cont’d) 13. Disconnect the right and left stabiliser spring to the 16. Swing the knuckle forward. Turn the stabilizer stabiliser link spring to bring the stabilizer end to underside of the drive shaft. Bring the stabilizer spring of the opposite side to the underside of the driveshaft, too.

  • Page 833: Steering Gearbox

    Power Steering Gearbox 17-38 Removal (cont’d) 19. Remove the 10 mm attaching bolts of the steering 22. Move the steering gearbox toward the passenger’s gearbox mounting bracket B. Do not remove the side frame hole and pulling it. bracket. For vehicle’s with RHD only; remove the supply line clamp from the bracket B.

  • Page 834: Disassembly

    Power Steering Gearbox 17-39 Disassembly Steering Rack Disassembly Unscrew both rack ends with a wrench. Be careful not to damage the rack surface with the wrench. Note these items during disassembly: Remove the lock washer. Before disassemble of the gearbox, wash it off with solvent and a brush.
  • Page 835 Power Steering Gearbox 17-40 Disassembly (cont’d) Hold the steering gearbox in a vice with soft jaws. Be 12. Drill a 3 mm (0.12 in) diameter hole approximately careful not to damage the housing with the jaws of the 2.5 - 3.0 mm (0.10-0.12 in) in depth in the staked vice.
  • Page 836 Power Steering Gearbox 17-41 Disassembly (cont’d) 14. Place a depth socket wrench on the steering rack. 17. Insert the special tools into the cylinder. Make sure that the special tool is securely positioned on the backup ring edges. Be careful not to damage the inner surface of the cylinder with the special tool.

  • Page 837: Pinion Shaft

    Power Steering Gearbox 17-42 Disassembly (cont’d) 19. Carefully pry the piston seal ring and O-ring off the Valve Body Unit Disassembly piston rack. Be careful not to damage the inside of seal 20. Before removing the valve housing, apply vinyl ring groove and piston edges when removing the seal tape to splines of the pinion shaft.
  • Page 838 Power Steering Gearbox 17-43 Disassembly (cont’d) 23. Check for wear, burrs and other damage to the edges of 25. Using a cutter or an equivalent tool, cut and the grooves in the sleeve. remove the four seal rings from the sleeve. Be NOTE: the pinion shaft and sleeve are a precision careful not to damage the edges of the sleeve matched set.
  • Page 839 Power Steering Gearbox 17-44 Disassembly (cont’d) 27. Remove the valve oil seal and backup ring from the pinion shaft. Note these items during disassembly: Inspect the ball bearing by rotating the outer race slowly. If there is any excessive play, replace the pinion shaft and sleeve as an assembly.

  • Page 840: Reassembly

    Always replace the O-rings and rubber seals with new ones before assembly. Apply power steering fluid or steering grease (HONDA P/N: 08733-B070E) to the parts indicated in the assembly procedures. Do not allow dust, dirt or other foreign materials to enter the power steering system.

  • Page 841: Ball Bearing

    Power Steering Gearbox 17-46 Reassembly (cont’d) Valve Body Unit Reassembly Apply power steering fluid to the surface of the valve seal ring that was installed on the pinion Apply grease to the ball bearing and install it on the shaft. pinion shaft using a hydraulic press.
  • Page 842 Power Steering Gearbox 17-47 Reassembly (cont’d) 13. Apply power steering fluid to the surface of the special 18. Apply power steering fluid to the surface of the tool. Set the new seal rings over the special tool from pinion shaft. Assembly the sleeve over the pinion the smaller diameter end of the tool, and expand the shaft by aligning the locating pin on the inside of seal rings.
  • Page 843 Power Steering Gearbox 17-48 Disassembly (cont’d) 21. Apply vinyl tape to the pinion shaft, then coat the vinyl Steering Rack Reassembly tape with power steering fluid. 25. Coat the piston seal ring guide with power steering 22. Insert the pinion shaft into the valve housing. Be careful fluid, then slide it onto the rack, big end first.
  • Page 844 Power Steering Gearbox 17-49 Reassembly (cont’d) 31. Wrap vinyl tape around the rack teeth and rack end 36. Grease the steering rack teeth, then insert the edges, and coat the surface of the tape with the power steering rack into the gearbox housing . Be careful steering fluid.
  • Page 845 Power Steering Gearbox 17-50 Reassembly (cont’d) 40. Wrap vinyl tape around the rack end edges, and coat 45. Install the steering gearbox in a vise with soft jaws the surface of the tape with the power steering fluid. as shown. Do not clamp the cylinder in the vise. Make sure that the vinyl tape is wrapped carefully so that there is no stepped portion.
  • Page 846 Power Steering Gearbox 17-51 Reassembly (cont’d) 49. Select the shim(s). Only reinstall the original shim(s) 50. Set the selected shims on the bearing surface of when the steering gearbox is reassembled without the gearbox housing. replacing the pinion shaft, valve housing, and gearbox 51.

  • Page 847: Lock Washer

    Power Steering Gearbox 17-52 Reassembly (cont’d) 55. Install the return hose joint, cylinder lines A and B. 61. Install the lock washer, and screw each rack end Note these items during reassembly: into the rack while holding the lock washer so its Clean the joints thoroughly.
  • Page 848 Power Steering Gearbox 17-53 Reassembly (cont’d) 64. Apply a light coat of silicone grease to the contact NOTE: The ear portions of the band (close point) portions of the rack grooves and boot. should be the specified angle shown below 65.

  • Page 849: Installation

    Power Steering Gearbox 17-54 Installation Install the steering gearbox mounting cushions and Install the 10 mm gearbox mounting bolts on the brackets on the steering gearbox as shown. Position the gearbox driver’s side. The mounting bolts are mounting cushion B so that the dimension between the loosely firs, then tighten them securely.
  • Page 850 Power Steering Gearbox 17-55 Installation (cont’d) Insert the stabiliser spring into the engine compartment 11. Install the right and left stabilizer holders on the through the hole in the frame of the passenger’s side. respective bushings and loosely tighten the NOTE: Do not interchange the stabiliser spring mounting bolts.

  • Page 851: Steering Shaft

    Power Steering Gearbox 17-56 Installation (cont’d) 14. Connect the return hose securely, and tighten the 18. Install the steering joint, and reconnect the steering adjustable hose clamp. shaft and pinion shaft. Make sure the steering joint is connected as follows: Insert the upper end of the steering joint onto the steering shaft (line up the bolt hole with the flat portion on the shaft).
  • Page 852 Power Steering Gearbox 17-57 Installation (cont’d) 20. Install the steering joint cover. 22. Install the front wheels. 23. Fill the system with power steering fluid, and bleed air from the system (See Page 17-18). 24. After installation, perform the following checks. Start the engine, allow it to idle, and turn the steering wheel from lock -to-lock several times to warm up the fluid.
  • Page 853 Power Steering Gearbox 17-58 Ball Joint Boot Replacement Remove the boot from the tie-rod end, and wipe the old grease off the ball pin. Pack the lower area of the ball pin with fresh grease. BOOT INSTALLATION SECTION, Wipe off the grease. BALL PIN TAPERED SECTION, Wipe off the grease.

  • Page 855: Special Tools

    Special Tools 18-2 | Ref No. Tool Number Description | Qty | Remark | 07MAC - SL00200 | Ball Joint Remover, 28 mm | 07MGK - 0010100 | Wheel Alignment Gauge Attachment | 07746 - 0010200 | Driver Attachment, 37 x 40 mm | 077-46 - 0010300 | Driver Attachment, 42 x 47 mm | 07749 - 0010000...

  • Page 856: Component Location Index

    Component Location 18-3 Index Front Suspension: 1. FRONT DAMPER 2. KNUCKLE 3. LOWER ARM 4. FRONT STABILISER BAR Rear Suspension: 1. REAR DAMPER 2. SPRING 3. LOWER LINK 4. UPPER LINK 5. REAR STABILISER BAR 6. AXLE BEAM 7. PANHARD ROD...
  • Page 857 Wheel Alignment 18-4 Service Information Camber NOTE: For proper inspection/adjustment of the wheel Inspection alignment, check and adjust the following before checking Remove the wheel cap. the alignment. Remove the hub cap from the rear wheel hub (see Check that the suspension is not modified. page 18-19).
  • Page 858 Wheel Alignment 18-5 Caster Toe Inspection/Alignment Inspection Inspection Remove the wheel cap. Centre steering wheel spokes. Raise the car and set the turning radius gauges beneath NOTE: Measure difference in toe measurements the front wheels and place boards under the rear wheels with the wheels pointed straight ahead.
  • Page 859 Wheel Alignment 18-6 Turning Angle Inspection Bearing End Play Jack up the front of the vehicle. Set the turning radius Raise the vehicle off the ground and support it with gauges beneath the front wheels, then lower the vehicle. safety stands in the proper locations (see section Jack up the rear of the vehicle.
  • Page 860 Wheel Alignment 18-7 Wheel Runout Raise the vehicle off the ground and support it with safety stands in the proper locations (see section 1). Check for bent or deformed wheels. Attach the dial gauge as shown. Measure the wheel runout by turning the wheel. Front and Rear Wheel Axial Runout: Standard: Steel Wheel:...
  • Page 861 Front Suspension 18-8 Suspension Arms Replacement Note the following items during replacement: Replace the self-locking nuts after removal. The vehicle should be on the ground before any bolts or nuts connected to rubber mounts or bushings are tightened. Before tightening the upper and lower mounting nuts on the stabiliser link, adjust the location of the link with the suspension under vehicle load. After installing the suspension arm, check the front wheel alignment and adjust if necessary (See Page 18-5).
  • Page 862 Note the following items during replacement: Use only genuine Honda wheel weights for aluminium wheels. Non-genuine wheel weights may corrode and damage the aluminium wheels On the aluminium wheels remove the centre cap from the inside of the wheel after removing the wheel.

