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Chapters

Troubleshooting

   Also See for HONDA S2000

   Summary of Contents for HONDA S2000

  • Page 3

    FOTileEl symbol. The purpose of this message is to help prevent damage to your vehicle, other property, or the environment. First Edition 09/2002 1,104pages HONDA MOTOR CO., LTD. All Rights Reserved Service Publication Office Specifications apply to U.S.A. end Canada A3 s€clions with *includ6 SRS compon€nts;...

  • Page 11: Table Of Contents

    General Information Chassis and Paint Codes- ....2 0 0 0 M o d e l 1 - 2 Chassis and Paint Codes- 2 0 0 1 M o d e l .

  • Page 12: Model

    [[rrtltr c d e f g h a , Manutacturer, Make and Type of Vehicle a. Engine Type JHM: HONDA MOTOR CO., LTD F20C1i 2.0 A DOHC VTEC Sequential Multiport HONDA Passenger vehicle Fuel-injected engine Line, Body and Engine Type b.

  • Page 13

    Manutacturer, Make and Type of Vehicle a. Engine Type F2,C'li 2.0 A DOHC VTEC Sequenlial Multiport JHM: HONDA MOTOR CO.. LTD Fuel-injected engine HONDA Passenger vehicle Line, Body and Engine Type b. Serial Number U .

  • Page 14

    F20C1 rrttirt c d e f g h Manutacturer, Make and Type of Vehicle a. Engine Type JHM: HONDA MOTOR CO.. LTD F20C1: 2.0 0 DOHC VTEC Sequential Multiport Fuel-injected engine HONDA Passenger vehicle Line, Body and Engine Type b. Serial Number AP1: S2000/F20C1 U .

  • Page 15

    F20C1: 2.0 0 DOHC VTEC Sequential Multiport J H M : H O N D A M O T O R C O . , L T D Fuel-injected engine HONDA Passenger vehicle b. Serial Number Line, Body and Engine Type U .

  • Page 16: Ldentification Number Locations

    General Information ldentification Number Locations Engine Numbel Vehicle ldentilication Numbel lVlN) Transmission Numbe. (located under transmission)

  • Page 17: Warning/caution Label Locations

    Warning/Caution Label Locations DRIVER MODULE DANGER CABLE REEL CAUTION EXPLOSIVE/FLAMMABLE INSTALLATION OF THE SRS CABLE REEL IS MUST NOT EXCEED STORAGE TEMPERATURES CRITICAL TO THE PROPER OPERATION OF THE SRS SYSTEM. 2OO'F I93'CI, FOR PROPER HANDLING STORAGE REFER TO THE SERVICE MANUAL FOR DETAILEO ANO DISPOSAL PROCEDURES, REFER TO SERVICE INSTALLATION INSTRUCTIONS.

  • Page 18

    General Information Warning/Caution Label Locations (cont'dl SRS WARNING INFORMATION SRS INFORMATION U,S,A, model Canada model : t \ \ t I r ! I a CAUTION TO AVOID SERIOUS INJURY: DEATH OR SERIOUS INJURY CAN OCCUR. . FOR MAXIMUM SAFETY PROTECTION .

  • Page 19

    SRS WARNING {HOOD) SUPPLEMENTAL RESTRAINT SYSTEM (SRSI THIS VEHICLE IS EOUIPPED WITH DRIVER AND FRONT SEAT PASSENGER AIRBAGS. ALL SRS ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. TAMPERING WITH, DISCONNECTING, OR USING ELECTRICAL TEST EOUIPMENT ON THE SRS WIRING CAN MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIOENTAL FIRING OF THE INFLATOR.

  • Page 20

    General Information Warning/Caution Label Locations (cont'd) 1 - 1 0...

  • Page 21

    Under-hood Emission Control Label (2000-2002 Modelsl Engine and Evaporative Families: Emission Group ldentilication Engine Family: Example: O R M A T I O N V E H I C L E E M I S S I O N C O N T R O L 2 HNX V 02.0 DYC r [ t - r OATALYST lili;81.lll;...

  • Page 22: Under-hood Emission

    NEW LEV PASSENGER CARS AND CALIFORNIA REGULATIONS APPLICABLE TO 2003 MODEL YEAR 2 HNX B O13O AAA NEW LEV PASSENGER CARS. T f t r I Model Year 3: 2003 Manutacturer Subcode HNX: HONDA Family Type R: EVAP/ORVR Canister Work Capacity Sequence Characters 1-12...

  • Page 23: Lift And Support Points

    Lift and Support Points Floor Jack lf you are going to remove heavy components such as suspension or the fuel tank from the rear of the vehicle, 1. Block the rear wheels when raising the front of the first suooort the front of the vehicle with a tall safety vehicle;...

  • Page 24: T O W I N

    General lnformation Towing lf the vehicle needs to be towed, call a professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. lt is very dangerous. . This vehicle can only be transported on a flat-bed. .

  • Page 25: Part S M A R K I N

    Parts Marking To deter vehicle theft, certain major components are marked with the vehicle identification number {VlN). Original parts have sell-adhesive labels. Replacement body parts will have self-adhesive labels, and the replacement engine and transmission will have the VIN plate attached with a break-off bolt. NOTE: Be careful not to damage the parts marking labels during body repair.

  • Page 26: Service Precaution

    General Information Service Precaution Adhesive Wheel Balance Weight The wheels of this model are not designed to mount the balance weight on the outer side of the wheel. Instead, mount the self-adhesive balance weight on the inner side of the wheels. Note the following service tips and install the weights securely.

  • Page 27: R E V I S E D C O M P O N E N T T E R M

    J 1 9 3 0 . l f y o u f i n d a t e r m o r a b b r e v i a t i o n i n a ' 0 1 o r l a t e r m a n u a l t h a t i s u n f a m i l i a r t o y o u , c h e c k t h i s l i s t . I f a term is not listed below, it did not change. '01 or Later odels '00 and Earlier Models New Abbreviations Description Honda Abbreviations Description SAE recommendation Heated Oxygen Sensor (for A,/F SENSOR HO2S...

  • Page 28

    General Information Revised Component Terms (cont'd) '00 and Earlier Models '01 or Later odels Description Honda Abbreviations Description New Abbreviations SAE recommendation Intake Air Bypass Control IAB Control Solenoid Intake l\4anifold Runner I M R C S o l e n o i d V a l v e...

  • Page 29

    Specifications...

  • Page 30

    Standards and Service Limits Electrical Item Measurement Standard or New Service Limit Oualification l g n i t i o n c o i l R a t e d v o h a g € 1 2 V Firing order 1 3 4 2 Spark plug Tvpe...

  • Page 31

    nder Head Service Limit Stand.rd or New Measurement Oualificetion 0.05 mm {0.002 in.) H e a d 104.95' 105.05 mm (4.132- 4.136 in.) H e i g h t 0.05 0.15 mm (0.002 0.006 in.) 0.30 mm (0.012 in.) E n d p l a v C a m s h a f t 0.'15 mm (0.006 in.) Camshaft -to-holder oil clearance...

  • Page 32

    Standards and Service Limits Enqine Block Item Measuremont Clualification Standard or New Service Limit B l o c k 0.07 mm (0.003 in.)max. 0 . 1 0 m m ( 0 . 0 0 4 i n . ) Bore diameter 87.010 87.020 mm (3.4256 3.4260 in.

  • Page 33

    Standard or New Servic€ Limit Measurement Item Oualification 7 . 6 0 ( 8 . 0 U S q t , 6 . 7 l m p q 0 C o o l a n t c a p a c i t y ( i n c l u d e s e n g i n e , E n g i n e o v e r h a u l R a d i a t o r 6 .

  • Page 34

    Standards and Service Limits Manual Transmission Measurement Standard or New Service Limit Oualitidtion 1 . 4 8 0 ( 1 . 5 6 U S q t . , 1 . 3 0 l m p q t ) Transmission A t f l u i d c h a n q e C a p a c i t y 1 .

  • Page 35

    Service Limit Measuremenl Standard or New item Oualification 50.009 50.025 mm Countershaft reverse gear {1.9689 1.969s in.) 26.38 26.46 mm (1.039 1.042 in.) 26.26 mm 11.034 in.i Thickness 0.3 mm (0.012 in.) End play 0.04- 0.22 mm {0.002 0.009 in.) o.D.

  • Page 36

    Standards and Service Limits Differential itom Measurement Oualification Slenderd or New Service Limit Capacity 0 . 7 4 0 ( 0 . 7 8 U S q t . , 0 . 6 5 l m p q t ) D i f f e r e n t a a l o i l A t o i l c h a n o e 0.77 4 (0.81 US qt., 0.68lmp qt)

  • Page 37

    Brakes Standard or New Service Limit Measurement Ouelificetion llem Parking brake Distance traveled wh€n 1 3 c l i c k s s h o u l d l o c k t h e b r a k € s pulled with 196 N (20 kgf, 44 lbfl oI lever Pedal height (carpet removed)

  • Page 38

    Design Specifications Item M€a3uremeift Ouelilicetion Specificstion O I M E N S I O N S 4 , 1 2 0 m m ( 1 6 2 . 2 i n . ) O v e r a l l l e n g t h '1,750 mm (68.9 in.) O v e r a l l w i d t h O v o r a l l h e i g h t...

  • Page 39

    Clualification Specmcetion Measurement Item Electric, oowerassisted rack and pinion STEERING Type O v e r a l l r a t i o 2 . 4 Turns, lock-to-lock 3 6 0 m m ( 1 4 . 1 i n . ) S t e e r i n g w h e e l d i a m e t e r Independent double wishbone, coil spring with stabilizer Front...

  • Page 40

    Specilication Itsm Moasuroment Clualificetion 12V 36 AH/s hours ELECTRICAL Battery 1 2 V - 1 . 0 k W RATIN GS Starter 1 2 V 1 0 5 A Alternator Fuses 100A, 40A, 30A, 20A, 15A, r0A,7.5A UndeFhood fuse/relay box 70A, 604, 30A, 20A Underhood sub fuse/relay 20A, 15A, 10A,7.5A...

  • Page 41

    Body Specifications Unit mm lin.l 2-13...

  • Page 42

    Maintenance Lubricants and Fluids ....Maintenance Schedule for Normal Conditions (2000 Modell Listed by Distance/Time ..... Maintenance Schedule for Severe Conditions {2000 Model) Listed bv Distance/Time ..... Maintenance Schedule for Normal and Severe Conditions (2000 Modell Listed by Maintenance/ltem.......... Maintenance Schedule for Normal Conditions t2001-2003 Modelsl Listed by Distance/Time .....

  • Page 43: Lubricants And Fluids

    * 1: Always use Honda Manual Transmission Fluid (MTF). Using motor oil can cause stiffer shifting because it does not contain the Drooer additives. * 2:Always use Honda DOT 3 Brake Fluid. Using a non Honda brake fluid can cause corrosion and decrease the life of the system.

  • Page 44

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

  • Page 45: Maintenance Schedule For Normal Conditions

    Replace brake fluid (see page 19 8). Use Honda DOT 3 Brake Fluid. Fillto between marks on reservoir. Replace coolant (see page 10'8) Capacity: 6.5 q {6.9 US qt, 5.7 lmp qt}. Use Honda All Season Antifreeze/coolant Type 2. mi/144,000 km/ 6 y€ars Reolace transmission tluid.

  • Page 46

    Do the items in pans A, B, and C as required for mileage/time interval listed. R e p l a c e e n g i n e o i l ( s e e p a g e 8 - 5 ) . C a p a c i t y w i t h o u t { i l t e r c h a n g e : 4 . 5 0 ( 4 . 8 U S q t , 4 . 0 l m p q t ) , w i t h f i l t e r c h a n g e : 4 . 8 0 ( 5 . 1 U S q t , 4 . 2 l m p q t ) .

  • Page 47

    According to state and lederal rogulations, tailure to do the maintenance items marked with asterisk ( * ) will not void customer's emissions warranties. Howevet. Honda r€commends that allmaintenance services be done at the recommended interval to ansure long-tetm reliability.

  • Page 48

    Check parking brake adjustment. Should be fully applied within I to 13 clicks Lubricate locks, latches, and hinges with Honda white lithium grease. Inspect brake hoses and lines (in;luding ABS). Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage {see page 19-26).

  • Page 49: Maintenance Schedule For Normal And Severe Conditions

    Maintenance Schedule for Normal and Severe Conditions (2000 Modell Listed by Maintenance ltem Service at the indicated distance or time, whichever comes first. . lf driven in normal conditions, do items with a dot (a). . l f d r i v e n i n s e v e r e c o n d i t i o n s o r n o r m a l l y d r i v e n i n C a n a d a , d o t h e c i r c l e ( O l a n d d o t ( O l i t e m s . miles x 1000 3.75 1.5 11.25 15 1 8 7 5 22.5 26.25 30...

  • Page 50

    93.75 97.5 101.25105 108.75 112.5 11.25 15 78.75 86.25 90 41.25 15 18.75 56.25 60 63.75 187 't92 61t2 7 1t2 4112 5112 31t2 Normal Conditions: Every 7,500 miles (12,000 kmlor 1 year Severe Conditions: Every 3,750 miles (6,000 km) or 6 months Normal Conditions: Every other oil change Severe Conditions: Every oil change A d j u s t o n l y i l n o i s y .

  • Page 51: Maintenance Schedule For Normal

    Replace transmission fluid. 1.48 0 11.56 US qt, 1.30 lmp qt). Use Honda MTF (see page '13-3). 120,000 years, then replace every 60,000 mi/96,000 km/5 years BeDlace enqine coolant (see page 10-8). Capacitv:6.5 4 (6.9 US qt,5.7 lmp at). Use Honda All Season Antifreeze/coolant Tvpe 2. 3 - 1 0...

  • Page 52

    Do the items in parts A, B, C, and D as tequired for mileage/time interval listed ( 5 . 1 u S q t , 4 . 2 R e p l a c e e n g i n e o i t ( s e e p a g e 8 - 5 ) . , . C a p a c i t y w i r h o u t { i l t e r c h a n g e : 4 . 5 0 ( 4 . 8 u s q t , 4 . 0 l m p q t ) , w i t h f i l t e r c h a n g e : 4 . 8 0 l m p q t ) C h e c k t i r e i n f l a t i o n a n d c o n d i t i o n .

  • Page 53: Maintenance Schedule For Severe Conditions

    E Replace transmission fluid. '1.48 011.56 US qt, 1.30lmp qt). UseHonda MTF {see page 13-3). 120,000 mi/1 years, then every 60,000 mi/ 96,000 km/ 5 years lf Beolace enqine coolant (see paqe 1O 8)- Capacitv: 6.5 0 (6.9 US qt.5.7 lmo qt). Use Honda Allseason Antifreeze/coolant Tvoe 2. 3-12...

  • Page 54

    Check parking brake adiustment. lt should be fully applied within I to 13 clicks. Lubricate all hinges,locks and latches with Honda white lithium grease. Inspect brake hoies and lines (including ABSi. Check the master cylinder, proportioning control valve, and ABS modulator for damage and leakage (see page 19-26)- checli fluid leveis and condition of fluids;...

  • Page 55: Maintenance Schedule For Normal

    'According to state and tederal regulations, failure to dothe maintenance items marked with an asterisk 1'lwill notvoid customer's emissions warranties, However. Honda recommends that all maintenance services be done atthe recommended intervalto ensure long,term reliability. NOTE: l lfthe vehicle is driven in d usty cond itions, replacethe air cleaner element every l5,000 miles 124,000 kml, if not, replace itevery 30,0OO miles (a8,O00 km).

  • Page 56

    93.75 97.5 10125 105 108.75 112.5 78.75 82.5 86 25 67.5 71.25 15 41.25 45 48.75 52.5 5625 1 6 8 1 8 1 1 4 4 1 0 8 t 1 4 5112 6 1 1 2 4112 Normal Conditions: Everv 7,500 miles (12,000 km) ot 1 year Severe Conditions: Every 3,750 miles (6,000 km) or 6 months Normal Conditions: Every 15,000 miles 124,000 km)or 1 year Severe Conditions: Every oil change...

  • Page 57

    Engine Electrical Engine Electrical SoecialTools Starting System Component Location Index ..,..Circuit Diagram Starter Circuit Troubleshooting Clutch lnterlock Switch Test Starter Solenoid Test ....Starter Performance Test StarterReplacement ....,.. 4-10 Starter Overhaul .,...,....lgnition System 4-16 Component Location Index ....4-' tl Circuit Diagram 4- 18...

  • Page 58

    Engine Electrical SpecialTools Number Tool Number Description 07746-0010400 Attachment, 52 x 55 mm 07749-0010000 Driver -"-FJ ..-NN {^-''...

  • Page 59: Starting System

    Starting System Component Location Index CLUTCH INTERLOCK SWITCH est, page 4-6 ENGINE CONTROL MODULE IECMI IGNITION SWITCH ENGINE START SWITCH STARTER Troubleshooting, page 4-5 Solenoid Test, page 4-7 Performance. page 4-7 Replacement, page 4'8 Overhaul, page 4-10...

  • Page 60: Circuit Diagram

    Starting System Circuit Diagram...

  • Page 61: Starter Circuit Troubleshooting

    Starter Circuit Troubleshooting 4. Check the battery condition. Check electrical NOTE: . Air temperature must be between 59'and 100"F (15' connections at the battery, the negative battery cable to body, engine ground cables, and the a n d 3 8 " C ) d u r i n g t h i s p r o c e d u r e . .

  • Page 62: Clutch Lnterlock Switch Test

    Starting System Starter Circu it Troubleshootin g Clutch lnterlock Switch Test (cont'dl 1. Disconnect the connector from the clutch interlock switch, then remove the clutch interlock switch. 6. Check the following wires in the order listed until you find the open circuit. .

  • Page 63: Starter Solenoid Test

    Starter Performance Test Starter Solenoid Test Disconnect the wires from the S terminal and the 1. Check the hold-in coilfor continuity between the S M t e r m i n a l . terminal and the armature housing lground). There should be continuitv.

  • Page 64: Starterreplacement

    Starting System Stafter Performance Test {cont'dl Starter Replacement ' 1 . Make sure you have the anti-theft code for the radio, 5. Disconnectthe battery from the starter body. lfthe pinion retracts immediately, it is working properly. then write down the frequencies for the radio's preset buttons.

  • Page 65

    Disconnect the 4P connector (A) from the alternator 7. Disconnect the starter cable from the B terminal on the staner solenoid (A), then disconnect the (B), and disconnect the BLK wire from the alternator B lerminal (C). BLK,^/VHTwire from the S terminal (C). E x 1 .

  • Page 66: Starter Overhaul

    Starting System Starter Overhaul Disassembly/Reassembly I x 1.25 mm 8 r '1.25 mm 9 N.m (0.9 kgf m,7 lbt.ft) STARTER SOLENOID PINION DRIVE LEVER WASHER "'j@ ,/,.",o,^,,. 6x1omm 8 3 N m 1 o 8 8 k s r m ' @ n / #ffi #.,\ o u .

  • Page 67

    1. Remove the staner (see page 4-8). 5. Check the commutator diameter, lf the diameter is below the service limit, reDlace the armature. 2. Disassemble the staner. Commutator Diameter Standard {New}:28.0-28.1 mm {1.102 1.106 in.l Armature Inspection and Test 27.5 mm (1.083 in.l Seryice Limit: 3.

  • Page 68

    Starting System Starter Overhaul (cont'dl 7. Check the mica depth (A). lf the mica is too high (B), 9 . Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. undercut the mica with a hacksaw blade to the proper depth.

  • Page 69

    Starter Brush Holder Test Starter Brush Inspection 14. Check that there is no continuity between the (+ ) 11. lvleasure the brush length. lf it is not within the b r u s h h o l d e r { A ) a n d ( ) b r u s h h o l d e r ( B ) . l f t h e r e service limit, replace the brush holder assembly.

  • Page 70

    Starting System Stafter Overhaul (cont'dl '16. Pry 1 8 . Install the starter end cover (A) to retain the brush back each brush spring with a screwdriver. then h o l d e r ( B ) . position the brush about halfway out of its holder, and release the spring to hold it there.

  • Page 71

    Overrunning Clutch Inspection ,|9. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly. 20. Hold the planetary gear shaft (A), and turn the overrunning clutch assembly (B) both ways. lf it does not lock in either direction or it locks in both directions, reDlace it.

  • Page 72: Lgnition System

    lgnition System Gomponent Location Index IGNITION COIL/IGNITION CONTROL MODULE (ICMIASSEMBLIES '.ilt, -i\l;.,,,t1.'.---l t\]. SPARK PLUGS Inspection, page 4-19 4-16...

  • Page 73

    Circuit Diagram MAIN UNDIR- H@D FUST/iEIAY 4-17...

  • Page 74

    Aim the light toward the pointer {A). Check the ignition timing under no load conditions: Connect the Honda PGM Tester to the data link headlights, blower fan, and alr conditioner are not connector {DLC), and check for DTC's. lf a DTC is operating.

  • Page 75

    Spark Plug Inspection 2 . D o n o t a d j u s t t h e g a p o f p l a t i n u m t i p p l u g s ( A ) ; Inspect the electrodes and ceramic insulator.

  • Page 76: Component Location Index

    Charging System Component Location Index INDICATOR CHARGING SYSTEM IGNITION SWITCH _ . - '_=__=;:==,,,ii _1. i\ _:-- = , , ! : r l i \ ' \ \,\ \. -ai- - -----*\ - - - - - - - - r - l ' - .

  • Page 77

    Circuit Diagram MAINUNDER HOODfUSE/RTLAYEOX N o . { 1 { l O A l / : : \ N o l 2 i O A l G202 4-21...

