Table Of Contents - Honda Accord Repair Manual

Table of Contents

Introduction2
General Information3
Chassis And Engine Codes4
Vehicle Identification Number4
Engine Serial Number4
Transmission Number4
Identification Number Locations5
Label Locations6
A20A4 Engine (Ks Model) Shown; Other Engine Similer6
Sedan6
Lift And Support Points7
Hoist7
Floor Jack8
Safety Stands9
Towing10
Preparation Of Work11
Special Caution Items For This Car11
Electrical14
Symbol Marks17
Special Tools18
Newly Provided Tools19
Special Tools (Common With Other Models)19
Engine Removal/Installation19
Cylinder Head/Valve Train20
Engine Block20
Engine Lubrication21
Fuel And Carburetor21
Clutch21
Manual Transmission22
Automatic Transmission23
Differential24
Steering24
Power Steering25
Suspension26
Brake27
Body28
Specifications29
Standard And Service Limits30
Cooling31
Fuel And Emissions31
Manual Transmission (A1/A2)32
Automatic Transmission (F4: 2000 Engine)33
Automatic Transmission (C9: 1600 Engine)35
Driveshaft37
Engine Electrical38
Design Specifications39
European Model39
Kq Model44
General Export Model46
Body Specifications47
4 D Sedan47
Aerodeck48
Glass Back49
Maintenance50
Lubrication Points51
Recommended Engine Oil (Se Or Sf Grade Only)51
Engine Oil Viscosity For Ambient Temperature Ranges51
Required Maintenance Schedule53
Engine54
Power Steering Pump61
A/C Compressor61
Alternator61
Illustrated Index65
Cylinder Head67
Removal (Engine Removal Not Required)67
A20A4 Engine (Other Engines, Go To 13)67
Other Engines (A20A4 Engine, Go To 20)67
Camshaft Pulley68
Camshaft68
Removal68
Inspection68
Rocker Arms70
Overhaul70
Intake And Exhaust Valves71
Clearance71
Replacement71
Valve Seat Reconditioning72
Valve Guide-To-Valve Stem Clearance73
Warpage73
Valve Guide74
Reaming74
Valve Spring, Valve75
Valve Spring Installation Sequence75
Valve Installation75
Cam/Rocker Arm And Camshaft Seal/Pulley76
Installation76
Cylinder Head: Installation77
Timing Belt78
Positioning Crankshaft Before Installing Timing Belt79
Tension Adjustment80
Valve: Adjustment81
A20A Engine Shown; A16A Engine Similar83
Flywheel Replacement (Manual Transmission)85
Connecting Rod End Play85
Drive Plate Replacement (Automatic Transmission)85
Crankshaft End Play85
Main Bearing86
Rod Bearing86
Selection87
Crank Bore Code Lubrication (Marks)87
Rod Code Location (Numbers)87
Bearing Identification87
Crankshaft/Piston: Removal88
Crankshaft: Inspection89
Alignment89
Out-Of-Round And Taper89
Piston90
Piston-To-Block Clearance90
Cylinder Block: Inspection91
Piston Pin92
Bore Honing92
Connecting Rod: Selection93
Piston Pin: Installation93
Piston Ring95
End Gap95
Land Clearances96
Piston: Installation97
Crankshaft: Installation97
Oil Seal: Installation98
Oil Level: Inspection101
Engine Oil: Replacement101
Oil Filter: Replacement102
Oil Pressure: Test102
Oil Pump: Illustrated Index103
Oil Pump: Removal/Inspection104
Oil Filter Base: Inspection105
Intake Manifold/Exhaust System106
Intake Manifold107
A20A4 Engine107
A20A1 Engine Shown; A20A2 And A16A1 Engine Similar108
European Model Engine And Ky Model Engine109
Kg And Kw Model Engine (With Catalytic Converter)110
Exhaust Manifold111
Other Engine Model111
Exhaust Pipe And Muffler112
European Mode Engine112
Exhaust Pipe And Muffler: Replacement113
Catalytic Converter: Replacement114
Catalytic Converter Torque Sequence114
Radiator: Replacement116
A20A2 Engine Shown: A20A1 And A16A1 Engine Similar117
Radiator118
Refilling And Bleeding118
Cap Testing119
Radiator Testing119
Thermostat: Replacement120
Thermostat/Water Pump121
Thermostat Testing121
Water Pump Replacement121
Temperature Gauge122
Fan Thermosensor123
Testing123
Temperature Gauge Sending Unit, Belt Adjustment124
Temperature Gauge Sending Unit Testing124
Fuel And Emission Controls (Carbureted Engine)125
Interconnect Diagram126
A16A1 Kg, Kf, Kw (M/T) Model126
A16A1 Kg, Kf, Kw (A/T) And Kt Model126
A20A2 Kf, Kg, Kw, Ke, Ky Model127
A20A2 Kp, Kt Model128
A20A2 Ks (A/T) Model128
A20A2 Ks (M/T) Model129
Control Box129
A20A2 Kx Model130
A20A2 Kq Model131
Vacuum And Electrical Connections132
A16A1 Kf, Kg, Kw (M/T) Model132
A16A1 Kg, Kw, Kf (A/T) And Kt Model133
A20A2 Kf, Kg, Kw, Ke, Ky (M/T) Model134
A20A2 Kf, Kg, Kw, Ke, Ky (A/T) Model135
Wiring Diagram141
Except A20A2 Kq, Kx, Ks Model141
A20A2 Ks Model142
A20A2 Kx, Kq Model143
Carburetor144
Index144
Idle Speed/Mixture145
Inspection/Adjustment145
A20A2 Kq, Kx Model145
Other Model147
Idle Speed (Cars With Air Conditioner)148
Throttle/Choke Cable149
Throttle Cable Inspection/Adjustment149
Idle-Drop Method149
Removal/Installation150
Throttle Cable Installation151
Choke Cable Adjustment151
A16A1 Model151
Float Level: Inspection/Adjustment152
Automatic Choke152
Choke Coil Tension And Linkage152
A20A2 Model152
Fast Unloader153
Choke Opener154
Kq, Kx Model154
Cranking Leak System156
Choke Coil Heater156
Fast Idle Adjustment157
Linkage Adjustment157