  • Page 863: Brake Disc

    Front Suspension 18-10 Knuckle/Hub Replacement (cont’d) Loosen the wheel nuts slightly. Remove the 6 mm brake disc retaining screws. Raise the front of the vehicle and support it with safety stands in the proper locations (see section 1). Remove the wheel nits and wheel. Raise the locking tab on the spindle nut, then remove the nut.
  • Page 865 Front Suspension 18-11 Knuckle/Hub Replacement (cont’d) 12. Clean any dirt or grease off the ball joint. 17. Once the special tool is in place turn the adjusting 13. Remove the cotter pin from the steering arm and bolt as necessary to make the jaws parallel. Then remove the nut.
  • Page 866 Front Suspension 18-12 Knuckle/Hub Replacement (cont’d) 20. Remove the 8 mm self-locking nut and separate the 24. Remove the damper pinch bolt and pull out the stabiliser link from the lower arm. knuckle from the damper end. 25. Pull the knuckle outward and remove the driveshaft outboard joint from the knuckle by tapping the driveshaft end with a plastic hammer then remove the knuckle.
  • Page 867 Front Suspension 18-13 Knuckle/Hub Replacement (cont’d) 28. Press the wheel bearing out of the knuckle using the 30. Wash the knuckle and hub thoroughly in high flash special tools and a press. point solvent before reassembly. 31. Press a new wheel bearing into the knuckle using the old bearing, a plate, the special tool and a press.

  • Page 868: Lower Arm

    Front Suspension 18-14 Knuckle/Hub Replacement (cont’d) Ball Joint Boot Replacement 35. Install the knuckle in the reverse order of removal and pay particular attention to the following items: Be careful not to damage the ball joint boots when Do not contaminate the boot installation section with installing the knuckle.

  • Page 869: Front Damper Removal

    Front Damper 18-15 Removal Disassembly/Inspection Remove the front wheels. Disassembly Remove the wheel sensor wire from the knuckle and Compress the damper spring with the spring damper. Do not disconnect the wheel sensor connector. compressor according to the manufacturer’s Separate the stabiliser bar from the lower arm (step 20 instructions.
  • Page 870 Front Damper 18-16 Disassembly/Inspection (cont’d) Inspection Reassemble all parts, except the spring. Push on the damper assembly as shown. WOODEN BLOCK Check for smooth operation through a full stroke, both compression and extension. The damper should move smoothly. If it does not (no compression or extension) the gas is leaking and the damper should be replaced.
  • Page 871 Front Damper 18-17 Reassembly Installation Install the damper unit on a spring compressor. Loosely install the damper on the frame with the Assemble the damper in reverse order of removal aligning tab facing inside, then loosely install the except the damper mounting washer and self-locking two flange nuts.
  • Page 872 Rear Suspension 18-18 Suspension Arms Replacement Note these items during replacement: Replace the self-locking nuts after removal. Any bolts or nuts connected to rubber mounts or bushings should be tightened with the vehicle on the ground. After installing the suspension arm, check the rear wheel alignment (See Page 18-4).

  • Page 873: Rear Brake Assembly

    Replacement NOTE: Use only genuine Honda wheel weights for aluminium wheels. No-genuine wheel weights may corrode and damage aluminium wheels. Before installing the brake drum, clean the mating surfaces of the rear hub and the brake drum. before install the wheel, clean the mating surfaces of the brake drum and inside the wheel.
  • Page 874 Rear Wheel Bearing 18-20 Replacement (cont’d) Loosen the wheel nuts slightly. Remove the rear driveshaft from the rear axle beam (see section 16). Raise the rear of the vehicle and support it with safety Remove the rear wheel bearing from the axle stands in the proper locations (see section 1).
  • Page 875 Rear Spring/Bump Stop 18-21 Removal Installation Raise the rear of the vehicle and make sure it is Install the bump stop. Install the spring and the upper spring seat. securely supported. Remove the rear wheel. Loosely install the stabiliser link to the body. Remove the flange bolt from the rear axle beam.

  • Page 876: Rear Damper Removal

    Rear Damper 18-22 Removal Inspection Raise the rear of the vehicle and make sure it is securely supported. remove the rear wheel. Remove the flange bolt from the rear axle beam. REAR DAMPER REAR AXLE BEAM FLANGE BOLT, 10 x 1.25 mm Remove the damper access panel.
  • Page 877 Rear Damper Damper Disposal 18-23 Installation Loosely install the self-locking nut on the top of the damper. The dampers contain nitrogen gas and oil under pressure. The pressure must be relieved before disposal to prevent explosion and possible injury when scrapping. Place the damper on a level surface with its rod end extended and drill a hole 2 - 3 mm (0.078 - 0.118 in) diameter in the body to release the gas.

  • Page 879: Special Tools

    Special Tools 19-A-2 | Ref No. Tool Number Description | Qty Remark | 07JAG - SD40100 | Pushrod Adjustment Gauge | 07404 - 5790301 | Vacuum Gauge | 07406 - 5790201 | Pressure Gauge | 07410 - 5790101 | Pressure Gauge Attachment C | 07410 - 5790501 | Tube Joint Adapter | 07510 - 6340101...
  • Page 880 Component Location 19-A-3 Index NOTE: LHD type is shown, RHD type is symmetrical. 1. MASTER CYLINDER Removal/Installation, (See Page 19-A-13) Master Cylinder Disassembly, (See Page 19-A-14) Master Cylinder Reassembly, (See Page 19-A-15) Bleeding, (See Page 19-A-7) Brake Fluid Level Switch Test, (See Page 19-A-8)
  • Page 881 Inspection and Adjustment 19-A-4 Brake System Rubber Parts and Brake Booster Brake Booster (A) Caliper Piston Seal and Piston Boots (D) Check brake operation by applying the brakes. Check brake operation by applying the brakes. If the brakes do not work properly, check the brake Visually check for damage or signs of fluid booster.
  • Page 882 Inspection and Adjustment 19-A-5 Brake Pedal Pedal Height Screw in the brake switch until its plunger is fully depressed (threaded end touching the pad on the Disconnect the brake switch connector, loosen the pedal arm). Then back off the switch 1/4 turn to brake switch locknut and back off the brake switch until make 0.3 mm (0.01 in) of clearance between the it is no longer touching the brake pedal.

  • Page 883: Parking Brake Lever

    Inspection and Adjustment 19-A-6 Parking Brake Inspection Adjustment Pull the parking brake lever with 196 N (20 kgf, 44 lbf) NOTE: After rear brake shoes servicing, loosen the force to fully apply the parking brake. The parking brake parking brake adjusting nut, start the engine and lever should be located within the specified notches.

  • Page 884: Bleeding Sequence

    Bleeding NOTE: FRONT Do not reuse the drained fluid. Use only clean Genuine Honda brake fluid or an equivalent DOT3 or DOT4 brake fluid. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. Do not spill brake fluid on the vehicle, it may damage the paint;...
  • Page 885 Inspection and Adjustment 19-A-8 Brake System Indicator Circuit Diagram/Parking Brake Fluid Level Switch Test Brake Switch Test Parking Brake Switch Test Brake Fluid Level Switch Test Remove the rear console and disconnect the connector Remove the reservoir cap. Check that the float from the switch.

  • Page 886: Backing Plate

    Front Brake Pads 19-A-9 Inspection and Replacement Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include the pad backing plate thickness. Frequent inhalation of brake pad dust, regardless of material Brake Pad Thickness: composition, could be hazardous to your health.
  • Page 887 Front Brake Pads 19-A-10 Inspection and Replacement (cont’d) Apply Molykote M77 grease or Daikalub 528D grease to 11. Push in the piston so that the caliper will fit over the the pad side of the shims and back of the pads. Wipe pads.
  • Page 888 Front Brake Disc 19-A-11 Disc Runout Inspection Disc Thickness and Parallelism Inspection Loosen the front wheel nuts slightly, then raise the Loosen the front wheel nuts slightly, then raise the vehicle and support on safety stands. Remove the front vehicle and support on safety stands. Remove the wheels.
  • Page 889 When reusing the pads, always reinstall the brake pads in their original positions to prevent loss of braking efficiency. Do not reuse the drained fluid. Use only clean Genuine Honda brake fluid or an equivalent DOR3 or DOT4 brake fluid. Coat the piston and caliper bore with clean brake fluid.