  • Page 78: Charging Circuit Troubleshooting

    Gharging System Charging Circuit Troubleshooting 8. Connect the alternator 4P connector terminal No. 3 lf the charging system indicator does not come on or t o b o d y g r o u n d w i t h a j u m p e r w i r e . T u r n t h e does not go off, or the battery is dead or low, test the i g n i t i o n s w i t c h O N ( l l ) .

  • Page 79

    Alternator and Regulator Circuit Test L Raise the engine speed to 2.000 rpm, and hold it t h e r e . l. Be sure the battery connections are good, and that ls there voltage Iess than 13.5 V? the battery is sufficiently charged and in good condition (see page 22 39).

  • Page 80

    Charging System Charging Circuit Troubleshooting (cont'd) Alternator Control System Test 7. Check for continuity between the ECM connector C t e r m i n a l N o . 2 a n d b o d y g r o u n d . 1 .

  • Page 81

    Alternator-compressor Belt Inspection and Replacement 1. Check that the pointer (A) onthe auto-tensioner housing is not beyond the edge of the indicator rib {B} on the tensioner base. Move the auto-tensioner (A) to relieve tension from the alternator belt (B), and remove the alternator- compressor belt.

  • Page 82: Alternator Reolacement

    Charging System Alternator Replacement 1. Make sure you have the anti-theft code for the radio, 5. Remove the mounting bolts, then remove the then write down the frequencies for the radio's alternator. preset buftons. 10 x 1.25 mm 44 N.m 14.5 kgf.m,33lbf.ft) 2.

  • Page 83: Auto-tensioner Inspection/replacement

    Auto-Tensioner Inspection/Replacement Attach a torque wrench (A) to the pulley bolt. 1 . Check whether there is a change in the position of M e a s u r e t h e t o r q u e o n t h e t e n s i o n e r i n t e r n a l s p r i n g the auto-tensioner before starting the engine and with moving the torque wrench in the direction after starting the engine, lf there is a change in the...

  • Page 84

    Charging System Auto-Tensioner Inspection/Replacement (cont'dl 8. Remove the pulley bolt (left-hand threads), and 6. Remove the auto-tensioner. replace the tensioner pulley, (i1.3 kgf.m.31 lbl.ftl 8 x 1.25 mm 22 N.m {2.2 kgf.m, 16lbl'ft) 8 x 1.25 mm 22 N.m (2.2 kgt.m, 16lbf ftl 7.

  • Page 85: Alternator Overhaul

    Alternator Overhaul Exploded View STATOR BEARING DRIVE.END COVER RETAINER FRONT BEARING " (,D GJ_ 'sl:'d !0ii^> *-!/ | u/ // ''-:t _ \ i i J.F^FI, \:iii -"..- -\\- 'sraroa BRUSH HOLDER - '--.- - .. IBt9uo* Xi.Altfi"" PULLEY LOCKNUT l 1 1 N .

  • Page 86

    Charging System Alternator Overhaul (cont'd) 5. Remove the washer nut (A) and insulator (B) from Special Tools Required the "B" terminal, then remove the end cover (C) . Driver 07749-0010000 . Attachment, 52 x 55 mm 07746-0010400 a n d d u s t s e a l ( D ) . NOTE: Refer to the Exploded View as needed during t h i s p r o c e d u r e .

  • Page 87

    7. Remove the voltage regulator. JThJF. R:i-.. /rss56\ (Y'W-s\ PH]{{]d I l l l l / € l r \n""^- \!)Lbl h o u s i n g ( B ) , 10. Remove the four insulators (A), rear 8. Remove the four screws (A), then remove the a n d w a s h e r ( C ) .

  • Page 88

    Charging System Alternator Overhaul (cont'dl 11. (lf you are not replacing the front bearing and/or 14. With a hammer and commercially available tools rear bearing, go to step 18). Remove the rotorfrom shown, install a new rear bearing on the rotor shaft. the stator drive end housino.

  • Page 89

    '16. Rectifier Test Supportthe stator housing in a vise, and drive out the front bearing with a brass drift (A) and hammer. 18. Check for continuity in each direction, between the B terminal and P terminals, and between the E t e r m i n a l a n d P t e r m i n a l s o f e a c h d i o d e p a i r , All diodes should have continuity in only one direction.

  • Page 90

    Charging System Alternator Overhaul (cont'd) Alternator Brush Inspection Stator Test 19. Measure the length of both brushes (A) with a 22. Check that there is continuity between each pair of v e r n i e r c a l i p e r ( B ) . leads (A).

  • Page 91

    Cruise Control Component Location Index CRUISE CONTROL INDICATOR LIGHT BRAKE PEDAL POSITION SWITCH Test, page 4 47 Adjustment, page 19'6 CONTROL SET/RESUME SWITCH Test, page 4 42 Beplacement, page 4-42 CRUISE CONTROL MAIN SWITCH Test, page 4 40 page 4-41 Replacement, CRUISE CONTROL UNIT Input Test, page 4 38...

  • Page 92: Circuit Diagram

    Cruise Control Circuit Diagram cnu$ coMtot i ir $[rdr rG BUrcSW mAxtSW MA SYr cxutsE @flxo( uul MoroB loloR acruAToi otfN cr05r cl,uTor cnustm s|€tooilftB ctu.Totsw BmlY$ lliffi* 4-36...

  • Page 93: Symptom Troubleshooting Index

    Symptom Troubleshooting Index N O T E : ' T h e n u m b e r s i n t h e t a b l e s h o w t h e t r o u b l e s h o o t i n g s e q u e n c e . .

  • Page 94: Cruise Control Unit Input Test

    Gruise Gontrol Cruise Control Unit Input Test SRS components are located in this area, review the SRS component locations, precautions, and procedures in the SRS section (24) before performing repairs or service. 1 . R e m o v e t h e k n e e b o l s t e r u n d e r t h e s t e e r i n g c o l u m n . 2 .

  • Page 95

    Test: Desired result Cavity Wire color Test condition Possible cause it result is not obtained Blown No. 47 (10 A) ( No. 47 Check for voltage to ground: LT GRN/ l g n i t i o n s w i t c h O N ( l l ) , m a i n s w i t c h O N ( 1 5 A ) ) f u s e i n t h e m a i n There should be battery voltage.

  • Page 96: Main Switch Test

    Cruise Gontrol Main Switch Test 1 . C a r e f u l l y p r y t h e c r u i s e c o n t r o l m a i n s w i t c h o u t o f Check for continuity betlveen the No.2 and No.3 t h e i n s t r u m e n t p a n e l , t h e n d i s c o n n e c t t h e t e r m i n a l s .

  • Page 97: Main Switch/lndicator/lllumination Test

    Main Switch/lndicator/lllumination Main Switch/lndicator Bulb Test Replacement 1. Carefully pry the cruise control mainswitch(A) out 1 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . T u r n t h e l i g h t i n g of the instrument oanel, then disconnect the switch and the cruise control main switch {A) ON.

  • Page 98: Sevresume Switch Test

    Gruise Control Set/Resume Switch Replacement Set/Resume Switch Test 1 . Remove the two screws securing the seVresume 1. Remove the two screws securing the sevresume switch, then remove the switch. switch, then remove the switch. . : - Disconnect the connector from the switch. SWITCH CONNECTOR SET/RESUME Replace the switch.

  • Page 99: Cruise Control Actuator Test

    Cruise Gontrol Actuator Test With power and ground slill connected as in step 3, 1. Disconnect the 4P connector from the cruise connect battery power to the No. 4 terminal and control actuator. ground to No. 3 terminal, and check that the output linkage starts to turn from full closed position and stops at full opened position by the motor in the actuator.

  • Page 100: Cruise Control Actuator Replacement

    Cruise Gontrol Cruise Control Actuator Replacement 3. Remove the cruise control actuator assembly. 1 . Remove the actuator cover. and disconnect the 4P connector from the cruise control actuator. 7.2 rbr.ft r {./3;k?#ff'ksr.m. Disconnect the actuator cable end (A) from the o u t p u t l i n k a g e ( B ) .

  • Page 101: Actuator Cable Replacement

    Actuator Gable Replacement 3. Remove the accelerator pedal assembly. Remove the actuator cover, and disconnect the 4P conneclor from the cruise control actuator. 6 x 1 . 0 m m 1 3 N . m (1.3 kgf.m, 9.4 tbf.ftl 4. Disconnect the actuator cable end (A) from the arm (B) on the accelerator pedal assembly {C).

  • Page 102: Actuator Cable Adjustment

    Cruise Control Actuator Cable Adjustment 5. Turn the adjusting nut {A) until it is I mm (0.35 in.) Hold the cable sheath, removing all slack from the away from lhe actuator cable bracket when the throttle cable. throftle linkage starts open. Turn the adjusting nut (A) until it is 3 mm (1/8 in, ) away from the throttle cable bracket, 9 mm {0.35 in.)

  • Page 103: Clutch Pedal Position Switch Test

    Clutch Pedal Position Switch Test Brake Pedal Position Switch Test 1. Disconnect the connector from the clutch Dedal 1. Disconnectthe brake pedal position switch Dosition switch, then remove the switch. connector, and remove the switch. 2. Check for continuity between the No. 1 and the Checkthe clutch Dedal oosition switch connector No.

  • Page 105

    Engine Assembly Engine Removal 6. Disconectthe engine control module (ECM) N O T E : connectors (A) from the EcM. . Use fender covers to avoid damaging painted surfaces. . To avoid damage, unplug the wiring connectors carefully while holding the connector portion. .

  • Page 106

    9. Remove the throttle cable (A) by loosening the 1 1. Remove the battery cable (A) from the main locknut (B), then slipping the cable end out of the under-hood fuse/relay box, then remove the harness clamos (B). accelerator linkage. Take care not to bend the cable when removing it.

  • Page 107

    Engine Assembly Engine Removal (cont'dl Relieve the fuel pressure (see page 11-105). 1 4 . 17. Remove the two bolts securing the engine stop bracket. Remove the fuel feed hose (A), fuel return hose (B) t 5 . and brake booster vacuum hose (C). 1 8 .

  • Page 108

    23. Remove the engine stop bracket cushion (A), then remove the engine stop bracket (B). *----/-,:' rl\l 24. Lower the hoist. 25. Remove the heater hoses (A) and lower radiator h o s e ( B ) . (cont'd)

  • Page 109

    Engine Assembly Engine Removal (cont'd) 28. Remove the support nut from the left side engine 2 1 . Attach the chain hoist to the engine as shown. Take care not to damage the VTEC solenoid valve. mount bracket. Remove the support nut (A) and four mounting bolts (B), then remove the right side engine mount bracket {C).

  • Page 110

    Engine Installation 1. Installthe accessory brackets, and tighten their bolts to the specified torques. 10 x 1.25 mm i*il N.m 14.5 kgf.m,33 lbf.ftl 10 x 1.25 mm 38 N.m (3.9 kgf.m,28 lbt.ftl Green bolts. 8 x 1 .25 mm 22 N.m 12.2 kgt.m, 16lbt.ftl (cont'd)

  • Page 111

    Engine Assembly Engine Installation (cont'd) 2. Install the engine into position in the vehicle. 4. Tighten the support nut on the left side engine mount bracket. /12 x 1.25 rnfi Reinstall the mounting bolts/support nuts in / 54N m 15.5 ksrni, a0 '}t.ttl the sequence given.

  • Page 112

    6. lnstall the heater hoses (A) and lower radiator hose Install the front tires/wheels. ( B ) . 1 0 . Lower the hoist. 1 1 . Tighten the two bolts securing the engine stop bracket. " f f i t 12.

  • Page 113

    Engine Assembly Engine Installation (cont'dl Install the brake booster vacuum hose (A), fuel 16. Connect the ECM connectors (A) andmainwire 1 3 . harness connector (B), return hose (B) and fuel feed hose (C), using new washers (D). 14. Push the engine control module {ECM) connectors through the bulkhead, then installthe grommet (A).

  • Page 114

    20. Install the throttle cable (see page 11-125), then 1 8 . I n s t a l l t h e e l e c t r i c a l p o w e r s t e e r i n g ( E P S ) c o n t r o l a d j u s t t h e c a b l e ( s e e p a g e 1 1 - 1 2 4 ) .

  • Page 115

    Engine Mechanical Cylinder Head ..... 6-2 Soecial Tobls Comoonent Location lndex ....,,....... 6-6 DTC Troubleshooting ........ VTEC Solenoid Valve Test ..... 6-10 VTEC Rocker Arms Test ..... 6-12 Valve Clearance Adjustment Crankshaft Pulley Removal and lnstallation ....6-14 .

  • Page 116: Cylinder Head

    Cylinder Head SpecialTools Ref.No. Tool Number Description OTHAH-PJ7O,1OB V a l v e G u i d e R e a m e r , 5 . 5 m m 07JAA-001020A Socket, 19 mm 07JAB-001020A H o l d e r H a n d l e 07JAB-001040A Holder Attachment, 50 mm 07LAK-PR30r...

  • Page 117

    Component Location Index TDC1 SENSOR o-*'"o E ,"'*o"' RUBBER sEAL Bl------ Installation, page 6-53 'ii'ti' lS...''.-. i :-=-'J @,^-r5 \..-:@ DOWEL PIN EXHAUST CAMSHAFT InspecIron, page 6-36 RUBBER SEAL INTAKE CAMSHAFT GEAR DOWEL PIN i--\_.. EXHAUST CAMSHAFT s)'.i\ ROCKER ARM GEAR ASSEMBLY Overhaul,...

  • Page 118

    Cylinder Head Component Location Index (cont'd) EXHAUST VALVE GUIDE Inspection, page 6-39 Replacement, page 6 40 VALVE KEEPERS EXHAUST VALVE SEAL VALVE WASHER WASHER CAM CHAIN AUTO-TENSIONER EXHAUST VALVE v" Removal, page 6-38 Installation, page 6 44 DOWEL PIN INTAKE VALVE Removal, page 6 38 Inslallation, page 6-44...

  • Page 119

    CAM CHAIN Removal, page 6-15 Installation, page 6-19 CAM CHAIN GUIDE CHAIN CASE ICKPI SENSOR IDLER PULLEY BASE IDLER PULLEY COLLAR IDLER PULLEY PULLEY BOLT page 6-'14 Eeplacement, CRANKSHAFT PULLEY page 6-14 Replacement, CHAIN CASE OIL SEAL Installation, page 6-24...

  • Page 120: Dtc Troubleshooting

    Cylinder Head DTC Troubleshooting DTC P1259: A problem in the WEC Oil 6. Disconnecl the VTEC oil pressure switch 2P Pressure Switch circuit or VTEC Solenoid connector. Valve circuit. 7. Check for continuity on the VTEC oil pressure SpecialTools Bequired switch between the pressure switch 2P connector .

  • Page 121

    14. Remove the VTEC oil pressure switch (A) and 10. Measure voltage across the VTEC oil pressure i n s t a l l t h e s p e c i a l t o o l s a s s h o w n , t h e n r e i n s t a l l t h e switch harness 2P connector.

  • Page 122

    Gylinder Head DTC Troubleshooting (cont'd) With the battery positive terminal still connected to 27. Check for continuity between the VTEC solenoid the VTEC solenoid valve, measure voltage between valve 1P connector terminal and body ground. C 1 0 a n d b o d y g r o u n d . VTEC SOLENOID VALVE HARNESS 1P CONNECTOR ECM CONNECTOR C {13P)

  • Page 123: Vtec Solenoid Valve Test

    VTEC Solenoid Valve Test ' 1 . 4. lf the filter is not clogged. push the VTEC solenoid Disconnect the 1 P connector from the VTEC valve with your finger and check its movement. s o l e n o i d v a l v e . lf the VTEC solenoid valve is normal, check the e n g i n e o i l p r e s s u r e , Measure resistance between the terminal and body...

  • Page 124

    Gylinder Head WEC Rocker Arms Test Check that the air pressure on the shop air Special Tools Required . Gauge joint adapter 07LAK-PR30100 compressor gauge indicator is over 400 kPa . WEC air adapter 07ZAJ-PNAA100 (4 kgflcm',57 psi). Make sure no water in the air hose and air compressor tank.

  • Page 125

    9. With the specified air pressure applied and the piston at TDC, move the secondary rocker arm (A). The mid rocker arm (B). primary rocker arm (C) and secondary rocker arm should move together. lf the three rocker arms do not move together, replace the rocker arms as a set.

  • Page 126: Valve Clearance Adjustment

    Cylinder Head Valve Clearance Adjustment 4. Insert the feeler gauge (A) between the adjusting NOTE; Adjust the valves only when the cylinder head temoerature is less than 100'F (38"C). screw and the end ofthe valve stem and slide it b a c k a n d f o r t h ; y o u s h o u l d f e e l a s l i g h t a m o u n t o f d r a o .

  • Page 127

    '180'clockwise (camshaft 7. Rotatethe crankshaft 180' clockwise (camshaft 11. Rotate the crankshaft gears turn 90") gears turn 90') Check and. if necessary, adjust the valve clearance Check and, if necessary, adjust the valve clearance o n N o . 3 c y l i n d e r . o n N o .

  • Page 128: Crankshaft Pulley Removal And Lnstallation

    Cylinder Head Crankshaft Pulley Removal and lnstallation Installation Special Tools Required . H o l d e r h a n d l e 0 7 J A B - 0 0 1 0 2 0 A . Holder attachment, 50 mm 07JAB-0010404 1 .

  • Page 129: Cam Chain Removal

    Cam Chain Removal Special Tools Required 6. Remove the vacuum tank. . Holder handle 07JAB-0010204 . Holder attachment, 50 mm 07JAB-0010404 . Socket, 19 mm 07JAA-0010204 or a commercially available 19 mm socket NOTE: . Use fender covers to avoid damaging painted surfaces.

  • Page 130

    Cylinder Head Cam Chain Removal (cont'dl 9. Remove the water bypass hose (A), then remove Remove the auto-tensioner (see page 4-27! - 1 1 . the three bolts (B) securing the water bypass tube {c). 1 2 . Remove the alternator {see page 4-26). Remove the idler pulley (A), then remove the idler p u l l e y b a s e ( B ) , 1 0 .

  • Page 131

    21. Remove the engine wire harness connectors and Thread a nut onto the 5 x 0.8 mm bolt, then thread w i r e h a r n e s s c l a m p s f r o m t h e c y l i n d e r h e a d a n d the bolt into the maintenance hole in the cam chain auto-tensioner (see step 24 on page 6-29).

  • Page 132

    Gylinder Head Gam Chain Removal (cont'dl 40. Hold the pulley with holder handle (A) and holder 4 3 . R e m o v e t h e o i l p u m p c h a i n g u i d e . attachment (B).

  • Page 133: Cam Chain Installation

    Cam Chain Installation Special Tools Required 2. Install the cam chain with the colored piece (A) . Holder handle 07JAB-0010204 aligned with the punch mark (B) on the crankshaft . Holder attachment,50 mm 07JAB-0010404 sDrocKel. . Socket, 19 mm 07JAA-001020A or a commercially available '19 mm socket 1.

  • Page 134

    Gylinder Head Cam Chain Installation (cont'd) Remove old liquid gasket from the oil pan mating 4. Remove old liquid gasket from the chain case surfaces, bolts and bolt holes. mating surfaces, bolts and bolt holes, Clean and dry the oil pan mating surfaces. 5.

  • Page 135

    12. Clean the bolt (A), washer (B), pulley (C)and 14. Measure the diameter of each cylinder head bolt at crankshaft (D). Lubricate as shown below. point A and point B (see step 1 on page 6-45). lf either diameter is less than 1 1.5 mm (0.45 in.), O: Clean replace the cylinder head bolt.

  • Page 136

    Gylinder Head Cam Chain Installation (cont'dl 29. Apply engine oil to the idler gear center bolt 26. Installthe cam chain on the sprocketwith the punch mark (A) aligned with the center of the two threads. Install a new O-ring on the bolt. colored pieces (B).

  • Page 137

    Installthe alternator (see page 4-26). Installthe exhaust manifold using new gaskets and new self-locking nuts {see step 3'l on page 6-50). Installthe auto-tensioner {see page 4-27). 5 7 . Installthe exhaust manifold bracket. Make sure the Install the water pump pulley. smooth sides of the washers face the exhaust manifold bracket (see step 32 on page 6-50).

  • Page 138: Chain Case Oil Seal Installation

    Gylinder Head Cam Chain Installation (cont'dl Chain Case Oil Seal Installation Special Tools Required Install the alternator-compressor belt. . Driver 07749-0010000 . Attachment, 52 x 55 mm 07746-0010400 6 1 . lnstall the vacuum tank. 1. Use the specialtools to drive a new oil seal squarely into the chain case to the specified installed height.

  • Page 139

    Cylinder Head Removal NOTE: 6. Move the auto-tensioner (A) to remove tension ' U s e f e n d e r c o v e r s t o a v o i d d a m a g i n g p a i n t e d from the alternator belt (B), then remove the su rfaces.

  • Page 140

    Cylinder Head Cylinder Head Removal (cont'd) 1 1. Remove the bolt (A) securing the intake manifold 8. Relieve fuel pressure. bracket, and remove the air hose (B). 9. Remove the fuelfeed hose (A), fuel returnhose{B) and brake booster vacuum hose (C). tt',,;Z:i ".':::-G i..€-.

  • Page 141

    13. Remove two bolts (A) securing the intake manifold 1 5 . Remove the four bolts securing the exhaust bracket, and remove the water bypass hose (B). manifold cover. " \ , , ) , l - i 16. Remove the three bolts (A). and loosen the bolt {B), t h e n r e m o v e t h e h e a t s h i e l d ( C : .