1St Stage Clearance157
2Nd Stage Clearance158
3Rd Stage Clearance158
Manual Choke159
Choke Cover-Replacement159
Power Valve: Inspection161
Primary Slow Mixture Cut-Off Solenoid Valve: Testing163
Vacuum Controlled Secondary: Inspection164
A/C Idle Boost Control System165
System Inspection165
Dashpot System166
A/T Model And Kp, Kt, Kq, Kx (M/T) Model166
Kf, Kg, Kw, Ky, Ks (M/T) Model166
Throttle Control Valve Inspection167
Except Ks (M/T) Model167
Ks (M/T) Model168
Cranking Opener Solenoid Valve Inspection169
Kf, Kg, Kw, Ke, Ky, Ks (M/T) Model169
Speed Sensor Inspection170
Throttle Controller Adjusting171
Primary Bore Heater (Early Fuel Evaporator System)172
Efe Heater Inspection173
Efe Heater Control Unit Inspection173
Carburetor: Replacement Of Attached Parts174
Emission Controls176
Crankcase Control System177
Pcv Valve177
Blow-By Filter177
Evaporative Control System: Inspection178
Thermovalve B179
Charcol Canister180
Air Vent Cut-Off Diaphragm181
Carburetor Thermovalve182
Two-Way Valve183
Ky, Kt, Kq Models183
Intake Air Control System: Inspection184
Ignition Timing Control System: Inspection185
A16A1 Model And A20A2 Kp, Kt Model185
A20A2 Model (Except Kp, Kt)186
Egr System: Inspection187
Air Injection System188
Air Suction Valve Inspection188
Egr Valve188
Catalytic Converter: Inspection191
Solenoid Valve Control Unit192
Electrical Connection192
Troubleshooting193
Ks Model194
Speed Sensor195
Thermoswitch195
Intake Air Temperature Switch196
Clutch Switch196
Vacuum Switchs197
Vacuum Switch A197
Vacuum Switch B197
Air Conditioner Switch Signal198
Vacuum Switch C198
Fuel199
Fuel Filters: Replacement200
Fuel Pump: Testing200
Fuel Gauge: Testing202
Fuel Gauge Sending Unit: Testing/Replacement202
Low Fuel Warning Light: Testing203
Fuel Cut-Off Valve: Replacement204
Fuel Tank: Replacement205
Fuel And Emission Controls (Fuel Injected Engine)206
Except Ke Model207
Ke Model208
Product View210
Throttle Cable211
Vacuum And Electrical Connection212
Except Ke And Kx Model213
Interconnect Diagram: Ke Model215
Interconnect Diagram: Kx Model217
Pgm-Fi: Troubleshooting219
Self-Diagnosis Indicator: Troubleshooting221
Self-Diagnosis Indicator Remains Off - The Dash Warning Light Is Not Lit223
Self-Diagnosis Indicator Remains Off - The Dash Warning Light Is Lit223
Self Diagnosis Indicator Blinks Once [Kx Model]224
Self Diagnosis Indicator Blinks Three Times226
Self Diagnosis Indicator Blinks Five Times227
Self Diagnosis Indicator Blinks Six Times228
Self Diagnosis Indicator Blinks Seven Times229
Self Diagnosis Indicator Blinks Eight Times229
Self Diagnosis Indicator Blinks Nine Times230
Self Diagnosis Indicator Blinks Ten Times230
Self Diagnosis Indicator Blinks Eleven Times [Except Kx Model]231
Self Diagnosis Indicator Blinks Thirteen Times232
Idle Control: Troubleshooting233
Starter Switch Signal Inspection235
Alternator Fr Terminal Signal Inspection235
A/T Shift Position Signal Inspection236
Air Conditioner Switch Signal Inspection237
Idle Control Solenoid Valve Inspection237
A/T Idle Control Solenoid Valve Inspection238
A/C Idle Boost Solenoid Valve Inspection238
Sensors239
Oxygen Sensor [Kx Model]239
Idle Mixture Adjustor (Ima) Sensor239
Manifold Absolute Pressure (Map) Sensor240
Intake Air Temperature (Ta) Sensor241
Coolant Temperature (Tw) Sensor241
Throttle Angle Sensor242
Crank Angle Sensor243
Atmospheric Pressure (Pa) Sensor243
Cyl Sensor Inspection243
Tdc Sensor Inspection243
Solenoid Valves244
Idle Control Solenoid Valve244
A/T Idle Control Solenoid Valve244
A/C Idle Boost Solenoid Valve245
Air Intake System246
Throttle Body Disassembly246
Idle Speed Inspection247
Idle Mixture Inspection248
Throttle Control System248
Fast Idle Valve249
Fuel System250
Fuel Pressure Relieving250
Injector Testing251
Injector Replacement252
Fuel System Resistor Testing253
Fuel Pressure Testing253
Pressure Regulator254
Fuel Filter Replacement255
Fuel Pump Inspection255
Fuel Pump Replacement257
Main Relay Testing257
Harness Testing258
Fuel Cut-Off System260
Crankcase Controls260
Ignition Timing Controls261
Cold Advance Solenoid Valve263
Transaxle264
Clutch: Illustrated Index266
Adjustment267
Release Bearing: Removal268
Pressure Plate: Removal/Inspection270
Clutch Disc: Inspection271
Flywheel: Inspection/Removal272
Flywheel And Clutch: Installation272
Transmission Assy: Removal275
Oil Level Inspection275
Oil Change275
Transmission Housing: Disassembly279
Reverse Fork281
Countershaft/Mainshaft: Removal281
Shift Shaft Clearance281
Differential Oil Seal: Removal283
Bearings And Seals283
Replacement (Clutch Housing)283
Bearings285
Replacement (Trans Housing)285
Mainshaft: Index286
Countershaft: Index287
Gear And Synchro Ring: Inspections288
Synchronizer Sleeve, Shift Shaft289
Shift Fork To Synchronizer Sleeve Clearance289
Synchronizer Sleeve And Hub Inspections289
Installing Synchronizer Hubs In Sleeves289
Mainshaft: Inspection290
Countershaft: Inspection290