  • Page 890: Vacuum Hose

    Master Cylinder/Brake Booster 19-A-13 Removal/Installation 11. Install the brake booster and master cylinder in the reverse order of removal and note the following items: Do not spill brake fluid on the vehicle, it may damage the Replace all rubber parts with new ones paint.
  • Page 891 Master Cylinder/Brake Booster 19-A-14 Disassembly Remove the master cylinder (See Page 19-A-13). Remove the reservoir cap and strainer from the reservoir. Remove the rod seal from the brake booster side. Remove the reservoir seal from the reservoir cap. Remove the circlip while pushing in the secondary piston. ROD SEAL, Replace CIRCLIP, Replace SECONDARY PISTON...
  • Page 892 Do not mix different brands of brake fluid as they may not be compatible. Do not reuse the drained fluid. Use only clean Genuine Honda brake fluid or an equivalent DOT3 or DOT4 brake fluid. Replace the master cylinder if the bore is damaged or worn. Do not hone or attempt to refinish the bore.
  • Page 893 Master Cylinder/Brake Booster 19-A-16 Reassembly (cont’d) Coat the cups of a new primary piston with clean brake Install a new circlip while pushing in the secondary fluid, then install the primary piston into the master piston. cylinder. Apply the recommended seal grease in the master cylinder seal set to a new rod seal and install it onto the mating face of the brake booster.
  • Page 894 Master Cylinder/Brake Booster 19-A-17 Pushrod Clearance Adjustment NOTE: Master cylinder pushrod-to piston clearance must be NOTE: If the clearance between the gauge body and checked and adjustments made, if necessary, before adjusting nut is 0.4 mm (0.02 in), the pushrod-to-piston installing master cylinder.
  • Page 895 Master Cylinder/Brake Booster 19-A-18 Brake Booster Inspection Leak Test Function Test Install the vacuum gauge between the brake booster Install the vacuum gauge the same way as in the and check valve. leak test. Connect the oil pressure gauges to the master cylinder using the attachments (special tools) as shown.
  • Page 896 Master Cylinder/Brake Booster 19-A-19 Brake Booster Inspection (cont’d) The following pressures should be observed at the Check Valve Test pressure gauges in each vacuum. Disconnect the brake booster vacuum hose at the Vacuum kPa booster. (mmHg, in.Hg) (kgf, lbf) (kgf/cm2, psi) Start the engine and let it idle.
  • Page 897 Rear Drum Brakes 19-A-20 Index/Inspection Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use a vacuum cleaner. NOTE: Contaminated brake linings or drums reduce stopping ability.
  • Page 898 Rear Drum Brakes 19-A-21 Index/Inspection (cont’d) Check the wheel cylinder for leakage. Measure the inside diameter of the brake drum Check the brake linings for cracking, glazing, wear or using the inside vernier calipers. contamination. Drum Inside Diameter: Measure the brake lining thickness. Standard: Brake Lining Thickness: 199.9 - 200.0 mm (7.870 - 7.874 in)

  • Page 899: Parking Brake Lever

    Rear Drum Brakes 19-A-22 Brake Shoes Replacement Disassembly Remove the wavy washer, parking brake lever and pivot pin from the brake shoe by removing the Remove the tension pins by pushing the retainer springs U-clip. and turning them. PIVOT PIN TENSIONER PINS PARKING BRAKE LEVER RETAINER SPRINGS...
  • Page 900 Rear Drum Brakes 19-A-23 Brake Shoes Replacement(cont’d) Connect the parking brake cable to the parking brake Clean the threaded portions of clevis A and B. lever. Coat the threads of the clevis with grease. To Apply grease on each sliding surface. shorten the clevis, turn the adjuster bolt.
  • Page 901 Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. Do not reuse the drained fluid. Use only clean Genuine Honda brake fluid or an equivalent DOT3 or DOT4 brake fluid. Lubricate all parts with clean brake fluid during reassembly.
  • Page 902 Brake Hose and Line 19-A-25 Inspection/Torque Specifications Inspect the brake hoses for damage, deterioration, leaks, interference and twisting. Check the brake lines for damage, rusting and leakage. Also check for bent brake lines. Check for leaks at hose and line joints or connections and retighten if necessary. Check the master cylinder, proportioning control valve and ABS modulator unit for damage and leakage.

  • Page 903: Brake Hose

    Brake Hose and Line 19-A-26 Brake Hose Replacement NOTE: Install the brake hose bracket and brake hose on Before reassembling check that all parts are free of dust the knuckle first, then connect the brake hose tot and other foreign particles. he caliper with the banjo bolt and new sealing Replace parts with new ones whenever specified to do washers.

  • Page 904: Parking Brake Cable

    Parking Brake Cable 19-A-27 Inspection/Replacement NOTE: The parking brake cables must not be bent or distorted. This will lead to stiff operation and premature cable failure. 1. PARKING BRAKE LEVER Check for smooth operation 2. PARKING BRAKE CABLE Check for faulty movement 3.

  • Page 906: Special Tools

    Special Tools 19-B-2 | Ref No. Tool Number Description | Qty Remark | 07PAZ -0010100 | SCS Short Connector...

  • Page 907: Components Locations

    Components Locations 19-B-3 1. MODULATOR ASSEMBLY (ABS CONTROL UNIT/MODULATOR UNIT) 2. UNDER-HOOD FUSE/RELAY BOX 3. RIGHT-REAR WHEEL SENSOR 4. LEFT-REAR WHEEL SENSOR 5. UNDER-DASH FUSE/RELAY BOX 6. LEFT-FRONT WHEEL SENSOR 7. SERVICE CHECK CONNECTOR (2P) 8. RIGHT-FRONT WHEEL SENSOR GAUGE ASSEMBLY UNDER-HOOD FUSE/RELAY BOX 1.
  • Page 908 Anti-lock Brake System (ABS) 19-B-4 Features/Construction When the brake pedal is depressed during driving, the wheels can lock before the vehicle comes to a stop. In such an event, the manoeuvrability of the vehicle is reduced if the front wheels are locked, and the stability of the vehicle is reduced if the rear wheels are locked, creating an extremely unstable condition. The ABS precisely controls the slip rate of the wheels to ensure maximum grip force from the tyres, and it thereby ensures manoeuvrability and stability of the vehicle.
  • Page 909 The ABS system can be diagnosed with the Honda PGM Tester. The ALB Checker cannot be used with this system. For air bleeding, and checking wheel sensor signals, use the Honda PGM Tester. See the Honda PGM Tester user’s manuals for...
  • Page 910 Anti-lock Brake System (ABS) 19-B-6 Features/Construction (Cont’d) ABS Modulator The ABS modulator consists of the inlet solenoid valve, outlet solenoid valve, reservoir, pump, pump motor and the damping chamber. The modulator reduces the caliper fluid pressure directly. It is a circulating-type modulator because the brake fluid circulates through the caliper, reservoir and the master cylinder. The hydraulic control has three modes: pressure intensifying, pressure retaining and pressure reducing modes.
  • Page 911 Anti-lock Brake System (ABS) 19-B-7 Features/Construction (cont’d) Wheel Sensor The wheel sensors are the magnetic contactless type. As the gear pulsar teeth rotate past the wheel sensor’s magnetic coil, AC current is generated. The AC frequency changes in accordance with the wheel speed. The ABS control unit detects the wheel sensor signal frequency and thereby detects the wheel speed. Wheel Speed and Modulator Control When the wheel speed drops sharply below the vehicle speed, the outlet valve opens momentarily to reduce the caliper fluid pressure.
  • Page 912 Anti-lock Brake System (ABS) 19-B-8 Features/Construction (cont’d) Electronic Brake Distribution (EBD) The ABS control unit controls the front and rear brake force distribution suitably according to load movement by changing of carrying condition or deceleration to use the brake force when braking.
  • Page 913 Anti-lock Brake System (ABS) 19-B-9 Features/Construction (cont’d) EBD Control If braking with deceleration more than a certain value, the inlet valve closes to retaining the brake fluid pressure when the rear wheel speed drops below the front wheel speed. When the rear wheel speed drops further, the outlet valve opens momentarily to reduce the brake fluid pressure.

  • Page 914: Circuit Diagram

    Circuit Diagram 19-B-10...
  • Page 915 Circuit Diagram 19-B-11 (cont’d)

  • Page 916: Abs Control Unit Terminal Arrangement

    1 turn/second above (Reference) Oscilloscope: 0.15 Vp-p or above LT BLU | Communicates with (Data link connector) the Honda PGM Tester GND1 Ground (Ground 1) Power source for the 9-GND Every time Battery Voltage | (Battery 1)
  • Page 917 ABS Control Unit Terminal Arrangement 19-B-13 (cont’d) Terminal Wire colour| Terminal sign Description Measurement (Terminal name) Terminal Conditions (Ignition switch ON (II) Voltage GRN/WHT | STOP Detects brake switch 18-GND Brake pedal | Depressed | Battery Voltage signal GRN/WHT | STOP Detects brake switch 18-GND...