  • Page 142

    Gylinder Head Cylinder Head Removal (cont'dl 17. Remove the exhaust manifold cover, then remove 1 9 . R e m o v e t h e i g n i t i o n c o i l c o v e r { A ) , t h e n r e m o v e t h e the exhaust manifold bracket (A) and the exhaust manifold (B).

  • Page 143

    Remove the end cover (A) and nozzle (B) from the 21. Remove the cylinder head cover, cam chain auto-tensioner. Thread a nut {A) onto a 5 x 0.8 mm bolt that is at least 40 mm long (B), then thread the bolt into the maintenance hole in the cam chain auto-tensioner.

  • Page 144

    Cylinder Head Cylinder Head Removal (cont'dl 26, Remove the cam chain auto-tensioner. Remove the camshaft holders and camshafts. Insert the bolts (A) into the rocker shaft holder. then remove the rocker arm assembly {B). 27. Loosen the rocker arm adjusting screws (A). 30.

  • Page 145: Camshaft Gear Removal

    Camshaft Gear Removal 1 . Remove the dipstick, positive crankcase ventilation 31. Remove the cylinder head bolts. To prevent (PCV) hose and breather hose (see step 18 on page warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all the bolts are 6-28).

  • Page 146: Cylinder Head Inspection For Warpage

    Cylinder Head Cylinder Head Inspection for Warpage 1 . Remove the cylinder head (see page 6-25). Inspect the camshaft (see page 6-36). Check the cylinder head for warpage. Measure along the edges. and three ways across the center. . lf warpage is less than 0.05 mm (0.002 in.) cylinder head resurfacing is not required.

  • Page 147: Rocker Arms And Shafts Disassembly/reassembly

    Rocker Arms and Shafts Disassembly/Reassembly NOTE: . l d e n t i f y p a r t s a s t h e y a r e r e m o v e d t o e n s u r e r e i n s t a l l a t i o n i n t h e i r o r i g i n a l l o c a t i o n s .

  • Page 148: Rocker Arms And Shafts Inspection

    Cylinder Head Rocker Arms and Shafts Inspection 1 . Remove the dipstick, positive crankcase ventilation 9. Measure the inside diameter of the rocker arm. and {PCV) hose and breather hose (see step 18 on page check it for an out-of-round condition, 6-28).

  • Page 149

    11. Inspect the rocker arm pistons (A). Push each piston manually. lf it does not move smoothly, replace the rocker arm assemDry. NOTE: . When reassembling the primary rocker arm (B), carefully apply air pressure to its oil passage. . Apply oil to the pistons when reassembling. 6-35...

  • Page 150: Camshaft Lnsoection

    Cylinder Head Camshaft Inspection NOTE: Do not rotate the camshaft during inspection. 1 0 . Z e r o t h e d i a l i n d i c a t o r a g a i n s t t h e e n d o f t h e camshaft, then push the camshaft back and forth 1.

  • Page 151

    1 8 . M e a s u r e c a m l o b e h e i g h t . 16. Remove the camshaft holders. Measure the widest portion of plastigage on each journal. Cam Lobe Height Standard (New): .

  • Page 152: Valves, Springs, And Valve Seals Removal

    Cylinder Head Valves, Springs, and Valve Seals Removal Special Tools Bequired 4. Installthe valve guide seal remover. Valve spring compressor attachment 077 57 -P J'1010A ldentify the valves and valve springs as they are removed so that each item can be reinstalled in its o r i g i n a l p o s i t i o n .

  • Page 153: Valve Inspection

    Valve Stem-to-Guide Clearance Valve Inspection lnspection 1 . Remove the valves (see page 6-38) 1 . Remove the valves (see page 6-38) Measure the valve in these areas. Slide the valve out of its guide about 10 mm, then Intake Valve Dimensions measure the guide-to-stem clearance with a dial A Standard lNewl: 35.90-36.10 mm ( 1 .

  • Page 154: Valve Guide Reolacement

    Cylinder Head Valve Guide Replacement Special Tools Requir6d 5. Working from the camshaft side, use the driver and . Valve guide driver, 5.5 mm 07742-0010'100 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 .

  • Page 155

    1 0 . Coat both reamer and valve guide with cutting oil. 9 . A p p l y a t h i n c o a t o f c l e a n e n g i n e o i l t o t h e o u t s i d e of the new valve guide.

  • Page 156: Valve Seat Reconditioning

    Cylinder Head Valve Seat Reconditioning 1 . Inspect valve stem-to-guide clearance (see page 6- 6, After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound (A) to the 39). lf the valve guides are worn, replace them (see page 6-40) before cutting the valve seats.

  • Page 157

    8. Insert the inlake and exhaust valves in the head and measure valve stem installed height (A). Intake Valve Stem Installed Height: Standard (New): 44.1 - 44.4 mm {1.736 - 1.748 in.) Service Limit: 44.7 mm 11.760 in.) Exhaust Valve Stem Installed Height: Standard (New): 44.2 44.5 mm {1.740 - 1.752 in.) 44.8 mm (1.764 in.)

  • Page 158: Valves, Springs, And Valve Seals Installation

    Gylinder Head Valves, Springs, and Valve Seals Installation 5 . 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 . P l a c e t h e Special Tools Required end of the valve spring with closely wound coils Valve spring compressor attachment 07757-PJ1010A...

  • Page 159: Camshaft Gear Installation

    Camshaft Gear Installation Cylinder Head Installation 1. Installthe camshaft gear (A). 1. Measure the diameter of each cylinder head bolt at ooint A and ooint B. lf either diameter is less than 1 . 5 m m ( 0 . 4 5 i n . ) , r e p l a c e t h e c y l i n d e r h e a d b o l t . B 50 mm {2.0 in.) A 45 mm 11.8 in.) *'h,i...

  • Page 160

    Cylinder Head Gylinder Head Installation (cont'd) Installthe dowel pins (A) and the new cylinder head Install the cylinder head on the block. gasket (B). A p p l y e n g i n e o i l t o t h e t h r e a d s a n d u n d e r t h e h e a d s o f a l l t h e c y l i n d e r h e a d b o l t s .

  • Page 161

    1 1 . Make sure the crankshaft pulley is at top dead 14. Install the cam chain on the sprocket, then fitthe center (TDC). Align the TDC mark (A) on the idler gear collar into the cylinder head. crankshaft pulley with the pointer (B) on the chain 15.

  • Page 162

    Gylinder Head Cylinder Head Installation (cont'd) 21. lnstallthe cam chain auto-tensioner (A) in the 18. Clamp the cam chain auto-tensioner in a soft-iawed cylinder head with new O-rings (B). v i s e . 19. Turn the 5 x 0.8 mm bolt (A) clockwise to compress the bottom of the auto-tensioner, then insert the set p i n ( B ) , P / N 1 4 5 1 1 - P C X - 0 0 5 .

  • Page 163

    lnstall the rocker arm assembly. 28. Make sure the camshaft gears are at TDC. Check the alignment of the TDC marks {A) on the cam chain sprocket with the cylinder head surface. Adjust the valve clearance (see page 6-12). Install the cylinder head cover (see page 6-53). 25.

  • Page 164

    Gylinder Head Cylinder Head Installation (cont'd) Install the exhaust manifold (A) using new gaskets Put the exhaust manifold cover on the exhaust 3 1 . (B) and new self-locking nuts (C). manifo ld. 10 x 1 ,25 mm lnstall the heat shield. 44 N.m (4.5 kgf.m.33lbt.ftl Install the exhaust manifold bracket (D).

  • Page 165

    36. Installthe intake manifold (Alwith a new gasket (B). 37. Installthe water bypass hose (A), and tighten the two bolts (Bl securing the intake manifold bracket. 8 x 1.25 mm 22N.n kgl.m, 16 lbl ft) t\-.-- 10 x 1.25 mm il4 N.m {,1.5 kgf.m,33 lbf.ft}...

  • Page 166

    Cylinder Head Cylinder Head Installation (cont'd) 41. Installthe brake booster vacuum hose (A), tuel Installthe air hose (A), and tighten the bolt (B) return hose (B) and fuel feed hose (C). using new securing the intake manifold bracket. w a s h e r s ( D ) . '10 x 1.25 mm 44 N.m {,1.5 kgf.m.33 lbt.ftl...

  • Page 167: Cylinder Head Cover Installation

    Cylinder Head Cover Installation 44. Installthe throttle cable (see page 11-125), then Install the head cover gasket in the groove of the adjust the cable (see page 11-1241. cylinder head cover. 45. After installation. check that alltubes, hoses and Set the spark plug seal (A) on the spark plug tube. connectors are installed correctly.

  • Page 168

    Gylinder Head Cylinder Head Cover Installation (cont'dl 8 . I n s t a l l t h e i g n i t i o n c o i l s ( A ) , t h e n i n s t a l l t h e i g n i t i o n 3.

  • Page 169

    Engine Mechanical Engine Block SpecialTools ..... 7-2 Component Location Index ....,..,..,,.., Flywheel Removal and Installation ......Connecting Rod and Crankshaft End Play Inspection ....Crankshaft Main Bearing Replacement ...... Connecting Rod Bearing Replacement ...... 7 -11 Crankshaft and Pistons Removal ....-....Crankshaft Inspection ......

  • Page 170: Engine Block

    Engine Block Special Tools Description Tool Number Ref.No. R i n g G e a r H o l d e r 07LAB-PV00100 S e a l D r i v e r O7LAD.PT3O1OA 07749-0010000 Driver 07948-SB00101 Driver Attachment...

  • Page 171: Component Location Index

    Component Location Index LOWER BLOCK OOWEL PIN WASHER *i'h ' " h \ : \-lY, 'ri .;:-':1// MAIN BEARINGS Oilclearance, page 7-7 Selection, FLYWHEEL step 1 on page 7 8 CRANKSHAFT OIL SEAL Installation, page 7 26 CRANKSHAFT THRUST WASHERS End play, page 7-6 Runout, Taper and Out-of-Round, p a g e i 1 3...

  • Page 172

    Engine Block Component Location Index (cont'dl ( a:x t > : < SNAPRNG \ffi (': l/ ra?-.-.',, ^-,0 \prsroN \g< Removal, page 7-'17 Installation, step 1 on page 7-'19 Inspection, step 1 on page 7-18 PISTON R e m o v a l , p a g e 7 - 1 1 page 7'14 Measurement, CONNECTING ROD...

  • Page 173: Flywheel Removal And Installation

    Flywheel Removal and Installation Special Tools Required Ring gear holder 07LAB-PV00100 1. Rem ove the tra nsm ission (see page 13-5), 2. Remove the pressure plate and clutch disk {see page 12-7). 3. Remove the eight flywheel bolts.then separate the flywheel from the crankshaft flange.

  • Page 174: Connecting Rod And Crankshaft End Play Inspection

    Engine Block Connecting Rod and Crankshaft End Play Inspection 1 . Remove the oil pump (see page 8-9). 4. Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back Measure the connecting rod end play with a feeler gauge between the connecting rod and crankshaft.

  • Page 175: Crankshaft Main Bearing Replacement

    Crankshaft Main Bearing Replacement Main Bearing Clearance Inspection 6. lf the plastigage measures too wide or too narrow, (remove the engine if it's still in the vehicle), remove the crankshaft, and remove the upper half To check main bearing-to-journal oil clearance, remove the lower block and bearing halves.

  • Page 176

    Engine Block Crankshaft Main Bearing Replacement {cont'd) Main Bearing Selection Main Journal Code Location 2. The main journal codes are stamped on the No. 1 Crankshaft Bore Code Location weo. 1. Numbers or letters or bars have been stamped on the end of the block as a code for the size of each of the 5 main journal bores.

  • Page 177: Connecting Rod Bearing Replacement

    Connecting Rod Bearing Replacement Rod Bearing Clearance Inspection Rod Bearing Selestion 1. Inspect each connecting rod for cracks and heat 1. Remove the connecting rod cap and bearing half ( s e e p a g e 7 - ' 1 1 ) . damage.

  • Page 178

    Engine Block Connecting Rod Bearing Replacement (cont'd) Use the big end bore codes and rod journal codes Connecting Rod Journal Code Location to select appropriate replacement bearings from 3. The connecting rod journal codes are stamped on the following table. t h e N o .

  • Page 179: Crankshaft And Pistons Removal

    Crankshaft and Piston Removal 1. Remove the cam chain (see page 6-15). 5. Remove the lower block and bearings. Keep all bearings in order. 2. Remove the oil pump (see step 1 on page 8-9). 3. Remove the 8 mm bolts. 'ffff$ll: 6 .

  • Page 180

    Engine Block Crankshaft and Piston Removal (cont'dl lf you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. lf the ridge is not removed, it may damage the piston as it is pushed out, 9 .

  • Page 181: Crankshaft Inspection

    Crankshaft Inspection Straightness Out-of-Round and Taper 6. Place the cylinder block on the surface plate. 1. Remove the crankshaft from the cvlinder block (see p a g e 7 - 1 1 ) . 7 . C l e a n a n d i n s t a l l t h e b e a r i n g s o n t h e N o . 1 a n d No.

  • Page 182

    Engine Block Block and Piston Inspection 1 . Remove the crankshaft and pistons (see page 7-1 1). 4. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. lf Check the Diston for distortion or cracks. measurements in any cylinder are beyond the Oversize Bore Service Limit, replace the block.

  • Page 183

    7. Calculate the difference between the cylinder bore Scored or scratched cylinder bores must be honed. diameter and the piston diarneter. lf the clearance is near or exceeds the service limit, inspect the Check the top of the block for warpage. Measure Diston and cvlinder block for excessive wear.

  • Page 184

    Engine Block Cylinder Honing The cylinder liners are made wlth FRM ({iber rein{orced metal). Hone the cylinders only as described here. 1. Measure the cylinder bores (see step 3 on page 7- 14). lf the engine block is to be reused, hone the cVlinders and remeasure the bores.

  • Page 185: Piston, Pin And Connecting Rod Replacement

    Piston, Pin, and Connecting Rod Replacement Disassembly 4, Heat the piston and connecting rod assembly to '158"F {70'C), then remove the approximately 1. Remove the piston from the cylinder block (see p i s t o n p i n . p a g e 7 1 1 ) .

  • Page 186

    Engine Block Piston, Pin, and Connecting Rod Replacement {cont'd) Inspection 3. Check the difference between the Diston Din diameter and piston pin hole diameter in the piston. NOTE: Inspect the piston, piston pin and connecting rod when they are at room temperature. Piston Pin-to-Piston Clearance: Standard {New): 0.0030 to +0.0060 mm 1 .

  • Page 187

    4. Installthe piston pin (A). Assemble the piston (B) Reassembly "lN" mark and connecting rod (C)with the {D) and the reference mark (E) on the same side. 1 . I n s t a l l a n e w p i s t o n p i n s n a p r i n g ( A ) . Coat the piston pin bore in the piston and the connecting rod, and the piston pin with engine oil.

  • Page 188: Piston Ring Replacement

    Engine Block Piston Ring Replacement Remove the piston from the cylinder block (see 4. Using a piston, push a new ring (A) into the c y l i n d e r b o r e 1 5 2 0 m m ( 0 . 6 0 . 8 i n . ) f r o m t h e p a g e 7 - 1 1 ) .

  • Page 189

    6. Installthe rings as shown. The top ring (A) has a R1 7 . Rotate the rings in their grooves to make sure they mark and the second ring (B) has a R2 mark. The do not bind. manufacturing marks (C) must be facing upward. Position the ring end gaps as shown: About 90' OIL RING GAP...

  • Page 190: Piston Fnstallation

    Engine Block Piston Installation lf the crankshaft is already installed 6, Checkthe connecting rod bearing clearance with plastigage {see page 7-9). 1. Set the crankshaft to bottom dead center (BDC) for 7 . A p p l y e n g i n e o i l t o t h e t h r e a d s o f t h e c o n n e c t i n g e a c h c y l i n d e r .

  • Page 191

    lf the crankshaft is not installed Remove the connecting rod caps, then install the ring compressor, and check that the bearing is securely in place. Position the arrow (A) facing the timing chain side o f t h e e n g i n e . Position the piston in the cylinder.

  • Page 192: Crankshaft Lnstallation

    Engine Block Crankshaft Installation 1 0 . Special Tools Required Tighten the connecting rod bolts in sequence to 25 . Driver 07749-0010000 N.m (2.5 kgf m, 18 ibf ft). . Driver attachment 07948-S800101 1 1 . Tighten the connecting rod bolts an additional 90'. 1 .

  • Page 193

    1 3 . Put the lower block on the cvlinder block. 17. Use the sDecialtools to drive a new oil seal squarely into the block to the specified installed 1 4 . Tighten the bearing cap bolts is sequence to height.

  • Page 194: Transmission End Crankshaft Seal

    Engine Block Pulley End Crankshaft Seal Transmission End Crankshaft Seal Installation - In Car lnstallation - In Car Special Tools Required Special Tools Required ' Seal driver 07LAD-PT3o10A . Driver 07749-0010000 . Driver attachment 07948-S800101 1. Dry the crankshaft oil seal housing. 1.

  • Page 195

    Engine Mechanical...

  • Page 196

    Engine Lubrication SpecialTools Number Tool Number Description 0 7 9 1 2 - 6 1 1 0 0 0 1 O i l F i l t e r W r e n c h...

  • Page 197

    Component Location Index OIL PAN BAFFLE PLATE +DRAINBOLT OIL PUMP Overhaul, page 8-8 Inspection, step 6 on page 8-10 KNOCK SENSOR page 8.7 OIL PUMP CHAIN TENSIONER CRANKSHAFT ENGINE OIL COOLER ENGINE OIL COOLER CENTEN BOLT OIL PUMP CHAIN GUIDE CHAIN CASE ENGINE OIL PRESSURE SWITCH Circuit Diagram, page 22-47...

  • Page 198

    1. Connect a tachometer or a Honda PGN4 Tester. 2 . R e m o v e t h e e n g i n e o i l p r e s s u r e s w i t c h , a n d i n s t a l l a n o i l p r e s s u r e g a u g e ( A ) .

  • Page 199

    Engine Oil Replacement NOTE: Under normal conditions, the oilfilter should be replaced at every other oil change. Under severe conditions. the oil filter should be reolaced at each oil c n a n g e . Change interval Evory 7,500 miles (12.000 kml or 12 months (Normal conditions) Every 3,750 miles (6.000 kml or 6 months {Severe conditionsl.

  • Page 200

    Engine Lubrication Engine Oil Filter Replacement 5. lf eight numbers (1 to 8) are printed around the SpecialTools Required outside of the filter, use the following procedure to Oil Filter Wrench 07912-61 1000'1 tighten the filter. . Spin the filter on until its seal lightly seats against 1.

  • Page 201

    OilJet Inspection 1 . R e m o v e t h e o i l i e t , a n d i n s p e c t i t a s f o l l o w s . M a k e s u r e t h a t a 1 .

  • Page 202

    Engine Lubrication OilPump Overhaul Exploded View PUMP COVER DOWEL PIN OUTER ROTOR PUMP HOUSING DOWEL PIN RELIEF VALVE Valve must slide treely in housing bore. Replace if scored. SEALING BOLT 39 N.m (i0.0 kgl.m,29lbf.ltl 6 x 1 . 0 m m 12 N.m DOWEL PINS (1.2 kgf.m,8.7 lbf.ftl...

  • Page 203

    4. Remove the three bolts securing the oil pump. Removal 1. Remove the cam chain (see page 6-'15). 2 , R e m o v e t h e o i l p u m p c h a i n t e n s i o n e r . 5.

  • Page 204

    Engine Lubrication Oil Pump Overhaul (cont'd) Inspection 9. Check the housing-to-outer rotor radial clearance between the outer rotor (A) and pump housing (B). 6. Remove the DumD cover. lf lhe housing-to-outer rotor radial clearance exceeds the service limit, reolace the outer rotor a n d o i l p u m p h o u s i n g .

  • Page 205

    13. Tighten the bolts on the oil pump. Installation x 1.25 mm 1 1 . S q u e e z e t h e n e w o i l p u m p c h a i n t e n s i o n e r ( A ) , t h e n 22 N.m (2.2 ksf.m, 16 lbl ft) i n s t a l l t h e s e t c l i p ( B ) o n i t a s s h o w n .

  • Page 206

    Engine Lubrication Oil Pump Overhaul (cont'dl Set the crankshaft sprocket so that the No. 1 piston 1 1 . I n s t a l l t h e o i l p u m p c h a i n g u i d e ( A ) a n d o i l p u m p is at top dead center (TDC).

  • Page 207

    Engine Mechanical Intake Manifold and Exhaust System Intake Manifold Removal/lnstallation ..........Exhaust Manifold Removal/lnstallation Exhaust Pipe and Muffler Replacement .....

  • Page 208

    Intake Manifold and Exhaust System Intake Manifold RemovaUlnstallation NOTE: Use new O-rings and gaskets when reassembling. 5 x 0 . 8 m m 6 N . m AIR CONTROL VALVE tbf.ft) {0.6 kgf m, TNTAKE AtR TEMPERATURE {rAT)SENSOR 8 x 1 . 2 5 m m 22 N.m 8 x 1 .

  • Page 209

    Exhaust Manifold RemovaUlnstallation NOTE: Use new gaskets and self-locking nuts when reassembling. 8 x 'l.25 mm 22 N.m (2.2 ksf.m, 16 lbt ftl 6 x 1 . 0 m m 1 2 N . m {1.2 kg{ m, 8.7 rbf.ftt 0 f o '14 N.m {1.4 kgf.m, 10 lbt ft}...

  • Page 210

    Intake Manifold and Exhaust System Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self{ocking nuts when reassembling. SELF.LOCKING 6 x 1 , 0 m m 10 x 1.25 mm 1 2 N . m 33 N.m (1.2 kgl.m,8.7 lbf.ftl (3.,1kgf.m,25 lbl'ft) Replace.

