INTRODUCTION [- How to Use This Manual, ———_______ This supplement contains information for HONDA ACCORD, Reter ta following shop manuals for service procedures and data not included in this supplement, Description Code HONDA ACCORD MAINTENANCE, REPAI AND CONSTRUCTION 93 628N700 HONDA ACCORD SUPPLEMENT 93, 625N720 HONDA ACCORD SUPPLEMENT 94 628N721 HONDA ACCORD SUPPLEMENT 95, | 62sw722 ‘The first page of each section is marked with a black tab that lines Lup with one of the thumb index tabs on this page. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as 2 quick reference system. Special Information, _______ ERMINE iacicates a strong possibility of severe personal injury (or loss of life if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed NOTE: Gives helpful information. CAUTION: Detailed descriptions of standard workshop procedures, safety principles and service operations are not inckided. Please note that this manual contains warnings and cautions against some specit- ic service methods which could cause PERSONAL INJURY, damage a vehicle or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by HONDA MOTOR might be done, or of the possi. ble hazardous consequences of every conceivable way, nor could HONDA MOTOR investigate all such ways. Anyone using service procedures or tools, whether or not recommended by HONDA MOTOR, must satisty himself thoroughly that neither personal safety nor vehicle safety will be jeopardized. All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publica tion may be reproduced, stored in retrieval system, of transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. marked sections are not included in this manual First Edition 12/95 404 pages HONDA MOTOR CO., LTD. Al Rights Reserved Service Publication Office General Info Special Tools Specifications Maintenance Engine Cooling Fuel and Emissions Transaxle *Steering Brakes |_ (Including [ABS }) *Body “Electrical _ (Including | SRS }) AAs soctions with * Include SRS components: special precautions ate required when servicingOutline of Model Changes CODE NO. REFERENCE ial DESCRIPTION (e2anr20|ezanras|sesnraa|ezsn72s| SECTION General 230 modeladded ° — | 2.08 KS model added oo —_— 1.8 model added o — 22 model added o a3 ‘Maintenance schedule changed © Traine 223 engine type added 5 foazt, O00 etincn vv lerance modited Rear mount bracket Changed ° — Changed * Torque value of radiator fan self locking nut 5 + Connecting pipe (H23A3 engine) + Water pump FIBAS engine added ° — F2222 (SOHC VTEC! engine added © [5.6.7,8,9,10 Cylinder head cover installation procedures changed o 6 PGM-FI Changed for 2.3 € model addition * Vacuum connections + Eloctrical connections + Heated oxygen sensor (HO2S) + TOCICKPICYP sensor eo + Starting air valve + Fast idle thermo valve += Throttle body + Intake air bypass (IAB) control system + Intake air control system Main wire harness changed © — FIBAS engine added © — F222 engine added Adopted + Immobilizer system + Fuel tube/quick connect fittings Changed 2 a + Fuel filter + Vacuum connections + Maintenance schedule of clear element Manual ‘Countershaft 2nd gear synchro system changed ° = Transmission | Changed = Countershaft clearance inspection ° 7 + Reverse idle gear shaft torque ‘Manual transmission fluid designation changed o 3rem DESCRIPTION L ‘CODE NUMBER | REFERENCE (62SN720|62SN721|628N722|62SN723| SECTION ‘Automatic Transmission Changed for 2.31 model addition + Road test shift schedule + Stall speed RPM + Pressure testing fluid pressure + 1st/2nd clutch assembly ° Circuit diegram modified Changed + Reverso idler gear shift and holder + Main vaive body assembly + Secondary shaft assembly + Clutch discs and pistons + Throttle control cable inspection and adjustment, Discontinued + Right side cover protector + Magnet on ATF strainer Changed + Ist-hold clutch plates + Secondary shaft axial clearance specification + Torque value of the transmission housing bolts Added + Ist clutch dises Changed + Hydraulic circuit + Electronic A/T control system + Self-diagnosis indicator light + Shift schedule + Automatic transmission fluid designation + Gear shift selector ‘Steering Power steering system changed Brake Application of brake pads changed due to 2.3! model addition Changed + Torque value of rear brake caliper bracket mounting bolt for conventional brakes + Anti-lock Brake System (ABS) Possible to replace the reservoir and the accumulator of the modulator unit Changed + Replacement parts of front and rear brake caliper, + Master cylinder + Brake booster inspection procedures 1 ABS system Body ‘Added + Front spoiler for 2.2 model + Trunk spoiler for 2.3 ° model ° ‘Some protectors of doors added Changed + Front bumper, front grille, sunroof and emblem Adopted + S-way power adjustable driver's soat | + High mount brake ightOutline of Model Changes ] REFERENCE rem SCRIPTION ‘CODE NUMBER Des | EEEEEEEEL CODE: URIBE HESEEIE } [e2snv720|628N721 62sN722|62sN723| ‘SECTION Electrical Changed + Ignition system (2.3 mode!) + Power supply circuit + Starter mounting bolt torque value changed (MT) | Keyless entry system added (KE) ‘Added + Cruise control system (KE model) + Supplemental Restraint System (SRS} Type I! Changed + Power supply circuit + AT gear position indicator circuit + Trunk light + Location of head light washer switch (KE model) + Horn system + Supplemental Restraint System (SRS) Type I! Changed + Keyless entry and Security alarm system F2222 engine added Adopted + B-way power adjustable driver's seat + Immobilizer system Changed + SRS-type il + Fuge amperage, wire colors and fuse No, and ground: No.General Information Chassis and Engine Numbers Identification Number Locations . SRS Warning/Caution Label Locations .. Caution/Informat Locations . AbbreviationsChassis and Engine Numbers Vehicle Identification Number (VIN) ‘SHH CE7 510010 00001 ae 2 Line, Body and Engine Type ‘CET: ACCORD SEDAN/F18A3 CEB: ACCORD SEDAN/F20Z1 CES: ACCORD SEDAN/F22Z2 Body and Transmission Type. ———! 4-door Sedan/5-speed Manual 6: 4-door Sedan/4-speed Automatic Vehicle Grade (Series) 118i 2:1.8i8 3: 18iLS {| 4: 1.83 (CE7), 2.01 (CEB) 5: 1.818 (CE7), 2.015 (CEB) | 6: 1.8iLS (CET), 2.01LS (CEB), | 8: 201ES (CES), 22iVTEC (CES) | ee Factory Code J ______ | sna “sn | ne 1-2 7 Engine Number F18A3 - 300001 Engine Type FIBAS: 18 SOHC 16,alves Sequential Mutiport Fuskinjocted 115 PS engine Unleaded gasoline with CATA 2.00 SOHE 16valves Sequential Multipart FueLinjected 121 PS engine | Unieaded gasoline with CATA 2.20 SOHC 16-valves VIEC | Sequential Muttipore | Fuctinjacted 150 PS engine Unieaded gasoline with CATA Serial Number anal F20Z1: F272: [- Transmission Number Ma7A- 1000001 Mon Transmission Type. ——— MA7A: Automatic N2Cé: Manual for F2021 engine N2D4: Manual for F2222 engine N2E5: Manual for F18A3 engine N2S4: Manual for F18A3 engine Serial Number ‘Automatic: 1000007- Manual: Except N2ES: 3000001 ~ N25: 1000001~ro icable Area Code/VIN/Engine Number/Transmission Number wove, |APPUCABLE | GRADE | TRANSMISSION| yg VEMICLE enone | TRANSMission ‘Rea CODE | NaMe | Tyre NTICAT NOMBER wuMBen MT | SHEETS 004000001 | Faas Eo00007- | NaEEAoRDDD™ ia sMT ‘SHHCE75400U000001~ F18A3-E300001~ | N2S4-3000001~ 5MT ‘SHHCE75200U000001~ | F18A3-£300001- | N2ES-1000001~ a 4aT ‘SHHCE76500U000001~ F18A3-£300001~ | M47A-1000001~ | |~ 5MT ‘SHHCE75300U000001~ F18A3-£300001~ | N2E5-1000001~ | 1sits [sur | swncevseoovooec0:- | Freaa-e30000t- | as4-3000001~ #AT__| SHHCETes09U000001- | Fras esoooot- | MTA. Too000T= cq 18S [swt | stce7sroouoeoorr= | Fens escocor- | N2Se->00000%~ shit] SHHCERScoou000001- | Fa02t-eso0001- | N2C4 2000001- 2018 4AT | SHHCE86600U000001- | F20Z1-£300001- | m47A-1000007. es Se sors [tat | StHessero0uo0000. | Faozi-es0000r- | mara 1000001~ suit | SHHCERseo0U000001- | Fa0zi-€s00007- | N2Ge 3000001- [sat sttcesssoouce000- —| Faoz.es00001- | ma7A-r000001~ SMT__| SHHCE95700U000001- | Faaz2€800001- | NaD4-300000"- (2.2i vTEC| 5MT SHHCE95800U000001~ F2222-£300001- | N2D4-3000001- — ‘at__| SHHCESee00U000001- | £2322 €300001- | w47A-1000007- 208 | swt | saHcE8ssoou000001. | raaei-€300001- | Nace. 200000%- mous [SMT | SHHCE8Ss0qucoo001 | radz1 £30000". | Nace 300000;- Ks @AT_| SHHCEBS=09U000001- | F2222-€900001- | Nab«3000001~ Lavrecl___ SMT] SHH¥cEseeooUc00001~ | r2222 360000. | w47A- 1000007 =o SHHICETS¢00U000001- | F1#A3-€300001- | N2S4-3000001~ is | sw | SCE reeoouooo00%= | FreASEao000%~ | W2SeS00000%~ Swit _| SHHCE7se00U000001- Fas-€50000%- | N2Se-3000007= 18S | aat__| swHceTeeoouoe0001- | Fveas-es00001- | w#7A-100000"- | 2.01 SMT | SHHCEB5400U000007~ F20Z1-E300001~ | N2C4-3000001~ vos [SMT] SAHCERSso0¥000001-— Faoet-es00001- | N2Ce 9000001= KE 4aT | SHHCE86500U000001- F20Z1-E300001~ | M47A-1000001~ | ous [SMT] SAHCESseo0U00000% | Faoet-es00001- | Nace 3000001- ‘4at___| SANE es00u000001-—| F20z1-Esoo0D1- | Ma7A.To00001~ Foes [SMT] StHcEasro0u000001- | raozt-esn0001- | N2G¥3000001- dat] SHHCEB67o0UD00001- | Faazt-eso0001— | m47A-1000001~ pavrecl___5MT__| SHHCE9s800U000001- | Faazaeatoooi- | N2D« 300000". “4AT | SHHCE®6000U000001 | F22z2-£300007~ —|-Ms7A-T000001- 1-3Identification Number Locations 1-4SRS Warning/Caution Label Locations Ea NOTE: LHD modol is shown; RHD model is similar DRIVER MODULE CAUTION LABEL CABLE REEL ‘BAM INFLATOR LABEL CAUTION LABEL SRS CAUTION TAG ‘SAS WARNING TABEL DRIVER CAUTION (printed on sunvison BAM INFLATOR LABEL (FRONT SEAT PASSENGER) FRONT SEAT PASSENGER MODULE CAUTION LABEL ‘SRS UNIT ‘CAUTION LABEL STEERING COLUMN CAUTION LABEL NOTE: LHD model has two caution abete HD model has one caution label. 1-5Caution/Information Label LocationsAbbreviations Alc. ALT ABS ArT ATE AIF AMP ANT ASSY ‘AUX APPROX, ATOC AUTO ATT ACL API BARO BAT BTOC BDC cKP cye CAT or CATA co cy pc CARB comp cpu cHG o1 bic orc DIFF DoH Pt EVAP EGR ECM ecT x ELD Fl EPS Air Conditioning, Air Conditioner Alternator Anti-lock Brake System Automatic Transmission ‘Automatic Transmission Fluid Air Fuel Ratio Ampere (s} Antenna Assembly Auxiliary Approximately After Top Dead Center ‘Automatic Attachment Air Cleaner ‘American Petroleum Institute Barometric Battery Before Top Dead Center Bottom Dead Center Crankshaft Position Cylinder Position Catalytic Convertor Carbon Monoxide Cylinder Clutch Pressure Control Carburetor Complete Central Processing Unit Charge Distributor Ignition Data Link Connector Diagnostic Trouble Code Differential Double Overhead Camshaft Dual Point Injection Evaporative Exhaust Gas Recirculation Engine Contro! Module Engine Coolant Temperature Exhaust Electrical Load Detector Electronic Fuel injection Electrical Power Steering List of automotive abbreviations which may be used in shop manual F FP FWo FR FL FSR FIA GAL GND HB Ho2s Hc ae lac lan. on lat ima IN IG or IGN 1D 1D or 1.0, IN WNT Ks L LH LHD uc tsb LF LR La LED Front Fuel Pump Front Wheel Drive Front Right Front Left Fail Safe Relay Fuel Injection Air Gallon Ground Hatchback Heated Oxygen Sensor Hydrocarbons Intake Air Bypass Idle Air Control Intake Air Resonator Ignition Control Module Intake Air Temperature Idle Mixture Adjustment Intake Ignition Identification Inside Diameter Injection Intermittent Knock Sensor Left Loft Handle Left Handle Drive Lock-up Clutch Limited Slip Differential Left Front Left Rear Inline Four Cylinder (engine) Light Emitting Diode fcont’a) 1-7Abbreviations r- (cont'd) mis Manual Steering scs Service Check Signal MAP | Manifold Absolute Pressure sec Second mi | Matfunetion indicator Light Secondary mrt Manual Transmission McK | Motor Check 1 Torave max. — | Maximum Tem | Transmission Control Module min Minimum twe | thwee Way Catalytic Converter Pt Multi Point injection toc | Top Dead Center 18 Throttle Body N Neutral re Throttle Position Nox | Nitrogen, Oxides of tc Torque Converter Ti Timing Belt 028 | oxygen Sensor TiN Too! Number 08D —_| On-board Diagnostic Tes | Traction Control System 00 or 0.0.) Outside Diometer vss | Vehicle Speed Sensor P Park VTEC | Virable Valve Timing & Vaive Lit PAIR | Pulsed Secondary Air Injection Electronic Control PsP. Power Steering Pressure ve Viscous Coupling Pev | Positive Crankcase Ventilation vin Vehicle Identification Number Proportioning Control Valve YVIS | Variable Volume Intake System PIs Power Steering Pome | Programmed fuel Injection w with PGM.IG | Programmed Ignition wio | without Pal Primary WOT | Wide Open Throttle PIN Part Number PL Pilot Light Two Whee! Drive pain | Pump Motor Relay Four Wheel Drive psw | Pressure Switch Two Wheel Steering PSF Power Steoring Fluid Four Wheel Steering 4:speed Automatic Transmission ary Ovary S-speed Manual Transmission Park R Right Reverse aR Roar Right iN Neutral RHD | Right Handle Drive [bs Drive (1st through 4th gear) REF | Reference 3 Drive (1st through 3rd gear) RL Roor Left 2 Second RON Research Octane Number 7 First ist Low (gean sae Society of Automotive Engineers 2no | Second (gear SOHC | Single Overhead Comshatt 3R0 Third (geen SOL Solenoid 4TH Fourth (gear) SPEC | Specification STH Fitth (goer) Sik Sun Root SRS Supplemental Restraint Systom STO Stendard sw SwitehSpecial Tools Individual too! lists are located at the front of each section,Specifications Standards and Service Limits Design Specifications Body Specifications . . 3-12 . 