  • Page 918: Troubleshooting Precautions

    Troubleshooting Precautions 19-B-14 ABS Indicator If the system is OK, the ABS indicator goes off two seconds after turning the ignition switch ON (II) without starting the engine, and then comes on again and goes off after two seconds. This occurs because the ABS control unit is turned on by the IG2 power source. The ABS indicator comes on when the ABS control unit detects a problem in the system.
  • Page 919 ABS Function Test To simulate ABS operation and activate the solenoid valves and pump, use the Honda PGM Tester. Connect the PGM Tester to the 3P Data Link Connector (DLC). When the System Select menu is displayed, select the ABS Test Mode menu and follow the tester’s prompts.
  • Page 920 The DTC indication stops and the ABS control unit executes the software function if at least one of the following conditions is satisfied: The vehicle is not stopped. The ABS control unit receives the normal signal (which is for the ABS control unit) from a Honda PGM Tester. The SCS short connector is disconnected during this procedure.
  • Page 921 The SCS short connector is disconnected during this service. The ABS control unit receives the normal signal (which is for the ABS control unit) from a Honda PGM Tester. The brake pedal is not operated according to the indicator indication.
  • Page 922 *3: The brake system indicator comes on when the ABS control unit detects more than one wheel problem. *4: This code is indicated only when the Honda PGM Tester is used. *5: Failure code of communication mode for the Honda PGM Tester is 82.
  • Page 923 Troubleshooting 19-B-19 Brake System Indicator Does Not Go Off...
  • Page 924 Troubleshooting 19-B-20 ABS Indicator Does Not Come On...
  • Page 925 Troubleshooting 19-B-21 ABS Indicator Does Not Come On (cont’d)
  • Page 926 Troubleshooting 19-B-22 ABS Indicator Does Not Go Off (No DTC)
  • Page 927 Troubleshooting 19-B-23 ABS Indicator Does Not Go Off (No DTC) (cont’d)
  • Page 928 Troubleshooting 19-B-24 DTC 11, 13, 15, 17: Wheel Sensor...
  • Page 929 Troubleshooting 19-B-25 DTC 12, 14, 16, 18: Wheel Sensor/Pulser...
  • Page 930 Troubleshooting 19-B-26 DTC 31, 32, 33, 34, 35, 36, 37, 38: Solenoid...
  • Page 931 Troubleshooting 19-B-27 DTC 51, 52, 53: ABS Pump Motor...
  • Page 932 Troubleshooting 19-B-28 DTC 54: Main Relay...
  • Page 933 Troubleshooting 19-B-29 DTC 61: Ignition Voltage...
  • Page 934 Troubleshooting 19-B-30 DTC 81: Central Processing Unit (CPU) To go to the pages referenced on the diagram above, click on the following: (See Page 19-B-16)
  • Page 935 Modulator Assembly 19-B-31 Removal/Installation Note: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. Take care not to damage or deform the brake lines during removal and installation. To prevent the brake fluid from flowing, plug and cover the hose ends and joints with a shop towel or equivalent material.

  • Page 936: Wheel Sensor

    Pulsers/Wheel Sensors 19-B-32 Inspection Wheel Sensor Replacement Check the front and rear pulser for chipped or damaged Install the sensors carefully to avoid twisting the wires. teeth. Front Measure the air gap between the wheel sensor and When installing the front wheel sensor, pass the sensor pulser all the way around while rotating the pulser.
  • Page 938 Door 20-2 Component Location Index 1. DOOR WEATHERSTRIP 2. CENTRE CHANNEL TAPE, Replacement, (See Page 20-11) 3. UPPER CHANNEL TAPE, Replacement, (See Page 20-11) 4. DOOR MOLDING 5. DOOR, Replacement,. (See Page 20-13) 6. HINGE 7. DETENT ROD 8. PULL POCKET BRACKET 9.
  • Page 939 Door 20-3 Component Location Index (cont’d) 1. GLASS, Replacement, (See Page 20-9) 2. CENTRE LOWER CHANNEL 3. GLASS RUN CHANNEL 4. FRONT LOWER CHANNEL 5. BUSH 6. OUTER HANDLE, Replacement, (See Page 20-5) 7. OUTER HANDLE PROTECTOR 8. ROD CRANK 9.

  • Page 940: Door Panel

    Door 20-4 Door Panel Removal and Installation Remove the inner handle case. Take care not to scratch Release the clips that hold the door panel with a the door panel. trim pad remover (commercially available), then remove the door panel by pulling it upward. : Screw location, 1 HOOK INNER HANDLE...
  • Page 941 Door 20-5 Door Outer Handle Replacement NOTE: Wear gloves to protect your hands when removing Disconnect the cylinder rod. Release the retainer and installing the outer handle. clip, then remove the lock cylinder. Raise the glass fully. Remove Door panel (See Page 20-4).
  • Page 942 Door 20-6 Door Outer Handle Replacement (cont’d) Remove the outer handle protector from the outer Pull out the outer handle. Pry the outer handle rod handles out of its joint using diagonal cutter. NOTE: To ease reassembly, note distance ( A) of the outer handle rod on the joint, before disconnect it.
  • Page 943 Door 20-7 Door Outer Handle Replacement (cont’d) Door Latch Replacement Install in the reverse order of removal, and note the NOTE: Wear gloves to protect your hands when following items: replacing the door latch. Make sure the connector is plugged in properly and Raise the glass fully.
  • Page 944 Door 20-8 Door Latch Replacement (cont’d) Remove the bolt, then remove the rod protector. Remove the screws, then remove the inner handle and rod crank. : Bolt location, 1 : Screw locations, 3 ROD PROTECTOR Detach the rear lock rod from the rod crank. Remove the inner handle rod, then disconnect the power door lock actuator connector.
  • Page 945 Door 20-9 Door Glass and Regulator Replacement NOTE: Wear gloves to protect your hands when removing Disconnect and detach the connector and harness and installing the glass and regulator. clip from the door. Scribe a line around the roller Remove: guide bolt to show the original adjustment.
  • Page 946 Door 20-10 Door Glass and Regulator Replacement (cont’d) Scribe a line across the regulator and sector gear. Install in the reverse order of removal and note the following items: Roll the glass up and down to see if it moves freely without binding.
  • Page 947 Door 20-11 Door Channel Tape Replacement NOTE Remove the following parts. Keep dust away from the working area. Upper channel tape replacement When working at lower temperatures, heat the door Power mirror (See Page 20-15). channel and door channel tape with a hair dryer. Door weatherstrip (See Page 20-2).
  • Page 948 Door 20-12 Door Channel Tape Replacement (cont’d) 1. UPPER CHANNEL TAPE 2. 2 mm (0.08 in) 3. Align 4. CENTRE CHANNEL TAPE 5. CENTRE/UPPER CHANNEL TAPE 6. Outside...
  • Page 949 Door 20-13 Door Position Adjustment NOTE: After installing the door, check for a flush fit with the Check that the door and body edges are parallel, if body, then check for equal gaps between the front, rear and necessary, adjust the door cushions. bottom door edges and the body.
  • Page 950 Mirrors 20-14 Component Location Index 1. POWER MIRROR, Replacement (See Page 20-15). 2. MIRROR MOUNT COVER 3. MIRROR 4. MIRROR HOLDER, Replacement, (See Page 20-16). Without roof spoiler With roof spoiler 1. MIRROR HOLDER 2. STAY BASE 3. LOCK BOLT 4.
  • Page 951 Mirrors 20-15 Mirror Replacement Lower the glass fully. Loosen the screw, then remove the mirror. Remove Door Panel (See Page 20-4). Plastic cover (See Page 20-2). Carefully pry out the mirror mount cover by hand. : Clip locations, 2 SCREW MIRROR Install in the reverse order of removal and note the following items:...
  • Page 952 Mirrors 20-16 Mirror Holder Replacement Rearview Mirror Replacement NOTE: Without roof spoiler Take care not to scratch the mirror. Remove the stay cover Wear gloves to remove and install the mirror holder. Carefully pull out the bottom edge of the mirror holder by hand.
  • Page 953 Mirrors 20-17 Rearview Mirror Replacement (cont’d) With roof spoiler If necessary, remove the lock bolt (left-handed bolt). Remove the lock washer and spring from the Remove the stay cover. mirror stay. STAY COVER HOOKS Loosen the screw, then slide the rearview mirror down toward the bottom of the windshield.
  • Page 954 Glass 20-18 Component Location Index The numbers after the part names show the quantities of the parts used. 1. WINDSHIELD MOLDING 2. MOLDING UPPER SEAL, 2 3. UPPER RUBBER DAM 4. MOLDING SIDE SEAL, 2 5. FASTENER, 2 (Self-adhesive-type, body side) 6.
  • Page 955 Glass 20-19 Component Location Index (cont’d) 1. QUARTER GLASS REAR TRIM 2. UPPER RUBBER DAM 3. QUARTER GLASS, Replacement, (See Page 20-30). 4. UPPER CLIP (Self-adhesive-type) 5. QUARTER GLASS FRONT TRIM 6. LOWER CLIP (Self-adhesive-type) 7. LOWER RUBBER DAM 8. REAR CLIP 9.
  • Page 956 Glass 20-20 Windshield Replacement NOTE: Apply protective tape. Using an awl, make a hole Wear gloves to remove and install the windshield. through the rubber dam adhesive and dashboard Use seat covers to avoid damaging any surfaces. seal from inside the vehicle. Push piano wire Use glass adhesive set, P/N, 08C73-X0230N.
  • Page 957 Glass 20-21 Windshield Replacement (cont’d) 10. Glue the upper rubber dam, lower rubber dam and 11. Apply primer (3M N-200, or equivalent) to the fasteners to the inside face of the windshield as shown: areas between the alignment marks of the Be sure the rubber dam, fasteners and dashboard windshield.
  • Page 958 Glass 20-22 Windshield Replacement (cont’d) 12. Glue the molding upper seal and molding side seal to 13. Install the fastener and glass brackets to the body. the molding. Be careful not to touch the windshield where adhesive will be applied. FASTENER ALIGNMENT MARK GLASS BRACKET...
  • Page 959 Glass 20-23 Windshield Replacement (cont’d) 16. With a sponge, apply a light coat of glass primer around 17. With a sponge, apply a light coat of body primer to the edge of the windshield between the rubber dam and the original adhesive remaining around the molding as shown, then lightly wipe if off with gauze or windshield opening flange.
  • Page 960 Glass 20-24 Windshield Replacement (cont’d) 18. Pack adhesive into the cartridge without air pockets to 19. Use suction cups to hold the windshield over the ensure continuous delivery. Put the cartridge in a opening, align it with the alignment marks made in caulking gun and run a bead of adhesive around the step 14 and set it down on the adhesive.
  • Page 961 Glass 20-25 Rear Window Replacement NOTE: With a putty knife, scrape the old adhesive smooth Wear gloves to remove and install the rear window. to a thickness of about 2 mm (0.08 in) on the Use seat covers to avoid damaging any surfaces. bonding surface around the entire rear window Do not damage the rear window defogger grid lines and opening flange.
  • Page 962 Glass 20-26 Rear Window Replacement (cont’d) Glue the fasteners and rubber dams to the inside face of 10. Glue the fasteners to the tailgate. the rear window as shown: Be sure the fasteners and rubber dams line up with the alignment marks. Be careful not to touch the rear window where adhesive will be applied.
  • Page 963 Glass 20-27 Rear Window Replacement 12. With a sponge, apply a light coat of glass primer around 13. With a sponge, apply a light coat of body primer to the edge of the rear window as shown, then lightly wipe the original adhesive remaining around the rear it off with gauze or cheesecloth: window opening flange.
  • Page 964 Glass 20-28 Rear Window Replacement (cont’d) 14. Pack adhesive into the cartridge without air pockets to 15. Use suction cups to hold the rear window over the ensure continuous delivery. Put the cartridge in a opening, align it with the alignment marks you caulking gun and run a bead of adhesive around the made in step 11, and set it down on the adhesive.
  • Page 965 Glass 20-29 Rear Window Molding Replacement NOTE: Clean the rear window molding. Wear gloves to remove and install the rear window. Apply primer (3M C-100 or equivalent) to the areas Do not damage the rear window defogger grid lines, between the rear window Molding as shown, then window antenna grid lines and terminals apply glass adhesive.
  • Page 966 Glass 20-30 Quarter Glass Replacement NOTE: Set the quarter glass front trim, then install the Wear gloves to remove and install the quarter glass. upper clip and lower clip. Use seat covers to avoid damaging any surface. Use glass adhesive set P/N, 08C73-X0230N. Remove: Rear side shelf (See Page...
  • Page 967 Glass 20-31 Quarter Glass Replacement (cont’d) 10. Install the rear clip as shown. 12. With a sponge, apply a light coat of glass primer to the inside face of the quarter glass as shown, then lightly wipe it of with gauze or cheesecloth. Do not apply body primer to the quarter glass and do not get body and glass primer sponges mixed up.
  • Page 968 Glass 20-32 Quarter Glass Replacement (cont’d) 13. With a sponge, apply a light coat of body primer to the 15. Pack adhesive into the cartridge without air original adhesive remaining around the quarter glass pockets to ensure continuous delivery. Put the opening flange.
  • Page 969 Glass 20-33 Quarter Glass Replacement (cont’d) 16. Use suction cups to hold the quarter glass over the opening and set it down on the adhesive. Lightly push on the quarter glass until its edges are fully seated on the adhesive all the way around. Do not open or close the doors until the adhesive is dry.
  • Page 970 Sunroof 20-34 Component Location Index 1. GLASS SEAL, Installation, (See Page 20-36) 2. RUBBER 3. GLASS HOLDER 4. GLASS, Replacement, (See Page 20-35). 5. CLIP 6. REAR DRAIN TUBE, Replacement (See Page 20-39) 7. REAR DRAIN VALVE 8. SUNSHADE LOCK 9.
  • Page 971 Sunroof 20-35 Glass Replacement Remove the sunshade. Remove the bolts from the lock assy, then remove Remove the screw, then remove the lock cover. the nuts. : Screw location, 1 : Bolt locations, 3 : Nut locations, 2 HOOKS LOCK COVER Remove the roof trim.
  • Page 972 Sunroof 20-36 Glass Replacement (cont’d) Glass Seal Installation The glass is removed in the push up. Install the glass seal as shown. GLASS HINGES Install in the reverse order of removal. Check for water leaks. Do not use high-pressure water. CENTRE MARK ALIGNMENT MARK GLASS SEAL...
  • Page 973 Sunroof 20-37 Lock Assy/Hinge Replacement 1. HINGE SEAT : Screw locations, 6 2. HINGE COLLAR 3. HINGE 4. GLASS HOLDER 5. GLASS 6. RUBBER 7. LOCK ASSY.
  • Page 974 Sunroof 20-38 Main Seal Replacement Remove the glass (See Page 20-35). Install the main seal as shown. Remove the main seal from the body. MAIN SEAL CENTRE MARK ALIGNMENT MARK Scrape or wipe the excess adhesive off with putty MAIN SEAL knife or towel.
  • Page 975 Sunroof 20-39 Drain Tube Replacement Remove: Headliner (See Page 20-44). Rear side trim (See Page 20-41). Kick panel (See Page 20-41). Fuse box (driver’s side as necessary) ECM/PCM (front passenger’s side as necessary) NOTE: Before pulling out the drain tube, tie a string to the end of it so it can be reinstalled. 1.
  • Page 976 Interior Trim 20-40 Component Location Index SRS components are located in the areas marked with an asterisk (*). Review the SRS component locations, precautions and procedures in the SRS section (24) before performing repairs or service. 1. ROOF SIDE PAD (See Page 20-44).
  • Page 977 Interior Trim 20-41 Trim Removal and Installation NOTE: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to bend or scratch the trim and panels. Wear gloves to protect your hands. 1. REAR PILLAR TRIM : Clip locations 2.