  • Page 211: Comoonent Location Index

    Engine Cooling Cooling System 10-2 Comoonent Location Index ...,..,..10-5 Radiator Cao Test ....1 p - 5 Radiator Test 10-6 Fan Motor Test ThermostatTest ...... 10-6 Water Pump Inspection tu- I Water Pump Replacement 10-7 Coolant Replacement ..... 10-8 1 0 - 1 0 Thermostat ReDlacement Radiator and Fan Reolacement .....

  • Page 212

    Cooling System Component Location Index RADIATOR Replacement, page 10'1 1 RADIATOR CAP UPPER RADIA COOLANT /'-' RESERVOIR .""*oY LOWER O-RING FAN MOTOR RADIATOR FAN SWITCH Test, page'10-6 Test, page 10-18 Replacement, DRAIN PLUG p a g e 1 0 - 1 1 RADIATOR FAN SHROUD Replacement, page 10-1 1 TOR HOSE...

  • Page 213

    IDLE AIR CONTROL IIAC) VALVE HEATER VALVE OIL COOLER BYPASS HOSE BYPASS TUBE WATER THERMOSTAT COVER HEATER HOSES -.,!,'jj uppenmDrAroRHosE LOWER RADIATOR HOSE (cont'd) 10-3...

  • Page 214

    Cooling System Component Location Index {cont'd) - - i ' - : ' f . ENGINE COOLANT TEMPERATURE l r r € _ ' , {ECTI SENSOR O.RING WATER OUTLET COVER THERMOSTAT page 10-'l0 Replacement, Inspection, page 10-6 THENMOSTAT COVER l) o'\, RUBBER SEAL THERMOSTAT...

  • Page 215

    Radiator Cap Test Radiator Test 1. Remove the radiator cap (A). wet its seal with 1. Wait until the engine is cool, then carefully remove engine coolant, then install it on the pressure tester the radiator cap and fill the radiator with engine ( B ) ( c o m m e r c i a l l y a v a i l a b l e ) .

  • Page 216: Fan Motor Test

    Cooling System Fan Motor Test Thermostat Test 1. Disconnect the 2P connectors from the radiator fan Replace the thermostat if it is open at room motor (A) and condenser fan motor (B). temperature. To test a closed thermostat: 1. Suspend the thermostat (A) in a container of water. Do not let the thermometer (B) touch the bottom of the hot container.

  • Page 217: Water Pump Inspection Tu- I

    Water Pump Replacement Water Pump Inspection Loosen the water pump pulley bolts. Loosen the water pump pulley bolts. Move the auto-tensioner to remove tension from fMove the auto-tensioner to remove tension from the alternator-compressor belt. then remove the the alternator-compressor belt, then remove the alternator-compressor belt (see step 8 on page 6- alternator-compressor belt (see step 8 on page 6- 1 5 ) .

  • Page 218: Coolant Replacement

    7 . R e m o v e , d r a i n , a n d r e i n s t a l l t h e r e s e r v o i r . F i l l t h e maximum heat. tank to the MAX mark with Honda All Season Antifreeze/Coolant Type 2 (P/N O1999-9001).

  • Page 219

    With the radiator cap off, start the engine and let it run until warmed up {radiator fan comes on at least twice). Then, if necessary, add more Honda All Season Antifreeze/Coolant Type 2 to bring the level back up to the bottom of the filler neck.

  • Page 220: Thermostat Redlacement 1 0 - 1

    Cooling System Thermostat Replacement Y r t --/./ /';-'s, "1,'-'lt' ../...

  • Page 221

    Radiator and Fans Replacement UPPEF RADIA TOR HOSE LOWER CUSHION 6 x 1 . 0 m m 7 N.m (0.7 kgf.m,5lbf.ftl RADIATOR FAN SHROUD ASSEMBLY 1 . 0 m m 7 N.m {0.7 kgl.m, 5 lbf ftl A/C CONDENSER FAN RADIATOR SHROUD ASSEMBLY swtTcH...

  • Page 222: Fan Controls

    Fan Controls Component Location Index UNDER-HOOD FUSE/RELAY A/C CONDENSER FAN RELAY Test, step 10 on page 23-41 RADIATOB FAN RELAY Test, step 10 on page 23-41 RADIATOR FAN SWITCH RADIATOR FAN ASSEMBLY Test, page 10 18 Motor Test, page 10 6 A/C CONDENSER FAN ASSEMBLY Motor Test, page 10-6 10-12...

  • Page 223: Symptom Troubleshooting Index

    Symptom Troubleshooting Index Before performing any troubleshooting procedures check: . Fuses . Grounds . Cleanliness and tightness of all connectors SYMPTOM PROCEDURE Radiator Fan Circuit Troubleshooting {see page 10-15). Radiator tan does not run at all Radiator Fan Switch Circuit Troubleshooting (Open) Radiator fan does not run for engine cooling.

  • Page 224

    Fan Controls Circuit Diagram MAIfl UNOEE-HOOD FUSE/8ETAY GflnoN swtTcH / 8AT \ \ c 2 8 l IG2 HOT h ON II|| G201 G301 -mhrito 1 0 - 1 4...

  • Page 225

    Radiator Fan Gircuit Troubleshooting 1 . C h e c k t h e N o . 5 7 { 2 0 A } f u s e i n t h e m a i n u n d e r - h o o d 4.

  • Page 226

    Fan Gontrols Radiator Fan Circuit Troubleshooting (cont'd) 9 . Reinstall the radiator fan relay. Disconnect the radiator fan motor 2P connector. 1 0 . Disconnect the radiator fan switch 2P connector. Check for continuity between the No. 2 terminal of the radiator fan relay 4P socket and the No.

  • Page 227: Radiator Fan Switch Circuit Troubleshooting (open)

    Radiator Fan Switch Circuit Radiator Fan Switch Circuit Troubleshooting (Openl Troubleshooting (Shon) 1. Disconnect the radiator fan switch 2P connector. 1, Remove the radiator fan relay from the main under- hood fuse/relay box, and test it (see page22-401. 2. Turn the ignition switch ON (ll). ls the rclay OK? 3.

  • Page 228: Radiator Fan Switch Test

    Fan Gontrols Radiator Fan Switch Test NOTE: Bleed air from the cooling system after installing the radiator fan switch (see page 10-81. 1. Remove the radiator fan switch from the radiator ( s e e p a g e ' ! 0 - 1 1 ) . 2.

  • Page 229

    Fuel and Emissions Fuel and Emissions Systems Fuel Pressu re Regulator S p e c i a l T o o l s ......R e p 1 a c e m e n t 1 1 - 2 .

  • Page 230: Fuel And Emissions Systems

    Fuel and Emissions Systems SpecialTools Description Tool Number Ref. No. A973X-O41.XXXXX Vacuum Pump/Gauge, 0 30 in.Hg Vacuum/Pressure Gauge. 0 4 in.Hg 07JAz-0010008 07sAz-001000A Backprobe Set 07vAJ-0040100 Fuel Pressure Gauge Adapter 07406-004000A F u e l P r e s s u r e G a u o e ---) Aitt".' M"...

  • Page 231

    1 . S t a r t t h e e n g i n e a n d c h e c k t h e M l L . NOTE; . Freeze data indicates the engine conditions when 2. lf the l\4lL stays on, connect the Honda PGM Tester the first malfunction, misfire or fuel trim (A) or an OBDII scan tool to the data link connector malfunction was detected.

  • Page 232: General Troubleshooting

    2 . R e m o v e t h e l e f t s i d e k i c k p a n e l ( A ) t o e x p o s e t h e manual that came with the scan tool or Honda PGM E C M ( B ) .

  • Page 233

    How to Troubleshoot Circuits at the ECM How to Substitute the ECM for Testing Purposes Special Tools Required Use this procedure if you need a known-good ECM to . Digital multimeter KS-AHfvl-32-003 (1)or a test a vehicle. lt allows you to swap a ECM from a "donor"...

  • Page 234: Dtc Troubleshooting Index

    D T C S a r e i n d i c a t e d b y a b l i n k i n g l v l a l f u n c t i o n I n d i c a t o r L a m p ( M l L ) w h e n t h e S C S s e r v i c e s i g n a l l i n e i s jumped with the Honda PGM Tester.

  • Page 235

    ( s e e p a g e 1 1 - 4 5 ) Hiqher Than Exoected These DTCS are indicated by a blinking lvllL when the SCS service signal line is jumped with the Honda PG fvl Tester. (cont'd)

  • Page 236

    ( s e e p a g e 1 1 - 8 0 ) l\4alfunction These DTCs are indicated by a blinking MIL when the SCS service signal line is jumped with the Honda PGM Tester. 1 1 - 8...

  • Page 237: I N D E X

    Symptom Troubleshooting Index These symptoms DO NOT trigger Diagnostic Trouble Codes (DTCs) or cause the Malfunction Indicator Lamp (MlL) to come on. lf the MIL is reported on, check for DTCS. lf the vehicle has one of these symptoms, do the diagnostic procedure for it, in the sequence listed, until you find the cause.

  • Page 238: System Descriptions

    Fuel and Emissions Systems System Descriptions Elestronic Control System The functions of the fuel and emissions control systems are managed by the engine control module (ECM). Fail-safe Function When an abnormality occurs in the signal from a sensor, the ECM ignores the signal and assumes a pre-programmed value for the sensor that allows the enqine to continue to run.

  • Page 239

    EGM Data You can retrieve data from the ECM by connecting the OBD ll scan tool or the Honda PGM Tester to the Data Link Connector (DLC). The items listed in the table below conform to SAE recommended practice. The Honda PGlvl Tester also reads data beyond that recommended by SAE to help you find the causes of intermittent problems.

  • Page 240

    5'+ 5" BTDC with the conditions. S C S s e r v i c e s i g n a l l i n e jumped with the Honda P G M Calculated CLV is the engine load calculated from the lvlAp data.

  • Page 241

    EGM Electrical Connections To ECTGAUGE To fiADIATOB FAN aELAY, MDIATOR FAN SWITCH OBATTERY{lOOA}'A OBACK UP ACC(3OA)*A osroP{10A)*A IMMOBIIEEN INDICAIOR LIGIIT OIGl MAINI4OA)'A Oacc snsAl*A To IMMOaILIZER RECEIVER @AIR PUMP{60A}*B Io TMMOBIUZEF RECETvER ONo.25 EAcK uPl7.5A).c .IEST OrNo.6 ACGnsAl.c O I N o , 5 I N S T R U M E N T L I G H T B A C K U P L I G H T { 7 . 5 A ) * C @ N o .

  • Page 242

    Fuel and Emissions Systems System Descriptions (cont'dl ECM Electrical Connections (cont'dl No.2 IGNITION COIL AIR CONTiOL SOLENOID VALVE VIECPNESSURE 11-14...

  • Page 243

    ECM Inputs and Outputs at Connector A (32P) Wire side of female terminals NOTE: Standard battery voltage is 12 V. Description Signal ferminal name Terminal Wire color With ignition switch ON (ll): duty controlled Sends ECT signal to ECT YEUGBN W i t h i g n i t i o n s w i t c h O N ( l l ) : b a t t e r y v o l t a g e SAVS (AIR CONTROL VALVE D r i v e s a i r c o n t r o l v a l v e...

  • Page 244

    Fuel and Emissions Systems System Descriptions (cont'dl EGM Inputs and Outputs at Connector A (32P) Wire side of female terminals NOTEr Standard battery voltage is 12 V. Terminal Wire color ferminal name Description Signel K L I N E S e n d s a n d r e c e i v e s s c a n t o o l W i t h i g n i t i o n s w i t c h O N { l l ) : b a t t e r y v o t t a g e s t q n a l , BLU/ORN STS {STARTER SWITCH...

  • Page 245

    ECM Inputs and Outputs at Connector B (25P1 Wire side of female terminals NOTE: Standard battery voltage is 12 V. Description Signel Terminsl Wire color Terminal name numb6r Power source for ECM control With ignition switch ON (ll): battery voltage YEUBLK IGPl (POWER SOURCE) With ionition switch OFFi about 0 V Ground for ECM control...

  • Page 246

    Fuel and Emissions Systems System Descriptions (cont'd) ECM Inputs and Outputs at Connector C (31P} W i r e s i d e o f f e m a l e t e r m i n a l s PO2SHTC (PRIMARY HEATED Drives primary heared oxygen OXYGTN SENSOF HFATER...

  • Page 247

    Terminalname D6c.iption Signal Terminal Wire color numoel Detects CMP (TDC) sensor A. With engine running: pulses TDClP (CAMSHAFT POSITION G B N (CMP) SENSOR (TOP DEAD CENTEF {TDC) SENSORiA P S I D F ) Ground for CMP (TDC) sensor TDClM (CAMSHAFT POSITION (CMP}SENSOR (TOP DEAD CENTER (TDC) SENSOR)A M...

  • Page 248

    Fuel and Emissions Systems System Descriptions (cont'd) Vacuum Hose Routing FUEL PRESSURE REGULATOR AIR CONTROL VALVE VACUUM CONTROL SOLENOID VALVE AIR CONTROL VALVE FRONT OF VEHICLE PURGE JOINT {i,Z?\''AW'*7 EVAPORATIVE EMtSStON IEVAP} CANISTER PURGE VALVE AIR CONTROL VACUUM RESERVOIR 11-20...

  • Page 249

    Vacuum Distribution 1 PRIMARY HEATEO OXYGEN SENSOR (PRIMARY HO2S) O EVAPoRATIVE EMISSIoN {EVAP} CANISTER FILTER (SENSOR 1) EMISSION {EVAP) CANISTER PURGE @0 EVAPORATIVE VALVE i, SECONDARY HEATED OXYGEN SENSOR {SECONDARY EMISSION (EVAPI CANISTER VENT 4!] EVAPORATIVE HO2SI TSENSOR 2l SHUT VALVE MANIFOLD ABSOLUTE PRESSURE {MAP) SENSOR EMISSION (EVAP) TWO WAY VALVE €E EVAPORATIVE...

  • Page 250

    Fuel and Emissions Systems System Descriptions (conf d) PGM-FI System Engine Coolant Temperature (ECT) Sensor The ECT sensor is a temperature dependent resistor The Programmed Fuel Injection (PGM-Fl) system is a (thermistor). The resistance of the thermistor decreases sequential multiport fuel injection system. as the engine coolant temperature increases.

  • Page 251

    Primary and Secondary Heated Oxygen Sensors Iniector Timing and Duration The ECM contains the memory for basic discharge {HO2Sl duration at various engine speeds and manifold The heated oxygen sensors detect the oxygen content pressures. The basic discharge duration, after being in the exhaust gas, then sends a signal to the ECM which varies the duration of injeclion accordingly.

  • Page 252

    Fuel and Emissions Systems System Descriptions (cont'd) Throttle Position (TPl Sensor ldle Control System The TP sensor is a potentiometer connected to the thronle valve shaft. As the throttle position changes. the When the engine is cold, the A,,/C compressor is on. the sensor varies the signal voltage to the ECM.

  • Page 253

    Fuel Supply System Intake Air System Fuel Cut-off Control Refer to the System Diagram to see the functional During deceleration with the throttle valve closed, layout ofthe system. current to the injectors is cut off to improve fuel economy at speeds over 1,050 rpm Throttle Body Fuel cut-off action also occurs when engine speed The throttle body is a single-barrel side draft type.

  • Page 254

    Fuel and Emissions Systems System Descriptions (cont'dl Evaporative Emission (EVAPI Control Positive Crankcase Ventilation {PCV} System System The PCV valve prevents blow-by gases from escaping Refer to the System Diagram to see the functional into the atmosphere by venting them into the intake lavout of the system.

  • Page 255

    ldle Control System The idle speed of the engine is controlled by the ldle Air Control (lAC) valve: . After the engine starts, the IAC valve opens for a certain amount of time. The amount of air is increased to raise the idle soeed.

  • Page 256

    Fuel and Emissions Systems System Descriptions (cont'dl Pulsed Secondary Air Injection The Pulsed Secondary Air Injection advances the activation of the catalytic converter and reduces the hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) in the exhaust gas. The system operates after the engine starts under the followig conditions: .

  • Page 257

    Evaporative Emission {EVAP} Control Diagram The EVAP controls minimize the amount of fuel vapor escaping to the atmosphere. Vapor from the fuel tank is temporarily stored in the EVAP canister until it can be purged from the canister into the engine and burneo. ' T h e E V A P c a n i s t e r i s p u r g e d b y d r a w i n g f r e s h a i r t h r o u g h i t a n d a p o r t o n t h e i n t a k e m a n i f o l d .

  • Page 258

    Fuel and Emissions Systems System Descriptions [cont'd) ECM Circuit Diagram u""' "r./neo :Ffl - G R N / h E D M A P S E N S O R lf-- ECTSENSOR L - l IATS€NSOF H t l TPSENSOF HO2S(SENSOBI) SECONDARY HO2S ISENSOR 2)

  • Page 259

    __fffil YEL/BtU -.1 fFq!l elulwrlt _,_{9M_erutwrr -1f-- - B R N / Y E L AIR PUMP ELECTRIC CUNfiENTSENSOR G30r T f-l -S'.Er".f- -i"\ VAfVE --t-1 T t---_--------_---1 l l l i - , . , - . - . 1 t i t i ( A ) l I l r v l [ F l...

  • Page 260

    Fuel and Emissions Systems System Descriptions {cont'd) ECM Circuit Diagram (cont'dl T--- L p l No.2INJECIoR No.3III|JECTOR L____9 | No.alNJECToR To EPS CONISO! UNr 11-32...

  • Page 261

    No,1 IGNITION COIL Tr--.-.----------- iYEr --- r--l_l ," r/GRN ----l ff-------tr-|.---)SpaFx rcM I L-rftr\ PLUG I I ll ------Lf: No.2lGNlllON COIL F-----,------t lfr---+sPARKl I LjTF- PruG I No.3lGNlTlON COlt PIUG No.4 lGNlllON COt! eurrr ---!-auler t q l l - l AN CONTFOL SOI.ENOIDVALVE ---f---r...

  • Page 262

    Fuel and Emissions Systems System Descriptions (cont'd) ECM Circuit Diagram (cont'd) r Y E L COOLANT GAUGE TACHOMETER c303 J l--Btu---------------l TACHOMETER -CONNECTOR 1 1 - 3 4...

  • Page 263

    VTEC OIL PR€SSURE c102 JUNCTION CONNECTOR -caoa -ctot |-8tK.-------l}-B|.I-.--l}_Btx DATALIN( CONNECTOR (cont'd) 1 1 - 3 5...

  • Page 264

    Fuel and Emissions Systems System Descriptions (cont'd) ECM Circuit Diagram (cont'dl F U S E S A:No.21 STARTEF SIGNAUt.5A) B:No.2 FUEL PUMP SBS(t5A) c : N o . 6 A C G ( 1 5 A ) DrNo.5 INSTAUMENT LrGHT __,__\r_ aacK uPticttllT.5A) E : N o .

  • Page 265

    "-'_ PBESSURESWITCH n.o --95;--""rr"ro UNDEB,DASH FUSE/REUYAOX _w|lfler-x ________J$l _w"T/u*" _______{f"v BBAKE PEDA! POSTTTONSWITCH "o,ur,rr"roa a l- c20t- ---- -]-wHr/GRN CONNECTORC CONNECTOS A WHT/G8N WHT/GRN BLK/YEL LK,/YEI" CONNECIOS D FUSES F:No,25 AACK UP{7.5A1 G : S T O P ( r 0 A l FTBACK UPACC(3OA) lrlGl MAIN(aoA) J : A C G S ( l 5 A l...

  • Page 266

    In some states, pan disconnected or when the ECM is cleared with the OBD ll scan tool or Honda PGM Tester. of the emissions testing is to make sure these codes are . Low ambient temperatures or excessive stop-and-go set to complete.

  • Page 267

    ECM is cleared with the proceoure. . All readiness codes are cleared when the battery is OBD ll scan tool or Honda PGM Tester. . The enable criteria musl be repeated ifthe intake air disconnected or when the ECM is cleared with the temperature (lAT) drops lower then 36'F (20'C) from OBD ll scan tool or Honda PGM Tester.

  • Page 268

    Fuel and Emissions Systems How to Set Readiness Codes (cont'dl Misfire Monitor and Readiness Code ' This readiness code is always setto available because misfiring is continuously monitored . Monitoring pauses, and the misfire counter resets, if the vehicle is driven over a rough road .

  • Page 269

    PGM-Fl System Gomponent Location Index CAMSHAFT POSITION {CMPI SENSOR {TOP DEAD CENTER (TDC)2 SENSOR) B page 1 1-7'1 Troubleshooting, CAMSHAFT POSITION (CMP) SENSOR {TOP DEAD CENTER {TCD) SENSOR} A TroLrbleshooting. p a g e 1 1 - 7 1 INTAKE AIR TEMPERATURE IIATI SENSOR Troubleshooting, p a g e 1 1 ' 4 6...

  • Page 270: Component Location Index

    PGM-FI System Component Location Index (cont'd) il-..:-- DATA LINK CONNECTOR IDLCI ('02-03 models) General Troubleshootino lnformation. p a g e 1 1 - 3 11-42...

  • Page 271

    DTG Troubleshooting DTC P0107: MAP Sensor Circuit Low Voltage 8. Turn the ignition switch OFF. 9. Disconnect the ECM connector C (31P). 1. Turn the ignition switch ON (ll) 10. Check for continuity between MAP sensor 2. Check the MAP with the scan tool. connector terminal No, 3 and body ground.