Wear290
Runout290
Reassembly And Measurement291
Mainshaft Assembly291
Countershaft Assembly291
Mainshaft Measurements292
Countershaft Measurements294
Replacement Thrust Washers294
Shift Arm Holder: Index295
Clearances295
Shift Arm/Selector Arm296
Shift Rod And Shift Arm Holder296
Shift Guide Clearance296
Interlock Clearance296
Shift Arm/Gear Selector Arm297
Shift Rod: Installation297
Shift Rod Guide Clearance297
Shift Arm Holder Assy: Installation298
Transmission Assy: Reassembly298
Differential Oil Seal: Installation303
Transmission Assy: Installation304
Car Raised On Hoist304
Car On Ground304
Gearshift Mechanism305
Overhau305
Back-Up Light Switch: Testing306
Description308
Torque Converter, Gears, And Clutches308
Hydraulic Control308
Lock-Up Mechanism308
Road Test312
Pressure Test313
Stall Speed: Test314
Checking/Charging314
Transmission: Removal315
Transmission Housing: Removal318
Mainshaft/Countershaft: Removal322
Governor Valve: Removal322
Main Valve Body: Removal323
Control Shaft: Removal327
Disassembly/Reassembly327
One-Way Clutch/Parking Gear328
Disassembly And Inspection328
Main Valve Body: Disassembly329
Secondary Valve330
Disassembly/Inspection/Reassembly330
Valve Body: Repair331
Main Valve Body: Reassembly332
Regulator Valve Body: Disassembly/Inspection334
Reassembly334
Lock-Up Shift Valve Body: Disassembly/Inspection335
Servo Valve Body: Disassembly/Inspection/Reassembly336
Governor Valve: Disassembly/Inspection/Reassembly337
Mainshaft: Disassembly/Inspection/Reassembly338
Countershaft: Disassembly/Inspection/Reassembly339
Countershaft/Mainshaft340
Clearance Measurements340
Replacement Spacer Collars341
Replacement Splined Thrust Washers341
Clutch: Disassembly343
Clutch: Disassembly/Inspection346
Clutch: Reassembly348
Differential And Seal: Replacement352
Bearings And Seals: Replacement353
Torque Converter Housing353
End Cover355
Throttle Control Shaft: Installation356
Transmission: Reassembly356
Torque Converter: Disassembly370
Transmission: Installation371
Console Switch: Test/Replacement373
Inhibiter Switch373
Shift Indicator Light374
Shift Indicator Panel: Adjustment374
Check And Installation374
Gearshift Selector: Overhaul375
Shift Cable: Adjustment376
Throttle Control Cable Bracket377
Throttle Control Cable377
Adjustment (Carbureted Engine)377
Adjustment/Inspection (Carbureted Engine)377
Adjustment/Inspection (Fuel-Injected Engine)379
Differential (Manual Transmission)381
Differential (Automatic Transmission)382
Backlash Inspection383
Bearing Replacement383
Inspection/Disassembly384
Differential: Reassembly385
Differential: Installation387
Driveshafts390
Driveshafts: Removal391
Driveshafts: Reassembly393
Manual Steering: Index395
Steering Wheel Rotational Play396
Steering Effort Check396
Rack Guide Adjustment396
Gearbox: Removal:installation397
Gearbox: Disassembly/Inspection399
Rack End Bushing Installation400
Pinion Bearing Installation400
Gearbox: Reassembly401
Steering Wheel: Disassembly/Reassembly402
Column: Disassembly/Inspection403
Column: Reassembly405
Steering Lock409
Steering Lock Replacement409
Lock Cylinder Replacement409
Power Steering: Index410
Troubleshooting: General411
Noise And Vibration414
Troubleshooting: Fluid Leaks415
Pump Belt Adjustment416
Fluid Replacement417
On-Car Checks417
Pump Pressure Check417
Assist Check With Car Parked418
Assist Check419
Speed Sensor Replacement419
Pump: Inspection420
Pump: Replacement421
Preload Inspection421
Control Valve Inspection And Replacement422
Pump423
Pump: Resealing425
Control Unit: Disassembly428
Assembly432
Gearbox: Inspection434
Gearbox: Removal435
Gearbox: Resealing437
Suspension: Index454
Wheel Alignment455
Camber Inspection455
Caster Inspection/Alignment455
Front Wheel Toe Inspection/Adjustment456
Rear Wheel Toe Adjustment457
Turning Angle Inspection/Adjustment457
Wheel Measurement458
Bearing End Play458
Front Suspension: Disassembly And Inspection459
Torque Specification461
Lower Ball Joint Replacement462
Knuckle/Hub Replacement463
Upper Arm Bushing Replacement467
Damper Removal468
Damper Disassembly And Inspection469
Damper Reassembly470
Damper Installation470
Rear Suspension: Inspection471
Drum Brake Model471
Disc Brake Model472
Torque Spec473
Dis/Assembly Precautions475
Hub Unit Bearing Replacement475
Ball Joint Removal476
Damper Disassembly/Inspection477
Brakes479
Without 4W-Alb: Index480
Bleeding481
Bleeding Sequence481
Maintenance And Inspection482
Brake Fluid Level482
Booster Test482
Leak Test482
Pedal Height Adjustment483
Check Valve Test483
Parking Brake Adjustment484
Run-Out484
Thickness And Parallelism485
Front Brakes: Inspection486
Brake Pad: Inspection/Replacement487
Brake Caliper: Disassembly488
Master Cylinder, Booster And Proportioning Valve: Index490
Master Cylinder: Overhaul/Inspection491
Master Cylinder: Disassembly492
Primary Piston Assembly493
Secondary Piston Assembly493
Piston Guide Assembly493