  • Page 978: Interior Trim

    Interior Trim 20-42 Trim Removal and Installation (cont’d) 1. REAR CENTRE SHELF : Bolt, screw locations : Clip locations 2. A portion 3. B portion 4. SPARE TYRE LID 5. CARGO AREA LIGHT Remove the rear pillar trim. (See Page 20-41).
  • Page 979 Interior Trim 20-43 Trim Removal and Installation (cont’d) 1. PULL POCKET : Clip locations 2. TAILGATE TRIM 3. PIN Install in the reverse order of removal and note the following items: Replace any damaged clips. Before installing the anchor bolts, make sure there are no twists or kinks in the seat belts.
  • Page 980 Interior Trim 20-44 Headliner Removal and Installation NOTE: When prying with a flat tip screwdriver, wrap it with protective tape to prevent damage. Take care not to bend and scratch the headliner. Be careful not to damage the dashboard and other interior trim. Remove: Interior light (see section 23) Rearview mirror (without roof garnish spoiler,...
  • Page 981 Interior Trim 20-45 Headliner Removal and Installation (cont’d) Remove the roof side pad and roof side absorber. 1. ROOF SIDE ABSORBER : Clip locations, 7 2. ROOF SIDE PAD Install in the reverse order of removal.
  • Page 982 Interior Trim 20-46 Carpet Replacement SRS components are located in this area. Review the SRS component locations, precautions and procedures in the SRS section (24) before performing repairs or service. NOTE: Wear gloves to protect your hands. Take care not to damage, wrinkle or twist the carpet. Be careful not to damage the dashboard or other interior trim pieces.
  • Page 983 Console 20-47 Front/Rear Console Removal and Installation NOTE: When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Take care not to scratch the front seat, dashboard and related parts. Take care not to bend the parking brake cables. 1.
  • Page 984 Dashboard 20-48 Instrument Panel Removal and Installation Centre Panel Removal and Installation NOTE: NOTE: When prying with a flat-tip screwdriver, wrap it with When prying with a flat-tip screwdriver, wrap it with protective tape and apply protective tape around the protective tape and apply protective tape around related parts, to prevent damage.

  • Page 985: Glove Box

    Dashboard 20-49 Glove Box Removal and Installation Upper Box Lid Removal and Installation NOTE: Take care not to scratch the dashboard and related NOTE: Take care not to scratch the dashboard and parts. related parts. Remove the bolts, then remove the glove box. Remove the bolts, then remove the upper box lid.
  • Page 986 Dashboard 20-50 Driver Pocket Removal and Installation Driver Upper Pocket Removal and Installation NOTE: Take care not to scratch the dashboard and related NOTE: Take care not to scratch the dashboard and parts. related parts. Remove the screw. Detach the hooks. Detach the clip and hooks, then remove the driver Detach the clips, then remove the driver upper pocket.
  • Page 987 Dashboard 20-51 Dashboard Removal and Installation SRS components are located in this area. Review the SRS component locations, precautions and procedures in the SRS section (24) before performing repairs or service. NOTE: When prying with a flat-tip screwdriver, wrap it with protective tape and apply protective tape around the related parts, to prevent damage. An assistant is helpful when removing and installing the dashboard.
  • Page 988 Dashboard 20-52 Steering Hanger Beam Replacement SRS components are located in this area. Review the SRS component locations, precautions and procedures in the SRS section (24) before performing repairs or service. NOTE: When prying with a flat-tip screwdriver, wrap it with protective tape and apply protective tape around the related parts, to prevent damage. An assistant is helpful when removing and installing the steering hanger beam.

  • Page 989: Rear Seat

    Seats 20-53 Component Location Index 1. REAR SEAT Removal and Installation, (See Page 20-59). Seat-back Latch Removal and Installation, (See Page 20-60). Seat-back Cover Replacement, (See Page 20-61). Seat Cushion Cover Replacement, (See Page 20-61). 2. FRONT SEATS Removal and Installation, (See Page 20-54).
  • Page 990 Seats 20-54 Front Seat Removal and Installation Remove the seat track end covers and remove the bolts Lift up the front seat, then disconnect the seat belt securing the front seat. When prying with a flat-tip switch or seat heater connector. screwdriver, wrap it with protective tape to prevent damage.

