HONDA Civic Service Manual

1996-2000.
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Service manual - 1434 pages
User manual - 511 pages
Owner's manual - 470 pages
   
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   Also See for HONDA Civic

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   Summary of Contents for HONDA Civic

  • Page 2: Mark

    INJURY, damage a vohicle or make il unsafe. Ploase undorstand that these warnings cannot covsr all conceivable weys in which service. whelher or not iocommgndod bY HONDA. mighi bo done, or ol tho possiblG hazardou3 consgquonces of ev€aY conceivablg way, nor could HONDA invqstigato all 3uch way3. AnYono using...

  • Page 3: Table Of Contents

    General Information Ghassis and Paint Codes ....... ldentification Number Locations ..1-32 Warning/Caution Label Locations ..1-33 Under-hood Emissions ..1-37 Control Label ..Lift and Support Points 1-41 Lift and Safety Stands ....... 1-42 Floor Jack ........ 1-43 Towing...

  • Page 4

    2 H G E J 6 3 2 * T H I 0 0 0 0 1 D16Y7 1500001 Manufacturel, Make and Engine Type Type of Vehicle D 16Y7: 1600 SOHC 16-vatves 2HG: HONDA OF CANADA Sequential Multiport M F G . , I N C . Fuel-injected Engine HONDA Passenger Serial Number...

  • Page 5

    Multiport Fuel-injected Engine HONDA Passenger vehicle 2HG: HONDA OF CANADA U . S . A : D 1 6 Y 7 , D l 6 Y g 1 5 0 0 0 0 1 - M F G . , I N C .

  • Page 6

    Chassis and Paint Codes U.S. 1996 Model (2-door Coupe) Engine Number I H G E J 6 1 2 * T L 0 0 0 0 0 1 1300001 Engine Type D16Y5: 1600 SOHC WEC E 16-vatves Sequential Multiport Fuel-injected Engine D 16Y7: 1600 SOHC 16-vatves Sequential Multiport Line.

  • Page 7

    2 H G E J 6 3 2 * T H 0 0 0 0 0 1 Manulacturer, Make and D16Y7: 1600 SOHC'16-valves Type of Vehicle Sequential MultiPort 2HGr HONDA OF CANADA Fuel-injected Engine HONDA Passenger v e h i c l e Line, Body and Engino Type...

  • Page 8

    I H G : H O N D A O F A M E R T C A Sequential N4ultiport M F G , , I N C . Fuel-injected Engine HONDA Passenger Serial Number vehicle Line, Body and Engine Type...

  • Page 9

    CANADA 1996 Model (2-door CouPe) Engine Number 1 H G E J 6 1 2 . T L 0 0 0 0 0 1 D16Y7: 1600 SOHC l6-valves Sequential MultiPort Fuel-injected Engine D16Y8: 1600 SOHC VlEC 16-valves Sequential MultiPort Fuel-injected Engine Line, Body and Engine TYPe Serial Number EJ6: ClVlC2-door/D16Y7...

  • Page 10

    2 H G E J 6 3 2 * V H 1 0 0 0 0 1 Manufac-turer, Make and Type of Vehicle D16Y7: 1600 SOHC 16-vatves 2HG: HONDA OF CANADA Sequential Multiport M F G . , I N C . Fuel-iniected Engine...

  • Page 11

    J H M E J 6 5 2 * V S 0 0 0 0 0 1 Manulaqturer. Make and D16Y7: 1600 SOHC 16-valves Sequential Type of Vehicle Multiport Fuel-iniected Engine HONDA MOTOR CO., D16Y8: 1600 SOHC WEC 16-valves Sequentral LTD. MultiPort Fuel-injected Engine HONDA Passenger...

  • Page 12

    Chassis and Paint Codes U.S. 1997 Model (2-door Coupe) Engine Number D16Y5 - 2300001 Engine Typ6 D16Y5: 1600 SOHC VTEC-E 16 vatves Sequential Multiport Fuel-injected Engine D16Y7: 1600 SOHC 16-valves Sequential Multiport Lino. Eody and Engine Typ6 Fuel-injected Engine EJ6: ClVlC2-door/D16y7 Dl6Y8r 1600 SOHC VTEC 16 vatves EJ7: ClVlC2-door/Dl6Yb Sequential Multiport...

  • Page 13

    2 H G E J 6 3 2 * V H 0 0 0 0 0 1 Manufacturer, Make and '1600 SOHC 16-valves D16Y7: Type oI Vehicle Sequential MultiPon 2HG: HONDA OF CANADA Fuel-iniected Engine M F G . , I N C . HONDA Passenger vehicle Line, Body and Engine TYPe...

  • Page 14

    Chassis and Paint Godes CANADA 1997 Modet (4-door Sedan) l H G E J 6 5 3 * V L 8 0 0 o o l D16Y7 2750001 1600 SOHC 16-vatves Sequential Multiport Fuel-injected Engine Line, Body and Engine Type EJ6: ClvtC4-door/D16y7 Body Typ€...

  • Page 15

    CANADA 1997 Model (2-door CouPel Engine Number D16Y7 2750001 1 H G E J 6 1 2 * V L 8 0 0 0 0 1 Engins Typs D16Y7: 1600 SOHC 16-valves Sequential MultiPort 1 H G : H O N D A O F A M E R I C A Fuel-injected Engine D16Y8: l600 SOHC VTEC 16-valves Sequential MultiPort...

  • Page 16

    Vehicle ldenti{ication Number 2 H G E J 6 3 2 . W H 1 0 0 0 0 1 Manufactursr, Mak€ and Type of Vehicle D16Y7: '1600 SOHC l6-valves 2HG: HONDA OF CANADA Sequential Multiport MFG., INC. Fuel-injected Engine HONDA Passenger vehicle Lin€, Body and Engine Type...

  • Page 17

    Multiport Fuel-injected Engine HONDA Passenger Serial Number v e h i c l e JAPAN: D16Y7. D16Y8 - 3300001- HONDA OF AMERICA U.S.A : D16Y7, D16Y8 - 3500001^ M F G . , I N C . HONDA Passenger vehicle...

  • Page 18: Ghassis And Paint Codes

    Ghassis and Paint Codes U.S. 1998 Model (2,door Coupel Engine Number l H G E J 6 1 2 * W L 0 0 0 0 0 1 D16Y5 3300001 Engine Type D16Y5: 1600 SOHC WEC-E l6,vatves Sequential Multiport Fuel-injected Engine D16Y7: 1600 SOHC 16-valves Sequential Multiport Line, Body and Enginc Type...

  • Page 19

    2 H G E J 6 3 2 + W H 0 0 0 0 0 1 Manulacturet, Make and 1600 SOHC 16-valves Type of Vehicle Sequential lvlultiPort 2HG: HONDA OF CANADA E n g i n e F u e l - i n j e c t e d HONDA Passenger vehicle...

  • Page 20

    Vehicle ldentification Number 2HG .I 900001 Manufacturer, Make and Type of Vehicte D16Y7: 1600 SOHC 16-valves 2HG: HONDA OF CANADA Sequential Multiport M F G , , I N C . Fuel-injected Engine HONDA passenger v e h i c l e 3 7 5 0 0 0 1 - : U .

  • Page 21

    1 H G : H O N D A O F A M E R I C A Fuel iniected Engine M F G , , I N C , D16Y8: 1600 SOHC VTEC 16-valves HONDA Passenger Sequential MultiPon v e h i c l e Fuel-iniected Engine...

  • Page 22

    2 H G E J 6 3 2 * X H 1 0 0 0 0 1 Manufacturer, Make and Type of Vehicte D'16Y7: 1600 SOHC l6-vatves 2HG: HONDA OF CANADA Sequential Multipon M F G . . t N C . Fuel-injected Engine...

  • Page 23

    1 H G : H O N D A O F A M E R I C A D16Y8: HONDA Passenger vehicle U.S.A : D16Y7. D16Y8- 4500001- HONDA OF CANADA M F G . , I N C . HONDA Passenger vehicle HONDA MOTOR CO., LTD.

  • Page 24

    1 H G E J 6 1 2 * X L 0 0 0 0 0 1 Manutacturer, Make and Engine Type Type of Vehicle 81642:'1600 DOHC VTEC 16 vatves '1HG: HONDA OF AMERTCA Sequential Multiport M F G . , I N C . Fuel-injected Engine HONDA Passenger Dl6Y5: 1600 SOHC WEC-E 16 vatves...

  • Page 25

    2 H G E J 6 3 2 * X H 0 0 0 0 0 1 Engine Type Manufacturer, Make and D16Y7: 1600 SOHC 16-valves Type of Vehicl€ Sequential Multiport 2HG: HONDA OF CANADA Fuel-injected Engine l\4FG., lNC. HONDA Passenger v e h i c l e Line, Body and Engine Type...

  • Page 26

    D 1 6 Y 7 4 7 0 0 0 0 1 Manufaclurer, Make and Engine Type Type ot Vehicle D 16Y7: 1 600 SOHC 16-valves Sequential JHM: HONDA MOTOR CO., Multiport Fuel-injected Engine LTD. HONDA Passenger JAPAN: D16Y7 - 4700001- vehicle U.S.A : D'16Y7 - 4750001-...

  • Page 27

    H G r H O N D A O F A M E R I C A I Fuel injected Engine M F G , , I N C . D16Y7: 1600 SOHC 16'valves HONDA Passenger Sequential MultiPort v e h i c l e Line. Body and Engine TyPe -...

  • Page 28

    2 H G E J 6 3 2 * H 1 0 0 0 0 1 5500001 D 16Y7 Manufacturer, Make and Type of Vehicle Dl6Y7: 1600 SOHC I6-valves Sequenlal 2HG: HONDA OF CANADA Mu ltiport Fuel-injected Engine M F G , , I N C . HONDA Passenger Vehicle Line, Body and Engine Type EJ6: ClVlC3-door/D16Y7 Body Type and T.ansmission Type...

  • Page 29

    J H M E J 6 5 2 * Y S 0 0 0 0 0 1 Engine Type Manufacturer, Makg and D16Y7: 1600 SOHC 16-valves Sequential Type of Vehicle Multiport Fuel-iniected Engine JHM: HONDA MOTOR CO., D16Y8: 1600 SOHC VTEC 16-valves LTD. Sequential Multiport Fuel-iniected HONDA Passenger E n g i n e...

  • Page 30

    H G E J 6 1 2 * Y 1 0 0 0 0 0 1 D16Y5 - 5300001 Manufacturer. Make and Engino Type Type ol Vehicle Bl642; 1600 DOHC WEC '16-vatves '1HG: HONDA OF AMERICA Sequential Multiport Fuel-injected t\4FG., tNC. E n g i n e HONDA Passenger D'I6Y5: 1600 SOHC WEC-E 16.vatves Vehicle...

  • Page 31

    2 H G E J 6 3 2 * Y H 0 0 0 0 0 1 Manufaqturor, Make and D16Y7: 1600 SOHC 16-valves Sequential Type of Vehicle Multiport Fuel-injected Engine 2HG: HONDA OF CANADA Se1i8l Number HONDA Passenger Vehicle Line, Body and Engine Type...

  • Page 32

    D 1 6 Y 7 Manufaqturer, Makg and Engine Type Type ot Vehicle D't6Y7 | 1600 SOHC 16-valves Sequential JHM: HONDA MOTOR CO., Multiport Fuel-injected Engine LTD. HONDA Passenger J a p a n : 5 7 0 0 0 0 1 - Vehicle U.S.A.: 5750001-...

  • Page 33

    1 H G : H O N D A O F A M E R I C A E n g i n e M F G , , I N C . '1600 SOHC 16-valves Sequential HONDA Passenger Dl6Y7: Multiport Fuel-injected Engine V e h i c l e...

  • Page 34: Ldentification Number Locations

    ldentification Number Locations Vehicle ld6ntification Numbsr (VlN) Number 1-32...

  • Page 35: Warning/caution Label Locations

    Warning/Caution Label Locations '96 -99 model C: DRIVER MODULE OANGER A: CABLE REEL CAUTION A: DANGER TO SERVICE MANUAL FOR DETAILED INSTRUC. EXPLOSIVE/FLAMMABLE TtoNs. CONTACT WITH ACIO. WATER OR HEAVY METALS SUCH AS COPPER. I.EAD OR MERCURY MAY PRODUCE HARMFUL AND IRRITATING GASES OR EXPLOSIVE COMPOUNDS, '00 model STOBAGE TEMPERATURES MUST NOT EXCEED 2OO'F...

  • Page 36

    Warnin g/Gaution Label Locations (cont'dl -==-J v7777m7na D: DRIVER INFORMATION: CANADA mod6l l'96 - gtt modell U.S. model l'98, 39 model) WARNING ALWAYS WEAR YOUR SEAT BELT OEATH OR SERIOUS INJURY CAN OCCUR. THIS CAR IS EOUIPPED WITH A DRIVER AIRBAG AND A C H I L D R E N 1 2 A N D U N O E R C A N B E K I L L E D B Y T H E FRONT SEAT PASSENGER AIRBAG' AS A SUPPLEMEN- AIREAG.

  • Page 37

    I: FRONT SEAT PASSENGER MOOULE DANGER CANADA model ('00 model) DANGER CAUTION EXPLOSIVE/FLAMMABLE TO AVOID SERIOUS INJURYT CONTACT WITH ACID, WATER OR HEAVY METALS SUCH FOR MAXIMUM SAFETY PROTECTION lN ALL TYPES OF AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM. CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY F U L A N D I R R I T A T I N G G A S E S O R E X P L O S I V E C O M - BELT.

  • Page 38

    Warning/Caution Label Locations (cont'd) 191t7 CANADA Mod6l 1 - 3 6...

  • Page 39: Under-hood Emissions Control Label

    V : 1 9 9 7 TIEB l FULL N US€ Manufacturel 11211 .?2E AO2 HONDA MoTOR C0 , tTD H N : H o n d a Storage System 50ST {50 States): 1 : C a n i s t e r THIS VEHICLE CONFORMS TO U.S, EPA AND STATE OF...

  • Page 40

    Under-hood Emissions Control Label (lggg model) Emission Group ldentification Engine and Evaporative Families Example: Engine Family: v 0 ' t . 6 J L 2 H N X Model Year W: 1998 Manufacturer o R 3 . ' @ M | L E S | 3 , @ | f r l w ! c s H N X : H o n d a Type V: Light Duty Vehicle/Passenger...

  • Page 41

    C O L D SPARTPLU6CAP Type R: ORVR Canister Work CaPacitY (gramsl Sequence Characters HONDA MOTOECO LTD FEDERAL TIER 1: THIS VEHICLE CONFORMS TO U.S, EPA REGULATIONS '1999 MODEL YEAR NEW PASSENGER APPLICABLE TO CARS. CALIFORNIA + NLEV {RESTRICTEDI TLEV:...

  • Page 42

    Engine Family: Y H N X V 0 1 , 6 J F 1 Model Yeal Y; 2000 Manufaqturer oRs'MM|LESt4,0oorml,wtscN HNX: Honda Type V: Light Duty Vehicle/passenger VEHICLE EMISSION CONTROL INFOBI\4ATION Displacoment T8ISVEH CLE CONFOfiMS TO U,S EPA RECIJLATIONS Sequence Charaqtgrs...

  • Page 43: Lift And Support Points Lift And Safety Stands

    Lift and SupPort Points Lift and SafetY Stands hatch' and trunk lid are to be when heavv rear components such as suspension' fuel tank' spare tire' t!ffi when substantial weight is lemoved from the rear removed, place additional wetght Inihe luggage arga before hoisting. vehicle to tip tolward on the hoisi of the vehicls.

  • Page 44: Floor Jack

    Lift and Support Points Floor Jack Apply the parking brake and block the wheets that are not being lifted. Always use safety stands whon working on or undel any vehicle that is supported by only a iack. When lifting the rear of the vehicle, put the gearshift Never attempt to use a bumper jack for lifting or lever in reverse (Automatic transmission/Cw in E supporting the vehicle.

  • Page 45: Towing

    Towing Front: lf the vehicle needs to be towed, call a professional tow- ing service. Never tow the vehicle behind another vehi cle with iust a rope or chain lt is very dangerous' Emergency Towing There are three popular methods of towing a vehicle: Flat-bed Equipment - The operator loads the vehicle on the back of a truck.

  • Page 46

    The Special Tools Section of this manual has been omitted intentionally. Each section in the manual that requires the use of special tools has them listed separately for that section.

  • Page 47

    Specifications Standards and Service Limits "'.".'.""' 3-2 "... ""' 3-20 Design Specif ications,..'..,.'..'.."'."'." 3-23 Body Specifications...

  • Page 48

    Standards and Service Limits Cylinder Head/Valve Train (Dt6y5, Dt6y7, D ( u r b Y 5 , u l 6 Y 7 , D l 6 Y g e n l Sines) -Section6 - MEASUREMENT S T A N D A R D I N F W T Compression 250 rpm and wide open throftle kPa {kgf/cm,, psi)

  • Page 49

    U n i t o f i e n g t h : m m ( ! n ) Cylinder Head/Valve Train (816A2 engine) - Section SERVICE LIMIT STANDARD INEW) MEASUREMENT 2 5 0 r p m ( m i n r i a n d N o m i n a l 930 (9.5, 135) Minimum...

  • Page 50

    Standards and Service Limits Engine Block {Dl6Y5, D16Y7, Dt6y8 enginesl - Section ,n7 _-- MEASUREMENT STANDAFO INEW} SERVICE LIMIT Cylinder block Warpage of deck surface 0.07 10.003) max. 0.10 (0.004) Bore diameter 75.00 75.02 (2.953 - 2.954) 75.07 (2.956) Bore taper 0.05 (0.002) Reboring limit 0.5 (0.02)

  • Page 51

    U n l t o f l e n g t h : r n m ( n ) Engine Block (816A2 engine) - Section 7 SERVICE LIMIT STANOARD {NEW) MEASUREMENT 0.05 (0.002) 0.08 {0.03) Warpage of deck surface C y l i n d e r b l o c k 8 1 .

  • Page 52

    Standards and Service Limits Engine Lubrication (B16A2 engine) (cont,d) - Section 8 MEASUREMENT STANDARD INFWI E n g i n e o i l Capacity f (uS qt, lmp qt) 4.8 (5.1, 4.2) for eng;ne overhaul 4.0 (4.2, 3.5) for oil change, ;ncludin g o i l f i l t e r 3 .

  • Page 53

    U n i t o f l e n g t h : m m ( i n ) Fuel and Emi ssion - Section STANOARO (NEW) MEASUREMENT Pressure wilh fuel pressure regulator vacuum hose Fuel paessure disconnected kPa (kgvcm' , Psi) regulator 260 310 (2.7 - 3.2, 38 - 46) D16Y5...

  • Page 54

    Standards and Service Limits Manual Transmission S40 - Section 13 MEASUREMENT STANDARD INEW} SEBVICE LIMIT Capacity | (US qt, tmp qt) ' 1 . 9 ( 2 . 0 , 1 . 7 ) f o r o v e r h a u l 1 .

  • Page 55

    U n i t o f l e n g t h : m m ( i n ) Manual Transmission S4C - Section 13 SERVICE LIMIT STANDARD {NEW) M€ASUREMENT 2 . 3 ( 2 . 4 , 2 . 0 ) f o r o v e r h a u l Capacity | (US qt, lmp qt) T r a n s m i s s i o n o i l...

  • Page 56

    Standards and Service Limits S4C (cont'd) - Section 13 Manual Transmission MEASUREMENT STANDARD (NEW) SERVICE LIMIT Reverse idler gear t.D. 20.016 - 20.043 (0.7880 -0.7891) 20.09 (0.7909) Gear-to reverse gear shaft clearance 0.036 - 0.084 {0.0014 - 0.0033) 0.16 (0.006) Ring to-gear clearance (Ring pushed against gear) Synchro ring 0.73 - 1.18 (0.029 0.046)

  • Page 57: Table Of Contents

    U n i t o f l e n g t h i m m ( i n ) ansmtssron - tssron Section 14 Automatic T SERVICE LIMIT STANOARD {NEWI MEASUREMENT 5.9 (6.2, 5.2)Ior overhaul Capacity f (US qt, lmp qti Transmission 2.7 (2.9, 2.4) for fluid chanse f l u i d...

  • Page 58

    Standards and Service Limits Automatic Transmission (cont'd) - Section l4 MEASUREMENT STANOARD {NEW) SERVICE LIMIT Diameter of needle bearing contact area On mainshaft stator shaft bearing 22.980 22.993 10.9047 0.9052|j On mainshaft 2nd gear 3 5 . 9 7 5 3 5 . 9 9 1 ( 1 . 4 1 6 3 - 1 . 4 1 6 9 ) On mainshaft 4th gear collar 3 1 .

  • Page 59

    U n ; t o f l e n g t h : m m { i n ) Automatic T nsmtsston Section 14 SEBVICE LIMIT STANDARD INEW) MEASUREMENT 3.97 4.00 10.156 - 0.157) M a i n s h a f t 2 n d g e a r t h r u s t w a s h e r t h i c k n e s s Transmission 4.02 - 4.05 (0.158 0.159) 4 .

  • Page 60

    Standards and Service Limits Section '14 Automatic Transmission (cont'd) STANDARD {NEW} MEASUREMENT o.D. Wire Dia. Free Longth No. ol Coils Springs Hegulator valve spring A 1 . 8 { 0 . 0 7 1 ) 14.7 (0.584) 87.8 (3.457) 1 6 . 5 Regulato.

  • Page 61

    [ J n i t o f l e n g t h : m m ( i n ) Section 14 SERVICE LIMIT MEASUBEMENT STANDARD {NEW} 3.4 - 3.5 10.134 - 0.138) Discoloration Forward clutch end plate thickness Mark 1 or 15 3 .

  • Page 62

    Standards and Service Limits CW {cont'd) Section 14 MEASUREMENT STANDARD {NEW} SERVICE LIMIT Transmission T h r u s t s h i m , 2 5 x 3 1 m m t h i c k n e s s rlz-r-osr-o.o+o oolrr I Wr"r - d-"-"g"d...

  • Page 63

    D o n o t r u n f o r m o r e t h a n 5 s e c o n d s ) . k P a ( k g t c m ? , p s i ) HONDA Power Steering Fluid Recommended power steering fluid P o w e r s t e e r i n g 0.85 (0.90,0.75) at disassembly...

  • Page 64

    Standards and Service Limits Suspension - Section 18 MEASUREMENT STANOARO INEW} SERVICE LIMIT Camber Front 0 " 0 0 ' 1 1 " a l g n m e n l - 1 . 1 1 ' Rear Caster Front 1'40' I 1"...

  • Page 65

    U n i t o f e n g l h : m m { n ) Electrical Section 23 STANDARD {NEW} MEASUREMENT lgnition coil Rated voltage V Primary winding resistance at 68'F (20'C) o HITACHI 0.45 0.55 0.63 0.11 Secondary winding resastance at 68'F 120"C) kO 22.4 - 33.6 HITACHI...

  • Page 66

    Design Specifications ITEM METRIC ENGLISH NOTE DII/IENSIONS Overall Length 2 door Coupe/4 door Sedan (,96 98) 4,445 mm 1 7 5 . 0 i n ('99,' 00) 4,450 mm 115.2 in (,96, ,97) 2 door Hatchback 4 , 1 7 0 m m 164.2 in ('98 - 00) 4 , 1 8 0 m m...

  • Page 67

    NorEs ENGLISH merntc trEM r'4 rg MllSUBA r.u, l.z kw SfAnff n i*nt-i- W"'gf,t Single plate dry, diaphragm spring Clutch Type CLUTCH Torque converter Multi plates wet sanP, hYdraulic 2 5 s q i n 160 cm, Clutch Facing Area Synchronized 5-speed forward, 1 reverse Transmission Type T R A N S M I S S I O N...

  • Page 68

    Design Specifications (cont'd) ITEM METRIC ENGLISH NOTE STEERING Tvpe Power assisted, rack and pinion SYSTEM R a c k a n d p i n i o n Overall Ratio 1 l . 1 20.3 Turns, Lock-to Lock 3 . 6 4..1 Steering Wheel Dia.

  • Page 69

    Body Specifications U n i t : m m ( i n ) 2-door Coupe: lt t9) gtt't...

  • Page 70

    Body Specifications (cont'd) L i f 2-door Hatchback: U n i t : m m ( i n ) (t t9] gre'r 3-24...

  • Page 71

    U n i t : m m ( i n ) 4-door Sedan: (r'tsl 06€'l 3-25...

  • Page 72

    Maintenance .""."".' 4'2 Lubrication Points Maintenance Schedule for 1996 Model '.""" 4-4 Normal Gonditions ."""" 4-6 Severe Conditions Maintenance Schedule for 1997 Model ."""' 4-8 Normal Conditions ..""' 4-10 Severe Conditions Maintenance Schedule for 1998 Model """" 4'12 Normal Conditions .""""...

  • Page 73

    *4: Always use Genuine Honda life. DoT3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and dec.ease the life of the svstem. *5: Always use Genuine Honda Power steering Fluid.

  • Page 74

    NOTE: Lubricate all hinges, latches and locks once a year' ln corrosive areas, more frequent lubrication is necessary' We recommend Honda White Lithium Grease'...

  • Page 95

    Engine Engine Removal/lnstallation ....Gylinder Head/Valve Train ......7-1 Engine Bfock ..... 8-1 Engine Lubrication Intake Manifold/Exhaust System ..9'1 ..10-1 Cooling...

  • Page 96

    En g ine Removal/l nstallation "..'.'5'2 Removal lgr" '.' 5-12 lnstaf lation...

  • Page 97

    Engine RemovaUlnstallation Removal Remove the battery and battery base. . Make sure iacks and salety stands are placed ploperly and hoist brackets are attached to the correct posi- 8 x 1 . 2 5 m m tions on the engine. 24 N.m (2.4 kgf.m, 17 lbf ftl .

  • Page 98

    016Y5, Dl6Y& 815A2 engin€sl Remove the intake air duct and air cleaner housing. D i s c o n n e c t t h e I A T s e n s o r c o n n e c t o r , t h e n D16Y, ongino: remove the intake 8ir duct and air cleaner hous- Ing.

  • Page 99

    Engine Removal/lnstallation Removal (cont'dl 10. Relieve fuel pressure (see section l1). 12. Remove the brake booster vacuum hose, fuel return hose and vacuum hose. Do not smoke while working on the fuel system, Keep open flame or spark away from the D16Y7 engine: wolk area.

  • Page 100

    1 4 , Disconnect the connectors from the PCM. 13. Remove the throftle cable by loosening the locknut, then slip the cable end out of the accelerator link- R e m o v e t h e g r o m m e t a n d w i r e h a r n e s s c l a m p s , a g e .

  • Page 101

    Engine Removal/lnstailation Removal (cont'dl Dl6Y5. DrGYr, D16Y8 enginas: '18. Remove the ransmission ground cable and hose ct8mo. -1. Remove the mounting bolt and lock bolt, then remove the P/S pump belt and pump. 6 x '1.0 mm HOSE CLAMP MOUNTING BOLT 8 x 1.25 mm 24 N.m {2.4 kgl.m, 17 tbf.ftl LOCK BOLT...

  • Page 102

    24. Remove the front tires/wheels and splash shield. 20. Remove the shift cable (CVT) LOCKNUT 29 N.m {3.0 kgf m,22lbf'ft} WASHER CLIP Pt-Aslc u x l.u mm 6 x 1 . 0 m m SHIELD 9.8Nm(1 0 kqt'm, 7.2lbf.ftl SHIFT CABLE Drain the engine coolant (see page 10-7).

  • Page 103

    Engine Removal/lnstallation Removal(cont'dl 29. Remove the Ay'C compressor. 31. Remove exhaust pipe A. NOTE: Do not disconnect the Ay'C hoses. Dl6Y5. D16Y7 engines: 8 x 1.25 mm 22 N.m 12.2 ksl.m. 16 tbI.fr) Replace. 8x 1.25 mm A/C COMPRESSOR A/C COMPRESSOR 24 N.m (2.{ kgf.m, t7 tbtft} SELF.LOCKING 8 x 1.25 mm...

  • Page 104

    Lower the hoist. 81642 engine: HO2S CONNECTOR Remove the upper and lower radiator hoses and ,& heater hoses, 8 x 1.25 mm 16 rbt.ftl 22N,n 12 2 kdl'rn, Replace. GASKETS Replace. UPPER RADIATOR HOSE Replace. SELF.LOCKING 8 x 1.25 mm 16 N.m t1.6 kg{ m, 12 lbl'ft) Replace.

  • Page 105

    Engine RemovaUlnstallation Removal(cont'd) 38. Attach the chain hoist to the engine. HOISTING BRACKET Install on the cylinder head w i t h a 8 x 1 . 2 5 m m b o l t . 5 - 1 0...

  • Page 106

    41. Remove the uPPsr bracket. 39. Remove the left and right front mount and bracket' UPPER 4 2 . R e m o v e t h e t r a n s m i s s i o n m o u n t b r a c k e t , t h e n remove the transmission mount.

  • Page 107

    Engine RemovaUlnstallation Installation Brackei Bolts Torque Specifications: Dl5Y5, Dl6Y7, Dl6Y8 €nginss 10 x 1.25 mm 10 x 1.25 mm 44 N.m {4.5 kgt m, 54 N.m {5.5 kgf.m, 33 tbr.ftl 40 rbf.ftl D16Y5, D16Y8 engines (M/Tl: 10 x 1.25 mm REAR STIFFENER 44 N.m 14.5 kgf.m, 33 tbf.frt...

  • Page 108

    816A2 engine P/S PUMP BRACKET REAR STIFFENER SIDE ENGINE MOUNT BRACKET t0 x 1.25 mm ia{ N.m (i1.5 kgt rn, 33 lbt.tr) 1 2 x 1 . 2 5 n m 8 x 1.25 mm 57 N.m {5.8 kgf,m, 24 N.m (2.4 kgl.m, 12 tbl.ttl 17lbf.ft) 10 x 1.25 mm...

  • Page 109

    Engine Removal/lnstallation Installation (cont'd) Engino Inst!llation: Install the engine in the reverse order of removal. Beinstall the mount bolts/nuts in the following sequence. Failure to follow these procedures may cause excessive nois€ and vibration, and reduce bushing life. Install the transmission mount and bracket, then tighten the bolts on the frame side, NOTE;...

  • Page 110

    4. Tighten the bolvnuts on the transmission mount Install the rear mount bracket, then tighten the bolts bracket in the numbe.ed sequence shown (O - O). in the numbered sequence shown (O - @). CVT: O 12 x 1.25 mm @ t2 x t.2s mm 59 N.m (6.0 kgl'm, 7,1N.m (7.5 kg{ m, 54 lbf ftl...

  • Page 111

    Engine Removal/lnstallation Installation (cont'd) Except CVT: Perform the following: . Clean the areas where the driveshaft(s) and the intermediate shaft contact the transmission (dif_ ferential) thoroughly with solvent or carburetor cteaner, and dry with compressed air. . Check that the set rings on the ends of the drive_ shaft and intermediate shaft click into place.

  • Page 112

    Mount and Brackst Bohs/Nuts Torque Value Spocitications: A: '10 x 1.25 mm 64 N.m {6.5 kgl'm, 47 lbf'ft} B : 1 0 i 1 . 2 5 m m 44 N.m {4.5 kgim,33 lbtft) REAR MOUNT C : 1 2 x 1 . 2 5 m m 83 N.m 18.5 kgt'm, 61 lbf'ft) D : 1 2 x 1 .

  • Page 113

    Cylinder Head/Valve Train Dl6Y5, D16Y7, Dl6Y8 engines Cylinder Head ..... G2 Special Tools lllustrated Index ....... 6-23 VTEC Control System 6-27 ....Removal Troubleshooting Flowchart .." 6-3 ....6-40 Warpage VTEG Solenoid Valve ..... 6-45 lnstallation ...." 6-6 Inspection Rocker Arms VTEC Rocker Arms 6-30 ....

  • Page 114

    Special Tools Ref. No. Tool Number OTHAH _ PJTOl OB Valve Guide Reamer, 5.5 mm 6-43 0 7 J A A - 0 0 1 0 1 0 A Socket, 17 mm 6 - 1 6 07JAB - 0010204 H o l d e r H a n d l e o - t o OTLAJ _ PR3O2OB Air Stopper...

  • Page 115

    VTEC Control System Troubleshooting Flowchart rrouble code (Drc) Pr25e: A probrem in the vrEc Pressure switch circuit or tFtrsrl #ilH:::lj1t:"J:T,?ffnostic Reter to page 1 l-38 th roug h 1 1-55 before trou bleshooting. The MIL has been reoorted on. DTC P1259 is sto.ed. Check the VTEC Cont.ol Syst6m: 1.

  • Page 116

    VTEC Control System Troubleshooting Flowchart (cont'd) VTEC PRESSURE SwlTCH 2P (From page 6-3) CONNECTOR Test the VTEC Pr6suro Switch Wiro: Nleasure voltage across the VTEC pressure switch 2P connector. Wire side of female Rcpai. opon in tho wire (€rmrnats brtw.en VTEC pr6.urc switch and G101.

  • Page 117

    VTEC SOLENOID VALVE (From page 6'4) 1P CONNECTOR Terminalside of male terminal Test the VTEC Solenoid Valve: 1. Turn the ignition switch OFF. 2. Disconnect the wEC solenoid valve 1P connector. 3 . A t t a c h t h e b a t t e r y p o s i t a v e terminal to the VTEC solenoid valve terminal.

  • Page 118

    VTEC Solenoid Valve Inspection D i s c o n n e c t t h e 1 P c o n n e c t o r f r o m t h e V T E C s o l e - lf the filter is not clogged, push the VTEC solenoid noid valve.

  • Page 119

    VTEC Rocker Arms Manual Inspection (D16YB engine) Manual Inspection (D16Y5 engine) Set the No. 1 piston at TDC. Set the No. 1 piston at TDC. Remove the cylinder head cover. Remove the cylinder head cover. NOTE: Reter to page 6-46 when installing the cylin- NOTE: Refer to page 6-46 when installing the cylin- der head cover.

  • Page 120

    VTEC Rocker Arms Inspection Using SpecialTools (Dl6Y5 enginel CAUTION: Remove the sealing bolt from the inspection hole . Before using th6 Valve Inspection Tool, make 3ure and connect the an air pressure regulator with a 0 - that ths air pressure gaugo on the air comptsssor 100 psi gauge.

  • Page 121

    Stop applying air pressure and push up the timing 5. With the specified air pressure appli€d, push up the plate; the synchronizing piston will snap back to its timing plate; the synchronizing piston will pop out original position. and engage the intake secondary rocker arm. Visually check the disengagement of the synchro- Visually check the engagement of the synchronizing nizing pistons.

  • Page 122

    VTEC Rocker Arms Inspection Using Special Tools (D16Y8 enginel CAUTION: Remove the sealing bolt from the inspection hole o Before using the Valve Inspection Tool. mak6 sure ancl connect an air pressure regulator with a 0 - 100 that the air pressure gauge on the air comprsssor psi gauge.

  • Page 123

    Remove the special tools. Loosen the regulator valve on the valve inspection tool and apply the specified air pressure. U s e a 1 0 m m d i a m e t e r r o d t o d e p r e s s e a c h l o s t motion assembly through its full movement.

  • Page 124

    Valve Clearance Adjustment NOTE: Loosen the locknut, and turn the adjustment screw . Valves should be adjusted only when the cylindsr until the feeler gauge slides back and forth with a head temperature is less than 100"F (38"C). sliOht amount of drag, .

  • Page 125

    ' 1 8 0 ' c o u n t e r c l o c k w i s e t o 6. Tighten the locknut, and check the clearance again. R o t a t e t h e c r a n k s h a f t b r i n g N o .

  • Page 126

    Valve Seals Replacement (Cylinder head removal not requiredl N O T E : C y l i n d e r h e a d r e m o v a l i s n o t r e q u i r e d i n t h i s Intake Valve Seals: procedure.

  • Page 127

    1 6 . Using a downward motion on the lever arm, com- 10. Using a downward motion on the lever arm, com- press the valve spring and remove the keepers from .press the valve spring and remove the keepers from t h e v a l v e s t e m .

  • Page 128

    Crankshaft Pulley and Pulley Bolt Replacement W h e n i n s t a l l i n g a n d t i g h t e n i n g t h e p u l l e y . f o l l o w t h e Tighten the pulley bolt to the specified torque.

  • Page 129

    Timing Belt Illustrated lndex NOTE: Refer to page 6-20 for how to position the crankshaft and pulley before installing the belt. Mark the direction of rotation on the belt before removing. a Do not use the upper cover and lower cover for storing removed items, .

  • Page 130

    Timing Belt Inspection Tension Adjustment Remove the cylinder head cover. CAUTION: lt*ays aa;j"t the timing bett rension with the engine cold. . R e f e r t o p a g e 6 4 6 w h e n i n s t a l l i n g . NOTE: Remove the upper cover (see page 6 19).

  • Page 131

    Removal Remove the dipstick, then remove the upper cover NOTE: and idler PulleY bracket Replace the timing belt at 105,000 miles (168.000 km) according to the maintenance schedule (normal con- NOTE: Do not use the upper cover to store removed ditions/severe conditions).

  • Page 132

    Timing Belt Removal (cont'd) lnstallation 9. Remove the CKF sensor from the oI pump. Install the timing belt in the reverse order of removal; Only key points are described here. set rhe timing belt drive pulley so that the No. 1 pis- ton as at top dead center (TDC), Align the groove on the timing belt drive pulley to the pointer on the oil p u m p .

  • Page 133

    9. Check that the crankshaft pulley and camshaft pul- Install the timing belt tightly in the sequence shown' ley are both at TDC. OTiming belt drive pullev (crankshaft) )@Adjusting pulley -towater pump pulley J@Camshatt pulley' CRANKSHAFT PULLEY: NOTE: Make sure the timing belt drive pulley and camshaft PulleY are at TDC (wHrTE) CAMSHAFT PULLEY:...

  • Page 134

    Crankshaft Speed Fluctuation (CKF) Sensor Replacement Remove the cylinder head cover. NOTE: Refer to page 6-46 when installing. Remove the crankshaft pulley (see page 6_16), R e m o v e t h e u p p e r c o v e r a n d d i p s t i c k / t u b e { s e e p a g e 6 - 1 9 ) .

  • Page 135

    Gylinder Head lllustrated Index CAUTION: (38'C) before removing the cylinder . To avoid damage, wait until the engine coolant temperatule drops below 100"F head. . When handling a metal gasket, take care not to fold it or damage the contact surface' NOTEr Use new O-rings and gaskets when reassembling' 6 x 1 .

  • Page 136

    Cylinder Head lllustrated Index (cont'dl - / ) "or to reassembring, crean at the parts in sorvent, dry them and appry rubricant to anv contact oarts. D16Y7 engine: 8 x 1.25 mm 20 N.m (2.0 kgt.m, 14 tbt.ftl Apply engine oil to the ROCK€R ARM ASSEMBLY Removal, page 6 30...

  • Page 137

    D16Y5 engine: I x 1.25 mm 20 N.m (2,0 kgf m, 14 lbf ft) Apply engine oilto the threads. ROCKEB ARM 6 x 1 . 0 m m ASSEMBLY 12 N.m 11.2 kgf m, 8.7 lbf'ftl Femoval, page 6-30 Apply engine oilto the Inspection, Page 6-34 threads.

  • Page 138

    Cylinder Head lllustrated Index (cont'dl e,.io"o reassembring, crean at the parts in sorvent, dry them and appry rubricant to any contact parts. D16Y8 engine: LOST MOTION 20 N.m 12.0 kgl.m, 14 tbf.ft) LOST MOTION ASSEMBLY Apply engine oit to the ASSEMgLY HOLDER threads.

  • Page 139

    Removal Remove the throttle cable by loosening the locknut, Engine removal is not required for this procedure then slip the cable end out of the throttle linkage Make sure iacks and salety stands are !!!s@ NOTE: propetty and hoist brackets are attached to the f ta"eata"ea .

  • Page 140

    Cylinder Head Removal (cont'd) 9. Relieve fuel pressure (see section 11), 1 1. Remove the brake booster vacuum hose. fuel return hose and vacuum hose (see page S_4). Do not smoke while working on tho fuel system. Ke6p opgn flame or gpark away from lhe 12.

  • Page 141

    1 5 . Remove the spark plug caps and distributor from 13. Remove the upper radiator hose' heater hose and the cylinder head. water bYPass hose Remove the uPPer bracket. WATER EYPASS NOTE: HOSE . U s e a j a c k t o s u p p o r t t h e e n g i n e b e f o r e t h e UPPER upper bracket is removed.

  • Page 142

    Cylinder Head Rocker Arms Removal (cont'd) Removal 1 8 . Remove the timing belt {see page 6-19). 1. Loosen the adjusting screws. 1 9 . Remove the camshaft pulley and back cover, ADJUSTING SCREWS CAMSHAFT PULLEY Clean when installing. 8 x 1.25 mm 6 x 1 .

  • Page 143

    Disassembly/Reassembly N O T E : ldentify parts as they are removed to ensure reinstallation in original locations' lnsDect rocker shafts and rocker arms (see page 6-35). . Rocker arms must be installed in the same position if reused. . w h e n r e m o v i n g o r i n s t a l l i n g t h e r o c k e r a r m a s s e m b l y , d o n o t r e m o v e t h e c a m s h a f t h o l d e r b o l t s . T h e b o l t s w i l l k e e p t h e holders, springs and rocker arms on the shaft.

  • Page 144

    Rocker Arms Disassembly/Reassembly (cont'dl NOTE: ldentify pans as they are removed to ensure reinstallation in original locations. . Inspect rocker shafts and rocker arms (see page 6-34). Rocker arms must be installed in the same position if reused. t when removing or installing the rockerarm assembly, do not remove the camshaft holder bolts.

  • Page 145

    D16Y8 engine: INTAKE SOCKER SHAFT ROCKER SI{AFT ROCKER ARMS NUBBER BAND COLLAR COLLAR No. 'l CAMSHAFT No. 2 CAMSHAFT No. 3 CAMSHAFT No. 4 CAMSHAFT HOLDER HOLDER HOLDER HOLOER No. 5 CAMSHAFT HOLDER R(rcKER SHAFT SPRING ARM B EXHAUST ROCKER SHAFT Letter "A"...

  • Page 146

    Rocker Arms and Lost Motion Assemblies Inspection (D16Y5, Dt6Y8 enginesl N O T E r W h e n r e a s s e m b l i n g t h e p r i m a r y r o c k e r a r m , DI6YS engine: c a r e f u l l y a p p l y a i r p r e s s u r e t o t h e o i l p a s s a g e o f t h e rocker arm.