Brake Booster: Index And Inspection494
8'' Booster494
9'' Booster495
Brake Booster: Disassembly496
Rebuild Kit498
Pushrod Clearance Adjustment511
Brake Booster512
Pushrod Adjustment512
Proportioning Valve: Description513
Rear Drum Brake: Index And Inspection514
Rear Drum Brake: Disassembly516
Wheel Cylinder: Disassembly And Inspection518
Rear Disc Brake: Inspection519
Rear Brake Pad/Disc: Inspection And Replacement520
Rear Caliper: Disassembly522
Brake Hoses/Pipes: Inspection528
Parking Brake: Disassembly And Reassembly529
Switches530
Parking Brake Switch Test530
Test530
4W-Alb (4-Wheel Anti-Lock Brake) System: Index531
Power Unit Accumulator532
Fluid Delivery532
Pump Delivery532
Accumulator Delivery532
4W-Alb533
Functional Test533
Alb Checker Operation534
Inspection Points535
4W-Alb Troubleshooting536
Brake Booster/Master Cylinder/Modulator/Power Unit/Accumulator: Index545
Master Cylinder: Index/Inspection546
Master Cylinder: Reassembly548
Master Cylinder/Brake Booster550
Modulator551
Draining High Pressure Brake Fluid551
Modulator Assy: Index/Inspection552
Reservoir553
Solenoid553
Brake Fluid Draining553
Piston/Stroke Switch: Removal556
Piston Disassembly557
Stroke Switch Inspection557
Piston/Stroke Switch558
Piston Assembly558
Power Unit: Index/Inspection560
Pump Assy: Reassembly562
Accu,Ulator: Index/Inspection563
Accumulator: Disassembly/Assembly564
Control Unit/Fall Safe Relay: Replacement564
Air Bleeding (General)565
Manual Bleeding566
Main Hydraulic Brake System566
Alb Control Hydraulic Brake System568
Bleeding With Solenoid568
Bleeding With Bleed Screw D And E568
Air Bleeding (With A Pressure Changer)569
Main Brake System569
Alb Control System569
Air Bleeding (With A Vacuum Changer)570
Pulsers/Sensors: Inspection571
Sensor: Replacement572
Pulser: Replacement573
Relay: Inspection574
Doors: Index576
Sedan Front576
Sedan Rear577
Hatchback578
Front Door Disassembly579
Rear Door Disassembly583
Doors: Assembly586
Door Position Adjustment588
Door Striker Adjustment588
Power Door Minor: Removal589
Mirror Glass Replacement589
Door Mirror: Removal590
Windshield, Rear And Quarter Window Glass: Index591
Windshield, Rear And Quarter Window Glass594
Parts594
Tools594
Workable Time595
Hardening Time595
Notes595
Windshield596
Broken Glass Removal596
Sedan Rear Window: Removal602
Tailgate Window: Removal607
Tailgate Upper Window: Removal613
Tailgate Window Glass: Removal617
Quarter Glass: Replacement621
Rear Quarter Window Glass: Removal623
Sunroof: Index630
Glass Height Adjustment631
Sunroof632
Rear Edge Closing Adjustment632
Wind Deflector Adjustment632
Glass And Sunshade Replacement633
Motor, Drain Tube And Frame Replacement634
Cable Replacement635
Rear Bracket Disassembly635
Closing Drag Check (Motor Removed)635
Wind Deflector Installation636
Closing Force Check (Motor Installed)636
Interior Trim: Replacement637
Headliner: Replacement640
Front Seat: Exploded View641
With Belt Feeder642
Seat Cover: Replacement643
Front Seat Back643
Front Seat Cushion643
Belt Feeder: Removal644
Rear Seat: Replacement646
Sedan (Type I)646
Sedan (Type Ii)647
Rear Seat Lock: Replacement649
Front Seat Belts: Replacement650
Rear Seat Belts: Replacement651
Seat Belt: Inspection652
Tetractor Inspection652
On-The-Car Belt Inspection652
Center Console: Replacement653
Protecter Cover Replacement653
Carpet: Replacement654
Rerview Mirror: Replacement655
Intrument Panel: Replacement655
Gauges: Replacement656
Nippon Seiki656
Nd657
Digital Gauge658
Dashboard Components: Removal/Installation659
Dashboard: Replacement661
Front Bumper: Replacement663
Rear Bumper: Replacement664
Hood: Replacement/Adjustment665
Trunk Lid: Replacement/Adjustment666
Tailgate: Replacement/Adjustment667
Tailgate: Replacement/Adjuster668
Opener And Latch: Replacement669
Wiper671
Front Wiper And Motor Replacement671
Rear Wiper And Motor Replacement672
Washer System: Replacement673
Retractor Motor: Replacement674
Headlights675
Replacement (Retractable Headlight)675
Replacement (Other Headlight)675
Headlights: Adjustment676
Headlight Wiper Motor Replacement676
Retractable Model676
Other Models676
Lights677
Taillights Replacement677
Side Turn Light Replacement677
Rear Fog Light Replacement677
Day Light System Replacement678
Interior Light Replacement678
Position Light Replacement678
Vanity Mirror Light678
Front Turn/Position Light Replacement679
License Light Replacement679
Luggage Light679
Spot Light679
Frame Repair Chart680
Heater And Air Conditioner681
Heater682
Heater: Illustrated Index683
Button Type683
Lever Type684
Heater Door Positions685
Circuit Diagram686
Troubleshooting/Connector Information687
Blower Replacement688
Blower Overhaul688
Heater Assembly Replacement689
Heater Core Replacement/Overhaul691
Control Cable Adjustment And Installation692
Air Mix Cable692
Heater Valve Cable692
Heater Function Cable (Lever Type Only)692
Heater Control Removal693
Heater Control Disassembly694