  • Page 991: Seat Cushion

    Seats 20-55 Front Seat Disassembly and Reassembly NOTE: Take care not to scratch the body or tear the seat covers. When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage. Driver’s: 1. HEADREST 2. Forward 3. HOOK 4.
  • Page 992 Seats 20-56 Front Seat Disassembly and Reassembly (cont’d) Passenger’s: 1. HEADREST 2. Forward 3. HOOK 4. PIVOT NUT, 8 x 1.25 mm. (22 Nm 2.2 kgf/m, 16 lbf/ft) 5. PIVOT WASHER 6. SEAT CUSHION 7. CLIP 8. CENTRE COVER 9. 10 x 1.25 mm 47 Nm (4.8 kgf/m, 35 lbf/ft) 10.
  • Page 993 Seats 20-57 Front Seat Cover Replacement) NOTE: Fold back the seat-back cover, then release all Take care not to tear the seams or damage the seat inside springs. covers. Wear glovers to protect your hands. Seat Back cover: Fold the seat-back forward. Release the hook.
  • Page 994 Seats 20-58 Front Seat Cover Replacement (cont’d) Seat cushion cover: Install in the reverse order of removal and note the following items: Remove the front seat (See Page 20-54). To prevent wrinkles when installing a seat Remove the seat cushion (See Page 20-55).
  • Page 995 Seats 20-59 Rear Seat Removal and Installation NOTE: Take care not to scratch the body or tear the seat covers. 1. PIVOT BRACKET, 6 x 1.0 mm : Bolt locations 9.8 Nm (1.0 kgf/m, 7.2 lbf/ft) 2. SEAT BELT BUCKLE 3.
  • Page 996 Seats 20-60 Rear Seat-back Striker Replacement Rear Seat-back Latch Replacement NOTE: Take care not to scratch the interior trim and related NOTE: Take care not to scratch the seat cover. parts. Remove the seat-back (See Page 20-59). Remove the rear side trim panel seat (See Page 20-41).
  • Page 997 Seats 20-61 Rear Seat Cover Replacement NOTE: Release the hooks and unzip the cover, then fold Take care not tear the seams or damage the seat back the seat cover. covers. Wear gloves to protect your hands. Seat-back cover: Remove the seat-backs seat (See Page 20-59).

  • Page 998: Seat Cushion Cover

    Seats 20-62 Rear Seat Cover Replacement (cont’d) Pull back the edge of the seat-back cover all the way Seat cushion cover: around and release the clips, then remove the seat-back Remove the seat cushion (See Page 20-59). cover. Release all the clips. CLIP SEAT CUSHION COVER Pull back of the seat-back cover all the way around...
  • Page 999 Seats 20-63 Rear Seat Cover Replacement (cont’d) Install in the reverse order of removal and note these items: To prevent wrinkles when installing a seat cushion cover, make sure the material is stretched evenly over the pad before securing the clips, hooks and inside springs Replace the release clips with new ones using commercially available upholstery ring pliers.
  • Page 1000 Bumpers 20-64 Front Bumper Removal and Installation NOTE: An assistant is helpful when removing the front bumper. Take care not to scratch the front grille, front bumper and body. Wear gloves to protect your hands. 1. HOOK : Screw locations : Clip locations 2.
  • Page 1001 Bumpers 20-65 Front Bumper Removal and Installation (cont’d) 1. FRONT BUMPER UPPER BEAM : Bolt locations 2. FRONT BUMPER BEAM Install in the reverse order of removal and note the following items: After reinstalling the upper beam, adjust the aim of the headlights (see section 23). Make sure the front bumper engages the clips and hooks of the upper beam.
  • Page 1002 Bumpers 20-66 Rear Bumper Removal and Installation (cont’d) NOTE: An assistant is helpful when removing the rear bumper. Take care not to scratch the rear bumper and body. Wear gloves to protect your hands. 1. REAR BUMPER EXTENSION : Bolt locations : Nut locations, 4 : Clip locations, 13 2.
  • Page 1003 Hood 20-67 Replacement NOTE: An assistant is helpful when removing and installing the hood. Take care not to damage the hood and body. 1. HOOD : Bolt locations, 4 2. WINDSHIELD WASHER NOZZLES 3. CLIPS 4. CLIP 5. HOOK 6. WINDSHIELD WASHER TUBE Install in the reverse order of removal and note the following items: Make sure the hood opens properly and locks securely.
  • Page 1004 Hood 20-68 Adjustment Remove the front grille seat (See Page 20-76). Slightly loosen each hood hinge bolt. Adjust the hood alignment in this sequence. Adjust the hood right and left, as well as fore and aft, by using the elongated holes on the hood hinge. Turn the hood edge cushions, as necessary, to make the hood fit flush with the body at front and side edges.
  • Page 1005 Hood 20-69 Adjustment (cont’d) Hood Insulator Replacement Tighten each bolt securely. NOTE: Take care not to scratch the hood. Check that the hood opens properly and locks securely. Remove the hood insulator. Grease each location of the hood latch and hood hinge Disconnect the windshield washer tubes from as indicated by the arrows.
  • Page 1006 Hood 20-70 Hood Seal Rubber Replacement Using a clip remover, detach the clips, then remove the hood seal rubbers. If equipped, remove the hood front seal rubber. Take care not to scratch the hood. : Clip locations, 5 HOOD HOOD SEAL RUBBER CLIP Install in the reverse order of removal;...
  • Page 1007 Tailgate 20-71 Replacement NOTE: An assistant is helpful when removing the tailgate. Take care not to scratch the tailgate. Wear gloves to protect your hands. Remove the tailgate trim. Disconnect the rear wiper motor connector, rear window defogger connector, rear license light connector, tailgate latch switch connector, tailgate latch actuator connector and rear washer tube.
  • Page 1008 Tailgate 20-72 Replacement (cont’d) Remove the open stay from the open stay bracket. Remove the bolts, then remove the tailgate. 1. TAILGATE : Bolt locations, 4 : Nut locations, 2 2. OPEN STAY 3. OPEN STAY BRACKET Remove the open stay from the tailgate. Install in the reverse order of removal and note the following items: Make sure the connectors and wire harness are routed properly.
  • Page 1009 Tailgate 20-73 Replacement (cont’d) NOTE: Before adjusting the tailgate, loosen each bolt and nut slightly. The support struts should be removed. Adjust the tailgate hinges right and left, as well as fore and aft, by using the elongated holes. Turn the tailgate edge cushions, as necessary, to make the tailgate fit flush with the body at each side. Adjust the tailgate fit to the tailgate opening by moving the striker.
  • Page 1010 Tailgate 20-74 Tailgate Open Stay Replacement NOTE: Remove the rear pillar trim (See Page 20-41). An assistant is helpful when removing the tailgate. Remove the bolts, then remove the open stay Take care not to scratch the tailgate and interior trim. bracket.
  • Page 1011 Tailgate 20-75 Tailgate Weatherstrip Installation Locate the painted alignment mark on the tailgate weatherstrip. Align the painted mark to the centre of tailgate. Make sure there are no wrinkles in the weatherstrip. TAILGATE WEATHERSTRIP ALIGNMENT MARK Inside BODY STEEL CORE Check for water leaks.

  • Page 1012: Exterior Trim

    Exterior Trim 20-76 Front Grille Removal and Installation Rear License Trim Removal and Installation NOTE: Take care not to scratch the front bumper and related NOTE: Take care not to scratch the front bumper and parts. related parts. Remove the clips and release the hook from the front Remove the tailgate trim seat (See Page 20-41).
  • Page 1013 Exterior Trim 20-77 Tailgate Lower Trim Removal and Installation Tailgate Lower Trim Disassembly NOTE: Take care not to scratch the tailgate and related parts. NOTE: Take care not to scratch the tailgate lower trim. Remove the tailgate trim seat (See Page 20-41).
  • Page 1014 Exterior Trim 20-78 Roof Spoiler/Roof Side Trim Removal and Installation NOTE: Take care not to scratch the body and related parts. Using a flat-tip screwdriver wrapped with protective tape. Remove the caps from the roof spoiler, then remove the bolts (use Torx T-30 bit). Slide the roof spoiler behind and remove it.
  • Page 1015 Exterior Trim 20-79 Roof Spoiler/Roof Side Trim Removal and Installation (cont’d) Remove the caps from the roof side trim, then remove the nuts. Lift and slide the roof side trim behind and remove it. 1. ROOF SIDE CLIP : Nut locations 2.
  • Page 1016 Exterior Trim 20-80 Roof Side Trim Disassembly NOTE: Take care not to scratch the roof side trim. 1. HOOKS : Bolt, screw locations 2. ROOF SIDE TRIM 3. ROOF SIDE TRIM BRACKET 4. ROOF SIDE CLIP...

  • Page 1017: Protective Tape

    Exterior Trim 20-81 Roof Molding Replacement NOTE: Take care not to scratch the body. Using a flat-tip screwdriver wrapped with protective tape. Use protective tape on the body. 1. WINDSHIELD MOLDING 2. ROOF MOLDING 3. PIN 4. PROTECTIVE TAPE Install in the reverse order of removal and make sure the roof molding is installed securely.
  • Page 1018 Exterior Trim 20-82 Side Sill Panel Replacement Remove the side sill panel. Pull the inner fender back as necessary and remove the expansion clips. Slide the side sill panel forward and remove it. Side clips will stay in the body. Remove the side clips from the body.
  • Page 1019 Exterior Trim 20-83 Roof Side Trim Disassembly NOTE: Take care not to scratch the body and related parts. Remove the bolts and clips, then remove the splash shield 1. FRONT BUMPER : Bolt locations, 2 : Clip locations 2. SPLASH SHIELD Remove the screws and clips, then remove the inner fender.