3-16Standards and Service Limits (— Cylinder Head/Valve Train — Section 6 ae Soe en ee Syne =e oo =reed | age eee Valve spring | Free length F222 engine 1N ‘51.08 (2011) — aaa = aalleseata = K | Baaeeee tes | | EX, 0.078 ~ 0.054 (0.0007 - 0.0021) 0.08 (0.003)[— Engine Block — Section 7 BT) Unit of lengths mm (in MEASUREMENT [STANDARD (NEW) SERVICE LNT Cylinder black | Warpage of deck surface ‘0.67 (0.008) max 0.7010.008) | Bore diameter Aort | 85.010 ~85.020 (33468-33472) | 95.070(2-2492) Borst | s5.000-85.010(3.3465-3.3408) | 85.070 (32402) Bore taper aaa } 0.05 2.002) Reboring limit 0510.02) Piston Skit O.D.—[at2i mm @8in) from) NoLatter | 849908990 93487 —aaaE) | 84.970 (3.3453) bottom of skirt LewerB | 84970-8¢980(3.3453- 33457) | 4.960 (3.2449), Clearance in evlinder 0.020 ~ 0.080 0.0008 0.0016) | 0.08 (0.002) Groove width tfor ring) Top | 1.220-1.230(0.0880-0.0484) | 9.25 10.049) Second | 1.220-1.230(0.0880-0.0484) | 1.25 (0.049) oil 2.905 -2.825 (0.1108-0.1112) __| 2.880.112) Piston ring ing o-groave clearance Too. 0.035 - 0.060 0.0014 0.0028) | 0.13 (0.008) Second | 0030-0055 (0.0012-0.0022) | 0.1310.008) ing end gap Top (020-035 10.008 - 0.078) 0.600.024) Second | 0.40-0.86 (0.016 - 0.022), 0.7010.028) oi (0.20 -0.70 0.008 - 0.028) 0.80 10.03 Piston Pin OD. 21.994 - 22.000 (0.8889 - 08861) | — Pin-to-piston clearance 0.010 0.022 (0.0008-0.0009) | —— Connecting ted | Fin-tood interference 0.013 -0.032 (0.0005 0.0013) | —— ‘Small ond bore diameter 21.968 - 21.981 (0.8649 -0.8654) | Large end bore diameter Nominal £2222 engine 5101200 —— Excopt F2222 engine 48.01.89) = | End play installed on crankshaft 0.15 ~0.30 (0.006 0.012) 0.40 (0.016) Crankshaft ‘Maia journal diemeter No, 2jaurnal 48.976 - 50.000 1.9676 - 18685) | —— No. 3 journal 49.972 «9.996 11.9674 19683) | —— No. 1 and No.4 journals | 49.984 - 50,008 (1.9679 - 1.9688) | —— No. 5 journal 48,988 ~ 50.012 1.9680 15690) | —— Rod journal diameter 2222 engine 47.978 48,000 (1.8888 18898) | —— Except F2222 engine ‘44976 45.000 (17707-17717) | —— Taper (0.005 0.0002) max 1.008 0.0002) Our-ot round 0.005 0.0002) max 10.008 0.0002) End play 0.10 -0.35 (0.008 0.018) 4s (0.018) ‘Total runout 0.03 0.001) 0.08 0.002) Besrings ‘Main bearing-tajournal No.2 journal 0.021 ~ 0.046 (0.0008 -a0078) | 0.050 0.0020) oil clearance No. 3 journal 0.025 0.049 (0.0010-a.0018) | 0.085 10.0022) No. 1and No, & journals | 0.013 0.037 10.0005~-0.0018) | 0.080 (0.0020) No. 8 journal 0.008 -0.033 (0.0008 -c.0013) | 0.040(0.0016) Rod besring-tojournal £2222 engine 0.021 ~0.088 (0.0008-0.0018) | 0.085 (0.0022) it clesrance Except F222 engine 0.015 ~0.043 (0.0008 0.0017) __| 0,050 0.0020), Balancer shat’ | Journal diameter No.1 front journal 42.722 ~ 42.736 1.6820 - 1.6824) | 4271 (1.681) No.1 reat journal 20938 - 20.950 (0.824 0.8248) | 20920824) No. 2 front and roar journals 38,712 - 38.72441.5241- 15246] | 38.70(1.524) No.3 front and rear journals 34.722 - 34.73641.3670- 13675} | 34.71 (1.367) Journal taper 10.008 0.0002) = End play Front 0.10 0.40 (0.004 0.016) a . Fear 0.04 0.15 (0.002 0.008) = Total runout 0.02 (0.001) max | 0.03.0.00n Sheftto-bearing ol clearance No. 1 rear journal 0.050 ~0.075 (0.0020-0.0020) | 0.09 (0.004 No.1 front, No.3 front and rear journal 0.066 - 0.098 (.0025-0.0039) | 0.12 (0.006), No.2 font and rear journals 0.076 ~0.108 (0.0030 - 0.0043) __| 0.130.006), Bolancershatt | 10. ‘No. 1 front journal 42.800 = 42.820 (1.5350 - 1.6956) | 42.63 (1.686) bearing No. 1 rear journal 21.000 21.013 (0.8268 0.8273) | 21.02 0.828) No.2 front and roar journals 38.800 ~ 36.820 1.5276- 15283) | 38.83 (1.529) No.3 front and vear journals 34.200 - 34.820 1.9701 1.3700) _| 3483(1.379) 3-3Standard: — Engine Lubri Is and Service Limits ication — Section 8 Pa (kale, psi) ticle 313,000 min- (ror MEASUREMENT [STANDARD INEW) SERVICE LIMIT Engine oft Capacity Excopi F2222 engine | 49162, 43) for engine overhaul AUS at. imp at 38 (40, 23) forall change, including ker 35 (87, 3:1) for oll change, without iter F222 engine 56 (6.9, £9) for engine overnaul 43 (45, 38) for oll change, including fier 7 40 (42, 35) for oll change, without fitor Gilpam inner to-outer rotor clearance 1.02 0.16 10.00% - 0.006), (0.20 10.008) Pump housing to-outor rotor clearance 0.10 0.19 (0.004 0.007) 0.2 (0.008) Pump housing to-rotor axial clearance 0.02.07 10.001 - 0.003), 0.12 (0.008) Roliet valve Proscura sotting at engine oilemp. 60°C 76°F) 10.0.7, 10) min. 35036, 50) min, [— Cooling — Section 10 Thermoswitch “OFF” temperature °C CF) Fan timer "ON" temperature °C.(F) Fan timor "OFF" temperawure CF) easuneweNT STANDARO iNew) Tatar Saori canety Beopl FEE engine | WI 63 67S) er overt Sacinee £7 189.2 fa costo enange ee io aa am: 62108 68} forovena | (Satetee Sat sesoni 25 a2 dattorconlmenange F222 engine wr 34050 oa er evemeal E5\62,521 for conan enonge wr $5105, 8a forever Ba teace Her asl change lf Resonior capaciy_¢ (US at in a os anasst Faditorcap [Opening pressure Po lot. sl 96-125 (095-15. 14= 1) Thermos] Stote opens "ST 76=a0 68-76) Puy open co) Sage oR fa sen S103 min in Goaing Ton | Thermoswith “ON tamparture “ETAT 90-86 gt) Subtract 27 (413) from actual “ON” temperature 103-109 (217-226), Subtract 2~ 5 14~ 8) from actual “ON" temperature r~ Fuel and Emi issions — Section 11 MEASUREMENT STANDARD (NEW) SERVICE LNT Fuel pressure Fuel pressure with regulator vacuum hese discon 280-530 (28-33, 40-47) regulator nected KPa kgler’, psi) : Ful tank Capacity € (US gal.Imp ga) e572, 183) Engine Fest idle speed min (rom) 7.400: 200 Tle sped min" (rpm) (with headlights and cooling fan of 770-50 (MIT: neural 770 50 [A: [oF [B position) ale CO_% 0.3% max .[— Clutch — Section 12 Unit of length: me tin) | service unar MEASUREMENT. | STANDARD (NEW) Clutch pedal Clutch pedal height to the floor | 210 (8.27) — ae | Sense wae = : paseenmee asin : nies [aaron Tot sot a aaa neat ae see -— Manual Transmission — Section 13 wensvnevent sTanoano evn serves unt [SBR imrencen ome of ada aca 8 Fou emis iat | Bea _ noe sista es faut Taos Po oon ssa eas_—TaRGT | S00 oT Eapty teacwbe aes | omens ree, Pease reer al Ecteth Diameter of 1st gear contact area B } 39.984 ~ 40,000 (1.5742~ 1.5748) | 39.93 (1.572) Blazes | Sacer ae ee Barty sgcossuor naa | Sees Sposa 1 Sea act (cae Lasee —| OT Graeme [Od ae wanes | REE Sine | Su : Som comet | (Mainshaft 4th 0.0. a8 37.989 ~ 38,000 (1.4956- 1.4961) | 37.94 (1.494) masmsed | Stam o] GOS. | Rage ee | Br arto gx sat cence ietomean ee” | Rese Se er Sion aooy | S88 (cont'd 3-5Standards and Service Limits -— Manual Transmission — Section 13 (cont'd) kPa tkglor®, psi (Gi oF) position) “ih clutch pressure at 2,000 min (rpm (Dd position 34d and 2nd clutch pressure st 2,000 min" (rpm) (Di position) {hotle flly-closed 9008.0, 128) throttle more than 2/8 open 590 (63,75) throttle fully closed 1 900 (9.0, 128) {throttle more than 218 open 500180, 7) throttle ully-ctosed 900 (9.0, 128) throttle more than 2/8 open MEASUREMENT STANDARD (NEW) [SERVICE UNIT Reverse shift fork | Pawi groove width 130-133 1051-052) — Forketo-everse iler gear clearance 05-1.11002-008) 1810.07) Groove width" aa | 7.05~7.2510.278- 0.285) — mB | 74-77 (029-030) = | Forcto-stvreverse shit shat clearence"? sta | 0050.35 10.002 0.014) 05 (0.02) a8 | 04-08 10.0203) 19 (0.08) Shift arm 1D, 15.873 ~ 16.000 (0.6280 — 0.6709) Shift arm-to-shaft clesrance 10.008 ~ 0.059 (,0002 - 0.0023), | Shift fork diameter st contact srea 128 - 13.0 (0.508 - 0.612) = [_Shiftarmto-shift fork shat clearance 02-085 (0.008 - 0.020), 06 0.024) Select lover ‘Shaft outer diame 15881 — 15.988 (0.6276 —o.8767) | — a ‘Shift arm cover clesrence 0.032 0.102 (0.0013-0.0040) | —— ‘Shit lever 0. 15901 16.966 (0.6276 - 0.6287) | —— ‘Transmission housing clearance 0.021 ~ 0.081 (0,.0008-0.0016) | —— Interlock Bore diameter 75.00 16.05 10.630 0.632), = Shift arm clearance 0.022 0.103 (0.0013-0.0083) | ——— #7; Measuring points "2: Meaeuring points a A 8 [— Automatic Transmission — Section 14 MEASUREMENT [STANDARD (NEW) SERVICE LIMIT Transmission fuid | Capacity € 10S qt, Imp at) BO (6,53) for overhaul — 2.4 (2.6, 2.1 for fluid change 7 Hydraulic pressure | Line preseura a¢ 2000 min" (rpm) 185085, 120) 0018.0, 17a) ‘hottie more than 2/8 OTA, 87 throne fully closed t 800 (80, 114) throttle more thaa 2/8 open 50145, 6) thot flly-cloged 00 8.0, 114) throttle more than 2/8 open (Check with ear on level ground) “ad clih pressure at 2,000 min" Irom) {850-800 85-80, 121-128) | 800 60, 114) {position ‘stand ts-hold clutch pressure at 2,000 min- (rpm) | 850-800 (85-80, 121128) | 600180, 11a) {Gi position) | Throttle B pressure Throttle fully closed | 010, 0) — Throtte fully open___|_850-300185-9.0, 121-128) _| 9006.0, 114) Stall speed mi (pen) 2550 72500 - 2600 3-67 5 , nit ofenath mm tnd ,— Automatic Transmission — Section 14 (cont'd) = MEASUREMENT STANDARD (NEW) SERVICE LIMIT Ciach ‘iutch Tinta clearance Tethold 0801.00 0031-0039 — ‘st 2nd 0.65 0.85 0.026003) — 3rd, ath 04-06 (0018-00024) Clutch return spring fee length tat, 2nd, 3rd, ath | 3351.32) saza {luton ce thickness {198-200 10074 0.079) Unti' grooves worn out {Clutch plate thickness "st. 1st hold 1.95~ 2.05 (0.077 -0.081) Discoloration 2a, 2.55- 2.65 (0.100 0.108) Discoloration ra ath 2.25 2.35 (0.089 0.089) Discoloration ‘hutch end plate thickness ‘Maret 2.05 ~2.10 (0.081 - 0.083) Discoloration Mark2 2.15-220 0.085 0.087 Mare3 225-2:3010009 0.099) Mark & 2335-240 (0.093 0.084) Mares 2.45250 0.096 0.088) Mark 2'55~ 2.60 0.100 0.102) Mare 2.65 ~2,7010.104 0.108) Marea | 275-2.80(0.108 -0.1101 ’ Mark 235~2.90/0.112 0.118) Distolortion Valve Body ‘Stator shal needle bearing contact ID. “Torque converte side 27,000 27.021 (1.0620 - 1.0636) | Wear of damage Oi pump side 29.000 29 013 (1 1417-11422), ll pump gear side clearance 03-605 2.001 0.002 0.07 (0.000) Oil pump geartobody clearance Drive 0.210-0.265 10.0083-0.0104 | -——~ Driven 0.070 0.126 10.0028 - 0.0089) i pump driven gear Lb, Oil pump shaft 0.. 14016 - 14034 (08518 -0.5825) 13.980 ~ 13.890 (0.5504 — 0.5508), ‘Wear or damage Weat or damage Shitting dovicw, parking brako and throttle control system Reverse shift fork finger thickness Parking brake ratchet paw Parking brake gear ‘Throttle cam stopper height 5.90 600 (0.232 -0.796) 17.0 17.1 (0869-0673) 5.40 (0.213) Wear or other defect Wear or other dofect ‘Serve body ‘Shift fork shaft bore 1D, 14.000 - 14.006 (0.5512 - 0.8514) 14.008 - 14.010 (0.5514 0.5516) 14011-14015 (05516 0.5516) Shift fork shaft valve bore LO. 37.000 - 37.039 1.4867 - 1.4882) _| 97.085 (1.4585) Regulator valve | Sealing ring contact ID. '35.000 - 35.025 (13780 1.3789) | 35.05 1.2709) body ‘Ascurnulator body | Sealing ring contact 1D. 32,000 - 32.025 (1.2808 1.2606) | 32.080 11.2618) ‘Stator shaft Sealing ring contact 1D. 28,000 29.013 1.1617 ~ 1.1422) | 20.08011.1437), Transmission Diameter of needle bearing contact area (On mainshatt of stator shot On mainshaft of 3ed gear collar On mainshaft of sth gear collar On countershatt of 1st gear collar On countershatt of tth gear collar On countershatt of parking gear On countershatt of reverse gear On secondary shaft of It gear On secondary shaft of 2nd gear On reverse idler goar shaft Inside diameter MMainshatt ra gear Mainshatt &th gear Countorshatt et gear CCountershaft 4th gear Countarshaft everso gear Countershattidier gear Secondary shaft 1st gear Secondary shaft 2nd geor Reverse idler gear shaft holder 22.984 - 23.000 (0.9049 - 0.9055) 45.984 ~ 45.000 (1.8104 1.8110) 3.984 ~ 32.000 (1.2592 - 1.2598) 40.984 ~ 41.000 (1.6135 1.6142) 31.975 31.997 (1.2589 - 1.2595) 39.884 ~ 40.000(1.5782 - 15748) 35.979 - 36.000 (1.4165 - 1.4173) 531.975 31.991 (1.2589 - 1.2598) 3.975 ~ 31,991 (1.2689 - 1.2895) 13.880 - 14.000 0.5508 - 0.5612) 52.000 - 52.019 (20872 - 2.0480) 38.005 ~ 38.021 (1.4968 ~ 14968) 447.000 «7.016 (1.8504 ~ 1.8510) 138.000 - 38.016 1.4961 - 1.4967) 42.000 - €2.016 (1.6598 - 1.6542) 448.000 €8.016 (1.8898 ~ 1.8904) 36.000 - 35.016 (1.4173 1.6179) | 37.000 - 37.016 1.4567 — 14573) | e800 — 14.326 10.5827 - 015636) Wear or damage Wear or damage (conta)Standards and Service Limits [— Automatic Transmission — Section 14 (cont'd) MEASUREMENT STANDARD (NEW) SERVICE LIMIT Tranemission (con's) Mainaha 87d gear colar length ‘Mainshaft ath gear collar length Countershatt Yet gear collar length Thrust wachor thickness ‘Countershaft Tat gear Countershaft idler goor Secondary shaft 2nd gear CCountershatt parking gear length Secondary shaft tst gear distance collar length 1950~ 19.55 (0768-0770) 4750-47-55 (1870-1872) 27.50 ~ 27.55 (1.083 ~ 1.088), 1.48 ~ 180 0.057 - 0.089) 3.45355 (0.196 0.140), 435-445 (0.171 0.175), 25.030 - 25.048 0.9854 - 0.9861) 44.95 5.00 (0195-0197), Wear or damage Wear or damage Wear or damage Wear or damage Wear or demage Wear or demage Wear or domage Wear or demage ‘Secondary shaft 2nd gear spine washer thickness 35 x 53 mm “402 — 4.05 (0.156 0.159) 407 - 4.10 (0.160- 0.160) 412 4.15 (0.162 0.163) 417-420 (0.164 0.165), 422-425 (0.166- 0.167) 427 ~ 4.30 (0.168 0.168) 432 — 4.35 (0.170 -0.171) 437 ~ 4.40 (0.172-0.173) 442 — 4.45 (0.174 0.178) ‘STANDARD (NEW) MEASUREMENT Wire Din OD. Free Length | No.of Coils Spring Regulator valve spring A F1BAS engine recor | 1470878) | 95.613:362) 195 F2021,F2222 engines rswomn | 17057) | 97803457 165. Regulator valve spring 8 | F18A3 engine 1810071) 6iosre) |“ 44.0(7792) 15 £2021, F2222 engines 1810070 sevos7e | 44011732) 127 Stator reaction spring FIEAS engine ssio2m | s7aqara | 90310.199) 23 F2023, F222? engines asia | asaciazeq | 30311395) 192 Torque converter check valve spring 1.1 (0.083), aos) | 38.2 (1.508) uo Relief vaive spring 10 (0.039), 3403s) | 30.1 (1539) 154 Cooler reiet valve spring 1.0 (0.038), aoa | wacae) | 170 2nd orifice contra valve spring 0.610.028) 8510260) | s6.4(2610) 25.0 Gnitice control vaive spring 0.710.028) 65(0260) | 525 (2067) tea ‘Ah exhaust valve epring oioos | 7110260 | aeerszn 72 “Throttle valve B adjusting spring 0.3 (0031) 9210.26) | 90.0(1.181) 30 ‘Throttle valve B spring 1.410.055), 85.030) | 4151638) 105 1.4 (0.055), sss) | asiese m2 161000551 350335) | 41.5(1838) wa 1-2 shit valve epting 0.910.035) 36(0.336) | 40.441591) us 2.3/3-4 shit valve spring 0.9 (0.035), 7.610.288) | 57.0(2:244) 268 ‘sthold accumulator spring so(ors | 2aorses | 64712547) 73 {st eccumulator spring A 2310081) | 163,06) | 109.618.3151 209 tet accumulator spring 8 isioom 3.026) | 70512776) 153 4th accumulator spring zayorns) | 22010866) | 90.1 13.547) 109 2nd accumulator sing 3500133) | 22010866) | 910.583) 108 5rd accumulator spring 2900118) | 17510689) | sog¢as2n 161 Lock-up shift valve spring 09 (0.035) 7810299) | 7327 (20021 320 LLeckcup timing valve spring 98 (030 8510260) | 51.1202) ra Servo contral valve spring 10 (0.038), arco3is) | 528(20711 224 CPC valve spring 1.410.055) 94.0370) | 33011299) 105 Modulator valve spring 1.4 (0.058), s4ios70 | 33011200) 105 {lock-up contrat vaive spring 0.710.028) 6610260) | 35,1518) 2465, 0:7 (0.028) 86(0.260) | 98.0(1.496) 248 07 (0028) 8610260) | 33.011535) 248 3rd kek down valve spring 1.010.039), 781029) | 48.3(1:902) 158 Main orifice control valve spring 1.110.083), 7.110.280) | _49.111933) Ry 3-8[— Ditferenti Unit of length: rom fin) 1 (Manual transmission) — Section 15. | mens MENT srawoanoiem | __ sence unr comer, a | Si2e“aoioreToaste” | o72:0005 pinion Backlash Pinion gear-to-pnion shaft clearance (0.05 -0.15 (0.002 0/006) ir) 18.082 - 18.086 (0.7103 -0.7113) 0.055 ~ 0.095 (0.0022 - 0.0037), ‘Adjust with @ Shien 0.75 0.008) Tapered rolier_ | Starting torque Nm ikg-om, Ib-in) 14-26 (14-26, 12-79) “Adjust with @ Bhim bearing proloae (Differential (Automatic transmission) — Section 15 MEASUREMENT [STANDARD (NEW) SERVICE LMT Diferentii carrier | Pinion shaft contact arealD. 8.000 — 18.078 0.7087 - 07098) | —— Carreeto-pinion shaft clearance 0.017 -0.047 (0.0007 0.0013) | 0.100.004) Driveshaft contact area. 28.005 ~ 28.025 (1.1026-1,1033) | ~~ Carrier to-driveshatt clearence (0.026 ~ 0.068 (0.0910 0.0026) _| 0.12 (0.0051 Differential pinion ‘ear Backlash Pinion geatto-pinion shaft clearance ‘0.05 ~ 0.15 (0.002 0.008) 10. 18.042 ~ 18.086 (0.7109 ~ 0.7113) 0.059 - 0.095 (0.0023 - 0.0037), ‘Aalust with 9 shim 0.12 0.008) Tapered roller beating preload Starting torave ‘New bearing Lem gem, bin) Reused bearing 28-40 (28-40, 24-35) 25-37 25-37, 22-33) ‘Adjust witha shiew [— Steering — Section 17 MEASUREMENT [STANDARD (NEW) ‘Siearing whe Rotational play at steering wheel circumference 0-1010-04) Gearbox "Angle of rack-guide-screw loosened irom locked postion | 20°F Pump Pump pressure with shutoff valve closed KPa tkolem pal)_| 7.200 @,000 (72 60, 1.024 — 1,136) Power steering fui Recommended fuia Fluid capacity {US at mp at) System Reservoir Honda powor steering fluid-V 111.18,097) 0153 1056,0.47) Powor stearing belt" Defloction with 1ODN [10 ke, 22 Ibe) between pulleys ¥8.0- 160 (0.51 0.83) with used belt M10 1200 (0.43 -0.47) wth new belt Beit tonsion N ike, bal Measured with belt tension gouge 400 = 650 (40-56, 88 121) with used belt 1780 900 (75 90, 15 ~ 198) with new belt * When using @ new belt, adjust deflection oF tension to new values, Run tha engine for 5 minutes then turn it of- Readjust deflection or torsion 0 Used belt values 3-9Standards and Service Limits J Suspension — Section 18 MEASUREMENT STANDARD (NEW) SERVICE LNT ‘Wheel alignment | Camber Front OE Rear -9°30' £0 Coster Front 300s | Total too Front 0+300+0.12) Roar IN 20 200.08 + 0.08) | Front wheel tuning angle Inward whost 39°00 82 _ Outward whee 30°00) What Fim runout (Aurminum wheal) Beal | 0-07 10-0) 7010.06) Radiat | 0-0.710 000 15000) Fim runout (Stee! wh Axil | 0-1.010-008) 2910.08) ____ Radiat | 0-1.010- 008 1.50.06) Wheel bearing | End play Front | 0-0.05 00.002) — eer | 000810 0.0021 — [- Brakes — Section 19 MEASUREMENT STANDARD (NEW) SERVICE LIMIT Parking broke Play n stroke 200 N (20 kg, 44 tbe) lever force “To bo locked when pulled 717 notches Foot brake pedal ‘Master ovlinder Dise brake Pedal height (with floor mat removed) MT ar Free play jinder | Piston to pushrod clearence Dise thickness 130(75) 1357.7) i=siane 0-008 (0-0016) | — 2301091) 20) 10.0038), 80030 Dise runout Front — 0.1010.008) Rear = 0.10 0.008) Dise paratetiem Front and rear — 0.015 (0.0006) Podthickness Front «FIBA, F20Z1(Mm) | 125 (0.49) 1.80.06) Feozi an, F22z2 | 110 (043) 118 (0.06) Roar 9.0 (0.35) 115:0.06) ‘Characteristics ‘Vacuum fem fin Ha Pedal Force ke (bel Line Proseure kPa (glen, pall 010) 20 «aay [820 (9.4, 130) minimums Without ABS: 300 (11.8) 20144) | $800 (66, 00) minimurn 500 19.7) 20148) 8,500 (87, 1,200) minimut 201 20 (44) ‘810 (8.5, 120) minimum win ABs 300 (11.8) 2014s) 16,100 (62, 880) rinimurn 500 19.7) 20144) 8.200 (83.2, 1.200) minimum 3-10— Air Conditios ing — Section 22 MEASUREMENT Unit of langth: mam find STANDARD (NEW) ir conditioning system Lubricant type: ND O1L8 P/N38E99 - PRI — 003 or 38899 — PAT AO; ‘Lubricant capacity Condens / (For Refrigerant HFC 134a (R-T34aN) 10-20 (1 -2/3,0.4 07) mt thos. imp on Evaporator | zo-a0a8- 671.9 Line oo joas.on Receiver Lowes) _ Compressor Turco yp! NO-OIL8 PNGERGD PAY - 003 or 35890 PAT AO4 For Reigerant HFC-T8Ha (ASH F Lobrant eapaciy mi os. Imp c=) 10 Fev 6) | Stor coi wtsanee ot 20° 6°90 sores Pulley so pressure pote esrones 38 10%s 0020 0000 Compressor Deletion wih 109 N (10 ko, 22s) 100-120 039-047 with used bot bat Deen te lays 15-7010 18-020) with now bee Belt tension N tkg bs) Measured with belt tonsion gouge “250 600 (45 - 60, 99-132) with used Bele 950 — 1,150 (95 ~ 15,209 ~ 254) with new belt [— Electrical — Section 23 Brush spring tension inow)_N (ka, Ibs) [MEASUREMENT [STANDARD (NEW) Taniion coi ated vortoge V 2 Primary winding resistance 0 at 20°C (68°F) 08-08 Secondary winding resistance kat 20°C (68°F) | aris 7 Spank Plug Type ‘See section 23 Gap _ 45.35 (0083 Su) ignition ming AL idle = BT 152 (Red) ‘Alternator bekt™ | Without AIC Deflection with 100.N (10 kg, 22 Tbs) 10-12 (0.39 0.47) with used belt | between pulleys 85 — 1110.33- 0.43) with new belt | Belt ension N (ka be) ‘300 450 (30-45, 6699) with used belt | Measured with belt tension gauge {450660 45 65,99 - 143) with new belt With AC Deflection with 109 N(10;kg, 22 ibs) 10- 12 0.39 -0.47) with used belt between pulleys a 4.5 7(0.18 0.28 with new belt Belt onsion N (ko, Tbs) 50 600 (@8 - 60, 99 ~ 132) with used bok L_ Measured with belt tension gauge £950 1,180 (98 ~ 116, 208 ~ 254) with new bel (MEASUREMENT ‘STANDARD (NEW! ‘SERVICE LIMIT ‘Aternator [ Oupur 135 a har — | coil resisrance trator -30 Slip ring 0. 1441057) 1401055) Brush fength 105 10.47) 55(022) LL Brush spring tonsion_g (om) _ 300-360 (10.6 ~ 12.7) Starter mater Tyoe | Spur gear reduction, prmanent magnet Mica dopth 04-08 10.016 -0.0201 0°15 (0.006) Commutator runout | 0-002 10-o.00080 0.05 (0.02) Commutator O.D. | 280-28.111.102- 1.108) | 27:511.08) Brush length 158-162 (062-088) 10.9 (0:33) 16 18(16-18, 35-40) = When using @ new bel, adjust deflection or tension te new values. Run he engine for § minutes then tur tof, Readjust deflection or tension tovused belt values, 3-11Design Specifications rem ernie encusn notes DIMENSIONS | Overall Lenath 7585 mm Tea in Overall ath 1720 mm erin Sera oh 1360 mm Stn Wectbace inom iontin Track rontRese vareisomm | sesBdin | Ground Cleronce "aE on atin | Seating Capacity. five | ween Car Weight: KG model / Tae Syn OR SRS 1200k9 2278108 | oRSAS: Orivers SMT DRIAS SRS, ABS 13e0k9 2aaaoe ‘irbog SMT DRIAS SRS, ABS, Sm vase 2290 Im | ofS Sas. 1s BMT OR SRS, ABs ists 2eniioe | Divers and BMT DWVAS SRS, ABS, Sk v2ssto 2800 lb Pansengors SA On ons, ABs vaoks asiolbe Rigs SAT BRAS SAS, ABS, Sk 1Saekp Zssolbe | sit Sunroot rus BT BRSAS, gs, We Yorks Zespioe | AC:AI Conditioner SMT DA SAS ABS varsks Zan ios SMT DIVAS SRS. ABS, Sm vasak9 2800 [os SAT BRAS SRS. ABS. SR vse 2550 los ueies Sw DRIAS SRS Aas, We Yok | Zsrolbs 2OLS SMT DASAS, ABs 13ssk9 208 os SMT DIVAS SAS, ABS 300s 2808 os SMT DRIAS SRS, ABS, SR 13139 205 be SAT DRA SRS. ABS 10K 2822 los SAT BRAS SRS. ABS, SR 13089 2561 Ios 20S SMT DRIAS SRS ABS, SAC 1ako 2800 os TAT BRAS SRS, ABS. SAE ter Soraioe 22WTEC Skit BRAS SRS, ABS 1209 2510 os SMT OWVAS SRS, ABS, SIR, AC "3e5ia 25ers TAT ORAS SRS, ABS. SIR, NE 1369 3.053 Ibe Woight Distribution rronReath KG mod Ta Sur On sa 7508510 1.950124 tos BMT DHVAS SRS, ABS 7ees12 9 418901, 128 tos SMT DR/AS SRS. ABS, SiR Trast9 49 17081144 fo 1sis Sir DA'sAS, Abs east ko 1360127 to SMT DHVAS SAS, ARS, Sm irasio ko 17001344 IAT OR SRS, ABS conts to 17789135 to 4aT DHAS SRS, ABS, Sm srese3 ko 1797188 tos reus Sir Brens aus ave Soaeo9 6 S712 te SMT OA SAS, ABS east ko 4300127 SMT DIVAS SAS. A@S, Sm irastots 1708114 ts {AT DRias SRS, ABS, SR St5829 69 Uorareaioe | 1S Sir DRVASSAS. ABS, AC “32090 9 Veeniraeios | | 2018 Shar Dn sas. ass 252 ko 170671449 os | SMT OR/AS SRS, ABS: TIBI522 kg 1.715/1,151 tbs | Stir ORAS SRS, ABS, SIR 70529 ko 17297168 os | UAT DWvas SRS. ABS 810820 69 1967146 0s | {AT DRIAS SRS. ABS, SIR S16827 io 13987362 Ibe 20S SMT OAS SRS, ABS. SIR, AC S10827 io 1701162 4A" OWAS SRS, ABS. SAE 82282510 1836767 Ios 221V1EC SMT BWVAS SRS. ABS See25 ko 17507 187 los SMT OF/AS SRS, ABS. SIR, AC #25890 60 13107 168 oe EAT OWAS SRS, ABS, SRA 5551590 kg 1895168 oe 3-12| rem METRIC ENGLISH NOTES WEIGHT | Corb Weight KS modet 28s Shr Baas bes. ass Vols joa | Casas ‘AT BRAS She: ABS Be ieee | oni Sas aaivrec Shr Biss SRS ABS Void | Zain | Beters ans le ry weanog | vmenames | ate oor Zots Shr Oras Ses, aas west | USeatstite | Sea Soationer TAT ORAS SRE. ABS sioszotg | Tastes | 2aivrec ah Baas She Abs foseatg | rsa er ie {AT BRAS SRS, ABS desets | tmenisrie | _ ‘Curb Weight: KE model T | 1s SUTORAS SRS ASS, sm we Zesois | Avoy TBts Sir owas an Abs. om ae Zio — | onn Sas {AT BRAS See: aus’ St ‘me Heeelee | Berton zo tr Daag ns on ime Bem | Barco 38s Sh bans SAS, ABs, se Zessiee | _Knoot ‘aT DRIAs She; ABS: St ues Zeeries | sheet zoes tir Beas she age SR Ac we Zor | {AT BRAS She: ABS ik AE ed | Sots aaiviec Shit BAAS SAS AS SI A we ase | ir BRAS sre: ABs: om Ged soi gh lsrinaton Comets Re mee | Sey Oras es oes sm reasistg | ravorsezns | | Bs, ir Same Sh Aon Soest | toeriectn 18ts Shr Bas sn abe’ Traeons | Voarses Sar Dnas sre: ass: on fests | Uaunnissios | | 2a, Shr Beas StS Se Hosts | Yeouvtes is Ber Bees Shs ass: Sn sees | trots zous Sur Baas see Aes Sm foeawoig | Toesritantes | wey Bees See a8s. Se feces | levies | noes Sur buns sns,ass-smac | — stvssots | rea eotea | aavite tur brassrs-assemac | giassony | teieriesice | Ukr onassns assem ac | Seomaong | tecevveenes Max Parinne Woon eceouas ENGINE | Tyee F22Z2 engine ‘Water-cooled, 4-stroke SOHC VTEC | sept £2222 engine wa SStinsnestae sone | | sercesegs ee onrdere e etavese Bore and Stroke FI8A3 engine 85.0 x 81.5 mm 3.35 x3.21in | | Fay ening Sorsonn | santas | recente Umraminy | inestin Valve Train 2222 engine Excopt £2222 engine Bolt driven, SOHC VTEC 4 valves por cylinder, Belt driven, SOMC 4 valves per cylinder 3-13Design Specifications (— (cont'd) re METRIC ENGLISH Notes ENGINE cont'd) | Lubrication System Forced and wet sump, rochoid pump Oil Pump Displacement [Atoll temp, 38 5°C (98°F)] 1738 /rminute 2 6,000 purnp rin rpc) Fuel Required Promium UNLEADED grade gasoline with ‘95 Research Octane Number or higher ‘Water Pump Displacement (Atcoolant tomp. 40°C (104°F 1) 160 f/minute a 6,000 pump rin (opm) ‘STARTER Type ‘Spur gear reduction, permanent magnet Normal Output ak, 1.6 kW Nominal Voltage mV Hour Rating 30 seconds Direction of Rotation Countorclockwige as viewed from gear end. Weight 35h0 pe Tbs cute Clutch Type: wr ‘Single plate dry, diaphragm spring aT Torque conve Clutch Facing Area wr atom | 3888040 TRANSMISSION | Transmission MT ‘Synchronized Speed forward, 1 reverse aT Electronically controlled ‘speed forward automatic, 'reverse Primary Reduction Direct 1:1 Manuel Trensmission Type N2es [nase | Nace | Nabe Engine woe FieAs Foozt_[Fazzz ‘Gear Ratio Ist 3288) 3288 | 3205 | 3.286 2nd 107 | ve0r | ve0r | 1207 ora vies | 1230 | ates | 1269 ath os | o933 | osca | oes sth ess | o7s7 | 0735 | o7s7 Reverse 3000 | 3000 | 3000 | S000 Final Reduation Gear type Single helical gear Gesrratio | 4062 | 4255 | 4266 | 4.266 ‘Automate Transmission Engine type | F18A3, F20zt Faz ‘Gear Ratio 1st 2736 2736 2nd 333 1485 3rd 1028 1.028 ah 731 0731 Reverse 2087 2047 Final Reduction ‘Gear type ‘Single helical gear Gear 4.285 4.133 ‘AIR CONDTIONING | Cosling Capacity 1.100 Keath 76269 BTU ‘Compressor Typerae ‘Swash-plata/NIPPONDENSO No. of Cylinder 10 Capacity teemirev | 109 eusnirev Max Speed 18,800 min (rom) Lubricant Capacity 160m 1 flo, 58imp oz No-one ‘Condenser Tee Corrugated fn Evaporator Type Coreugated fin Blower Type Sirocco fon Motor input 209 W maxs12V Speed Control S.epeed ‘Max: opacity 420 mh Ti rag3¢ cu-fun Temp, Control ice pe ‘Compressor Clutch Type Div, single plate, poly V-belt drive