Fan Switch Test695
Rec Switch Test (Lever Type)695
Control Panel Test (Button Type)696
Fresh/Rec Switch696
Function Switch696
Heater Control Troubleshooting697
View From Wire Side697
Recirculation Control Motor Testing698
Function Control Motor Testing698
Air Conditioner699
Air Conditioner: Illustrated Index700
Electrical Troubleshooting702
Performance Test704
Service Tips705
Compressor Troubleshooting706
Compressor Replacement707
Clutch Inspection708
Compressor Clutch Overhaul709
Shaft Seal Removal710
Shaft Seal Installation712
Evaporator Replacement714
Evaporator Overhaul715
Condenser Replacement716
Discharge Procedure717
System Evacuation718
System Charging719
Idle Adjustment720
Carbureted Engine720
Fuel-Injected Engine720
Thermostat Test721
Clutch Relay Testing721
Diode Test721
A/C Switch Test722
A/C Switch Input Test722
Delay Control Unit Trouble Shooting723
Engine Electrical: Illustrated Index726
Before Troubleshooting726
While You're Working726
Ignition Timing Inspection And Setting728
A16A1 And A20A1 Engines729
Ignition730
Spark Plug Inspection730
Ignition Coil Test731
Ignition Wire Inspection And Test731
Radio Condenser Capacity Test732
Distributor Top End Inspection732
Igniter Unit Test733
Advance Diaphragm Inspection734
Distributor Removal/Installation734
Distributor Overhaul736
Reluctor Replacement738
Distributor Coupling Installation738
Charging739
Battery Test739
Variation Of Specific Gravity Temperature739
Charge Warning Light Test741
Alternator Belt Adjustment741
Alternator Replacement742
Alternator And Regulator Test742
Alternator Overhaul744
Rectifier Test745
Alternator Brush Inspection745
Rotor Slip Ring Test746
Stator Test746
Starter Test746
Starter Replacement748
Starter Solenoid Test749
Starter Overhaul (Direct Drive 0.8 Kw Hitachi)750
Direct Drive 0.8 Kw Nd751
Starter Overhaul (Gear Reduction 1.0 Kw And 1.4 Kw Nd)752
Gear Reduction 1.0 Kw And 1.4 Kw Mitsuba)753
Overrunning Clutch Check754
Starter Field Winding Test754
Solenoid Plunger Inspection (Nd)754
Starter Brush Holder Test755
Starter Brush Inspection755
Armature Inspection And Test756
Starter Reassembly758
Body Electrical759
Illustrated Index (Engine Compartment And Front)760
Dashboard Area761
Illustrated Index (Door)764
Floor765
Illustrated Index (Roof And Tail)766
Ignition Switch: Test767
Electrical Switch Replacement767
Combination Switch: Test768
Turn Signal/Hazard Switch768
Interior Light, Clock770
Interior Light Test770
Clock Input Test770
Horn Test771
Switch Test771
Dashlight Brighhtness Control772
Controller Test772
With Analog Meter772
With Digital Meter772
Control Unit Test773
Rear Window Defogger774
With Illumination774
Without Illumination774
Cigarette Lighter775
Wipers/Washers776
Windshield And Rear Window Wiper/Washer776
Headlight Wiper/Washer777
Windshield Wiper Motor Test778
Rear Window Wiper Motor Test779
Headlight Wiper/Washer Switch Test779
Headlight Wiper Motor Test780
Left Motor780
Right Motor780
Headlight Washer Control Unit Test781
Washer Motor Test782
Washer Pump Test782
Power Door Mirror783
Actuator Test783
Power Door Locks: Wiring Diagram784
Door Lock Switch Test785
Driver's Door Actuator Test786
Passenger Door Actuators Test786
Power Windows: Wiring Diagram788
Passenger Door Switch Test790
Driver's Door Switch Test791
Driver's Door Motor Test792
Passenger Door Motor Test792
Control Unit Input/Output793
Sunroof: Wiring Diagram794
Motor Test794
Cruise Control: Wiring Diagram796
Main Switch Test798
Set/Resume Switch Test798
Brake Light Switch Test799
Actuator Solenoid Test799
Cruise Control: Actuator Test800
Actuator/Cable Replacement801
Actuator Cable Adjustment801
Cruise Control: Actuator Disassembly802
Control Unit Input Test803
Ignition Key Light804
Ignition Key Light Timer Test804
Seat Belt Reminder System805
Seat Belt Timer Test805
Heated Seat806
Sound System806
Terminal Arrangement806
Power Antenna Switch Test807
Power Antenna Motor Test807
Gauge Assembly808
Wiring/Circuit Diagram (Analog Meter)808
L.h. Drive808
R.h. Drive809
Wiring/Circuit Diagram (Digital Meter)810
Digital Display And Control Unit811
Connector/Terminal Arrangement812
Analog Meter812
Digital Meter813
Input/Output (Analog Meter)814
Bulb Location816
Trip Meter Button Test818
Speed Alarm Beeper Test819
Brake Warning Bulb Check Circuit819
Light-On Warning System: Wiring Diagram820
Chime Test820
Input Test821
Safety Indicator: Wiring Diagram822
Indicator Test824
Brake Light Failure Sensor Test826
Brake Light Circuit Failure Sensor Test827
Shift Lever Position Indicator: Wiring Diagram828
Console Switch Test828
Indicator Input Test829
Headlights: Wiring Diagram830
Retractable Headlight830
Day-Time Running Light832
Troubleshooting (Retractable Headlight)833
Running Light Relay Test834
Retractor Switch Test834
Retractor Motor Test835
Retractor Relay Test835
Development Aims841
4 Door Sedan841
Glass-Back841
Engine-Frame842
Major Equipment843