  • Page 1020: Air Outlet

    Exterior Trim 20-84 Fuel Pipe Protector Removal and Installation Air Outlet Removal and Installation NOTE: Take care not to scratch the body. NOTE: Take care not to scratch the body and related Remove the clips, then remove the fuel pipe protector. parts.
  • Page 1021 Exterior Trim 20-85 Fenderwell Trim Replacement Protection Tape Replacement NOTE: The steel core in the fenderwell trim cannot be Align the application tape with the front portion of rear restored to its original shape once it has been bent. Replace fender edge, as shown, then press the protection tape the fenderwell trim when the steel core is bent.
  • Page 1022 Openers 20-86 Component Location Index 1. TAILGATE LOCK CYLINDER, Replacement, (See Page 20-93). 2. TAILGATE HANDLE, Replacement, (See Page 20-92). 3. TAILGATE OPENER CABLE, 4. FUEL LID LATCH, Replacement, (See Page 20-91). 5. TAILGATE LATCH, Replacement, (See Page 20-92). 6. FUEL LID OPENER, Replacement, (See Page 20-90).
  • Page 1023 Openers 20-87 Hood Opener Cable Replacement NOTE: Take care not to scratch the body and related parts. Remove: Front Grille (See Page 20-76). Inner fender (See Page 20-83). Kick panel (See Page 20-41). Disconnect the hood opener cable from the hood latch (See Page 20-89).
  • Page 1024 Openers 20-88 Fuel Lid Opener Cable Replacement NOTE: Take care not to scratch the body and related parts. Remove: Side trim (See Page 20-41). Rear seat-back (See Page 20-59). Rear seat cushion (See Page 20-59). Rear side (See Page 20-41). Carpet as necessary, (See Page 20-46).

  • Page 1025: Hood Release Handle

    Openers 20-89 Hood Release Handle Replacement Hood Latch Replacement NOTE: Take care not to scratch the body and related parts. NOTE: Take care not to scratch the body and related parts. Remove the kick panel (See Page 20-41). Remove the bolts, then remove the hood release handle. Remove the front bumper (See Page 20-64).

  • Page 1026: Hood Latch

    Openers 20-90 Hood Latch Replacement (cont’d) Fuel Lid Opener Replacement Install in the reverse order of removal and note these NOTE: Take care not to scratch the related parts. items: Remove: Grease each location of the hood latch indicated by Side trim (See Page 20-41).
  • Page 1027 Openers 20-91 Fuel Lid Opener Replacement NOTE: Take care not to scratch the related parts. Install in the reverse order of removal and note these items: Remove the left side trim (See Page 20-41). Grease each location indicted by the arrows. Turn the fuel lid latch 90°...
  • Page 1028 Openers 20-92 Tailgate Handle Replacement (cont’d) Tailgate Latch Replacement NOTE: Take care not to scratch the related parts. NOTE: Take care not to scratch the related parts. Remove the rear license trim (See Page 20-76). Remove the tailgate trim See Page 20-77).

  • Page 1029: Tailgate Lock Cylinder

    Openers 20-93 Tailgate Lock Cylinder Replacement NOTE: Take care not to scratch the related parts. Remove the tailgate trim (See Page 20-77). Disconnect the cylinder rod, then remove the bolt. : Bolt location, 1 TAILGATE LOCK CYLINDER CYLINDER ROD Turn the tailgate lock cylinder and remove it. TAILGATE LOCK CYLINDER Install in the reverse order of removal, make sure the cylinder cord is connected properly.
  • Page 1030 3. HOOD 4. CLIP 5. PIN 6. ADHESIVE TAPE 7. REAR H STICKER 8. APPLICATION TAPE 9. ALIGNMENT MARK 10. HR-V STICKER 11. Edge of the rear window. 12. Edge of the tailgate. 13. 3 mm (0.12 in). 14. HONDA STICKER...
  • Page 1031 Sub-frame 20-95 Sub-frame Replacement Sub-frame Torque After loosening the sub-frame mounting bolts, be sure to replace them with new ones. 1. LINK BRACKET 2. To body 3. SPECIAL BOLT, 12 x 1.5 mm 54 Nm (5.5 kgf/m, 40 lbf/ft) 4. SPECIAL BOLT, 14 x 1.5 mm 74 Nm (7.5 kgf/m, 54 lbf/ft), Replace.
  • Page 1032 Frame Repair Chart 20-96 Top view: Unit: mm (in) Ø : Inner diameter...
  • Page 1033 Frame Repair Chart 20-97 (cont’d)
  • Page 1034 Frame Repair Chart 20-98 (cont’d) Side view: Unit: mm (in) Ø : Inner diameter...
  • Page 1035 Frame Repair Chart 20-99 (cont’d)
  • Page 1037 Component Location 21-2 Index SRS Components are located in this area. Review the SRS component locations, precautions and procedures in the SRS section (24) before performing repairs or service. NOTE: LHD type is shown, RHD type is symmetrical. 1. HEATER UNIT Replacement, (See Page 21-16)

  • Page 1038: Circuit Diagram

    Circuit Diagram 21-3...
  • Page 1039 Troubleshooting 21-4 Symptom Chart Note the following items before troubleshooting a symptom: Check the engine coolant level, and allow the engine to warm up before troubleshooting. Any abnormality must be corrected before continuing the test. Because of the precise measurements needed, use a digital circuit tester when testing. Before performing any troubleshooting procedures check: Fuse No.
  • Page 1040 Troubleshooting 21-5 Blower Motor Speed...
  • Page 1041 Troubleshooting 21-6 Blower Motor...
  • Page 1042 Troubleshooting 21-7 Blower Motor (cont’d)
  • Page 1043 Troubleshooting 21-8 Blower Motor (cont’d)
  • Page 1044 Troubleshooting 21-9 Recirculation Control Motor To go to the page referenced on the diagram above, click on the following: (See Page 21-13)
  • Page 1045 Troubleshooting 21-10 Recirculation Control Motor (cont’d)

  • Page 1046: Heater Fan Switch Test

    Relays Heater Fan Switch 21-11 Test Test There should be continuity between the No. 3 and No. 4 Check for continuity between the terminals in each terminals when power and ground are connected to the No.1 switch position according to the table. and No.
  • Page 1047 Recirculation Control/A/C Switch 21-12 Replacement Test NOTE: LHD type is shown, RHD type is symmetrical. Check for continuity between the terminals in each Remove the centre panel (see section 20) switch position according to the table. Remove the self-tapping screws and the recirculation control/A/C switch from the centre panel.

  • Page 1048: Recirculation Control Motor Test

    Recirculation Control Motor 21-13 Test Replacement Disconnect the 5P connector from the recirculation NOTE: LHD type is shown, RHD is symmetrical. control motor. Disconnect the 5P connector from the recirculation Connect battery power to the No. 5 terminal and ground control motor.
  • Page 1049 Heater Control Panel 21-14 Replacement NOTE: LHD type is shown, RHD type is symmetrical. Install in the reverse order of removal, and note Disconnect the air mix control cable and the mode these items: control cable from the heater unit (See Page 21-20).
  • Page 1050 Heater Control Panel 21-15 Overhaul AIR MIX CONTROL CABLE MODE CONTROL CABLE HEATER FAN SWITCH Test, (See Page 21-11) Control Cable Replacement Cut the inner cable on the slider side of the cable holder, then remove both pieces of the inner cable. SLIDER STOPS CABLE HOUSING...
  • Page 1051 Heater Unit 21-16 Replacement SRS components are located in this area. review the SRS Slide the clamps back, then disconnect the inlet component locations, precautions and procedures in the SRS and outlet heater hoses from the heater unit. section (24) before performing repairs or service. Engine coolant will run out when the hoses are NOTE: LHD type is shown, RHD type is symmetrical.
  • Page 1052 Heater Unit 21-17 Replacement (cont’d) Remove the dashboard (see section 20). With air conditioning; remove the evaporator (See Remove the mounting bolts in the following sequence, Page 22-26). then remove the steering hanger beam. Without air conditioning; disconnect the connector from the recirculation control motor, then remove the clip, the wire harness clip, the self-tapping screws, the mounting bolts, the mounting nut and...
  • Page 1053 Heater Core 21-18 Replacement NOTE: Reassemble in the reverse order of disassembly LHD type is shown, RHD type is symmetrical. and note these items: The heater core can be replaced without removing the Make sure that there are is no air leakage. blower motor and the blower resistor.

  • Page 1054: Blower Motor Replacement

    Blower Motor Mode Control 21-19 Replacement Adjustment NOTE: LHD type is shown, RHD type is symmetrical. NOTE: LHD type is shown, RHD type is symmetrical. Loosen the one mounting bolt as shown, and remove From under the dash, disconnect the mode control the wire harness clip, the mounting bolts and the cable housing from the clamp, and disconnect the steering hanger beam.
  • Page 1055 Temperature Control 21-20 Adjustment Air Mix Control Cable Heater Valve Cable NOTE: LHD type is shown, RHD type is symmetrical. NOTE: LHD type is shown, RHD type is symmetrical. From under the hood, open the clamp, then disconnect From under the hood, open the clamp, then the heater valve cable from the heater arm.