  • Page 147

    Rocker Arms and Shafts Clearance Inspection M e a s u r e t h e i n s i d e d i a m e t e r o f t h e r o c k e r a r m a n d Measure both the intake rocker shaft and exhaust rocker check for an out of-round condition.

  • Page 148

    Gamshaft 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 ofthe camshaft. 1.

  • Page 149

    Check the cam lobe height wear. Remove the camshaft holders. then measure the widest ponion of the plastigage on each journal. Cam lobe height standard (New) U n i t m m ( i n ) Camshaft-to-Holder Oil Clearance: EXHAUST INTAKE Standard lNew):0.050 - 0.08!t mm {0.002 - 0.004 in}...

  • Page 150

    Valves, Valve Springs and Valve Seals Removal N O T E : l d e n t i f y v a l v e s a n d v a l v e s p r i n g s a s t h e y a r e Install the valve guide seal remover.

  • Page 151

    Valve Guides Valve Movement Measure the guide-to-stem clearance with a dial indi- cator while rocking the stem in the direction of normal thrust (wobble method). lniake Valve Stem-to-Guide Clearance: St8ndard lNew): 0.04 - 0.10 mm 10.002 - 0.004 in) 0.16 mm 10.006 in) Service Limit: Exhaust Valvs Stem-to-Guide Glearance: Standard {New}: 0.10 - 0.16 mm...

  • Page 152

    Cylinder Head Valve Seats Warpage Reconditioning '1. Renew N O T E : l f t h e c a m s h a f t - t o - h o l d e r o i l c l e a r a n c e s ( s e e the valve seats in the cylinder head using a page 6-36) are not within specification, the cylinder head valve seat cutter.

  • Page 153

    Valve Guides Replacement 1 . As illustrated below, use a commercially-available air-impact valve guide driver attachment modified to fit the diameter of the valve guides. In most cases. the same procedure can be done using the special tool and a conventional hammer. VALVE SEAT VALVE GUIDE DRIVER...

  • Page 154

    Valve Guides Replacement (cont'd) Working from the camshaft side, use the driver and Apply a thin coat of clean engine oil to the outside a n a i r h a m m e r t o d r i v e t h e g u i d e a b o u t 2 m m ( 0 . 1 i n ) of the new valve guide.

  • Page 155

    Valves lnstallation Reaming Coat valve stems with engine oil. Insert the valves NOTE: For new valve guides only. in the valve guides. 1. Coat both the reamer and valve guide with cufting NOTE: Make sure lhe valves move up and clown o r l .

  • Page 156

    Camshaft/Rocker Arms and Valves Camshaft Seal/Pulley Installation (cont'd) Installation 4 . I n s t a l l t h e v a l v e s p r i n g a n d v a l v e r e t a i n e r . t h e n CAUTION: install the valve spring compressor.

  • Page 157

    Cylinder Head lnstallation 4. Apply liquid gasket (Part No. 08718 - 0001 or 08718 - lnstallthe cylinder head in the reverse order of removal: 0003) to the head mating surfaces of the No. 1 and NOTE: No.5 camshaft holders. . Always use a new head gasket. - Apply liquid gasket to the shaded areas .

  • Page 158

    Cylinder Head Installation (cont'dl Position the camshaft correctly (see page 6-20). 7 . Installthe timing belt (see page 6-20). Tighten the cylinder head bolts sequentially in four Adjust the valve clearance (see page el2), steps. Install the head cover gasket in the groove of the rsr st.p: O - @ 20 N.m (2.0 kgf.m, 14 lbf'ft| c y l i n d e r h e a d c o v e r , S e a t t h e r e c e s s e s f o r t h e 2nd srep: O - @ 49 N.m (5.0 kgf.m, 36 tbtft)

  • Page 159

    12. Tighten the nuts in two or thre€ steps. In the final 1 1 . W h e n i n s t a l l i n g t h e c y l i n d e r h e a d c o v e r , h o l d t h e step, tighten all bolts, in sequence, to 9 8 N'm (1.0 head cover gasket in the groove by placing your fin- kgf.m, 7.2 lbf.ft).

  • Page 160

    Gylinder Head/Valve Train 816A2 engine Rocker Arms ..... 6'50 Special Tools VTEC Contlol System Disassembly/Reassembly ....6'72 Troubfeshooting Flowchart .... 6-51 Rocker Arms and Lost Motion Assemblies VTEC Solenoid Valve ..""' 6-73 Inspection ...""'..5-54 Inspection Rocker Arms and Shafts VTEC Rocker Arms Clearance Inspection ..'..."'....

  • Page 161

    Special Tools Ref. No. I Tool Number Description Page Relerence o T H A H P J 7 0 1 0 B V a l v e G u i d e R e a m e r , 5 . 5 m m 6-81 0 7 J A A - 0 0 1 0 2 0 A Socket, 19 mm...

  • Page 162

    VTEC Control SYstem Troubleshooting Flowchart A problem in the WEC Pressure Switch circuit or The scan tool indicates Diagnostic Trouble Code {DTC) Pl259: VTEC Solenoid Valve circuit Refer to page 1'l-38 through 11 55 before troubleshooting The MIL has been teported on. DTC P1259 is siored.

  • Page 163

    VTEC Control System Troubleshooting Flowchart (cont,d) VTEC PRESSURE SWITCH 2P (From page 6-5l l CONNECTOR Test tha VTEC P.es3uro Switch Wi.e: Measure voltage across the VTEC pressure switch 2P connector. Wire side of temale Ropair opon in the wiro batwoen terminals VIEC pr...urc switch and G lot .

  • Page 164

    VTEC SOLENOID VALVE (From page 6-52) 1P CONNECTOR T e r m i n a l s i d e o f m a l e t e r m i n a l Test the VTEC Solenoid Valve: 1. Turn the ignition switch OFF 2.

  • Page 165

    VTEC Solenoid Valve VTEC Rocker Arms Inspection Manual Inspection 1 . R e m o v e t h e V T E C s o l e n o i d v a l v e a s s e m b l y f r o m 1.

  • Page 166

    Inspection Using SPecial Tools CAUTION: Remove the cylinder head cover. B€fore using tho Yalvo inspeciion tool, mako suro that ths air pre3sure gauge on the air comprossor NOTE: Refer to page 6-88 when installing the cylin- indicatos ovor /rco kPa (,1 kgf/cm', 57 psi) der head cover.

  • Page 167

    VTEC Rocker Arms Inspection Using Special Tools (cont,dl L o o s e n t h e v a l v e o n t h e r e g u l a t o r a n d a p p l y t h e specified air pressure.

  • Page 168

    Valve Glearance Adjustment Adjust valves on No. 1 cylinder. NOTE: lntako: 0.15 - 0.19 mm {0'006 - 0.007 in) . Valves should be adjusted only when the cylinder ExhaGt 0.17 - 0.21 mm {0'007 - 0 008 inl head temperaturs is less than 100'F (38'C)' .

  • Page 169

    Valve Clearance Adjustment {cont'd) 5. Tighten the locknut and recheck clearance. R o t a t e t h e c r a n k s h a f t ' 1 8 0 . c o u n t e r c l o c k w i s e t o Repeat adjustment if necessary.

  • Page 170

    Crankshaft PulleY and PulleY Bolt Replacement When installing and tightening the pulley, follow the procedure below' Clean, remove any oil, and lubricate points shown below a : C l e a n x : Bemove anY oll a: Lubricate CRANKSHAFT PULLEY BOLT X X X X X BELT...

  • Page 171

    Timing Belt lllustrated Index NOTE: . Refer to page 6-59 for positioning crankshaft and pulley before installing belt. Mark the direction of rotation on the belt before removino. a Do not use the middle cover and lower cover for storing r'emoved items. .

  • Page 172

    Tension Adiustment Inspection CAUTION: Always adiust timing belt tension with the Remove the cylinder head cover. engine cold. NOTE: Refer to page 6-86 when installing the cylin- NOTE: der head cover. . The tensioner is spring-loaded to apply proper ten sion to the belt automatically after making the follow- Inspect the timing belt for cracks and oil or coolant ing adjustment.

  • Page 173

    Timing Belt Removal NOTE: Loosen the mounting nut and lock bolt, then remove Replace the timing belt at 105,000 mites (168,000 km) the alternator belt. according to the maintenance schedule (normal con- ditions/severe conditions). LOCK BOLT lf the vehicle is regularly driven in one or more of the 8 x 1.25 mm following conditions, replace the timing belt at 60,OOO 24 N.m {2.4 kgt.m.

  • Page 174

    lnstallation Install the timing belt in the reverse order of removal; Remove the crankshaft pulley (see page 6-59). Only key points are described here. Remove the cylinder head cover' 1. Set the timing belt drive pulley so that the No. 1 pis' ton is at top dead center (TDC).

  • Page 175

    Timing Belt lnstallation (cont'dl Install the timing belt tightly in the sequence shown. 9. Check that the crankshaft pulley and camshaft pul- @ T i m i n g b e l t d r i v e p u l l e y ( c r a n k s h a f t ) + @ leys are both at TDC.

  • Page 176

    Cylinder Head lllustrated Index CAUTION: (38"C1 bofote . To avoid damaging the cylinder head, wait until the engine coolant tempsraturo drops below 100"F removing it, gasket. . when handling a metal gasket, take caro not to fold the gaskot or damage the contact surface of the NOTE: Use new O-rings and gaskets when reassembling.

  • Page 177

    Cylinder Head lllustrated Index (cont'dl CYLINDER HEAD BOLTS INTAKE VALVE SPRING INNER 1 1 x 1 . 5 m m 83 N.m {8.5 kg{.m, 61 Apply engine oil VALVE KEEPERS to threads. SPRING RETAINER INTAKE VAI.VE SPRING OUTER valvEKEEPEBS\:""j"*' VALVE SEAL Replace.

  • Page 178

    Removal Loosen the idler pulley bracket bolt and adjusting Engine removal is not required for this procedure. b o l t , t h e n r e m o v e t h e a i r c o n d i t i o n i n g ( A / C ) c o m - Make sure jacks and safety stands are placed pressor belt.

  • Page 179

    Cylinder Head Removal (cont'd) 8. Remove the P/S pump lower bracket. 11. Remove the brake booster vacuum hose, fuel return hose and vacuum hose (see page 5 4). 8 x 1.25 mm T SHIELD 24 N.m 12.4 kgf.m, 12. Remove the water bypass hose and positive crankcase 17 tbtftl ventilation (PCV) hose.

  • Page 180

    Remove the spark plug caps and distributor form 1 6 . 14. Remove the upper radiator hose, heater hose and the cylinder head. water bvpass hose. Remove the upper bracket. 1 7 . HEATER WATER BYPASS NOTE: Use a jack to support the engine before removing the upp€r bracket is removed.

  • Page 181

    Cylinder Head Removal (cont'dl 1 9 . Remove the timing belt {see page 6-62). 24. Remove the camshaft holder plates, camshaft hold- ers and camshafts. Remove the back cover and camshaft pulleys. CYLINDER HEAD CAMSHAFT PLUG HOLDER PLATE Replace. BACK COVER €...

  • Page 182

    Rocker Arms Removal '1. Hold the rocker arms together with a rubber band to 3 . S c r e w 1 2 m m b o l t s i n t o t h e r o c k e r a r m s h a f t s . Remove each rocker arm set while slowly pulling prevent them from separating.

  • Page 183

    Rocker Arms Disassembly/Reassembly CAUTION: After installing the rocker shaft oritice, make suro thot the orifics is correctly installed in the hole of rocker shaft by trying to turn the rocker shaft. ll the orifice is in place, it should not turn. NOTE: ldentify parts as they are removed to ensure reinstallation in original locations.

  • Page 184

    Rocker Arms and Lost Motion Assemblies Inspection Remove the lost motion assembly from the cylinder NOTE: When reassembling the primary rocker arm, care- head and inspect it. Test it by pushing the plunger fully apply air pressure to the oil passage of the rocker with your finger, a r m .

  • Page 185

    Rocker Arms and Shafts Clearance Inspection Measure both the intake rocker shaft and exhaust rocker Measure the inside diameter of each rocker arm and shaft. check for out-of-round condition 1. Measure diameter of shaft at the first rocker loca- Rocker Arm-to-Shaft Clearance: t r o n .

  • Page 186

    Camshafts Inspection NOTE: Do not rotate the camshaft during inspection. Removg the rocker arms and rocker shafts. Put the camshafts and camshaft holders on the cylin- der head. and then tighten the bolts to the specified torque. Specified Torque: O -@: 8 mm botts 27 N.m {2.8 kgf.m,20 lbt'ft) Apply engine oil to the threads, O - @: 6 mm bolts 9.8 N.m (1.0 kgf m, 7.2 lbf'ft) Remove the bolts.

  • Page 187

    Gamshafts Inspection (cont'dl lf the camshaft-to-holder oil clearance is out of tol- Check the cam lobe height. erance: Cam lobe height standard (New): - And the camshaft has already been replaced, you must replace the cylinder head. INTAKE EXHAUST lf the camshaft has not been replaced, first check 33.088 mm 32.785 mm PRIMARY...

  • Page 188

    Valves, Valve Springs and Valve Seals Removal Installthe valve guide seal remover. NOTE: ldentify valves and valve springs as they are removed so that each item can be reinstalled in its origi- VALVE GUIDE SEAL REMOVER nal Dosition. COMMERCIALLY AVAILABLE Ltst-E P/N 571100 ()R KD3350 Using an appropriate-sized socket and plastic mal- let, lightly tap the valve retainer to loosen the valve...

  • Page 189

    Valve Seats Reconditioning 1. Renew the valve seats in the cylinder head with a 5. After resufacing the seat. inspect for even valve valve seat cutter. s e a t i n g : A p p l y P r u s s i a n B l u e C o m p o u n d t o t h e valve face, and insert the valve in its original loca- N O T E : l f a n y g u i d e s a r e w o r n ( s e e p a g e 6 - 7 9 ) ,...

  • Page 190

    Valve Guides Cylinder Head Valve Movement Warpage Measure the guide-to-stem clearance with a dial indica- NOTE: lf camshaft-to-holder oil clearances (see page 475) t o r w h i l e r o c k i n g t h e s t e m i n t h e d i r e c t i o n o f n o r m a l are not within specification, the head cannot be resurfaced.

  • Page 191

    Valve Guides Replacement 1. As illustrated below, use a commerciallv available Working from the camshaft side, use the driver and air-impact valve guide driver attachment modified an air hammer to drive the guide about 2 mm (0.1 in) t o f i t t h e d i a m e t e r o f t h e v a l v e g u i d e s . l n m o s t towards the combustion chamber.

  • Page 192

    Reaming NOTE: For new valve guides onlY. Apply a thin coat of clean engine oil to the outside of the new valve guide. Install the guide from the 1. Coat both reamer and valve guide with cufting oil. camshaft side of the head; use the special tool to drive the guide in to the specified installed height.

  • Page 193

    Valves Installation Coat the valve stems with oil. lnsert the valves into l n s t a l l t h e v a l v e s p r i n g a n d v a l v e r e t a i n e r , t h e n the valve guides.

  • Page 194

    Rocker Arms lnstallation 4. Clean and install the rocker shaft orifices with new l n s t a l l t h e r o c k e r a r m s i n t h e r e v e r s e o r d e r o f O - r i n g s .

  • Page 195

    Cylinder Head Installation lnstall the cylinder head in the reverse order of removal: 2, Tighten the cylinder head bolts in two steps. In the first step, tighten all bolts in sequence to about 29 NOTE: N.m (3.0 kgf.m, 22 tbf.ftl. ln the final step, tighten in .

  • Page 196

    lnstall the camshaft holders and camshaft holder lnstall the camshafts and camshaft oil seals. plaIe. NOTE: The arrows marked on the camshaft holders NOTE: should point to the timing belt. . lnstallthe camshafts with the keyway facing up. lnstall the oil seal withthespring side facing in. CAMSHAFT .

  • Page 197

    Cylinder Head Installation (cont'dl 1 0 . A l i g n t h e m a r k s o n t h e c y l i n d e r h e a d p l u g t o t h e 14.

  • Page 198

    16. Tighten the nuts in two or three steps. In the final 15. When installing the cylinder head cover, hold the step, tighten all nuts, in sequence, to 9 8 N'm {1 0 head cover gasket in the groove by placing your fin- kgf.m, 7.2 lbf.ft).

  • Page 199

    Engine Block Cylinder Block ..." 7-2 Speciaf Tools ....7-16 lnspec'tion lllustlated Index ...."..'....7-17 Bore Honing Flywheel and Drive Plate Piston Pins """'.' 7-7 Repf acement ...,...'.7-17 Removal Connecting Rod and Crankshaft .....7-18 lnstallation ..."..7-8 End Play .'....7-19 Inspection Main Bearings Connecting Rods ....

  • Page 200

    Special Tools Ref. No. Tool Numbel 07LAB - PV00100 R i n g G e a r H o l d e r 07749 - 0010000 Driver 7 - 2 2 , 2 9 07947 - SB00200 Seal Driver 7.29 07948 - SB00'101 Driver Attachment 7 - 2 2 , 2 9...

  • Page 201

    lllustrated Index runricate att internal parts with engine oil during reassembly' NOTE: pumpcase before installingthem' o Apply liquid gaskettothe mating surfaces ofthe right side cover and oil U s e l i q u i d g a s k e t , p a r t N o 0 8 7 1 8 - 0 0 0 1 o r 0 8 7 1 8 - 0 0 0 3 ' .

  • Page 202

    lllustrated Index (cont'dl Luoricate att internal parts with engine oil during reassembly. NOTE: Apply liquid gasket to the mating surfaces ofthe rightside coverand oil pumpcase before installingthem. Use liquid gasket, part No. 08718 - 0001 or 087,18 _ OOO3. . Clean the oil pan gasket mating surfaces before installing it. 6 x 1 .

  • Page 203

    D16Y5, D16Y8 engines: OIL PAN Refer to page 7-25 WASHER Apply liquid gasket to DRAIN BOLT Replace. when installing. these points. 39 N.m 14.0 kgt'm, FLYWHEEL COVER 29 lbl.tt) (M/T} 1 2 x 1 . 0 m m 1 1 8 N . m 6 x 1 .

  • Page 204

    lllustrated Index (cont'd) NOTE: New rod bearings must be selected by matching connecting rod assembly and crankshaft identification markings ( s e e p a g e 7 , 1 1 ) . Lubricate all internal parts with engine oil during PISTON INSTALLATION DIRECTION: reassembtv.

  • Page 205

    Flywheel and Drive Plate Replacement Automatic Transmission: Manual Transmission: Remove the six drive plate bolts, then separate the drive 816A2 engine: olate from the crankshaft flange. Atter installation, tighten Remove the eight flywheel bolts, then separate the fly- the bolts in a crisscross Pattern. w h e e l f r o m t h e c r a n k s h a f t f l a n g e .

  • Page 206

    Connecting Rod and Crankshaft End Play Connecling Bod End Play: Push the crankshaft firmly away from the dial indicator, Standard (Newl: 0.15 - 0.30 mm and zero the dial against the end of the crankshaft. Then 10.006 - 0.012 inl pull the crankshaft firmly back toward the indicator;...

  • Page 207

    Main Bearings Glearance 1 . T o c h e c k m a i n b e a r i n g - t o - j o u r n a l o i l c l e a r a n c e . remove the main caps and bearing halves.

  • Page 208

    Main Bearing Selection CAUTION: lf the codes are indecipherable because of an D16Y5, D16Y7, D16Y8 engines: accumulation of dirt and dust, do not scrub them with a Letters have been stamped on the end of the block as a wire brush or scraper. Clean them only with solvent ol code for the size of each of the 5 main journal bores.

  • Page 209

    Connecting Rod Bearings Selection Clearance CAUTION: lf the codes are indecipherable because of Remove the connecting rod cap and bearing half an accumulation of dirt and dust, do not sclub them with a wile brush or scraper. Clean them only with sol- C l e a n t h e c r a n k s h a f t r o d i o u r n a l a n d b e a r i n g h a l f vent or detergent, with a clean shop towel.

  • Page 210

    Pistons and Crankshaft Removal 1. Remove the oil pan assembly. Remove the oil screen. Remove the right side cover. R€move the oil pump. 816A2 engine 816A2 engin€ OIL SCREEN OIL PUMP D16Y5, Dl6Y7, D16Y8 ongines D16Y5, D1oyr, D16Y8 engin.s RIGHT SIDE O-RING Replace.

  • Page 211

    Remove the upper bearing halves from the connect- Remove the bolts and the bearing caps. ing rods and set them aside with their respective CAUTION: To prevenl warpago unscrow lhe bolts caos. in s€quence 1/3 turn at a tims, r€paat the soquence 1 0 .

  • Page 212

    Crankshaft Inspection . Clean the crankshaft oil passages with pipe cleaners Out-of-Round and Tapet or a suitable brush. . Measure out-of-round at the middle of each rod . Check the keyway and threads. and main journal in two places. Alignment a The difference between measurements on each journal must not be more than the service limit.

  • Page 213

    Pistons Inspection Calculate the difference between the cylinder bore 1 . Check the piston for distortion or cracks, diameter (see page 7-16) and the piston diameter. N O T E : l f a c y l i n d e r i s b o r e d . a n o v e r s i z e d p i s t o n Piston-to-Cylinder Clsarance must be used.

  • Page 214

    Cylinder Block Inspection Measure wear and taper in directions X and y at three lf the measurements in any cylinder are beyond levels in each cvlinder as shown. the Oversize Bore Service Limit, replace the block. lf the block is to be rebored. refer to piston Clear- ance Inspection (see page 7-15) after reboring.

  • Page 215

    Piston Pins Cylinder Block Removal Bore Honing Measure cylinder bores as shown on page 7-16. lf the Assemble the special tool as shown. block is to be reused, hone the cylinders and remea- PISTON BASE HEAD sure the bores. 07973 - SBtx)too Hone cylinder bores with honing oil 8nd a fine (400 grit) stone in a 60 degree cross-hatch pattern.

  • Page 216

    Connecting Rods Piston Pins Selection Installation Each rod falls into one of four tolerance ranges {from O to Use a hydraulic press for installation. + 0.024 mm (0 to + 0.0009 in), in 0.006 mm (0.0002 in) increments) depending on the size of its big end bore. lt,s .

  • Page 217

    lnspection Measure the piston pin-to-piston clearance. Measure the diameter of the piston pin. NOTE: Check the piston for distortion or cracks. Piston Pin Diametel: B16A2 engine: lf the piston pin clearance is greater than 0.024 mm Standard {New): 20.994 - 21.000 mm ( 0 .

  • Page 218

    Piston Rings End Gap Replacement 1 . Using a piston, push a new ring into the cylinder Using a ring expander. remove the old piston rings. bore 15 - 20 mm (0.6 - 0.8 in) from the bottom. Clean all ring grooves thoroughly. Measure the piston ring end-gap with a feeler gauge: NOTE: lf the gap is too small, check to see if you have...

  • Page 219

    Ring-to-Groove Clearance Alignment 1. Installthe rings as shown. After installing a new set of rings, measure ring-to- groove clearances: NOTE: The manufacturing marks must be facing upward. Top Ring Clearance Standard (New): TOP RING (Chrome) B16A2 angine: 0.045 - 0.070 mm (0.0018 - 0.(X128 in) Dl6Y5, Dt6Y7, Dl6Y8 engin€s: 0.035 - 0.060 mm {0.0014 - 0.002'l in) service Limit: 0.13 mm (o.fixi in)

  • Page 220

    Piston Rings Crankshaft Oil Seal Alignment (cont'dl Installation The seal surface on the block should be dry. Apply a light coat of oil to the c.ankshaft and to MARK t h e l i p o f t h e s e a l . TOP RING ---.>...

  • Page 221

    Grankshaft Pistons lnstallation lnstallation Before installing the crankshaft, apply a coat of B e f o r e i n s t a l l i n g t h e p i s t o n s , a p p l y a c o a t o f engine oil to the main bearings and rod bearings.

  • Page 222

    Crankshaft Installation (cont'd) I n s t a l l t h e m a i n b e a r i n g c a p s . NOTE: Check clearance with plastigage (see page 7-9), then Use liquid gasket, part No. 08718 - 0001 or08718- tighten the bearing cap bolts in 2 steps.

  • Page 223

    Apply liquid gasket to the oil pump mating surtace 81642 ongin€: of the block, then install the oil pump on the cylin- der block. RIGHT SIDE Apply grease to the lips of the oil seals. Thgn, align the inner rotor with the crankshaft and i n s t a l l t h e o i l p u m p .

  • Page 224

    Crankshaft Oil Pan Installation (cont'd) Installation NOTE: D16Y5, Dl6Yg engines: . Apply a light coat of oil to the crankshaft and io t h e l i p o f s e a l . 1 . I n s t a l l t h e o i l p a n g a s k e t o n t h e o i l p a n . U s e n e w O - r i n g s a n d a p p l y o i l w h e n i n s t a l l i n g t h e m .

  • Page 225

    816A2, D16Y7 engines: Apply liquid gasket to the block mating surfaces of the oil pan, then install it. Apply liquid gasket to the 1 . A p p l y l i q u i d g a s k e t o n t h e o i l p u m p a n d r i g h t s i d e shaded areas.

  • Page 226

    Oil Pan lnstallation (cont'dl Install the oil pan gasket and oil pan Tighten the bolts and nuts finger tight at six points as shown below. NOTE: a Use a new oil pan gasket. . I n s t a l l t h e o i l p a n n o m o r e t h a n f i v e m i n u t e s after applying liquid gasket.

  • Page 227

    Oil Seals lnstallation Measure the flvwheel-end seal thickness and the oil NOTE: seal housing depth. Using the special tool. drive the . Engine removal is not required. flywheel-end seal into the rear cover to the point . The crankshaft oil seal housing should be dry. where the clearance between the bottom of the oil Apply a light coat of grease to the crankshaft and to seal and the right side cover is 0.5 - 0.8 mm (0.02...

  • Page 228

    Engine Lubrication "'.""".8'2 SpecialTools ...'..' 8-3 lllustrated Index ... Engine Oil ..'..".."'. Inspection Replacement..'..".'.'..."..".." OilFilter Rep1acement....".'...'..'..'.'...". Oil Pressure '..' 8-9 Testing OilJet (B16A2 engine) ...'.'..".."'..8-10 Inspection O i l P u m p 8-11 ..'...'..'."""' overhaul.'..'..8-1 3 Removal/lnspection/lnstallation...

  • Page 229

    Special Tools Ref. No. Toot Number 07746 - 0010400 Attachment, 52 x 55 mm 07749 - 0010000 Driver 0 7 9 1 2 - 6 1 1 0 0 0 1 Oil Filter Wrench \ l l...

  • Page 230

    lllustrated Index CAUTION: Do not overiighten the drain bolt. NOTE: Use new O-rings when reassembling . Apply oil to O-rings before installation . Use liquid gasket, Part No 08718 - 0001 or 08718 - 6 x 1 . 0 m m 0003.

  • Page 231

    lllustrated Index (cont'dl NOTE: CAUTION: Do not overtighten the drain bolt. Use new O-rings when reassembling. . Apply oil to O-rings before instaltal|on. ENGINE OIL PBESSURE SWITCH 18 N.m (1.8 kgtm, 13 tbt.trl Use liquid gasket, Part No. 08718 0001 or 0e719 1/8 in.

  • Page 232

    CAUTION: Do not overtightsn the drain bolt. NOTE: . Use new O-rings when reassembling. . Apply oil to O-rings before installation. . Use liquid gasket, Part No 08718 - 0001 or 08718 ENGINE OIL PRESSURE SWITCH 0003. 18 N,m l'1.8 kgf.m, 13 lbf.ftl .

  • Page 233

    Engine Oil Inspection Replacement 1 . Park the vehicle on level ground, and turn off CAUTION: Removo the drain boli carefully while engine. Allow the oil a few minutes to drain back engine is hot; the hot oil may causo scalding. into the oil pan so the dipstick will show the actual level.

  • Page 234

    Reinstall the drain bolt with a new washer. and rbfill the engine with the recommended oil. "Energy Requirement API Service Grade: Use an Conserving" SJ grade oil or an "Energy Conserving ll" SH grade oil, SAE 5W - 30 preferred You can also use an oil that bears the mark.

  • Page 235

    Oil Filter Replacement Install the oil filter by hand. After the engine has been run, the exhaust pipe will be hot; be careful when working around ihe exhaust After the rubber seal seats, tighten the oil filter clock_ pipe. wise with the oil filter wrench. Be careful when loosening the drain bolt whils the engine is hot.

  • Page 236

    Oil Pressure Testing lf the oil pressure warning Iight stays on with the engine Use this procedure to tighten the filter if eight num- running, check the engine oil level. It the oil level is cor- bers (1 to 8) are printed on the surface of the filter. rect: 1) Make a mark on the oil filter base under the num- 1.

  • Page 237

    OilJet (B1642 engine) Inspection 1 . Remove the oil jet (see page 8-3) and inspect it as follows. M a k e s u r e t h a t a 1 . 1 m m ( 0 . 0 4 i n ) d i a m e t e r d r i l l will go through the nozzte hole (j.2 mm (0.05 in) diameter).

  • Page 238

    Oil Pump Overhaul NOTE: . Use new O rings when reassembllng. . Apply oil to O-rings before installation. - 0003 Use liquid gasket, Part No. 08718 - 0001 or 08718 . The rotors must be installed to the same direction in order' o After reassembly, check that the rolors move without binding' B15A2 engine: 6 x 1 .

  • Page 239

    O i l Pump Overhaul (cont'dl NOIE: . U s e n e w O r i n g s w h e n r e a s s e m b l i n g . . Apply oil to O rings before instalraUon. U s e l i q u i d g a s k e t , P a r r N o .

  • Page 240

    Removal/lnspection/lnstallation 1 0 . R e m o v e t h e s c r e w s f r o m t h e p u m p h o u s i n g , t h e n D r a i n t h e e n g i n e o i l .

  • Page 241

    Oil Pump RemovaUlnspection/lnstallation (cont'dl 13. Check the housing-to-outer rotor radial clearance. 17. Reassemble the oil pump, applying thread lock to l f t h e h o u s i n g - t o - o u t e r r o t o r r a d i a l c l e a r a n c e the pump housing screws.

  • Page 242

    lnstall the oil screen. 22. Installthe oil pump on the cylinder block. Apply grease to the lip ot the oil pump seal. Install the oil pan (see pages 7-26 or 7-27). Then. install the oil pump onto the crankshaft. When the pump is in place, clean any excess grease NOTE: Clean the oil pan gasket mating surfaces.

  • Page 243

    lntake Manifold/Exhaust System lntake Manifold Replacement ........Exhaust Manifold Rep|acement ........". Exhaust Pipe and Muffler Replacement .......'.'.".. Three Way Catalytic Converter {TWCI 9-12 ...."'. Inspection Heated Oxygen Sensor (HO2SI 9-12 Rep|acement ......'..".." r f o...

  • Page 244

    Intake Manifold Replacement NOTE: Use new O-rings and gaskets when reassemblinq. CAUTION: . Check tor folds or scratchos on the surface of tbe gasket. . Replace with a now gasket if damaged. D16Y7 engine: 8 x 1.25 mm 22 N.m 12.2 kgtm, 16 tbtftl INTAKE MANIFOLD Replace if cracked or if mating surfaces are...

  • Page 245

    D16Y5 engine: 6 x 1 . 0 m m 12 N'm (1.2 kgl.m,8.? lbf'ft) EGR CHAMBER INIAKE MANIFOLD Replace if cracked or 8 x 1.25 mm if mating surfaces are 21 N m (2.1 kgf.m, d a m a g e o , 15 tbtft) EXHAUST GAS RECIRCULATION...

  • Page 246

    lntake Manifold Replacement (cont'dl NOTE: Use new O,rings and gaskets when reassembling. CAUTION: . Check lor folds or scratches on the surface of the gasket. . Replace with a new gasket il damaged. D16Y8 engine: INTAKE MANIFOLD Replace if cracked or if mating surfaces are oamageo, INTAKE AIR CONTROL...

  • Page 247

    816A2 engine: INTAKE MANIFOLD Replace if cracked or if mating surfaces are oamageo, t_-l n ""\-- 8 x 1.25 mm 22 N.rA 12.2 kgl.trr, VlCd>-^ 16 tbtftt INTAKE AIR CONTROL IIACI VALVE Al N-m 12.2 kgt.m, MANIFOLD 8 x 1.25 mm 16 tbt.ftl 8 x 1.25 mm BRACKET...

  • Page 248

    Exhaust Manifold Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. CAUTION: . Check for folds or scratch€s on the surface of the gasket. . Replace with a new gasket it damaged. D16Y5. D16Y7 engines: PRIMARY HEATED OXYGEN SENSOR IPRIMAFY HO2SI I x 1.25 mm 44 N.m {4.5 kgf m, 33 lbtft)

  • Page 249

    D15Y8 engine: 8 x 1.25 mm GASKET 2,1 N.m (2.a kgf'm, Replace. 17 tbf.ftl 8 x 1.25 mm 31 N.m 13.2 kgf'm, 23 lbf.ftl Replace. PRIMARY HO2S 44 N.m (4.5 kgf.m, 33 lbtft) Replacement, page 9-13 EXHAUST MANIFOLD BRACKET 10 x 1.25 rnm /r4 N.m {4.5 kgf.m, 33 lbf.ft) (cont'd)

  • Page 250

    Exhaust Manifold Replacement (cont'dl NOTE: Use new gaskets and self-locking nuts when reassembljng. CAUTION: . Check for folds or scratches on the surface ot the gask€t. . R€place with a new gaskot if damagod, B16A2 engine: GASKET R e p l a c e . 10 x 1.25 mm 44 N.m {4.4 kgt.m, 33 tbl.ft)

  • Page 251

    Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling D16Y5, D16Y7 engines: EXHAUST PIPE TIP MUFFLER 6 x 1 . 0 m m 9.8 N.m 11.0 kgt m, 7.2 lbf'ftl HEAT SHIELO oP---------------- 8 x 1.25 mm 22 N.m 12.2 kg .m, 16 tbf.f Replace.

  • Page 252

    Exhaust Pipe and Muffler Replacement {cont'dl NOTE: Use new gaskets and self-locking nuts when reassembling. D16Y8 engine: MUFFLER d'*'ou"'"'""' 6 x 1 . 0 m m 9.8 N.m (1.0 ksf m,7.2lbf ft) 8 x 1.25 mm 22 N.rn 12.2 kgl.m, 16 tbt.ft) Replace.

  • Page 253

    816A2 engino: _.,. EXHAUST PIPE MUFFLER GASKET Replace. \ 6 r 1 . o m m 9.8 N m 11.0 kgf'm, 7.2 lbl'ttl 8 x 1.25 mm 2. N'm 12.2 kgl-m, t6 tbtf0 Replace. Tighten the bolts in steps, alternatrng side-to-side.

  • Page 254

    HO2S Inspection Replacement Using a flashlight, make a visual check for plugging, Primary HO2S: melting and cracking of the catalyst. 1. Remove the primary HO2S. D16Y5, D16Y7 engines: D16Y5, D15Y7 engines: D i s c o n n e c t t h e p r i m a r y H O 2 S c o n n e c t o r , t h e n remove the cover.

  • Page 255

    Secondsry H02S: Bt6A2, Dl6Y8 engines: 1. Remove the secondary HO2S Disconnect the primary HO2S connector then remove the primary HO2S. Dl6Y5, Dt6Y7 engines: 816A2 engine a . D i s c o n n e c t t h e s e c o n d a r y H O 2 S c o n n e c t o r . then remove the secondary HO2S' 02 SENSOR PRIMARY...

  • Page 256

    HO2S Replacement (cont'd) Remove the secondarv HO2S. 02 SENSOR WRENCH SECONOARY HO2S 4,r N.m (4.5 kgf.m, 33 tbf.ft) I n s t a l l t h e s e c o n d a r y H O 2 S i n r e v e r s e o r d e r o f removat.

  • Page 257

    Cooling ""' 10-2 fllustrated Index ."..."... Radiator 10-6 Replacement .'..'.."..." Engine Coolant Refilling and 10-7 Bleeding 10-9 Cap Testing 10-9 Testing Thermostat 1 0 - 1 0 Replacement .....'..1 0 - 1 0 Testing Engine Goolant TemPerature (ECT) Switch """...

  • Page 258

    lllustrated Index system is under high pressure when the CAUTION: lf any engine coolant spills on painted por- engine is hot. To avoid dangsr of rsleasing scalding tions of the body, rinse it off immediately. engine coolant, removo the cap only when the engine is coot.

  • Page 259

    Engine Hose Connections: D15Y7 engine: IAC VALVE WATEF BYPASS THERMOSTAT HOUSING CONNECTING PIPE HEATER VALVE HOSES {cont'd) 1 0 - 3...

  • Page 260

    lllustrated Index (cont'd) Engine Hose Connections: D16Y5, D16Y8 engines: IAC VALVE {A/T) Replace. WATER BYPASS HOSE IAC VALVE (M/TI THERMOSTAT HOUSING O.RING Replace. CONNECTING PIPE HEATER VALVE HEATER HOS€S 1 0 - 4...

  • Page 261

    Engine Hose Conneqtions: 81642 engine: THERMOSTAT HOUSING CONNECTING PIPE O-RING Replace. WATER BYPASS HOSE ENGINE OIL COOLER HEATER VALVE HEATER HOSES 1 0 - 5...

  • Page 262

    Radiator Replacement Drain the engine coolant. Remove the fan shroud assemblies and other parts from the radiator. R e m o v e t h e u p p e r a n d l o w e r r a d i a t o r h o s e s , a n d ATF cooler hoses.

  • Page 263

    Engine Coolant Refilling and Bleeding B1642 engin€: CAUTION: when pouring engine coolant, be sure to shut the relay box lid and not to lst coolant spill on the eleqtrical parts or the paint. lf any coolant spills, rinse it WASHER Replace.

  • Page 264

    NOTE: o Use only genuine Honda antifreeze/coolant. . For best corrosion protection. the coolant con_ c e n t r a t i o n m u s t b e m a i n t a i n e d y e a r _ r o u n d a t 50% minimum.

  • Page 265

    Testing Cap Testing Wait until the engine is cool, then carefully remove 1. Remove the radiator cap, wet its seal with engine t h e r a d i a t o r c a p a n d f i l l t h e r a d i a t o r w i t h e n g i n e coolant, then install it on the pressure tester' coolant to the top of the tiller neck Attach the pressure tester to the radiator and apply...

  • Page 266

    Thermostat Replacement NOTE: Use a new O-ring when reassemblinq. THERMOSTAT Install with pin up. THERMOSTAT THERMOSTAT HOUSING ENGINE COOLANT TEMPERATURE {ECT) swtTcH 6 x 1 . 0 m m 24 N.m {2.4 kgf.m, t7 tbf.ft) 12 N.m {1.2 kgf.m,8.7 tbf.frl 1 0 - 1 0...

  • Page 267

    EGT Switch Testing Testing Romoving the EcT swhch while lhs engine Replace the thermostat if it is open at room temperature' i!-ot can cause the coolant to sPray out, seriously scald- ing you. Always lst th€ ongine and rediator cool down To test a closed thermostat: before removing ihe ECT switch.

  • Page 268

    Water Pump lllustrated Index NOTE: Use new O-rings when reassembrrng. . Use liquid gasket, Part No. 08718 - 0OOl or 087 t8 _ 0003. O16Y5, D16Y7, D16Y8 engines: ECT GAUGE SENDING UNIT 6 x 1 . 0 m m 9 N.m {0.9 kgI.m, 9.8 N.m {1.0 kgf.m, 7 tbnftl 7.2 tbt.ft'|...

  • Page 269

    815A2 engine: WATER OUTLET COVER Apply liquid gasket to mating surface. 6 x 1 . 0 m m 9.8 N.m {1.0 kgl'm, 7,2 tbl.ftt ECT GAUGE SENDING UNIT 9 N.m (0,9 kgf.m, ENGINE COOLANT 7 rbf.ft) (ECT) TEMPERATURE Apply liquid gasket SENSOR to the threads.

  • Page 270

    Water Pump Inspection Replacement Remove the timing belt (see section 6). Remove the timing belt (see section 6). T u r n t h e w a t e r p u m p p u l l e y c o u n t e r c l o c k w i s e . Remove the water pump by removing five bolts.

  • Page 271

    Fuel and Emrsslons ldle Control System .., .." . . , . 1 1 - 2 S o e c i a l T o o f s .... 11-190 System Doscriplion Component Locations Troubleshooting Flowcharts .

  • Page 272

    Special Tools Special Tools R€f. No. Tool Number Dsscription Pagr Reference A973X_041 _ XXXXX Vacuum Pump/Gauge, 0 - 30 in.H9 11-251,256, 257 , 273,27 4, 283,284, 286, 288, 289, 291, 294,296,297 07JAZ - 0010008 Vacuum/Pressure Gauge, 0 - 4 in.Hg 11-294,295 07PAZ - 0010100 SCS Service Connector...

  • Page 273

    Gomponent Locations lndex D16Y5 engine: THROTTLE POSITION ITP) MANIFOLD ABSOLUTE SENSOR PRESSURE IMAPI SENSOR Troubleshooting, page 1 1-132 Troubleshooting, page 1'l-115 EXHAUST GAS RECIRCULATION IDLE AIR CONTROL (IAC) VALVE IEGRI VALVE and EXHAUST GAS {M/T) RECIRCULATION IEGRI VALVE page 1 1-194 Troubleshooting, LIFT SENSOR Troubleshooting, page'l 1-254...

  • Page 274

    Component Locations Index (cont'd) THROTTLE POSITION {TPI SENSOR D16Y8 enginc: MANIFOLO ABSOLUTE Troubleshooting, page 1 1-132 PRESSURE {MAPI SENSOR INTAKE AIR TEMPERATURE Troubleshooting, page 1 1-1 15 IIATISENSOR Troubleshooting, page 1 1,124 IDI.E AIR CONTROL IIACI VALVE lMtfl ELECTRICAL LOAD Troubleshooting, page 1 1-194 DETECTOR IELDI {USAI Troubleshooting, page 1 1-179...

  • Page 275

    D16Y7 engine: MANIFOLD ABSOLUTE THROTTLE POSITION ITPI PRESSURE (MAPI SENSOR SENSOR Troubleshooting, Page 1 1-1 15 Troubleshooting, r1-132 INTAKE AIR TEMPERATURE VEHICLE SPEED SENSOR (VSSI IIATI SENSOR Page 1 1-176 Troubleshooting, page 11 124 Troubleshooting, LOAO ELECTRICAL (ELD) IUSA} DETECTOR POWER STEERll\lG PRESSURE Page 11'179 Troubleshooting,...