  • Page 272: Dtc Troubleshooting

    PGM-FI System DTC Troubleshooting (cont'dl DTC P0108: MAP Sensor Circuit High Voltage 9. l\4easure voltage between MAP sensor connector t e r m i n a l s N o . 1 a n d N o . 2 . 1.

  • Page 273

    DTC Pl129: MAP Sensor Signal Higher Than DTC Pl128: MAP Sensor Signal Lower Than Expected Expected Start the engine. Hold the engine at 3,000 rpm with 1 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . no load (in neutral) until the radiator fan comes on, then let it idle.

  • Page 274

    IAT and ECT will have the same value. 2. Checkthe lATwith the scan lool. ls the cortect ambient temperature indicated? ls302"F (150"C)or higher (or H-Limit in Honda mode of PGM Tester) or 0 V indicated? YES Intermittent failure, system is OK at this time.

  • Page 275

    Turn the ignition switch ON (ll) ECM CONNECTOR C {3IP) 2. Check the IAT with the scan tool. ls " 4"F ( 20'C) ot less (or L-Limit in Honda 9 1 0 mode ot PGM Tester) or 5 V indicated?

  • Page 276

    2. Check the ECT with the scan tool. then reckeck for DTC P0116. ls 302"F (150"C) or higher (or H-Limit in Honda 1. Start the engine. Hold the engine at 3,000 rpm with mode of PGM Tester) or 0 V indicated? no load (in neutral) until the radiator fan comes on, then let it idle.

  • Page 277

    2. Check the ECT with the scan tool. ECM CONNECTOR C {31P) 4"F ( 20"C) or less (or L-Limit in Honda mode ot PGM Tester) or 5 V indicated? 9 1 0 YES Go to step 3.

  • Page 278

    PGM-FI System DTC Troubleshooting (cont'dl DTC P0122: TP Sensor Circuit Low Voltage 8. At the sensor side, measure resistance between TP sensor 3P connector terminals No. 1 and No. 2 with 1. Turn the ignition switch oNfll) the throttle {ully closed. TP SENSOR 3P CONNECTOR 2.

  • Page 279

    DTC Pl121: TP Sensor Signal Lower Than Turn the ignition switch ON (ll). 1 1 . Expected fMeasure voltage between ECM connector 1 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) t e r m i n a l s C 1 8 a n d C 2 7 .

  • Page 280

    PGM-FISystem DTG Troubleshooting (cont'd) DfC P1122:TP Sensor Signal Higher Than ExDected 1. Turn the ignition switch oN (ll). 2. Check the thronle position with the scan tool. ls 14.1o/o ot Iess indicated when the throttle is f ullv clo6ed? YES - Intermittent failure, system is OK at this t r m e .

  • Page 281

    DTC P0123: TP Sensor Circuit High Voltage 7. Measure voltage between ECM connector t e r m i n a l s C ' 1 8 a n d C 2 8 , 1 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . ECM CONNECTOR C {31P) 2.

  • Page 282

    PGM-FI System DTC Troubleshootihg (cont'd) DTG P0128: Cooling System Malfunction ('02-03 modelsl NOTE: lf the DTCS listed below are stored at the same time as DTC P0128. troubleshoot those DTCs first. then recheck for P0128. P0107, P0108, P1128, P1129t Manifold Absolute Pressure (MAP) Sensor P 1 1 0 6 , P ' 1 1 0 7 , P 1 1 0 8 : B a r o m e t r i c P r e s s u r e ( B A R O ) Sensor...

  • Page 283

    DTC P0131: Primary HO2S (Sensor 1) Circuit 1 1. Check for continuity between primary HO2S Low Voltage ( S e n s o r 1 ) 4 P c o n n e c t o r t e r m i n a l N o , 1 a n d b o d y g rou nd.

  • Page 284

    PGM-FI System DTC Troubleshooting (cont'd) DTC P0132: Primary HO2S (Sensor llCircuit Turn the ignition switch ON (ll). High Voltage Check the primary HO2S (Sensor output voltage 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) . with the scan tool.

  • Page 285

    DTC P0133: Primary HO2S (Sensor 1) Circuit Slow Response NOTE: lf DTC P0131, P0132 and/or P0135 are stored at the same time as DTC P0133, troubleshoot those DTCS first, then recheck for DTC P0133. 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 | . 2.

  • Page 286

    PGM-FI System DTG Troubleshooting (cont'dl DTC P0137: Secondary HO2S (Sensor 2) 10. Check for continuity between secondary HO2S Circuit Low Voltage (Sensor 2) 4P connector terminal No. 2 and body g rou nd. 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) . HO2S SECONDARY ISENSOR 2l irP CONNECTOR...

  • Page 287

    DTC P0138: Secondary HO2S (Sensor 2) Turn the ignition switch ON (ll). Circuit High Voltage Check the secondary HO2S (Sensor 2) output 1. Reset the Eclvl (see page 1 1-41. voltage with the scan tool. 2. Start the engine. Hold the engine at 3,000 rpm with ls there 0.6 V or more? no load (in neutral) until the radiator fan comes on.

  • Page 288

    PGM-Fl System DTC Troubleshooting (cont'd) DTG P0139: Secondary HO2S (Sensor 2) Slow Resoonse 1 . R e s e t t h e E C M { s e e p a g e 1 1 - 4 1 . 2.

  • Page 289

    DTC P0135: Primary HO2S (Sensor 1) Heater 6. At the HO2S side, check continuity be&veen body Circuit Malfunction ground and HO2S 4P connector terminals No. 3 a n d N o . 4 i n d i v i d u a l l y . DTC P0141: Secondary HO2S(Sensor Heater Circuit Malf unction PRIMARY HO2S (Sonsoi'll...

  • Page 290

    PGM-FISystem DTG Troubleshooting (cont'dl 13. Turn the ignition switch OFF. Turn the ignition switch OFF. 14. Reconnect the HO2S 4P connector. 1 0 . Disconnect ECM connector C {31P) 15. Disconnect the ECM connector C (31P)' 1 1 . Check for continuity between the connector t e r m i n a l C 1 ( C 1 1 ) * a n d b o d y g r o u n d .

  • Page 291

    DTC P0171: Fuel System Too Lean 4. Turn the ignition switch OFF. DTC P0172: Fuel System Too Rich 5. With a vacuum pump, apply vacuum to the EVAP canister purge valve from the intake manifold side. NOTE: lf some of the DTCS listed below are stored at the same time as DTCP0171 and/or P0'172, Does it hold vacuum? troubleshoot those DTCS first, then recheck for P0171...

  • Page 292

    PGM-FISystem DTC Troubleshooting (cont'd) DTC P0300: Random Misfire and Any Combination of the Following: DTC P0301: No. 1 Cylinder Misfire DTG P0302: No. 2 Cylinder Misfire DTG P0303: No. 3 Cylinder Misfire DTC P0304: No. 4 Cylinder Misfire NOTE: . l f t h e m i s f i r i n g i s f r e q u e n t e n o u g h t o t r i g g e r d e t e c t i o n o f i n c r e a s e d e m i s s i o n s d u r i n g t w o c o n s e c u t i v e d r i v i n g c y c l e s , the MIL will come on, and DTC P0300 {and some combination of P0301 through P0304) will be stored.

  • Page 293

    DTC P0301: No. 1 Cylinder Misfire 7 . Determine which cylinder(s) had the misfire. DTC P0302: No. 2 Cylinder Misfire Does the misfire occut in the othet cylinder wherc the ignition coil was exchanged? DTC P0303: No. 3 Cylinder Misfire Y E S R e p l a c e t h e f a u l t y i g n i t i o n c o i l .

  • Page 294

    PGM-FI System DTC Troubleshooting {cont'd) 24. Check for continuity between ignition coil 3P 17. Check for a DTC or Temporary DTC with the scan connector terminal No. 2 and body ground. r o o l . IGNITION COIL 3P CONNECTOR ls DTC P0301, P0302, P0303 ot P0304, ol Temporary DTC P1399 indicated? YES'- Go to step 18.

  • Page 295

    26. Check for continuity between body ground and the 27. Con nect the a ppropriate ign ition coil 3P connector ECM connector terminal (see table). to body ground wilh a jumper wire terminal No. {see table). ECM CONNECTOR C {31P) IGPLSl {WHT} IGNITION COIL 3P CONNECTOR IGPL33...

  • Page 296

    PGM-FI System DTC Troubleshooting (cont'd) 29. Check the engine compression (see page 6-32). 36. Measure resistance betvveen iniector 2P connector t e r m i n a l s N o . 1 a n d N o . 2 . ls the engine compression OK? INJECTOR 2P CONNECTOR YES Substitute a known-good ECM and recheck...

  • Page 297

    45, Measure voltage between injector 2P connector 48. Connect injector 2P connector terminal No. I to t e r m j n a l N o . 2 a n d b o d y g r o u n d . body ground with a jumper wire (see table).

  • Page 298

    PGM-FI System DTC Troubleshooting (cont'd) DTC P0325: Knock Sensor Circuit Malfunction 7. Connect knock sensor connector terminal No. 1to body ground with a jumper wire. 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) . KNOCK SENSOR 1P CONNECTOR 2.

  • Page 299

    DTC P1361: CMP (TDC) Sensor A ,ntermittent 6. Checkfor continuity to body ground on all Interruption t e r m i n a l s i n d i v i d u a l l y . DTC Pl362: CMP (TDC) Sensor A No Signal CMP (TDC} SENSOR A 2P CONNECTOR DTC P1366: CMP (TDC) Sensor B Intermittent CMP (TDC) SENSOR B 2P CONNECTOR*...

  • Page 300

    PGM-FISystem DTC Troubleshooting {cont'd) '10. 7 . Reconnect CMP {TDC) sensor A and CMP (TDC) Check for continuity between body ground and ECM connector teminal C20 (C29) * . sensor B * 2P connectors. ECM CONNECTOR C (31P) Disconnect ECI\4 connector C (31P). lvleasure resistance between ECM connector TDC lP IGRNI t e r m i n a l s C 2 0 a n d C 2 1 ( C 2 9 a n d C 3 0 ) * .

  • Page 301

    DTC P0335: CKP Sensor No Signal 5. Check for continuity between CKP sensor 3P connector termlnal No. I and body ground and DTC P0336: CKP Sensor lntermittent t e r m i n a l N o . 2 a n d b o d y g r o u n d i n d i v i d u a l l y . Interruption CKP SENSOR 3P CONNECTOR 1 .

  • Page 302

    PGM-FI System DTC Troubleshooting (cont'dl 8. Check for continuity between ECM connector terminal C8 and body ground. ECM CONNECTOR C 13,IP) CKP+ (BLU} Wire side of female terminals ls therc continuity? YES Repair short in the wire between ECM t e r m i n a l C 8 a n d t h e C K P s e n s o r . I NO Substitute a known-good ECM and recheck (see page 1 1-5).

  • Page 303

    DTC P0500: VSS Circuit Malfunction 10. Measure voltage between ECM connector terminal C 2 8 a n d b o d y g r o u n d . 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) ECM CONNECTOR C {31P} 2.

  • Page 304

    PGM-FI System DTC Troubleshooting (cont'dl 12. Turn the ignition switch OFF. 21. Measure voltage between ECM connector terminals A9 and B20. 13. Reconnect the VSS 3P connector. ECM CONNECTORS 1 4 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . B (25P) 1 5 .

  • Page 305

    DTC Pl107: BARO Sensor Circuit Low Voltage DTC Pl106: BARO Sensor Range/Perfoma Problem DTC Pl108: BARO Sensor Circuit High Voltage 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) 1 .

  • Page 306

    PGM-FI System DTC Troubleshooting (cont'd) DTC P1297: ELD Circuit Low Voltage 8. Turn the ignition switch OFF. 1. Reset the ECI\4 (see page 11-4). 9. Disconnect ECM connector A (32P). 2. Stan the engine. 10. Check for continuity between ECM connector t e r m i n a l A 3 0 a n d b o d y g r o u n d .

  • Page 307

    DTC P1298: ELD Circuit High Voltage 9. Connect ELD 3P connector terminal No. 3 to body g r o u n d w i t h a j u m p e r w i r e . 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) ELD 3P CONNECTOR 2 .

  • Page 308

    PGM-FI System DTC Troubleshooting {cont'd) DTC Pl607: ECM Internal Circuit Malfunction 12. Check for continuity between ELD 3P connector t e r m i n a l N o , 2 a n d b o d y g r o u n d . 1 .

  • Page 309: Mil Circuit Troubleshooting

    MIL Circuit Troubleshooting 3. Try to stan the engine. 1 . Turn the ignition switch ON { ll), and watch the M a l f u n c t i o n I n d i c a t o r L a m p ( M l L ) . n ^ a .

  • Page 310

    PGM-FI System MIL Circuit Troubleshooting (cont'd) 1 . Turn the ignition switch OFF. 1 0 . D i s c o n n e c t E C N 4 c o n n e c t o r C { 3 1 P ) . I n s p e c t t h e A C G S ( 1 5 A ) f u s e i n t h e m a i n u n d e r - Check for continuity between body ground and 1 1 .

  • Page 311

    B 2 2 l . a Turn the ignition switch OFF. 2 1 . Connect an OBD ll scan tool/Honda PGM Tester ( s e e p a g e 1 1 - 3 ) . Turn the ignition switch ON (ll).

  • Page 312

    PGM-FI System MIL Circuit Troubleshooting (cont'dl 24. Turn the ignition switch OFF. Turn the ignition switch ON (ll). 25. Disconnect ECM connector A (32P). Measure voltage between ECM connector terminal 4 1 0 a n d b o d y g r o u n d . 26.

  • Page 313: Dlc Circuit Troubleshooting

    DLC Circuit Troubleshooting lf the ECM does not communicate with the OBD ll scan 3. Measure voltage between DLC terminals No.8 and tool, Honda PGM Tester, or l/M test equipment, do this N o . 1 3 . troubleshooti ng procedure.

  • Page 314

    DLC Circuit Troubleshooting (cont'd) 7 . Disconnect ECM connector A (32P). Make sure the ls there continuity? OBD ll scan tooi or Honda PGM Tester is disconnected from the DLC. YES Substitute a known-good ECM and recheck (see page 11-5). lfthe symptom/indication goes Check for continuity between DLC terminal No.

  • Page 315

    lnjector Replacement Relieve the fuel pressure (see page'11-105). Remove the fuel rail cover (A), then disconnect the connectors from the injectors (B). 1 2 N . m (1.2 kgf,m, 8.7lbf.ft) {1.2 kgf m, 8.7 rbf.ftl 3 . D i s c o n n e c t t h e v a c u u m h o s e a n d f u e l r e t u r n h o s e f r o m t h e f u e l p r e s s u r e r e g u l a t o r { C ) . P l a c e a r a g o r s h o p t o w e l over the hoses before disconnecting them.

  • Page 316: Injectors Replacement

    PGM-FISystem Injector Replacement (cont'dl 9. Slide new cushion rings (A) onto the injectors (B). 12 N.m 11.2 kgf.m,8.7 lbt ft) 10. Coat new O-rings (C)with clean engine oil, and put them on the iniectors. 11. Insert the injectors into the fuel rail (D). 1 2 .

  • Page 317: Primary Ho2s Replacement

    Primary HO2S Replacement Secondary HO2S Replacement 1. Disconnect the primary HO2S 4P connector (A). l. Dlsconnect the secondary HO2S 4P connector (A). 2. Remove the primary HO2S (B). 2. Remove the secondary HO2S (B). ___1-l ,/' .,' ,' ., 'i>1-:l .

  • Page 318: Ldle Gontrol System

    ldle Gontrol System Component Location Index t-'t'tt' -- -''"-- - - "";t 1 1 - 9 0...

  • Page 319: Dtc Troubleshooting

    DTC Troubleshooting DTC P0505: ldle Control System Malfunction 7. Block both the upper and the lower ports (A) in the throttle body with your fingers. NOTE: lf DTC Pl519 is stored atthe same time as DTC P0505, troubleshooting DTC P1519 first, then recheck for DTC P0505.

  • Page 320

    ldle Control System DTC Troubleshooting (cont'd) DTC Pl519: IAC Valve Circuit Malfunction 8. Check for continuity between body ground and IAC v a l v e 3 P c o n n e c t o r t e r m i n a l N o . 1 . 1 .

  • Page 321

    13. Remove the jumper wire from the IAC valve 3P 1 1. Connect IAC valve 3P connector terminals No. 1 and No. 3 with a iumoer wire. connector, then reconnect the IAC valve 3P connector. 't4. Turn the ignition switch ON (ll). IAC VALVE 3P CONNECTOR 1 5 .

  • Page 322

    ldle Control System A/C Signal Circuit Troubleshooting 8. Momentarily connect ECM connector terminals A17 1. Turn the ignition switch OFF. and B20 with a iumoerwire several tames. 2. Disconnect the A/C pressure switch connector. ECM CONNECTORS A (32P) 3 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . 4.

  • Page 323

    '16. 14. Check for continuity between body ground and Measure voltage between ECM connector ECM connector terminal 427. t e r m i n a l s A 2 7 a n d 8 2 0 . ECM CONNECTORS ECM CONNECTOR A (32P) A (32P) 1 8 19 20 21 25 26 21...

  • Page 324

    ldle Control System Alternator FR Signal Circuit Troubleshooting 1 1 , Connect alternator 4P connector terminal No 4 to 1. Disconnect the alternator 4P connector. body ground with a jumPer wire. 2. Turn the ignition switch ON (ll) ALT 4P CONNECTOR 3.

  • Page 325: Starter Switch Signal Circuit

    Starter Switch Signal Circuit Troubleshooting 15. Check for continuity between body ground and ECM connector terminal C5. NOTE: The clutch pedal must be pressed. ECM CONNECTOR C 13lPI 1. Measure voltage between Eclvl connector terminals A24 and 820 with the lgnition switch in ALTF {WHT/RED) the ON {ll) position and the engine start button pressed.

  • Page 326

    ldle Gontrol System Electrical Power Steering (EPS) Signal Circuit Troubleshooting T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . 9, Measure voltage between EPS control unitterminal N o .

  • Page 327: Brake Pedal Position Switch Signal Circuit

    Brake Pedal Position Switch Signal Circuit Troubleshooting 13. lMeasure voltage between EPS control unit terminal N o . 1 3 a n d b o d y g r o u n d . 1 , C h e c k t h e b r a k e l i g h t s . EPS CONTROL UNIT 14P CONNECTOR Are the brake lights on without prcssing the brake pedal?

  • Page 328: Ldle Speed Inspection 1 1 - 1 0

    . Replace the ECM or disconnect its connector' - Spark plugs . Reset the ECM. - Ail cleaner NOTE. Eras\ng DTCS N\th Honda PGM Testei does - PC\ system require the idle learn procedure to be done again. ' On Canadian models. pullthe parking brake lever up.

  • Page 329

    Fuel Supply System Component Location Index FUEL PRESSURE REGULATOR Replacement, page 1 1-1 13 FUEL RAIL FUEL FILL CAP FUEL TANK page 11 115 Replacement, FUEL PUMP T e s t , p a g e 1 1 l 0 7 Replacement, page 11 114 FUEL FILTER Replacement, page 11-1 13...

  • Page 330

    Fuel Supply System PGM-Fl Main Relay Circuit Troubleshooting 4 . Check for a blown ACG S (15 A) fuse in the under- Turn the ignition switch OFF, then disconnect the hood fuse/relay box. PGM-Fl main relay 7P connector. Check for continuity between body ground and ls the luse blown? PGM-Fl main relay 7P connector terminal No.

  • Page 331

    7. Push the clutch pedal in, then turn the ignition 10. Check for continuity between PGM-FI mainrelayTP switch ON (ll), and press the engine start bufton. connector terminal No. 1 and ECM connector Measure voltage between body ground and PGM-Fl t e r m i n a l A 1 5 .

  • Page 332: Pgm-fl Main Relay Circuit

    Fuel Supply System PGM-Fl Main Relay Circuit Troubleshooting (cont'd) 1 3 . T u r n t h e i g n i t i o n s w i t c h O F F , t h e n O N ( l l ) a g a i n , 15.

  • Page 333: Fuel Pressure Relieving

    Fuel Pressure Test Fuel Pressure Relieving Special Tools Required Before disconnecting fuel lines or hoses, release . Fuel pressure gauge 07406-004000A pressure from the system by loosening the fuel . Fuel pressure gauge adapter 07VAJ-0040100 pulsation damper on top of the fuel rail. 1, Make sure you have the anti-theft code for the radio, 1.

  • Page 334

    FuelSupply System Fuel Pressure Test {cont'd) Remove the fuel pulsation damper from the fuel 1 4 . W i t h t h e e n g i n e r u n n i n g , u n p i n c h a n d r e c o n n e c t the vacuum hose and read the gauge again.

  • Page 335: Fuel Pump Test

    Fuel Pump Test Turn the ignition switch ON (ll). lf you suspect a problem with the fuel pump, check that the fuel pump actually runs; when it is ON, you will hear some noise if you listen to the fuel fill port with the fuel Check that banery voltage is available between fuel fill cap removed.

  • Page 336

    Fuel Supply System Fuel Line Inspection Check the fuel system lines, hoses, and fuel filter for damage, leaks, or deterioration, and replace parts as needed. 22 N.m (2.2 kgt.m, 16lbf.ft) 37 N.m (3.8 kgt m, 27 lbf.ft) 1 1 - 1 0 8...

  • Page 337

    Check all hose clamps and retighten if necessary. : Do not disconnect the hose from the line at these ioints. Clamo in the middle. 1 0 - 1 5 m m {0.39-0.59 in.) Clamp in the middle. 1 1 - 1 0 9...