4 Door843
3 Door845
Chassis Number847
Europe, General847
Engine Number848
Canadian Model849
Australian Model860
Engine: Description865
Cylinder Block866
Crankshaft866
Lightweight And Compact 2.0 Liter Fc Block866
Cylinder Block Specifications866
Piston Specifications867
Oversized Piston867
Flywheel (Drive Plate)868
Timing Belt Specifications868
Valve Timing (At 1 Mm Lift)869
Cylinder Head Gasket870
Bearing Cap Baffle Plate870
Oil Filter871
Oil Filter Specifications871
Engine Mounting872
Fuel: Description874
Fuel Pump875
Specifications (Efi)875
Carburetor: Description876
Features876
Choke Opener System878
Kc, Kx, Kq Types879
Unloader Mechanism880
Fast Idle Mechanism880
Kx, Kq Only881
Power Valve882
Ks Only882
Accelerator Pump883
Carburetor Heat Riser884
Secondary Diaphragm Vacuum Bypass System885
Idle Boost Control (A/C)886
Ptc Heater887
Pgm-Fi888
Kc888
Kf, Kg, Kw, Ke-Mt/At889
Kx-Mt/At890
Ks-Mt/At891
Throttle Controle System895
Idle Control System895
Idle Adjuster (Bypass Circuit)896
Electronic Control System897
Oxygen Sensor (Kc, Kx)898
Positive Crankcase Ventilation System900
Evaporative Controls (Kc)901
Emission Systems903
Kc, Kq906
Kf, Kg, Kw, Ke, Ky-At907
Kf, Kg, Kw, Ke, Ky-Mt908
1.6 Kg, Kw, Kf, Singapore-At909
1.6 Kg, Kw, Kf, Singapore-Mt910
Ks-Mt912
Ks-At913
Fuel Tank Venting914
Shed Valve914
Thermovalve914
Catalytic Converter916
Throttle Controls917
Dashpot System (Standard For Some Types)917
Throttle Opener (Ks-Mt)917
Secondary Air Supply System918
Throttle Controller (Standard For Some Types)918
Egr920
Chassis921
Clutch Assist Mechanism922
Automatic Transmission: Description923
Construction923
Flat Design Shift Indicator924
Selector Level Detent924
Throttle Control Cable Linkage925
Broad Range Lock-Up System926
Lock-Up Arrangement926
Lock-Up Release In 4Th Speed Range926
Hydraulic Pressure Control Components927
Points Of Modifications Of '86 Ym927
2-3 Shift Valve927
C.p.c. (Clutch Pressure Control) Valve928
Oriffice Control Valve (2Nd)928
Lc Cut Valve928
Lc Shift Valve928
Newly Provided Components929
Lc Control Valve929
Lc Timing Valve A929
Lc Timing Valve B929
Shift Timing Valve930
Timing Accumulator Piston930
3-2 Timing Valve930
Kick Down Valve930
Secondary Valve Body931
Reverse Control Valve931
Regulator Valve Body932
Lock-Up Valve Body932
Explanation Of Schematic Diagram Of Hydraulic System933
Neutral935
In 3Rd Speed Range937
In 1St Speed Range938
In 2Nd Speed Range With Lock-Up Clutch Released939
In 2Nd Speed Range Lock-Up Control Mode940
In 3Rd Speed Range With Lock-Up Clutch Released941
In 3Rd Speed Range Ock-Up Control Mode942
In 3Rd Speed Range Full Lock-Up Mode943
In 4Th Speed Range Lock-Up Control Mode944
In 4Th Speed Range Full Lock-Up Mode945
Reverse946
Park947
Steering Wheel948
Steering Yoke Joint948
Energy-Absorbing Steering Column949
Tilt Steering950
Construction And Operation950
Front Suspension952
Damper953
Steering Knuckle953
Upper And Lower Arms953
Rear Suspension954
Knuckle955
Upper Arm955
Lower Arm955
Rear Wheel Alignment956
Rear Wheel Alignment Adjustment Mechanism956
Axle957
Front Axle957
Rear Axle957
Other Features Include957
Front Disc Brake958
Front Brake Specifications958
Rear Brake (Drum Type)959
Rear Drum Brake Specifications959
Rear Disc Brake960
Rear Disc Brake Specifications960
Automatic Self-Adjustment Mechanism961
Operation (1) (Normal Brake Operation)961
Operation (2) (Excessive Adjustment Prevention Operation)961
Operation (3) (Adjustment Mechanism Operation)961
Body: Construction963
Wheel964
Flush Surface Exterior965
Front Window Side Drip966
Rear Window (4-Door Model)967
Quarter Windows (3-Door Model)968
Sky-Roof Window (3-Door Model)969
Tail Gate Window (3-Door Model)970
Guide Clip971
Seat Belt Buckle & Side Adjuster972
Belt Feeder System (3-Door Model)973
Purpose973
Operation973
Rotary Unit974
Cable Joint975
Door Checker976
Components976
Shoulder Anchor Adjuster (4-Door Model)977
Stepless Adjustment Seat Lifter978
Walk-In Seat979
Instrument Panel980
Piano-Touch Switches981
Digital Lock981
Rear Seat982
Separate Seat Back Type (3D)982
Single Seat Back (4D)982
Seat Belt983
Double-Sensing Lock Mechanism984
G-Sensing984
Webbing Sensing Operation985
Combination Meters987
Safety Indicator988
Liquid Crystal Digital Meters989
Liquid Crustal Panel Construction (Guest Host Type)990
Liquid Crustal Elements990
Electronic Navigator992
How To Operate Controls992
Semi-Concealed Front Wipers993
Washer Interconnected Wipers993
Washer Interconnected Wiper Unit With Variable Intermittent994
Front Wiper Motor995
Rear Wiper996
Retractor Circuit Condition And Various Lighting Switch Positions998
One-Motion Passing Mechanism1000
Operation By Retractor Switch1001
Warning Lamp Mechanism1001
Failsafe Mechanism1002
Emergency Knob1002
Retractable Circuit Diagram1003
Heating And Air Conditioning1004
Ventilation Outlet (4D)1005
Heater Blower1006
Upper Dashboard1007
Face Cool Control1008