  • Page 276

    Component Locations Index (cont'dl MANIFOLO AESOLUTE PRESSURE IMAPI SENSOR INTAKE AIR TEMPERATURE Troubleshooting. page 11-1 19 IOLE AIR CONTROL {IAC) VALVE {IAT} SENSOR Bl6A2 engine: Troubleshooting, page 1 1,196 Troubleshooting, page 1'1-125 THROTTLE POSITION ITPI ELECTRICAL LOAD SENSOR DETECTOR IELDI (USA) Troubleshooting, page 11-134 Troubleshooting, page 1 1-180 POWER STEERING PRESSURE...

  • Page 277

    CLUTCH SWITCH lDl6Y5 ongino M,/TI Troubleshooting, page 1 1-218 Sell-diagnostic Procedures. p a g e 1 1 8 1 '9!, - 0o modol3: '96 - 98 modsls: PGM.FI MAIN RELAY Rslay Testing, page 11-237 Troubleshooting, page 1 1-238 PGM.FI MAIN RELAY Relay Testing, page l1 237 Troubleshooting, pago 1'! 238 ENGINE CONTROL MODU1T...

  • Page 278

    Component Locations Index (cont'dl '96 D16Y8 engine (coupel, '97 D16Y7 engine (coupe: KL model, sedan: KL (LXl model), '97 D16Y8 engine (coupe: all models, sedan: KL modell,'98-all models: FUEI- VAPOR PIPE FUEL GAUGE SENDING UNIT FUEL PUMP FUEL FEED PIPE Testing, see section 23 Testing, page 11 236 FUEL FILTER...

  • Page 279

    '99 - 00 models: EVAPORATIVE EMISSION IEVAP} PURGE CONTROL SOLENOID VALVE FUEL GAUGE SENDING UNIT Troubleshooting, page 1 1'288 Testing, see section 23 ONBOARD REFUELING VAPOR R€COVERY IORVRI FUEL VAPOR PIPE VENT SHUT VALVE FUEL FEED PIPE Test, page 11 296 FUEL FILTER FUEI- PUMP page 11-235...

  • Page 280

    Component Locations Index (cont'd) D16Y5, D16Y8 ongine: THROTTLE BODY (TBI Inspection, page 1 1-247 THROTTLE CABLE lnspection/Adjustment. page 1 1 -244 Removal, page 11-248 AIR CLEANER IACLI Disassembly, page 11 249 Installation, page 11 245 Replacement, page 11-244 RESONATOR AIR {FIA} CONTROL POSITIVE CRANKCASE VAIVE VENTILATION IPCV) VALVE...

  • Page 281

    816A2 engine: THROTTLE BODY {T8) Inspection. page 11-247 Removal, page 1 '1-248 Disassembly, page 1 1-249 THROTTLE CABLE AIR CLEANER (ACLI lnspection/Adiustment, page 1 1 -244 Replacement, Page 11-244 lnstallation, page 1 1-245 POSITIVE CRANKCASE VENTILATION IPCVI VALVE Inspection, page 1 1-266 1 1 - 1 1...

  • Page 282

    System Description Vacuum Connections D16Y5 engin6 ('96 - 97 modelsl: To EVAPORATIVE EMISSION MANIFOLD (EVAPI ABSOLUTE TWO WAY VALVE PRESSURE IMAPI SENSOR EXHAUST GAS BECIRCULATION (EGR) VALVE end EXHAUST GAS RECIRCULATION IEGR) VALVE EXHAUST GAS RECIRCULATION LIFT SENSOR (EGR) CONTROL SOLENOID VALVE {CVT} .'.-' €VAPORATIVE...

  • Page 283

    D16Y5 engine l'98 - 00 models): EVAPORATIVE EMISSION {EVAPI CONTROL CANISTER VENT SHUT VALVE To EVAPORATIVE EMISSION tEVAPI THREE WAY VALVE {98 model) To EVAPORATIVE EMISSION To EVAPORATIVE EMISSION IEVAP' CONTBOLCANISTER l'99 - 00 modelsl {EVAP) FILTER 1'99 - 00 modelsl TWO WAY VALVE EXHAUST GAS RECIRCULATION (EGRI VALVE and EXHAUST GAS...

  • Page 284

    System Description Vacuum Connections {cont'd} Dl6Y8 engine l'96 - 98 models): EVAPORATIVE EMISSION (EVAPI CONTROL CANISTER VENT SHUT VALVE {'96 coupe,'97 coupe: all models, '97 sedan: KL model. 'g8-modelsl To EVAPOBATIVE EMISSION IEVAPI THREE WAY VALVE '97 coupe: all models. To EVAPORATIVE EMISSION {'96 coupe, '97 sedan: KL model.

  • Page 285

    Dl6Y8 ongino ('99 - 00 modols): EMISSION (EVAP} €VAPORATIVE CONTROL CANISTER VENT SHUT VALVE To EVAPORATIVE EMISSION To EVAPORATIVE EMISSION {EVAPI CONTROL CANISTER (EVAPI FILTER TWO WAY VALVE EVAPORATIVE EMISSION IEVAPI PURGE CONTNOL CANISTER To CRUISE CONTROL DIAPHRAGM (with cruise control) FRONT OF VEHICI-E REGULATOR {cont'd)

  • Page 286

    System Description Vacuum Connections (cont'dl D16Y7 engine ('96 models,'97 coupe: KA. Kc models, '97 sedan: KA, Kc, KL lDx) models,'97 hatchback: all modelsl: FUEL PRESSURE EVAPORATIVE REGULATOR EMISSION (EVAPI PURGE CONTROL To EVAPORATIVE MANIFOLD ABSOTUTE EMISSION {EVAP} PRESSURE (MAP) TWO WAY VALVE To CRUISE CONTROL DIAPHRAGM...

  • Page 287

    Dl6YT engine ('97 coupe: KL model,'97 sedan: KL ILX) model,'98 model"gg model"oo model): To EVAPORATIVE EMISSION {EVAP} THREE WAY VALVE EVAPORATIVE EMISSION {EVAP) l'97 coupe: KL model, '97 sedan: KL (LX) model, CONTROL CANISTER '98 modell VENT SHUT VALVE To EVAPORATIVE EMISSION To EVAPORATIVE EMISSION EVAPORATIVE EMISSION (EVAP) {EVAP) CONTROL CANISTER...

  • Page 288

    System Description Vacuum Gonnections (cont'd) B16A2 engine: EVAPORATIVE EMISSION (EVAPI CONTROL CANISTER VENT SHUT VALVE To EVAPORATIVE EMISSION (EVAPI CONTROL CANISTER To EVAPOBATTVE EM|SS|ON FILTER (EVAPI TWO WAY VALVE EVAPORATIVE EMISSION IEVAPI PUBGE CONTROL SOLENOID VALVE MANIFOI.D ABSOLUIE (MAPI SENSOR PRESSURE EVAPORATIVE EMISSION {EVAPI...

  • Page 289

    Dl6Y5 engine ('96 - 97 modelsl: :li Vacuum hose No *: CVT only FUEL TANK EVAPORATIVE EMISSTON {EVAP) VALVE PRIMARY HEATED OXYGEN SENSOR {PRIMARY HO2S, AIR CLEANER SENSOR 1' RESONATOR SECONDARY HEATED OXYGEN SENSOR (SECONDARY POSITIVE CRANKCASE VENTIL/ATION IPCVI VALVE HO2S.

  • Page 290

    System Description Vacuum Connections (cont'd) D16Y5 engine ('98 modet): -: Vacuum hose No, *: CW only il) PRIMAFY HEATED OXYGEN SENSOR IPRIMARY HO2S. (9 POSITIVE CRANKCASE VENTILATION {PCV} VALVE SENSOR 1) ?!J EXHAUST GAS BECIRCULATION (EGR}CONTROL O SECoNDARY HEATEo oxYGEN sENsoR {sEcoNDARY SOLENOIO VALVE HO2S.

  • Page 291

    D16Y5 engine ('99 - 00 modelsl: @ EXHAUST GAS RECIRCULATION IEGR} CONTROL (PBIMARY HO2S, O) PRIMARY HEATED OXYGEN SENSOR SOLENOID VALVE SENSOR 1) (EGR) VAI-VE 6 EXHAUST GAS RECTRCULATION O SECONDARY HEATEO OXYGEN SENSOR {SECONDARY cls nectRcuLATloN IEGR) vALvE LIFT rf exxlust HO2S.

  • Page 292

    System Description Vacuum Connections (cont'd) D16Y8 engine ('96 sedan, '97 sedan: KA, KC modelsl: {M/T} F @ i H i i F l (A/T) ENGINE coor-rruri i + i nfi | l/A. ( O r ) l / U [ | \)l#t,/ PRIMARY HEATED OXYGEN SENSOR (PRIMARY HO2S.

  • Page 293

    D16Y8 engine l'96 coupe.'97 coup6: all models.'97 sodan: KL modol.'98 modell: AIR CLEANER PRIMARY HEATEO OXYGEN SENSOR IPRIMARY HO2S, RESONATOR SENSOR 1) POSITIVE CRANKCASE VENTILATION (PCV) VALVE SECONDARY HEATED OXYGEN SENSOR ISECONDARY EVAPORATIVE EMISSION IEVAPI PURGE CONTROL HO2S. SENSOR 2l SOLENOID VALVE MANIFOLD ABSOLUTE PRESSURE IMAPI SENSOR EVAPORATIVE EMISSION {EVAPI CONTROL CANISIER...

  • Page 294

    System Description Vacuum Connections (cont'dl D16Y8 engine l'99 - 00 modetsl: IM TTI ^ 14 [l(2i) - f r 1ry| * o ' * - COOLANT ii8'x'", * (]-i PAIMARY HEATEO OXYGEN SENSOR {PRIMARY HO2S, .19) EVAPORATIVE EMIssIoN {EVAP) PURGE coNTBoL SENSOR 1) SOLENOID VALVE ..2r SECONOARY HEATEO OXycEN SENSOB ISECONDARY...

  • Page 295

    D I 6 Y T e n g i n e ( ' 9 6 m o d e | . , 9 7 c o u p e : K A , K c m o d e | s , , 9 7 s e d a n : K A , K C , K L { D x } m o d e t s , ' g T h a t c h b a c k : a | | m o d e l s } : COOLANT FUEL PUMP IFPI PRIMARY HEATED OXYGEN SENSOR (PRIMARY HOzS,...

  • Page 296

    System Description Vacuum Connections (cont'd) Dl6Y7 angin6 ('97 coup.: KL mod€l, sedan: KL (LX) model,,9g modet): i1] PRIMARY HEATED OXYGEN SENSOR (PRIMARY HO2S, (tO RESONATOR SENSOR 1) l? PoSITIVE cRANKcAsE VENTILATIoN IPcv}VALVE E) SECONDARY HEATED OXYGEN SENSOR {SECONDARY IA EVAPORANVE EMISSION TEVAPI PURGE CONTROL HO2S, SENSOR 2l SOLENOID VALVE €l MANTFOLD ABSOT_UTE PRESSUnE tMAp) SENSOR...

  • Page 297

    Dl6Y7 engins ('99 - 00 modelsl: 6d POSITIVE CRANKCASE VENTILATION (PCV) VALVE PRIMARY HEATED OXYGEN SENSOR {PRIMARY HO2S, 6 rvapoamve eutssloN tEvAP) PURGE coNTRoL SENSOR 1) SOLENOID VALVE iiconoanv neareo oxYGEN sENsoR ISECoNDARY CO PURGE JOINT HO2S, 9ENSOR 2) 6 evlponnnve eutssloN (EvAPl coNTRoL cANlsrER MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR i evlponnnve eussloN {EVAP} BYPASS solrNolD ENGINE COOLANT TEMPERATURE (ECT} SENSOR...

  • Page 298

    System Description Vacuum Connections (cont'd) 816A2 engine: (' PRIMARY HEATED OXYGEN SENSOR IPRIMARY HO2S. @ EvApoRATtvE EMtsstoN tEvAp) puRGE coNTRoL SENSOR 1l SOLENOID VALVE .?) SECONDARY HEATED OXYGEN SENSOR {SECONDARY @ PURGE JoINT HO2S, SENSOR 2) €t EvApoRATtvE EMtsstoN (EVApt coNTRoL caNtsTER 13] MANIFOLD ABSoLUTE PRESSURE (MAP) sENsoB QA EVAPORATIVE EMISSION (EVAP) BYPASS SOLENOID...

  • Page 299

    Electrical Gonnections ('96 - 98 Models,'99 - 00 Dl6Y5 engine with M/T) To A/C PlEStUnC 6wrctt clEc{ .2. Arr pt6rt, DraYt .nlh.t I .a: arr .nd Drar, .nsrF .a: AfI .nd Drart .ndn =.5 Er..d afr.nd Dla\t 6eh. r?, cvt (D,t6ys ddn.tDd Oiew d!lh.

  • Page 300

    System Description Electrical Connections ('96 - 98 Models, ,99 - 00 D16Y5 engine with M/Tl (cont'd) SENSOF PRESSURE SENSOE s E N s o R * 3 c-rrusren vem srur vtvrlf; E G R solENoto vALvE *3 wec soLeton vltve'!2 SENSOR S P E E D s E N s o R ' 2 COUNTEFSHAFI...

  • Page 301

    SEiV|qE CHECK @NI\IECIOR [ * - l-.i-*.,*,. @NI\ECIOR r-Bu( (cont'd) ceor 1 1 - 3 1...

  • Page 302

    System Description Electrical Connections ('96 - 98 Models, ,99 - 00 Dl6y5 engine with M/T) (cont'd) ptozs'" pozslttc*rr Ho2s (sENsoF l) c125 WHT,'RED'l s02sHTc -BLK/WHT aLKlyeL! wrlaeo!{-L wrzneo.=r.: GFN/BLr-I FcFN,wHr J alvwrr'Ll ar-x,rvnr, f--fi"-r".^'--] Ho2s (sENsoR 2) ;lcnr-caz c r l s * ' u LraeL*ro pozsntc*lu H O 2 S ( S E N S O R '...

  • Page 303

    PSP SWITCHI c 1 t 7 / Y E L J l r . ^ r ' \ - r atu/wHT =..'-_ wHr---] FaMrr=ll L_id-ll 8r-x,--L- IT GRN/WI{T CAI\IISTER VENT tr--+r calT 66s' fr:-l l - B L ! ( - - - l f .

  • Page 304

    System Description Electrical Connestions {'96 - gB Models, ,99 - 00 Dl6yS engine with M/T) (cont'dl s€N90fi rDic M sEt\tsoi RET' ct(P P CXP M YEUGifl CIG M FI F']E E T T i T 8At{/ aR / !R|{/ AAX/ lhx/ ALJ(I &...

  • Page 305

    LC B' NCSC' (cont'd) 1 1 - 3 5...

  • Page 306

    System Description Electrical Connections ('96 - 98 Models,'99 - 00 Dl6Y5 engine with M/Tl (cont'dl cart c5o2 Cl3i C,ta6 c5t2 t--l o",.uonr. l FSIX' GA|l/OfiN F Y E I Orl0 C50il c5t0 GRN/aaX: GRN/BIXI. d Y E r . LrGiN' LT GRflr- 8r"K/8ru 8rK/8ru...

  • Page 307

    UGIfI &AMRY o5A) 60a) ct31 -wHT/gtU WH'/ALU -BLVRED A//C CIUICH c354 GRN/REO f"* u o€R.HOOD FUSE/REIAY BOX *t*'fi F*n* I lsrc Aros^ 8ru/wHr -.1 f*-__l YEUGRN |i il?-\.p--lI n c B l l l P I I / | P F I J E L I I I l n * l l l...

  • Page 308

    System Description Electrical Connections ('96 - 98 Models, '99 - 00 Dl6Y5 engine with M/Tl (cont'dl EVA? EVPASS I " l c13r c4a6 R€D/ _ l t o.3a r- r--------------- GRII r c r r GRt{n'Y}rP-___-.l ) caQ I lJ/c ol25 Srli$},€...

  • Page 309

    Electrical Connestions ('99 - 00 Models except Dl6Y5 engine with M/Tl FUEI II{JECIOBS L ChUISE COXTnOI UNII lo CO|IPi€33OR CUrrcH BEI Y lo A/c PRESSUiE alYrc|l To FAoIAIOR FAI REL Y EcT3wllcll SENSOF FIJSES: (D IN1ERIOR UGHT O5A) ' @ BACK UP O5A* @HonN (15A).

  • Page 310

    System Description Electrical Connections ('99 - 00 Models except Dl6Y5 engine with M/Tl (cont'd) EVAP PURGE CONTROL c26 ECT SoLENOtOVAIVE E C T S E N S O R EVAP COI{TROL CANISIE R c25 tAT I A T S E N S O R ta-t EVAP BYPASS SOI.ENOID VALVE "Eso! 87...

  • Page 311

    DRIVE PULLEY SPEED SENSOR GAUGE ASSEMALY ORIVEN PULLEY SPEED SENSOR SECONOARY GEAB SHAFT SPEED SENSOR SOLENOID To INTERLOCK CONIBOL UNIT *l : USA model *2: a/T(D16Y/, D16Y8 engine) ,.3: CW(016Y5 engine) *4: A/T and D16W engine *5: Except A/T and Dl5Y7 engine *6: Cw(Dl6Y5 engine), Dl5Y8 engine and 816A2 engine E c M / P c M B ( 2 5 P ) E c M / P c M A ( 3 2 P )

  • Page 312

    System Description Electrical Connections ('99 - 00 Models except D16Y5 engine with M/Tl (cont'dl UFTSENSOR sEnucE cSEcK CONNEC'OR ABS CONTROL UNIT _r "* CONI{ECTOR "to' aLul- _--r ".* f *31ou..." "on"t"to" lll*, 1 1-4 2...

  • Page 313

    llo2s (sENsoR t SECONOARY HO2S (SENSOR 2) I- wrrzneo'f15151 FCA ,a[HT -] f- FELWWHI.- FFi/v\^- F ETJVWrfT'--I l+ HO2S (gENSOR 2) 11-43...

  • Page 314

    System Description Electrical Gonnections ('99 - 00 Models except Dl6yS engine with M/T) (cont'd) "u, LB|.X'--Jf-ll cad__J PsP swrcH' h/wFDl t + l 1"" VTEC soLEt{oto VALVE c l i a BLTC.YEL ----J----] neozvef- -l neo,"yrr.'--{l- ---5 EVAP PUBGE CONTROL SOLENOIDVALVE clat EVAP CONTROL...

  • Page 315

    -E--l Y $rsoi / . J r D c Y SEr$Oi I f--A o' v) sEr,rsoi I |f-------l ' cM _L:_---J DIgIRIBUTOR tr:-l t E l C K F S E N S O R EiN/ AFN/ ar-xl ELxl BRN/ ELxt EFN/ BFN/...

  • Page 316

    System Description Electrical Connections ('99 - 00 Models except Dl6Y5 engine with M/Tl (cont'd) cl09 racvP*{ BLK/eLu SOLENOID VALVE MAINSHAFT SPEEO SENSOR c l l a COUN'IERSHAFTSPEED SENSOR c121 U N E A R SOL€NOIDVALVE 1 1 - 4 6...

  • Page 317

    " f 'ORN iFx/ ' - L c!o4 crro qF /ELKT lrcnf R E D aLuT At c€AR PO3tllOl{ SWlrCH wnnrd#"Si"*fi[* " BLU GR + 35111'o,- u",, F 'h MDIA'OR FAr{ FELAY' CnXr# To A/C SwlICH BLI,IREO + (cont'dl 11-47...

  • Page 318

    System Description Electrical Connections ('99 - 00 Models except Dl6Y5 engine with M/Tl (cont'dl DRIVE PULIEY SPEEO SENSOF SECONDAFY GEAF SHAFT SPEEO SENSOR PNK/BLK YE!' SCLSM PNK/BIU INHSOL cnvauC c131 CrKa GFN/Brf cnvsuC GEAF POSII|ON SWITCH 11-48...

  • Page 319

    A/CO-UfAl E L D ' ' BLtCWlfi - UNDER-HOOD FUSE/RELAY BOX YEVGRI{ sLrc\t/trt BLvwHr c501 UNDER-DASH FUg€/FELAY AOX (cont'd) 11-49...

  • Page 320

    System Description Electrical Connections ('gg - 00 Models except Dl6y5 engine with M/Tl (cont'd) Elt^-l 'tF'tF r_ c446 - l l-- ,.,- ,.u vever-u cnrzer-rc-{f cnnzar-x, CsO5 -r-\ YELI6RN BLK __1\ \'----l Ft,EL PUMP YEL/GRN YEL/GRN YEVELU YEVBLU lr cat' LT GRN2 qar/auC qaN/eud...

  • Page 321

    System Connectors [Fuel Pumpl '95 - 98 models, '99 - 00 Dl6Y5 engine with M/T: c793|.,.s c792*r,.'5 *1r USA mod€l c7931...15 '2: A/T {O16Y7, D16Y8 ensine} c565 13: CVT {O16Y5 ensin€l *4: A/T ind D16Y7 .ngane *5: ExceFt A/T end D16Y7 engine '6: A/T lDl6Y8 enginel *7: CvT (Dl6Y5 enginoland 016Yg engine '8: ,96 Dl6YB engine {coupe),'97 Dl6Y8 sngine...

  • Page 322

    System Description System Connectors IEngine Compartment] '96 - '98 Dl6Y5, Dl6Y8 engin€, '99 - O0 Dt6y5 engine wirh M/f: 11-52...

  • Page 323

    c106 Cl0,r c105 c102 :lo. {C.nadal r'fr] r'Trtt l ' l r l l r l . l B f f i f f i l6mrrrnru I l6lwtr,eED' ElilrwA----l E|BFIvBLK lTltHtBtu__l l6lga-tnEcl--l c 1 1 4 c 1 1 3 * 1 c109..

  • Page 324

    System Description System Gonnectors [Engine Compartmentl (cont,d) 36 - 98 Dl6Y5, Dl6Y8 engine, ,99 - O0 Dt6y5 engine with M/T: C1,&r.3 c139r" c120 c354r1 c122 G101 11-54...

  • Page 325

    c 1 t 7 c l 1 6 c112 c 1 t 5 c l 1 1 r'ffi] f'TBLir-l lO BLX,YEI l6lEtu^tHr__-l c125 c120 c122 c123 c121*' c 1 1 8 " 16lwrrin+o' t Y E U G F N trl-clrl---] liSlcFN/BLK I REO!

  • Page 326

    System Description System Connectors lEngine Compartmentl {cont,dl 36 - 98 D15Y7 €ngine: 1 1 - 5 6...

  • Page 327

    c104 c105 c1o4 c102 c 1 0 1 lcanadal r'ftl f,ftl l 3 l . l W H T / F E D . I WHT/BLU BLI(YEL | ? l E F N / 8 L K ' I YEVGflN B L K ' f3TBr--/BEo-l Y E V B E D...

  • Page 328

    System Description System Connectors IEngine Compartment] (cont,d) '96 - 98 Dl6Y7 .ngin.: 1 1 - 5 8...

  • Page 329

    c 1 1 4 c109 r'ff;t Flo-'u l ! v e u g L x ' I ftFwatu;'--l c123 cl18 {A/T} c l 1 7 r'ftr F l r l lolFED/wHr I YEUGNN I O I G F N ' fdl'.,c---_l fd-cRN/8tK'_]l B E F...

  • Page 330

    System Description System Gonnectors lDash and Floor] '96 - 98 modols, 'gtl - 00 Dl6yS engine with M/T: 1 1 - 6 0...

  • Page 331

    crlo tA/Tl ' t l 12 8 l s l r o 6 t 7 tffii lEr.r.r,ll l l l r l n E o ' l 1 l s l x , ^ / t l ' l ? I B L X l l l s l ' ( ^ , ! H r 13 wHT,aLK l-r-lw'r/cFNl'l...

  • Page 332

    System Description System Connectors lDash and Floorl (contd) '96 - 98 models,'99 - 00 Dl6Y5 engine with M/T: c432*13 1 1-6 2...

  • Page 333

    lOl6Y?.ngir.l (O16Y5, Dl6Y8.nlin.3l C134 {EC[r,l/FCMal ct33.r tFcM-B) c t32 {ECt/r/pcM-a) t 6 1 7 1E 12 t 3 29 30 c{t3 ca3l cr35lEcM/PCM-D) f'Tfl'n r o l r t 12 t 3 I-IBLffiHJ-I Tttr-Ei ltlcRr'r/wlr FltEtstK l-''lwHtREcp liELx/wNr' FfwNr/RED''_l lTltHr/BL( F I r t 9 t 0 a l 5...

  • Page 334

    System Description System Connectors IEngine Compaftment] '99 - 00 D16Y5 ICVT), D16Y8 engine: cl14 C142'3 *1: USA model '2: A/T {D16Y7, O16Y8 engine) *3: CVT lD16Y5 engine) *4:A/T and D16Y7 engine *5: Except A/T and D16Y7 engine *6: CVT {D16Y5 engine). O16YB engin€...

  • Page 335

    c'r04 c'r02 c 1 0 1 _"1on {Canada) f f i f f i r'fil--dl l r l 2 3 l l 3 { l lSltHr/REo" lElwHr/FED"- xrvef lttl-R^r/BLr- F]-wHrr+r/BLU I lSfBruritnEp - c l 1 3 * , C11,t c109*.

  • Page 336

    System Description System Conneetors IEngine Compartment] (cont'd) '9!l - 00 Dl6Y5 {CvT}, Dl6Y8 onginol C14,0*3 c139 cl20 c1{{} c122 1 1 - 6 6...

  • Page 337

    c l 1 7 c112 l 1 2 l 3 l t 1 l 2 l |6l;LKr-----l 8 B L K lOlELK,^/EL I BLK' Y E U E L K I I tlsLU^/vHl YEVBLK] B L K I ELKI YEUBLKI Y E U E L K I A L K I YEVBLK'...

  • Page 338

    System Description System Connectors lEngine Compartmentl (cont'dl '99 - 00 D16Y7 engine: 1 1 - 6 8...

  • Page 339

    c10s C1oia c104*, c102 c 1 0 1 {Canade) rftr r'ffi-a f'tr] c 1 1 2 c10B c107 c106 c3o2 c 1 1 3 r ' (for example, YEUBLK' Different wires with the same color have been given a number suftix to distinguish them NOTE: .

  • Page 340

    System Description System Connectors [En gine Compartmentl (cont,d] '99 - 0O D16Y7 €ngin€: 1 1-7 0...

  • Page 341

    c l 1 6 c 1 1 5 c 1 1 a c l 1 0 c109 r'ft] 8TK?YEL GBN/8TKI flofr-N 2 BLICYEL GffN/8TK1 I t I Y E U B L K , I BLK/YEL GNN/aLK? IEIBLvBLU' I BLfiEL GRN/BLK BLK/YEI GRN/BLX'...

  • Page 342

    System Description System Connectors [Engine Compartment] (cont'dl 816A2 engins: 1 1 - 7 2...

  • Page 343

    C10,1 c102 c104 c105 c 1 0 1 (Canadal F1+..r I r l z 3 l l 1 2 3 l l 1 2 l l-f.l --.l 16lwHrsEo. ffl'wHnr€D" WHT/BLU .1' BLKYEL ItrERlxBLa__l I 2 B L K / Y E L YEUGRN B L K I ftlwHri BLUIl'l...

  • Page 344

    System Description System Connectors [Engine Gompartmentl (cont'd] 81642 enginoi 11 -7 4...

  • Page 345

    c122 c112 c l 1 7 r'trTl l-iln'eo*r,vHr__-l 16lBLK,-__-l l[lcRNiBLitl]l lO BLX,\,E[ 16l Btu/wil- Cliro C1'11 l6l-ciN/YEL' c'54*1 f r l z l s l fflErKwH---l l O l B L r f6lGrrunEp Different wires with the same color have been given a number suffix to distinguish them (for example, YEUBLK1 NOTE: .

  • Page 346

    System Description System Connectors [Dash and Floor] ('99 - fil models except D16Y5 engine with M/Tl 1 1 - 7 6...

  • Page 347

    8 l 7 l 6 l e t 0 r l ! 2 1 a L ( LTATU 1 7 1 8 9 t 0 l 2 13111 / ,/ ./ie / 1 A l , / 2 0 t 0 t 1 ' S€cuitAr.h Sysi.m elz5...

  • Page 348

    System Description System Connectors lDash and Floor] (cont'dl ('99 - 00 mod€ls oxc€pt Dl6Y5 ongine with M/T) 1 1 - 7 8...

  • Page 349

    ct3r c 1 3 0 1 l z 3 l t / X 6 1 7 8 9 t o t 8 t 9 12 13 t 5 t a cr35lPcl|.D,€ cr35 lPCM-Dr: cr34 tEcM/PCM-C) ca32 ' t / E e t|0 a t 6 l r l 2 l 3 l - 1 .

  • Page 350

    System Descriptions System Connectors lFuel Pump] ('9!, - 00 models 6xcept Dl6Y5 ongino with M/T) c565 c568 c792 c793 NOTE: o Different wires with the same color have been given a number suffix to distinguish them (for example, YEUBLKI and YEVBLK, are not the same). O: Related to Fuel and Emissions System.

  • Page 351

    A. When the MIL has come on: ,1. connect the Honda PGM Tester or an oBD ll scan tool to the 16P Data Link connector (DLC) located near the left kick panel.

  • Page 352

    Either of the following actions will reset the ECM/PCM. Use the OBD ll scan tool or Honda pGM Tester to clear the EClM,s/pCM,s memory. NorE: see the oBD ll scan tool or Honda PGM Tester user's manuals for specific operating instructions.

  • Page 353

    connectors, remove the right lf the inspection for a particular code requires voltage or resistance checks at the ECM/PCM equipped. unbolt the EcM/ kick panel. Pull the carpet back to expose the ECM/PCM. Remove the ABS control unit if so as described below PCM bolt.

  • Page 354

    Troubleshooting Troubleshooting Procedures (cont,dl CAUTION: . Punqturing ihe insulation on a wirs can cause poor or intermiftent electricar connections. I Bring the test€r probe into contacl with the terminatlrom the terminal side of wire harnesg conncctors in the gngin€ compartment. For temale connectors, iust touch lightly with the tester probe and do not inse.t the probe.

  • Page 355

    Probable Cause List lFor th€ DTC Chart, see page 11-971 *: '99 - 00 models System Page Probable Gause Engine Control Module (ECM)/Powertrain Control Module (l'uM) 1 1 - 1 0 7 11-230,231 't't-237 PGM-Fl main relay Section 23 l ^ ^ i t i ^ n c w e t a m selrsor Crankshaft Position/fop Dead Center/Cylinder Fosltlon sensor clrculr' Lr\F...

  • Page 356

    Troubleshooting Procedures (cont,dl ECM/PCM Data By connecting the OBD ll scan tool or the Honda pGM Tester to the l6p data link connector (DLC), various data can be retrieved from the EcM/PcM. The items Iisted in the table below conform to the sAE recommended practice.

  • Page 357

    F eeza Data Operating Value Descriotion Data "open" or "closed"' At idle speed: closed Loop status is indicated as HO2S Closed: Based on the HO2S output, the ECM/PCM deter- Feedback mines the airlfuel ratio and controls the amount of inject- Loop Status ed fuel.

  • Page 358

    Troubleshooting E n gine/P_o,weft ra in Control Module Term inal Arra n gement ('96 - 98 Models, '99 - 00 Dl6yS engine with M/T) - ECM/PCM CONNECTOR A I32PI INJ3 INJ2 I N J 6 I N J l I G P l ALTC IGP2 2A 25...

  • Page 359

    PCM CONNECTOR B {25P) Wire side of {emale terminals CONNECTOR B (25P)', NOTE: Standard battery voltage is 12 v' Wire Terminal Signal erminal Description name numoer c o t o l Wii-ignnion switctr oN {ll}: pulses Ground for linear solenoid valve LS_ (LINEAR SOLENOID VALVE - SIDE) -Drii6l...

  • Page 360

    Troubleshooting Engine/P_o_wgrtrain Control Module Terminal Arrangement ('96 - 98 Models '99 - 00 Dt6y5 engine with M/T) tc'oniOi ECM/PCM CONNECTOR C {31PI CKFP CXPP TDCP ALTF 21 25 Wire side of female terminals ECM/PCM CONNECTOR C (31PI NOTE: Standard baftery voltage is 12 V To.min!l Wira Torminal...

  • Page 361

    ECM/PCM CONNECTOR D I16P) Wire side ot female terminals ECM/PCM CONNECTOR D l16P) NOTE: Standard battery voltage is 12 V Wire Terminal Signal Te.minal Dor.ription n!me color numb€r With throttle fully open: about 4.8 V TPS (THROTTLE Detects TP sensor signal. POSITION With throttle fully closedl about 0.5 V RED/BLK...

  • Page 362

    Troubleshooting Engine/P_o,wertrain Control Module Terminal Arrangement ('99 - 00 Models except Dl6Y5 engine with M/Tl ECM/PCM CONNECTOR A I32PI ECM/PCM CONNECTOR A (32P) Wire side ot temale terminals NOTE: Standard battery voltage is l2 V Sign!l 2WSS (EVAP 8YPAsS SOLENOID Drives EVAP bypass solenoid vatve, With gn'tion swnch ON (lll banery votlage VSV {EVAP CONTNOL CANISTER...

  • Page 363

    ECM/PCM CONNECTOR B (25PI Wire side of female terminals FCM CONNECTOR B {25P) NOTE: Standard battery voltage is 12 V Sign.l whh ignilion swilch ON (ll)ibatteryvoltage Powor sou rca for the ECM/PCM conlrolcir IGP1 IPOWER SOUflCE) With ignition switch OFF:0 V YELtsLK Less than 1.0 V at slltimes Ground fo.

  • Page 364

    Troubleshooting Eng ine/P_owertrain Control Module Term inal Arrangement ('99 - 00 Models except Dl6Y5 engine with M/Tl (cont,d) ECM/FCM CONNECTOR C 13lPI ECM/PCM CONNECTOR C {31P) Wire side of female terminals NOTE; Standard i s 1 2 V . Sig.al PO2SHTC (PNIMARY HEATEO Drivss primary hoated orygen sensof With ignition switch ON (lr)rbanery volage...

  • Page 365

    ECM/PCM CONNECTOR O {16P) Wire side ol temale terminals ECM/PCM CONNECTOR D {16P) (D16Y7, D16Y8 enginel NOTE: Standard battery voltage is 12 V. 5i!ml With lock-up ON: httery vollage Orivos look-up controlsol€noid wlv€ a. LCA (LOCK.UPCON]ROL Y E L With lock-up OFFi 0 V SOLENOID VALVE A) pos' ln E posnion, in 1st lnd 2nd eoat ,n E...

  • Page 366

    Troubleshooting En gine/P_oweft ra in Control Module Termina I Arran gement ('99 - 00 Models except Dl6YS engine with M/Tl (cont,dl ECM/PCM Connectol D (16P1 ECM/PCM CONNECTON D (r6P) W i r e s i d e o f f e m a l e t e r m i n a t s ECM/PCM CONNECTOR D {16P) (Dl6YS engine: CVTI NOTE: Standard battery voltage is 12 V f€rminal...

  • Page 367

    Diagnostic Trouble Code (DTCI Chart Probable Cause Page Delection liem {MlL indication*l . Vacuu m connection Manifold Absolute . MAP sensor 11 1 1 5 Pressure Circuit Problem Range/Performance Open or short in MAP sensor circuit Manifold Absolute Pressure Circuit MAP sensor 't1'l P0107...

  • Page 368

    Troubleshooting ,Jla Diagnostic Trouble Code (DTCI Chat (cont'dl Datection hsm Probablo Cause Page lMlL indicationl Secondary Heated Oxygen Sensor Short in Secondary HO2S lSensor 2) circuit (63) P0137 Circuit Low Voltage Secondary H02S {Sensor 2) 1 1 - 1 5 3 (Sensor 2) ECM/PCI\4 Secondary Heated Oxygen Sensor...

  • Page 369

    , ' o Probable C.use Page Detoction lt€m {MlL indication} EVAP Purge Control Solenoid Vaive Evaporative Emission Control Open or short in EVAP Purge Control System Insufficient Solenoid Valve circuit Purge Flow 11-271 (92) P0441*5 EVAP Control Canister Vacuum lines ECM/PCM .

  • Page 370

    Troubleshooting Diagnostic Trouble Code (DTGI Chart (cont'dl Detection lt6m Probablc Cause Page (MlL indicationl Open or short in Primarv HO2S (Sensor 1 Primary Heated Oxygen Sensor (Sensor 1) Circuit Primary H02S (Sensor 1) (48) 1 1- 146 P1162+1 Malfunction . Primary HO2S (Sensor 1) Primary Heated Oxygen Sensor (Sensor '1) Circuit ( 6 1 )

  • Page 371

    Page Detection ltem Probable Cause (MlL indicationl . CKF sensor Crankshaft Speed (54i 1 1 1 8 3 P 1 3 3 6 Fluctuation Sensor Intermittent Interruption Crankshaft Speed CKF sensor (54) CKF sensor circuit 1 1 - ' 1 8 3 P1337 Fluctuation Sensor ECM,PCM...

  • Page 372

    Troubleshooting Diagnostic Trouble Code (DTCI Ghart (cont'd) Detegtion hom Page Probablo Csuss lMlL indicationl EGR Valve EGR valve (with lift sensor) Lift Insufficient EGR valve lift sensor circuit EGR control solenoid valve (A,/I) Detected 't1-256 EGR control solenoid valve circuit P 1 4 9 1 * ! \ 1 2 J E G R l i n e...

  • Page 373

    How to Read Flowcharts A flowchart is designed to be used from start to final repair. lt's like a map showing you the shortest distance. But beware: "map" anywhere but a "stop" symbol, you can easily get lost. lf you go off the tSrARTl Describes the conditions or situation to start a troubleshooting flowchart.

  • Page 374

    PGM-FI System System Description E N G I N E C O N T R O L M O D U L E ( E C M Y POWERTRAIN CONTROL MODULE (PCM) INPUTS OUTPUTS CKP/TDC/CYP Sensor Fuel Iniectors MAP Sensor PGM-Fl Main Belay {Fuel Pump) M I L IAT Sensor...

  • Page 375

    Fuel Cut-off Control During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at speeds over the following rpm: D 1 6 Y 5 e n g i n e ( M / T ) : 8 5 0 r p m D]6Y5 engine (CVT), D'16Y8 engine (USA M/T): 920 rpm Dl6Y8 engine (USA A,/I), D16Y7 engine (USA A,/T);910 rpm D16Y8 engine (Canada M/T), D16Y7 engine (canada): 990 rpm...

  • Page 376

    PGM-FI System System Description (cont'dl Lean Burn Control {D16Y5 engine: CvT) TOC/CKP/CYP SENSOR MAP SENSOR CKF SENSOR Comparison oI current air fuel ratio to target ratio The lean burn control system is based on the characteristic increase in crankshaft angular acceleration which occurs in when the air-fuel ratio gets leaner.

  • Page 377

    Engine Control Module/Powertrain Control Module (ECM/PCM) t'96 - 98 Models,'99 - 00 Dl6Y5 engine with M/Tl NOTE: lf th is svmptom is intermittent, check for a loose fuse No. 25 {METER 7.5 A) in the The Malfunc{ion Indicator Lamp underdash {use/relay box, a poor connection at ECM/PCM terminal A18, or an intermit {MlLl never comes on (even lor tent ooen in the GRN/ORN wire between the ECM/PCM (A18) and the gauge assemblv.

  • Page 378

    {coupe: all models, sedan: KL modeti,'98,all models} tool or Honda PGM Tester. PGM-FImain relay . See the OBD ll scan tool or Honda PGM Tester user's manuals lor specitic operating instructions. Go to troubleshooting p.oc€dur€s Are any DTC{s) indicated? (se€...

  • Page 379

    l F r o m p a g e 1 1 1 0 8 ) Check for a short in the wire {MlL linell 1. Turn the ignition switch OFF. 2. Disconnect the Eclvl/PCM con- nector A (32P). 3. Turn the ignition switch ON {ll). Ropair short to body gtound in the wir.

  • Page 380

    PGM-FI System Engine Control Module/Powertrain Control Module (ECM/pCMl ('96 - 98 Models, '99 - 00 D16Y5 engine with M/Tl (cont,dl ( F r o m p a g e 1 1 - 1 0 9 ) ECM/PCM CONNECTOR D {16P} Replace the sensor that caused Does the N4lL go OFF? VCCl {YEL/RED}...

  • Page 381

    Dt6Y8 engine (coupe: all mod;ls, sedanl KL model),'98-all models,'99-al' models' '00-all models. PGM'FI main relay . See the oBD ll scan tool or Honda PGM Tester user's manuals for specific operating instructrons, Repair shott or open in tho wire bstwoon No. 25 IMETER) l?.5 A)tuse and gauga tsom_...

  • Page 382

    PGM-FI System Module (ECM/PCM) Engine Control Module/Powertrain Control ('99 - 00 Model except Dl6Y5 (M/Tl (cont'd) engine) ( F r o m p a g e ' 1 1 - 1 1 1 ) Check loi an open in the wires (lGP linesl: 1.

  • Page 383

    A n i n t e r m i t t e n t s h o r t i n t h e w i r e b e t w e e n t h e E C M / P C M . s"" it'" Oab ll scan tool or Honda PGM Tester user's manuals for specific operating C h e c k t h e D i a g n o s t i c T r o u b l e instructions.

  • Page 384

    PGM-FI System Engine Gontrol Module/Powertrain Control Module (ECM/PCMI ('99 - 00 Models except Dl6Y5 engine with M/T) (cont'dl { F r o m p a g e 1 1 1 l 3 ) Check for a short in the wi.e lMlL linelr 1.

  • Page 385

    Manifold Absolute Pressure (MAP) Sensor ('96 Models) problem (vacuum leak) in the The scan tool indicates Diagnostic Trouble Code (DTC) P0106: A mechanical Manifold Absolute Pressure (MAP) Sensor system' T h e M A P s e n s o r c o n v e r t s m a n i f o I d a b s o I u t e p r e s s u r e i n t o e i e c t r i c a I s i g n a | s a n d i n p U t s t h e E c M / P c M ' OUTPUT VOLTAGE ( v 1 3 .

  • Page 386

    PGM-FI System Manifold Absolute Pressure (MAP) Sensor ('96 Modelsl (cont'dl ( F r o m p a g e 1 1 - 1 1 5 i { F r o m p a g e 1 1 - 1 1 5 ) Chock to.

  • Page 387

    Manifold Absolute Pressure {MAP} Sensor ('96 - 98 Models,'99 - 00 D16Y5 engine with M/T) (high vacuum) problem in the The scan tool indicates Diagnostic Trouble Code (DTC) PO107: A low voltage Manifold Absolute Pressure (MAP) sensor. Tho MIL has been roport€d on. DTC P0107 is storod.