  • Page 1057: Special Tools

    Special Tools 22-2 | Ref No. Tool Number Description | Qty Remark | 07JGG - 0010100 | Belt Tension Gauge | 07NAB - HAC0101 | A/C Clutch Holder | 07947 - 6340300 | Drive Attachment | 07965 - 6920500 | Hub Assembly Guide Attachment...
  • Page 1058 Component Location 22-3 Index NOTE: LHD type is shown, RHD type is symmetrical. 1. SERVICE VALVE (LOW PRESSURE SIDE) 2. SERVICE VALVE (HIGH PRESSURE SIDE) 3. EVAPORATOR , Replacement, (See Page 22-26) Overhaul, (See Page 22-27) A/C FILTER, Replacement, (See Page 22-37) A/C THERMOSTAT , Test, (See Page...

  • Page 1059: A/C Pressure Switch

    Component Location 22-4 Index (cont’d) NOTE: LHD type is shown, RHD type is symmetrical. 1. BLOWER MOTOR RELAY, Test, (See Page 21-11) RADIATOR FAN RELAY, CONDENSER FAN RELAY, COMPRESSOR CLUTCH RELAY (Located in the under-hood fuse/relay box) Test, (See Page 22-23) 2.
  • Page 1060 Description 22-5 The air conditioner system removes heat from the passenger compartment by circulating refrigerant through the systems as shown below. 1. SUCTION LINE (LOW-PRESSURE SIDE) 2. EVAPORATOR 3. DISCHARGE LINE (HIGH-PRESSURE SIDE) 4. CONDENSER LINE 5. LIQUID LINE 6. RECEIVER/DRYER 7.

  • Page 1061: Circuit Diagram

    Circuit Diagram 22-6...
  • Page 1062 Troubleshooting 22-7 Symptom Chart Note the following items before troubleshooting a symptom: Check the engine coolant level and allow the engine to warm up before troubleshooting. Any abnormality must be corrected before continuing the test. Because of the precise measurements needed, us a digital circuit tester when testing. Before performing any troubleshooting procedures check: Fuses No.
  • Page 1063 Troubleshooting 22-8 Radiator Fan To go to the page referenced on the diagram above, click on the following: (See Page 22-23)
  • Page 1064 Troubleshooting 22-9 Radiator Fan (cont’d)
  • Page 1065 Troubleshooting 22-10 Radiator Fan (cont’d)
  • Page 1066 Troubleshooting 22-11 Condenser Fan To go to the page referenced on the diagram above, click on the following: (See Page 22-23)
  • Page 1067 Troubleshooting 22-12 Condenser Fan (cont’d)
  • Page 1068 Troubleshooting 22-13 Condenser Fan (cont’d)
  • Page 1069 Troubleshooting 22-14 Both Fans...
  • Page 1070 Troubleshooting 22-15 Radiator Fan Switch...
  • Page 1071 Troubleshooting 22-16 Compressor To go to the pages referenced on the diagram above, click on the following: (See Page 22-23)
  • Page 1072 Troubleshooting 22-17 Compressor (cont’d) To go to the pages referenced on the diagram above, click on the following: (See Page 22-31)
  • Page 1073 Troubleshooting 22-18 Compressor (cont’d)
  • Page 1074 Troubleshooting 22-19 A/C System...
  • Page 1075 Troubleshooting 22-20 A/C System (cont’d)
  • Page 1076 Troubleshooting 22-21 A/C System (cont’d)
  • Page 1077 Troubleshooting 22-22 A/C System (cont’d) To go to the page referenced on the diagram above, click on the following: (See Page 22-11)
  • Page 1078 A/C Thermostat Relays 22-23 Test Test Connect battery power to the No. 3 terminal, ground the No. There should be continuity between the No. 1 and No. 2 2 terminal and connect a test light between the No. 1 and No. terminals when power and ground are connected t the 3 terminals.

  • Page 1079: A/C Service Tips And Precautions

    A/C Service Tips and Precautions 22-24 The air conditioning system uses HFC-134a (R-134a) refrigerant and polyalkyleneglycol (PAG) refrigerant oil*, which are not compatible with CFC-12 (R-12) refrigerant and mineral oil. Do not use R-12 refrigerant or mineral oil in this system and do not attempt to use R-12 servicing equipment; damage to the air conditioning system or your servicing equipment will result.

  • Page 1080: A/C System Torque Specifications

    A/C System Torque Specifications 22-25 NOTE: LHD type is shown, RHD type is symmetrical. A. SUCTION LINE B. EVAPORATOR C. RECEIVER LINE B D. RECEIVER LINE A E. RECEIVER/DRYER F. CONDENSER LINE G. COMPRESSOR BRACKET H. CONDENSER CONDENSER J. SUCTION HOSE K.
  • Page 1081 Evaporator 22-26 Replacement NOTE: LHD type is shown, RHD type is symmetrical. Install in the reverse order of removal and note the following items: Discharge the refrigerant (See Page 22-38). If you are installing a new evaporator, add Remove the bolts, then disconnect the suction and refrigerant oil (KEIHIN Sp-10) (See Page receiver lines from the evaporator.

  • Page 1082: Recirculation Control

    Evaporator 22-27 Overhaul NOTE: LHD type is shown, RHD type is symmetrical. Reassemble in the reverse order of disassembly Remove the filter lid, then pull out the A/C filters. and note the following items: Remove the self-tapping screws and the recirculation Replace the O-rings with new ones at each control motor.

  • Page 1083: Compressor Replacement

    Compressor 22-28 Replacement NOTE: LHD type is shown, RHD type is similar. Loosen the centre nut of the idler pulley and the If the compressor is marginally operable, run the engine adjusting bolt, then remove the A/C compressor at idle speed and let the air conditioning work for a few belt from the pulleys.
  • Page 1084 Compressor 22-29 Replacement (cont’d) If necessary remove the compressor bracket as follows: Install in the reverse order of removal and note the Remove the nut and washer from the left front following items: mount. When tightening the nut to the left front If you are installing a new compressor, drain mount, make sure the washer is set properly on the all the refrigerant oil form the removed...
  • Page 1085 Compressor 22-30 Illustrated Index 1. CENTRE NUT, Replace 2. ARMATURE PLATE , Inspection (See Page 22-31) 3. SHIM(S), Replace 4. SNAP RING B, Replace 5. ROTOR PULLEY, Inspection (See Page 22-31) 6. SNAP RING A, Replace 7. FIELD COIL, Inspection (See Page 22-31) 8.
  • Page 1086 Compressor 22-31 Clutch Inspection Check the plated parts of the armature plate for colour Release the field coil connector from the holder, changes, peeling or other damage. If there is damage, then disconnect it. Check the thermal protector for replace the clutch set. continuity.

  • Page 1087: Compressor Clutch Overhaul

    Compressor 22-32 Clutch Overhaul Remove the centre nut while holding the armature plate Remove the snap ring B with snap ring pliers. Be with the special tool. careful not to damage the rotor pulley and compressor. A/C CLUTCH HOLDER, 07NAB-HAC0100 CENTRE NUT, 17.6 Nm (1.8 kgf/m, 13 lbf/ft), Replace ARMATURE PLATE SNAP RING B, Replace...
  • Page 1088 Compressor 22-33 Clutch Overhaul (cont’d) Remove the bolt, holder, screw and clamp, then Position the rotor pulley squarely over the field coil. disconnect the field coil connector. Remove the snap Press the rotor pulley onto the compressor boss ring A with snap ring pliers, then remove the field coil. with the special tool.

  • Page 1089: Ground Terminal

    Compressor 22-34 Thermal Protector Replacement Relief Valve Replacement Remove the bolt, the ground terminal and the holder. Discharge the refrigerant (See Page 22-38). Disconnect the field coil connector, then remove the Remove the relief valve and the O-ring. Plug the thermal protector.
  • Page 1090 A/C Compressor Belt 22-35 Adjustment Deflection Method Tension Gauge Method Apply a force of 98 N (10 kgf, 22 lbf) and measure the Attach the special tool to the A/C compressor belt deflection between the A/C compressor and the as shown below and measure the tension of the crankshaft pulley.

  • Page 1091: Discharge Line

    Condenser 22-36 Replacement NOTE: LHD type is shown, RHD type is similar. Remove the wire harness clip, bolts and upper mount bracket. Discharge the refrigerant (See Page 22-38). Disconnect the condenser fan connector and remove the wire harness clips and the compressor clutch connector from the condenser fan shroud.

  • Page 1092: Condenser Assembly

    Condenser A/C Filter 22-37 Replacement (cont’d) Replacement Remove the condenser assembly by lifting it up. Be NOTE: LHD type is shown, RHD type is symmetrical. careful not to damage the condenser fins when Remove the glove box (see section20). removing the condenser assembly. Remove the filter lid from the evaporator, then pull out the lower A/C filter and the upper A/C filter.
  • Page 1093 A/C System Service 22-38 Discharge NOTE: Use only a gauge set for refrigerant HFC-134a (R-134a). Connect the R-134a gauge set as shown. Air conditioning refrigerant or lubricant vapour can Disconnect the centre hose of the gauge set and irritate your eyes, nose and throat. place the free end in a shop towel.
  • Page 1094 A/C System Service 22-39 Evacuation NOTE: Connect the R-134a gauge set, pump and Use only a gauge set for refrigerant HFC-134a (R-134a). refrigerant containers (cans of R-134a) as shown. Us a vacuum pump adapter which is equipped with a Start the pump, then open both pressure valves check valve to prevent backflow of the vacuum pump oil.

This manual is also suitable for:

Hr-v 2000Hr-v 2001

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