  • Page 338

    Fuel Supply System Fuel Line/Ouick-Connect Fittings Fuel Line/Ouick-Connect Fittings Precautions Removal 1 . R e l i e v e f u e l p r e s s u r e ( s e e p a g e 1 1 - 1 0 5 ) . The fuel tube/qulck-connect fittings assembly connects the in-tank fuel DumD to the fuel feed line and the fuel r e t u r n l i n e .

  • Page 339

    Fuel Line/Ouick-Connect Fittings lnstallation 4. Checkthe contact area (A) o{ the line (Bl for dirt and o a m a g e . 1. Check the contact area (A) of the line (B) for dirt and . lf the surface is dirty, clean it.. .

  • Page 340

    Fuel Supply System Fuel Line/Ouick-Connect Fittings Installation (cont'dl 3. Before connecting a new fuel tube/quick-connect Reconnection to existing retainer: fitting assembly {A), remove the old retainer from t h e m a t i n g l i n e . 5.

  • Page 341: Fuel Pressure Regulator

    Fuel Filter Replacement Fuel Pressure Regulator Replacement The fuel filter should be reDlaced whenever the fuel pressure drops belowthe specified value (320 370 kPa, 3 . 3 3 . 8 k g f l c m ' , 4 7 5 4 p s i w i t h t h e f u e l p r e s s u r e 1.

  • Page 342

    Fuel Supply System Fuel Pump/Fuel Gauge Sending Unit Replacement 9. Remove the bracket (A), the fuelfilter (B), the fuel 1. Remove the reartray (see page 20-71). g a u g e s e n d i n g u n i t ( C ) , t h e h o s e ( D ) , a n d t h e w i r e h a r n e s s ( E ) .

  • Page 343

    Fuel Tank Replacement Removal 7, Disconnect both ABS rear wheel sensors2P connectors (A), and push the connectors out (B). 1 . R e m o v e t h e f u e l f i l l c a p . 2 .

  • Page 344

    FuelSupply System Fuel Tank Replacement (cont'd) 13. Disconnect both parking brake cables (A), and 11. Remove the bolts from both ABS rear wheel sensor move them out of the way harness brackets (A). 6 x 1 . 0 m m 9.8 N.m {1.0 kgf.m,7.2 lbf.ft) NoTE: Left side is shown 12.

  • Page 345

    15. Remove the flange bolt (A)from both rear dampers 17. Remove the muffler {A). ( B ) . - '')/,. '|d:<;.:'.f: 6 i . - / g - J : f : 10 x 1,25 mm 33 N.m {3.4 kgf.m,25 lbt.ftl NOTE: Left side is shown.

  • Page 346

    Fuel Supply System Fuel Tank Replacement (cont'd) 19. Disconnect the fueltank vapor vent tube (A). then 21. Place a jack or other support under the rear remove the bolt (B) and the EVAP canister (C). suspension subframe (A). Remove the mounting bolts (B) and the rear suspension subframe (A).

  • Page 347

    Fuel Gauge Sending Unit Test Installation NOTE: For the fuel gauge system circuit diagram, refer t o t h e G a u g e s C i r c u i t D i a g r a m ( s e e p a g e 2 2 - 4 4 ) . 1 .

  • Page 348: Fuel Gauge Sending Unit

    FuelSupply System Fuel Gauge Sending Unit Test Low Fuel Indicator Test (cont'd) Do the fuel gauge sendlng unit test (see page 1 1- 1 1 9 ) . 6. Turn the ignition switch OFF. . lf the system is OK, go to step 2. .

  • Page 349

    Intake Air System Component Location Index ,,.,,,r,,?i-. AIR CLEANER Replacement, page 1 1-123 THROTTLE CABLE Adiustment, page I 1-'124 p a g e 1 1 - 1 2 5 R e m o v a l / l n s t a l l a t i o n , THROTTLE BOOY Test, page 11-122 Removal/lnstallat;on, paqe 1 1-126...

  • Page 350: Throttle Bodytest

    hake Air System Throttle Body Test NOTE; Do not adjust the throftle stop screw. lt is preset al the factory. 1. Wlth the engine off, check the throttle cable operation.The cable should operate without b i n d i n g o r s t i c k i n g . .

  • Page 351

    Air Cleaner Element Replacement CLEANER HOUSING COVER AIR CLEANER ELEMENT / , 1 ,// i ,. /// 2,1.:^ I l'.. , - l ' \ L|u",,..'/ t..:-+:'-.'::9 AIR CLEANER HOUSING 11-123...

  • Page 352

    Intake Air System Throttle Cable Adjustment Check cable free play at the throttle linkage. Cable f r e e p l a y ( A ) s h o u l d b e 4 6 m m ( 3 / 1 6 - l i a i n . ) . l f f r e e p l a y ( A ) i s n o t w i t h i n s p e c ( 4 - 6 m m , 3 / 1 6 1 / 4 in.) loosen the locknut (B), turn the adjusting nut (C) until the free play (A) is as specified, then...

  • Page 353

    Throttle Cable Removal/lnstallation 1. Fully open the throttle valve, then remove the 5. Remove the throttle cable (A) and the actuator throttle cable {A)from the throttle link (B). cable (B) from the accelerator pedal bracket (C). 6. Install in the reverse order of removal. 7.

  • Page 354

    Intake Air System Throttle Body Removal/lnstallation NOTE; . Do not adiust the throttle stop screw. . After reassem bly, adju st the cru ise co ntrol actuator ca ble (see page 4-46), a nd the th rottle cable (see page 1 1- 124). .

  • Page 355

    Throttle Body Disassembly/Reassembly 2 1 N m 10.21 kgf m. 1.5 lbt.ft) MAP SENSOR TP SENSOR 11-127...

  • Page 356

    Catalytic Converter System DTC Troubleshooting DTC P0420: Catalytic System Efficiency Below Threshold NOTE: lf some of the DTCS listed below are stored at the same time as DTC P0420, troubleshoot those DTCS first, then recheck for DTC P0420. P0137, P0138: Secondary Heated oxygen Sensor (secondary H02S) (Sensor 2) P0141: Secondary H02S (Sensor 2) heater 1 .

  • Page 357: Pcv System

    PCV System PCV Valve Inspection and Test 1 . Check the PCV valve (A), hoses (B), and connections for leaks or restrictions. At idle, make sure there is a clicking sound from the PCV valve when the hose between the PCV valve and intake manifold is lightly pinched {A)with your f i n g e r s o r p l i e r s .

  • Page 358: Evap System

    EVAP System Component Location Index (FTP} SENSOR FUEL TANK PRESSURE FUEL TANK VAPOR CONTROL VALVE Test, page l1'146 Replacement, page 11 147 : - - " ( t'",. :';':" - -.,,,, t ,.-;;../tttt EMISSION (EVAP) EVAPORATIVE | ..- - . . : BYPASS SOLENOID VALVE ' .

  • Page 359

    Ait973X-041- 2. Turn the ignition switch ON(ll). 3. Monitor FTP sensor voltage with the Honda PG lvl Tester, or measure voltage between ECM 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 360

    4 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . 5. Monitor FTP sensor voltage with the Honda PGM Tester. or measure voltage between body ground and EClvl connector terminal A29.

  • Page 361

    4 . T u r n t h e i g n i t i o n s w i t c h O N ( l l ) . Is there about 5 V? 5. lvlonitor FTP sensor voltage with the Honda PGM Tester. or measure voltage between body ground YES Replace the FTP sensor.I...

  • Page 362

    EVAP System DTC Troubleshooting (cont'd) 11. Measure voltage between FTP sensor 3P connector Turn the ignition switch OFF. t e r m i n a l s N o . 2 a n d N o . 3 . Reinstall the fuel fill cap. FTP SENSOR 3P CONNECTOR Disconnect the FTP sensor 3P connector.

  • Page 363

    DTC Pl456: EVAP Control System Leakage EVAP Canister Purge Valve Test (Fuel Tank Svstem) 3. Disconnect the vacuum hose from the EVAP purge joint (A), and connect a vacuum pump to the hose. The fuel system is designed to allow specified maximum vacuum and pressure conditions.

  • Page 364

    EVAP System DTC Troubleshooting (cont'd) Check for continuity between EVAP canister purge EVAP Bypass Solenoid Valve Test v a l v e 2 P c o n n e c t o r t e r m i n a l N o . 2 a n d b o d y g r o u n d . 1 1.

  • Page 365

    Turn the ignition switch ON (ll). 1 8 . Turn the ignition switch OFF. t t . 1 9 . Measure voltage between EVAP bypass solenoid Disconnect the EVAP bypass solenoid valve 2P t o . valve 2P connector terminal No. 1 and body ground. connector.

  • Page 366

    A973X-041- While monitoring FTP sensor voltage with the Honda PGM Tester, or measuring the voltage between ECM connector terminals A29 and C18, slowly pump the vacuum pump until the voltage drops to about 1.5 volts. Turn the ignition switch ON (ll).

  • Page 367

    NO - Replace the fuel tank vapor control valve.I "clicks". then monitor the Tighten the fuel cap 3 5 t . FTP readings with the Honda PGM Tester. Start the engine, and let it idle for 5 minutes. ls there continuity? Check the FTP sensor reading.

  • Page 368

    EVAP System DTC Troubleshooting (cont'dl DTC Pl457: EVAP Control System Leakage 2. Connect ECM connector terminal 46 to bodv (EVAP Canister Svstem) g r o u n d w i t h a j u m p e r w i r e . ECM CONNECTOR A I32P) The fuel system is designed to allow specified maximum vacuum and pressure conditions.

  • Page 369

    Turn the ignition switch ON (ll). EVAP Bypass Solenoid Valve Test 10. Disconnect both vacuum hoses from the EVAP two Measure voltage between EVAP purge canister way valve {A), and connect a vacuum pump to the valve 2P connector terminal No. 1 and body ground. canister port on the two way valve.

  • Page 370

    EVAP System DTC Troubleshooting {cont'd) EVAP Canister Vent Shut Valve Test 18. Disconnect the vacuum hose from the EVAP canister vent filter, and connect a vacuum pumo to the hose. 4973X-041-XX) ls therc continuity? YES- Go to step 16. NO-Replace the EVAP bypass solenoid valve (A) a n d o - r i n g s ( B ) .

  • Page 371

    Turn the ignition switch ON (ll). While monitoring FTP sensor voltage with the J t . Honda PGM Tester, or measuring voltage between ls there battety voltage? ECM connector terminals A29 and C18, slowly p u m p t h e v a c u u m p u m p .

  • Page 372

    While monitoring FTP sensor voltage with the Honda PGM Tester, or measuring voltage between E C M 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 , s l o w l y T u r n t h e i g n i t i o n s w i t c h O N ( l l ) .

  • Page 373: Evap Two Way Valve Test

    EVAP Two Way Valve Test 5. Slowly pressurize the vapor line while watching the R e m o v e t h e f u e l f i l l c a p . gauge. The pressure should stabilize momentarily a b o v e 1 .

  • Page 374

    EVAP System Fuel Tank Vapor Control Valve Test Valve Test SpecialTools Required V a c u u m p u m p / g a u g e , 0 3 0 i n . H g A 9 7 3 X - 0 4 1 - X X X X X 1 .

  • Page 375

    Fuel Tank Vapor Control Valve Replacement 7. Connect a second vacuum pump to the fuel tank vapor signal hose (A). R e m o v e t h e f u e l t a n k ( s e e p a g e 1 1 - 1 1 5 ) . Remove the fuel tank vapor control valve (A) from t h e f u e l t a n k ( B ) .

  • Page 376: Component Location Index

    Pulsed Secondary Air Injection System Component Location Index AIR CONTROL VALVE VACUUM CONTROL SOLENOIO VALVE page 1 1-'153 Troubleshooting, AIR CONTROL VALVE page 1 1-153 Troubleshooting, ,/':: \i,\ - = - 'l-i '' ---=\-: ..'.':. \r.. ELECTRICAL CURRENT SENSOR AIR PUMP Removal/lnstallation, page 1 1-160 Removal/lnstallation, page'1 1-159 Troubleshootjng, page 1 1-156...

  • Page 377: Dtc Troubleshooting

    DTC Troubleshooting DTC P0410: Air Pump Circuit Malfunction 1 1. At the left engine compartment wire harness side, measure voltage between air pump electrical 1 . R e s e t t h e E C I M ( s e e p a g e 1 1 - 4 ) . current sensol 2P connector terminal No.

  • Page 378

    Pulsed Secondary Air Injection System DTC Troubleshooting (cont'd) 21. Connect large air pump relay 2P connector 14. Reconnect the air ou m o electrical current sensor. t e r m i n a l s N o . 1 a n d N o . 2 w i t h a i u m o e r w i r e . 15.

  • Page 379

    Disconnect ECM connector A (32P). 29. Check for continuity between ECM connector terminal A28 and body ground 2 7 . Check for the continuity betvveen ECM connector terminal A28 and body ground. ECM CONNECTOR A I32PI A (32P) ECM CONNECTOR 12 13 17 1 8 19 20 21 12 13...

  • Page 380

    Pulsed Secondary Air lnjection System DTC Troubleshootang (cont'd) 33. Check for continuity between large air pump relay 2 Turn the ignition switch OFF. P c o n n e c t o r t e r m i n a l N o . 2 a n d a i r p u m p 2 P D o t h e a i r p u m p r e l a y t e s t ( s e e p a g e 1 1 - 1 6 0 ) .

  • Page 381

    DTC P0411: SecondaryAir Injection System 9. Disconnect the vacuum hose from the air control lncorrect Flow valve (A), and connect a vacuum gauge to the hose. 1 . R e s e t t h e E C M ( s e e p a g e 1 1 - 4 ) . 2.

  • Page 382

    Pulsed Secondary Air Iniection System DTC Troubleshooting (cont'dl Disconnect the air control valve vacuum control 1 8 . Disconnect ECM connector A {32P), 1 4 . solenoid valve 2P connector. Check for continuity between air control valve 1 5 . Turn the ignition switch ON (ll).

  • Page 383

    DTC Pl410: Air Pumo Malfunction 1 . R e s e t t h e E C M { s e e p a g e 1 1 - 4 ) . 2. Make sure the engine coolant temperature is over 32 'F (0"C) and below 158 'F (60'C) with the scan tool.

  • Page 384

    Pulsed Secondary Air Iniection System DTC Troubleshooting (cont'd) DTC Pl415: Air Pump Electrical Current 8. Turn the ignition switch OFF. Sensor Circuit Low Voltage 9. Disconnectthe ECIM connector C (31P). 1 . R e s e t t h e E C M ( s e e p a g e 1 1 4 ) . 10.

  • Page 385

    12. Check for continuity betlveen ECM connector 16. Measure voltage between body ground and ECM t e r m i n a l s C 2 4 a n d C 1 8 . connector terminal C24. ECM CONNECTOR C (31P) ECM CONNECTOR C {3IP} 9 10 2A 21...

  • Page 386

    Pulsed Secondary Air lniection System DTC Troubleshooting (cont'd) DTC Pl416: Air Pump Electric Current Sensor Measure voltage between ECM connector Circuit High Voltage t e r m i n a l s C 1 8 a n d C 2 8 . C (31PI ECM CONNECTOR 1 .

  • Page 387: Air Pump/air Pump Relay Removal/lnstallation

    Air Pump/Air Pump Relay Removal/lnstallation Remove the front bumper (see page 20-92). R e m o v e t h e a i r p u m p ( A ) , a n d t h e a i r p u m p r e l a y ( B ) . 8 x 1.25 mm 22N.m 12.2 kgt m, 15 tbf.ft)

  • Page 388

    Pulsed Secondary Air Injection System Air Pump Electrical Current Sensor Air Pump Relay Test RemovaUlnstallation Check for continuity between the terminals according to t h e t a b l e . 1. Pull away the left inner fender as necessary {see .

  • Page 390

    Transaxle Glutch SpecialTools ..12-2 Component Location Index ........12-3 Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment ..... 12-4 Clutch MasterCylinder Replacement ..... 12-5 Slave Cylinder Replacement ..12-6 Cf utch Replacement ......12-l...

  • Page 391

    Clutch SpecialTools Description Ref. No. Tool Number o) (a R i n g G e a r H o l d e r 1 00 or 07924-PD20003 07LAB-PVO0 Clutch Alignment Shaft 07LAF-PT00110 Attachment, 32 x 37 mm 07746-0010200 Driver 07749-0010000 R e m o v e r H a n d l e 0 7 9 3 6 - 3 7 1 0 1 0 0 .a )/...

  • Page 392

    Gomponent Location Index CLUTCH PEOAL Adjustment, page l2-4 RESERVOIR RELEASE FORK M/T ASSEMBLY LOCK PIN CLUTCH LINE RELEASE FORK BOOT CLUTCH HOSE CLIP Replace. SLAVE CYLINDER Replacement, page 12-6 CLUTCH HOSE CLUTCH DISC Removal, page 12 7 s t e p I o n p a g e 1 2 - 1 1 l n s t a l l a t i o n , BANJO BOLT RELEASE BEARING...

  • Page 393

    Glutch Clutch Pedal, Clutch Pedal Position Switch, and Clutch Interlock Switch Adjustment 5. Turn the clutch pedal position switch {B) in an NOTE: . To checkthe clutch pedal position switch (see page 4- additional 3/4 to 1 turn. 4 7 ) . 6.

  • Page 394

    Clutch Master Cylinder Replacement NOTE: Do not spill brake fluid on the vehicle; it may 4. Bemove the clutch master cylinder (A). damage the paint; if brake fluid does contact the paint. wash it off immediately with water -.--1i:,.'1. 1. The brake fluid may be sucked out through the top ,-_-::-:-:=---_-,;.,1,'a) of the master cylinder reservoir (A) with a syringe.

  • Page 395

    . Refill the clutch master cylinder with fluid when d o n e . . Always use only Honda DOT 3 brake fluid. . Confirm clutch operation, and check for leaking f l u i d . (Brake Ass€mbly Lubel A p p 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 t o t h e t i p o f t h e s l a v e c y l i n d e r r o d .

  • Page 396

    Clutch Replacement 5. Inspect the fingers of the diaphragm spring (A) lor Special Tools Required . Clutch alignment shaft 07LAF-PToo110 wear at the release bearing contact area. . R e m o v e r h a n d l e 0 7 9 3 6 - 3 7 1 0 1 0 0 .

  • Page 397

    Glutch Clutch Replacement (cont'd) 8. Remove the clutch disc and sDecial tools. 11. Measure the rivet depth from the lining surface (A) to rivets (B), on both sides. lf the rivet depth is less than the service limit, replace the clutch disc. Standard lNew): 1.2 1.7 mm {0.047-0.067 in.) 0.2 mm (0.00e in.l...

  • Page 398

    Flywheel Replacement Flywheel lnspection 1. lnspect the ring gear teeth for wear and damage. 1 . I n s t a l l t h e s p e c i a l t o o l . 2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.

  • Page 399

    Clutch Clutch Replacement (cont'dl Release Bearing Inspection 4. Drive the new ball bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the bearing surface. Check the release bearing for excessive play by spinning it by hand.

  • Page 400

    Clutch Disc and Pressure Plate Installation 6. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent w a r p i n g t h e d i a p h r a g m s p r i n g . 1 .

  • Page 401

    Transaxle Countershaft Reassembly ..13-41 Manual Transmission Secondary Shaft Disassembly ... 13-45 13-2 S o e c i a l T o o l s Secondary Shaft Inspection ..13-45 Transmission Fluid Inspection Secondary Shaft Reassembly ..13-46 13-3 a n d R e o l a c e m e n t ..... 13-3 Shift Forks Clearance Back-up Light Switch Test ..

  • Page 402: Manual Transmission

    Manual Transmission SpecialTools Ref.No. Tool Number Description " q 0 7 G A J - P G 2 0 1 1 0 M a i n s h a f t H o l d e r "(9 07GAJ-PG20130 M a i n s h a f t B a s e 07JAB-0010204 H o l d e r H a n d l e 07LAD-PW5060'r...

  • Page 403: Back-up Light Switch Test

    Back-Up Light Switch Test Transmission Fluid Inspection and Replacement 1. Disconnectthe back-up light switch (A) 2P connector, 1 . P a r k t h e v e h i c l e o n l e v e l g r o u n d , a n d t u r n t h e e n g i n e O F F .

  • Page 404

    Manual Transmission Gearshift Mechanism Replacement t'vER KN.B .ttt"''n LOCKNUT 1 0 x 1 . 2 5 m m 9 N.m {0.9 kgf.m,7lbf ft) BOOT HOLDER SEIFT BOOT //-'/'-" SHIFT LEVER BOOT C 6 x 1 . 0 m m 9.8 N m 11.0 kgf m, 7.2tbf.tt) SHIFT LEVER SPRING '"...

  • Page 405

    Transmission Removal Remove the center console (seepage20-76). NOTE: Use fender covers to avoid damaging painted surfaces, Remove the boot holder {A) and the shift boot (B). 1 . D i s c o n n e c t t h e n e g a t i v e ( ) c a b l e f i r s t , t h e n t h e positive (+ ) cable from the battery.

  • Page 406

    Manual Transmission Transmission Removal (cont'd) 6 . R e m o v e t h e a i r c l e a n e r h o u s i n g a s s e m b l y . Remove the alternator-comDressor belt and the alternator (see page 4-25).

  • Page 407

    14. Disconnect the TDC1 (A) and TDC2 {B) sensor 12. Remove the heat shield (A), then remove the connectors. exhaust manifold cover. ' 1 5 . R e m o v e t h e s D l a s h s h i e l d . 13.

  • Page 408

    Manual Transmission Transmission Removal (cont'dl 16. Disconnect the 2P connector (A) from the steering 1 9 . Disconnect the heated oxygen sensor (HO25) {A), secondary heated oxygen sensor {secondary HO2S) (B), and the back-up light switch (C) connectors, then remove the wire harness from the transmission.