Power Consumption 40W max/t2V Rafigerant Type FC-1340 (F-19348) Quantity 059 | 26.5 wor 3-14rem meme | enous noves STEERING SYSTEW | Type Powered, nd ond non Svea Ratio ee Sure Lec Lock ms String Whee mater som “| _s80n SUSPENSION | ype, Font Indepondan dole wishbone col sping with ster Tyee Roar Indopotnt Sette wane, ol ping wt star Shock Absorb. Fron and Totoro, hyve ivopon goed WHEEL ATGRRENT | Camber Front oor ror 4 caster Seo Sia Toe Front aimm oin fo 1n20'mm Indin BRAKE STEN | Typo" Font Pane assisted saausng ventiatd die row ower ntcedwltaduaing ash ase ad Suc Av ort "eyeq3, 2021 a4 foaem’n2 106s0inx2 rhaas an Foods ocwsa | aSoscinas fear macmad tasanin ee Parking Bato Machancal ating, ror whe kat ae Sze and Sry informatio label re pase 12) ELECTRICAL aie 1257 AW HR e 1av-7 ano Kee starter wv en atrsstor oR Pusen In the under-dash fuseirelay box In the under hood fuse/relay box 15A,10A, 158,30 TSA 108, 1A, 20A, 0A, 404,50, 808 In the under-hood ABS fuse box 204, 40 Heedighs 12V~s5 wit) Front Turn Signal Lights 12-23 WiVELLOW) Front Parking Lights 12v-sw Side Tuen Signal Lights v-sw Rear Turn Signal Lights wv-2iw BrakerTailignts 12V-215W High Mount Brake Light v-zw Back-up Lights wv-2w Rear Fog Light v2 License Pate Lights 2v-8w Ceiling tinterion Lights 12V_8W 12V-34W Trunk (Boot Lights wV-34W Door Courtesy Lights RV-34W Glove Box Light 12V-5w Gauge Lights wV-14,3W IncieatorLightsLamps 12V-0.84, 1.12, 1.4 W, LED Warning Lights BV-ia lamination and Pilot Lights 12V-086, 086,1.12, .4W Heater tlumination Lights wav- naw’ 3-15Body SpecificationsMaintenance Lubrication Points ... Maintenance Schedule ..Lubrication Points For the details of lubrication points and types of lubricants to be applied, refer to the illustrated index and various work procedure (such as Assembly/Reassembly, Replacement, Overhaul, installation, etc.) contained in each section. LUBRICATION POINTS | LUBRICANT | yen ‘iways vse 0 fotelicont oli Hat eaya “API Ser Ee} vice 8G or SH." [ae | SAE Viscosity: Seo chart below. | | | | Transmission ~ TManuat | Honda Genuine MTF* ‘Automatic Genuine Honda ATF PREMIUM (Automatic Trans: | mission Fluid-PREMIUM} or DEXRON® Il or {IL | Automatic transmission fluid TE [Brake tine [Brake fluid DOTS or DOTS “a | Gitch Line Brake fuid DOTS of OTS ing grease (PIN 0878380708) | Urea grease UM264 (P/N 41211 —PY5~305) i le = Tove pivots (Manual Tanamosion | 7 | Release fork (Manual Transmission) I I Scone a 9 | Throttle cable end | 10 | Steering whee! (except cars with SRS olbag) 11 | Select lever (automatic Transmission) 12 | Pedal inage | {15 | Battery terminals | 14 | Brote master evn pushrod | 15 | Tonk ninges ond latches 16 | Door ninges uppariower and latches 17 | Door open dotenes 18 | Fuel fill lid | 18 | Hood hinges ond hood fateh | Multi-purpose grease 21 | AIG compressor a Compressor oll ND-OILG (P/N 38899—PR7—003 or | A7—AO1 “22 | Roar broke ca 23 | Pos Rust-preventive agent Hondo power steering Tid-V Select the oil for the car according to this chart: CAUTION: Used engine oll may cause skin cancer if repeat- edly left in contact with the skin for prolonged periods. 35 G0%e Although this is unlikely unless you handle used oll on a daily basis, itis sil advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil CT Toor Ambient temperature 77 lf Honda MF is not available, you may use an API service SG or SH-rated motor oil with a viscosity of SAE 10W-30 or 10W-40 temporarily. Motor oil can cause increased transmission wear and higher shifting effort, 42ay 4-3Maintenance Schedule Normal Conditions: ‘uo fopew Sb olelelelelelelelel- es Sea oe eee ae Te ss hes + + an 0 athe the te $ + $ a A 5 + z 5 O a + z = z _ . 4 + + Pe oa oe othe ts Sesh abet on oTuroeTot oe | mee ee ele ee ananx] ozt | sor 96 +8 te 09 oY oe 9m a ‘sym 000'L x | Tedd 10 op Gp OBR Wo opHIDS FLALETIEW HUONBLOD BANS BW FOPACE SuOpLOD BUMID DAAGE HH PRIDE SOURVOTA OTIC) BION Bi MOP 4-4Severe Conditions: ‘rb s98ed uo anpayag sauevoeyy suonpuo ION a4, Moje} RoYE Nok ‘uoNLO® 618A, © 8Pun ATIYNOISYDIO WON 8109 9H “ILON ‘eae ay Taye BAA OF WaT TUT Gaia yuenser erueuydens osdsa 6B 9 . ele ele lel lelele ae av avou9 16 se c008 C001 Mons Fase vcs oo Pa HS Boa SOLE . oulaen|mon|aon]| oe [as PS ins" wa . ee tee ee Rt FEIT ° . . ° . . ° : * ° ° ete oS Kane VB WAP aD suo oar 45Engine Engine Removal/Installation ... Cylinder Head/Valve Train Engine Block Engine Lubrication .... Intake Manifold/Exhaust System . Cooling ..Engine Removal/Installation Special Tools .... Engine Removal/Installation ... [ Outline of Model Change +__F2222 engine has been adopted.Special Tools Ret. No. | ToolNumber —_| Description __|_aty | Page Reference ® O7KAK-SJ4o101 | Engine Tilt Hanger Set _ [a 59 5-2Engine Removal/Installation b=] ‘* Make sure jacks and safety stands are placed properly ‘and hoist brackets are attached to the correct posi- tions on the engine. © Make sure the car will not roll off stands and fall while you are working under it. cauTiOn: ‘© Use fender covers to avoid damaging painted surfaces. ‘© Unspecified items are common. © Unplug the wiring connectors carefully while hol the connector portion to avoid damage. © Mark all wiring and hoses to avoid misconnection. ‘Also, be sure that they do not contact other wiring or hoses, or interfere with other parts. 1. Secure the hood as far open as possible. 2. Disconnact the battery negative terminal first, then the positive terminal 3. Remove the radiator cap Use eare when removing the radiator ap t0 avoid scalding by hot coolant or steam 4. Raise the hoist to full height. 5. Remove the front wheels and the splash shield 6x10mm ON (10 kgm, 7 Ibe 6. Loosen the drain plug from the cadiator. 7. Drain the transmission oil or fluid. Reinstall the drain plug using a new washer. 8. Drain the engine oil. Reinstall the drain bolt using a new washer. CAUTION: Do not overtighten the drain bolt. 8. Lower the hoist. 10. Remove the intake air duct and air cleaner housing, 8x1.0mm 10 Nm (10 kgm, 7A INTAKE AIR. uct ‘AIR CLEANER HousinG 11. Remove the resonator cover. RESONATOR cover, (cont'd) 5-3Engine Removal/Installation r (cont'd) 12. Remove the battery, battery cable and battery base, 8x1.25mm tae 22.Nm (22 kgm, 16 Ib) BASE 6x1.0mm AON (1.0 kom, Tb BATTERY CABLE 13. Remove the starter cable and transmission ground cable. TRANSMISSION GROUND CABLE 6x 10mm TONm (1 kgm, 7h 8x 125 mm 9Nm (09 Kom, 7A STARTER CABLE 14. Relieve fuel pressure by slowly loosening the service ‘bolt on the fuel rail about one turn. BF bo not smoke while working on f spark away from wor 18, Remove the fue! feed hose, fuel return hose and vac- ‘uum hose. FUEL FEED SERVICE BOLT TaN (12 kom, HOSE wasen S2Nt2K0 Replace. WASHER 4 Replace. wasHER Replace. 221m 22 kgm, ase vacuum HOSE FUEL RETURN Hose 16. Disconnect the engine wire harness connectors on the left side of the engine compartment. 6x1.0mm YON (10 kgm, ENGINE WIRE Tie HARNESS 5-417. Remove the throttle cable by loosen the locknut, then slip the cable end out of the throttle linkage. NOTE: '* Take care not to bend the cable when removing it Always replace any kinked cable with a new one. '* Adjust the throttle cable when installing, ‘THROTTLE ‘CABLE NUT tocknur —_AbsusTING 18. Disconnect the engine wire harness connectors on the right side of the engine compartment. 18. Remove the battery cable from the under-hood fuse/ relay box. BATTERY (CABLE 6x 1.0mm TONm (LO kgm, 7th ENGINE WIRE HARNESS CONNECTORS 20. Remove the evaporative emission (EVAP) control canister hose and vacuum hose. EvaP CONTROL CANISTER HOSE VACUUM HOSE 21, Remove the brake booster vacuum hose and vac: ‘uum hoses, Remove the engine mount control vacuum hose am. BRAKE BOOSTER VACUUM HOSE ‘VACUUM HOSE am vacuum HOSES (conta) 5-5Engine Removal/Installation r (cont'd) 22. Remove the engine ground cable. 6x1.0mm AON (1.0 kgm, 7 tot) ENGINE GROUND CABLE 23, Remove the condenser fan shroud, then install a pro- tect plate to the radiator. 6x 1.0mm CONDENSER FAN 7 Berm (0.7 kg, 5 tt) SHROUD 26. Remove the adjusting bolt and mounting nuts, then remove the power steering (P/S) pump balt and pump, NOTE: Do not disconnect the P/S hoses. MOUNTING NUT 841.28 mm 22Nm (22 kom, ra) Ps PUMP pe BELT 25, Loosen the adjusting bol, locknut and mounting bolt, ‘then remove the alternator belt. MOUNTING BOLT 10% 1.25 mm 45 Nm (65 kg-m, 33 tb-H) ALTERNATOR BELT ADJUSTING —_Logk NUT pour 8125 mm 2aNm 22 kgm, 16H 5-626. Remove the air conditioning (A/C) compressor. NOTE: Do not disconnect the AC hoses. ac COMPRESSOR MOUNTING BOLTS 8x 1.25 mm 22Nem (22 kgm, Remove the connector. tem 27. Remove the upper and lower radiator hoses and heater hoses. HEATER HOSES LOWER RADIATOR UpPER RADIATOR HOSE HOSE 28. Remove the automatic transmission fluid (ATF) cooler hoses. arr COOLER Hoses 29. Remove the clutch damper assembly (M/T) NOTE: Take care, not to bend the pipe. CLUTCH HOSE JOINT 8x1.25 mm Jom (2.2 kgm, i) (conta 5-7Engine Removal/Installation r (cont'd) 30. Raise the hoist to full height. 31. Disconnect the heated oxygen sensor (HO2S) con: nector, then remove exhaust pipe A. SELF-LOCKING NUT GASKETS. 851.25 mm oplace, 18m (1B kgm, 13 tbe) Replace. GaskeT Foplace. CONNECTOR SELF-LOCKING NUT 101.25 mm seurtogane nur 38m (3.4 kom, 25 b-) 10%125mm oor 155 Rem (5.5 kgm, 40 Ib.) Replace 32, Remove the shift cable (A/T) Note: '® Take care not to bend the cable when removing it. Always replace any kinked cable with a new one. ‘© Adjust the shift cable when installing. Lock WASHER Replace. SHIFT CABLE AO Nien (1.0 hair, 7 to-ft) 81.25 mm eNm (8 kom, Bib 33. 34, 26, 36, Remove the damper forks. CAUTION: Replace the self-locking bolts if you can sily thread a non-self-locking nut past their nylon locking inserts (It should require 1 Nem (0.1 kg-m, 0.7, lb-ft of torque to turn the nut on the bot Disconnect the suspension lower arm ball joints. Remove the driveshafts CAUTION: Take care not to damage the oil seal when removing the driveshaft. ‘Swing the driveshaft under the fender. NoTE: © Coat all precision-finished surface with clean engine oil. ‘© Tie plastic bags over the driveshaft ends. 5-837. Lower the hoist 38, Attach the chain hoist to the engine. O7KAK - 5140101 ENGINE TILT HANGER SET fcont’a) 5-9Engine Removal/installation r (cont'd) 39, Remove the rear mount bolt. REAR MOUNT BOLT REAR MOUNT REAR MOUNT BRACKET 40, Remove the front mount bolt. FRONT MOUNT TORQUE ROD Bou FRONT MOUNT BRACKET a“ Remove the side engine mount. SIDE ENGINE mount ‘TRANSMISSION MOUNT Raise the chain hoist to remove all slack from the chain, Check that the engine is completely free of vacuum hoses, fuel and coolant hoses and electrical wiring. 3. Slowly raise the engine approximately 150 mm {6 in). Check once again that all hoses and wires have been disconnected from the engine, Raise the engine all the way and remove it from theue Value Specifications; Bracket Bolts/Nuts Tora)Cylinder Head/Valve Train 62 Special Tools . Variable Valve Timing and Valve Lift Electronic Control (VTEC) Solenoid Valve Troubleshooting Flowchart 6-3 Inspection es 65 VTEC Rocker Arms Manual Inspection .. 6-6 Inspection Using Special Tools ...... 6-6 Valve Clearance Adjustment .. ses 69 Crankshaft Pulley and Pulley Bolt Replacement es... 6-11 Timing Belt and Timing Balancer Belt Mlustrated Index Timing Belt Inspection Timing Balancer Belt Inspection .... 6-13 Tension Adjustment .. Removal Installation Outline of Model Changes Cylinder Head Mlustrated Index . Removal Installation .. Rocker Arm Assembly Removal Rocker Arms Overhaul .. Inspection Lost Motion Assemblies Inspection Camshaft/Rocker Arms and Camshaft Seal/Pulley Installation a Cylinder Head Cover Installation .. 6-31 + F2222 engine has been adopted. Compare to F20Z1 engine main difference are: + VTEC control system + Rocker arms, + The procedure for installing the ylinder head cover has been changed.Special Tools Too! Number (O7JAA ~ 0010200 (7a - 0010200 | o7LaG-Prz0100 | o7Las—Pa30101 (O7LAJ ~ PR30201 | o7MAB—Pya0t00 ‘O7NAJ- PO70100, [__ 07406 - 0070001 6-2 Description Socket Wrench, 19 mm Handle Balancer Shaft Lock Pin Valve Inspection Set Air Stopper Pulley Holder Attachment, HEX 50 mm Oil Pressure Gauge Attachment Low Pressure Gauge == + [en ie 64Variable Valve Timing and Valve Lift Electronic bese Control (VTEC) Solenoid Valve [- Troubleshooting Flowchart ‘The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Cade (DTC) 21: A problem in the VTEC Solenoid Vaive circuit Refer to page 11-8 through 11-12 before troubleshooting = The MIL has been reported on. = With the SCS short connector connected, code 21 Is in cated (Check the VTEC Control System: 1. Do the engine control module (ECM) Reset Procedure Starethe angine, Warm up engine to normal operating temperature (the Tadistor fan comas on) | 4 Dothe Road Test* Ig MIL on and dooe it indicate code 21? * Road Test: [Accelerate in Tet gear to an engine peed over 4,000 mi (pm, Hold that engine spacd fora least two soconds. Ifthe MiL does not como on during the fist road test, repeat this test two more ies Intermittent failure, system is OK at this time, Check for poor connections or loose wires at VTEC solenoid ws ra vrec souenow vatve aaeee Connecton ‘Test the VTEC Solenoid Valve: | | TS*hute te getter sch FF. 2 itcomme te VTEC solnois valve connect TERMINAL sD OF 2, Chas Tor comtnuity beweon @) materemana VTEC solenoid valve connec 2 Torito ane buy ground ——— xo Weer aoa > * a ermrae ECM CONNECTOR A 2001 ves TPL [sle[7]8]9]wln]aye ne 15 [16 nal /[as|es VIS (GRNYELY Tost the VTEC Solenoid Valve Wire: Cheek for continuity between VTEC Solenoid valve connector terminal {nd AS terminal on the ECM can: vrec soLENoID VALVE CONNECTOR —___| WIRE SIDE OF FEMALE. ‘TERMINALS VTEC solenoid valve connector. ves Lwreee (To page 6-4) (cont'a) 6-3Variable Valve Timing and Valve Lift Electronic Control (VTEC) Solenoid Valve [- Troubleshooting Flowchart (cont'd) (From page 6:3) TEC Valve | Check for ‘continuity between VTEC [Retest No \VTEC SOLENOID VALVE CONNECTOR WIRE SIDE OF FEMALE ©) Tenn —— ‘Test the VTEC Solana ] "connect the VTEC sol 2. Remove the 10 mm bolt, and install the epecial tools a6 shown, then reinstall the 10, mm bot 3. Connect a tachometer. 