  • Page 388

    PGM-FI System Manifold Absolute Pressure (MAp) Sensor ('96 - 98 Models,'99 - 00 D16Y5 engine with M/Tl (cont,d) ( F r o m p a g e 1 1 - 1 1 7 ) ls approx. 2 kPa ('15 mmHg, 0.6 in.Hg) or less indicated? MAP SENSOR 3P CONNECTOR IC1l1I Check for a short in ihe wire...

  • Page 389

    Manifold Absolute Pressure (MAP) Sensor (;gg - OO Models except Dl6Y5 engine with M/T) (high vacuuml problem in the The scan tool indicates Diagnostrc Trouble Code (DTC) PO1O7: A low input Manifold Absolute Pressure (MAP) sensor' signals and inputs the ECM/PCM' The MAp sensor converts manifold absolute pressure into electrical OUTPUT VOLTAGE...

  • Page 390

    PGM-FI System Manifold Absolute Pressure (MApl Sensor ('99 - 00 Models except Dl6yS engine with M/T) (cont,dl ( F r o m p a g e 1 1 1 1 9 ) Check for an open or shon in the MAP s€nsor: C h e c k t h e M A P w i t h t h e s c a n tool.

  • Page 391

    Manifold Absolute Pressure (MAPI Sensor - i;idlga lil;dels,'99 - 00 Dl6Y5 ensine with M/T) voltage (low vacuum) problem in the The scan tool indicates Diagnostrc Trouble code (DTC) Po108: A high Manifold Absolute Pressure (MAP) sensor. The MIL has been reported on OTC m108 is stolod.

  • Page 392

    PGM-FI System Manifold Absolute Pressure (MAPI Sensor ('99 - 00 Models except D16YS engine with M/T) (contd) The scan tool indicates Diagnostic Trouble Code (DTC) P0108: A high voltage flow vacuum) problem in the Manifold Absolute Pfessure (MAp) sensor, Tho MIL has boon rcDortod on. DTC ml 08 b stolod.

  • Page 393

    Manifold Absolute Pressure (MAP) Sensor (cont'dl (MAP) lower than The scan tool indicates Diagnostic Trouble code (DTc) P1128: Manifold Absolute Pressure exoected. Tho MIL has been t€Ported on. DTC P1128 is stored. Problem verification: 1. Turn the ignition switch ON (ll). 2.

  • Page 394

    PGM-FI System Intake Air Temperature (lAT) Sensor ('96 - 97 Models) The scan tool indicates Diagnostic Trouble code (DTC) P0111: A range/performance problem in the lntake Aar Temperature (lAT) 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.

  • Page 395

    . a2 .. toa rra rrl l:rt t.al 20 0 20 ro ao ao too t2ot.cl INTAXIE AIR TEMPEFATURE ls 302'F (150"C) or hagher (or H Limit in Honda mode ot PGM Tester) or 0 V indicated? ls the correct ambrent temper Roolac€ tho IAT 3ensor.

  • Page 396

    -4'F 1-20"C) or less (or L Limit Intermittent tailuJe, systom is OK at this time, Check to. poor con- in Honda mode of PGNI Tester) or nections or loose wir.s at C112 5 V indicated? {lAT senso.l .nd ECM/PCM,...

  • Page 397

    Intormittont f.iluro, tyrtom i. OK ls -4"F (-20"C) or less (or L-Limit .t thi! tim.. Chocl for Poor con' in Honda mode of PGM Tester) or nactions or looso wit6 !t C112 5 V indicated? tlAT ..n!or) rnd ECM/PCftl,...

  • Page 398

    PGM-FI System Engine Coolant Temperature (ECTI Sensor The scan tool indicates Diagnostic Trouble code (DTC) P0116; A range/performance problem in the Engrne 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 oetow.

  • Page 399

    Intermittont failulo, sy3tom it OK ls 302"F (150"C) or higher {or at thk tim., Chock for Poor oon- H-Limit in Honda mode of n.ctions or loo!. wiraa at C122 PGM Tester) or 0 V indicated? IECT 3en orl and ECM/FCM.

  • Page 400

    Intcrmitt.nt failui.. rydom is OK ls -4"F (-20'C) or less (or L-Limit at thir timc. Chack for Door con- in Honda mode ol PGM Tester) or naction! or loor! wiaar at C122 5 V indicated? IECT ..n.orl .nd ECM/rcM,...

  • Page 401

    OK ls -4'F (-20"C) or less lor L-Limit at thb timo. Check lor poor con' in Honda mode o{ PGM Tester) or nections or 10036 wiraa at C122 5 V indicated? {ECT ssnsorl and ECM/rcM.

  • Page 402

    PGM-FI System Throttle Position ITP) Sensor ('96 - 98 Models,'99 - 00 D16Y5 engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) P0122: A low voltage problem in the Throttle Position (TP) sensor circuit. The TP Sensor is a potentiometer. lt is connected to the throttle valve shaft. As the throttle position changes, the throttle position sensor varies the voltage signal to the ECM/PCM.

  • Page 403

    {From page l1'132} ls there approx. 0.5 - 0.9 k0? 'P SENSOR 3P CONNECTOR Check for an opsn or 3hort in tho TP sensor: Measure resislance between the T P s e n s o r t e r m i n a l N o . 2 a n d No.

  • Page 404

    PGM-FI System Throttle Position (TPl Sensor ('99 - 00 Models except D16Y5 engine with M/T) scan tool indicates Diaqnosttc Trouble Code (DTC) P0122: A low voltage problem in the Throttle position lTO12Z _TI { | r, sensoa crrcurl. The TP Sensor is a potantiometer. lt is connected to the throttle valve shaft. As the throttle position changes, the throttle position sensor varies the voltage signal to the ECM/PCM.

  • Page 405

    (From page 11-134) TP SENSOR 3P CONNECTOR lsrhere approx.0.5 - 0.9 ko? Chock for an open or 3hort in the TP 3en30r: Measure resistance between the TP sensor 3P connector terminals No. 2 and No. 3 with the throttle tully closed. Terminal side ol male terminals ls there approx.4.5 k0? Check for .n opon in th€...

  • Page 406

    PGM-FI System Throttle Position (TP) Sensor (€6 - 98 Models, 39 - 00 D16Y5 engine with M/T) The scan tool indicates Diagnostic Trouble Code (DTC) P0123: A high voltage problem in the Throttle Position (TP) sensor circuit. The MIL has been reportod on. DTC P0123 is sto.ed.

  • Page 407

    Throttle Position (TP) Sensor ('99 - 00 Models except D16Y5 engine with M/Tl The scan tool indicates Diagnostic Trouble Code {DTC) P0123: A high voltage problem in the Throftle Position {TP) sensor circuit. The MIL has been reported on DTC P0123 is slored. Problem verification: 1 .

  • Page 408

    PGM-FI System Throttle Position (TP) Sensor (cont'd) I Pl 121 | The sca n tool indicates Diag nostic Trouble Code (DTC) Pl 121: Throttle Position (TP) lower than expected. The MIL hss been.eported on. DIC P1121 i. stored. Problem vedficatiod: 1.

  • Page 409

    Primary Heated Oxygen Sensor {Primary HO2SI (Sensor 1) ('96 - 98 Models except Dl6Y5 engine with M/Tl The Heated Oxygen Sensor (HO2S) detects the oxygen content in the exhaust gas and signals the ECM/PCM. In operation, the ECM/PCM receives the sjgnals from the sensor and varies the duration during which fuel is injected To stabilize the sensor,s output, the sensor has an internal heater.

  • Page 410

    PGM-FI System Primary Heated Oxygen Sensor (Primary HO2S) (sensor 1l ('96 - 98 Models except Dl6Y5 engine with M/T) (cont'dl ( F r o m p a g e 1 1 - 1 3 9 ) Check for a shon in the HO2S: 1.

  • Page 411

    Primary Heated Oxygen Sensor (Primary- Fjq?S) (Sensor 1l ('99 - 0b Models exiept D16Y5 engine with M/T) T h e H e a t e d o x y g e n s e n s o r s ( H o 2 S ) d e t e c t t h e o x y g e n c o n t e n t i n t h e e x h a u s t g a s a n d s i g n a | s t h e E c M / P c M ' | n o p e r a t i varies the duration during which fuel is injected.

  • Page 412

    PGM-FI System Primary Heated Oxygen Sensor (Primary HO2SI (Sensor 1) ('99 - 00 Models except Dl6Y5 engine with M/T) (cont'd) ( F r o m p a g e 1 1 1 4 1 ) Chock fo. a shori in the HO2S: 1.

  • Page 413

    Primary Heated Oxygen Sensor (Primary HO2SI (Sensor 1) ('96 - 9b Models except Dl6Y5 engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) P0132: A high voltage problem in the Primary Heated Oxygen Sensor (Primary H02S) (Sensor'l) circuit. Probl€m verification: 1.

  • Page 414

    PGM-FI System Primary Heated Oxygen Sensor (Primary HO2SI (Sensor 1) ('99 - 00 Models except D16Y5 engine with M/T) The scan tool indicates Diagnostic Trouble Code (DTC) P0132: A high voltage problem in the primary Heated Oxygen Sensor (Primary HO2S) {Sensor I ) circuit. The MIL has been reported on.

  • Page 415

    Primary Heated Oxygen Sensor (Primary HO2S) (Sensor 1l Primary Heated The scan tool indicates Diagnostic Trouble Code (DTC) P0133: A slow response problem in the tFol3al Oxygen Sensor {Primary H02S) (Sensor 1) circuit. The scan tool indicates Diagnostic Trouble code (DTC) Pl163: A slow response problem in the Primary Heated I P 1 1 6 3 Oxygen Sensor (Primary HO2S) (Sensor 1)circuit...

  • Page 416

    PGM-FI System Itil-"w Heated Oxygen Sensor (primary HO2S) (sensor 1l (Dl6Y5 engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) p1162: A malfunction in the primary Heated Oxygen Sensor (Primary HO2S) (Sensor 1) circutt. Doscription The Primary Heated orygen sensor (Primary Ho2s) {sensor 1) operates over a wide airlfuel range. The primary Ho2S (Sensor 1) is installed in the exhaust manifold.

  • Page 417

    ECM CONNECTORS l F r o m p a g e ' 1 1 - 1 4 6 ) D {15P) c (31Pl Check the ECM input vottage {lP-/ VS- lino): 1. Turn the ignition switch OFF. 2 Turn the ignition switch ON (ll) (GRN/BLKI 3 .

  • Page 418

    PGM-FI System Primary Heated Oxygen Sensor (Primary HO2SI (sensor l) (Dl6Y5 engine with M/T) (cont'd) ( F r o m p a g e 1 l - 1 4 7 ) ( F r o m p a g e 1 1 1 4 7 ) Substitute a known-good ECM and rechock.

  • Page 419

    ( F r o m p a g e 1 1 ' 1 4 8 ) ( F r o m p a g e 1 1 1 4 8 ) Roplac€ th€ Primary HOzS (Sen' ls there lessthan 2.8 V? sor 11.

  • Page 420

    PGM-FI System l:in1.".fy Heated Oxygen Sensor (primary HO2SI (sensor 1l (D16Y5 engine with M/D (cont'd) The scan toor indicates Diagnosti" code (DTC) pl164: A range/performance probrem in the primary -Tl:y|* Heated Oxygen Sensor (primary HO2S) (Sensor 1)circuit. The MIL has beon reponed on. DTC P1164 is stored.

  • Page 421

    (DTC) P1168; A low voltage problem in the Primary Heated The scan tool indicates Diagnostic Trouble Code Oxygen Sensor (Primarv Ho2S) (Sensor 1) LABEL circuit' The MIL has b6€n reponed on' DTC P1168 is storcd Problem vedfication: 1. Do the ECM Reset Procedure 2.

  • Page 422

    PGM-FI System IiT-"-w Heated 9{ygglSensor (primary HO2SI (Sensor 1) (Dl6Y5 engine with M/Tl lconr'd) scan tool indicates Diagnostic Trouble code (DTc) P1169: A high volrage probtem in the pnmary Heated 1T1163 Ih" Uxygen Sensor {primary HO2S) (Sensor .l) LABEL circuit. The MIL hrs been reported on.

  • Page 423

    (Sensor 2l Secondary Heated Oxygen Sensor {secondary HO2S) problem in the Secondary Heated The scan tool indicates Diagnostic Trouble Code (DTC) P0137: A low voltage Oxygen Sensor (Secondary HO2S) (Sensor 2) circuit' Tho MIL has been reported on DTC P0137 is stored. Problem verification: 1.

  • Page 424

    PGM-FI System 9ggoqOfry Heated Oxygen Sensor (Secondary HO2S) {sensor 2l ('96 - 98 Models; '99 - 00 D16YS engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) PO'138: A high voltag€ problem in the Secondary Heated Oxygen Sensor (Secondary HO2SI (sensor 2) circuit. Ths MIL ha3 bcen r6port.d on.

  • Page 425

    Secondary Heated Oxygen Sensor (SecondarytlO2S) (Sensor 2l ('99 - 00 lilodels except DtGYS engine with M/T) problem in the secondary Heated The scan tool indicates Diagnostic Trouble code (DTC) P0138: A high voltage Oxygen Sensor (Secondary H02S) (Sensor 2) circuit. The MIL has beon reportod on.

  • Page 426

    PGM-FI System Secondary Heated Oxygen Sensor (Secondary HO2S) {sensor 2l The scan tool indic€tes Diagnostic Trouble Code {DTC) P0139: A slow response probtem in the Secondary Heated [FO13a]l Uxygen Sensor (HOzS) (Sensor 2) circuit. The MIL has been reported on. DTC P0139 is stored.

  • Page 427

    Heated Oxygen Sensor (HO2SI Heater ('96 - 98 Mbdels,'99 - 00 Dl6Y5 engine with M/Tl probl€m in the Primary Heated The scan tool indicates Diagnostrc Trouble code (DTC) P0135: An electrical tFo135l Oxygen Sensor (Primary HOiS) (Sensor 1) Heater system (Except D16Y5 engine with M/T)' Heated oxygen sensor The;can tool indicates Diagnostic Trouble code (DTC) P0141: A problem in the secondary iPol4tl...

  • Page 428

    PGM-FI System Heated Oxygen Sensor (HO2S) Heater ('96 - 98 Models,'99 - 00 D16Y5 engine with M/T) (cont'dl ( F r o m p a g e 1 1 - 1 5 7 ) PRIMARY HO2S {SENSOR 1I 4P CONNECTOR {c1231 SECONDARY HO2S {SENSOR 2} 4P...

  • Page 429

    Heated Oxygen Sensor (HO2S) Heater i'ss - oo Mb-dels except D16Y5 engine with M/Tl problem in the Primary Heated The scan toot indicates Diagnostic Trouble Code (DTC) P0135: An electrical Fo13sl with M/T)' Oxygen Sensor (Primary ttOiS) (Sensor 1) Heater system {Except D15Y5 engine -scan Heated Oigen Sensor tool indicates Diagnostic Trouble Code (DTC) P0141;...

  • Page 430

    PGM-FI System Heated Oxygen Sensor (HO2S) Heater ('99 - 00 Models except D16Y5 engine with M/T) (cont'dl PRIMARY HO2S ISENSOR 1I 4P CONNECTOB ( F r o m p a g e 1 1 - 1 5 9 ) {c123) SECONDANY HO2S ISENSOR 2} 4P coNNECTOR (C125)*...

  • Page 431

    Heated Oxygen Sensor (HO2SI Heater (Dl6Y5 engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) P1166: An electrical problem in the Primary Heated Oxygen Sensor (Primary H02S) Heater system. The MIL has been lePorted DTC Pl166 b stored. Problem verilication: 1.

  • Page 432

    PGM-FI System Heated Oxygen Sensor (HO2S) Heater (Dl6Y5 engine with M/Tl (cont'd) PRIMARY HO2S (SENSOR 1} 8P CONNECTOR {Cl45I ( F r o m p a g e 1 1 - 1 6 1 ) PO2SHTC {BtK/WHT) Ch6ck the PO2SHTC circuit: 1.

  • Page 433

    The scan tool indicates Diagnostic Trouble Code (DTC) Pl167: A system malfunction in the Primary Heated Orygen Sensor {Primary HO2S) (Sensor 1) Heater circuit The MIL has be€n reported on. DTC Pl167 i3 3tored. Problem Veritication: 1. Do the ECM Reset Procedure. 2 .

  • Page 434

    PGM-FI System Fuel Supply System D017-il Th""""ntool indicates Diagnostic Troubte Code {DTC) p0171;Thefuet system istoo lean. 1P0172 | fne scan tool indicates Dlagnostic Trouble Code (DTC) P0172:Thefuel system istoo rich. Description By monitoring the Long Term Fuel Trim, long term malfunctions in the fuel system will be detected. lf a malfunction has been detected during two consecutive trips, the MIL will come on and DTC P0171 and/or P0172 will be stored.

  • Page 435

    Troubleshooting Flowchart The MIL ha3 b€on rePorled on. DTC P0171 a^dlot P0172 arc stored, is the fuel pressure OK? Check the fuel pt€ssure regulator ls the fuel pressure too high and fusl re{urn pipe. ortoo low? Check the Primary HO2S: 1 .

  • Page 436

    PGM-FI System Random Misfire The scan tool indicates Diagnostic Trouble Code (DTC) lFoioo l*u o, [FTioo l*' *' and P 0 3 0 0 * 5 o r P 1 3 0 0 * 3 * 1 a n d s o m e o f P 0 3 0 1 - P 0 3 0 4 : P0304 Random misfire.

  • Page 437

    Misfire Detected in One Cylinder P0301 | The scan tool indicates Diagnostic Trouble Code (DTC) P0301: Cylinder 1 misfire detected. [F03O2l 16"""untool indicates Diagnostic Trouble code (DTc) P0302: Cylinder2 misfire detected. [FO3Ofl 16" ".un toot indicates Diagnostic Troubte Code (DTC) P0303; Cylinder 3 misfire detected. I P0304 I ths..rr tool indicates Diagnostic Trouble Code (DTC) PO3O4: Cylinder 4 misfire detected.

  • Page 438

    PGM-FI System Misfire in Detected One Gylinder (cont'dl Troubleshootin g Flowchart The MIL has been reoorted on. DTC P0301. P0302. P0303, or P030il is indicated. Check the fuel iniecto. lunction: Stan the engine, and listen for a clicking sound at the fuel injector in the problem cylinder.

  • Page 439

    ( F r o m p a g e 1 1 ' 1 6 8 ) Intermittent misfire due to spark ls DTC P0301, P0302, P0303, plug fouling, etc. (firing is OK ar or P0304 indicated? this time). Does the misfire occur in the Replace the faulty spark plug.

  • Page 440

    PGM-FI System Knock Sensor (KSl ('96 - 98 D16Y5 engine with CW and'96 - 98 D16Y8 engine) tool indicates Diagnostic Trouble Code (DTC) P0325: A malfunction in the circuit of the Knock sensor Forr-l I,3,."""" The MIL has bgen roportsd on. DTC PO:t25 is stored.

  • Page 441

    '99 - 00 D16Y8 engine and Knock sensor (Ks) r99 - 00 D16Y5 engine with cw, 816A2 engine The scan tool indicates Diagnostic Trouble Code (DTC) P0325: A malfunction in the circuit of the Knock Sensor { K S } . The MIL has been reported on.

  • Page 442

    PGM-FI System Crankshaft Position/Top Dead Genter/Gylinder Position (CKP/TDC/CYP) Sensor ('96 - 98 Models, '!n - 00 D16Y5 engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) P0335: A malfunction in the Crankshaft position (CKp) tFos3sl sensor circuit. The scan tool indicates Diagnostic Trouble Code (DTC) P0336: A range/performance problem in the Crankshaft tFffi6l Position (CKP) sensor circuit.

  • Page 443

    (From page | 1-172) DISTRIBUTOR Check fo. a sho.t in the CKP/ 10P CoNNECTOR {C1201 TDC/CYP sensor: TDC P (GRNI C h e c k f o r c o n t i n u i t y t o b o d Y ground on both terminals of the i n d i c a t e d s e n s o r i n d i v i d u a l l y 1*see table).

  • Page 444

    PGM-FI System Crankshaft Position/Top Dead Center/Cylinder Position (CKP/TDC/CYPI Sensor f99 - 00 Models except D16Y5 engine with M/T) The scan tool indicates Diagnostic Trouble Code (DTC) P0335: A malfunction in the Crankshaft Position (CKP) l-Fos3sl sensor circuit. The scan tool indicates Diagnostic Trouble Code (DTC) P0336: A range/performance problem in the Crankshaft tFos36l Position (CKP) sensor circuit.

  • Page 445

    Dl6Y5.816A2 engine: DISTRIEUTOR l0P coNNECTOR {C120) (From page 11-174) C h o c k f o r . 3 h o r t i n l h o C K P / Tlrc s6n3o.: C h e c k { o r c o n t i n u i t y t o b o d y ground on both tsrminals of the indicated sensor individuallY.

  • Page 446

    PGM-FI System Vehicle Speed Sensor (VSSI ('96 - 98 Models,'99 - 00 D16Y5 engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) P0500: A malfunction problem in the Vehicle Speed Sensor (VSS) circuit Iexcept A!/T (D16Y7, D16Y8 engine)1. The scan tool indicates Diagnostic Trouble Code (DTC) P0501: A range/performance problem in the Vehicle Speed Sensor (VSS) circuit [A,rT {D16Y7, D16Y8 engine)].

  • Page 447

    Vehicle Speed Sensor (VSS) ('99 - 00 Models except Dl6Y5 engine with M/T) T h e s c a n t o o | i n d i c a t e s D i a g n o s t i c T r o u b | e c o d e ( D T c ) P o 5 o 0 : A m a | f u n c t i o n p r o b l e m i n t h e V e h i c | e s fFosoo-l Sensor (VSS) circuit lexcept A//T (D16Y/, D16Y8 engine)l' T h e s c a n t o o | i n d i c a t e s D i a g n o s t | c T r o u b | e C o d e ( D T C ) P o 5 o 1 : A r a n g e / p e r f o r m a n c e p r o b | e m i n t h e...

  • Page 448

    PGM-FI System Barometric Pressure (BAROI Sensor The scan tool indicates Diagnostic Trouble code (DTC) Pi106: A range/performance problem in the Baromerrrc Pressure (BARO) Sensor circuit. The MIL ha3 been r€Dortsd on. DTC Pl106 is stored. Problem verification: 1 . D o t h e E C M / P C M r e s e t p r o - cedure, 2 .

  • Page 449

    - 00 D16Y5 engine with M/T} Electrical Load Detector (ELDI {'96 - 98 Models,'tn (DTC) P1297: A low voltage problem in the Electrical Load The scan tool indicates Diagnostic Trouble code Detector (ELD) circuit. Problem verification: '!. Do the ECM/PCM Reset Pro- cedure.

  • Page 450

    PGM-Fl System Elestrical Load Detector |ELD) t'glf - 00 Models except D16y5 engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) P'1297; A low voltage probtem in the Electrical Load Detector (ELD) circuit. Problem verilication: 1. Do the ECM/PCM Reset Pro- cedure.

  • Page 451

    - 98 Models''99 - 00 D16Y5 engine with M/T) Elestrical Load Detector (ELD) f96 T h e s c a n t o o l i n d i c a t e s D i a g n o s t i c T r o u b l e C o d e ( D T C ) P 1 2 9 8 : A h i g h v o l t a g e p r o b l e m i n t h e E l e c t r i c a l Detector (ELD) circuit Problom vcrificttion: 1.

  • Page 452

    PGM-FI System Elestrical Load Detector (ELDI ('99 - 00 Models except D16y5 engine with M/Tl The scan tool indicates Diagnostic Trouble code (DTCI Pl298: A high vottage problem in the Etectrical Load Detector (ELD) circuit. Problem ve.itication: 1. Do the ECN4/PCM Reset pro cedure.

  • Page 453

    Crankshaft Speed Fluctuation (GKFI Sensor . '99 - 00 D16Y5 engine with M/Tl firC- 48 Models, (DTC) P1336; Intermiftent interruption in the Crankshaft Speed The scan tool indicates Diagnostic Trouble Code fPrk6l Fluctuation (CKF) sensor circuit. T h e s c a n t o o I i n d i c a t e s D i a g n o s t i c T r o u b | e c o d e { D T C ) P 1 3 3 7 : N o s i g n a I i n t h e c r a n k s h a f t s p e e d F | u c t u a t i o lFr3g7-l sensor circuit.

  • Page 454

    PGM-FI System Crankshaft Speed Fluctuation (GKFI Sensor ('96 - 98 Models,'99 - 00 D16V5 engine with M/Tl (cont,d) (From page 11 183) Check lor an open in the wires ICKF lines): 1. Reconnect the CKF sensor 3p 2. Dlsconnect the ECM/PCM con- ECM/PCM CONN€CTOR C (31P} nector C (31P).

  • Page 455

    Crankshaft Speed Fluctuation (CKF) Sensor - ('99 - 00 Mociels except D16Y5 engine with M/T) speed The scan tool indicates Diagnostic Trouble code (DTC) P1336: Intermittent interruption in the crankshaft Ftu6l Fluctuation (CKF) sensor circuit Fluctuation (CKF) The scan tool indicates Diagnostic Trouble Code (DTC) P1337: No signal in the Crankshaft Speed tF13g7l sensor circuat, Description...

  • Page 456

    PGM-FI System Crankshaft Speed Fluctuation (GKFI Sensor ('99 - 00 Models except D16YS engine with M/Tl (cont,d) (Frorn page l1-185) Check Ior an opsn in the wires (CKF lines): 1. Reconnect the CKF sensor 3p connector. 2. Disconnect the ECM/PCM con- nector C {31P}.

  • Page 457

    (CKP/TDC/CYPI Sensor Crankshaft Position/Top Dead Center/Cylinder Position T h e s c a n t o o | i n d i c a t e s D i a g n o s t i c T r o u b | e c o d e ( D T c ) P 1 3 5 9 : A p r o b | e m i n t h e c r a n k s h a f t P o s j t i o n / T o p D e sensor circuit' Center/Cvlinder Position (CKP/TDC/CYP) The MIL has been reported on...

  • Page 458

    PGM-FI System ECM/PCM lnternal Circuit [Fi6oil th" """n tool indicates Diagnostic Trouble code (DTc) p1607: An EcM/pcM lnternal circuit probtem. The MIL has been reported on. DTC P1607 is stored. Problern verif ication: 1. Do the ECN4/PCM Reset pro- cedure. 2.

  • Page 459

    A/T Signal (TMA/TMBI ('96 - 98 Dl6Y5 engine with GW) Code (DTC) P1681: TIVA,/TMB signal line failure [F16551l Th" ""un toot indicates Diagnostic Trouble ECM CONNECTOR C 131P} TMA IGRYI Problem verification: 1. Do the ECM Reset Procedure. 2. Drive the vehicle Ior several miles at varying speeds lnt.rmittent failure, system is OK at ihis time.

  • Page 460

    ldle Control System System Description The idle speed ot the engine is controlled by the ldle Air Control (lAC) Valve. The valve changes the amount of air bypassing into the intake manifold in response to electric current controlled bv the ECM/PCM.

  • Page 461

    of air is increased to raise the idle speed 1 . After the engine starts, the lAc valve opens for a certain time. The amount about 150 - 300 rpm. proper fast idle speed. The amount of When the coolant temperature is tow, the IAC valve is opened to obtain the bypassed air is thus controlled in relation to the engine coolant temperature' IOLE SPEED lrpml...

  • Page 462

    ldle Control System ldle ControlSystem lF0505 l Th" """n tool indicates Diagnostic Trouble Code (DTC) PO5O5: tdte controt system malfunction. NOTE: lf DTC P1508 or P1509 is stored at the same time as DTC P0505, troubleshoot DTC p1508 or p1bog first. then recheck for DTC P0505.

  • Page 463

    { F r o m p a g e 1 1 - 1 9 2 ) Check the IAC valve: Disconnect the 3P connector from the IAC valve. 1D16Y5, D16Y8 engine with M/T 81642 engine) Check the IAC valve: D i s c o n n e c t t h e 2 P c o n n e c t o r from the IAC valve.

  • Page 464

    ldle Control System ldle Air Control (lACl Vatve ('96 - 98 Dl6ys, Dl6yB engine with M/Tl The scan tool indicates Diagnostic Trouble Code (DTC) P1508: A problem in the ldle Air Controt flAC) varve circuit. The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM in order to maintain the proper idle speed.

  • Page 465

    ( F r o m p a g e 1 1 - 1 9 4 ) Repair open or short in the wire b e t w e e n E C M l A l 2 l a n d I A C Check the IAC valve Iunction: Momentarily connect ECM con- n e c t o r t e r m i n a l s A 1 2 a n d A 1 0...

  • Page 466

    ldle Gontrol System ldle Air Control (lAG) Valve ('99 - 00 Dl6Y8 engine with M/T, Bt6A2 enginel scan tool indicates Diagnostic Trouble Code (DTC) P1508: A problem in the ldle Air Controt AC) vatve [Fl50g l ]h" C t r C U t t . The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM in order to maintain the proper idle speed.

  • Page 467

    { F r o m p a g e 1 1 - 1 9 6 ) Repair opon or short in lhe wire ls there battery voltage? between EcM lBzl) and lAc valve. Check the IAC valve fundion: Momentarily connect ECM con- nector terminals 823 and 82 with a iumpe.

  • Page 468

    ldle Control System ldle Air Control (lAC) Valve ('96 - 98 A/T and Dl6Y7 enginel 1P1509 Thescantool indicates Diagnostic Trouble Code (DTC) P1509: A problem in the idle Air Control (tAC)valve circuit. The (Rotary) IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM/PCM in order to maintain the proper idle speed, BIMETAL The MIL has b€€n roported on.

  • Page 469

    lFrom page 11-198) IAC VALVE 3P CONNECTOR IClG'} Chock for an opon in tho wilo (lGP lins): '1. Turn the ignition switch OFF. IGP IYEL/BIX) 2. Disconnect the IAC valve 3P connector, 3. Turn the ignition switch ON (ll), 4. At the wire hamess, measure voltage between IAC valve 3P connector terminal No.

  • Page 470

    ldle Gontrol System ldle Air Control {lACl Valve ('99 - 00 A/T and Dl6Y7 enginel 1P1509 lThescantool indicates Diagnostic Trouble Code (DTC) P1509:A problem inthe idleAirControl (lAC)valve circuit. The (Rotary) IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM/PCM in order to maintain the proper idle speed.

  • Page 471

    (From page 11 200) IAC VALVE 3P CONNECTOR {C1O9I Check toi an open in thg wire {lGP line): 1. Turn the ignition switch OFF. IGP (YEL/BLK) 2. Disconnect the IAC valve 3P connector. 3. Turn the ignition switch ON (ll) 4, At the wire harness, measure voltage between IAC valve 3P Wire side of female terminals...

  • Page 472

    ldle Control System Starter Switch Signal ('96 - 98 Models,'99 - 00 D16Y5 engine with M/Tl Thjs signals the ECM/PCM when the engine is cranking. NOTE: . A/T: Transmission in E or E position . M/T: in neutral ECM/PCM CONNECTORS a l32Pl Check tor an open or short in the wire ISTS linel:...

  • Page 473

    Starter Switch Signal ('99 - 00 Models except Dl6Y5 engine with M/T) This signals the ECM/PCM when the engine is cranking NOTE: . M/f: Clutch pedal must be depressed. . A,/T: Transmission in E or E position ECM,/PCM CONNECTORS Ch€ck for an open or short in the wire {STS linel: Measure voltage between ECM/ P C [ / | c o n n e c t o r t e r m i n a l s A 2 4...

  • Page 474

    ldle Gontrol System Air Gonditioning Signal ('96 - 98 Models, '99 - 00 Dl6Y5 engine with M/Tl This sjgnals the ECM/PCM when there is a demand for cooling from the air conditioning system. ECM/PCM CONNECTORS a {32P1 c l3lPl LGl IBRN/8LKI ACS {BLU/RED) 12 't3 C h e c k f o r a s h o r t i n t h e w i r e...

  • Page 475

    (From page 11-204) UNDER.HOOD FUSE/BELAY BOX 9P CONNECTOR 1C352) Check for an open in the wir€ (ACC linel: Momentarily connect underhood ls there a clicking noise from fuse/relay box 9P connector teF the IVC compressor clutch? minal No. 5 to body ground with JUMPER ACC (BLK/RI ACC (BLK/REDI...

  • Page 476

    ldle Control System Air Conditioning Signal ('99 - 00 Models except Dl6Y5 engine with M/Tl This signals the ECM/PCM when there is a demand for cooling from the air conditioning system. ECM/PCM CONNECTORS a l32P) C h o c k t o r a s h o r t i n i h e w i . e (ACS lin6): 1.

  • Page 477

    (From page 11-206) UNDER-HOOO FUSE/RELAY sox 9P coNNEcroR lca52l Check for an open in the wite IACC lino): Momentarily connect under_hood ls there a clicking noise from luse/relay box 9P connector teF the Iy'C compressor clutch? minal No. 5 to body ground with JUMP€R ACC (8LK/REDI WIRE...

  • Page 478

    ldle Control System Alternator (ALTI FR Signal {'96 - 98 Models,'99 - 00 Dl6y5 engine with M/Tl This signals the ECM/PCM when the Alternator (ALT) is charging. ECM/PCM CONNECTORS Inspoction of ALT FR Signal. a {32P) c {31P) (BRN/BLK) Check tor a short in tfte wire (ALT F linel: 1.

  • Page 479

    M/T) Alternator (ALT) FR Signal ('99 - 00 Models except Dl6Y5 engine with This signals the ECM/PCM when the Alternator {ALT) is charging ECM/PCM CONNECTORS lnsoeclion oI ALT FB Signal. Check {or a short in the wire {ALT F line): 1.

  • Page 480

    ldle Control System Brake Switch Signal ('96 - 98 Models, '99 - 00 Dl6YS engine with M/Tl This signals the ECM/PCM when the brake pedal is deoressed. Inspection of Brake Switch Signal. Are the brake lights on without depressing the brake pedal? Depress the brake pedal.

  • Page 481

    Brake Switch Signal ('99 - 00 Models except Dl6Y5 engine with M/Tl This signals the ECM/PCM when the brake pedal is depressed lnsoection ot Brake Switch signal. Are the brake lights on without depressing the brake Pedal? Depress the brake Pedal Inspect the HoRN {15 A} fuse in the underhood fuse/ relay box' Do the brake lights come on?

  • Page 482

    ldle Control System lgy"t9!"_"ring Pressure (PSPI Switch Signal ('96 - 98 Models, '99 - 00 DlGy5 engine witn fU/f) (USAI This signals the ECM/ PCN4 when the power steering load is high. Inspection o{ PSP switch signal. ECM/PCM CONNECTORS Check for an opon in the wire {PSP SW linelr 1.

  • Page 483

    ( F r o m p a g e 1 1 2 1 2 ) C h e c k l o r a 3 h o r t i n t h e P S P ECM/PCM CONNECTORS switch: 1.

  • Page 484

    ldle Control System Power Steering Pressure (PSP) Switch Signal ('99 - 00 Models except Dl6y5 engine with M/T) (USAI This signals the ECM/PCM when the power steering load is high. ECM/PCM CONNEgTORS Inspoction ot PSP switch signal. Check for an op€n in the wire (PSP SW linel: 1.

  • Page 485

    (From page 11'2141 ECM/PCM CONNECTORS C h e c k l o r a s h o r t i n t h o P S P swhch: 1. Turn the ignition switch OFF 2. Disconnect the 2P connector from the PSP switch 3.

  • Page 486

    ldle Control System Automatic Transaxle (CVTI Gear Position Signal ('96 -98 D16Y5 engine with CW) This signals the ECM when the transmission is in @ or @ position. Check the operation oI the A/T gear position switch: 1. Turn the ignition switch ON flt). 2.

  • Page 487

    ( F r o m p a g e 1 1 - 2 1 6 ) R e p a i r o p e n i n t h e w i r e between the ECM {C291 and lhe Ituge assomblv.

  • Page 488

    ldle Control System Clutch Switch Signal (Dl6YS engine with M/Tl This signals the ECM when the clutch is engaged. Inrpaction ot dutch rwitch signal. ECM CONNECTORS A {32P} LGl (BRN/BLK) Check for on opon in the wiro (CLSW linel: '!. Turn the ignition switch ON (ll).

  • Page 489

    { F r o m p a g e 1 1 - 2 1 8 ) CLUTCH SWITCH 2P CONNECTOR j - t Check lho clutch switch: 1. Turn the ignition switch OFF. 2. Disconnect the 2P connector from the clutch switch. ls voltage less than 1.0 V? 3.

  • Page 490

    ldle Control System ldle Speed Setting Inspection/Adiustmenl Adjust the idle speed, if necessary, by removing the cap and turning the idle adjusting screw. '96, '97 Dl6Y5. '96 - 00 Dl5Y8 sngine with M/T NOTE; After adjusting the idle speed in this step, NOTE: recheck the ignition timing (see section 23).

  • Page 491

    '96.'97 D16Y5 engine with CVT,'96 - 00 D16Y8 ongins with A/T and'96 - 00 Dl6Y7 €ngine IDLE ADJUSTING Adiust the idle speed using a Honda PGM Tester if pos- sible. lf not, use the following procedure: NOTEI Leave the IAC valve connected .

  • Page 492

    ldle Control System ldle Speed Setting (cont'dl Inspeqtion/Adiustment lf necessary, adjust the idle speed, by removrng lne cap and turning the idle adjusting screw. 38 D16Y5 engine whh M/T,'99 - 00 81642 engine After adjusting the idle speed recheck the ignitlon timing (see section 23).

  • Page 493

    Remove the cap and turn the idle adiusting screw '98 - 0O D16Y5 ongine with CvT 1/2-turn clockwise or counterclockwlse IDLE Adjust the idle speed using a Honda PGM Tester if pos- sible. lf not, use the following procedure: NOTE: Leave the IAC valve connected.

  • Page 494

    Fuel Supply System Fuel Lines NoTE: Check fuel system lines, hoses, fuel filter, and other components lor damage, leaks and deterioration, and replace if necessary. ,ee.- /.,/ ...,.' ..4,/ 22 N.m (2.2 kgt.m, 16lbf.ft) (D16Y5 engine: 28 N.m 2.8 kgtm, 21 lbf ft) The illustration shows'99 00 models.

  • Page 495

    '96 - 98 models: NOTE: Check all hose clamps and retighten if necessarY. FUEL FILTER PRESSURE REGULATOR FUEL TANK FUEL GAUGE SENDING UNIT BASE GASKET R e p l a c e . C l a m p I n r h e m i d d l e C l a m p i n t h e m i d d l e 1 0 - 1 4 m m (0.39 - 0.55 inl...

  • Page 496

    Fuel Supply System Fuel Lines (cont'dl .99 - 00 models: NOTE: Check all hose clamps and retighten if necessary. : Do not disconnect the hose from the pipe. ONBOARD REFUELING VAPOR BECOVERY IORVRI VENT SHUT VALVE FUEL lt N.rn l1.a kgt.m, GAUGE r0 lbt ftl ftr, n'fo'...

  • Page 497

    Fittings Fuel Tube/Ouick-Gonnect Disconnestion Precautions Do not smoke while working on the luel Do not smoke while working on the fuel system. Keep open llames away lrom youl work area. system, Keep open flames away from your work a.ea' 1. Relieve fuel pressure (see pages 11'230,2311. The fuel tube/quick-connect fittings assembly connects the in tank fuel pump with the fuel feed pipe.

  • Page 498

    Fuel Supply System Fuel Tube/Ouick-Connect Fittings (cont'd) 5. To prevent damage and keep out toreign matter, Connection c o v e r t h e d i s c o n n e c t e d c o n n e c t o r a n d o i o e e n d with plastic bags.

  • Page 499

    Make sure the connection is secure and the pawls Belore connecting a new fuel tube/quick-connect fining are firmly locked into place; check visually and by assembly, remove the old retainer from the mating pipe pulling the connector. with the tabs pulled apan, remove and discard the retarner...

  • Page 500

    Fuel Supply System System Description The fuel supply system consists of a fuel tank, in-tank Inspoction high pressure fuel pump, PGM-FI main relay, fuelfilter, fuel pressure regulator, fuel injectors. and fuel delivery 1. Relieve fuel pressure. and return lines. This system delivers pressure-regu- lated fuel to the fuel injectors and cuts the fuel delivery Remove the service bolt on the fuel filter while hold- when the engine is not running.

  • Page 501

    Fuel Pressure {'97 and later Models) Inspaqtion ReliGving Before disconnecting tuel pipes or hoses, release pres- 1. Relieve fuel pressure. sure from the system by loosening the 12 mm banjo bolt on top of the fuel filter. Remove the 12 mm banjo bolt from the fuel filter while holding the fuel Jilter with another wrench Attach the special tools.

  • Page 502

    Fuel Supply System Fuel Injectors Replacement Do not smoke when working on the tuel systgm, Keep gp6n flames away from your work area Relieve the fuel pressure (see pages 11-230,231J. 2. Disconnect the connectors from thefuel injectors (D16Y7 engine: Remove the air cleaner). 3.

  • Page 503

    81642 engine: 12 N.m {1.2 kgl m; 8.? lbt.ft) FUEL PRESSURE REGULATOR O.RING Replace. cusHloN RING Replace. EVAP PURGE CONTROL SOLENOID VALVE SEAL RING Replace. 7. Slide new cushion rings onto the fuel injectors. 8. Coat newO-ringswith clean engineoil, and putthem onthefuel injectors. 9.

  • Page 504

    Fuel Supply System Fuel Pressure Regulator Te3ting Reolacement Do not smoke during the tast. Keep open Do not smoke while working on luel sys- flamcs away from your work arsa. tem. Keep open flame away from your work area, 1. Attach the special tool(s) to the service port on the 1.

  • Page 505

    FuelFilter ,96 MODELS: Replacement 12 mm BANJO . Do not smoke whilc working on fuel system. Keep BOLT open flame away from your work arsa. 33 N.m . While replacing the tuel filter, be catelul to koep a (3.4 kgl.m, sale distance betwoen battery torminals and any 25 rbf.ftl tools.

  • Page 506

    Fuel Supply System Fuel Pump Testing Replacement Do not smoke during the test, Keep open Do not smoke while working on tuel svs- flame away from your work atea, tem. Keep open llames away from your work area. lf you suspect a problem with the fuel pump, check that the 1.

  • Page 507

    PGM-FlMain Relay Relay Testing Description T h e P G M - F l m a i n r e l a v a c t u a l l v c o n t a i n s t w o i n d i v i d u a l relays.