  • Page 409

    24, Remove the release fork boot (A), then carefully 21. Remove the exhaust manifold bracket (A) and the remove the slave cylinder (B). Do not operate the e x h a u s t m a n i f o l d ( B ) . clutch pedal once the slave cylinder has been removed.

  • Page 410

    Manual Transmission Transmission Removal (cont'dl Remove the five lower transmission mounting Lower the front subframe in until it touches the four bolts. loosened mounting bolts. Place the floor jack under the transmission, and remove the three transmission rear mount bolts. 1 .

  • Page 411

    33. Remove the three upper tra nsm ission mounting bolts. Pull the transmission away from the engine until it clears the mainshaft, then lower the transmission o n t h e j a c k . Remove the transmission rear mount from the t r a n s m i s s i o n h o u s i n g .

  • Page 412: Transmission Disassembly

    Manual Transmission Transmission Disassembly Exploded View-Rear Cover @)--"'' x_=----' -"'t-': 7*_-3 =--D ----=P=\ -\.1) t--rr-.._ --=-g t\if5 8'... q- ,/-- f1 \ l l . ' o*--.-- \a'o 13-12...

  • Page 413

    (D 27 mm LOCKNUT O 8 mm SPECIAL BOLT Replace. 31 N.m {3.1 kgf.m,22lbf.ttl '162 * 0 - 162 N.m (16.5 - 0 * 16.5 kgt.m, @ SHIFT LEVER HOUSING 1 1 9 * 0 * ' l 1 9 l b f . f t l (} 6 mm FLANGE BOLT O 27 mm SPRING WASHER 12 N m 11.2 kgf.m,8.7 lbf.ft)

  • Page 414

    Manual Transmission Transmission Disassembly (cont'd) Exploded View-Transmission Housing @---'-r..^ ,,--t\ o \-:) t //// rA d , ( 9 H ,./ G) @ x\,, -cr\\-_- 13-14...

  • Page 415

    .]) 29 mm LOCKNUT {Left-hand threads) Q]) FILLER PLUG Replace. 44 N.m (4.5 kgt.m,33lbf ft) 172 *0 * 172 N.m (17.5 - 0 * 17.5 kgf,m, @ WASHER 127-0-127lbf.ltl Replace. (2) 29 mm SPRING WASHER @ SET SCREW O 30 x 64x20 mm NEEDLE BEARING @ SPRING L.

  • Page 416

    Manual Transmission Transmission Disassembly (cont'd) Exploded View-Clutch Housing 61 - \ 1-----.-' S:.-------t trE) ^Qg- -.'A ^-- -,--@ @--=-ssR-'-, " e.., €- -.-e FJ-.- *--"-"*9 1 3 - 1 6...

  • Page 417

    O coUNTERSHAFTASSEMBLy ( l 8 x , l 0 P l N O 68 mm SNAP RING (} SELECT RETURN SPRING 1O MAINSHAFT ASSEMBLY @ CLUTCH RELEASE HANGER O 64 mm SPRING WASHER ED RELEASE HANGER SPRING O otL GUrDE TUBE (} 8 mm SPECIAL BOLT 27 N.m {2.8 kgf m.20 lbf.ft} G] REVERSE SHAFT HOLDER...

  • Page 418

    Manual Transmission Transmission Disassembly (cont'd) 3. Remove the I mm flange bolts in a crisscross Special Tools Required . F l a n g e h o l d e r 0 7 R A B - T B 4 0 1 0 8 pattern in several stePs, .

  • Page 419

    6. Raise the 27 mm locknut tab from the qroove in the 8. Remove the 27 mm locknut (A), spring washer (B). secondarv shaft. b a c k - u p r i n g ( C ) , a n d O - r i n g { D ) , Install the special tool onto the companion flange, and loosen the 27 mm locknut.

  • Page 420

    Manual Transmission Transmission Disassembly {cont'd} 13. Remove the bearing outer race (A) and shim (B) 1 0 . R e m o v e t h e o i l s e a l . from the rear cover (C). 1 l.

  • Page 421

    Transmission Housing Removal 3 . I n s t a l l t h e s p e c i a l l o o l o n t o t h e m a i n s h a f t s p l i n e , and loosen the 29 mm locknut (left-hand threads).

  • Page 422

    Manual Transmission Transmission Disassembly (cont'd) Remove the needle bearing (A) using a 7. Remove the 6 mm flange bolts, then remove the oil pump plate (A), spring, steel ball, and oil pump c o m m e r c i a l l y a v a i l a b l e b e a r i n g p u l l e r ( B ) a s s h o w n . rotors (B).

  • Page 423

    '12. Remove the bearing outer race (A) usingthe special tool as shown, then remove the shim (B) a n d o i l g u i d e p l a t e S . 3/8" .16 SLIDE HAMMER (commerciallv available) 07736-A010008 Remove the 8 mm tlange bolts in a crisscross oattern in several steos.

  • Page 424

    Manual Transmission Transmission Disassembly (cont'dl Remove the circlip (A). then remove the suction 1 6 . R e m o v e t h e o i l g u i d e t u b e ( A ) a n d m a g n e t ( B ) . 1 4 .

  • Page 425

    1 8 . R e m o v e t h e 1 0 m m f l a n g e b o l t , t h e n r e m o v e t h e I 2 1 .

  • Page 426

    Manual Transmission Transmission Disassembly (cont'dl Remove the 6 mm flange bolts and release bearing g u i d e ( A ) . Remove the I mm special bolts, clutch release h a n g e r ( B ) a n d r e l e a s e h a n g e r s p r i n g ( C ) . 2 7 .

  • Page 427: Mainshaft Assembly Clearance Inspection

    Mainshaft Assembly Clearance Inspection 2. lvleasure the distance of the distance collar. NOTE: . lf replacement is required, always replace the . lf distance is notwithin the standard, replace the synchro sleeve and hub as a set. distance collar with a new one .

  • Page 428

    Manual Transmission Mainshaft Assembly Clearance Inspection {cont'd) 4. Measure the clearance between 4th gear (A) and 6. fMeasure the thickness of 4th gear. d i s t a n c e c o l l a r ( B ) . l f t h e c l e a r a n c e i s m o r e t h a n t h e service limit, go to step 5.

  • Page 429

    10. Measure the clearance between 6th gear (A) and 8, Measure distance O on the distance cotrar. the mainshaft (B). lf the clearance is more than the service limit, go to step 11. . l f d i s t a n c e O i s n o t w i t h i n t h e s t a n d a r d , r e p l a c e the distance collar with a new one.

  • Page 430: Mainshaft Disassembly

    Manual Transmission Mainshaft Disassembly Support ball bearing (A) with a commercially Remove the 42 x 47 x 30.5 mm needle bearing, available bearing separator, and remove the ball distance collar,sth gear, synchro ring, and synchro bearing using a press as shown. s p r i n g .

  • Page 431: Mainshaft Inspection

    Mainshaft Inspection 3. Inspect for runout by supporting both ends of 1. Inspect the gear surface and the bearing surface for mainshaft. Rotate the mainshaft two complete w e a r a n o o a m a g e . revolutions when measuring the runout.

  • Page 432: Mainshaft Reassembly

    Manual Transmission Mainshaft Reassembly Exploded View ANGULAR BALL BEARING Check for wear and operation. Thin edge of the outer Note the direction of race faces 3rd gear installation. RING /,,,sYNcHRo GEAR SYNCHRO '//,,.3RD SPRING 3 5 x 4 0 x 3 5 m m 5TH/6TH SYNCHRO NEEOLE BEARING...

  • Page 433

    4. Press the 5th/6th synchro hub using the specialtool Special Tools Required as shown. After installing, checkthe operation of . D r i v e r , 4 0 m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0 the 5th/6th svnchro hub and sleeve.

  • Page 434

    Manual Transmission Mainshaft Reassembly (cont'd) Installthe 3rd/4th synchro hub (A) and sleeve (B) by 9. Install the double cone synchro (A)and synchro aligning the stops (C). sprlng (B) as shown. 1 0 . I n s t a l l t h e d i s t a n c e c o l l a r ( A ) , 3 5 x 4 0 x 3 5 m m Press the 3rd/4th synchro hub using the special tool n e e d l e b e a r i n g ( B ) , a n d 3 r d g e a r ( C ) .

  • Page 435: Shift Arm Rod Assembly Disassembly/reassembly

    Shift Arm Rod Assembly Disassembly/Reassembly 1 1 . I n s t a l l t h e a n g u l a r b a l l b e a r i n g ( A ) w i t h t h e t h i n edge of the outer race facing 3rd gear (B).

  • Page 436

    Manual Transmission Gountershaft Assembly Glearance Inspection NOTE: lf replacement is required, always replace the 2. Measure the thickness of 2nd gear. synchro sleeve and hub as a set. . l f t h e t h i c k n e s s o f 2 n d g e a r i s l e s s t h a n t h e service limit, replace 2nd gear with a new one.

  • Page 437

    6. Measure the clearance between reverse gear (A) 4. Measure distance O on the distance cottar. and the distance collar {B). lf the clearance is more than the service limit, go to step 7. . lf distance O is notwithinthe standard, replace the distance collar wilh a new one.

  • Page 438: Countershaft Disassembly

    Manual Transmission Countershaft Assembly Clearance Countershaft Disassembly lnspection (cont'dl 1. Remove the needle bearing. 8. fvleasure the thickness of reverse gear. . lf the thickness of reverse gear is less than the service limit, replace reverse gear with a new one. .

  • Page 439

    6. Remove the ball bearing using a press as shown. 3. Raise the 27 mm locknut tab from the groove in the countershaft. PRESS 7. Remove the remaining parts from the countershaft. 4. Securely clamp the 4th and 5th gears in a bench vise with wood blocks (A).

  • Page 440

    Manual Transmission Gountershaft lnspection 1. Inspect the gear surface and the bearing surface for 3. Inspectfor runout by supporting both ends of w e a r a n d d a m a g e . countershaft. Rotate the countershaft two complete revolutions when measuring the runout.

  • Page 441: Countershaft Reassembly

    Countershaft Reassembly Exploded View lST/2ND SYNCHRO HUS /R\ i.wj------=..-34 x s7 x 20 mm sYNcHRo SPRTNG :|::513;:*|.""0 DOUBLE CONE SYNCHRO FRICTION DAMPER lST GEAR 5 1 x 5 7 x 2 3 m m NEEDLE BEARING Check for wear and operation.

  • Page 442

    Manual Transmission Countershaft Reassembly (cont'd) Special Tools Required 4 . I n s t a l l t h e s y n c h r o s p r i n g ( A ) a n d d o u b l e c o n e .

  • Page 443

    I n s t a l l t h e 5 l x 5 7 x 2 3 m m n e e d l e b e a r i n g , d i s t a n c e 1 0 .

  • Page 444

    Manual Transmission Gountershaft Reassembly (cont'd) 14. Stake the locknut tab into the groove. 16. lnstall the needle beafl ng. bearing inner race (A) using the 1 5 . l n s t a l l t h e n e e d l e a press as shown.

  • Page 445: Secondary Shaft Disassembly

    Secondary Shaft Disassembly Secondary Shaft Inspection '1. Inspect the gear surface and the bearing surface lor Remove the tapered roller bearings using a commercially available bearing separator and a w e a r a n d d a m a g e . press as shown.

  • Page 446: Secondary Shaft Reassembly

    Manual Transmission Secondary Shaft Inspection (cont'd) Secondary Shaft Reassembly Special Tools Requir€d lnspect for runout by supporting both ends of . Attachment. 45 mm 07947-6890300 secondary shaft. Rotate the secondary shaft two . Bearing attachment 07LAD-PW50601 complete revolutions when measuring the runout. lf the runout is more than the service limit, replace ' 1 .

  • Page 447

    Shift Forks Clearance Inspection NOTE: lf replacement is required. always replace the 3. Measure the clearance between each shift fork, reverse shift piece and shift arm A. lf the clearance synchro sleeve and hub as a set. exceeds the service limit, go to step 4. 1.

  • Page 448

    Manual Transmission Shift Forks Clearance Inspection (cont'dl Measure the clearance between the 1-2 shift lever REVERSE SHIFT PIECE and each shift fork and shift piece. lf the clearance exceeds the service limit, go to step 6. Standard: 0-0./r mm (0-0.016 in.l Service Limit: 0.5 mm (0.020 in.) 6 .

  • Page 449: Shift Forks Disassembly/reassembly

    Shift Forks Disassembly/Reassembly Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. s-6 sHtFT 3-4 SHTFT 1.2 SHIFT FORK !=n6.+ 3-,1SHIFT PIECE x 22 SPRING PIN Replace. REVEFSE SHIFT PIECE 13-49...

  • Page 450

    Manual Transmission Synchro Ring and Gear Inspection 1. Inspect the inside of the synchro ring (A) for wear. 4. Inspect the gear hub thrust surface 1A) for wear. Inspect the cone surface (B) for wear and Inspect the synchro sleeve teeth and matching rougnness, teeth on the synchro ring (B) for wear (rounded off).

  • Page 451

    Synchro Sleeve and Hub lnspection and Reassembly Double Cone Synchro-to-Gear Clearance Standard: O: Outer Synchro Fing to Synchro Cone 1. lnspect gear teeth on all synchro hubs and synchro 1st,2nd, gear:0.70 1.09 mm (0.028 0.043 in.) sleeves for rounded off corners, which indicate 3rd.4th gear:0.90 1.39 mm (0.035 0.055 in.) w e a r .

  • Page 452

    Manual Transmission Oil Pump Glearance Inspection 3 . M e a s u r e t h e a x i a l c l e a r a n c e o n t h e p u m p r o t o r . l f 1 .

  • Page 453: Secondary Shaft Preload Adjustment

    Secondary Shaft Preload Adjustment 1 . I n s t a l l t h e o i l g u i d e p l a t e S , s h i m ( A ) a n d t h e 5.

  • Page 454: Mainshaft Thrust Clearance Adiustment

    Manual Transmission Mainshaft Thrust Clearance Adiustment 5. Seat the mainshaft fully by tapping its end with a Special Tools Required . M a i n s h a f t h o l d e r 0 7 G A J ' P G 2 0 1 1 0 p l a s t i c h a m m e r .

  • Page 455: Transmission Reassembly

    Transmission Reassembly 82 mm Shim Special Tools Required . Driver 07749-0010000 . Attachment, 42 x 47 mm 07746-0010300 Parts Number Thickness 23931-PR8-F000 0 . 6 0 m m ( 0 . 0 2 3 6 i n . Attachment,62 x 68 mm 07746-0010500 23932-PR8-F000 0 .63 mm (0.0248 .

  • Page 456

    Manual Transmission Transmission Reassembly (cont'd) 6 . I n s t a l l t h e 1 - 2 s h i f t p i e c e . Install the thrust washer (A) and 64 mm spring washer (B).

  • Page 457

    9 . I n s t a l l t h e s h i f t r o d ( A ) i n t o t h e i n t e r l o c k a s s e m b l y 12.

  • Page 458

    Manual Transmission Transmission Reassembly (cont'd) Install the oil pump strainer (A), suction guide (B), 1 7 . I n s t a l l t h e o i l g u i d e p l a t e S a n d s h i m { A ) , t h e n t 5 .

  • Page 459

    21. Apply liquid gasket (P/N 08718-0001) to the threads 1 9 . I n s t a l l t h e 1 4 x 2 0 d o w e l p i n s ( A ) , t r a n s m i s s i o n of the set screws (A), then install the steel balls and h o u s i n g ( B ) .

  • Page 460

    Manual Transmission Transmission Reassembly {cont'dl Installthe oil pump outer rotor S, steel ball (A), 27. Installthe needle bearing (A) on the countershaft s p r i n g { B ) , o i l p u m p p l a t e ( C ) . using the special tool as shown.

  • Page 461

    31. Install the oil pump gear and oil pump gear shaft. 29. Install the special tool on the mainshaft, then tighten the 29 mm locknut (left-hand threads) to the specified value. Torque 172- 0 -- 172 N.m ( 1 7 . 5 - 0 - * 1 7 . 5 k 9 1 . m , 127- o - 127 lbf.ttl .

  • Page 462

    Manual Transmission Transmission Reassembly (cont'dl Rear Cover Installation 3. Installthe secondary shaft assembly into the rear cover, NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricate to any contact su rfaces. 1 . I n s t a l l t h e b e a r i n g o u t e r r a c e ( A ) u s i n g t h e s p e c i a l tools as shown.

  • Page 463

    7 . I n s t a l l t h e O - r i n g ( A ) , b a c k - u p r i n g ( B ) , s p r i n g 5 .

  • Page 464

    Manual Transmission Transmission Reassembly (cont'd) '11, 9. Stake the 27 mm locknut tab into the oroove. Remove the dirty oil fromthe rear cover sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Be sure to seal the entire circumference of the bolt holes to prevent oil r e a K a g e .

  • Page 465

    1 5 . I n s t a l l t h e s h i f t l e v e r h o u s i n g . 13. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.

  • Page 466: Transmission Installation

    Manual Transmission Transmission Installation 1 . I n s t a l l t h e t r a n s m i s s i o n r e a r m o u n t l A i . 4 .

  • Page 467

    9. Place a floor jack under the front subframe and the 7 . I n s t a l l t h e w i r e h a r n e s s ( A ) t o t h e t r a n s m i s s i o n , then connect the Dick-uo sensor connector (B).

  • Page 468

    Manual Transmission Transmission Installation (cont'd) Install the propeller shaft (see page 16-18). Remove the shop towel, and install the release fork 1 5 . onto the release hanger, Install the gasket {A), exhaust manifold (B), and the t o . Apply super high urea greese (P/N 08798-9002)to exhaust manifold bracket (C).

  • Page 469

    20. Reconnect the torque sensor 3P connector (A), and 18. Install the wire harness (A) onto the transmission, i n s t a l l t h e w i r e h a r n e s s c l a m p ( B ) . then connect the heated oxygen sensor (H02S) (B), secondary heated oxygen sensor (secondary HO2S) {C), and the back-up light switch (D)

  • Page 470

    Manual Transmission Transmission lnstallation (cont'd) 23. Connect the TDC1 (A) and TDC2 (B) sensor 25. Install the heat shield. connectors. Installthe upper intake manifold bracket mounting 6 x 1 . 0 m m bolt (A) and upper starter motor mounting bolt (B). 9.8 N.m (1.0 kgf.m, 7.2lbf.ftl Connect the hose (C) to the suction varve.

  • Page 471

    3 0 . I n s t a l l t h e a i r c l e a n e r h o u s i n g a s s e m b l y . 27. Install the Ay'C compressor, then connect the 1 P connecror.

  • Page 472

    Manual Transmission Transmission Installation (cont'd) Install the battery. Connect the positive (+ ) cable 32. Installthe shift boot and the boot holder. first, then the negative ( ) cable to the battery. Check the transmission fluid {see page l3-3). 3 7 . Test-drive the vehicle.

  • Page 473

    Transaxle Rear Differential ..... 15-2 Soecial Tools Precautio ns for Torsen Type Limited Slip Differential (LSD) ......... 15-3 Torsen Type Limited Slip Differential (LSD) Operation Check ......15-3 ... 15-4 System Description ....Differential Oil Inspection and Replacement ..... 15-6 Differential Removal ......

  • Page 474: Rear Differential

    Rear Differential SpecialTools Ret. No. Tool Number Description 07JAD-P190100 Oil Seal Driver 07JAB-001020A H o l d e r H a n d l e 07LAD-PW50601 Attachment, 40 x 50 mm l.D. 07MAC-S100200 Ball Joint Remover. 28 mm 07MAD-PR90100 Attachment, 45 x 55 mm l.D. 07NAD,PX40100 Attachment, 78 x 80 mm OTRAB-TB4O,1OB...

  • Page 475: Precautions For Torsen Type Limited Slip Differential (lsd)

    Precautions for Torsen Type Torsen Type Limited Slip Limited Slip Differential (LSD) Differential (LSDI Operational Check . The Torsen differentials are mechanical limited slip The Torsen type limited slip differential (LSD) differentials which deliver the available Dower to the distributes optimum power between the two driving wheels and axles with the most grip or resistance as axles according to the difference in torque demanded the engine torque output increases.

  • Page 476: System Description

    Rear Differential System Description The vehicle uses the Torsen type limited slip differential (LSD) which is rubber mounted to the sub-frame Construct'ron . The Torsen type LSD assembly consists of the two side gears, eight planetary gears, three side washers, tvvo center washers, a gear case cover and a gear case.

  • Page 477

    Operation . Straight-road driving The differential carriel and gears rotate together as a unit when both wheels rotate at the same speed. Turning eflort from the final driven gears are directlv transmitted to both wheels. . When rounding a curve When the vehicle rounds a curve, the differential allows the outer wheel to rotate a little faster than the Inner wheel.

  • Page 478: Differential Oil Inspection And Replacement

    Rear Differential Differential Oil Inspection and Replacement 5 . C l e a n t h e d r a i n p l u g , t h e n r e i n s t a l l w i t h a n e w With the vehicle on level ground, inspect the w a s h e r , a n d r e f i l l t h e d i f f e r e n t i a l w i t h t h e differential oil with engine OFF.

  • Page 479: Differential Removal

    Differential Removal Special Tools Required 5. Make a reference marks (A) across the inboard ioint Ball joint remover,2S mm 07N4AC-S100200 (B) and the rear differential (C). 1. Make a reference marks across the propeller shaft, the transmission, and the rear differential, then remove the propeller shaft (see page 16-17).

  • Page 480

    Rear Differential Diff erential Removal (cont'd) 1 1. Remove the four differential mount A mounting 8. Remove the canister cover. bolts, '12. Lower the rear differential onthefloorjack. Place a floor jack under the rear differential Remove the four differential mount bracket B 1 0 .