Heater Unit1010
Air Conditioner With Mode Control1013
Special Information1014
Outline Of Model Changes1015
Chassis And Engine Numbers1017
Chassis Number (All Models)1018
A20A4 Engine (Ks Model) Shown; Other Engine Similar1019
Optional Tools1036
Cylinder Head/Valve Train Except B20A2 Engine1038
Cylinder Head/Valve Train B20A2 Engine1038
Engine Block Except B20A2 Engine1039
Engine Block B20A2 Engine1039
Engine Lubrication Except B20A2 Engine1040
Engine Lubrication B20A2 Engine1040
Manual Transmission B21042
Automatic Transmission (F4)1043
Automatic Transmission (C9)1045
Description: Outline1065
Description: Piston1067
Description: Connecting Rod1067
Valve Train1068
Description: Camshaft1069
Description: Valve Mechanism1069
Description: Lubrication System1071
Oil Pump1072
Buffle Plate And Bearing Cap1072
Cylinder Head/Valve Train: Illustrated Index1082
Cylinder Head: Removal (Engine Removal Not Required)1084
Camshaft Pulleys: Removal1085
Camshafts: Inspection1085
Valves: Replacement1087
Valve Seats: Reconditioning1088
Valve Guides: Replacement1090
Valve Springs, Valves1091
Camshaft/Rocker Arms And Camshaft Seals/Pulleys: Installation1093
Timing Belt: Replacement1095
Engine Block: Illustrated Index1100
Main Bearings: Clearance1103
Rod Bearings: Clearance1103
Main Bearings: Selection1104
Rod Bearings: Selection1104
Crank Bore Code Location (Letters)1104
Pistons: Inspection1107
Piston Pins: Removal1109
Connecting Rods: Selection1110
Piston Pins: Installation1110
Piston Rings: End Gap1112
Pistons: Installation1114
Oil Pump Side1116
R. Side Cover Side1116
Engine Lubrication: Illustrated Index1118
Engine Oil: Level Inspection1119
Intake Manifold: Illustrated Index1125
Exhaust Manifold: Illustrated Index1126
Radiator: Cap Testing1131
Water Pump: Replacement1133
Charcoal Canister1139
B20A2 Engine1142
Crank Sensor Inspection1166
Crank Angle Sensor Disassembly1166
Crank Angle Sensor Reassembly1168
Crank Angle Sensor Installation1168
Secondary Air Supply System: Description1171
Air Valve Control Solenoid Valve1172
Ignition Timing Controls: Description1173
Clutch Type B2: For B20A2 Engine1177
Clutch: Adjustment1178
Manual Transmission Type B2: For B20A2 Engine1180
Outline Of Model Changes, Special Tools1181
Transmission Assembly: Removal1182
Oil Capacity1182
Reverse Shift Fork/5Th Reverse Shift Fork1188
Reverse Shift Fork/Reverse Idle Gear1188
Shift Arm Holder/Shift Piece1189
Selector Arm/Interlock1190
Shift Arm Holder: Disassembly1191
Shift Fork: Removal1194
Countrshaft Bearing (Clutch Housing)1194
Mainshaft Bearing/Oil Seal (Clutch Housing)1195
Mainshaft/Countershaft1195
Thrust Shim Selection1195
Mainshaft Assembly: Index1197
Countershaft Assembly: Index1198
Gear And Synchro Ring: Inspection1199
Shift Fork/Synchro Sleeve/Synchro Hub/Shift Piece1200
Shift Fork To Synchro Sleeve Clearance1200
Synchro Sleeve And Hub Inspection1200
Installing Synchro Hubs In Sleeves1200
Transmission Assembly: Reassembly1206
Transmission Assembly: Installation1211
Back-Up Light Switch: Test1212
Gearshift Mechanism: Overhaul1213
Outline Of Model Change1214
Installation Note1215
Dinamic Damper Installation1215
Intermediate Shaft: Inspection1216
Intermediate Shaft: Replacement1217
Inspection (Drum Brake Model)1221
Inspection (Disc Brake Model)1222
Torque Spec (Drum Brake Model)1223
Torque Spec (Disc Brake Model)1224
Front Brake: Inspection1226
Brake Disc: Run-Out Inspection1230
Thickness And Parallelism Inspection1230
Toyo Denso1235
Breaker Plate Installation (Hitachi)1236
Hitachi1236
Distributor Overhaul (B20A2 Engine)1237
A20A1 Engine1238
A20A3 Engine1240
Alternator Belt Adjustment (B20A2 Engine)1242
Alternator Replacement (B20A2 Engine)1243
Lighting System (Ke Model): Circuit Diagram1245
Lighting System (Ke Model): Component Location Index1247
Dim-Dip Control Unit Input/Output Test1249
Resistor Test1250
Gauge Assembly (Analog): Description1251
Coolant Temperature Gauge1252
Zener Voltage1252
Circuit Diagram (L.h. Drive)1254
Circuit Diagram (R.h. Drive)1255
Engine Serial Number (Sohc Engine)1259
Engine Serial Number (Dohc Engine)1259
Abbreviation1274
Existing Tools (Common With Other Models)1276
Intake Manifold: Replacement1310
Exhaust Manifold: Replacement1312
A16A1 Engine And A20A2 (Kp, Kq, Kt) Engine1315
Fuel-Injected Engine (B20A8, A20A3)1319
Component Locations: B20A81320
Vacuum Connections: B20A81324
Vacuum Connections: A20A31326
Electrical Connections: B20A81330
Symptom-To-System Chart1332
Troubleshooting Procedures1336
Symptom-To-Sub System Chart1362
Solenoid Valve Test I1367
Solenoid Valve Test Ii1367
A/C Idle Boost Test1368
Fast Idle Control Test (A20A3)1370
A/T Idle Control Test (A20A3)1372
Alternator Fr Signal1375
Air Conditioning Signal1377
Vehicle Speed Signal1379
A/T Shift Position Signal (A20A3)1380
Fast Idle Control: Inspection1382
Idle Speed: Inspection/Adjustment1383
Fuel Supplu System1384
Fuel Pressure: Inspection1385
Relieving1385