  • Page 508

    Fuel Supply System PGM-FI Main Relay (cont'dl Circuit Troubleshootin g Engine will not start. lnsoection of PGM-FI main relay and relay harne$. PGM.FI MAIN RELAY 7P CONNECTOR {C443) Check for an open in the wire {GNO line}: {8LK) l. Turn the ignition switch OFF. 2.

  • Page 509

    ('96 - 98 models) Repair open or 3hort in the wire bstw€er the lGM-Fl main rolsy .nd the No. 31 STARTER {GRN/YELI SGNAL 17.5 A) tuse. ls there baftery voltage? Reolace the No. 31 STARTER SIGNAL (7.5 Al fu3o in the unde.-dash tusg/rolav box.

  • Page 510

    Fuel Supply System PGM-FI Main Relay (cont'd) _._(9x . qq -gqerll _ PGM.FI MAIN FELAY 7P CONNECTOR {C4€} Repair op€n or short in the wir€ betlveen the PGM-FI main relay and the No. 31 STARTER IGRN/YEL} ls there battery voltage? SIGNAL 17.5 A) fuse.

  • Page 511

    FuelTank '96 - 98 models: Replacement from your work ar'a' Do not smoke while working on fuel system' Keep open flame away 1. Relieve the fuel pressure (see pages \1-230' 23'll' 2. Remove the seat cushion (see section 20). 3. Remove the access panel from the floor' '97 D16Y/ engine(coupe: KL model' ('96 D]6Y8 engine (coupe) 4.

  • Page 512

    Fuel Supply System Fuel Tank {cont'dl 39 - (xt models: Replac6ment Do not smoke whire working on fuer system. Ke€p open frama away trom your work area. 1. Relievethefuel pressure (see pages 11-230,23'll. 2. Remove the seat cushion lsee section 2O). 3, Remove the access panel fromthefloor.

  • Page 513

    Intake Air System System DescriPtion pipe' Air C|eaner (ACL}, intake air duct, Thrott|e The system supp|ies air for a|| engine needs' |t consists of the intake air intake air pipe provides additional silencing Body (TB), ldle Air control (lAc) valve and intake manifold. A resonator in the as air is drawn into the system.

  • Page 514

    lntake Air System Air Cleaner (ACLI Throttle Cable N O T E : D o n o t c l e a n t h e A C L e l e m e n t i t w i t h c o m - Inspection/Adiustment pressed air {except dry type).

  • Page 515

    lnstallation 816A2 engine: Dl6Y5, Dr6Y8, D16Y, €ngine: 1. Open the throttle valve fully, then install the throttle cable in the throttle linkage, and install the cable LOCKNUT housing in the cable bracket. D16Y5, D16Y8 engins: LOCKNUT DEFLECTION ADJUSTING CABLE 1 0 - 1 2 m m BRACKET Bla- 112inl lf deflection is not within specs' loosen the locknut'...

  • Page 516

    Intake Air System Throttle Cable (cont'dl 4 . S e t t h e l o c k n u t o n t h e c a b l e b r a c k e t . A d j u s t t h e 816A2 engine: adjusting nut so that its free play is O mm.

  • Page 517

    Throttle BodY Dl6Y7 ongine: Description The throttle bodY is either a single-barrel side-draft type (D16Y5, D16Y8, 816A2 engine) or a down-draft type (D16Y/ engine). The lower portion ot the throttle valve is heated by engine coolant from the cylinder head' The idle adjusting screw which regulates the bypass air is located on the top of the throttle body IDLE AD.'USTING...

  • Page 518

    Intake Air System Throttle Body (cont'dl \ r J Removal D16Y5, Dl6Y8, 81642 engine: D15Y7 engine: IAT SENSOR AIR CLEANER {ACLI MAP SENSOR 22 N.m 12.2 kgl.m, 16 rbf.ftl GASKET R e p l a c e . THROTTLE CABLE NOTE: .

  • Page 519

    Disasssmbly Dl6Y5, Dl6Y8 engine: 2.1 N.m (0.21 ksf.m, 1.5 lblftl\ MAP SENSOR Troubleshooting, page 1 1'1 15 TP SENSOR IDLE AOJUSTING 3.5 N.m t0.35 kgl m,2.5 lblftl B16A2 sngine: SENSOR Troubleshooting, Page 1 1-1 19 z.'t N.m TP SENSOR 10.21 kgf'm, SENSOR Troubleshooting, Page 11 115 1.5 tbf.frl...

  • Page 520

    Intake Air System Fuel Injection Air (FlA) Controt System I'99 - 00 Dl6yg enginel Dsscription When the engine running lengine coolant below 149oF (6S"C)], the fuel Injection Air (FtA) Control Valve sends intake air to the fuel iniectors. FUEL INJECTOB E>...

  • Page 521

    Fuol Iniection Air {FlA) Contlol Valve T$ting 1. Start the engine. Remove the vacuum hose from the fitting on the intake air duct, and connect a vacuum gauge to the nose. NOTE: Engine coolant temperature must be below 149"F (65"C). VACUUM PUMP/GAUGE, 0 - 3 0 i n .

  • Page 522

    Emission Gontrol System System Description Three Way Catalytic Converter (TWCI The emission control system includes a Three Way Cata- lytic Convener (TWC), Exhaust Gas Recirculation (EGR) Doscription system,. Positive Crankcase Ventilation (pCV) system and The Three Way Catalytic Converter (TWC) is used to Evaporative Emission (EVAP) Control system.

  • Page 523

    (DTc) p0420: catatyst sysrem efficiency below threshold. lTo420l Th" """n toot indicates Diagnostic Troubte code Description output during stable driving This system evaluates the catalyst's capacity by means of the Ho2s {Primary and secondary) MIL comes on and DTC P0420 will conditions.

  • Page 524

    Emission Control System Exhaust Gas Recirculation (EGR) System (D16yS engine) Doscription The EGR system is designed to reduce oxides of nitrogen emissions (NOx) by recirculating exhaust gas through the EGR valve and the intake manifold into the combustion chambers. lt is composed of the EGR valve. EGR vacuum conrrot vatve. EGR control solenoid valve.

  • Page 525

    The scan tool indicates Dlagnostic Trouble cod€ {DTc} Po4ol: lnsufficient flow in the Exhaust Gas Recirculation (EGR) svstem. Doscription the changes in MAP before Deterioration (clogging, leakage, etc.) in the EGR line or EGR valve is detected by means of and after the operation of the EGR valve.

  • Page 526

    Emission Control System Exhaust Gas Recirculation (EGR) System (D16Y5 engine with GWI (cont'dl T_he scan tool indicates Diagnostic Trouble Code (OTC) P1491: A malfunction in the Exhaust Gas Recirculation lTl49il l E g h ) s v s t e m . CvT lM/T see page 1l-2611: The MIL has been reoorted on.

  • Page 527

    EGR VALVE #16 HOSE LIFT SENSOR (From page 11-256) Check fo. a mallunction in the EGF valv€: 1. ldove the vacuum pump/gauge PUMP/GAUGE,0 - 30 in.Hs to the EGR valve. 4 9 7 3 X - 0 4 1 - X X X X X 2.

  • Page 528

    Emission Gontrol System Exhaust Gas Recirculation (EGRI System (Dl6Y5 engine with CW) (cont'dl {From page 11-257} Chock lor an opcn or short in th. EGR v.lve lift .€nsor EGR VALVE LIFT SENSOR '1. Turn the ignition switch OFF. 3P CONNECTOR {Cl251 2.

  • Page 529

    (From page 11-258) ECM CONNECTOR O {I5PI Check for a 3hort in the wire {EGRL linel: C h e c k f o r c o n t i n u i t y b e t w e e n ECM/PCM connector terminal Dg Wire side of lemale terminals Repair op€n in the wire between...

  • Page 530

    Emission Control System Exhaust Gas Recirculation (EGR) System (Dl6Y5 engine with CW) (cont'dl (From page 11-259) EGR CONTROL SOLENOID VALVE 2P CONNECTOR {C142} Wire side ESOL of lemale Chock lor an open in the wire (E IRED) terminals SOL linsl: 1.

  • Page 531

    Exhaust Gas Recirculation System (D16Y5 engine with M/T) M/T: Th6 MIL ha3 b€on reponed on. DTC Pl,{tl is 3tored. Prcblem verification: 1. Do the ECM Reset Procedure. 2. Connect the SCS service con_ nector. 3 . S t a r t t h e e n g i n e . H o l d t h e engine at 3,000 rpm with no load (transmission in neutral) untilthe radiator fan comes on.

  • Page 532

    Emission Control System Exhaust Gas Recirculation System (D16Y5 engine with M/T) (cont'dl ( F r o m p a g e 1 1 - 2 6 1 ) ECM CONNECTOR D {16P) Check tor open in the wire (SG2 linel: M e a s u r e v o l t a g e b e t w e e n t h e E C M c o n n e c t o r t e r m i n a l s D 1 0 a n d D 1 1 .

  • Page 533

    lFrom page 11-262) ECM CONNECTOR D I16P' Chock for rn opon in the wire {EGR L linel: 1. Reconnect the EGR valve con nector. 2. Tu.n the ignition switch ON (ll). 3. Measure voltage betweon the PCM connector terminals Dg a n d D l 1 .

  • Page 534

    Emission Gontrol System Exhaust Gas Recirculation System (Dl6Y5 engine with M/Tl (cont'dl lFrom page 11 263) EGR VALVE 6P CONNECTOR {C144} Check lor an op€n in the wire (E- EGR line): 1. Turn the ignition switch OFF. 2. Disconnect the ECM connector, A (32P)trom the ECM.

  • Page 535

    (D16Y5 enginel Exhaust Gas Recirculation System Code {DTC) P1498: A high voltage problem in the Exhaust Gas The scan tool indicates Diagnostic Trouble Recirculation (EGRlvalve lift sensor circuit. The MIL has been reportod on. DTC P1498 is storod. Probl€m verification: 1.

  • Page 536

    Emission Control System Positive Crankcase Ventilation IPCVI System Descripiion lrcpection T h e P o s i t i v e C r a n k c a s e V e n t i l a t i o n ( P C V ) s y s t e m i s 1.

  • Page 537

    Evaporative Emission (EVAPI Controls Description The evaporative emission controls are designed to minimize the amount of fuel vapor escaping to the atmosphere. The system consists of the foliowing components: A. Evaporative Emission (EVAP) Control Canisto] An EVAP control canister is used for the temporary storage of fuel vapor until the fuel vapor can be purged from the EVAP control canister into the engine and burned.

  • Page 538

    Emission Control System Evaporative Emission IEVAPI Controls (cont'd) '96 D16Y8 ongins (coupol.'97 D16Y8 €ngino (coups: all mod€ls, sedan: KL model),'98 D16Y5 engine (all mod6lsl,'98 Dl5YB engine {all modols): From BLK/ No. 15 < ALTERNATOR EVAP PURG€ SP SENSOR CONTROL (7.5 A) FUEL SOLENOID VALVE TANK...

  • Page 539

    '96 Dl6Y5 engine,'96 D16Y8 engine (sodanl,'97 Dl6Y5 sngino,'97 Dl6Y8 sngine (sedan: KA, KC modols): EVAP PURGE EVAP CONYROL TWO WAY SOLENOID From VALVE No. 15 ALTERNATOR BLK/YEL__ _ < SP SENSOR VARIOUS SENSORS FUEL FILL D16Y7 engine {coupe: KA, KC models, sedan: KA. KC, Kl- IDX) modols, hatchback: all models}: '96 D16Y' engin.,.9? From No.

  • Page 540

    Emission Control System Evaporative Emission (EVAPI Controls (cont'd) '99 - 00 Dl6Yg engine,'99 - 00 Dl6Y5 €ngine,'99 - 00 81642 engine: From - No. 15 BLK/ FUEL YEL _ ALTERNATOR TANK SP SENSOR PRESSURE {7.5 A) SENSOR YELI EVAP GRN/ BYPASS SOLENOID VALVE...

  • Page 541

    ,96 D16Y5 engine,,96 D16r,gngino,,96 Dt6Y8 engine {3edan)' 37 D16Y5 engino..97 D16r, engine {coupe: KA, Kc mod- (s€dan: KA' KC mod€lsl: els. sedan: KA, KC, KL {DX} models. hatchback: all modols}''97 Dl6Y8 ongine (EVAP) control system The scan tool indicates Diagnostic Trouble code (DTC) P0441: Evaporative Emission insufficient purge flow.

  • Page 542

    Emission Gontrol System Evaporative Emission (EVAPI Controls (cont'dl (From page 11-271) ECM/PCM CONNECTOR D I32P} PGl IBLKI Check the EVAP purge control solenoid valvei 1 . R e c o n n e c t t h e E V A P p u r g e control solenoid valve 2P con- nector.

  • Page 543

    D16Y7, D16Y8 engine D16Y5 engine: (From page 11-272) Check lhe EVAP Purge control solsnoid valve: VACUUM VACUUM 1. Disconnect the vacuum hose PUMP/ PUMP/ from the EVAP controlcanister' GAUGE, GAUGE, 2. Connect the vacuum PumP to 0 - 30 in.Hg 0 - 30 in.Hg As73x - 0il1 - the hose and aPPIY vacuum...

  • Page 544

    Emission Control System Evaporative Emission (EVAP) Gontrols (cont'd) '99 - 0O models only: The scan tool indicates Diagnostic Trouble Code (DTC) P0451: The Fuel Tank Pressure sensor circuit range/ oerformance Droblem. ECM/PCM CONNECTORS Ths MIL has been reDortgd on. DTC m/$1 i3 stored. A (32P) Check the tuel tank pros3ure ser|- sor:...

  • Page 545

    (LX) modeu,'97 Fuel Tank Pro3sure sensor 196 D16Y8 engine (coupe).'97 D15Y7 engine {coupe: KL model, sedan: KL '98-all models) '99 - 00 D16Y5 engine with M/Tl: D16Y8 engine (coupe: all models, sedan: KL model, F o c 2 l : : i l " : " t o o l i n d i c a t e s D i a g n o s t i c T r o u b l e c o d e ( D T c ) P 0 4 5 2 : A | o w v o | t a g e p r o b | e m i n t h e F u e | T a n k P r e EcM/PCM.

  • Page 546

    Emission Control System Evaporative Emission (EVAP) Controls (cont'dl {From page 11-275) FUEL TANK PRESSURE SENSOR 3P CONNECTOR {C7921 PTANK Check to. ! short in the wiro {LT GRN) IPTANK linol: M e a s u r e v o l t a g e b e t w e e n t h e firel tank pressure sensor 3P con- nector No.

  • Page 547

    2. Bemove the fuel fill caP. PTANK {LT BLUI 3. Turn the ignition switch ON {ll) 4. Monitorthe FTP Sensor voltage with the Honda PGM Tester' or measure voltage between body lntermitlent tailure, 3Ystem b OK groLrnd and ECM/PCM connec_ at this time.

  • Page 548

    Emission Control System Evaporative Emission (EVAPI Controls {cont,dl ( F r o m p a g e 1 1 - 2 7 7 ) FUEL TANK PRESSURE SENSOR SU8-HABNESS 6P CONNECTOR 1C574 tC568)rt PTANK C h e c k f o r a s h o r t i n t h e w i r e {LT GRN} {PTANK line): A t t h e a c c e s s p a n e l s i d e , m e a...

  • Page 549

    (coupo: KL mode|' 3edan: KL (Lxl modg||',97 Fue| Tank Pr€ssure sensor 196 Dr6Y8 engine (coupe},,97 D16Y7 angino - 0O Dl6Y5 ongins with M/Tl: Dl6Y8 engine (coupe: all modeb, sedan: Ki model.'98'all modols) 39 r F o G ' l : : ; J l " t o o | i n d i c a t e s D i a g n o s t i c T r o u b | e c o d e ( o T c ) P 0 4 5 3 ; A h i g h v o | t a g e p r o b | e m i n t h e F u e | T a n k P r The MIL has beon reponed on DTC P0453 b stored.

  • Page 550

    Emission Control System Evaporative Emission (EVAPI Controls (cont'dl l F r o m p a g e 1 1 - 2 7 9 1 ECM/PCM CONNECTOR D {16PI Check for an open in the wire {PTANK line): Measure voltage between ECM/ P C M c o n n e c t o r t e r m i n a l s D 1 5 a n d D ] 1 .

  • Page 551

    '99 - 0O modols except Dl5Y5 engine with M/T: r F o 4 5 ' : : n " : " t o o I i n d i c a t e s D i a g n o s t i c T r o u b | e c o d e ( D T c ) P 0 4 5 3 : A h i g h v o | t a g e p r o b | e m i n t h e F U e l T a n k P The MIL has been reported on.

  • Page 552

    Emission Gontrol System Evaporative Emission (EVAP) Controls (cont'd) (From page 11-281) ECM/PCM CONNEfiORS a {32P) Check tor an open in th€ wire (PTANK line): Measure voltage between ECM/ PTANK ILT GRNI P C i / l c o n n e c t o r t e r m i n a l s A 2 9 a n d C 1 8 .

  • Page 553

    (LX) model)"g7 Dl6Y8 ongine (coupe: all mod- t,96 D16Y8 engine (coup6l,'9? Dl6Y7 engine (coupe: KL model, sedan: KL els, sedan: KL model,'98-8ll modelsl 39 - 00 Dl5Y5 engine with M/Tl: (EVAP) control system leak The scan tool indicates Diagnostic Trouble code (DTc) P1456: Evaporative Emission Fr4t6l detected (fuel tank sYsteml (EVAP) control system leak...

  • Page 554

    Emission Control System Evaporative Emission (EVAPI Controls (cont'dl (From page 1l-283) (From page l1-283) EVAP CONTROL CANISTER VENT SHUT VALVE 2P CONNECTOR IC141} Check for an open in tho wire l l t r t (lGl line): o) (8LK/YErl 1. Turn the ignition switch OFF. 2.

  • Page 555

    (From page 11-284) Check the EVAP pirrge control solenoid valvei 1. Disconnect the 2P connector lrom the EVAP purge control ls there vacuum? solenoid valve. 2. Ouickly raise the engine speed to 3,000 rpm. InsDect vacuum ho56 routing. ll OK, replace the EVAP Purge control solenoid valve.

  • Page 556

    Emission Control System Evaporative Emission (EVAPI Controls (cont'd) (From page 11'285) (From page 11 285) ECM/PCM CONNECTOR A {32P} P G l {BLK) Check lor an op€n in the wire {PCS line}: 1. Turn the ignition switch OFF. 2, Reconnect the 2P connector lo the EVAP purge control sole- noid valve.

  • Page 557

    (From page 11-286) ECM/PCM CONNECTOR A (32P) Check the EVAP bypa3s 3olenoid 1. Turn the ignition switch OFF. 2. Connect ECM/PCM connector '12 t t t 8 t 9 20 terminal A28 and body ground with a jumper wire. ChGck tor an opon in lho wite 3.

  • Page 558

    Emission Control System Evaporative Emission {EVAP) Controls (cont'dl '99 - 00 modols except Dl6Y5 engine with M/T: The scan tool indicates Diagnostic Trouble Code (DTC) P1456: Evaporative Emission (EVAP) control system leak tF1456-l detected (fuel tank svstem). The scan tool indicates Diagnostic Trouble Code (DTC) P1457: Evaporative Emission (EVAP) control system leak tP14sz-l detected (EVAP control canister system).

  • Page 559

    (From page 11-288) {From page l1 288} EVAP CONTROL CANISTER VENT SHUT VALVE 2P CONNECTOR IC141I Check for an open in tha wire (lGt linol: 1. Turn the ignition switch OFF. 2. Disconnect the 2P connector from the EVAP control canis- ter vent shut valve.

  • Page 560

    Emission Control System Evaporative Emission (EVAPI Controls (cont'dl (From page 11-289) Ch€ck the EVAP purge control solenoid valv6: 1. Disconnect the 2P connector from the EVAP purge control solenoid valve. 2. Ouickly raise the engine speed to 3,000 rpm. Insped vacuum hose routing. lf OK.

  • Page 561

    ECM/PCM CONNECTOR (From page 11-290) (From page l1 290) Check for an open in the wire {PCS lin6): 1. Turn the ignition switch OFF 2. Reconnect the 2P connector to the EVAP purge control sole- 3. Turn the ignition switch ON {ll). 4 .

  • Page 562

    Emission Control System Evaporative Emission (EVAPI Gontrols (cont'd) EVAP BYPASS SOLENOID VALVE ( F r o m p a g e l 1 ' 2 9 1 ) C h e c k f o r a s h o r t i n t h e w i r e {2WBS linel: Does the valve hold vacuum? Disconnect the 2P connector {rom...

  • Page 563

    (From page 11 292) (From page 11-292i Check toi an opon in the wiro (2wBS linol: 1. Turn the ignition switch OFF. 2. Reconnect the 2P connector to the EVAP bypass solenoid 3. Turn the ignition switch ON (ll). 4 . M e a s u r e v o l t a g e b e t w e e n ECM/PCM connector terminals 43 and 82.

  • Page 564

    Emission Control System Evaporative Emission (EVAPI Controls (cont'd) Evaporative Emission (EVAPI Two Way Valve Testing f96 D16Y5 engine,'96 D16Y7 engine,'96 D16Y8 ongine (sedanl,'97 D16Y5 engine,'97 Dl6Y7 engine {coupe: KA, l'96 DIGYS engine lcoupel,'97 Dl6Y7 engine (coupe: KL KC models, sedan: KA, KC, KL {DX} models, hatchback: model, sedan: KL (LX) modoll,'97 Dl6Y8 engine {coup€: '98-all modelsll: all modsls),'97 D16Y8 engine {sedan: KA, KC models}l:...

  • Page 565

    Slowly pressurize the vapor lin€ while watching the Evaporative Emission (EvAPl Two Way Valve T6ting gauge. '99 - 00 modols: T h e p r e s s u r e s h o u l d b e s t a b i l i z e m o m e n t a r i l y above 1.0 kPa (8 mmHg, 0.3 in.Hg).

  • Page 566

    Emission Gontrol System Evaporative Emission (EVAP) Controls (cont'dl ORVR Vent Shut Valve Test Vatve Tcst Float Test 1. Make sure the fueltank is lessthan halffull. 1. Make sure the fuel tank is less than half full. Remove the fuel fill cap. Remove the fuel fill cap to relieve the fuel tank pres- Remove the fuel hose joint protector.

  • Page 567

    ORVR Vent Shut Valve Replacement Connect a second vacuum pump to the OBVR signal nose. Remove the fuel tank (see page 1 1-242). Remove the ORVR vent shut valve from the fuel tank. VACUUM PUMP/ GAUGE.0 - 30 in.Hg lnstall oarts in the reverse order of removal. A973X - 041 - xxxxx Apply vacuum (1 pump) to the ORVR signal hose,...

  • Page 568

    Transaxle .""""" 12'1 cf utch 13-1 Manual Transmission ...."'.'..".'...'. Automatic Transmission ..".." ". 1 4-1 ... 15-1 Differential ." 16-1 Driveshafts...

  • Page 569

    Clutch ...12-2 Speciaf Tools ..f lfustrated Index ....12-3 clutch Pedal 12'4 ....Adjustment Clutch Master Cylinder ..12-5 Removal/lnstallation Slave Cylinder ..12'6 Removal/lnstallation Pressure Plate ..12-7 Removal/lnspection Clutch Disc ..12-8 Removal/lnspection Flywheel 12-9 ....... Inspection Replacement ........12-9 Clutch Disc, Pressure Plate 12-10...

  • Page 570

    Special Tools I t J Page Reterence Description Ref. No. Tool Number O T J A F _ P M 7 O 1 1 A 12-7 Clutch Alignment Disc OTJAF _ PM70124 1 2 - 7 , 8 , 1 0 , 1 1 Clutch Alignment Shaft ' t 2 - 7 , 9 , 1 0 , 1 1 07LAB - PV00100 or...

  • Page 571

    lllustrated Index NOTE: . Whenever the transmission is removed, clean and grease the release bearing sliding surface lf the parts marked with an asterisk (*) are removed, the clutch hydraulic system mustbe bled (seepage 12-6) Inspect the hoses for damage, leaks, interference, and twisting 'RESERVOIF TANK ASSIST SPRING LOCK PIN...

  • Page 572

    Glutch Pedal Adjustment T u r n t h e c l u t c h s w i t c h ( o r a d j u s t i n g b o l t ) i n a n a d d i - NOTE: tional 3/4 to 1 full turn.

  • Page 573

    Glutch Master Gylinder RemovaUlnstallation Remove the clutch master cylinder. CAU'NON: . Do not sDill brake lluid onthevehicle;it may damage the paint; if brake fluid does contact the paint, wash it off immediatelY with water. . Plug the end ofthe clutch line and reservoir hos€ with a shop towelto prevent brake tluid from coming out 1 .

  • Page 574

    . Refill the clutch master cylinder with fluid when done. . Always use Genuine Honda DOT 3 Brake Fluid. Remove the slave cylinder from the clutch housing. Using a non-Honda brake fluid can cause corro- sion and decrease the life of the system.

  • Page 575

    Pressure Plate Removal/lnsPection lnspect the pressure plate surface for wear' cracks, 1 . Inspect the fingers of the diaphragm spring for wear a n d b u r n i n g . at the release bearing contact area. Inspect for warpage using a straight edge and leeler Check the diaphragm spring fingers for height using g a u g e .

  • Page 576

    Clutch Disc RemovaUlnspection Remove the clutch disc and special tools. 4 . M e a s u r e t h e d e p t h f r o m t h e l i n i n g s u r f a c e t o t h e rivets, on both sides.

  • Page 577

    Flywheel Replacement Inspection 1. Installthe special tool. Inspect the ring gear teeth for wear and damage I n s p e c t t h e c l u t c h d i s c m a t i n g s u r f a c e o n t h e FLYWHEEL flywheel for wear, cracks, and burning.

  • Page 578

    Flywheel Clutch Disc, Pressure Plate Replacement (cont'dl Installation Drive the new ball bearing into the flywheel using 1 . I n s t a l l t h e s p e c i a l t o o l . the special tools as shown.

  • Page 579

    Release Bearing Removal/lnspection 1. Remove the release fork boot from the clutch hous- 4. Torque the mounting bolts in a crisscross pattern as I n g . s h o w n . T i g h t e n t h e m i n s e v e r a l s t e p s t o p r e v e n t warping the diaPhragm sPring.

  • Page 580

    Release Bearing Installation N O T E : U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e Move the release fork right and left to make sure (P/N 08798 - 9002).

  • Page 581

    Manual Transmission S40 Model (All except'99 - 00 2-door Si' SiR) 1 3 - 1 M a n u a l T r a n s m i s s i o n .." ..' . ' . . " .." . S4C Model ('99 - 00 2-door Si, SiRl 1 3 - 4 5 M a n u a l T r a n s m i s s i o n .

  • Page 582

    S40 Model (All except'99 - 00 2-door Si' SiR) Manual Transmission Shift Fork AssemblY ..'..13-2 Special Tools ."'... 13-25 lndex ....Maintenance 13'26 Clearance lnspection .".."..'.. 13-3 Transmission Oil ......MBS Shift Piece Inspection ..-..'.. 13'27 Back-up Light Switch Synchro Sleeve, Synchro Hub ..

  • Page 583

    Special Tools ly tr Ref. No. Tool Numbet Description Page Reference O T G A J P G 2 O 1 1 O Mainshaft Holder 13-38 OTGAJ PG2012O C o l l a r 13-37 07GAJ - PG20130 Mainshaft Base 13-37 07736 - A010004 Adjustable Bearing Puller, 25 - 40 mm...

  • Page 584

    Back-up Light Switch Maintenance Replacement Transmission Oil NOTE: To test the back-up light switch, see section 23 NOTE: Check the transmission oil with the engine OFF a n d t h e v e h i c l e o n l e v e l g r o u n d . Disconnect the connector, then remove the back-up light swirch connector from the connector clamp.

  • Page 585

    Troubleshooting Reverse Gear Noise Reduction System Whenever the clutch pedal is depressed to shift into reverse, the mainshaft continues to rotate because of its inertia. The resulting speed difference between mainshaft and reverse idler gear produces gear noise. The reverse gear noise reduction system employs a cam plate which was added to the reverse shift holder. When shifting into reverse, the sth/reverse shjft piece, connected to the shift lever, rotates the cam plate.

  • Page 586

    Transmission Assembly Removal Disconnect the vehicle speed sensor (VSS) connec- . Make sure iacks and safety stands are placed prop€dy, ror. and hoist brackets are atlach€d to correct position on the enginc. CONNECTOR . Apply parking brake and block rear whosls so car will nol roll olf stands and lall on you while working under CAUTION: Use fender covers to svoid damaging painted surfaces.

  • Page 587

    Transmission Assembly Removal (cont'dl '10. Remove Remove the driveshafts (see section 161. the shift rod and extension rod. NOTE: Coat all the precision finished surfaces with clean engine oil or grease. Tie plastic bags over the SI'IIFT BOD driveshaft ends, SET RING 1 0 x 1 .

  • Page 588

    14. Remove the right front mounvbracket. D16Y7 engine: ' l O x ' l . 2 5 m m 44 N'm (4.5 kgl.m, 33 rbf.frl 8 x 1 . 2 5 m m 24 N.m {2.4 kgl.m, ENGINE STIFFENER 1 0 X 1 . 2 5 m m It4 N'm (4.5 kqf'm,33 lbf'ltl Install the bolts in the cylinder head and attach a Replace.

  • Page 589

    Transmission Assembly Installation Removal(cont'd) Install the transmission assembly in the reverse order of 1 7 . R e m o v e t h e t h r e e u p p e r t r a n s m i s s i o n m o u n t i n g bolts and the lower starter mounting bolt, removal.

  • Page 590

    . Apply grease to the slave cylinder push rod. . Torque the mounting bolt and nuts in the sequence shown. N O T E : U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e 'l.25 mm O 1 2 x 1 .

  • Page 591

    lllustrated lndex Refer to the drawing below for transmission disassembly/reassembly, Clean all the parts thoroughly in solvent and dry with compressed air. luuricate attthe parts with oil before reassembty. NOTE: . This transmission uses no gaskets betvveen the major housings; use liquid gasket (PiN 08718-0001 or08718-0003) (see page 13-41).

  • Page 592

    Torque Value A - 15 N.m (1.5 kgf.m, 1'1 lbf.ft) B - 27 N.m (2.8 kgf.m. 20 lbift) C - 31 N.m {3.2 kgnm, 23 lbift) @ 72 mm THRUST SHIM l*11 O BALL BEARING (*T) @ 3RD//|TH SHIFT FORK 80 mm THRUST SHIM (*21 @ 5TH/REVERSE SHIFT FORK ANGULAR...

  • Page 593

    Transmission Housing Removal NOTE: Place the clutch housing on two pieces of wood Loosen the transmission housing attaching bolts in t h i c k e n o u g h t o k e e p t h e m a i n s h a f t f r o m h i t t i n g t h e a crisscross pattern in several steps, then remove workbench.

  • Page 594

    Reverse Shift Holder Glearance Inspection Measure the clearance between the reverse idler Measure the clearance between the reverse shift fork and sth/reverse shift piece pin. gear and the reverse shift fork. 0.5- 1.1 mm {0.02 - 0.0,1in) 0.05 - 0.35 mm 10.002 - 0.01,1 inl Standard: Standard: Service Limit 0.5 mm (0.02 in)

  • Page 595

    Mainshaft, Cou ntershaft, Reverse ldler Gear Shift Fork Removal Disassembly 1. Remove the reverse shift holder. 1 . R e m o v e t h e i n t e r l o c k g u i d e b o l t f r o m u n d e r t h e clutch housing.

  • Page 596

    Mainshaft Assembly lndex Note the following during reassembly: . The 3rd/4th and sth svnchro hubs are installed with a press . Install the angular ball bearing with the thin-edge outer race facing the sth synchro hub . Install the ball bearing with the ball cage facing up prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces the 3rd/4th and sth svnchro hubs.

  • Page 597

    Mainshaft Assembly Clearance Inspection NOTE: lf replacement is required, always replace the Measure the clearance between 4th gear and the synchro sleeve and hub as a set. spacer collar. 1. Measure the clearance between 2nd and 3rd gears, 0.06 - 0.19 mm 10.002 - 0.007 in) Standard: Service Limit: 0.31 mm 10.012 in) 0.06 - 0.21 mm 10.002 - 0.008 in)

  • Page 598

    Disassembly Remove the ball bearing using a bearing puller as Measure the clearance between the spacer collar and sth gear. shown. BEARING PULLER 0.06 - 0.19 mm 10.002 - 0.007 inl Standard: (Commercially Service Limit: 0.31 mm (0.012 inl availablel 4TH GEAR DIAL INDICATOR...

  • Page 599

    Mainshaft Assembly Disassembly (cont'd) Inspection ' 1 . I n s p e c t Support the 3rd gear on steel blocks, and press the t h e g e a r s u r f a c e a n d b e a r i n g s u r f a c e f o r mainshaft out of the 3rd/4th synchro hub as shown.

  • Page 600

    Reassembly ) r ' synchro hub using the special tools Install the sth CAUTION: When installing the 3rd/4th and 5th synchro ano a press. hubs, support th€ shaft on steel blocks, and insiall the synchro hubs using a press. NOTE: Refer to page 13-15 for reassembly sequence. DRIV€R, 40 mm I O.

  • Page 601

    Countershaft Assembly Index I . r NOTE: The 3rd, 4th, and sth gears are installed with a press. Prior_to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces except the 3rd, 4th, and 5th gears. Snap ring groove faces up.

  • Page 602

    Clearance Inspection Measure the clearance between 2nd and 3rd gears. NOTE: lf replacement is required, always replace the synchro sleeve and hub as a set. 0.04 - 0.12 mm (0.002 - 0.005 in) Standard: Servico Limit: 0.2,1 mm 10.009 in) 1.

  • Page 603

    Countershaft Assembly Disassembly CAUTION: Remove the gears using a press and steel Support 4th gear on steel blocks, and press the coun- blocks as shown. Use of a iaw-type puller can damage tershaft out of 5th and 4th gears as shown. the gear teeth.

  • Page 604

    Reassembly Inspection CAUTION: surfaces lor Inspect the gear surfaces and bearang . Press the 3rd,4th, and sth gears on the countershaft countershaft w e a r a n d d a m a g e , t h e n m e a s u r e t n e without lubrication.

  • Page 605

    Countershaft Assembly Reassembly (cont'd) 4. Suppon the countershaft on a steel block as shown Install the bearings in the direction shown using the and install 3rd gear using the special tools and a sDecialtools and a oress. press. CAUTION: Install ths bearings with a maximum pressure ot 7.8 kN {800 kgt, 5,786 lbfl.

  • Page 606

    Shift Fork AssemblY lndex to any contact parts' erio, ,o reassembling, clean all the parts in solvent, dry them, and apply lubricant 3RD/4TH SHIFT FORK 5THi REVERSE SHIFT FORK 1ST/2ND SHIFT FORK M8S SHIFT PIECE 5TH/REVERSE SHIFT PIECE 3RD/4TH SHIFT PIECE 13-25...

  • Page 607

    Shift Fork Assembly Clearance Inspection NOTE: The synchro sleeve and the synchro hub should Measure the clearance between the shift piece or be replaced as a set. shift fork and the shift arm B. Measure the clearance between each shift fork and 0.2 - 0.5 mm {0.008 - 0.02 in} Standard: its matching synchro sleeve.

  • Page 608

    Synchro Sleeve, Synchro Hub I nspection/l nstallati on MBS Shift Piece InsPection ' 1 . lnspect gear teeth on all synchro hubs and synchro 1. Measure the width of the MBS shift piece. s l e e v e s t o r r o u n d e d o f f c o r n e r s , w h i c h i n d i c a t e 6.9 - 7.1 mm 10 272 - 0.280 inl Standard;...

  • Page 609

    Synchro Ring, Gear Inspection 1. Inspect the synchro ring and gear. SYNCHRO A: Inspect the inside of the synchro ring for wear. B: Inspect the synchro sleeve teeth and matching teeth on the synchro ring for wear (rounded off). SYNCHRO r-\ /-\ oioi *-o* C: Inspect the synchro sleeve teeth and matching...

  • Page 610

    Shift Rod Removal 6. Remove shift arms C and B, and the interlock, then (5/16 in)' NOTE: The steel batlsareall of the same size remove the reverse select spring and retainer' 1. Remove the differential assembly' 7. Remove the shift arm A attaching bolt, the set ball spring bolt, set spring, and steel ball' R e m o v e t h e 2 8 m m p l u g b o l t a n d l s t / 2 n d s e l e c t s p r i n g .

  • Page 611

    Differential Backlash Inspection Place differential assembly on V-blocks, and install both driveshafts. OIAL THRUST SHIM Selective part BALL BEARING Check for wear and damage. DIFFERENTIAL C h e c k l o r c r a c k s . SPEEDOMETER DRIVE GEAR FrNAL DRTvEN...

  • Page 612

    Final Driven Gear RePlacement Bearing RePlacement 1, Remove the bolts in a crisscross pattern in several NOTE: Check bearings for wear and rough rotation lf steps, then remove the final driven gear from the the bearings are OK, removal is not necessary' ditferential carrier' '1.

  • Page 613

    Differential Thrust Shim Adjustment 1. Install the differential assembly, making sure it bot- Install the transmission housing (see page l3-41). toms in the clutch housing, using the special tool as shown. NOTE: Do not apply liquid gasket to the mating sur- face of the clutch housing.

  • Page 614

    80 mm THBUST SHIM: D16Y5. D16Y8 engines lf the clearance is more than the standard, select a new thrust shim from the following table Thickness Part Numbel NOTE: It the clearance measured in step 6 is within 1 . 0 m m ( 0 . 0 3 9 4 i n ) 41441 - PL3 - B00 the standard.

  • Page 615

    Clutch Housing Bearing Replacement Mainshaft Drive the new oil seal into the clutch housing using the specialtools as shown. 1. Remove the ball bearing using the special tool as shown. 3i8 " -16 SLIDE HAMMER (Commercially available) ATTACI{MENT, 42 x 47 mm 07746 -0010300 07749 -0010000 CLUTCH...

  • Page 616

    I n s t a l l t h e o i l g u i d e P l a t e , t h e n d r i v e t h e n e e d l e Cou ntershaft u s i n g t h e s p e c i a l b e a r i n g i n t o t h e c l u t c h h o u s i n g...

  • Page 617

    Mainshaft Thrust Shim Adjustment R e m o v e t h e t h r u s t s h i m a n d o i l g u i d e p l a t e f r o m Select the proper shim on the basis of the following the transmission housing.

  • Page 618

    7, Install the thrust washer and spring washer in the 70 mm THRUST SHIM: Dl6Y5, Dl6Y8 engin€s mainshaft. Thickness Part Number 23931 - PL3 - 800 0.60 mm 10.0236 in) 0.63 mm (0.0284 in) 2 3 9 3 2 - P L 3 - 8 0 0 0.66 mm (0.0260 in) 2 3 9 3 3 - P L 3 - 8 0 0 0.69 mm 10.0272 in)

  • Page 619

    Mainshaft Thrust Shim Adjustment (cont'dl A t t a c h t h e m a i n s h a f t h o l d e r t o t h e m a i n s h a f t a s e.

  • Page 620

    Transmission Reassembly NOTE: The steel balls are all ofthe same size (5/16 in). Insert shift arm shaft in the clutch housing. Install the collar, spring. and steel ball into the case. 1. Install the magnet and reverse lock cam. Compress the ball and insert the shift arm shaft, Set shift arm A on the clutch housing, then install Install shift arm C in shift arm A, then insert the shift the shift rod.

  • Page 621

    Transmission Reassembly lcont'dl 11. Position the 36 mm spring washer and washer onto 15. Install the reverse idler gear and reverse idler gear the mainshaft bearing. shaft. MAINSHAFT/COUNTERSHAFT SHIFT FORK ASSEMELIES REVERSE IDLER GEAR SHAFT Tape the mainshaft splines. Install the mainshaft, countershaft, and shift fork GEAR assemblies.

  • Page 622

    lnstall the dowel pins and the transmission housing. 17. Instali the oil gutter Plate. Lower the transmission housing with the snap ring pliers, and set the snap ring into the groove of the OIL GUTTER PTATE countershaft bearing. NOTE: Check that the snap ring is securely seated in the groove of the countershaft bearing 32 mm SEALING EOLT 25 N.m (2.5 kgf.m, 18lbf.ftl...

  • Page 623

    Transmission Reassembly (cont'd) 23, Tighten the transmission housing aftaching bolts in 2 5 . I n s t a l l t h e b a c k - u p l i g h t s w i t c h a n d t r a n s m i s s i o n t h e n u m b e r e d s e q u e n c e i n s e v e r a l s t e p s s h o w n hanger.

  • Page 624

    Oil Seals Replacement Clutch Housing: Transmission Housing: 1. Remove the oil seal from the clutch housing. 1. Remove the oil seal from the transmission housing. lnstall the oil seal into the ciutch housing using the l n s t a l l t h e o i l s e a l i n t o t h e t r a n s m i s s i o n h o u s i n g specialtools as shown.

  • Page 625

    Gearshift Mechanism Overhaul NOTE: . I n s p e c t r u b b e r p a r t s f o r w e a r a n d d a m a g e w h e n d i s a s s e m b l i n g ; r e p l a c e a n y w o r n o r d a m a g e d p a r t s . .

  • Page 626

    S4C Model ('99 - 00 2-door Si, SiR) Manual Transmission Countershaft Assembly ....' 13-46 Special Tools "..13-71 fndex ....Maintenance 1 3'75 Glearance Inspection'..'...'... 13-47 Transmission Oi1 ....'....13-76 Disassembly Back-up Light Switch .'....13'77 ...""" 13'47 fnspection Repfacement "..13'78 Reassembly Transmission Assembly Synchro Sleeve, Synchro Hub...

  • Page 627

    Special Tools SpecialTools Ref. No. Tool Number D€scription Remark 0 7 G A J - P G 2 0 1 1 0 Mainshaft Holder 13-90 07GAJ - PG20l30 Mainshaft Base 13-90 07JAD - PH80l0'1 Driver Attachment 13-96 07736 - A010004 Adjustable Bearing Puller,25 - 40 mm 13-86, 87 07746 - 0010300...

  • Page 628

    Back-up Light Switch Maintenance Replacement Transmission Oil NOTE: To check the back-up light switch, see section 23. NOTE: Check the oil with the engine OFF. and the vehi- cle on level ground. Disconnect the connector, then remove the back-up light switch connector from the connector clamp. Remove the oil filler plug, then check the level and condition of the oil.

  • Page 629

    Transmission Assembly Removal Bemove the wire harness clamps. Make sure iacks and safoty stands are placad plop- erly (3ee section l). Disconnect the starter motor cables and the vehicle speed sensor (VSS) connector. Apply parking braks and block rear wheels so car will not roll off stands and fall on you while working under il.