  • Page 481: Differential Case Assembly Removal And Installation

    Differential Case Assembly Removal and Installation 1. Remove the output shafts {A) from the differential 3. Remove the dirt and oilfrom the sealing surfaces. c a s e a s s e m b l y u s i n g t h e p r y b a r s ( B ) . Apply liquid gasket (P/N 08718-0001) to the sealing surface.

  • Page 482

    Rear Differential OilSeal Replacement 3 . l n s t a l l t h e o i l s e a l u s i n g t h e s p e c i a l t o o l s a s s h o w n . Special Tools Required Oil seal driver 07JAD-P190100 07JAO-P190100...

  • Page 483

    Backlash Inspection 1. Remove the output shafts and differential case 4. Measure the backlash of the ring gear, assembly (see page 15-9). . S e t t h e d i a l g a u g e t i p a t a r i g h t a n g l e t o t h e r i n g 2 .

  • Page 484: Differential Disassembly

    Rear Differential Differential Disassembly Exploded View I O D t \ l ,,df#w\, :\g/ X \ w \ \ , , w^@m '@ (fr'a BGA. f l t * \ rP,.l \, @ @ @ @ ) ?q6) \ (i*?

  • Page 485

    A:24 N.m 12.4 kgf m, 17 lbf.ft) B: 45 N.m (4.6 kqt.m,33 lbt.ft) C:22 N.m {2.2 kgf.m, '16lbf.ftl D: 75 N.m (7.6 kgt.m,55lbf.ft) E: 11 N m (1.1 kgf.m.8lbt.ft) O LOCKNUT @ BEARING CAP Reolace. @ LOCK PLATE _ 127-284 N.m (r3.0-29.0 kgf.m, 94-210 lbf.ftl @ OUTPUT SHAFT (a)DRIVE PINION WASHER @CLIP...

  • Page 486

    Rear Differential Differential Disassembly (cont'dl 3. Remove the output shafts. Special Tools Bequired . H o l d e r h a n d l e 0 7 J A B - 0 0 1 0 2 0 A . C o m p a n i o n J l a n g e h o l d e r 0 7 R A B ' T 8 4 0 1 0 8 1.

  • Page 487

    7. Remove the adjustment screws (A), bearing outer 5. Make a mark on the bearing cap. adjust screw, and races (B), and Torsen LSD assembly (C). differential carrier case. Remove the lock plates and beari n g c a p s . 8.

  • Page 488

    Rear Differential Differential Disassembly (cont'dl 1 1. Remove the bearing outer race (A), tapered roller Remove the companion flange using a bearing (B), thrust washer (C), and oil seal (D) from commercially available bearing puller as shown. the differential carrier housing. Remove the drive pinion (A) and pinion spacer (B) 1 0 .

  • Page 489

    13. Remove the tapered roller bearing (A) andthrust 15. Remove the ten mounting bolts in a crisscross washer (B) from the drive pinion (C) using a pattern in several steps, then remove the ring gear. commercially available bearing separator and a Dress as snown.

  • Page 490

    Rear Differential Differential Disassembly (cont'd) Differential Reassembly Special Tools Required 1 7 . R e m o v e t h e o i l s e a l s . . Attachment, 40 x 50 mm l.D. 07LAD-PW50601 . D r i v e r , 4 0 m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0 .

  • Page 491

    5. Installthe bearing outer races {A) into the 3. Install the tapered roller bearing using the special differential carrier housing using the special tools tools and a Dress as shown. a s s h o w n , lnstall the standard thrust washer 3.47 mm {0.1366 in.) (A) onto the drive pinion (B).

  • Page 492

    Rear Differentaal Differential Reassembly (cont'd) 6. Apply lubricant to the tapered roller bearing, then 8 . I n s t a l l t h e o i l s e a l u s i n g t h e c o m p a n i o n f l a n g e a n d install the drive pinion and pinion spacer into the soecial tool as shown.

  • Page 493

    1 2 . T i g h t e n t h e l o c k n u t t o 1 2 7 N . m ( 1 3 . 0 k g f . m . 1 0 . I n s t a l l t h e s p e c i a l t o o l t o t h e c o m p a n i o n f l a n g e , then tighten the locknut to 20 N.m (2.0 kgf.m, 94 lbf.ft), then remove the sDecial tool.

  • Page 494

    Rear Differential Differential Reassembly (cont'dl Install the Torsen LSD assembly (A), bearing outer 16. Measure the backlash of the ring gear. 1 4 . races (B), adjustment screws (C) onto the Set the dial gauge tip at a right angle to the ring differential carrier housing.

  • Page 495

    20. Check the tooth contact, and adjust it if needed. 17. Tighten the bearing cap mounting bolts. 45 N.m {4.6 kgt.m,33lbf.ftl . Toe Contact: Use a thinner thrust washer to move the drive pinion away from the ring gear. . Heel Contact: Use a thicker thrust washer to move the drive pinion toward from the ring gear.

  • Page 496

    Rear Differential Differential Reassembly (cont'dl 21. Rotate the Torsen LSD assembly several timesto Heel Contact assure proper tapered roller bearing contact. Measure the Torsen LSD assembly preload using t h e p u s h / p u l l g a u g e . .

  • Page 497

    25. Remove the dirty oilfrom the differential case 2 3 . I n s t a l l t h e o i l s e a l u s i n g t h e s p e c i a l t o o l s a s s h o w n . sealing surface.

  • Page 498

    Rear Differential Differential Reassembly (cont'd) Differential lnstallation 2 7 . Tighten the 10 mounting bolts in a crisscross Install the right and left differential mount bracket A to the rear differential (see page 15-29). pattern in several steps. Place the rear differential on the floor jack, and 24 N.m {2.4 kgf.m, 17 lbf.ft) raise it to the mounting level.

  • Page 499

    6. Install the rear suspension stiffener, 4. Installthe right and left differential mountbracketA mounting bolts. 10 x 1.25 mm 6 x 1 . 0 m m 4 5 N m 1 4 . 6 k g f . m , 1 0 x 1 .

  • Page 500: Differential Installation

    Rear Differential Differential Installation (cont'dl Install the ball joints onto the lower arms (A), then installthe castle nuts (B) and new cotter pins. NOTE: Make sure the ball joint boot is not damage or cracks. .a=:\ \mr{-B 69-78 N.m 6< {7.0-8.0 kgf.m.

  • Page 501

    Differential Mount Replacement NOTE: lf the installing the rear differential and mount assembles, tighten the differential mount bracket B mounting nuts first, then the differential mount bracket A mounting bolts, 12 x 1,25 mm 12 x'1.25 mm 64 N.m 16.5 kst.m, 47 lbt.ftl 75 N.m (7.6 kgf.m,55lbt.ft) 10 x 1.25 mm 4 5 N m...

  • Page 502

    Transaxle Driveline/Axle ..... 16-2 SpecialTools ......16-3 Driveshaft lnsoection ......16-3 Driveshafts Removal 16-5 Driveshafts Disassembly ........16-8 Driveshafts Reassembly ...... 16-15 Driveshafts lnstallation ....16-16 Propeller Shaft Inspection 16-17 Propeller Shaft Removal ....16-18 Propeller Shaft Installation ..........

  • Page 503: Driveline/axle

    Driveline/Axle SpecialTools Ref. No. Tool Number Descriotion 0TrvtAc-s100200 B a l l J o i n t R e m o v e r , 2 8 m m 07xAc-001020A Threaded Adaoter. 24 x 1.5 mm 16-2...

  • Page 504: Driveshafts Removal

    Driveshafts Removal Driveshaft Inspection Check the inboard boot (A) and outboard boot (B) Special Tools Required on the driveshaft (C) for cracks, damage, leaking Balljoint remover, 28 mm 07MAC-S100200 grease, and loose boot bands (D). lJ any damage is found, reDlace the boot and boot bands. 1.

  • Page 505

    Driveline/Axle Driveshafts Removal (cont'dl 7. Remove the ABS sensor harness (A) from the 1 1 . P u l l t h e k n u c k l e o u t w a r d , a n d r e m o v e t h e driveshaft outboard joint from the wheel hub using u p p e r a r m , a plastic hammer.

  • Page 506: Driveshafts Disassembly

    Driveshafts Disassembly 2 . M a k e a m a r k ( A ) o n e a c h r o l l e r ( B ) a n d i n b o a r d j o i n t Special Tools Required .

  • Page 507

    Driveline/Axle Driveshafts Disassembly (cont'd) Outboard Joint Side: Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot. 1. Pry up the three tabs (A)with a screwdriver, then lift up the end of the band. Be careful not to damage the boot.

  • Page 508

    3. Wipe offthe grease to expose the driveshaft and 8. Remove the stop ring from the driveshaft. the outboard joint inner race. 4. Make a mark (A) on the driveshaft {B) at the same position of the outboard joint end (C). Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the boot.

  • Page 509: Driveshafts Reassembly

    Driveline/Axle Driveshafts Reassembly Exploded View clRcLlP INBOARD BOOT o99 lt Use the grease included in the inboard boot set. ," spioen g Use the grease included in the inboard boot set. --------_l STOP RING Replace. DRIVESHAFT tu@a t----..\ BANDS - --.1 OUTBOARD JOINT 16-8...

  • Page 510

    Special Tools Required 5. Fit the rollers (A) onto the spider (B) asshown,and . Boot band tool, KD-3191 or equivalent, commercially note these items; a v a i l a b l e . Boot band pincers, Kent-Moore J-35910 or equivalent, .

  • Page 511

    Driveline/Axle Driveshafts Reassembly (cont'd) 10. lnstall the boot bands with the band end toward to 7. Fit the inboard joint onto the driveshaft, and note front of the vehicle. these items: . Reinstallthe inboard ioint onto the driveshaft by a l i g n i n g t h e m a r k s ( A ) o n t h e i n b o a r d j o i n t a n d the rollers.

  • Page 512

    13. Thread the free end ofthe band through the nose 16. Unwind the boot band tool, and cut off the excess free end ofthe band to leave a 5 .. 10 mm (0.2 0.4 section ofthe commercially available boot band tool KD-3191 or equivalent (A), and into the slot on in.)tail protruding from the clip.

  • Page 513

    Driveline/Axle Driveshafts Reassembly (cont'dl 5. lnse rt the driveshaft (A) into the outboard joint (B) Outboard Joint Side: until the stop ring (C) is close to the joint. 1 . Wrap the splines on the driveshaft with vinyl tape (A) to prevent damage to the outboard boot. To completely seat the outboard joint, pick up the driveshaft and joint, and drop them from about 10 Install the new ear clamp band (B) and outboard...

  • Page 514

    7. Check the alignment of the paint mark (A) with the 9. Adjust the length of the driveshafts to the figure o u t b o a r d j o i n t e n d ( B ) . below, then adjust the boots to halfway between full compression and full extension.

  • Page 515

    Driveline/Axle Driveshafts Reassembly (cont'd) Check the clearance between the closed ear portion Set the new ear clamp band (A) by threading the 1 1 . of the band. lf the clearance is not within the tab (B) into holes (C) of the band. standard.

  • Page 516

    Driveshafts Installation 1 . P u l l t h e k n u c k l e o u t w a r d . a n d i n s t a l l t h e o u t b o a r d 3.

  • Page 517: Propeller Shaft Inspection

    Driveline/Axle Driveshafts Installation (cont'dl Propeller Shaft Inspection Install a new spindle nut (A), then tighten the nut. 1 . Shift into neutrai position. After tightening, use a drift to stake the spindle nut Raise the vehicle off the ground, and suppon it with shoulder (B) against the driveshaft.

  • Page 518: Propeller Shaft Removal

    Propeller Shaft Removal Raise the vehicle off the ground, and make sure it's 5. lMake a reference mark (A) across the propeller shaft (B) and the rear differentialflange (C). securely supported. Remove the propeller shaft protector. 't-rt, Make a reference mark (A) across the propeller shaft (B) and the transmission flange (C).

  • Page 519: Propeller Shaft Installation

    Driveline/Axle Propeller Shaft Installation ' t . 3. Installthe propeller shaft protector (A). Install the propeller shaft (A) onto the rear differential (B) by aligning the reference marks (C). NOTE: When the propeller shaft is replaced, align the white marks (D) on the new propeller shaft with the white mark on the differential, SPECIAL BOLTS Replace.

  • Page 520

    Steering Steering ..... 17 -2 Speciaf Tools Component Location Index ......... 17-3 Steering Wheel Rotational Play Check ....... 17-4 Power Assist Check ......17-4 Steering Linkage and Gearbox Inspection ....17-5 Steering Wheel Removal ..........l7-6 Steering Wheel Disassembly and Reassembly ..17-7 Steering Wheel Installation .........

  • Page 521: Steering

    Steering Special Tools Tool Number DescriDtion Ref.No. Locknut Wrench, 43 mm 071\4AA-S10020A...

  • Page 522

    Component Location Index AIRBAG ASSEMBLY Removal/lnstallation. page 23-65 STEERING WHEEL Removal, page 17-6 Disassembly/Reassembly, p a g e 1 1 - j Installation, page 17-8 STEERING COLUMN Steering Column Removal and Installation, page 17-9 Steering Column Inspection, page 17-12 Steering Lock Replacement, p a g e ' 1 1 - 1 3 STEERING SHAFT Steering Shaft Removal and Installation,...

  • Page 523: Steering

    Steering Steering Wheel Rotational Play Power Assist Check Gheck ' 1 . Stan the engine, let it idle. 1. Turn the front wheels to the straight ahead position. Attach a commercially available spring scale to the steering wheel. With the engine idling and the v e h i c l e o n a c l e a n , d r y f l o o r , p u l l t h e s c a l e a s 2, lvleasure how fa r you can turn the steering wheel left and right without moving the front wheels.

  • Page 524: Steering Linkage And Gearbox Inspection

    Steering Linkage and Gearbox Inspection STEERING COLUMN lnspect for loose column mountinq bolts and nuts. STEERING JOINTS Check for loose ioint bolts. TIE.ROD LOCKNUT Check for loose locknut. \r,.-*oo a"o,o,-,-,o,", lnspect Ior faulty movement STEERING GEARBOX ano oamage. Inspect lor loose mounting bolts. GEARBOX MOUNTING CUSHIONS Inspect lor deterioration.

  • Page 525: Steering Wheel Removal

    Steering Steering Wheel Removal SRS components are located in this area, Review the 5 . I n s t a l l a c o m m e r c i a l l y a v a i l a b l e s t e e r i n g w h e e l puller (A) on the steering wheel (B).

  • Page 526

    Steering Wheel Disassembly/Reassembly STEERING WHEEL WHEEL LOWER COVER SLIDE SCREWS \ i** t Ag> {?'%\-l @ { ( # Y ' - / \ .o"{.,,*,. HORN PLATE HORN PLATE COVEB ACCESS PANEL CRUISE CONTROL SWITCH 17-7...

  • Page 527: Steering Wheel Installation

    Steering Steering Wheel Installation 1. Before installing the steering wheel, make sure the 3. lnstallthe steering wheet bolt and tighten it. front wheels are aligned straight ahead, then center 39 N m {4.0 kgf m,29lbf.ft} the cable reel (A). Do this by first rotating the cable reel clockwise unlil it stoos.

  • Page 528: Steering Column Removal And Installation

    Steering Column Removal and Installation SRS components are located in this area. Review the SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page 23-10). Removal 1. Record the radio station presets, and disconnect the battery. 2.

  • Page 529: Steering Shaft Removal And Installation

    Steering Steering Column Removal and Steering Shaft Removal and Installation (cont'dl Installation lnstallation Removal Remove the steering column (see page 17-9). 1 . I n s t a l l t h e s t e e r i n g c o l u m n , a n d m a k e s u r e t h e wires are not caught or pinched by any parts.

  • Page 530

    steering shaft (B) (from the engine companment). lnstallation Be sure the steering joint and steering shaft are aligned with the serrations; the joint should slip on 1, Apply multipurpose grease to the inside surface of t h e p i n i o n d u s t s e a l ( A ) . freelv.

  • Page 531

    Steering Steering Column/Steering Shaft Inspection Check the steering column ball bearing {A) and the steering joint bearings (B) for play and proper movement. lf any bearing is noisy or has excessive play, replace the steering column as an assembly. Check the retaining collar (C) for damage. lf it is damaged, replace the steering column as an assembly. Check the absorbing plates {D) for distortion or breakage.

  • Page 532: Steering Lock Replacement

    Steering Lock Replacement 1. Remove the steering column (see page 17-9), 2. Center DUnch each of the two shear bolts, and drill their heads off with a 5 mm {3/16 in.) drill bit. Be careful not to damage the switch body when removing the shear bolts.

  • Page 533

    Steering Rack Guide Adjustment 7. Tighten the locknut to 25 N.m (2.5 kgf.m, 18lbfft) Special Tools Roquired Locknut wrench, 43 mm 07MAA-S100204 while holding the rack guide screw. 1. Set the wheels in the straight ahead position. 8. Install the lower radiator clamp. 2.

  • Page 534

    Electrical Power Steering (EPSI EPS Gomponents S o e c i a l T o o l s t / - t o Component Location Index ....17-17 17 -18 General Troubleshooting Information DTC Troubleshooting Index 1 7 - 2 2 17-23 Symptom Troubleshooting Index ....

  • Page 535

    EPS Components Special Tools Description Ref.No. Tool Number 07MAC-S100200 B a l l J o i n t R e m o v e r , 2 S m m 07746-0010100 Attachment. 32 x 35 mm 07749-0010000 Driver 07974-6790000 O i l S e a l D r i v e r 17-16...

  • Page 536

    Component Location Index DATA LINK UNDER-HOOD FUSE BOX CONNECTOR I16PI GAUGE ASSEMBLY UNDEB.DASH FUSE/RELAY BOX MAIN UNDER-HOOD FUSE/RELAY BOX TOROUE SENSOR page 17-54 Torque Sensor Beplacement, EPS CONTROL UNIT EPS Control Unit Bemoval/ Installation, page 17-59 STEERING GEARBOX Steering Gearbox Removal and lnstallation, page 17-46 Steering Gearbox Ov€rhaul, page 17-53 Rack Guide Bemoval/lnstallation, page 17-54...

  • Page 537

    EPS Gomponents General Troubleshooting Information EPS Indicator The EPS control unit performs the following functions when a problem is detected by self-diagnosis: Under normal conditions. the EPS indicator comes on when the ignition switch is turned to the ON (ll) position, Turns on the EPS indicator.

  • Page 538

    Service Check Signal Circuit Method: connectors with a double outline. 1. With the ignition switch OFF, connect the Honda PGM Tester (A) to the 16P data link connector (DLC) 1. Ouestion the customer about the conditions when...

  • Page 539

    Add the long and short blinks together to determine the DTC. After determining the DTC. refer to the 1. With the ignition switch OFF, connect the Honda DTC troubleshooting index, PGM Tester (A) to the 16P data link connector (DLC)

  • Page 540

    OFF. This will return the svstem to the alert m o o e . 10. Disconnect the Honda PGM Tester from the DLC. Whith the vehicle on the ground, set the front wheels in the straight ahead driving position.

  • Page 541

    DTC Troubleshooting Index Note Detection ltem (see page 17-28) DTC: 1 Power relay stuck ON (see page l7-28) Drc 2 Fail-sate relay stuck ON {see page 17-28) LOW FET (Motor drive transistor) stuck ON DTC: 3 (see page '17-29) UP FET (Motor drive transistor) stuck ON DTC: 4 (see page 17-30) Open to body ground in the motor circuit...

  • Page 542

    Symptom Troubleshooting Index Diagnostic procedure Symptom Also check for EPS Indicator Circuit Troubleshooting (see page 17'42) EPS indicator does not come on EPS Indicator Circuit Troubleshooting (see page 17-42) EPS indicator does not go off and no DTC is stored EPS indicator does not stay 1.

  • Page 543

    EPS Components System Description EPS Control Unit lnputs and Outputs for Connector A (2P) EPS CONTROL UNITCONNECTOR A {2P} W i r e s i d e o f f e m a l e t e r m i n a l s . Terminel sign Description Tormanal...

  • Page 544

    EPS Control Unit Inputs and Outputs for Connector C (2P) EPS CONTROL UNIT CONNECTOR C I2PI W i r e s i d e o f f e m a l e t e r m i n a l s . Terminal Wire color Terminal sign...

  • Page 545

    EPS Components Circuit Diagram UNDER-OASH FUSE/RELAY AOX TOROU€ SENSOF GAUGE ASSEMBLY CONNECTOR A (1'P) TOROUE SENSOF 3P CONNECTOR GAUGE ASSEMELY CONNECTOA A (T2PI Term nal side of female tef minals GAUGE ASSEMBTY CONNECTOF C {2OP) Wre side oi le male rermina ls W i r e s i d e o i f e m a l e r e r m n a l s 17-26...

  • Page 546

    .L---r-_r CONTBOI UNIT CONNECTOR A (2P) EPSCONTEO! UNITCONNECTOR C {2P) MOTOA CONNECTOR I2P) l i ; c o n n a t o r ) l a : /-+' tllu t 2 t l l t 2 t 1 l e r m n a l s i d e o l f e m a l e l e r m i h a l s W r e s i d e o t i e m a e t e r m i n a l s T e r m i n a s i d e o f f e m a e t e r m n a l s...

  • Page 547

    EPS Components DTC Troubleshooting DTC 3: Lower FET Stuck ON DTC 1: Power Relay Stuck ON 1, Disconnect EPS control unit connector A (2P) and DTG 2: Fail-safe Relay Stuck ON the motor 2P connector. 1 . C l e a r t h e D T C . 2.

  • Page 548