4 Stortthe engine. 5. Warm up engine to normal operating temperature (the radiator fan comes on) 6. Check oil pressure at engine speeds of 1,000, 7,000 and +4000 min" rpm oid Yes Tost the VTEC Solenoid Valve: | 1. Tur the ignition switch OFF. 2. Disconnect the VTEC solenoid valve connector, 3. Atach the battery positive tr ‘minal tothe GRNMVEL torminal gine and check oll 'an engine speed 13,000 rie pen Inpressure above 2504028 NO Kafer 36 psi? ves 4 ‘Substitute a known-good ECM land recheck. I'symptom/indics- tion goes away, replace the orig pal ECM NOTE: Keep measuring time 2 short as possible because engine ix running with ‘Toad (les than one minute) is pressure below 3 (0.5. NO LOW PRESSURE GAUGE (07406 - 0070001 (E = | 22 Nm (22 kgm, ow pressure Gauce 16/1) ATTACHMENT ‘7NAS~P070100 LOW PRESSURE GAUGE (07406 - 0070001 valve 6-41 - Inspection Disconnect the 1P connector from the VTEC sol- enoid valve. Measure resistance between the terminal and body ground. Resistance: 14-30 0 If the resistance is within specifications, remove the VTEC solenoid vaive assembly from the cylinder head, and check the VTEC solenoid valve filter/O- ring for clogging. © If there is clogging, replace the engine oil filter and the engine oi VTEC SOLENOID VALVE ASSEMBLY VTEC SOLENOID VALVE FILTER/O-RING Replace. 6x 10mm Te neem (1.2 kg, 9 4 If the filter is not clogged, push the VTEC solencid valve with your finger and check its movernent. If the VTEC solenoid valve is normal, check the engine oil pressure. 6x 1.0mm T2Niem (12 ko-m, 9b) 6-5VTEC Rocker Arms (- Manual Inspection 1. Set the No. 1 piston at TOC. 2. Remove the eylinder head cover, NOTE: Refer to pages 6-31, 32 when installing cylin der head cover. 3, Push the intoke mid rocker arm on the No. 1 cylin= der manually 4. Check that the intake mid rocker arm moves inde. pendently of the primary and secondary intake rock PRIMARY ROCKER MID ROCKER ARM ARM ‘SECONDARY ROCKER ARM 15. Check the intake mid racker arm of each cylinder at Toc. ‘© If the intake mid rocker arm does not move, remove the mid, primary and secondary intake rocker arms as an assembly, and check that the pistons in the mid and primary rocker arms move smoothly. @ I any rocker arm needs replacing, replace the primary, mid, and secondary rocker arms as an assembly. [ Inspection Using Special Tools caUTION: © Before using the Valve Inspection To that the air pressure gauge on the ai Indicates over 400 kPa (4 kg/em:, 87 psi ‘@ Inspect the valve clearance before rocker arm inspec- tion. ‘© Cover the timing belt with a shop towel to protect the belt '* Check the intake primary rocker arm of each eylinder at TOC. make sure compressor 1. Remove the cylinder head cover. NOTE: Refer to pages 6-31, 32 when installing cylin: der head cover. 2. Plug the relief hole with the special tool Ain STOPPER o7LAd ~PRI0201 RELIEF HOLE 6-63. Remove the sealing bolt from the inspection hole, and connect the special too) NOTE: Remove any cil the bolt threads and cam shaft holder threads before retightening the sealing bolt. 10%1.0mm SEALING BOLT 20.Nem (2.0 kgm, 14 bf) VALVE INSPECTION, ser O7LAY - PRa0101 ‘Ain STOPPER mas PRa0201 INSPECTION HOLE. 4. Loosen the regulator valve on the valve inspection set and apply the specified air pressure to the rock: er arm synchronizing piston A/B. Specified Air Pressure: 400 kPa (4 kg/em*, 57 psi) 5. With the specified air pressure applied, push up the timing plate 2 - 3 mm (0.08 - 0.12 in) at plate end: the synchronizing piston will pop out and engage the intake mid, primary and secondary racker arms. Visually check the engagement of the synchronizing piston AB, NOTE: The synchronizing piston can be seen in the gap between the mid, secondary and primary rocker ‘© With the timing plate engaged in the groove on the timing piston, the piston is locked in the pushed out position. '* Do not apply too much force when pushing up the timing plate ‘Timing PLATE PRIMARY ROCKER ARM SECONDARY ROCKER ARM PRIMARY ROCKER MID ROCKER SECONDARY ARM ARM. ROCKER ARM TIMING — SYNCHRONIZING — SYNCHRONIZING PLATE PISTONA PISTON B (conta) 6-7VTEC Rocker Arms 6. Make sure that the intake primary and secondary rocker arms are mechanically connected by the pis ton and that the mid rocker arm does not move when pushed manually, PRIMARY ROCKER MID ROCKER ARM ARN ‘SECONDARY ROCKER ARM ‘© If any inteke mid rocker arm moves independent ly of the primary and secondary rocker arms, replace the rocker arms as a set -- Inspection Using Special Tools (cont'd) 7. Stop applying air pressure and push up the timing plate; the synchronizing pistons will snap back to its original position, Visually check the disengagement of the synchro- nizing pistons AVB. NOTE: © When the timing plate is pushed up, it releases the timing piston, letting the return spring move the synchronizing pistons to its original position. ‘© Replace the intake rocker arms as an assembly if either does not work correctly ‘SECONDARY PRIMARY ROCKER MID ROCKER ARN, ROCKER ARM ARM ‘Tnmins: Piston TIMING SYNCHRONZING SYNCHRONIZING PLATE —PISTONA PISTON 8 8, Remove the special tool 8. Check for smooth operation of each lost motion assembly. It is compressed slightly when the intake ‘mid rocker arm is lightly pushed and compressed deeply when the mid rocker arm is strangly pushed, © Replace the lost motion assembly if it does not move smoothly. 10. After inspection, check that the MIL does not come 6-8Valve Clearance — Adjustment Nore: © Valves should be adjusted cold when the cylinder head temperature is less than 38°C (100°F). ‘© After adjusting, retorque the crankshaft pulley bolt to 250 Nem (28.0 kg-m, 181 lb-ft). 1. Remove the cylinder head cover. NOTE: Refer to pages 6-31, 32 when installing cylin: der head cover. 2. Set No. 1 piston at TOC. “UP” mark on the camshaft pulley should be at top, and TDC grooves on the camshaft pulley should align with back cover upper surface. Number 1 Piston at TDC: ToC MARK 3. Adjust valves on No. 1 cylinder. Intake: 0.26 mm (0.010 in) + 0.02 mm (0.0008 in} Exhaust: 0.30 mm (0.012 in) + 0.02 mm (0.0008 in} 4, Loosen the locknut, and turn the adjusting screw until the feeler gauge slides back and forth with a slight amount of drag, Locknut FEELER GAUGE ADJUSTING ‘scREW Adjusting screw location: INTAKE ic eT flac Roy 1H 1 NR ARS SCE exHausT 5. Tighten the locknut and check clearance again. Repeat adjustment if necessary. FEELER GAUGE (cont'd) 6-9Valve Clearance 6. Rotate crankshaft 180° counterclockwise (Camshaft pulley turns 90°). The “UP” mark should be on the exhaust side. Adjust valves on No. 3 cylinder. Number 3 Piston at TOC: UP" MARK 7. Rotate crankshaft 180° counterclockwise to bring No. 4 piston to TDC. Both TDC grooves are once again visible. Adjust valves on No. 4 cylinder. Number 4 Piston at TDC: UP" MARK - Adjustment (eontt’ dd) -AtAAP@aa Aa 8, Rotate crankshaft 180° counterclockwise to bring No. 2 piston to TDC. The “UP" mark should be on the intake side, Adjust valves on No. 2 cylinder. Number 2 Piston at TDC: “UP MARKCrankshaft Pulley and Pulley Bolt - Replacement When installing and tightening the pulley, follow the procedure below. Clean, remove any oil and lubricate points shown below. ©: Clean x : Remove any oil CRANKSHAFT © : Lubricate puuLeY “Taming gett DRIVE PULLEY ‘CRANKSHAFT wasyen C x |X 0x 9 2 279 x |x| |x Ss 3f % [ex 8-48 98 x |xttx of 2 alo xD |x 8 3s x [ey dk 8 8 3 PULLEY BOLT TIMING BALANCER TMING BELT BELT DRIVE PULLEY GUIDE PLATE. Crankshaft pulley bolt size and torque value: 16x15 mm 250 Nem (25.0 kg-m, 181 tb-Ft) NOTE: Do not use the impact wrench when installing. HANDLE 07JAB = 0010200 PULLEY HOLDER ATTACHMENT, HEX 50 mm. (O7MAB ~ PY20100. SOCKET WRENCH, 19 mm ‘074A ~ 0910200 6-11Timing Belt and Timing Balancer Belt Ilustrated Index nore «Refer to page 6-17 for positioning crankshaft and pulley before installing the bet. © Mark the direction of rotation onthe belt before removing * Donot use the upper cover and lower caver for storing tems dsassembled, Clean the upper cover and lower cover before inteling, Replace the camshaft seals and crankshaft seal f there i ll eakage. © efor page 611 before installing timing belt ond timing belancer bel. 6x10 mm ‘only soapsuo to tesds and cylinder heed Replace when damaged Sata surace when roplacing ie rubber cena onl tan remove ay aapeute shor neta ing tuber soa CYLINDER HEAD cover Refer to pages 631, 92 ‘when installing. RUBBER SEALS Replace when damaged or deteriorated, UPPER COVER. RUBBER SEAL Replace when damaged of deteriorates 6x1.0 mm 2 Neen (12 kgm, 9 bt) 6x 1.0mm TON (1.0 kgm, 7b.) LOWER cover RUBBER SEAL Replace when damaged oF deteriorated, Replace when leaking, amaged or deteriorated. ‘Apply tiquid gasket st ‘the four corners ofthe recesses, page 6-31 (CRANKSHAFT PULLEY Foplacormont, page 6-11 PULLEY BOLT 161.5 mm £250 Nim (25.0 kgm, 0 Replacement, page 6-11 Dornetuse the impact wrench when installing ‘38 Nem (3.8 kgm, 27th.) ? 6x 10mm (GRO im 2 kom om ADJUSTING BOLT ae whom, apuustIne NUT ome fonmlsigen, ‘TIMING BALANCER ‘38 be) “Twine BELT Inspection, page 6-13, Adjustmont, page 6-14 Removal, page 615, Installation, page 6-17 ction, page 6-13 sage 6-15, page 6-17 Install with concave surface facing in 6-12[- Timing Belt Inspection 1. Disconnect the battery negative terminal first, then the positive terminal 2, Disconnect the alternator terminal and the connec tor, then remove the engine wire harness from the cylinder head cover. 3. Remove the cylinder head cover. ‘© Refer to pages 6-31, 32 when installing. 4. Remove the upper cover. 5. Inspect the timing belt for cracks and oll or coolant soaking Note: ‘¢ Replace the bolt if oil or coolant soaked. ‘© Remove any oil or solvent that gets on the belt. Inspect this arga for wear. Rotate and ins 6. After Inspecting, retorque the crankshaft pulley bolt 10 250 Nem (25.0 kgm, 181 lb-ft. b=] [- Timing Balancer Belt Inspection — 1, Disconnect the battery negative terminal first, then ‘the positive terminal 2, Disconnect the alternator terminal and the connec: tor, then remove the engine wire hamess from the cylinder head cover. 3. Remove the cylinder head cover. ‘© Refer to pages 6.31, 32 when installing. Remove the upper cover. Romove the crankshaft pulley. Remove the lower cover. Install the crankshaft pulley. Inspect the timing balancer belt for eracks and oil or coolant soaking, Nore: ‘© Replace the bolt if oll or coolant soaked. '* Remove any oil or solvent that gets on the belt. Inspect th Rotate pulley ‘and inspect bel, 8. After inspecting, retorque the erankshaft pulley bolt 10 250 Nem (25.0 kg-m, 181 lb-ft). 6-13Timing Belt and Timing Balancer Belt [- Tension Adjustment CAUTION: Always adjust timing belt tension with the ‘engine cold. Nore: © The tensioner is spring-loaded to apply proper ten- sion to the belt automatically after making the follow- ing adjustment. '® Always rotate the crankshaft counterclockwise when viewed from the pulley side. Rotating it clockwise may result in improper adjustment of the belt ten- '* Inspect the timing balancer belt before adjusting the belt tension: Do not loosen the adjusting nut more than one full turn. 1. Disconnect the battery negative terminal first, then the positive terminal 2. Disconnect the alternator terminal and the connec- tor, then remove the engine wire harness from the cylinder head cover. 3. Remove the cylinder head cover. (Refer to pages 6-31, 32 when installing.) 4. Set the No. 1 piston at TDC (see page 6-18} 5, Rotate the crankshaft five or six revolutions to set the belt 6. Sot the No. 1 piston at TOC. 7. Loosen the adjusting nut 2/9 1 turn ADJUSTING NUT 45m (45 kam, 33 b-40 Direction af 8 Rotate the crankshaft counterclockwise three testh ‘on the camshaft pulley, 9. Tighten the adjusting nut, 10. After adjusting, retorque the crankshaft pulley bolt 0 250 Nem (25.0 kgm, 181 lb-ft. 6-14be] 2. Remove the wheelwell splash shield (see page 53) 3. Loosen the adjusting bolt and mounting nuts, then remove the power steering (P/S) pump belt. ‘ADJUSTING B01T MOUNTING NUT 81.25 mm 22Nm 22 kom, 16 I-A) MOUNTING NUT 851.25 mm 22Nm (22 kom, eh P/S PUMP BELT r- Removal Note. 4. Loosen the adjusting bolt, mounting bolt and lock- ‘© Turn the crankshaft pulley so the No. 1 piston is at, ‘nut, then remove the alternator belt. top dead center (TDC) before removing the belt (see page 6-18). ‘© Inspect the water pump, MOUNTING BOLT 10% 125 mm 1. Disconnect the battery negative terminal first, then ss Nm as kom, the positive terminal Pulup ALTERNATOR ‘TERMINAL ALTERNATOR BELT Locknut 851.25 mm 22m (22 kgm, 16 lb-1) 6x1.0mm Bern (0.8 kee, 6 bt) 5. Remove the alternator terminal and connector. (cont'd) 6-15Timing Belt and Timing Balancer Belt [- Removal (cont'd) 6. Remove the side engine mount (see page 5-10). NOTE: ‘# Use the jack to support the engine before the side engine mount is removed. '® Make sure to place a cushion between the oi pan and the jack. 7. Remove the dipstick and the pipe DipsTicKy \ 17 6x 1.0mm 12Nm (1.2 kam, sibso one Replace. 