  • Page 630

    11. Disconnect the heated oxygen sensor (HO2S) con- 9 . R e m o v e t h e t h r e e u p p e r t r a n s m i s s i o n m o u n t i n g nector, then remove exhaust pip€...

  • Page 631

    Transmission Assembly Removal(cont'd) 14. Remove the driveshafts and the intermediate shaft 17. Remove the front and the rear engine stiffensrs. (see section 16). NOTE: Coat all precision the finished surfaces with clean engine oil or grease. Tie plastic bags over the driveshaft ends, 1 5 .

  • Page 632

    22. Remove the rear mount bracket bolts and the trans- 19. Remove the right front mounvbracket. mission mounting bolts 10 x 1 .25 mm ,14 N.m {4,5 kgf.m, SPECIAL BOLT Replace. 12 x 1.25 mm 1 4 x 1 . 5 m m 5{ N.m 16.5 kgf.m, 47 lbl.ft) 8il N.m (8.5 kgtm, WASHER...

  • Page 633

    Transmission Assembly lnstallation L f ; Install the transmission assembly in the reverse order of Torque the mounting bolt and nuts in the sequence removal. shown. Check that the busings are not twisted or offset. . Before installing, check that the two dowel pins are installed in the clutch housing.

  • Page 634

    . Apply grease to the slave cylinder push rod. N O T E : U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e (P/N 08798 - 9002).

  • Page 635

    lllustrated Index Refer to the drawing below for transmission disassembly/reassembly. Clean all the parts thoroughly in solvent and dry with compressed air. Luoricate att the pans with oil before reassembly. NOTE: . This transmission uses no gaskets between the majorhousings; use liquid gasket (P/N 08718-0001 or08718-0003) (see page '13-93).

  • Page 636

    Torque Value Bolt Size 12 N.m (1.2 kgnm, 8 lbf'ft) 6 x 1 . 0 m m 1 5 N . m ( 1 . 5 k g f ' m , 1 1 l b f f t ) 6 x 1 .

  • Page 637

    Transmission Housing Removal NOTE: Place the clutch housing on two pieces of wood Loosen the transmission housing attaching bolts in t h i c k e n o u g h t o k e e p t h e m a i n s h a f t f r o m h i t t i n g t h e a crisscross pattern in several steps, then remove workbench.

  • Page 638

    Reverse Shift Holder, Reverse ldler Gear Clearance Inspection Measure the clearance between the reverse shift Separate the transmission housing from the clutch holder and the 5th/reverse shift piece pin housing, and wipe it clean of the sealant. Standard: Remove the 72 mm thrust shim and the oil guide Revsrs.

  • Page 639

    Reverse Shift Holder, Reverse ldler Gear Clearance Inspection (cont'dl Removal Measure the clearance between the reverse 1. Remove the reverse shift holder. i d l e r gear and the reverse shift holder. 0.5 - 1.0 mm 10.02 - 0.04 inl Standard: REVERSE SHIFT HOLDEB Service Limit: 1.8 mm (0.07 inl...

  • Page 640

    Change Holder AssemblY Glearance InsPection Measure the clearance between the select arm and 1 . Measure the clearance between the shift piece and the interlock. the shift arm holder. 0.05 - 0.20 10 002 - 0.008 inl 0.1 - 0.3 mm {0.004 - 0.012 in) Standard: Standard: Service Limit:0.45 mm (0.018 inl...

  • Page 641

    Change Holder Assembly Clearance Inspection (cont'd) Measure the clearance between the select arm and 9. Measure the clearance between the shift arm holder t h e 1 0 m m s h i m . and the change piece. Standard: 0.01 - 0.2 mm (0.0004 - 0.008 in) 0.05 - 0.35 (0.fi)2 - 0.014 inl Standard;...

  • Page 642

    Removal Bemove the shift piece shaft. then remove the shift 11. Measure the clearance between the select arm and piece and the interlock. the change Piece. SHIFT PIECE SHAFT 0.05 - O'25 mm 10'002 - 0'010 in) Standard: Servica Limii: 0.5 mm {0.02 in) SELECT ARM INTERLOCK Remove the change holder assembly'...

  • Page 643

    Change Holder Assembly Disassembly/Reassembly P'io' to '"""sembring, crean aI the pans in sorvent, dry them and appry lubricant to any contact surfaces. l0 mm SH|M R€TURN SPRING ,o mm wAsHEF @@d. r ] 7 3 x 16 mm SpRtNG Replace. SELECT ARM 1 3 - 6 2...

  • Page 644

    Mainshaft, Countershaft, Shift Fork Removal Remove the chamber Plate. 1 . Remove the mainshaft and the countershaft assem- blies with the shift forks from the clutch housing. CLUTCH HOUSING NOTE: Tape the mainshaft spline before removing the mainshaft and the countershaft assemblies. Remove the spring washer and the washer' MAINSHAFT COUNTERSHAFT...

  • Page 645

    Shift Rod Removal 1. Remove the shift rod boots. 2 . R e m o v e t h e c h a n g e p i e c e a t t a c h i n g b o l t a n d t h e spring washer.

  • Page 646

    Shift Fork AssemblY lndex pans erior ro reassemblinq. clean all the parts in solvent, dry them and apply lubricant to any contact mm PIN PUNCH sTH/REVERSE SI{IFT FORK 3RD/4TH SHIFT FORK...

  • Page 647

    Shift Fork Assembly Clearance Inspection NOTE: The synchro sleeve and the synchro hub should Measure the clearance between the shift piece and be replaced as a set. the shift fork shafts. 1. Measure the clearance between each shift fork and 0.2 - 0.5 mm (0.008 - 0.02 inl Standard: its matching synchro sleeve.

  • Page 648

    Mainshaft AssemblY lndex Note the follow . The 3rd/4th and the 5th synchro hubs are installed with a press Install the angular ballbearing with the thin-edged cuter race facing the stop rrng' any contact su rfaces The Priorto reassembling. clean all the parts in solvent,drythem, and apply lu brica nt to them' 3rd/4th and the sth synchro hubs, however, should be installed with a press before lubricating ANGULAR BALL BEARING...

  • Page 649

    Mainshaft Assembly Clearance Inspection N O T E : l f r e p l a c e m e n t i s r e q u i r e d , a l w a y s r e D l a c e t h e lf the clearance is more than the service limit, mea- synchro sleeve and the synchro hub as a set.

  • Page 650

    lf distance @ is not within the standard. replace the Measure the clearance between 4th gear and the spacer collar with a new one. lf distance O is within spacer collar. the standard. measure the thickness of 4th gear' 0.06 - 0.21 mm (0.002 - 0.008 inl Standard: 31.12-31'17 mm {1.237 - 1.239 inl Servic€...

  • Page 651

    Mainshaft Assembly Clearance Inspection (cont'dl lf distance (E is not within the standard, replace the Measure the clearance between sth gear and t h e spacer collar with a new one. spacer collar. lf distance @ is within the standard, measure the 0.05 - 0.21 mm (0.002 - 0.008 inl thickness of 5th gear.

  • Page 652

    Disassembly 3 . S u p p o r t 3 r d g e a r o n s t e e l b l o c k s , a n d p r e s s t h e 1.

  • Page 653

    Mainshaft Assembly Inspection 1. Inspect the gear surfaces and the bearing surfaces Inspect for runout. lf the runout is more than the for wear and damage. then measure the mainshaft service limit, replace the mainshaft with a new one, at points A, B, and C. lf any parts of the mainshaft are less than the service limit, reDlace mainshaft Standard: 0.02 mm 10.0008 inl max.

  • Page 654

    Reassembly Install the sth synchro hub using the special tools CAUTION: and a press as snown. . Press the 3rd/4th and the 5th synchro hubs on the mainshaft without lubrication. o When installing the 3rd/,lth and the sth synchro PRESS DRIVER, {0 mm l.O.

  • Page 655

    Gountershaft Assembly Index The 4th and sth gears are installed with a press. NOTE: Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact surfaces. The 4th and 5th gears. however, should be installed with a press before lubricating them. SYNCHRO SPRING LOCKNUT Replace 1 0 8 "...

  • Page 656

    Clearance Inspection 1 . M e a s u r e t h e c l e a r a n c e b e t w e e n t h e 1 s t g e a r a n d M e a s u r e t h e c l e a r a n c e b e t w e e n t h e 2 n d a n d 3 r d gears.

  • Page 657

    Gountershaft Assembly Disassembly 1 . S e c u r e l y c l a m p t h e c o u n t e r s h a f t a s s e m b l v i n a Remove the bearing outer race, then remove the bench vise with wood blocks.

  • Page 658

    Inspection Inspect the gear surfaces and the bearing surfaces Insoect for runout. lf the runout is more than the for wear and damage, then measure the counter- service limit, reolace the countershaft with a new shaft at points A, B, and C. lf any parts of the coun- one.

  • Page 659

    Gountershaft Assembly Reassembly CAUTION: lnstall the reverse gear. . Pross 4th and sth gears on the countershaft without lubrication. I n s t a l l t h e s y n c h r o s p r i n g . a n d t h e d o u b l e c o n e .

  • Page 660

    '1'1. 9 . S u p p o r t t h e c o u n t e r s h a f t o n a s t e e l b l o c k , a n d Install the needle bearing, then install the ball bear- install 4th gear using the special tools and a press.

  • Page 661

    Synchro Sleeve, Synchro Hub Inspection Installation 1 , Inspect gear teeth on all synchro hubs and synchro When assembling the synchro sleeve and synchro hub, b e s u r e t o m a t c h t h e t h r e e s e t s o f l o n g e r t e e t h ( 1 2 0 sleeves for rounded off corners.

  • Page 662

    Synchro Ring, Gear Inspection SYNCHRO SPRING '1. Inspect the synchro ring and gear. A: Inspect the inside of the synchro ring for wear' SYNCHRO RING B: Inspect the synchro sleeve teeth and matching teeth on the synchro ring for wear (rounded off). GOOD WORN C: Inspect the synchro sleeve teeth and matching teeth on the gear for wear (rounded off).

  • Page 663

    Differential Index Backlash Inspection Place the differential assembly on V-blocks and install both axles. M e a s u r e t h e b a c k l a s h o f b o t h p i n i o n g e a r s . l f t h e backlash is not within the standard, replace the dif, ferential carrier.

  • Page 664

    Bearing Replacement Final Driven Gear Replacement '1. Remove the bolts in a crisscross pattern in several NOTE: Check the ball bearings for wear and rough rota- steps, and remove the final driven gear from the dif- tion. lf bearings are OK, removal is not necessary. ferential carrier.

  • Page 665

    Differential Thrust Shim Adjustment 1. Install the differential assembly, making sure it bot Install the transmission housing (see page 13-94). toms in the clutch housing, using the special tool as s h o w n . NOTE: Do not apply liquid gasket to the mating sur- face of the clutch housing.

  • Page 666

    8 . Remove the bolts and transmission housing. lf the clearance is not within the standard, select a new 80 mm shim from the following table. Beplace the 80 mm shim selected in step 7, then Standard: 0 - 0.10 mm (0 - 0.004 inl recheck the clearance.

  • Page 667

    Clutch Housing Bearing Replacement Mainshaft: Drive the new oil seal into the clutch housing using the special tools as shown. Remove the ball bearing using the special tools as shown. 3/81_ 16 SLIDE HAMMER { c o m m e r c i a l l y a v a i l a b l e ) ATTACHMENT, 42 x 47 mm HANOLE 07746 - 0010300...

  • Page 668

    Position the oil guide plate and new needle bearing Countershaft: in the bore of the ctutch housing, then drive in the needle bearing using the special tools as shown 1. Bend the tab on the lock washer down, then remove the bolt and bearing retainer plate.

  • Page 669

    Mainshaft Thrust Clearance Adjustment 1. Remove the 72 mm thrust shim and oil guide plate Measure distance @ between the end of the clutch from the transmission housing. housing and bearing inner race. NOTE; 72 mm THRUST SH|M . Use a straight edge and depth gauge. .

  • Page 670

    7. lnstallthe thrust shim selected and oil guide plate in 72 mm Thrust Shim the transmission housing. Thickness Part Number OIL GUIDE PLATE 72 mm THRUST 23931 - P21 000 0.60 mm {0.0236 in} TRANSMISSION 2 3 9 3 2 - P 2 1 - 0 0 0 0.63 mm 10.0248 in) HOUSING 0.66 mm (0.0260 in)

  • Page 671

    Mainshaft Thrust Clearance Adjustment (cont'd) 13. Check the thrust clearance in the manner described c. Seat the mainshaft fully by tapping its end with a oetow. plastic hammer. CAUTION: Measuremenl should be made at room d. Thread the mainshaft holder bolt in untjl it just tempetature.

  • Page 672

    Transmission ReassemblY 1. Install the new oil seal Set the change Piece. Install the shift rod Install the steel ball' the spring, and the set screw' Install the spring washer and change piece attach- ing bolt. Install the shift rod boots. 8 x 1 .

  • Page 673

    Transmission Reassembly (cont'd) 1 1 . I n s t a l l t h e c h a n g e h o l d e r a s s e m b l y . 13. Measure the distance @ after mounting the shift piece shaft.

  • Page 674

    Install the oil gutter plate. 1 7 . 15. Install the reverse change holder. Bend the hook of the oil gutter plate, then install the 1 8 . 16 mm sealing bolt. - 0001 or NOTE: Apply liquid gasket {P/N 08718 6 x 1 .

  • Page 675

    Transmission Reassembly (cont'dl Install the dowel pins. 23. Check that the snap ring is securely seated in the groove of the countershaft bearing. 2 1 . I n s t a l l t h e t r a n s m i s s i o n h o u s i n g b y a l i g n i n g t h e groove in the housing with the finger on the stop Dimension 6) as instalt6d: 4.6 - 8.3 mm f l n g .

  • Page 676

    l n s t a l l t h e s t e e l b a l l s , t h e s p r i n g s , a n d t h e s e t 25.

  • Page 677

    Oil Seals Replacement Trrn3mirdon Housing: Clutch Housing: 1. Remove the oil seal from the transmission housing. 1. Remove the oil seal from the clutch housing. OIL SEAL Replace. Install the oil seal into the transmission housing Install the oil seal into the clutch housing using the using the sp€cial tools as shown, specialtools as shown.

  • Page 678

    Gearshift Mechanism Overhaul NOTE: reDlace any worn or damaged Parts. . Inspect rubber parts for wear and damage when disassembling; . Install the spring pin and the clip on the change joint as shown' . Turn the shift rod boot so the hole is facing down as shown' Make sure the shift rod boot is installed on the shift rod' I x 1.25 mm 22 N.m 12.2 kgf.m, 16 lbf.ft)

  • Page 679

    Automatic Transmission "'..'.. "...'..' 14-1 Automatic Transmission'..Continuously Variable Transmission 14-193 (Cy1l ..t r o...

  • Page 680

    Automatic Transmission Valve Body ..'."".'-.-.' 14'2 Special Tools ....'..14-139 Repair ....14-3 .,....-..Description power Flow 14"6 Valve ..,....1,1-1i10 Assembly 14-13 Elestronic Control System .....'..'.'.. ATF Pump ..'.." 1'l-19 Hvdraulic Control 1 4 - 1 4 1 .

  • Page 681

    Special Tools l.- a Ref. No. Tool Number 07GAB - PF50101 Mainshaft Holder 1 4 - 1 3 3 , 1 8 0 ,6'\ 07GAE - PG40200 or Clutch Spring Compressor Bolt Assembly 14-160, 163 OTGAE - PG4O2OA 07HAC - PK4010A €) Housing Puller 1 4 - 1 3 5...

  • Page 682

    Description The automatic transmission is a 3-element torque converter and a dual-shaft electronically controlled unit which provides 4 soeeds forward and 1 reverse. Torque Convertel, Geats, and Clutches The torque converter consists of a pump, turbine and stator, assembled in a single unit. They are connected to the engine crankshaft so they turn together as a unit as the engine turns.

  • Page 683

    Description \ - a (cont'dl Gear Selection The shift lever has six positions: E PARK. E REVERSE, N NEUTRAL, E 1st through 4th gear ranges, E 1st through 3rd gear ranges, @ 2nd gear. Position De3cription E PARK Front wheels locked; park pawl engaged with pa* on countershaft. All clutches released. E REVERSE Reverse;...

  • Page 684

    One-way Clulch The one-way clutch is positioned between the countershaft 1st gear and the park gea., with the park gear splined to the counter- shatt, The 1st gear provides the outer race surface, and the park gear provides the inner race surface. The one-way clutch locks up when power is transmitted from the mainshaft 1st gear to thetountershaft 1st gear.

  • Page 685

    Description Power Flow 1ST GEAR 2ND GEAR 3RD GEAR TOROUE REVERSE PARK 3 R D 2 N D \ART CONVERTER GEAR GEAR POSMON\ CLUTCH CLUTCH CLUTCH CLUTCH 1 S T o * , o * 1 o * 1 O * r o + r o * 1 o * 1...

  • Page 686

    lXl Position Hydraulic pressure is not applied to the clutches. Power is not transmifted to the countershaft. E Position Hydraulic pressure is not applied to the clutches. Power is not transmitted to the countershaft. The countershaft is locked by the park pawl interlocking the park gear. TOROUE CONVERTER rST CLUTCH COUNTERSHAFT...

  • Page 687

    Description Power Flow (cont'dl lst Gesr (E or @ position) In lE or E position, the optimum gear is automatically selected from 1st,2nd,3rd and 4th gears, according to conditions such as the balance between throttle opening (engine load) and vehicle speed. 1.

  • Page 688

    2nd Gear {8, E or E position) E Position is provided to drive only 2nd gear. Hydraulic pressure is applied to the 2nd clutch on the mainshaft, and power is transmifted via the 2nd clutch to the mainshaft 2nd gear. Powet transmitted to the mainshaft 2nd gear is conveyed via tho countorshaft 2nd gear, which drivos the counter- shaft.

  • Page 689

    Description Power Flow (cont'dl 3rd Gear (bl or bd positionl 1. Hydraulic pressure is applied to the 3rd clutch. Power from the mainshaft 3rd gear is transmitted to the countershaft 3rd gear. Power is transmitted to the final drive gear, which drives the tinal driven gear. NOTE: Hydraulic pressure is also applied to the 1st clutch, but since the rotation speed of 3rd gear exceeds that of 1st gear, power from lst gear is cut off at the one-way clutch.

  • Page 690

    4th cear lE position) mainshaft 4th 1. Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshaft, causing the gear to rotate. Power is transmitted to the countershaft 4th gear' which drives the countershaft' Power is transmitted to the final drive gear, which drives the final driven gear' gear exceeds that of 1st NOTE: Hvdraulic pressure is also applied to the lst clutch, but since the rotation speed of 4th gear, power from 1st gear is cut off at the one-way clutch...

  • Page 691

    Description Power Flow (cont'd) El Po3ition 1, Hydraulic pressure is switched by the manual valve to the servo valve, which moves the reverse shift fork to the reverse position. The reverse shift fork engages with the reverse selector, reverse selector hub, and the countershaft reverse gear.

  • Page 692

    Electronic Control SYstem (PcM), sensors, a Iinear solenoid and four solenoid The electronac controt system consrsts of a Powertrain control Module The PCM is located valves, shifting and lock-up are electronically controlled for comfortable driving under all conditions below the dashboard, under the front lower panel on the passenger's side PGM-FI Control Sy3tem A/T Control SYstom...

  • Page 693

    Description Electronic Control System (cont'd) Shift Control The PCM instantaneously determines which gear should be selected by various signals sent from sensors, and actuates the shift control solenoid valves A and B to control shifting. Also. a Grade Logic Control System has been adopted to con- trol shifting in E position while the vehicle is ascending or descending a slope, or reducing speed.

  • Page 694

    GRADE LOGIC CONTROL SYSTEM How it works: The pCM compares actual driving conditions with driving conditions memorized in the PCM, based on the input from the vehicle speed sensor, the throttle position sensor, the barometoric pressure sensor, the engine coolant temperature sensor, the brake switch signal, and the shift lever position signal, to control shifting while a vehicle is ascending or descending a slope, or reducing speed.

  • Page 695

    Description Electronic Control System {cont'dl Ascending Control When the PCM determines that the vehicle is climbing a hill in E position, the system oxtends the sngagement area of 2nd gear and 3rd gear to prevent ths transmission from fr€quently shifting between 2nd and 3rd gears, and between 3rd and 4th gears, so the vehicle can run smooth and have more power when needed.

  • Page 696

    Circuit Diagram and Terminal Locations -'96 - 98 Modols IGNITIONSWiTCH IOCI( - UP CONTBOL SOTENOID VALVE A IGPl IGP2 vcc2 LOCK-UPCONTSOT soLtNoto valvE I SIIIFT CONTFOL sHrFrc0mioL SOLENOIDVATVE UI{EAR SOLENOIO 14-17...

  • Page 697

    Description Electronic Control System (cont'dl Circuit Diagram and Terminal Locations -'99 - O0 Models G N T O N S W I C H ,,--b. LOCK.UPCONIFOL SOLEI\Q D VALVE A IGP2 vcc2 LOCK UP CON'IROL S O L E N O D V A L V E B SH FI CONTROL SHIFTCONTFOL SOLENOIDVALVEE...

  • Page 698

    Hydraulic Control electronically controlled solenoids' The hydraulic control system is controlled by the ATF pump, valves, accumulators, and T h e A T F p U m p i s d r i v e n b y s p | | n e s o n t h e e n d o f t h e t o r q u e c o n v e r t e r W h i c h i s a t t a c h e d t o t h e e n g i n e . F | u i d f r o m p u m p f | o w s t h r o u g h t h e r e g u | a t o r v a | v e t o m a j n t a i n s p e c i f i e d p r e s s u r e t h r o u g h t h e m a i n v a | v e b o d y t o t h e m a n u a I v a | d i r e c t i n g p r e s s u r e t o e a c h o f t h e c | u t c h e s .

  • Page 699

    Description Hydraulic Control (cont'dl Msin Valve Body The main valve body houses the manual valve, the 1-2 shift valve, the 2nd orifice control valve, the cpB valve, the modu- lator valve' the servo control valve, and the relief valve. The primary functions of the main valve body are to swatch fluid pressure on and off and to control the hydraulic pressure going to the hydraulic control svstem.

  • Page 700

    Regulator Valve BodY valve body consists of the regulator valve' the The regulator valve body is located on the main valve body. The regulator vaive' torque-converter check valve, the cooler relief valve, and the lock-up control REGULATOR VALVE REGULATOR VALVE BODY CONVERIER COOLER RELIEF VALV€...

  • Page 701

    Description Hydraulic Control (cont'dl Regulator Valve The regulator valve maintains a constant hydraulic pressure from the ATF pump to the hydraulic control system, white also furnishing fluid to the lubricating system and torque converter. The fluid from the ATF pump flows through B and 8,.

  • Page 702

    Servo Body valve which is integrated with The servo body is located on the secondary valve body. The servo body contains the servo the reverse shift fork, and the accumulators 2NO ACCUMULA SERVO BODY 1ST ACCUMULATOR 3RD ACCUMULATOR SERVO VALVE/SHIFT FORK SHAFT '98 models;...

  • Page 703

    Description Hydraulic Flow l r a General Chart ol Hydraulic Pressure pegurator varve -_l- ATF Pump- Line pressure -f- Modurator pressure - Linear sorenoid -Clutch pressure Converter pressure -Torque t-Lubrication Pressure Distribution of Hydraulic Pressur€ Regulator Valve -]- Torque Converter pressure Lubrication pressure To regulate Line pressure Manual valve _...

  • Page 704

    @ Position (ATF) is drawn from (99) and dis- As the engine turns, the ATF pump also starts to operate, Automatic transmission fluid pressure (1). The line pressure (1) is regulated charged into (1). Then, ATF flowing from the ATF pump becomes the line (92) enters (94) of the torque converter through the lock-up by the regulator valve.

  • Page 705

    Description Hydraulic Flow (cont'd) L?j Position The line pressure (1) flows to the manual valve and the modulator valve. The line pressure (1) changes the trne pressure (4) and (25) at the manual valve. and changes to the modulator pressure at the modulator valve.

  • Page 706

    E! or l8! Position lst Gear The flow of fluid through the torque converter circuit is same as in E position, The line pressure tlows to the manual valve and the modulator valve. The line pressure changes to the modulator pr€ssure (6) at the modulator valve and to the line pressure (4) at the manual valve.

  • Page 707

    Description Hydraulic Flow (cont'd) 2nd G.!r As tha speed of the vehicle reaches the prescribed value, shift control solenoid valve A is turned oN by means of the PCM The modulator pressure {64} in the left end of the 1-2 shift valve is r€leased by turning shift controt sotenoid valve A oN The 1-2 shift valve is moved to the left side and uncovers the port to allow line pressure {5) to the z-3...

  • Page 708

    3rd Gear As the soeed of the vehicle reaches the prescribed value, shift control solenoid valve B is turned OFF by means ol the pCM. Shift control solenoid valve A remains ON. The modulator pressure (6) flows to the right end of the 1-2 shift valve and the left end oJ the 2-3 shift valve.

  • Page 709

    Description Hydraulic Flow lcont'dl 4th Goar {E Position} As the speed of the vehicle reaches the prescribed value, shift controlsolenoid valve A is turned OFF bymeans ofthe PCM Shift control solenoid valve B remains oFF. The modulator pressure (6) flows to the left end of the t-2 shift valve and the left end of the 3-4 shift valve.

  • Page 710

    E Position pressure (1) changes to the The flow of fluid through the torque convefter circuit is the same as in E position The line 'l-2 shift valve (3) changes to the line pressure (3') at the line pressure (3) and flows to the l-2 shift valve. The iine pressure (Reverse range position) and uncovers the port to and flows to the servo valve.

  • Page 711

    Description Hydraulic Flow (cont'd) lll Position The flow of fluid through the torque converter circuit is the same as in E position. The line pressure (1) changes to the line pressure (3) and flows to the l-2 shift valve. The line pressure (3) changes to the line pressure (3,) at the 1-2 shift valve and flows to the servo valve.

  • Page 712

    Lock-up System Lock-up Clutch 1. Ooeration (clutch onl with the lock-up clutch on, the fluid in the chamber between the torque converter cover and the lock-up piston is drained off, and the converter fluid exerts pressure through the piston against the torque converter cover, As a result, the conven- er turbine is locked to the convefter cover.

  • Page 713

    Description Lock-up System (cont'd) In B.rl position, in 3rd and 4th, and lDl_- position in 3rd. pressurized fluid is drajned from the back of the torque converter through a fluid passage. causing the lock-up piston to be held against the torque convener cover. As this takes place, the mainshaft rotates at the same speed as the engine crankshaft, Together with the hydraulic c o n t r o l , t h e P C M o p t i m i z e d t h e t i m i n g o f t h e l o c k _ u p...

  • Page 714

    No Lock-up . Lock-up Control Solenoid Valve A: OFF Lock-up Control Solenoid Valve B: OFF Linear Solenoid Pressure: High The pressurized fluid regulated by the modulator works on both ends of the lock-up shift valve. Under this condi- tion, the pressures working on both ends of the lock-up shift valve are equal, the lock-up shift valve is moved to the right side by the tension of the valve spring alone.

  • Page 715

    Description Lock-up System (cont'dl Half Lock-up . Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve 8: Duty Operation OFF - ON Linear Solenoid Pressure: Low The PCM switches the solenoid valve A on to release the modulator pressure in the left cavity of the lock_up shift valve.

  • Page 716

    Full Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: ON o Linear Solenoid Pressure: High W h e n t h e v e h i c l e s p e e d f u r t h e r i n c r e a s e s . t h e l i n e a r s o l e n o i d p r e s s u r e i s i n c r e a s e d t o h i g h i n a c c o r d a n c e with the linear solenoid controlled bv the PCM.

  • Page 717

    Description Lock-up System (cont'dl Deceleration Lock-up Lock-up Control Solenoid Valve A: ON Lock-up Control Solenoid Valve B: Duty Operation OFF - ON a Linear Solenoid Pressure: Low The PCM switches solenoid valve B on and off rapidly u n d e r c e r t a i n c o n d i t i o n s . T h e s l i g h t l o c k - u p a n d h a l f lock-up regions are maintained so as to lock the torque converter properly.

  • Page 718

    Component Locations POWERTRAIN CONTROL MODULE (PCM) TRANSAXLE {A/TI GEAR POSITION SWITCH COUNI€RSHAFT SPEED SENSOR SOI,TNOID VALVE ASSEMBLY SPEED SENSOR SOLENOID VALVE ASSEMBLY 1 + 3 9...

  • Page 719

    PGM Gircuit Diagram (A/T Control System: '96 - 98 Modelsl UNDEfl -HOOD FUSE/RELAY U N D E R D A S H No.41 (80A1 N0.42 l40A) N o . l 3 ( 1 5 A ) FUSE/REIAY 8OX No.47 {7.5 A) /8LU YEUBLK c 1 0...

  • Page 720

    SERVICE CHECK CONNECTOR NCSG ILS - ltc A ltc B ILS + ISH A ISH B Lo-l B RNiBLK MAINSHAFT SPEED SENSOR LOCK -UP CONTROL SHIF'CONTROL SOLENOIO VALVE SOTENOID VALVE ASSEMEI-Y ASSEMELY G 1 0 1 PCM Terminel Locations 14-41...

  • Page 721

    PCM Terminal Voltage/Measuring Gonditions ('96 - 9g Models) A/T Control System The PCM terminal voltage and measuring conditions are shown for the connector terminals that relate to the A"/T control system. The other PCM terminal voltage and measuring conditions are described in section I l. A l32P) Conn€ctot B I25P) Connector C ( 3 1 P ) C o n n g c t o r...

  • Page 722

    PCM CONNECTOR B {25P1 {cont'dl Measuring Conditions/Terminal Vohage Description Terminal Number Signal In 1st gear and 2nd gear in -q1, q11 position, Shift control solenoid valve B 8 1 1 S H B and in E] position: Battery voltage control In 3rd gear and 4th gear in lD.J, [Dr- position: 0 V When ignition switch is ON (ll), brake pedal B't2...

  • Page 723

    PCM Gircuit Diagram (A/T Gontrol System:'99 - 00 Models) UNOEF DASI FL]SE/FELAY ta T06 T Dr. UISEF,DASH FISSIEL YmX r,Jo 25 (7 5A) GAUGE ISSEMBLY Lr GRN -----l LTGRll l"-- eultru ----iF INT€RLOCK erk€Lu CCNTFOL uN|l ert*rll I STARTEF r-->l 14-44...

  • Page 724

    CONNECTOF SPEEO SENSOF 1 r 6 P ) "*ttot **" 1*u) ttt*'" ,5-, fl**',*" SHIFI CONTFOL solEt€to vALvE ASSEMSLY G401...

  • Page 725

    PCM Terminal Voltage/Measuring Conditions ('99 - 00 Models) A/T Control System The PCM terminal voltage and measuring condjtions are shown for the connector terminals that are related to the A//T con- trol system, The other PCM terminal voltage and measuring conditions are described in section ,11. PCM Connoctor Tgrminrl Locations PCM CONNECTOR A {32PI Terminal Numbel...

  • Page 726

    FCM CONNECTOR D {16P) Measuring Conditions/Torminal Vohage Do3cription Signal Terminal Number When lock-up is ON: Battery voltage Lock-up control solenoid valve A With no lock-up: 0 V control In E position, in 1st and 2nd gear in E, E Shift control solenoid valve B S H B position: Battery voltage control...

  • Page 727

    El indicator light or the MIL has been reported on, or lf a driveability problem is suspected, follow this procedure: 1. Connect the OBD ll Scan Tool (conforming to SAE J19781 or Honda PGM Tester to rhe 16p DLC. (See the OBD ll Scan Tool or Honda PGM Tester user's manual for specific instructions.

  • Page 728

    Chocking th€ Diagnostic Trouble Code (DTCI with the Servico Check Conneqtor and Sp€cialTool When the PCM senses an abnormality in the input or output systems, the @ indicator light in the gauge assembly will blink When the Service Check Connector (locat€d under the dash on the passengsr side) is connected with the special tool as shown, the E indicator light will blink the Diagnostic Trouble Code (DTC) when the ignition switch is turned ON (ll).

  • Page 729

    Troubleshooting Procedures (cont'dl Remove the kick panel on the passenger's side {see section 20}. Remove the PCM. and turn the PCM over. Inspect the circuit on the PCM according to the troubleshooting flowchart with the spocial tools and a digital multime- ter as shown.

  • Page 730

    Disconnecting the BACK UP fuse also cancels the radio preset stations and clock setting Make note of presets before removing the luse so you can reset them . in" gCfU memory can also be cleared by using the OBD ll Scan Tool or Honda PGM Tester' Final Procedure NOTE: This procedure must be done after any troubleshooting.

  • Page 731

    E indicator light indicates when the Data Link connector is connected to the Honda PGM Tester. *2: Whenever the Honda PGM Tester or Scan Tool detects an automatic transmission control system DTC, p07OO will set in the PGM-FI control svstem.

  • Page 732

    lf the self-diagnostic l-d indicator light does not blink, perform an inspection according to the table below. Ref. Page Inspection SYmPtom E indicator light does not come on tor two seconds after ignition 11-16 switch is first turned ON {ll}. E indicator light is on constantly (not blinking) whenever the ignition 1 4 - 7 8 switch is ON (ll).

  • Page 733

    E indicator tight indicates when the Data Link connector is connected to the Honda PGM Tester. *2: Whenever the Honda PGM Tester or scan Tool detects an automatic transmission control system DTc, p07oo will be set in the PGM-FI control svstem...

  • Page 734

    lf the self-diagnostic E indicator light does not blink and following symptoms appear, perform an inspection according to the table below. Reference page E i"dl.r." fiSh, 1."""". y{*fu 14- 101 oN (ll). 14-102 lE indicator light does not come on for two seconds after ignition switch is first turned 1 4 - 1 0 4 Shift lever cannot be moved from E position with the brake pedal deprsssed' 1 4 - 5 5...

  • Page 735

    Electrical Troubleshooting (,96 - gg Models) Troubleshooting Flowchart - Lock-up contror sorenoid Varve A NOTE: Record allfreeze data before you troubleshoot. . OBD ll Scrn Toot indicates Code Po$ible Cau3e P1753. . Disconnecled lock-up control . S e l f - d i a g n o s i s @ i n d i c a t o r solenoid valvo A connector light blinks once.

  • Page 736

    From page 14-56 PCM CONNECIOBS Ch6ck Lock-up Control Solenoid Valve A tor a Short Cilcuiti 1. Disconnect the 2P connector lrom the lock-up control sole- noid valve assemblY. 2. Check for continuity between the 85 and Ag or A22 termi- nats.

  • Page 737

    Electrical Troubleshooting ('96 - 9g Modelsl Troubleshooting Ftowchart - Lock-up control sorenoid Varve B NOTE: Record all freeze data before you troubleshoot. . OBD ll Scan Tool indicrtes Code Possible Cause P1758. . Disconnected lock-up control . Self-diagnosis E indicrtor light solenoid valve B connector blinkstwice.

  • Page 738

    From page 14 58 PCM CONNECTORS Check Lock-up Control Solenoid Valve B for a Short Circuh: 1. Disconnect the 2P connector from the lock-uP control sole' noid valve assefibly. 2. Check for continuity between the 84 and A9 or A22 terma- nals, Wire side oI lemale terminals Rgprir 3hort to ground in tho wite...

  • Page 739

    Electrical Troubleshooting ('96 - 9g Models) Troubleshooting Flowchart - A/T Gear position Switch (Shortl NOTE: Record allfreeze data before you troubleshoot. ' OBD ll Scln Toot indic.tes Cod6 Poiriblo Caus6 P1705. . Short in A/T go.. position . Sofidi.gno3b E indicato] tighr awhch wira blinksfivatim...

  • Page 740

    PCM CONNECTORS From page 1 4-60 '96: GRN'97 - 98: PNX Measuro ATP D3 Voltage: 1. Shift to all positions other than 2. Measure the voltage between B (25P1 the 88 and A9 or A22 termi- nals. Wire side ot female terminals C h .

  • Page 741

    Electrical Troubleshooting ('96 - gg Modelsl Troubleshooting Flowchart - A/T Gear position Switch (Open) NOTE: Record all freeze data before you troubleshoot. . OBD ll Scan Tool indicates Code Possible Causo P1706. . Disconnected A/T gear position . Self-di.gnosk E indicator tight switch conn€ctor blinks six timos.

  • Page 742

    From page 14-62 PCM CONNECTORS '95: GRN 37 -'98: PNK Measure ATP 03 Voltagei 1. Shift to E Position. 2. lvteasure the voltage between the 88 and A9 or A22 termi- n a l s . Wire side of female terminals Ropair open in tho wils between the 88 terminal .nd tho A/T goar oosition switch...

  • Page 743

    Electrical Troubleshooting ('96 - 98 Modelsl Troubleshooting Flowchart - Shift Gontrol Solenoid Valve A NOTE: Record all freeze data before you troubleshoot. ' OBD ll Scan Tool indicates Code Po$ible Cau3e P0753. . D i s c o n n e c t e d s h i f t c o n t r o l .

  • Page 744

    From page 14-64 PCM CONNECTORS Check Shift Control Sol.noid v.lve A loi a Short Circuh: '1. Disconnect the 2P connector from the shift control solenoid valve assemblY. 2. Check for continuity between the 83 and Ag or A22 terminals. Wire side o{ female terminals Roprir shon to ground in th.

  • Page 745

    Electrical Troubleshooting ('96 - g8 Modelsl Troubleshooting Flowchart - Shift Control Solenoid Valve B NOTE: Record allfreeze data before you troubleshoot, . OBD ll Scan Tool indic.tes Code Possible Cause P0758. ' Disconnected shift control . Solt-diagnosis E indicator light solenoid valve I connectol blinks eight times.

  • Page 746

    From page 14-66 PCM CONNECTORS C h e c k S h i f t C o n l r o l S o l € n o i d valve B tor a Short Circuit: 1. Disconnect the 2P connector , 2 l l r .

  • Page 747

    Electrical Troubleshooting ('gO - 98 Modelsl Troubleshooting Flowchart - Countershaft Speed Sensor NOTE; Record allfreeze data before you troubleshoot. . OBO ll Scln Tool indicat6 Code Po$iblo Causa m7z). ' Loosg or laulty conncction . S6lt-dirgnosis E indic.tol botwocn tho PCM and c.i hrr- light blink! nin.

  • Page 748

    PCM CONNECTOR 8 I25PI Measure CounteFhaft Sp€€d S6n- sor Resistance: 1 . C o n n e c t t h e c o u n t e r s h a f t speed sensor 2P connector, 2 , M e a s u r e t h e r e s i s t a n c e between the B23 and 822 tel m t n a l s .

  • Page 749

    Electrical Troubleshooting ('96 - 98 Modelsl Troubleshooting Flowchart - Mainshaft Speed Sensor NOTE: Record all freeze data before you troubleshoot. N O T E : C o d e P 0 7 1 5 ( 1 5 ) o n t h e P C M .

  • Page 750

    From page 14-70 PCM CONNECTOR B I25PI Mea3uro Main3haft speed sensor Resistance: 1. Connect the ma;nshaft sPeed sensol 2P connector, r e s i s t a n c e 2 . [ / l e a s u r e t h e between the 815 and 814 ter_ m i n a l s .

  • Page 751

    Electrical Troubleshooting ('96 - 98 Modelsl Troubleshooting Flowchart - Linear Solenoid NOTE: Record all freeze data before vou troubleshoot, OBO ll Scan Tool indicates Code Po$ible Caus6 P176a. . Disconnoctod lineaJ solonoid S e l f - d i a g n o s i 3 E i n d i c a t o r connectot light indicates Code 16,...

  • Page 752

    Ftom page 14-72 PCM CONNECTOR A I32P} Check the G.ound Circuit: Check for continuity between the A9 and A10 terminals. . R a p a i r o p a n i n t h e w i r o botweon th6 tormin.b Ag rnd A10 and G101.

  • Page 753

    Electrical Troubleshooting ('96 - 98 Models) Troubleshooting Flowchart - Lock-up Control System NOTE: Record all freeze data before vou troubleshoot. Possible Cause . OBD ll Sc6n Tool indicatG Code m7{0. Faulty Lock-up cont.ol system . Self-diagnosis E indicator light indicates Code 40. Check tor Another Code: Check whether the OBD ll scan t o o l o r t h e E...

  • Page 754

    Troubleshooting Flowchart - Shift Control System NOTE: Record all freeze data before vou troubleshoot. Possible Cause . OBD ll Scan Tool indicates Code P0730. Faulty shift control system . S e l l - d i a g n o s i s E i n d i c a t o r light indicates Code ill.

  • Page 755

    Electrical Troubleshooting ('96 - 98 Models) Troubleshooting Flowchart - E Indicator Light Does Not Gome On Tha E indicator light does nol come on when the ignition swhch is first turned ON (lll. {lt should come on tol about two s€conds.l Chock the SeJvico Check Connec- tor: Make sure the special tool (SCS...

  • Page 756

    From page 14-76 PCM CONNECTOR A I32PI Measure Powor Supply Cilcuit Voltage: 1. Turn the ignition switch ON (ll). 2. Measure the voltage between t e r m i n a l s A 9 a n d A 1 1 a n d b e t w e e n t e r m i n a l s A 2 2 a n d 424.

  • Page 757

    Electrical Troubleshooting ('96 - 98 Models) Troubleshooting Flowchart - E Indicator Light On Constantly Th6 E indicstor light is on con- st.ntly {not blinkingl whenevei the ignition switch is ON lll). PCM CONNECTOR B (25P) Measure 04 IND Voltage: 1. Turn the ignition switch OFF. 2.

  • Page 758

    Troubleshooting Flowchart - Brake Switch Signal Symptom Shift lever cannol b€ moved f.om B pGition with the brako podrl depr8sed. Check Brako Light Operation: Deoress the brake pedal. Rop.ir faulty braks switch cilcuit Are the brake lights ON? lsos soction 231. PCM CONNECTORS Measure SToP SW Vohag€: 1.

  • Page 759

    Electrical Troubleshooting ('99 - 00 Models) Troubleshooting Flowchart - Lock-up Control Solenoid Valve A NOTE: Record all freeze data before vou troubleshoot. . OBD ll Scan Tool indic.t6 Code Possible Cause P1753. . Disconnocted lock-uD control . S e l f - d i a g n o s i s @ i n d i c a t o r solenoid valve A/B alsembly light blink3 once.

  • Page 760

    PCM CONNECTOR B {25P} From page 14-80 Check lor continuity between the 8 2 0 t e r m i n a l a n d b o d y g r o u n d , I.G1 (BRN/BLKI a n d b e t w e e n t h e B 2 2 t e r m i n a l and body ground.