Fuel Injectors: Test1386
Injector Resistor: Test1388
Pressure Regulator: Test1388
Fuel Filter: Replacement1389
Main Relay: Test1391
Main Relay: Harness Test1392
Throttle Body: Inspection1395
Throttle Body: Disassembly1396
Dashpot System: Test1397
Air Valve Inspection1398
Air Valve Control Solenoid Valve Inspection1399
Tailpipe Emision: Inspection1401
Exhaust Gas Recirculation System1402
Egr System (B20A8)1402
Egr System (A20A3)1406
Positive Crankcase Ventilation System: Inspection1410
Evoparative Emission Controls: Test1411
Cold Engine1411
Hot Engine1411
Fuel And Emissions (Carbureted Engine)1413
Idle Speed/Mixture: Inspection/Adjustment (Kg, Ks)1428
Propane Enrichment Method1428
Inspection/Adjustment (Kx)1433
Idle Control System (A/T Only): Test1436
Power Valve: Test1437
Accelerator Pump: Inspection1438
Float Level: Adjustment1438
Vacuum Controlled Secondary: Test1439
Dashpot System (M/T Only): Test1440
Fast Idle: Inspection/Adjustment1441
Choke Coil Tension And Linkage: Inspection1441
Choke Coil Tension And Linkage: Check/Adjustment1442
Choke Coil Heater: Test1443
Choke Opener: Test1444
Fast Idle Unloader: Test1446
Fuel Pump: Replacement1449
Fuel Cut-Off Relay: Test1450
Throttle Cable: Replacement1453
Throttle Cable: Inspection/Adjustment1454
Intake Air Control System: Test1455
Feedback Control System: Test1458
Feedback Control Solenoid Valve1458
Air Bleed Valve B1459
Air Control Valve A1459
Air Control Valve B1460
Constant Vacuum Generator1460
Tailpipe Emissions: Inspection1461
Air Injection System: Test1462
Mixture Control System: Test1463
Egr System: Test1465
Positive Crankcase Ventilation System: Test1467
Evaporative Emission Controls: Test1468
Output/Input Summary1475
Control Unit Output Troubleshooting1476
Frequency Solenoid Valve C (A/T Only)1476
Idle Boost Solenoid Valve (A/T Only)1478
Primary Slow Mixture Cut-Off Solenoid Valve1482
Cranking Leak Solenoid Valve1484
Frequency Solenoid Valve A1486
Frequency Solenoid Valve B1488
Air Suction Control Solenoid Valve1492
Anti- Afterburn Control Solenoid Valve1494
Air Leak Solenoid Valve1497
Efe (Early Fuel Evaporator) System1498
Control Unit Input Troubleshooting1502
Power Sources And Ground1503
Ignition Coil Signal1510
Speed Pulser1511
Clutch Switch Signal1518
A/T Shift Position Signal1520
A/C Switch Signal1522
Automatic Transmission (F4 Type)1523
Secondary Valve Body: Disassembly/Inspection/Reassembly1524
Parking Gear: Removal/Installation1525
Cylinder End Seal Replacement1528
Brakes (Alb)1530
Technical Features: Outline1532
Technical Features: Speed Sensor1533
Technical Features: Modulator Unit1535
Technical Features: Power Unit1537
Technical Features: Operation1538
Slide Piston Function1540
Kickback1541
Pcv (Proportioning Control Valve) Function1541
Alb Checker: Function Test1546
Troubleshooting: Warning Light1548
Temporary Driving Conditions1548
Warning Light Circuit1548
Flow Chart1552
Problem Code 1: Hydraulic Controlled Components1552
Problem Code 4-4 To 4-12: Rear Speed Sensor1556
Problem Code 5-1 To 7-8: Speed Sensor1557
Problem Code 8-1 To 8-12: Front Solenoid Related Problem1558
Problem 8-15: Front Fail Safe Relay Circuit1559
Problem Code 9 Or 10: Rear Solenoid Related Problem1561
Problem Code 11: Rear Fail Safe Relay Circuit1562
Problem Code 12-1, 12-2, 12-4 Or 12-8: Front Solenoid1564
Problem Code 12-3: Front Right Solenoid And/Or Power Supply1565
Problem Code 12-12: Front Left Solenoid And/Or Power Supply Problem1566
Problem Code 13 Or 14: Rear Solenoid Related Problem1567
Brake Booster: Test1568
Hydraulic System: Index1569
Relieving Accumulator/Line Pressure1570
Modulator: Index/Inspection1575
Solenoid: Removal1576
Piston: Removal1577
Air Bleeding With Alb Checker1579
Control Unit: Replacement1580
Troubleshooting: Symptom Chart1584
Flow Chart - Blower1585
Flow Chart - Recirculation Control1588
Flow Chart - Function Control1590
Control Panel Switches (Button Type)1592
Function Control Motor1593
Recirculation Control Motor1593
'88 A/C High Side Adaptor1595
Cylinder Head/Valve Train Except B20A Engine1622
Cylinder Head/Valve Train B20A Engine1622
Engine Block Except B20A Engine1623
Engine Block B20A Engine1623
Engine Lubrication Except B20A Engine1624
Engine Lubrication B20A Engine1624
Kq And Ky Models1642
Maintenance Schedule1651
Engine Mount Torque Sequence1655
Sub Frame Torque Specifications1656
Crankshaft Pulley Bolt: Replacement1659
Component Locations1672
Vacuum Connections1674
Control Box (A/T Only)1674
Electrical Connections1676
Idle Speed/Mixture: Inspection/Adjustment1677
Control Unit: Output/Input Summary1681
Inspection Of Control Unit (Output To Efe Relay)1687
Parking Brake Stopper: Inspection/Adjustment1695
Conventional Brake1697
Alb1700
Master Cylinder: Assembly1703
High Mount Brake Light: Replacement1706
Cruise Control: Control Unit Input Test1708
Wipers/Washers: Wiring Diagram1710
Headlight Washer Control Unit Input Test1711