8. Remove the cylinder head cover. ‘© Referto pages when installing. 9. Remove the pulley bolt and crankshaft pulley (see page 6-11) 10. Remove the rubber seal from the adjusting nut, then remove the upper and lower covers. NOTE: Do not use the upper and lower covers for storing items disassembled, UPPER COVER ue 6x10 mm 12 Nei. kgm, Sime) RUBBER SEAL Feplace when C= — damaged or deteriorated. 8x1.0mm owen coven EET om Chews 9 Ibe 11. Loosen the adjusting nut 2/3 - 1 turn, Push the ten- sioner to remove tension from the timing belt and timing balancer belt, then ratighten the adjusting rut ADJUSTING NUT 45 Nim (45 kg, 33 Ih) NOTE: When removing the timing balancer belt only: Lock the timing belt adjuster arm in place by in. Stalling one of the 6 x 1.0 mm bolts, ¢ Loosen the adjusting nut 2/3 ~ 1 turn. Push the tensioner to remove tension from the timing bal ancer belt, then retighten the adjusting nut. ADJUSTING NUT 45Nm (48 kgm, 33) 12, Remove the timing balancer belt and timing bel. 6-16r Installation Install the timing belt and timing balancer belt in the reverse order of removal. Only key points are described h ‘© When installing only the timing balancer belt, go to step 13, NOTE: Clean the upper and lower covers before instal- lation. 1. Remove the timing balancer belt drive pulley (see page 6-12). 2. Set the timing belt drive pulley so that the No. 1 pis- ton is at top dead center (TDC). Align the dimple on the tooth of the timing belt drive pulley with the V pointer on the oil pump. POINTER ‘TOC MARK (DIMPLE) TMG BELT ney DRIVE PULLEY Clean, 4 Set the camshaft pulley s0 that the No. 1 piston is at Toc. Align the TDC mark on the camshaft pulley with the ‘back cover upper surface. ‘CAMSHAFT PULLEY coed “UP MARK ‘TOC MARKS Install the timing belt tightly in the sequence shown, @ Timing belt drive pulley (crankshatt) + @ Ad: justing pulley ~ @ Water pump pulley ~ @ Cam- shaft pulley. NOTE: Make sure the timing belt drive pulley and camshaft pulley are at TOC. ® (cont'd) 6-17[- Installation (cont'd) Timing Belt and Timing Balancer Belt 5. Loosen and retighten the adjusting nut to tension the timing bolt, 6. Install the timing balancer belt drive pulley and lower cover. 7. Install the crankshaft pulley, then tighten the pulley bolt (see page 6-11). 8. Rotate the crankshaft pulley about five or six turns counterclockwise so that the timing belt positions on the pulleys. 9. Adjust the timing belt tension (see page 6-14). 10. Make sure the crankshaft pulley and camshaft pulley are at TDC. ‘Toc MARK “UP MARK. Toc MARKS 1. 12. 13, 1“, 15 16. 0”. MAINTENANCE: HOLE If the camshaft or crankshaft pulley is not posi- tioned at TOC, remove the timing belt and adjust the positioning following the procedure on page 621, then reinstall the timing belt, Remove the crankshaft pulley and lower cover. Set the timing belt drive pulley so that the No.1 pis ton at TOC, Lock the timing belt adjuster arm in place by installing one of the 8x 1.0 mm bolts Loosen the adjusting nut 2/3 - 1 turn, and verify that the timing balancer belt adjuster moves freely. Push the tensioner to remove tension from the tim ing balancer belt, then retighten the adjusting nut. Align the rear balancer shaft pulley by using a special tool. Insert the special tool into the mainte: nance hole to the fix the rear balancer shaft REAR BALANCER SHAFT BALANCER SHAFT Lock PIN MAINTENANCE HOLE. REAR BALANCER WASHER Replace. BALANCER SHAFT Lock PIN O7LAG - Pr20100 +12 mm SEALING BOLT 30.Nem (3.0 kgm, 22 bf) 6-18b=] 18. Align the groove on the front balancer shaft pulley’ 9 20, a 22, 23, ‘with the pointer on the oi pump housing as shown, GROOVE PoInteR POWTER GROOVE Install the timing balancer belt. Loosen the adjust- ing nut 2/3 ~ 1 turn to tension the timing balancer belt Remove the special tool, then install the 12 mm sealing bolt. Install the crankshaft pulley, then tighten the pulley bolt (see page 6-11), ‘Turn the crankshaft pulley about one turn counter: clockwise, then tighten the adjusting nut. Remove the 6 x 1.0 mm bolt from the timing belt adjuster arm, 28 25. 26. 27. Remove the crankshatt pulley, then install the lower Install the rubber seal around the adjusting nut, NOTE: Do not loosen the adjusting nut. Install the crankshaft pulley, then tighten the pulley bolt (see page 6-11), After installation, adjust the tension of each belt. 6-19Cylinder Head Illustrated Index cauTion: © To avoid damaging the cylinder he: removing it. ‘# Inhanating a metal gasket, take care not to fold it or damage the contact surface of the gasket. , wait until the engine coolant temperature drops below 38°C (100°F) before NOTE: # Uso new O-rings and gaskets when reassembling. © Clean the oil contro! orifice before installing. fo treads and cylinder head contact ing the rubber seal, then remove any soepruds after intaling uber seal WASHER Roplace when damaged oF doterorated CYLINDER HEAD COVER Fferto pages 6-31, 32 when 8x125mm 22Ne 22 kgm, 16 bf) RUBBER SEAL Replace when damaged or deteriorated HEAD COVER GASKET Replace when leaking, damaged ro deteriorated. ‘Apply liquid gasket at the four comers of the recesses, page 6-31 CYLINDER HEAD BOLT 12x15 mm 100 Nim (10.0 kg-m, 720 Tightening, page 6-30 Apply clean engine ol to the threads, CYLINDER HEAD. Gasket Foplace 45 Nem (65 ko-m, 33 b-H 8x1.25 mm 22Nem (22 kg-m, 16 b-H Dowel PIN 6-207B Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact parts. ROCKER ARM ASSEMBLY Overhaul, page 6:26 Inepection, page 627 841.25 mm 22Nem (2.2 kg-m, 16 bt) LocknuT 6x1.0mm 70.78 me TON (1.0 kgem, 7 bt) 20m 2.0 kgm, 14 b-f) ‘Apply clean engine ol ‘Aalustmert, page 63 AALVE KEEPERS DOWEL PIN, SPRING RETAINER owcontro. & ~ ORIFICE | | INTAKE VALVE SPRING CAMSHAFT Replace INTAKE VALVE SEAL 6x1.0mm Replace. TaN (12 kom sb LVALVE SPRING SEAT VTEC SOLENOWD. VALVE INTAKE VALVE GUIDE FILTER Replat ‘CAMSHAFT PULLEY Removal, page 6:28 Installation, page 629 Clean, Lost motion. ASSEMBLY ‘VALVE KEEPERS. a 7 21.25 mm 38.Nem (3.8 kg-m, 27 Ib-f) SEAL ‘SPRING RETAIGER Installation, page 628 EXHAUST VALVE SPRING. EXHAUST VALVE SEAL. Replace. 6x 10mm T2Nm (12 kgm, VALVE SPRING SEAT cyuAven 6x 10mm HEAD AON (1.0 karen 7 tot EXHAUST VALVE Back COVER GUIDE Clean, RUBBER SEAL INTAKE VALVE Replace when damaged or deteriorated EXHAUST VALVE 6-21Cylinder Head p Removal Engine removal is not required for this procedure. Make sure jacks and safety stands are placed properly and hoist brackets are attached to co rect position on the eng CAUTION: © Use fender covers to avoid damaging painted sur- faces. ‘* Unplug the wiring connectors carefully while holding the connector portion to avoid damage. '* To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 38°C. (100°F} before loosening the retaining bolts. NoTE: ‘© Unspecified items are common between both engines. © Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts. Inspect the timing belt before removing the cylinder head. ‘© Turn the crankshaft pulley so that the No, 1 piston is at top dead conter (see page 6-18). 1. Disconnect the battery negative torminal first, thon the positive terminal. Drain the engine coolant. ¢ Remove the radiator cap to speed draining. 3, Remove the intake air duct (see page 5-3). 4 B ie CABLE LOCKNUT ‘NUT lation (PCV) hose, evaporative emission (EVAP) con, trol canister hose and vacuum hose. evap contRot CANISTER HOSE BREATHER 6-221, 6 Remove the brake booster vacuum hose and vacuum hoses (see page 5:5). 7. Remove the power steering (P/S) hose clamp, wire harness clamp and engine ground cable. GRouND CABLE Relieve fuel pressure, FROETIMY Do not smoke while working on fuel system, keep open flame or spark away from work area. Drain fuel only into an approved container. 9. Remove the fuel feed hose, fuel return hose and vacuum hose. WASHER FUELFEED WASHER Replace. HOSE Roplace. SERVICE BOLT 87 ib) Waster Replace. 22m @2kg-m, vacuum 16Ib-f FUELRETURN HOSE HOSE. Y2Nim (12 kgm, 10. Remove the battery cable and alternator connector (see page 6-15). 11. Remove the P/S pump belt and P/S pump (see page 56) 12. Remove the alternator belt (see page 6-18) 18. Remove the engine wire harness holder and water bypass hose. WATER BYPASS HOSE Enané vone wanwess S125. HOLDER 16 Ib-ft} 14. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and intake manifold, Four injector connectors Intake air temperature (IAT) sensor connector Idle air control (IAC) valve connector Throttle position sensor connector Manifold absolute pressure (MAP) sensor con- Engine coolant temperature (ECT) sensor con. ECT switch connector ECT gauge sonding unit connector \VTEC solenoid valve connector Exhaust gas recirculation (EGR) valve lift sensor connector ‘* TDCICKPICYP sensor connector (conv'a) 6-23Cylinder Head 15. 16. r Removal (cont'd) Remove the spark plug caps and distributor from the cylinder head, Remove the upper and lower radiator hoses and heater hose. Lower HEATER RADIATOR HOSE HOSE upper RADIATOR Remove the side engine mount (see page 6-10) NOTE: '# Use the jack to support the engine before the side engine mount is removed. ‘* Make sure to place a cushion between the oil pan and the jack. Remove the cylinder head cover. CYUNDER HEAD WASHER cover 18, Remove the timing belt (see page 6-15). 20. Remove the camshaft pulley and back cover. BACK COVER Cleon ‘CAMSHAFT PULLEY Clean, 21. Remove the splash shield (see page 5-2) 22. Remove the exhaust manifold bracket and selflock- ing nuts (see page 9-3). Remove the intake manifold bracket (see page 9-2) 24. Remove the cylinder head bolts, then remove the cylinder head. CAUTION: To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened. CYLINDER HEAD BOLT LOOSENING SEQUENCE o ® @ © 6-24Rocker Arm Assembly - Removal 1. Loosen the adjusting screws, then remove the bolts and the rocker arm assembly, NOTE: ‘© Unscrew the camshaft holder bolts two turns at a time, in a crisscross pattern to prevent damaging the valves or rocker arm assembly. When removing the rocker arm assembly, do not remove the camshaft holder bolts. The bolts will keep the camshaft holders, the springs and the rocker arms on the shafts, ADJUSTING SCREWS. ADJUSTING SCREWS. CAMSHAFT HOLDER BOLT LOOSENING SEQUENCE: 6-25Rocker Arms Overhaul NoTE: ‘Identify parts as they are removed to ensure reinstallation in original locations. ‘© Inspect rocker shafts and rocker arms (see page 6-27) '® Rocker arms must be installed in the same position if reused. '* When removing oF installing rocker arm assembly, do not remove the camshaft holder bolts. The bolts will Keep the holders, springs and rocker arms on the shaft. '* Bundle the rocker arms with a rubber band to keep them together as a set 7] Prior to eassembiing, clean all the parts in solvent, dry them, and apply lubricant to any contact parts. Lettar“8" is stamped Letter “A” is stamped EXHAUST ROCKER SHAFT EXHAUST ROCKER EXHAUST ROCKER, ARM ne seunort «5 renee HOLDER Ra i {)) HOLDER ri FRI 4 say rt Py wy Ms | vo. 2) No.3 No. & |sZoure| | SSibaer] | Sadowerr] | eee) noire a} | pt “NPAT Mega PY woes cr re ooo PLATE, ee = oS rac rocen 'ARM ASSEMBLY INTAKE ROCKER SHAFT 6-26r- Inspection NOTE: When reassembling the primary rocker arm, carefully apply air pressure to the oil passage of the rocker arm: 1. Inspect the rocker arm piston. Push it manually — If it does not move smoothly, replace the rocker arm assembly. SYNCHRONIZING PISTONE. SYNCHRONIZING PISTON A, ‘Timi ‘SPRING 9, Timing PISTON / ‘SECONDARY ROCKER ARM MID ROCKER ARM PRIMARY ROCKER ARM NoTE: ‘* Apply oil to the pistons when reassembling. © Bundle the rocker arms with a rubber band to keep them together as a set. NOTE: Set the timing plate and return spring as shown below. ‘TIMING PLATE RETURN SPRING ‘CAMSHAFT HOLDER Lost Motion Assemblies r Inspection be] 1. Remove the lost motion assembly from the eylinder hhead and inspect it. Pushing it gently with the finger will cause it to sink slightly. Increasing the force on it will cause itto sink deeper. = If the lost motion assembly does not move smoothly, replace it, Push Yost motion assemsry 6-27Camshaft/Rocker Arms and Camshaft Seal/Pulley [ Installation CAUTION: 4. Apply liquid gasket to the head mating surfaces of © Make sure that all rockers are in alignment with the No. 1 and No. § camshaft holders valves when torquing rocker assembly bolts. — Apply liquid gasket to the shaded areas, Valve locknuts should be loosened and adjusting serews backed off before installation. © To prevent rocker arm assembly from coming apart, ow oy leave camshaft holder bolts in the holes. =) 1. ator wiping down the comha, camshaft sel and ‘o] journals in the cylinder head, lubricate both sur- [ eee nenal naar IL : | 2. Clean and install the oil control orifice with a new oT ] ony ol, _ayams aed oncontmor—" B" ORIFICE | a oo Be errerceieton cecenaty ee elon maar bets ra ‘e*fane sure thatthe rocker arms are properly ee positioned on the valve stems. 