  • Page 761

    Electrical Troubleshooting ('99 - 00 Models) Troubleshooting Flowchart - Lock-up Control Solenoid Valve B NOTE| Record allfreeze data before you troubleshoot. ' OBD ll Scan Tool indic.tes Code Possibla Cause P1758. . Oisconnected lock-uD control . S e l f - d i a g n o s i s E i n d i c a t o r solenoid velve A/B assembly light blinks twice.

  • Page 762

    PCM CONNECTOR B (25PI From page 14-82 5 1 6 l0 1 1 / Check for continuitY between the 8 2 0 t e r m i n a l a n d b o d y g r o u n d , a n d b e t w e e n t h e 8 2 2 t e r m i n a l (BRN/BLKI LG1 (BRN/BLK)

  • Page 763

    Electrical Troubleshooting ('gg - 00 Models) Troubleshooting Flowchart - A/T Gear position Switch (Short) NOTE: Record all freeze data before you troubleshoot. . OBD ll Scan Tool indicrtB Code Po$ible Cause P1?05. ' S h o r t i n A / T g o . r p o s i t i o n .

  • Page 764

    From page 14-84 PCM CONNECTORS o t16Pl B {25P) Measule ATP NP Voltage: t V - s - 3 1 1 1 5 l 6 8 1 1 1. Shift to all positions other than pl or E. / \ 1 6 9 1 0 t 1 2 2.

  • Page 765

    ElectricalTroubleshooting ('gg - 00 Models) Troubleshooting Flowchart - A/T Gear position Switch (Short) (cont,dl FCM CONNECTORS B {25P) D l16Pl Measule ATP 2 Vohage: 1. Shift to all positions other than 9 1 0 1 / 1 1 3 / 151/)11 7 8 9 t 0 1 ,/ 20...

  • Page 766

    Troubleshooting Flowchart - A/T Gear Position Switch (Open) NOTE: Record allfreeze data before you troubleshoot. Po$ible Cause . OBO ll Scan Tool indicatd Codc . Disconnectod A/T goar position P1706. ' S s l f - d i a g n o s i s E i n d i c a t o r switch conngdor light blink3 six tim6.

  • Page 767

    Electrical Troubleshooting ('gg - 00 Models) Troubleshooting Flowchart - A/T Gear position Switch Open {cont,d) From page 14-87 PCM CONNECTORS B l2sPl D {16P) Moalure ATP 04 Vohago: 1. Shift to pll position. 4 1 5 6 2. Measure the voltage between 9 10 t5l/ 11)./...

  • Page 768

    Troubleshooting Flowchart - Shift Control Solenoid Valve A NOTE: Record allJreeze data before you troubleshoot. Possible Cru3. . OBD ll Scan Tool indic.ts6 Code ' Disconnectod 3hift control Pot53. . Solt-diagno.is E indicrtot light solonoid valva A/B a33emblY blinks seven time6. connactot .

  • Page 769

    Electrical Troubleshooting ('gg - 00 Models) Troubleshooting Flowchart - Shift Control Solenoid Valve A (cont,O) From page 14-89 PCM CONNECTOR B {25P} Check lor continuity between the 820 terminal and body ground, a n d b e t w e e n t h e 8 2 2 t e r m i n a l and body ground.

  • Page 770

    Troubleshooting Flowchart - Shift ControtSolenoid Valve B NOTE: Record all freeze data before you troubleshoot. Possiblg Cause . OBD ll Scan Tool indic.l6 Code . Disconnectgd ihilt control P0758. ' Self-diagnosb El indicator light solenoid valve A/B conneciot r Short or oDen in shift conlrol blinks eighl tim6.

  • Page 771

    Electrical Troubleshoot:ng ('gg - 00 Models) Troubleshooting Flowchart - Shift Control Solenoid Valve B (cont,dl From page'14-91 PCM CONNECTOR A {25PI Check for continuity between the 8 2 0 t e r m i n a l a n d b o d y g r o u n d , a n d b e t w e e n t h e 8 2 2 t e r m i n a l and body ground.

  • Page 772

    Troubleshooting Flowchart - Countershaft Speed Sensor NOTE: Record all freeze data before you troubleshoot Po$iblo Cause . OBD ll Scan Tool indicat6 Code . Loos€ or fsulty conneclion PO720. . Self-diagnosis E indicator light between the PCM and vehicle blinks nin6times. hainoss ' Disconnectod countersh.ft spoed senaof connoctor...

  • Page 773

    Electrical Troubleshooting ('gg - 00 Modelsl Troubleshooting Flowchart - Countershaft Speed Sensor (cont,d) From page 14-93 Measure CounteJahaft Speed PCM CONNECTOR D I16PI Sensor Circuit tor an Open: 1 . C o n n e c t t h e c o u n t e r s h a l t speed sensor connector, 2 .

  • Page 774

    Troubleshooting Flowchart - Mainshaft Speed Sensor NOTE: Record all freeze data before you troubleshoot. NOTE: Code P0715 (15) on the PCM doesn't Possible Causg always mean there's an electrrcal problem in . OBD ll Scan Tool indicates Code the mainshaft or countershaft speed sensor .

  • Page 775

    Electrical Troubleshooting ('gg - 00 Models) Troubleshooting Flowchart - Mainshaft Speed Sensor (cont,dl From page l4-95 PCM CONNECTOR D {16PI M e a s u r e M a i n s h a t t S p e e d Sensor Resistance: 1.

  • Page 776

    Troubleshooting Flowchart - Linear Solenoid NOTE: Record all freeze data before you troubleshoot. Poitibl. Cau3. . OBD ll Scln Tool indic.t.t Codo . Disconnacted linoaJ tolanoid P1768. . Self-diagnosis E indicltol indi- connaclol . Shorl or opon in linolr solonoid cat6 Cods 16.

  • Page 777

    Electrical Troubleshooting ('99 - 00 Modelsl Troubleshooting Flowchart - Linear Solenoid (cont'dl From page 14 97 C h e c k L i n e a . S o l e n o i d t o r a Short Ci.cuit: PCM CONNECTOR A {25PI Check for continuity between the body ground and the 88 terminal...

  • Page 778

    Troubleshooting Flowchart - Lock-up Control System NOTE: Record all freeze data before vou troubleshoot. Possibl€ Cause OBD ll Scan Tool indicates Code m14/J. Faulty Lock-up control sy3tem S€lf-diagnosis .D4l indicalor light indicates Code 40. Check for Another Code: C h e c k w h e t h e r t h e O B D l l s c a n t o o l o r t h e : E i n d i c a t o r l i g h t indicates another code, P e r f o r m t h e T r o u b l e s h o o t i n g...

  • Page 779

    Electrical Troubleshooting ('99 - 00 Modelsl Troubleshooting Flowchart - Shift Control System NOTE: Record allfreeze data before you troubleshoot. . OBD ll Scan Tool indicrtd Code Po33ibl. Crus6 m730. Frulty 3hift control ryrtom . S e l f - d i r g n o s i s E i n d i c a t o r light indicst€.

  • Page 780

    Troubleshooting Flowchart - El Indicator Light On Constantly The Dll indicator lighi is on con- stantly {not blinking) whenever the ignition switch is ON (lll. PCM CONNECTOR A I32P) Moasure D4 IND Voltage: 1. Turn the ignition switch OFF. 2 . D i s c o n n e c t t h e A { 3 2 P } c o n - nector from the PCM.

  • Page 781

    Electrical Troubleshooting ('99 - 00 Models) Troubleshooting Flowchart - E Indicator Light Does Not Come On The Pll indicator light does not c o m e o n w h e n t h e i g n i t i o n switch is fi.st turned ON (ll).

  • Page 782

    From page 14-102 PCM CONNECTORS Measu.e D4 IND Voltago: 1. Turn the ignition switch OFF. 2. Connect the B (2SPiconnector to the PCM. 3. Connect a digital multimeter to the A14 and 820 or 822 ter- 4. Turn the ignition switch ON (ll), and make sure that voltage is Wire side ol female terminals available for two seconds.

  • Page 783

    ElectricalTroubleshooting ('99 - 00 Modelsl Troubleshooting Flowchart - Brake Switch Signal Shift lever cannot be moved trom E position with tho b.ake pedal depressod. Check Brake Light Operation: Depress the brake pedal. Repair t ulty brake switch circuit Are the brake llghts ON? {see s€ction 23}.

  • Page 784

    Lock-up Gontrol Solenoid Valve A/B Assembly Replacement Test '1, Disconnect the 2P connector from the NOTE: Lock-up control solenoid valves A and I must bs tocK-up con- removed/replaced as an assembly. trol solenoid valve 1y'8 assembly. 1 . R e m o v e t h e m o u n t i n g b o l t s a n d l o c k - u p c o n t r o l TERMINAL SIOE OF solenoid valve Ay'B assemblv.

  • Page 785

    Shift Control Solenoid Valve A/B Assembly Test Replacement 1. Disconnect the 2P connector from the shift control NOTE: Shift control solenoid valves A and B must be solenoid valve A,/B assemblv. removed/replaced as an assembly. 1. Remove the mounting bolts and shift control solenoid valve A,/B assembly.

  • Page 786

    Linear Solenoid Assembly Test lf not, remove the linear solenoid assembly. 1. Disconnect the linear solenoid connector. Check that the linear solenoid fluid passage Ior dust or dirt. C o n n e c t t h e N o . 2 t e r m i n a l o f t h e l i n e a r s o l e n o i d LINEAR SOLENOID connector to the battery positive terminal and con- nect the No, 1 terminal to the battery negative terma-...

  • Page 787

    Mai nshaft/Cou ntershaft Linear Solenoid Assembly Speed Sensors Replacement Replacement 1. Remove the mounting bolts and the linear solenoid Remove the 6 mm bolt and the countershaft speed assemory. sensor from the right side cover. Clean the mounting surface 1 . 0 m m and flu id passages.

  • Page 788

    Symptom-to-Component Chart Hydraulic System C h e c k l h e s e l e m s o n C h e c k t h e s e i t e m s o n t h e SYMPTOM t h e N O T E S L I s t P R O B A B L E C A U S E L i s t...

  • Page 790

    Check these items,on th€^ ltems on the The following symptoms can be caused PROBABLE CAUSE DUE TO NOTES List by improper repair or assembly IMPROPER REPAIR List R 1 , R 2 Vehicle creeps in N position. Vehicle does not move in &l or Pll position. R 3 , R 1 1 Transmission locks up in E position.

  • Page 791

    Symptom-to-Component Chart Hydraulic System (cont'dl See flushing procedure, page 14-187 and 188. set idle rpm in gear to specified idle speed. lf still no good, adjust motor mounts as outlined in engine section of this manual. lf the large clutch piston O-ring is broken, inspect the piston groove for rough machining. lf the clutch pack is seized or is excessively worn.

  • Page 792

    Road Test NOTE: Warm up the engine to normal operating tem peratu re (the rad iator fan comes on )' 1. Apply parking brake and block the wheels. Start the engine, then shift to E position while depressing the brake Dedal, Depress the accelerator pedal and release it suddenly.

  • Page 793

    Road Test (cont'dl .91 Position: Dl6Y7 engine . Upshift lst + znd Throttle Opening Unit of speed 2nd * 3rd 3rd t 4th Lock-up ON 2 0 - 2 3 2 1 - 2 4 Throttle position sensor m p h 9 - 1 2 2 8 - 3 2 voltage: 0.75 V...

  • Page 794

    then shift from Dl position to Z position The Accelerate to about 35 mph (57 km/h) so the transmlssion is in 4th, vehicle should immediately begin slowing down from engine braking' -Dd position to damage E position at speeds ov6r 63 mph {100 km/hl; You mav CAUTION: Do not shift from -91 or the transmission.

  • Page 795

    Stall Speed Test CAUTION: . To prev€nt transmission damage, do not t6st stall speed for more than ro sgconds at a time. . Do not shift the levor while raising the engine speed. . Bo sule lo remove the pressure gauge betoro testing stall speed. Engage the parking brake, and block the front wheels.

  • Page 796

    Always use Genuine Honda Premium Formula Automatic Transmission Fluid (ATF).

  • Page 797

    . A l w a y s u s e G e n u i n e H o n d a p r e m i u m Formula Automatic Transmission Fluid (ATF). Using a non-Honda ATF can aftect shift quality. Automatic Transmission Fluid Capacity: 2.7 | |'2.9 US ql,2.a lmp qtl at Ghlnging...

  • Page 798

    Pressure Testing While testing, be caroful of th€ rotating front wheels. . Make sure lifts, iacks, and satoty stands are placod properly (see section 1)' CAUTION: . Beforo iesting, be sure the transmission fluid is tilled to tho proper level' .

  • Page 799

    Pressure Testing (cont'd) Line Pressure/1st Clutch Pressurc Measurement 1. Set the parking brake, and btock both rear wheels securely. Start the engine, and run it at 2,OOO rpm. Shift to N or E position, then measure line pressure. NoTE: Higher pressure may be indicated if measurements are made in shift lever positions other than @ or @ posi tron.

  • Page 800

    2nd, 3rd and 4th Clutch Pressure Measurement 1. Set the parking brake, and block both rear wheels securely' 2. Start the engine, and run it the engine at 2,000 rpm' pressure 3. Shift to E position, then measure 2nd clutch pressure 4.

  • Page 801

    Transmission Removal Remove the transmission ground cable, and discon_ Maks sure lifts, iacks and safety stands are placed nect the lock-up control solenoid connector. properly, and hoist bracket ate aftached to the cor_ rec{ position on the engine lsee section 1). Apply parking brake and block rear whoels so vehicle will not roll off stands and fall on you while working under it.

  • Page 802

    R e m o v e t h e d r a i n p l u g , a n d d r a i n t h e a u t o m a t i c Remove the transmission housing mounting bolts t r a n s m i s s i o n f l u i d ( A T F ) .

  • Page 803

    Transmission Removal(cont'd) '10. Remove the cotter pins and castle nuts, th€n separate 16. Remove the shift cable cover. then remove the shift the balljoints from the lower arms (see section 1gl. cable by removing the control lever, DAMPER PINCH BOLT CAUTION: Take car6 not to bond the shift cable.

  • Page 804

    23. Place a jack under the transmission. and ra6a :'. 19. Remove the engine stiffener and the torque con- transmission iust enough to take weight otf ol tF. verter cover. mounts. then remove the transmission mounl TRANSMISSION MOUNT BRACKET COVER Remove the eight drive plate bolts one at a tlme while rotating the crankshaft pulley.

  • Page 805

    lllustrated Index Transmission/End Cover a-'tEO 14-126...

  • Page 806

    @) END COVER O ROLLER @ lsT CLUTCH FEED PIPE O COLLAR @ O-RINGS Replace. O o-RING Replace. @ FEED PIPE FLANGE @ FEED PIPE FLANGE C) SNAP BING @ O-RING Replace. @ MAINSHAFT LOCKNUT (FLANGE NUTI 21 x 1 25 mm @ SNAP RING Replace.

  • Page 807

    lllustrated Index Transmission Housing :!_.. 14-128...

  • Page 808

    @ THRUST NEEDLE BEARING O LocK WASHER Replace, @ MAINSHAFI O REVERSE SHIFT FORK @ S€ALING RINGS, 35 mm REVERSE GEAR COLLAR O COUNTERSHAFT @ SEALING RING,29 mm REVERSE GEAR G) COUNTERSHAFT @} NEEDIE BEARING @ NEEDLE BEARING @ SET RING @ REVERSE SELECTOR @ sHrFT CONTROL SOLENOID VALVE A/B ASSEMSLY O REVERSE SELECTOR HUB...

  • Page 809

    lllustrated lndex Torque Converter Housing/Valve Body 14-130...

  • Page 810

    @ MAIN SEPARATOR PLATE O ATF FEED PIPE @ SUCTION PIPE COLLAR O ATF STRAINER @ ATF MAGNET O SERVO BODY '99 - 00 models servo body has integrally molded @ COUNTERSHAFT TOROUE CONVERTER HOUSING BEARING servo detent. @ ATF GUIDE PLATE @ SERVO SEPARATOR PLATE @ ToRoUE CONVERTER HOUSING (' SECONDARY VALVE BODY...

  • Page 811

    End Cover Removal NOTE: . Cleanall parts thoroughly in solvent or carburetor cleaner, and drywith compressed air, . Blow out all passages, . When removing the right side cover, replace the following: O-rings Mainshaft and countershaft locknuts Conical spring washgrs End cover gasket Lock washer - Sealing washers...

  • Page 812

    Remove the special tool from the mainshaft after Remove the 13 bolts securing the end cover, then removing the locknuts. remove the cover. Remove the 1st clutch and mainshaft 1st gear assem Slip the special tool onto the mainshaft as shown. bly and mainshaft 1st gear collar from the mainshaft.

  • Page 813

    Transmission Housing Removal TRANSMISSION HOUSING MOUNTING BOLTS 1 8 B o l t s TRANSMISSION HANGER TRANSMISSION HOUSING MAINSHAFT SUB.ASSEMBLY MAINSHAFT SENSOR WASHER lD16Y7 engine) SUB.ASSEMBLY MAINSHAFT SPEED SENSOR TRANSMISSION DIFFEBENTIAL HOUSING GASKET ASSEMBLY TOROUE CONVERTER HOUSING 14-134...

  • Page 815

    Torque Converter Housing/Valve Body Removal ATF FEEO PIP€ LOCK-UP VALVE BODY 6 x 1 . 0 m m SERVO DETENT STRAINER LOCK-UP SEPARATOR BASE PLATE ATF FEED REGULATOR PIPES VALVE SODY CONTROL DOWEL PIN SHAFT DETENT COOLER RELIEF VAL ARM SHAFT DETENT SERVO EODY SEPARATON...

  • Page 816

    1 3 . C I e a n t h e i n l e t o p e n i n g o f t h e A T F s t r a i n e r t h o r - NOTE;...

  • Page 817

    Valve Caps Description C a p s w i t h o n e p r o j e c t e d t i p a n d o n e f l a t e n d a r e Caps with hollow ends are installed with the hollow installed with the flat end toward the inside of the end away from the inside ofthe valve body.

  • Page 818

    Valve Body Repair Remove the #600 paper and thoroughly wash the NOTE: This repair is only necessary if one or more of entire valve body in solvent. then dry it with com- the valves in a valve body do not slide smoothly in their pressed air.

  • Page 819

    Valve Assembly NOTE: . Set the spring in the valve and install it in the valve Coat all parts with ATF before assembly. body. Push the spring in with a screwdriver, then install the spring seat. Install the valve, valve spring and cap in the valve body and secure with the roller.

  • Page 820

    ATF Pump Inspection Measure the side clearance of the ATF pump drave 1. Install the ATF pump gears and ATF pump driven and driven gears. gear shaft in the main valve body ATF Pump Gears Side {Radial) Clearance: NOTE: Standard (New): Lubricate all parts with ATF during inspection.

  • Page 821

    Main Valve Body Disassembly/lnspection/Reassembly NOTE: . Cleanall parts thoroughly in solvent or carburetor cleaner, and drywith compressed air. Blowoutall passages. Replace the valve body as an assembly if any pans are worn or damaged. . Check all valves for free movement. lf anyfail toslidefreely, see Valve Body Repairon page,l4-139. .

  • Page 822

    CHECK BALL CHECK BALLS CHECK BALLS MAIN VALVE BODY (Sectional viewl SPRING SPECIFICATIONS U n i t : m m ( i n ) Standard (New) Springs o.D. Free Length No. ot Coils Wire Dia. 8.6 (0.342) 3 7 . 1 ( 1 . 4 6 1 ) 1 .

  • Page 823

    Secondary Valve Body Disassembly/lnspection/Reassembly NOTE: . Cleanall parts thoroughly in solvent or carburetor cleaner. and drywith compressed air, Blowoutall passages. Replace the secondary valve body kit. P/N 27700 - P4R - 315 (The secondary valve body kit includes the linear solenoid assembly) if any parts are worn or damaged.

  • Page 824

    Regulator Valve Body Disassembly/lnspection/Reassembly NOTE: . cleanall parts thoroughly in solvent or carburetor cleaner, and drywith compressed air. Blowoutall passages Replace the valve body as an assembly if any parts are worn or damaged. . check allvalves for free movement. lf anyfail toslidetreely, see valve Body Repairon page 1+139. 1.

  • Page 825

    Servo Body Disassembly/lnspection/Reassembly NOTEI . clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. . Replace the valve body as an assembly if any parts are worn or damaged. . Coat all parts with ATF during assembly. .

  • Page 826

    Lock-up Valve BodY Disassembly/lnspection/Reassembly NOTE: with compressed air' Blow out all passages' . Clean all pans thoroughly in solvent or carburetor cleaner' and dry a Replace the valve body as an assembly if any parts are worn or d€maged' Valve Body Repairon page 14-'139' .

  • Page 827

    Mainshaft Disassembly/lnspestion/Reassembly NOTE: Lubricate all parts with ATF during reassembly. . I n s p e c t t h e t h r u s t n e e d l e b e a r i n g s a n d t h e n e e d l e b e a r i n g s f o r g a l l i n g a n d r o u g h m o v e m e n t , Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O_rings.

  • Page 828

    Inspection 3. Torque the mainshaft locknut to 29 N'm (3.0 kgf'm, a Clearance Measurement 22 tbt,ftl. NOTE: Lubricate all parts with ATF during assembly. NOTE: Mainshaft locknut has left-hand threads. 1, Remove the mainshaft bearing from the transmis- sion housing (see Page 14-1741. Assemble ths parts below on the mainshaft.

  • Page 829

    Mainshaft Inspection (cont'd) 5 . l f t h e c l e a r a n c e i s o u t o f t o l e r a n c e , r e m o v e t h e thrust washer and measure the thickness.

  • Page 830

    Countershaft Disassembly/lnspection/Reassembly NOTE: . Lubricate all parts with ATF before reassembly' galling and rough movement' tnrp"",,n",t -"t needle bearings and the needle bearings for prevent damaging the O-rings . Before installing the O-rings. wrap the shaft splines with tape to .

  • Page 831

    Countershaft Disassembly/Reassembly 1. Using a hydraulic press, press out the countershaft Assemble the parts on the countershaft as shown while supporting 4th gear. oetow. NOTE: Place an attachment between the press and NOTE; the countershaft to prevent damage to the shaft. .

  • Page 832

    Inspection r Clearance Measurement Install the reverse selector hub on the countershaft sub-assembly, and then press the reverse selector NOTE; Lubricate all parts with ATF during assembly hub using the special tool and a press as shown' 1. Remove the countershaft bearing from the trans- mission housing (see page l4-174) Installthe parts below on the countershaft using lhe special tool and a press as described on this page...

  • Page 833

    Gountershaft Inspection (cont'dl I n s t a l l t h e p a r t s b e l o w o n t h e c o u n t e r s h a f t s u b - Measure the clearance between the 2nd gear and a s s e m b t y , t h e n t o r q u e t h e l o c k n u t t o 2 9 N .

  • Page 834

    One-way Clutch Disassembly/lnspection/Reassembly Inspect the parts as followsl 1. Separate countershaft 1st gear from the park gear by turning the park gear in the direction shown PARK GEAR Inspecl the park gear for wear and scorrng. COUNTERSHAFT lST GEAR ONE-WAY CLUTCH Inspect the one-way clutch for damage and laulty movement.

  • Page 835

    Clutch lllustrated Index (A4RA, B4RA Transmission) 3RD CLUTCH CLUTCH O-RINGS DRUM Beplace. CLUTCH ptSTON CLUTCH END PLATE SNAP RING lST CLUTCH CLUTCH END SNAP RING SPRING RETAINER RETUNN SPRING CLUTCH DRUM CLUTCH PLATES Standard thickness: 1.6 mm (0.063 in) CHECK VALV€ 14-156...

  • Page 836

    2NDi4TH CLUTCH SNAP RING CLUTCH PISTON DISC SPRING SNAP RING SPRING RETAINER RETURN SPRING CHECK VALVE O.RINGS 4TH CLUTCH DRUM Replace. CLUTCH PLATES Standardthickness: O-RINGS 2.0 mm {0.079 in) Replace. SNAP RING 14-157...

  • Page 837

    Clutch lllustrated Index (M4RA Transmission) 3RD CLUTCH CLUTCH DRUM CLUTCH PISTON DISC SPRING CLUTCII END rST CLUTCH CLUTCH E D SI{AP RIiIG CLUTCH PLATES Standard thickness: 1.6 mm (0.063 in) CHECK VALVE 1 4 - 1 5 8...

  • Page 838

    SNAP RING 2ND/4TH CLUTCH CLUTCH PISTON VALVE 2.0 mm (0.079 in) 2ND CLUTCH DRUM CLUTCH PISTON RETURN SPRING RETURN SPRING \ l - . SNAP RING 1 4 - 1 5 9...

  • Page 839

    Clutch Disassembly 1 . Remove the snap ring. then remove the clutch end Installthe special tools as shown. plate, clutch discs and plates. CLUTCH SPRING COMPRESSOR SCREWDRIVER ATTACHMENT 07LAE -PX40,t 00 SNAP RING CLUTCH SPRING COMPRESSOR ATTACHMENT Remove the disc spring. 07LAE - PX()100 07HAE - P150100 NOTE: Except 2nd clutch.

  • Page 840

    Remove the snap ring. Then remove the special tools, CAUTION: lf eithd end of the 3pocial tool issotoveran spring retainer and return spring. area ot the spring rstainer which is unsupport€d by tho return spring, tho r€tain€l may be damagod. Bo eure the special tool is adiusted to have full contact with tha spring retainor.

  • Page 841

    Clutch Reassembly NOTE: Install the piston in the clutch drum, Apply pressure . C l e a n a l l p a r t s t h o r o u g h l y i n s o l v e n t o r c a r b u r e t o r and rotate to ensure proper seating, cleaner, and dry them with compressed air.

  • Page 842

    CAUTION: lf eithe. end of the sDecial tool is set Install the special tools as shown. over an area of the spring retainer which is unsup- ported by the rsturn spring, the ietainer may be CLUTCH SPRING damaged. Bs sure the special tool is adjusted to COMPRESSOR ATTACHMENT have full contact with the spring retainer.

  • Page 843

    Glutch Reassembly (cont'd) I n s t a l l t h e s n a p r i n g . 1 0 . Soak the clutch discs thoroughly in ATF for a mini- mum of 30 minutes. Starting with a clutch plate, alternately install the l l .

  • Page 844

    CLUTCH END PLATE 13. Measure the clearance between the clutch end plate and top disc with a dial indicator' Zero the dial indi- A4RA, g4RA Transmission: cator with the clutch end plate lowered and lift it up to the snap ring. The distance that the clutch end Thickness Part Number plate moves is the clearance between the clutch end...

  • Page 845

    Differential lllustrated lndex SET RING, 80 mrrt BOLT 1 0 r 1 . 0 m m '10'l N'm (10.3 k91.m,74.5 lbf.ftl efef Left-hand threads FINAL DRIVEN GEAR Inspect tor excessive wear. Install in this direction. BALL BEARING Inspect for faulty movement. DIFFERENTIAL CARRIER Insoect for cracks, R O L L E R , 5 x 1 0 m m...

  • Page 846

    Bearing Replacement Backlash lnspection NOTE: Check bearings for wear and rough rotation. lf 1. Place differential assembly on V-blocks and install bearings are OK, removal is not necessary. both axles. 1, Remove bearings using a bearing puller. BEARING PULLER (Commerci6lly available) Check backlash of both pinion gears Standard {Now): 0.05 - 0.15 mm {0.002 - 0.006 in) lf backlash is out of tolerance, replace the differen-...

  • Page 847

    Differential Diff erential Carrier Replacement Remove the final driven gear from the differential 5. Align the hooked end of the snap ring with the pin- carrier. ion shaft as shown, then install the snap ring in the differential carrier groovs. NOTE: The final driven gear bolts have left-hand SNAP RING threads.

  • Page 848

    Oil Seal Installation/Side Glearance OilSealRemoval 1. Install a 2.50 mm (0.098 in) set ring,80 mm in trans- Remov€ the differential assembly. mission housing. Remove the oil seal from the transmission housing, NOTE: Do not install the oil seal vet. RING, 80 mm TRAITISMISSlON HOUS|l{G OIL SEAL...

  • Page 849

    Differential Oil Seal Installation/Side Clearance (cont'd) 4. Tap on the transmission housing side of the differ- N4easure the clearance between the 80 mm set ring ential assembly with the special tool to seat the dif- and outer race of the ball bearino in the transmis- ferential assembly in the torque converter housing.

  • Page 850

    9. lnstall the new oil seal flush with the transmission housjng using the special tools as shown DRIVER 077i(} - 0010000 DRIVER ATTACHMENT, 68 mm PILOT. 079i17-6110501 2 6 x 3 0 m m 07JAO - PH80200 10. lnstall the new oil seal flush with the torque con- verter housing using the specialtools as shown DRIVER 07749 - 0010000...

  • Page 851

    Torque Converter Housing Bearings Mainshaft Bearing/Oil Seal Replacement Remove the mainshaft bearing and oil seal using Drive in the new mainshaft bearing until it bottoms the special tools as shown. in the housing using the special tools as shown. DRIVER 3/8"16 SLIOE HAMMER 077€...

  • Page 852

    Countershaft Bearing Replacement '1. Remove the countershaft bearing using the special tools as snown. 3,/8'.16 SLIDE HAMMER {Commerciallv available) AOJUSTABLE BEARING PULLER, 2 5 - { O m m 07736 - A0'1000A Install the ATF guide plate. Drive the new bearing into the housing using the special tools as shown.

  • Page 853

    Transmission Housing Bearings Mainshaft/Countershaft Bearings Replacement To remove the mainshaft and countershaft bearings Expand each snap ring with snap ring pliers, insert from the transmission housing, expand each snap t h e n e w b e a r i n g p a r t - w a y i n t o t h e h o u s i n g u s i n g ring with snap ring pliers, then push the bearing out the special tools and a press as shown, Install the using the special tools and a press as shown.

  • Page 854

    Park Stop Reverse ldler Gear Inspection/Adiustment lnstallation ' 1 . Set the park lever in the E position. 1, lnstall the reverse idler gear. Measure the distance between the park pawl shaft and the park lever roller pin as ahown. STANDARD: 72.9 - 73.9 mm 12.87 - 2.91 inl Measuring Install the reverse idler gear shaft holder and needle...

  • Page 855

    Transmission Reasembly NOTE; . Coat all parts with ATF. . Beplace the following parts: - O-rings Lock washers Gaskets Mainshaft and countershaft locknuts and conical spring washers Sealing washers TOROUE: l2 N.m (1.2 ksf'm,8.7 lbf.ft) 6 x 'l.0 mm 7 Bolts FEED PIPE: A LOCK.UP VALVE DOWEL PINS.

  • Page 856

    Install the servo body and separator plate on the 1 . Install the ATF magnet and suction pipe collar in the secondary valve body ('95 - 98 models: seven bolts. torque converter housing. if necessary. '99 - 00 models: eight boltsl. lnstall the main seDarator plate and the two dowel pins on the torque converter housang.

  • Page 857

    Transmission Reassembly (cont'd) TRANSMISSION HOUSING TRANSMISSION MOUNTING BOLTS HANGER 10 x 1.25 mm 4{ N.m {4.5 kg{.m,33 lbI.ft) Ufln TRANSMISSION HOUSING REVERSE GEAR $*U ./ COLLAR MAINSHAFT SUB.ASSEMBLY REVERSE GEAR _\,]ffil LOCK WASHER SHIFT FORK MAINSHAFT SPEED COUNTERSHAFT SENSOR WASHER SUB.ASSEMBLY (D16Y7 engine) MAINSHAFT...

  • Page 858

    lnstall the needle bearing, countershaft reverse gear l n s t a l l t h e r e v e r s e i d l e r g e a r a n d t h e g e a r s h a f t 2 1 .

  • Page 859

    Transmission Reassembly (cont'dl 26. Slip the special tool onto the mainshaft as shown, 3 1 . I n s t a l l t h e m a i n s h a f t 1 s t g e a r c o l l a r o n t h e m a i n _ shaft.

  • Page 860

    40. Instsllthe end cover with two dowel pinsandanew 36. Remove the special tool from mainshaft, then stake gasket (thirteen bolts)' each locknut using a 3.5 mm punch as shown' TOROUE: 12 N'm (1.2 tgf'm. 8.7 lbf'ft} COUNTERSHAFT LOCKNUT 0.7 - 1.2 mm (0.03 - 0.05 in) END COVER Set the park lever in the El position, then verify that...

  • Page 861

    Torque Converter/Drive plate 6 x 1 . 0 m m 12 N.m (1.2 kgt.m, 8.7 lbf.ft) 74 N.m 17.5 kgl.m, 54 lbf.ftl Torque in a ctisscaoss oattern. E PLATE 14-182...

  • Page 862

    Transmission lnstallation Install the transmission mount bracket. Flush the ATF cooler as described on page l4-187 and 14-188. 12 x 1.25 mm Install the torque converter assembly securely with 6il N.m {6.5 kgf.m, a7 lbf'ft) a new O-ring on the mainshaft 45 N.m {4.5 kgf.m, STARTER MOTOR 14 mm DOWEL PIN...

  • Page 863

    Transmission Installation (cont'dl 9. Attach the torque converter to the drive plate with 14. Install the control lever with a new lock washer to eight drive plate bolts and torque as follows: the control shaft, then install the shift cable cover. Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque.

  • Page 864

    20. Connect the mainshaft speed sensor, the linear sole- 16. Install a new set ring on the end of each driveshaft' noid and the shift control solenoid connectors. 17. Installthe right and left driveshafts (see ssction 16) CAUTION: Whil6 installing the driveshafE in the diffarential, be surs not lo allow du3t and othor for- SHIFT CONTROL SOLENOIO LINEAR SOITNO|o...

  • Page 865

    Transmission Installation {cont'd) Connect the lock-up control solenoid connector. and 24. Installthe intake air duct. install the transmission ground cable. D16Y7 engine: Install the intake air duct and the resonaror. 6 x '1.0 mm 12 N.m {1.2 kgf.m, 8.7 lbl.ft} D16Y8 engine: lnstall the intake air duct and the air cleaner hous_ ang assembly.

  • Page 866

    Cooler Flushing 7. With the water and air valves off, attach the water and To prevent iniury to. face and eyas, always !!!@ air suDolies to the flusher' lHot water if available.) -ea. safetv glasses ot a face shield when using the transmission flusher.

  • Page 867

    Transmission Cooler Flushing (cont'dl 1 7 . Make sure the transmission is in the E position. TOOL MAINTENANCE Fill the transmission with ATF, and run the engine for 30 seconds or until approximately 0.95 f (1.0 US Empty and rinse after each use. Fill the can with water qt.,0.8 lmp qt.) is discharged.

  • Page 868

    Shift Cable Removal/lnstallation Remove the shift cable holder. Make sure lifts are placed properly (see seqtion 1). Bemove the shift cable cover. 1. Remove the front console (see section 20). Remove the control Iever from the control shaft, then remove the shift cable. Take care not to bend Shift to E position, then remove the lock pin Jrom the cable when removing/installing it the adjuster.

  • Page 869

    Shift Cable Adjustment Make sure lifts are ptaced properly (see 3 . C h e c k t h a t t h e h o l e i n t h e a d j u s t e r i s p e r f e c t l y section 1).

  • Page 870

    Shift Lever PUSH KNOB SPRING SCBEW N.m {0.3 kgtm.2 lbf ft) Apply non-hardening thread lock sealant SCREW 3 N.m {0.3 kgif m,2 lblft) SILICONE GREASE GEAR POSITION INDICATOR PANEL COVER BUSHING SHIFT INDICATOR SILICONE GREASE LEVER SHIFT LOCK SCREW SHIFT LEVER ASSEMBLY 3 N.m {0.3 2/""*"...

  • Page 871

    Shift Indicator Panel ATF Cooler Hoses Adiustment Connection Check that the index mark on the indicator alions 1. Connect the ATF cooler hoses to the ATF cooler lines with the N mark on the shift indicator panel when and ATF cooler, and secure them with the clips as the transmission is in NEUTRAL.

  • Page 872

    Continuously Variable Transmission (CVTI lllustrated Index ....1 4 - 1 9 4 S p e c i a l T o o l s Transmission/Lower Valve BodY 1 4 - 1 9 5 .

  • Page 873

    Special Tools Ref. No. Tool Number 07GAE - PG40200 't4-322,325 Clutch Spring Compressor Bolt Assembly 07JAD - PH80200 Pilot. 26 x 30 mm 14-333 alr * 07LAE - PX40100 Clutch Spring Compressor Attachment 14-322,325 0 7 P M - 0 0 1 0 1 0 0 't4-235,293 SCS Service Connector 07sM- 0010004...

  • Page 874

    Description The Continuously Variable Transmission (CVT) is an electronically controlled automatic transmission with drive and driv en Oullevs, and a steel belt. The CVT provides non stage speeds forward and one reverse. The entire unit is positioned in l i n e w i t h t h e e n g i n e . Transmission Around the outside of the flywheel is a ring gear which meshes with the starter pinion when the engine is being staned.

  • Page 875

    Description (cont'd) Gear Sel€stion The shift lever has six positions: @ pARK, E REVERSE, E NEUTRAL, E DR|VE, g SECOND, and El LOW. Poshion De3cription E PARK Front wheels locked; park pawl engaged with the park gear on the driven pulley shaft. The start clutch and the forward clutch released.

  • Page 876

    STEEL BELT START CLUTCH INPUT SHAFT DRIVE PULLEY ATF FILTER 14-197...

  • Page 877

    Description Clutches/Reverse Brake/Planetary Gear/Pulleys Clulches/Reverse Brake T h e C V T u s e s t h e h y d r a u l i c a l l y - a c t u a t e d c l u t c h e s a n d b r a k e t o e n g a g e o r d i s e n g a g e t h e t r a n s m i s s i o n g e a r s .

  • Page 878

    ATF PUMP ATF PUMP DRIVEN SPROCKET DRIVE PULLEY FORWARD CLUTCH REVERSE BRAKE RING GEAR PISTON BEVERSE BRAKE FLYWHEEL CARRIER RING GEAR DRIVE PLATE PLANETARY PINION GEARS INPUT SHAFT ATF PUMP DRIVE CHAIN ATF PUMP DRIVE SPROCKET DRIVEN PULLEY SHAFT START CLUTCH FINAL DRIVE GEAR DRIVEN PULLEY SECONDARY GEAR...

  • Page 879

    Description Power Flow E 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. E Position .

  • Page 880

    E, E, and E Positions {Forward Rangel . Sta rt Clutch: engaged . Forward Clutch: engaged o Reverse Brake: released 1, The hydraulic pressure is applied to the forward clutch and the start clutch, and the sun gear drives the torward clutch.

  • Page 881

    Description Power Flow (cont'd) E Position . Sta rt Clutch: engaged . Forward Clutch: released . Reverse Brake: engaged 1. The hydraulic pressure is applied to the reverse brake and the start clutch. The sun gear drives the pinion gears, and the pinion gears revolve around the sun gear.

  • Page 882

    Electronic Control System ('96 - 98 Modelsl (TcM), sensors, three linear solenoids, and an The electronic control system consists of the Transmission control Module inhibitor solenoid. Shifting is electronically controlled under all conditions The TCIM is located below the dashboard, behind the kick panel on the driver's side' when the vehicle is The TcN4 controls the transmission to reduce engine speed and retain the engine's cooling efficiency driven with Iull throttle acceleration...

  • Page 883

    Description Electronic Control System ('gG - 98 Modelsl (cont'dl Circuit Diagram and Terminal Locations GNITIONSWITCN Pri - Pt coNTnoL LrN ns0LtN0t0 SIAiT CLUTCH CONTSOL LINEAFSOLENOID MAP(PBI sHtFT CONmOI LINIAftSOLENOID rtDiRxo i\\c-....- +B BFAXELIGHT PAS|(ING 8MI(E SWITCH i\--------.--_ rcr 26 12 1 3 t 6 1 7 14-204...

  • Page 884

    Electronic Gontrol System ('99 - 00 Modelsl (PCM). sensors, three linear solenoids and an The electronic controt system conststs of a Powertrain control Module Logic control system to control shift- inhibitor solenoid. shifting is electronically controlled under all conditions A Grade ing in E position while the vehicle is ascending or descending a slope' f n "...

  • Page 885

    Description Electronic Control System ('99 - 00 Modelsl (cont'dl Grade Logic Control System How it works: The PcM compares actual driving conditions with memorized driving conditions. based on the input from the vehicle speed sensor, the throttle position sensor, the manifold absolute pressure sensor, the engine coolant temperature sensor, the brake switch signal, and the shift lever position signal, to control shifting while the vehicle is ascending or descending a slope.

  • Page 886

    -'99 - 00 Models Circuit Diagram and Terminal Locations IGN1TIONSWTCH PH.PLCOiTSOL LINEAF SOLEI€ID IGPl SIAFT CLIJICH COTITROL LINEiF SOLET€IO vcc2 SHIFI CONTNOT LINEAR SOLEI{OIO INNIB TOF SOLETIOIO 14-207...

  • Page 887

    Description 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.

  • Page 888

    Secondary Valve Body valve accumulator' The secondary valve body contains the PH regulator valve. the clutch reducing valve' the start clutch and the shift inhibitor valve PH Regulator Valve pump. and supplies PH pressure to the The pi regulator valve maintains hydraulic pressure supplied from the ATF PH regulator valve by the PH control hvdraulic control circuit and the lubrication circuit.

  • Page 889

    Description Hydraulic Control {cont'dl PL Regulator Valve Body The PL regulator valve body contains the PL regulator valve and the PH-PL control valve. which is joined wirh the pH-pL control linear solenoid. The inhibitor solenoid is bolted on the pL regulator valve body. .

  • Page 890

    Shift Valve BodY linear solenoro. shift control valve. Both are ioined to the shift control The shift valve body contains the shift valve and the r tl'ft1il1rf"","" varve. The shift varve distributes is controred by shift varve pressure (sV) from the shift contror pulley' to shift the transmission' pi""aur"...

  • Page 891

    Description Hydraulic Flow General Chart of Hydraulic prossure 'Shift Valve . Shift inhibitor Vatve PH REGULATOR VALVE 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 892

    E Position A s t h e e n g i n e t u r n s . t h e A T F p u m p a | s o s t a r t s t o o p e r a t e . F | u i d f r o m t h e A T F p u m p f | o w s t o t h e P H r e g u | a t o r v a | v e a n d t c | U t c h r e d u c i n g v a | v e .

  • Page 893

    Description Hydraulic Flow (cont'dl lll position, at low spo€d range The flow of fluid up to the drive pulley, the driven pulley, and the clutch reducing valve is the same as in El position. The pulley ratio is low because the driven pulley receives high pressure (PH), and the drive pulley receives low pressure (pL), The clutch reducing pressure {cR) flows through the manual valve to the forwaro clutch, ttren forward ciulcn is engaged.

  • Page 894

    E position, at middle sPeed range A s t h e s p e e d o f t h e v e h i c | e r e a c h e s t h e p r e s c r i b e d V a | u e , t h e s h i f t c o n t r o | | i n e a r s o l e n o i d i s a c t i v a t e d b y t h e T c M o r P c T h e s h i f t c o n t r o | | i n e a r s o | e n o r o c o n t r o I s t t r e s n i f t c o n t r o I V a | v e t o a c t i v a t e s h i f t V a | v e p r e s s u r e ( S V ) ' c | u t c h r e d u c i n g valve pressure shift valve pressure (SV) at the shift control valve Shift...

  • Page 895

    Description Hydraulic Flow (cont'd) @ position, at high spe6d range As the speed of the vehicle reaches the prescribed value, the shift control linear sol€noid moves the shift contror vatve to increase shift valve pressure (SV) at the left end of the shift valve. ttre srrit vatve moves to the right side compared to its position at the middle pulley ratio.

  • Page 896

    E position pulley' and the clutch reducing valve is the same as in E position The The flow of fluid up to the drive pulley, the driven and the drive pulley receives low pressure {PL). pulley ratio is low b"car"" tt " o riu",i'prti"vi"""v"" t'igtr pressure.(pH) (RVS) to the the port that leads reverse brake pressure The manual valve is shifted into the B position, and it uncovers...

  • Page 897

    Description Hydraulic Flow (cont'dl E position Reverse Inhibitor Conirol lf the E position is selected while the veiicle is moving forward at speeds over 6 mph (10 km/h), the inhibitor solenoid doesn't turn off by means of the TcM or PCM Reverse inhibitor pressure (Rl) is not applied to the reverse inhibitor valve as the reverse inhibitor solenoid turns on.

  • Page 898

    E position position' pulley' and the clutch reducing valve is the same as in E The flow of fluid up to the drive pulley, the driven valve' and is control valve, the manual valve, and the shift control Clutch reducing pressure (CR) t'"*" i" ii" start clut;h intercepted bY those valves.

  • Page 899

    Description Hydraulic Flow (cont'd) lll position, when th€ electronic control system is fauhy. when the electronic control svstem (linear solenoids and sensors) is faulty, the transmission uses the pitot pipe pressure (PP) to 311o- rh" u"hicle to drive. when all linear solenoids and sensors are off because of a faulty electronrc 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 900

    system is faulty' E] position, when the elestronic Gontrol pulley' and the start clutch is the same as in El position The flow of tluid up to the drive pulley, the driven pressure {RVS} to the it uncovers the port that leads reverse brake The manual valve is shifted into the lE position' and (Rl) is applied to.the right end of the reverse inhibitor valve because reverse inhibitor valve.

  • Page 901

    Description Park Mechanism The park mechanism locks the transmission by engaging the park pawl with the park gear which is integral with the sec- ondary drive gear' The secondary drive gear engages with the secondary driven gear which engages wit-h the final driven gear.

  • Page 902

    Component Locations 36 - 98 Models BRAKE SWITCH ENGINE CONTROL MODULE IECMI AUTOMATIC TRANSAXLE (A/T} GEAR POSITION SWITCI{ SECONDARY GEAR SHAFT MANIFOLD ABSOLUTE SPEEO SENSOR IMAPI SENSOR THROTTI.I POSITION {TPI VEHICLE SPEEO SENSOR SENSOR {vss} /i/ i ,' / ,','4 DRIVEN PULLEY SPEED SENSOR ,i/:1...

  • Page 903

    '99 - 00 Models CONTROL AUTOMATIC TRANSAXLE IA/TI GEAR POS]TION SW]TCH MANIFOLD ABSOLUTE SECONDANY GEAR SHAFT IMAPI SENSOR SPEED SENSOR THROTTLE POS]TION ITP) SENSOR VEHICLE SPEED SENSOR tvss) DNVEN PUL]-EY SPEED SENSOR PH.PL CONTBOL START CLUTCH CONTROL LINEAB SOLENOIO LINEAR SOIENOID PULLEY SPEED SENSOR SHIFT CONTROL...

  • Page 904

    TCM Circuit Diagram ('96 - 98 Modelsl U N D E N . H O O D F U S E ] R E L A Y B O X No. 52 1l5A) N o . 4 l l 8 0 A ) N o . 4 7 ( 7 . 5 A ) PARKING BRAKE swrTcH...

  • Page 905

    WHT/RED ELUMHT B 2 O L B 5 | 'i- Lli:" wHT qED I GRN/BLK PNK,BLU 1 G8N/YEL J PNUSLK I T -.T-. T BLUIEL^^.,1,. BLKMHT I GRN{WHT-...1_... YFt -_..1_.-. I nro,wHr J GRNiBIK PNKiBLU I GBN,^vEt eruxialr I J wxitnro I nroieru wirr 'r--...

  • Page 906

    TCM Terminal Voltage/Measuring Gonditions ('96 - 98 Modelsl TCM Terminal Loc.tions 12 1 3 1 1 1 5 16 1 7 25 26 TCM-A l25P) Connecto. TCM-B (22P) Connectot TCM CONNECTOR A (26P} Terminal Numbet Signal Dsscription Moasuring Conditions/Torminsl Vohrgo SC LS_ Stan clutch control linear solenoid Engine idling, E position:...

  • Page 907

    TCM CONNECTOR B (22P} Measuring Conditions/Terminal Voltage Description Signal Terminal Numbel With inhibitor solenoid ON: Baftery voltage Inhibitor solenoid control S O L I N H With inhibitor solenoid OFF: 0 V With iqnition switch ON (ll): Approx.2.5 V MAP (PB) an if old Absol r-rte Pressure IMAP) With e;gine adling: Approx.

  • Page 908

    PCM Circuit Diagram (A/T Control System: 'gg - 00 Models) tGNtTtc{l UNDER.OASN SWTCH FUSF]NEUY 8OI UADEF D'SI FUSSFEUY 8OX r{o.2s (7 5A) iPrE: T ro sv ,:-- ^1 GETB POSITIoi{ 14-230...

  • Page 909

    EI€INE COOLTI'II TEUPEFATUFE SENSOF SPEED SEllsoF GFN8U .-l- u 0 0 u I NHIEITOR *fl&'u''!l^" iflfl.S$' ilillfSIft,' I soLEr,roro soLEl€|0 14-231...

  • Page 910

    PGM Terminal Voltage/Measuring Conditions ('99 - 00 Modelsl A/T Control System The PCM terminal voltage and measuring conditions are shown for the connector terminals that are related to the A/T con- trol system. The other PCM terminal voltage and measuring conditions are described in section 11. PICM Connoctor Terminrl Location3 Terminal Number Signal...

  • Page 911

    PCM CONNECTOR D {16P) Measuring Conditions/Terminal Voltage Description Signal Terminal Numbs] Depending on vehicle speed: Pulsing signal Secondary gear shaft speed When vehicle is stoPPed: APProx. 0 V sensor signal input With inhibitor solenoid ON: Battery voltage lnhibitor solenoid control S O L I N H With inhibitor solenoid OFF: 0 V Shift control linear solenoid...

  • Page 912

    A . W h e n t h e @ i n d i c a t o r l i g h t h a s c o m e o n : l connect the Honda PGM Tester or an oBD ll Scan Tool to the 16P Data Link Connector (DLc) located near the left kick panel.

  • Page 913

    connected to the B. DTCS will be indicated by the blinking of the E indicator light with the SCS service connector (2P) is located under the dash on the passen Service Check Connector as shown. (The Service Check Connector ger's side of the vehicle.) Turn the ignition switch ON (ll). i : j ,,,/ CONNECTOR...

  • Page 914

    Troubleshooting Procedures (cont'd) C. lf the inspection for a particular code requires voltage or resistance checks at the TCM or PCM connectors, remove the driver's side kick panel, and unbolt the TCM, and at the PCM connectors, remove the passenger's side kick panel, and unbolt the PCM.

  • Page 915

    BACK UP t7.s Al FusE . The TCM or PCM can also be cleared by using the OBD ll Scan Tool or Honda PGM Tester' OBD ll SCAN TOOL o. PGM TESTER...

  • Page 916

    P1890 Shift control system Blinks 14-259 l42l P1891 Start clutch control svstem Blinks (43) 14-260 *: The DTC in parentheses is the code @ indicator light indicates when the Data Link Connector is connected to the Honda PGM Tester. 14-23a...

  • Page 917

    lf the self-diagnostic E indicator light does not blink, perform an inspection according to the table below. Ref. page Inspection Symptom E indicator light does not come on for two seconds after ignition switch 14-262 is first turn on (ll). E indicator light is on constantly (not blinking) whenever the ignition 14-264 switch is on (ll).

  • Page 918

    P1890 Shift control system Blinks 14-245 \421 P1891 Start clutch control system Blinks (43) 14-286 r: The DTc in parentheses is the code E indicator light indicates when the Data Link connector is connected to the Honda PGM Tester. 14-240...

  • Page 919

    table below. lf the self-diagnostic E indicator light does not blink. perform an inspection according to the Ref. page Inspection SYmPtom IDI indicator light does not come on for two seconds after ignition switch 14-284 is first turned ON (ll). lE1 indicator light is on constantly (not blinking) whenever the ignition 14-290 switch is ON { ll).

  • Page 920

    Electrical Troubleshooting ('96 - 98 Modelsl Troubleshooting Flowchart - Throttle position (Tpl Sensor NOTE: Record all freeze data before you troubleshoot. . OBO ll Scan Tool indic.tes Code Possible Cause P1790. . Disconnected throftle position . Self-diagnosis E indicator light (TPl 3ensor connoctol blinks three times.

  • Page 921

    (VSS) Troubleshooting Flowchart - Vehicle Speed Sensor NOTE: Record all freeze data before you troubleshoot' Po$rible Ctuse . OBD ll Scan Tool indicates Code . D i s c o n n e c t e d v e h i c l e s p e e d P1791.

  • Page 922

    Electrical Troubleshooting ('96 - 9g Models) Troubleshooting Flowchart - A/T Gear position Switch (Short) NOTE: Record all freeze data before you troubleshoot. . OBD ll Scan Tool indicates Code Posrible Cause P1705. . S h o r t i n A / T g o . r p o s i t i o n .

  • Page 923

    TCM CONNECTOR A (26P) F r o m p a g e l 4 - 2 4 4 Measure ATP S Vollage: 1 . S h i f t t o a l l P o s i t i o n s o t h e r t h a n 2 .

  • Page 924

    Electrical Troubleshooting (,96 - 9g Models) Troubleshooting Flowchart - A/T Gear position Switch (Openf NOTE: Record all freeze data before you troubleshoot. . OBD ll Scan Toot indicat* Code Pos.ribls Cause P1706, . Disconnocted A/T gear position . Solf-diagnosis E indicator tight switch connector blinb six times.

  • Page 925

    TCM CONNECTOR A l26p) F r o m p a g e 1 4 2 4 6 Moasure ATP S Voltage: 1. Shift to E Position 2. Measure the voltage between the A8 and 413 or 426 termi n a l s , Wire side of female terminals Bepair open in the wir€...

  • Page 926

    Electrical Troubleshooting ('96 - 9g Models) Troubleshooting Flowchart - lgnition Coil NOTE: Record all freeze data before you troubleshoot, . OBD ll Scan Tool indicates Code Po3rible Cause POl25. . Dbconnected ignition coil con- . Soll-diagnosis E indicarol light nectol indicates Code 11.

  • Page 927

    Absolute Pressure {MAPI Sensor Troubleshooting Flowchart - Manifold NOTE: Record all freeze data before you troubleshoot PG.iblo Cau3€ . OBD ll Scan Tool indicates Code . Dkconnoctod manilold .bsoluto P1793, ore33urc IMAP) sensor connoc' . self-diagno3b E indicato. light indicat€s Code 12. .

  • Page 928

    Electrical Troubleshooting (,96 - 9g Modelsl Troubleshooting Flowchart - Shift Control Linear Solenoid NOTE: Record all freeze data before you troubleshoot. . OBD ll Scan Toot indicates Code Possible Cause P1870. ' Disconnected 3olenoid h.rn€is . Selt-dirgnosis [d indic.tor tight connoctor indicatos Code 30.

  • Page 929

    Troub|eshootingF|owchart_PH-PLControJLinearSo|enoid NOTE| Record all treeze data before you troubleshoot Possible cause . OBD ll Scan Tool indicates Codo ' Disconnected solenoid harness P1873. . sef-diagnosis E indicalor light connectof . Short or oPen in PH_PL control indicat6 Code 31. linear solenoid wire .

  • Page 930

    Electrical Troubleshooting ('96 - gg Modelsl Troubleshooting Flowchart - start clutch control Linear solenoid NOTE: Record all freeze data before you t.oubleshoot. . OBO ll Scan Tool indicatG Code Po$iblo C.u.o P1879. ' Di3aonnoctod solanoid harncat . Self-dilgno.is E indicator light connactol indiclt$ Code 32.

  • Page 931

    Troubleshooting Flowchart - Inhibitor Solenoid NOTE: Record all treeze data betore you troubleshoot Po$ibls Cause . OBD ll Scan Tool indic.td Code . Dbconnected solenoid hatness P1882. . Selt-di.gnGis E indicator lighl connedor ' Short or opon in inhibitor sole' indic.tos Code 33.

  • Page 932

    Electrical Troubleshooting {'96 - 9g Models) Troubleshooting Flowchart - Drive pulley Speed Sensor NOTE: Record all freeze data before you troubleshoot, ' OBD ll Scan Tool indicates Code Po$ible Cause P1885. . Oisconn€cted drive pulley speed . Self-diagnosis E indicator tight sensor connector indicates Code 34.

  • Page 933

    Troubleshooting Flowchart - Driven Pulley Speed Sensor NOTE: Record all freeze data before you troubleshoot' Po3sible Cause . OBD ll Scan Tool indicates Code . D i s c o n n e c t e d d t i v e n P u l l e Y P1886.

  • Page 934

    Electrical Troubleshooting ('96 - 98 Modelsl Troubleshooting Flowchart - Secondary Gear Shaft Speed Sensor NOTE: Record all freeze data before you troubleshoot. . OBD ll Scan Tool indicates Code Po$ible Cause P1888. . Disconnected secondary geal . Selt-diagnosis Iq indicator light shaft speod sen3or connectol indicates Code 36.

  • Page 935

    Troubleshooting Flowchart - TMA and TMB Signals NOTE: Record all freeze data before you troubleshoot' Possible Cause . OBD ll Scsn Tool indicate3 Codo . S h o r l o r o p . n i n T M A w i . o P1655.

  • Page 936

    Electrical Troubleshooting ('96 - 98 Models) Troubleshooting Flowchart - TMA and TMB Sigrrals (cont,d) from page 14 257 TCM CONNECTOR 8 {22P} Check TMB Wire Continuity: 1. Turn the ignirion switch OFF. 2. Disconnect the C (31P) connec, tor from the ECM, and the I (22P) connector from the TCM.

  • Page 937

    Troubleshooting Flowchart - Shift Control System NOTE: Record all freeze data before you troubleshoot. Po$ible Cause OgD ll Scan Tool indicates Code P'1890. Faulty 3hift control system Self-diagnosi3 E indicator light indicates Code 42. Check for Anolhet Code: C h e c k w h e t h e r t h e E i n d i c a t o r light indicates another code.

  • Page 938

    Electrical Troubleshooting ('96 - 98 Models) Troubleshooting Flowchart - Start Clutch Control System NOTE: Record all freeze data before you troubleshoot. Po$ible Ceuaa OBO ll Scan Tool indic.le3 Cod6 P1891. Frulty start clutch cont.ol 3ys- Solt-diagnosis E indicator light indicates Code (1. Check for Another Codo: C h e c k w h e t h e r t h e @ i n d i c a t o r light indicates another code.

  • Page 939

    F r o m p a g e 1 4 2 6 0 Check Stall Speed RPM: Measure the stall speed RPM (see page 14'298). ls the stall speed over 3,500 rpm? Warm Up Engine and Recheck Failure: 1 . W a r m u P t h e e n g i n e t o n o r ' m a l o p e r a t i n g t e m P e r a t u r e (the radiator fan comes on) 2.

  • Page 940

    Electrical Troubleshooting ('96 - 98 Modelsl Troubleshooting Flowchart - Pl Indicator Light Does Not Gome On The E Indicator light does not come on when the ignition switch is tirst turned ON {ll). {lt should come on for aboul two s€conds,) Chock the Service Check Connec- lot: Make sure the special tool (SCS...

  • Page 941

    Ftom page 14 262 TCM CONNECTOR A I26P) BLK/WHT Measure Powet SUPPIY Ci.cuit Voltage: 1. Turnthe ignition switch ON (ll) 2. Measure the voltage between 12 13 t e r m i n a l s A 1 2 a n d A 1 3 a n d b e t w e e n t e r m i n a l s A 2 5 a n d 1 6 1 7 426.

  • Page 942

    Electrical Troubleshooting ('96 - 98 Modelsl Troubleshooting Flowchart - lq Indicator Light On Constantly The E indic.tor light is on con- stantly {not blinking} whonever the ignilion switch is ON llll. TCM CONNECTOR A {26PI Measure D INO Voltage: 12 13 1.

  • Page 943

    Electrical Troubleshooting ('99 - 00 Models) Troubleshooting Flowchart - A/T Gear Position Switch (Short) NOTE: Record all freeze data before you troubleshoot. Po3sible Cause . oBD ll scln lool indicats code . Short in A/T gear po3ition 3witch P't705. . Self-diagnosb E indicator light .

  • Page 944

    Electrical Troubleshooting ('99 - 00 Models) Troubf eshooting Flowcharl - AIT Gear Position Switch {Short) {cont,d} From page 14 265 Measure ATP NP Voltage: '1. Shift to all positions A t32Pl other than B {25P) E o r I 2. Measure the voltage between the A9 and 820 or 922 te(mi- nals.

  • Page 945

    From page 14-266 PCM CONNECTORS M6asure ATP S Voliag€: B t2sP) D (16P1 1 . S h i f t t o a l l p o s i t i o n s o t h e r than E. 2.

  • Page 946

    Electrical Troubleshooting {'99 - 00 Models) Troubfeshooting Flowchaft- AIT Gear Position Switch (Openl NOTE: Record allfreeze data before vou troubleshoot. . OBD ll Scan Tool indicstE Code Po$ible Cau3e P1706. . Oilconnected A/T goar position . Selt-diagnGi! E indicato. light switch blinks six tim€a.

  • Page 947

    From page 14-268 Moasule ATP D voltago: 1. Shift to El position. B l25Pl A {32P} 2. Measure the voltage between the A7 and 820 or 822 termi nals. LG2 (BRN/BLKI LGl IBRN/BLK) Repair open in the wira betwo6n the A7 torminal and the A/T ge.r po3ition switch.

  • Page 948

    Electrical Troubleshooting {'99 - 00 Models} Troubleshooting Flowchart - A/T Gear Position Switch (Openl (cont'dl From page 14-8-269 PCM CONNECTORS B (25P1 Msasuro ATP L Voftage: 1. Shiftto E position. 2. Measure the voltage between the A22 and 820 or 822 termi- nals, Wire side of female terminals Bepair opon in the wiro bgtw€en...

  • Page 949

    Troubleshooting Flowchart - Shift Control Linear Solenoid NOTE: Record all freeze data before you troubleshoot Possiblc Cause . O B D l l S c a n T o o l i n d i c a t o s .

  • Page 950

    ('99 - 00 Models) ElectricalTroubleshooting Troubleshooting Flowchart - Shift Gontrol Linear Solenoid (cont'dl tuom page 14 271 SOI."ENOID HARNESS 8P CONNECTOR SH LSP M e a s u r e S h i f t C o n t r o l L i n e a r Solenoid R6sistance at the Sole- noid Hrrness Connector: 1.

  • Page 951

    Troubleshooting Flowchart - PH-PL Control Linear Solenoid NOTE: Record all freeze data before you troubleshoot. Possibls c.use . O B D l l S c a n T o o l i n d i c a t e s .

  • Page 952

    Electrical Troubleshooting ('99 - 00 Models) Troubleshooting Flowchart - PH-PL Gontrol Linear Solenoid (cont'd) From page l4-273 SOLENOID HARNESS 8P CONNECTOR Mea3ure PH-PL Control Linear HLC LSP Solenoid Rosistance at lhe Sole- noid Harness Connector: 1. Disconnect the solenoid har- ness 8P connector.

  • Page 953

    Troubleshooting Flowchart - Start Clutch Control Linear Solenoid NOTE: Record all freeze data before you troubleshoot' Po$ible Cause ' O B D l l S c a n T o o l i n d i c a t e s .

  • Page 954

    Electrical Troubleshooting ('gg - 00 Modelsl Troubleshooting Flowchart - start clutch control Linear solenoid (cont,d) Frcm page 14.275 Measurs Start Clutch Control SOLENOID HARNESS 8P CONNECTOR Linear Solenoid R€aistance at ths Solenoid Harne€s Connector: SC LSP 1. Disconnect the solenoid har- ness 8P connector.

  • Page 955

    Troubleshooting Flowchart - lnhibitor Solenoid NOTE: Record all freeze data before you troubleshoot' Po3sible Cause . O B D l l S c a n T o o l i n d i c a i e s . Oi3connec'ted solenoid harn6s Codo P'l882.

  • Page 956

    Electrical Troubleshooting ('99 - 00 Models) Troubleshooting Flowchart - Inhibitor Solenoid (cont'dl F t o m p a g e 1 4 - 2 7 7 SOLENOID HARNESS 8P CONNECTOR Mersure Inhibitor Solenoid R6b- t.nce at the Solenoid Harne3s Conn€ctor: 1.

  • Page 957

    Troubleshooting Flowchart - Drive Pulley Speed Sensor NOTE: Record allfreeze data before you troubleshoot' Possible Cau3€ . O B D l l S c a n T o o l i n d i c a t e s . D i s c o n n e c t e d d i i v e P u l l e Y Code Pl885.

  • Page 958

    Electrical Troubleshooting ('gg - 00 Models) Troubleshooting Flowchart - Drive pulley Speed Sensor (cont,d) From page 14-279 PCM CONNECTOR D {16P} Measure Drivo Pulley Speed Sen- sor Circuit tor an Open: 1 . C o n n e c t t h e d r i v e p u l l e y speed sensor connector, 2 .

  • Page 959

    Troubleshooting Flowchart - Driven Pulley Speed Sensor NOTE: Record all freeze data betore you troubleshoot' Po3sible Caus€ ' O B D l t S c . n T o o l i n d i c a t e s ' O i s c o n n e c t e d d r i v e n P u l l e Y Code Pl886.

  • Page 960

    Electrical Troubleshooting ['gg - 00 Models) Troubleshooting Flowchart - Driven pulley Speed Sensor (cont,dl From page l4 281 M6asure Driven Pulley Speed Sensor Circuit Ior an Op€n: 1 . C o n n e c t t h e d r i v e n p u l l e y speed sensor connector, 2 , M e a s u r e t h e r e s i s t a n c e...

  • Page 961

    Troubleshooting Flowchart - Secondary Gear Shaft Speed Sensor NOTE: Record all freeze data before you troubleshoot Po$ible Causo ' O B D l l S c a n T o o l i n d i c a t e s .

  • Page 962

    Electrical Troubleshooting ('gg - 00 Modelsl Troubleshooting Flowchart - Secondary Gear Shaft Speed Sensor (cont'd) From page 14 283 Moasu.€ Secondary Gaar Shaft S p o 6 d S o n s o r C i r c u i t t o r a n Openi 1.

  • Page 963

    Troubleshooting Flowchart - Shift Control System NOTE: Record allfreeze data before you troubleshoot Possible cause ' OBD ll Scan Tool indicates Codo Faultv shift control svstem P1Ato. . Self-diagnosis E indicator light indicatos Code 42. Check for Anoth€r Code: Check whether the E indicator light indicates another code.

  • Page 964

    Electrical Troubleshootang ('gg - 00 Models) Troubleshooting Flowchart - Start Clutch Control System NOTE: Record allfreeze data before you troubleshoot. . OBD ll Scan Tool indicates Code Possibl€ Cause P1891. Faultv start clutch control sys- . Self-diagnosis E indicator tight indicates Code 43.

  • Page 965

    From page 14'286 Check Srall Speed RPM: Measure the stall speed RPM (see page 14-298). ls the stall speed over 3,500 rPm? Warm Up Engine and Becheck F ilure: 1 . W a r m u p t h e e n g i n e t o n o r m a l o p e r a t a n g t e m P e r a t u r e (the radiator fan comes on).

  • Page 966

    Electrical Troubleshooting ('99 - 00 Models) Troubleshooting Flowchart - El Indicator Light Does Not Come On The D indicator light does not come on whon ths ignhion switch is tirst turned ON {lll. llt should come on tor about two s€conds.) Check the Service Check Connec- tor: Make sure the special tool {SCS...

  • Page 967

    From page 14-289 PCM CONNECTORS D {16P1 r s 1 / 7 Msaaure D IND Volt.ge: nn fT /fl 1. Turn the ignition switch OFF. 9 10 2. Connect tho B (25Plconnector - -T---=4'+:l 1311 o lzlzz ,rl/zs to the PCM. 3.

  • Page 968

    ElectricalTroubleshooting ('gg - 00 Models) Troubleshooting Flowchart - E Indicator Light On Constantly The E indicator light is on con- stantly {not blinkingl whenever the ignition switch is ON lll|. FCM CONNCCTOR D tl6PI Mersure D IND Voltage: 1. Turn the ignition switch OFF. 2 .

  • Page 969

    Linear Solenoids/lnhibitor Solenoid Test lf all ot the resistances are within the standard, a 1. Disconnect the 8P connector from the solenoid har- c l i c k i n g s o u n d s h o u l d b e h e a r d w h e n c o n n e c t r n g ness connector.

  • Page 970

    Drive Pulley/Driven Pulley/Secondary Gear Shaft Speed Sensors Replacement CAUTION: While replacing the speed sensor, be sure not to allow dust and other foreign parliclos to enter into the trans- mission. Disconnect the connectors for the drive pulley, the driven pulley, and the secondary gear shaft speed sensor. Remove the 6 mm bolt from the transmission housing, and remove the drive pulley.

  • Page 971

    1 . E n g a g e t h e p a r k i n g b r a k e , a n d b l o c k t h e f r o n t Connect the Honda PGM Tester. Check that the TCM wheels securely.

  • Page 972

    Symptom-to-Component Chart Hydraulic System SYMPTOM Check these items on the PBOBABLE CAUSE List ' t , 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , Engine runs, but vehicle does not move in any position. 1 0 , 2 0 , 3 4 , 3 5 , 3 6 , 3 8 , 4 1 Vehicle does not move in @, [.

  • Page 973

    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. S u n g e a r w o r n o r d a m a g e d . Final driven oear worn or damaqed, Secondary drive gear/secondary driven gear worn or damaged- Flywheel/drive plate worn or damaged.

  • Page 974

    NOTE: Throttle position sensor voltage represents the throttle opening. To monitor the throttle position sensor volt- age, use one of the following methods: A. Connect the Honda PGM Tester, and go to the PGM-FI Data List. OBD ll SCAN TOOL or HONOA PGM TESTER For road testing on '96 - 98 models, remove the drive/s side kick panel to expose the TCM;...

  • Page 975

    o @ position: Engino Speed rPm Vehiclo Speed Throttle Opening | 62 mph {100 km/h} 37 mph {60 km/h) 25 mph l/() km/h) 1,250 - 1,650 Throttle position sensor voltage: 0.75 V 2,700 - 3,300 2,650 - 3,250 2,500 - 3,100 Throttle position sensor voltage: 2'25 V Throttle position sensor voltage;...

  • Page 976

    Stall Speed Test CAUTION: . To prevent transmission damage, do not test stall sp€€d for mole than 10 seconds at a time. . Do not shift the lsver whils raising the engine speod. Be sure lo remove the pressure gauge before tosting stall speed. .

  • Page 977

    Genuine Honda CVT Fluid- Use Genuine Honda CW fluid only. Using other flu- i d s c a n a f f e c t t r a n s m i s s i o n o p e r a t i o n a n d m a y reduce transmission liJe.

  • Page 978

    Pressure Testing . While testing, be careful of the rot8ling front wheels. . M8k6 suro lifts, iacks, and satety stands are placed properly lsee section 11. CAUTION: . Before testing, be sur. the transmb3ion fluid is fillod to the propor lcvel. .

  • Page 979

    Start the engine. pressures at 1'500 rpm' Shift to the respective shift lever positions in the table, and measure the following . Forward Clutch Pressure Reverse Brake Pressure . Drive Pulley Pressure . Driven Pulley Pressure 8. Shift to E posltion, and measure the lubrication pressure at 3,000 rpm' FLUID PRESSURE SHIFT LEVER PROBABLE CAUSE...

  • Page 980

    Lower Valve Body Assembly Replacement Make sure lifts, iacks, and saf€ty stands 7. Remove the ATF cooler outlet line. are placsd prop€rly {sea section 1). 8. Remove the ATF cooler line bracket bolt. 9. Remove the ATF pan (fourteen bolts). 10.

  • Page 981

    ATF Filter Removal/lnstallation 6. Remove the ATF cooler outlet line. Make sure lifts, lEcks, snd safoty stands 7. Remove the ATF cooler line bracket bolt. ara pl8ced properly {sae section 1). 8. Remove the ATF pan (fourteen bolts) 9. Remove the ATF cooler inlet line from the ATF pan CAUTION: While removing and installing the ATF tilier, (three bolts).

  • Page 982

    Transmission Removal Disconnect the solenoid harness connector, the drive . Mako suro lifts. iacks, and satety stands are placod pulley speed sensor connector, and the ground cable properly, and hoi3t bracket are attached to lhe cor- terminals. rect position on the engine {see soction 1}. .

  • Page 983

    R e m o v e t h e d r a i n p l u g , a n d d r a i n t h € C V T f l u i d Disconnect the vehicle speed sensor (VSS) connec- Reinstall the drain plug with a new sealing washer.

  • Page 984

    Transmission Removal (cont'd) '16, 10. Remove the cotte. pins and castle nuts, then separate Remove the right front mounvbracket, the ball joints from the lower arm (see section 1g). -=V, /\<,\ SELF-LOCKING \ CASTLE I{UT COTTER Replace. oitupea rOax Replac6. ATF COOLER HOSE 't 1.

  • Page 985

    2 3 . R e m o v e t h e t r a n s m i s s i o n h o u s i n g m o u n t i n g b o l t Remove the distributor' and rear engine mounting bolts Atach a hoisting bracket to the engine, then lift the...

  • Page 986

    lllustrated Index Transmission/Lower Valve Body Assembly 14 - 3 0 8...

  • Page 987

    O ATF DIPSTICK O o-RING Replace. .' SOLENOID HARNESS CONNECTOR @ LOWER VALVE BODY ASSEMBLY O DOWEL PIN O LINE BOLT .i ATTf COOUR IruIET LINE B8ACKET BOLT truler LINE ASSEMBLY €] lrr cooua O SEALING WASHER RePIACE' G, ATF COOLER OUTLET PIPE 6) o-RING Replace.

  • Page 988

    lllustrated Index Transmission Housing/Flywheel Housing 14-310...

  • Page 989

    6) o-RING Replace. C O-RING Replace. €) START CLUTCH ATF FEED PIPE e) OIL SEAL RePlace CO O-RING Replace. .' FLYWHEEL HOUSING €I FEEO PIPE FLANGE O flVWneel }|OUSttttG GASKET Replace @ SNAP RING 6 DIFFERENTTALASSEMELY O' CONNECTOR BRACKET @ lrr plsslce uruE ASSEMBLY @ BALL BEARING O O-RING Replace 6} SNAP RING...

  • Page 990

    lllustrated Index Right Side Cover/lntermediate Housing .Fi.

  • Page 991

    HOUSING GASKET Replace' 6) TRANSMISSION O END COVER @ DOWEL PIN O ATF FEED PIPE @) ATF FEED PIPE O DOWEL PIN @ o-RING Replace. @ O-RING Replace. 60 o-RING Replace. G) FEED PIPE FLANGE @) DRIVE PULLEY SPEED SENSOR @ reeo ppe ruruce puru HANGER @ TRANSMISSION...

  • Page 992

    Transmission Housing/Lower Valve Body Assembty Removal NOTE: . Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. . Blow out all passages. . When removing the lower valve body, replace the followingl - O-rings - ATF pan gasket - Sealing washers O.RING Replace.

  • Page 993

    Remove the ATF cooler inlet iine bracket bolt' Remove the ATF cooler outlet line 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) Clean the inlet opening of the ATF strainer thoroughly with compressed air, then check that it is in good condition, and the inlet opening is not clogged'...

  • Page 994

    Transmission Housing/Flywheel Housing Removal NOTE: . Cleanall parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages. . When removing the transmission housing/flywheel housing, replace the following: - O-rings Secondary drive gear assembly - Sta rt clutch assemblv Flywheel housing gasket ATF PASSAGE LINE 8 x 125 mm BOLT...

  • Page 995

    10. Set the special tool on the start clutch' and attach the 1 . Remove the ATF passage line holder assembly' oawl of the special tool to the park gear securely as shown. Remove the flywheel housing (twenty bolts)' CAUTION: Remove the ATF passage line assembly (one bolt) .

  • Page 996

    End Cover/lntermediate Housing Removal NOTE: . Cleanall parts in solvent or carburetor cleansr, and drywith compressed air, Blow out all passages. . When removing the end cover/intermediate housing, replacs the following parts: O-rings - End cover gasket - Transmission housing gasket Sealing rings - Sealing washers 8 x 1 .25 mm BOLT...

  • Page 997

    11. Compress the return springs. then remove the snap Remove the end cover {three 6 mm bolts, eleven 8 ring mm bolts). C A U T I O N : l f t h e s p r i n g r e t a i n e r t a b i s o n t h e Remove the manualvalve body lines A and B rsverse braks piston, tho spting letainer may be damaged.

  • Page 998

    Manual Valve Body Disassembly/lnspection/Reassembly NOTE: . Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Elow out all passages. . Coat all parts with CVT Fluid during assembly. SPRING SEAT REVERSE INHIBITOR VALVE SPRING REVERSE INHIBITOR VALVE MANUAL VALVE MANUAL VALVE BODY...

  • Page 999

    Forward Clutch lllustrated Index CLUTCH ORUM DISC SPRING CLUTCH END PLATE CLUTCH PISTON SNAP RING 14-321...

  • Page 1000

    Forward Clutch Disassembly 1. Remove the snap ring, then remove the clutch end Install the specialtools as shown. plate, clutch discs, and plates. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE - PX40100 SNAP RING CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE - PXa0100 or 07HAE - P150100 Remove the disc spring.

  • Page 1001

    6. Wrap a shop rag around the clutch drum, and apply Compress the return sprlng. air pressure to the fluid passage to remove the piston. Place a finger tip on the other end while applying air pressure. OSHA-APPROVED 30 psi NOzzLE Remove the snap ring.

  • Page 1002

    Forward Glutch Reassembly NOTE: Install the piston in the clutch drum. Apply pressure . Clean all parts thoroughly in solvent or carburetor and rotate to ensure proper seatang, cleaner, and dry them with compressed air. Blow out all passages. NOTE: Lubricate the piston O-ring with CVT Fluid Lubricate all parts with CW Fluid before reassembly.

  • Page 1003

    Compress the return sPrlng' lnstallthe sDecialtools as shown. CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE - PX40100 CLUTCH SPNING COMPRESSOR ATTACI{MENT 07LAE - Pxil010o o. 07HAE - P150100 CLUTCI{ SPRING Install the snap ring. COMPRESSOR BOLT ASSEMBLY oTGAE-PG40200 CAUTION: lf either end of the special tool is set ovel an area of lhe spring retain€r which is unsupported by the return spring, tho retainsr may be damaged' Be sure the special lool is adiusted to have full con-...

  • Page 1004

    Forward Clutch Reassembly {cont'd) 9. Install the disc spring. 12. Installthe snap ring. NOTE: Installthe disc spring in the direction shown. DISC SPRING SNAP RING "arr"" o"u* 1 0 . Soak the clutch discs thoroughly in CW Fluid for a minimum of 30 minutes.

  • Page 1005

    15. It the clearance is out of tolerance, select a new ciutch 14. Measure the clearance between the clutch end plate end plate from the following table, then recheck. and toD disc with a dial indicator, Zero th€ dial indica- tor with the clutch end plate lowered, and lift it up to NOIE: lf ihe thickest clutch end plate is installed but the snap ring.

  • Page 1006

    Secondary Gear Shaft 25 x 35 mm Thrust Shim Selection 1. Measure the distance between the flywheel housing Calculate 25 x 35 mm thrust shim thickness bv fol- surface and the ball bearing as shown, then note lowing formula. the measurement (Measurement A). FORMULA;...

  • Page 1007

    Differential Bacl(lash Inspection lllustrated Index Place the differential assembly on V-blocks, and install BOLTS both axles. 1 0 x 1 . 0 m m 98 N.m 110.0 kgf.m, Check the backlash of both pinion gears. 72 tbl.ltl Left-hand threads Standard (Newl: 0.05 - 0.15 mm 10.002 - 0.006 in) PINION GEARS FII{AL ORIVEN GEAR BAIT EEANIM;...

  • Page 1008

    Differential Bearing Replacement Differential Carrier Replacement NOTE: Check the bearings for wear and rough rotation. 1. Remove the final driven gear from the differential lf the bearings are OK, removal is not necessary. carner. '1. Remove the ball bearings using a bearing puller.

  • Page 1009

    Oil Seal Installation/Side Clearance Oil Seal Removal 1. lnstall a 2.50 mm (0.098 in) thick 80 mm wide set Remove the differential assembly. r i n g i n t h e t r a n s m i s s i o n h o u s i n g . Remove the oil seal from the transmission housing.

  • Page 1010

    Differential Oil Seal Installation/Side Clearance (cont'dl Installthe flywheel housing, and tighten the bolts. Measure the clea.ance between the 80 mm set ring and outer race of the ball bearing in the transmis- sion housing. 1 .25 mm STANDARD: 0 - 0.15 mm (0 - 0.006 in) N m (3.0 kgt m,22 lbf.ttl DOWEL PIN lf the clearance is more than the standard, select a...

  • Page 1011

    Flywheel Housing Input Shaft Oil Seal Replacement 1. Remove the input shaft oil seal from the flywheel Install the oil seal in the transmission housing using h o u s i n g . the sDecial tools as shown. DRIVER 07749 - 0010d)0 OIL SEAL Instali the oil seal in the flywheel housing using the...

  • Page 1012

    Transmission Housing Bearings Driven Pulley Shaft Bearing Replacement 1. To remove the driven pulley shaft b'earing trom the Expand the snap ring with snap ring pliers, insert t r a n s m i s s i o n h o u s i n g , e x p a n d t h e s n a p r i n g w i t h the new bearing part-way into the housing using s n a p r i n g p l i e r s , t h e n p u s h t h e b e a r i n g o u t u s i n g the special tools and a press as shown.

  • Page 1013

    Flywheel Housing Bearing Secondary Gear Shaft Bearing Secondary Gear Shaft Bearing Replacement Replacement 1. Remove the secondary gear shaft bearing using the 1. Remove the secondary gear shaft bearing using the soecial tool as shown. special tools as shown. 3/8" - 16 SLIDE HAMMER 3/8"...

  • Page 1014

    Ring Gear Bearing Control Shaft Assembly Replacement RemovaUlnstallation Remove the ring gear bearing. Remove the bolt and lock washer. CONTROL SHAFT ASSEMBLY TRANSMISSION RING RING GEAR Install the new ring gear bearing until it bottoms in the ring gear. using the specialtools as shown, 6 r 1 .

  • Page 1015

    Transmission Reassembly CAUTION: While reassembling. be sure not to sllow dust and othor foreign particles to enter into the transmission. NOTE: . Coat all parts with CVT Fluid. . Replace the following parts: - O-rings - S e a l i n g r i n g s - Sealing washers Gaskets - Start clutch assembly and secondary drive gear...

  • Page 1016

    Compress the return springs, then install the snap lnstall the ATF feed pipe in the transmission hous- ring in the intermediate housing above the spring ing, and install the three ATF feed pipes with new retainer. O - r i n g s i n t h e t r a n s m i s s i o n h o u s i n g , Install the two dowel pins and new transmission hous- Verify that the snap ring end gap is correct' 1 0 .

  • Page 1017

    Transmission Reassembly (cont'dl lf the clearance is not within the standard, remove the 22. Verity that the outside diameter ol the snap ring is reverse brake end plate and measure its thickness. correct. 1 6 . Select and install a new reverse brake end Dlate. then recheck.

  • Page 1018

    lf the clearance is out of tolerance, remove the 25 x 26. Install the thrust washer, the thrust needle bearing' 31 mm thrust shim and measure its thickness' and the thrust washer on the carrier assembly' THRUST SHIM, Select and install a new 25 x 31 mm thrust shim. 3 1 .

  • Page 1019

    Transmission Reassembly (cont'd) 35. Verify that the snap ring end gap is correct. 39. Install the park pawl, spring, and shaft on the trans- mission housing, then move the control lever to anv M i n i m u m 1 8 m m ( 0 . 7 1 i n ) gear other than E position.

  • Page 1020

    lf the clearance is not within the standard, remove 44. Push the handle of the special tool, then tighten the the cotters and measure their thickness nut to seal the secondary drive gear assembly on the driven pulleY shaft securelY. Select and install new cotters, then recheck.

  • Page 1021

    Transmission Reassembly (cont'd) 53. Verify that the outside diameter of the snap ring is 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 correcr. M a x i m u m 2 6 .

  • Page 1022

    60. Install the ditferential assembly (one boltl' 61. Installthe ATF passage line assembly with new O-rings housing' 62. Install thethreedowel pinsand new flywheel housing gasket on the transmission (twenty bolts)' 63. Install the flywheel housing and connector bracket 64. Installthe ATF passage line holder assembly (two bolts)' 8 x 1.25 mm 29 N.m t3.o kg['m, 22 lbf'ttl 6 x 1 .

  • Page 1023

    Transmission Reassembly (cont'dl 65 lnstall the solenoid harness connector with a new O-ring (one bolt), then install the lower valve body assembly with three dowel pins (eight bolts). 66. Install the ATF strainer with a new O-ring (two bolts). 67. lf necessary, assemble the ATF pan, ATF filter, and the ATF cooler inlet line (see page 14_303). 68.

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