6. Tighten each bolt two turns at a time in the se- quence shown below to ensure that the rockers do rot bind on the valves. ‘Specified torque: ‘8 mm bolts: 22 Nem (2.2 kg-m, 16 Ib-ft) 6 mm bolts: 10 Nem (1.0 kg-m, 7 Ib-ft) N\ CAMSHAFT SEAL 6mm bots; 1, @, BB 7B Lubricate cam lobes after reassembly. 3, Turn the camshaft until its keyway is facing up. (No. 1 piston TOC) 6-287 8. Install the back cover. Install the key and the camshaft pulley onto the camshaft, then tighten the retaining bolt to the torque shown. ace con camsnarr mousy Key Cheam 81.25 mm 36m 38 kom, 27 tbs) 6x 1.0mm Y2Nm (12 kom, 9A Cylinder Head r Installation Install the cylinder head in the reverse order of removal: Note: © Always use a new head gasket. © Cylinder head and cylinder block surface must be cleat ‘© “UP mark on camshaft pulley should be at the top. ‘© Turn the crankshaft so the No. 1 piston is at TOC (see age 6-17) '* Clean the oil control orifice before installing, *# Do not use the upper cover and lower cover for stor- ing items disassembled. ‘© Clean the upper cover and lower cover before instal: lation, 1, Cylinder head dowel pins must be aligned, 2, Install a new cylinder head gasket CYLINDER HEAD GaskeT Replace. (cont'd) 6-29Cylinder Head r Installation (cont’d) 3, Position the camshaft correctly (see page 6-17). 4, Tighten the cylinder head bolts sequentially in three steps. ‘1st step torque: 40 Nm (4.0 kg-m, 29 lb-ft) 2nd step torque: 70 Nem (7.0 kg-m, 51 Ib-t) 3rd step torque: 100 Nim (10.0 kg-m, 72 Ib-ft) NoTE: ‘© We recommend using a beam-type torque wrench, When using a preset-type torque wrench, be sure to tighten slowly and not to overtighten. Ifa bolt makes any noise while you are torquing it, loosen the bolt, and retighten it from the Ist. step. CYLINDER HEAD BOLTS TORQUE SEQUENCE Tighten the solf-locking nuts, then install the exhaust ‘manifold bracket (see page 9-3). Install the intake manifold bracket (see page 9-2) Install the timing belt (see page 6-17) ‘Adjust the valve clearance (see page 6-9) 6-30Cylinder Head Cover he] Installation Install the head cover gasket in the groove of the cylinder head cover. Seat the recesses for the cam- shaft first, then work it into the groove around the outside edges. Note: @ Before installing the head cover gaskat, thor ‘oughly clean the seal and the groove. When installing, make sure the head cover gas- ket is seated securely in the corners of the cesses with no gap. ‘CORNERS OF THE RECESS HEAD COVER GASKET Clean, CORNERS OF THE RECESS CYLINDER HEAD covER, Apply liquid gasket to the head cover gasket at the four corners of the recesses, NOTE: ‘© Use liquid gasket, Part No, 0¥740 - 99986. ‘© Check that the mating surfaces are clean and dry before applying liquid gasket. # Do not install the parts if five minutes or more have elapsed since applying liquid gasket. In stead, reapply liquid gasket after removing old residue. * After assembly, wait at least 20 minutes before filing the engine with oil ‘Apply laud gasket to the shaded arsas. (cont'd) 6-31Cylinder Head Cover r Installation (cont'd) 3. When installing the cylinder head cover, hold the head cover gasket in the groove by placing your fin: gers on the camshaft contacting surfaces (top of the semicircles) Set the spark plug seal on the spark plug pipe (F222 engine only) Once the cylinder head cover is on the cylinder hhead, slide the cover slightly back and forth to seat the head cover gasket. NoTE: * Bofore installing the cylinder head cover, clean the cylinder head contacting surfaces with a shop towel # Do not touch the parts where liquid gasket was applied © Take care not to damage the spark plug seal when installing the cylinder head cover (F22Z2 engine only). ‘© Visually check the spark plug seal for damage (F222 engine only) © Replace the washer when damaged or deterio- rated 6x1.0mm YO Nem (1.0 kg-m, 7 bf) CYLINDER HEAD cover WASHER [SPARK PLUG SEAL Tighten the nuts in 2 oF 3 steps. In the final step, tighten all nuts, in sequence, to 10 Nem (1.0 kg-m, 7 Ib. NOTE: After assembly, wait at least 20 minutes before filing the engine with oil Except F222 engine: After installation, check that all tubes, hoses and connectors are installed correctly. 6-32Engine Block Main Bearings Selection ..... Connecting Rod Bearings Clearance .... Selection .... + F22Z2 engine has been adopted. Compare to F2021 engine main difference are: + Crankshaft + Connecting rods. [ Outline of Model ChangesMain Bearings r Selection CAUTION: If the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or seraper. Clean them only with sol- vent or detergent. Crankshaft Bore Code Location (Numbers, Letters or Bars) Numbers or Letters or Bars have been stamped on the fend of the block as a code for the size of each of the 5 main journal bores. Use them, and the numbers stamped on the crankshaft (codes for main journal size), to choose the correct bear- ings. ‘No.1 JOURNAL "No. 5 JOURNAL VULLEY END (FLYWHEEL END! Bearing Design PROJECTION Lower Bearing Identification —§ pe Larger crank bore Colorcode is onthe [ terAort [zeroed ]3orcorm|+ oro orm tsdge of the bearing. > Smatir bearing (Thicker Smaller Smaller NOTE: When using bearing halves of main bearing different colors it does not matter Journal (Thickery_ whieh color is used in the top or bottom, Main Journal Code Locations (Numbers or Bars) Except F22Z2 engine: ‘Main Journsl Code Locations (Numbers or Bars} £2222 engine: ‘The Main Journal Codes are stamped in one of the fol- lowing locations. ‘Main Journal Code Locations (Numbers oF [Main Journal Code Locations Numbers or No, 6 JOURNAL (FLYWHEEL END) No. 1 JOURNAL (PULLEY END) No, 1 CRANK WEB 7-2r- Clearance Connecting Rod Bearings be Remove the connecting rod cap and bearing halt, Clean the crankshaft rod journal and bearing half with a clean shop towel, Place plastigage across the rod journal. Reinstall the bearing half and cap, and torque the huts to: 47 Nem (4.7 kg-m, 94 Ib-f) NOTE: Do not rotate the crankshaft during inepe Remove the rod cap and bearing half and measure the widest part of the plastigage. 1g Rod Bearing-to-Journal Oil Clearance: (New): 0.021 - 0.049 mm (0.0008 - 0.0019 in) Service Limit: 0.06 mm (0.002 in} PLASTIGAGE STRIP If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new. complete bearing with the same color code (select the color as shown on the next pagel, and recheck the clearance. CAUTION: Do not fie, shim, or serape the bearings for the caps to adjust clearance. If the plastigage shows the clearance is still incor- rect, try the next larger or smaller bearing (the color listed above or below that one), and check ol ance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. 7-3Connecting Rod Bearings r Selection CAUTION: If the codes are indecipherable because of an accumulation of dirt and dust, do not serub them with a wire brush or scraper. Clean them only with sol- vent or detergent. Connecting Rod Journal Code Locations (Numbers or Bars) Numbers or Bars have been stamped an the side of each connecting rod as a code for the size of the big tend. Use it, and the letters or bars stamped on the crank (codes for rod journal size), to choose the correct bear- ings. f number oF bar ig stamped on bearing cap fand the other half Stamped on roa Bearing Dos coLoR 9 > Larger big ond bore Color code ison the tsdge of the bearing von ] ae > smattor bearing (Thicker aor | we [rm [vst [ene ‘Smaller Smaller fod) bearing journal (Thicker Connecting Red Journal Code Locations (Letters or Bars) Except F2222 engine: Connecting Red Journal Code Locations (Letters or Bors} F2222 engine: ‘The Connecting Rod Journal Codes are stamped in one. of the following locations. Conneeting Rod Journal Code Locations (Letters or Bars) Connecting Rod Journal Code Locations (Letters oF Bars) "No, 4 JOURNAL (FLYWHEEL END) No. 1 JOURNAL (PULLEY END} ‘No.1 CRANK WEB 7-4Engine Lubrication Illustrated Index Outline of Model Changes + F2222 engine has been adopted. Compare to F20Z1 engine main differences is engine oil cooler. + _Engine oil change interval has been changed. Change interval, refer to section of maintenance.Illustrated Index NoTE: Use new O-rings when reassembling. # Apply oil 0 O-rings betore installation. ‘© Use liquid gasket, Part No. 0Y740 ~ 99988. '* Clean the oil control orifice before installing, Clean the oil pan gasket mating surfaces before installing, ‘© Apply liquid gasket to the recesses of the oil pan gas- ket. FRONT TIMING. BALANCERBELT = 81.25 mm DRIVEN PULLEY 8125 mm 30Nm (3.0 kg-m, zien 8x 1.25 mn 25Nm 25 kg-m, 181b-4) BALANCER GEAR CASE 25.Nm (25 kam, 18 b-A) CAUTION: Do not overtighten the drain bolt. BALANCER DRIVEN GEAR WASHER on pump Apply liquid gasket to block mating surface. ‘o-nInGs Replace, ENGINE o1 18h 0 ‘Vain. BSPT (British standard pipe taper 28 threadaineh, Use proper liquid sealant ‘ou cooter CENTER BOLT 73m 7.3 kgm, 531bR) PIN, Gasket COOLER Replace. ——*€2> O-RING Roplace. OW scrEEN Apply liquid gasket here 6x1.0mm $2 thew 12 kg-m, 9 Ibs) ‘Olt PAN GASKET: Replace. on ran 8-2 washer, Replace, 6x10mm 4m (1-4 kgm, 10 -t) Apply liquid gasket to the threads. rain éoLt 14x18 mm 45 Nem (65 kgm, 33 tht) Do not overtigntenIntake Manifold/Exhaust System Intake Manifold Replacement Exhaust Manifold Replacement Exhaust Pipe and Muffler Replacement .. r Outline of Model Change — + F2222 engine has been adopted.Intake Manifold r Replacement NOTE: Use new O-rings end gaskets when reassembling. CAUTION: '¢ Check for folds or scratches on the surface of the gasket. © Replace with a new gasket if damaged. INTAKE MANIFOLD CHAMBER Replace feracked oF itmating surfaces are 8x12 mm domaged, 22Nm (22 kom, 16h o-nING Boost Replace. CHAMBER, 6x1.0mm asker Gaskers aNm(12 kom, Ropiace. Replace. ) stb-A ae Replace. INTAKE AIR ‘TEMPERATURE (MAT) SENSOR Nm Sky, Bbw 8x 1.25 mm o-nic 22 Nm (22 kg, place. town (DLE AIR CONTROL. (wo) VALVE FAST IDLE ‘THERMO VALVE 8x 1.25 mm 22Nm (22 kgm, ca 8x1.25 mm 2aNm(22ke-m, fee EGR CHANGER 6x 1.0mm EXHAUST GAS. 12Nm(12 kgm, RECIRCULATION stb (EGR) VALVE PLATE/GASKET asker Replace. Replace INTAKE MANIFOLD re Replace if cracked or mating surfaces are oe samaged, eked ‘THERMOSTAT HOUSING 8x125 mm 22m (22 kgm, 16 oH) 8x 1.25 mm 22Nm (22 kom, 16 tb-H) 9-2Exhaust Manifold [- Replacement NOTE: Use new gaskets and self-locking nuts when reassembling, CAUTION: ‘© Check for folds or scratches on the surface of the gasket, ‘© Replace with a new gasket if damaged, EXHAUST MANIFOLD BRACKET 22Nm (22 kom. 16 101.25 mm 45 New (45 haem, 33 Ib) 9-3Exhaust Pipe and Muffler r Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. va re Gasket Replace, exHausT PIPE 8. 6x10 mm TON (Oko, 7b ‘SELF-LOCKING NUT SELF-LOCKING NUT 30125 mm 40x 1.29 mm 85m Sm, (34 Nim (3.4 kg-m, 25 lb-ft) 40 Ib os Replace opice HEATED OXYGEN SENSOR (HO2S) 45 Nem (4.5 kgm, 33 Ibe) oe GASKET Replace. ‘THREE WAY CATALYTIC ‘CONVERTER (TWC) GASKET Foplace, exnhust PIPE A SELF-LOCKING NUT ‘SELF-LOCKING NUT 101.25 mm seurtocéhcnut 88128 mm 34 Rem (8.4 kgm, 25 tb-A) ees SNM ITBkg-m, 131.) Replace 55 Rim 55 kam, 40 1b) Replace, Replace 9-4Cooling Radiator Illustrated Index ... Water Pump Illustrated Index ... Outline of Model ChangeRadiator Illustrated Index Engine Hose Connections: on.cooter BYPASS HOSE FAST IDLE IDLE AIR CONTROL, THERMO VALVE tac) VALVE ENGINE O1L COOLER O-RING Replace, WATER ByPASS HOSE ‘THERMOSTAT Housine HEATER Hose HEATER HOSE 8x 1.25 men 22m (2.2 kgm, 16 -f) o-nINGS Foplace HEATER VALVE CONNECTING on cooten Pe BYPASS HOSE 81.25 mm 22Nm 22 kgm, 6A) 10-2Water Pump Illustrated Index NOTE: Use new O-rings when reassembling O-RING Replace, o.nING ENGINE COOLANT Replace. 81.25 mm ‘TEMPERATURE (ECT) 22.Nem 2.2 kgm, 16 Ib-H) Ect Gauce ‘SENDING UNIT 8Nm (09 kg-m, 7 Mot) ECT SWITCH A 28Nm 28 kam, O-RING — 20140 ECT swiTcH 8 pavd 24Nm (2.4 kgm, 7m WATER PUMP. wb THERMOSTAT HOUSING onINGs Replace 8x1.25 mm 22Nm22kgm, CONNECTING PIPE o-nines Replace. 6x1.0mm ENGINE OM 12Nen (1.2 kgm, 9b) COOLER 10-3Fuel and Emissions Special Tools Component Location Index .. System Description Vacuum Connect Electrical Connections ‘Troubleshooting Self-diagnostic Procedures Engine Control Module Terminal Arrangement .. 14 11-6 118 11-10 PGM-FI System Troubleshooting Flowcharts Engine Control Module Heated Oxygen Sensor Manifold Absolute Pressure Sensor Top Dead Center/Crankshaft Position/ Cylinder Position Sensor ... Engine Coolant Temperature Sensor Throttle Position Sensor Intake Air Temperature Sensor .. Barometric Pressure Sensor Ignition Output Signal .. Vehicle Speed Sensor AIT Fl Signal A/B Heated Oxygen Sensor Heater out e of Model Changes + F22Z2 engine has been added, + The immobilizer system has been introduced. + Fuel Filter has been modified. Idle Control System Troubleshooting Flowcharts Idle Air Control Valve Air Conditioning Signal .. Alternator FR Signal Transaxle (A/T) Gear ion Signal .. Starter Switch Signal . 1139 11-40 11-42 11-43 11-45, Fuel Supply System Fuel Lines . . Fuel Tube/Quick-Connect Fittings .. Fuel Injectors Fuel Filter PGM-FI Main Relay .. 11-46 11-47 11-50 11-51 11-52 Intake Air System Cleaner .. Intake Control System .. 11-55 11-56 Emission Control System Exhaust Gas Recirculation System Evaporative Emission Controls 11-58 11-62 Fue! Tube/Quick-Connect Fittings have been introduced. + Vacuum Connections has been changed. Maintenance Schedule of Air Cleaner element has been changed.Special Tools Too! Number Description ty (07PAZ~ 0010100 ‘SCS Short Connector 11-2Component Location Rs Index EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID VALVE F2222 engine: Troubleshooting, page 11-62 EXHAUST GAS RECIRCULATION (EGR) EXHAUST GAS RECIRCULATION (EGR) CONTROL SOLENOID VALVE ‘CONTROL VALVE ‘Troubleshooting, page 11-58, Troubleshooting, page 17-58 FAST IDLE THERMO VALVE ‘TOP DEAD CENTER? (CRANKSHAFT POSTON] CYLINDER POSITION (TOC/CKP/CYP) SENSOR Us buitinto the distributor) Troubleshooting, page 11-24 ‘MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR. ‘Troubleshooting. page 11-19 IDLE AIR CONTROL (1AC] VALVE roubleshooting, page 11-29 INTAKE Alf CONTROL SOLENOID VALVE ‘Troubleshooting, paga 11-56 INTAKE AIR TEMPERATURE WAT) SENSOR Troubleshooting, page 11:30 THROTTLE PosmON (TP! SENSOR ‘Troubleshooting, page 11:28, HEATED OXYGEN SENSOR (H02S) Troubleshooting, page 11-17 [EXHAUST GAS RECIRCULATION (EGR) VALVE Troubleshooting, page 11-58 IGNITION CONTROL MOSULE cM) (is bulitinto the istibutor! ‘Troubleshooting, page 11-23 VEHICLE SPEED SENSOR (vss) Troubleshooting, page 11.34 ENGINE COOLANT TEMPERATURE (ECT) SENSOR Troubleshooting, page 11-25 ‘All models: FUEL GAUGE SENDING UNIT EVAPORATIVE EMISSION (EVAP) TWO WAY VALVE FUEL FEED PIPE FUEL TANK FUEL FILTER Replacement. page 11-51 pees EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER, Troubleshooting, page 11-62 FUEL FILL CAP FUEL TUBE/QUICK-CONNECT FITTINGS Precautions, page 11-87 Disconnection, page 11-47 Connection, page 11-75, FUEL INJECTORS Testing, page 11-50 FUEL VAPOR PIPE FUEL RETURN PIPE 11-3System Description Vacuum Connections (F22Z2 engine) @ HEATED OXYGEN SENSOR (HO2S) {@ POSITIVE CRANKCASE VENTILATION (PCV) VALVE @ MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR {2 EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER @ ENGINE COOLANT TEMPERATURE (ECT) SENSOR 1 EVAPORATIVE EMISSION (EVAP) @ INTAKE AIR TEMPERATURE (IAT) SENSOR, PURGE CONTROL DIAPHRAGM VALVE @ IDLE AIR CONTROL (IAC) VALVE @ EVAPORATIVE EMISSION (EVAP) (@ FAST IDLE THERMO VALVE PURGE CONTROL SOLENOID VALVE @ FUELINJECTOR ® EVAPORATIVE EMISSION (EVAP) ® FUEL PRESSURE REGULATOR ~ TWO WAY VALVE @ FUEL FILTER FUEL TANK EVAPORATIVE EMISSION (EVAP) VALVE | neonwoer | SEueatune Sehons etd tn sruie colon’ npr neowe | BTINTARE AR Sec serial Wit gaiion sch OW a ono 0 =e ® teDWvE TEMPERATURE SENSOR) \V (depending on intake air temperature) uae owaniFOLD Sees MAP ene sana With ignon swith ON i: abou 3 V 3 | woven | Aesotvte Pressure sen tard aionr sens So (denchinn Soon ee yeti vec SENSOR VOLTAGE | Power source for WAP seston Wonton vio ON aboutV it} ennntt”] sa1 enon GA0UNG) | Ground for WAP sansor “ SCS SERVICE CHECK Detects servis chckconnoday | Wi he connec’ cnneaied OV ws |e | Senau Qgealtnesignalcocsng ove | Wahine connesaydiecnnedae abou § [ ‘EGAL (EGR VALVE LIFT SEN- ‘Detects EGA valve lift sensor sig- ‘During idling without vacuum: about 1.2 V wy | ween | 58a mS Bin ay are ao me CS TONGEN BENE Geis ovgen Sens TaRa | wm ote ty aponea aunng wing of | wormed tiny acne up eine asus Be eee uy done ow 8.8 v Trea | alr RERERENCE Provides veferencovotago © | Withigiion ston ON, aboutV ce’ | Yours Fou wn ontoh Etch one eusuu | ¥0C2 GENSOR VOLTAGE] | Provides sonsorvoige Win ignition wien ON about a | veow | Wa gton swatch OF 7a | eva | a2 enon GROUNO) | Berean 11-12 si: ¥2222 onaine "28/1 modalrs NOTE: if this symptom ie intermittent, check for 2 loose No, 8 TURN SIGNALS (10 Al fuse PGM-FI System 7 Engine Control Module (ECM) ‘The Malfunction Indicator Lamp | oo | —Bmes ata concomecon nce (su ane CREEP Prefers | Check the engin Try to start the er Check for an open in the wires a (P61, P62 ines [belos v6] Asal 977 Tae [7a 1 Tur the onion sted OF. (aanenmand P62 (BUR) ‘Does the engine start? NO. 2. Turn the ignition switch ON WIRE SIDE OF : | at vege FEMALE TERMINALS b loose vote between boy ves und ana conenrie 9 ¢ Finals A12, 25. . LT ‘Repair open inthe wires) between p Laas ECM (A12, A25) and G101 (located. 2. Connect the ECM connector terminal A? to body ground, Mal. (LT GAN/RED! a. Tarte ion ohh ON TELE ep te 7popapa ys] een + | [efshe 22 |23 | 71 25| 26) — place the wba 1 ] ts the MIL on? NO_| — Repair open wire between | ~ WIRE SIDE OF s {he EM (AM) andthe gouge | FEMALE TEROINALS ve ese. Substitute « tnown-good Eom sna recheck (se page 313) 1 Symotemfindstion goes nea race the oninel Eoa (cont 11-13PGM-FI System r- Engine Control Module (ECM) (cont'd) ‘The Malfunction Indicator Lamp (anit stays on or comes on after ‘wo seconds ee Check the inertia switch: Intermittent failure, system is OK Code (oT KE 2. Tryto star th 1" Connoet the SCS shon connec vice check con 2. Turn the ignition switch ON th 05 the MIL indicate any DTC? ine starting: 1." Remove the SCS short connec tor fram the service check con 2 engine, <__Didthe engine stan? >= No ‘ane ue INERTIA SWITCH 3P CONNECTOR [Disconnect the 3P connector 3 from the inertia switch. Jr i2ls| peseeeeeseeeies [eos repre Conneta neria atch 3 com Wxmeo nectar terminals No. 1 and No. 3 JUMPER WIRE [__necortemingi Not ne No ware sib€ oF Dow he Mi emin on? Replace the nia switch, Fade TEMHINALS cS NOTE "ten tere no code soe the ML wl stay on Ihe sen heck connector sho eee and the ignition switch is ON « [check for a Diagnostic Trewbio «it this eymptom is intermittent, check for: = Alloose ECU (ECM) (10 A) fuse inthe under-hood fuse/relay box = Aloose No. 2 FUEL PUMP (18 A) fuse inthe under-dash fuselrelay box. — An intormittont shor in the RED wire between the ECM (D13) and the service check — An intermittent open in the GRN/BLK wire between the service check connector and Ecmi022), — An intarmittent short in the LT GRN/RED wire between the ECM (A7) and the gauge sembly — An intermittent short in the YELIRED wiro between the ECM (010) and the MAP sensor. — An intermittent short in the YELIBLU wire between the ECM (O21) and the TP tensor (Or EGR valve lift sensor ECM CONNECTOR D (22) 2[74]5\6|7[e]*[w]n Zs 17 [18 || 20] 21] 22 Check the ECM output voltage ‘SCS (RED) {SCS tine WIRE SIDE OF 1. Turn the ignition ewiteh OFF FEMALE TERMINALS 2. Turn the igntion switch ON (i). | 3, Measure voltage between ECM connector terminals D12 and body groune. check for 3P open in the wi (Check the fuse: | Inspect ECU (Ect IM) (10.4) fuse in | _ theunder-hood fuseltelay box (To past ye1.18) + (SCS tine: yes | 1 Connect the SCS short con. Isthere approx 8V7_— > nector to service check con NO 2. Measure voltage betwoen ECM connector terminals D13 Repair short in the wire between land bedy ground ‘the ECM (D13) and the service L_snsboey around: Sense | (To page 11-15) 11-14Ei (rom page 11-14) (From page 11-14) + | Repair open in the wire between | yes the ECM (D13) and the # heck connector. T—<_tettere approx. sv? >> eI No * NOTE: Alter repair, disconnect the SCS short connecter, test-drive the ar, and rechock the MIL for a code, [Check tora shore in the wire MIL Tine 1" Romove the SCS short con. rector from the service check 2. Tur the ignition switch OFF. ae ce catannore tat eee lea 3. Disconnect ECM connector A —_ vo | ~ bettered 5s apna Et ee « Trsspaen ic 4m ves [= Replace Cu teow (10) fuse, | Repair short in the wire between ves 3 Suites? > No ‘Check the fuse: —_—_—_|____— Inspect the No. 2 FUEL PUMP (15 Substitute a known-good ECM Al fase Inthe under-desh fe! and recheck (see page 11-9). If relay box Symptom/indieation goes awa replace the original ECM. v0 te oat — Replace No. 2 FUEL PUMP. (5A) fuse. ae {heck fora short inthe sensors: | “Turn the ignition sate ON I, 2: bisconnest the 3° connector of ach sensor ono at atime! MAP sensor } STP sensor EGR valve itt sonsor nainon? >—-NO_| Replace the sensor that caused —NO__Raplace the sens | ves (To Page 11-18) (cond) 11-15PGM-FI System -— Engine Control Module (ECM) (cont'd) (rom page 11-15) Ss es tet vee, | 2 Disconnect ECM connector D :CM CONN jOR 0 (22) Barre ne Eo | 3. Check for continuity between a ~ aepar shart ip hee Very Pees ta oe eee ar ves FEMALE TERMINALS: aire Sas Sieoes cm connecrons - wir 1p 1 GP? ae eee eeaneeee re YELBLK) WELIBLX) gage, 1. Dieconnect the fuel injector and — IAC valve connectors | 2[3]4|8[6l7|e]7[s| 1] 12]13] vy2[2]4]s|6|7[6 S]uceeemerersct sil zia|/\2s|25| icv -minals A13, B1 individually. (WIRE SIDE OF FEMALE TERNUNALS: L pecans NO PGM-Fi main relay. cee ere Renn = ities ia (LG1, LG2: times. ECM CONNECTOR A (26P) eee 5 t[2[3|*[sle| 7) e)710] w [rl Garrone eM v4 [a5 [167 [v6| 197722] 7 i MamureSotoge between body WIRE SIDE OF FEMALE tor pemsea ener Wekenas Swan 6 eerste y othe a Re in the wire(s) between emo oo aets it app Sm ves (To page 11-18) (con'a 11-17PGM-FI System (From page 11-17) (Check the ECM input voltage: 1. Start the engine. Hold the fengina at 3,000 rpm (min) ‘with no load (MT in 2nd gear, {AUT in IN) oF [P] position) unt the radiator fan comes on, then let tile for atleast one ‘minute before test- driving 2. Measure voltage between ECM connector terminals DIB and A26. 3. Open the throttle wide open, then quickly release i. Is the voltage above 0.6 V at ‘wide open throttle t 4500 rpm {enie') and below 0.4 V when the totais quietly released No - Heated Oxygen Sensor (HO2S) (cont'd) ECM CONNECTORS {om 4500 rp (ni? / \ toi (Check the HOZS: 41. Turn the ignition switch OFF. 2. Disconnect the 4P connector from the HO2S, 3. At'the HO2S harness side, connect the battery positive terminal to terminal No. and battery negative terminal to terminal No. 4 4, Stare the engine, 5. After two minutes, measure voltage between HO2S 4P con: Rector terminals No.1 snd No.2. /tetho vonage above 06 V at swide open trate to #500 rpm {mine and below 0.4 V when the throti ie quickly released tom 4500 rpm (mia)? . ves Repair open of short in the wire ECM (D18) and the HO2S. ‘Substitute a known-good ECM ‘page 11-9). If A261 Dm) T[2]2]¢[s[6 7/8//iwlnwla] []2)7a]sle 718,98 win 14 15 |16|}18 [197/22 23/125 26] [7108777 ne 7 20] 2 22 tor | o2s WIRE SIDE OF ‘ern01x) | @—— mn FEMALE TERMINALS wane siDe OF FEMALE TERMINALS| HO2S 4? CONNECTOR be NOT Replace the HO2S. > ep ‘TERMINAL SIDE OF MALE TERMINALS. 11-18nek “GES TLS TL. The Mattunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 3: An electrical prob- zt i. lem in the Manifold Absolute Pressure (MAP) Sensor circuit. - Manifold Absolute Pressure (MAP) Sensor ‘The MAP sensor converts manifold absolute pressure into electrical signals and inputs the ECM. psseietessareses ‘our | = The aa has been: reported on. ‘SENSOR w vouraae With the SCS short connector | UNIT ~~ SS) asl ‘connected, code 3 i indicated. —— Problem verification: — 1g 4"bo the ECM Reset Procecire 19 2 Start the angine and allow it os fold Seeec ae) 256 tn. Ho) cava Too 360 360° 465600 GS TEE im Mo) READING isthe MiL on and dows incicate NO coe? eat ves Aections or loose wires between | ECM CONNECTOR D (22?) (crwrwern ‘the MAP sensor and the Ee veer Check the ECM output voltage eee (vetneD) (ect toa ort Check the ECM output voltage = urn the ignition saiten ects 7 7 alia 2% Turmthe ignon switch ON 1 Semtegnton switch OFF < el 83 Moasutevoltoge between ECM te eo 8 178 7[0l 23 22 connector terminals D10 end ee {rom the MAP sensor. | m1 ‘3. Turn the ignition switch ON (Hn, | en 4. Measure voltage between YES _ recap] WIRE SIDE OF FEMALE TERMINALS. 31 ‘crue —1____ em connecron D2) icuoeh he ecu onseae ata ‘and recheck (see page 11-9). If al fc ; | tymotomyindaton gees sway twtr) laazure voltage between ECM | ‘place the orginal ECM connectortrminasoS ond 011. | 71 = 2Vye[2 le] 7] 8] 9] 0 }o jes | Substitute » known-good ECM 13) 17 {18 | 7] 20] 21 | 22 | y ‘and recheck (see page 11-9) if << ithero apron v7 ES] an rachack (00 eet away, | WIRE SIDE OF FEMALE eee | Termanats No replace tho ogi! EON [eicroless Be oes Ea IMAP SENSOR 3° CONNECTOR Chea or an opin in the wire (S81 ina wre sive 1 "Yumtneiantionswien or. | Oe reanate ves | 7 omnes am | Seca an aeameTe EDS a Sonar Wt ‘3. Turmthe ignition switch ON (i, ] xo Measure voltage Betweon MAP | senaor 3° connector terminals veer | NovtandNo 2 mes IVEL/RED) —— Tho [ene open inthe wire between <_ethereenprox 5v7— >“ ] tee BGM TD11) and tho MAP cone v v (Te page 11-20) (To page 11-20) (cone 11-19PGM-FI System (rom page 11-19) (From page 1-19), ‘Check for an open in the wire (MAP ine Mesauee voltage betwoon MAP sensor 3P connector torminals No.2 and No. 3 (Check the MAP sensor: 4. "Turn the ignition switeh OFF. 2 Disconnect 3P connector from the MAP sensor, 3. Turn the ignition switch ON A, 4 Measure voltage between ECM Connector terminals D9 and on L os < coomenevt >| NO ‘Check for an open in the wire (VCC1 Fine): 1. Turnthe ignition switch OFF. 2. Disconnect the 3P connector from the MA? sonsor. Tora the ignition switch ON (i “Mescure voltage between MAP No. and body aroun. 2 4 < vo Check for # short in the wire (MAP line: 4. Turn the ignition switeh OFF. | 2 Disconnect ECM connector D (22) fram the ECM, 3. Check for continuity between ECM connector terminal D9 and body ground. lethere approx. 8V? > ves Is there continuity? ves < ‘Substitute » known-good ECM No Feplace the original ECM. Repair short in the wire - Manifold Absolute Pressure (MAP) Sensor (cont'd) MAP SENSOR 3P CONNECTOR WIRE SIDE OF FEMALE TERMINALS. sc (Grn/wn map (RED/GAN) v Saccece NO_| Repair open in the wire between Essie cereus ‘the ECM (D8) and the MAP sensor. = ECM CONNECTOR D (221 Replace the MAP sens nan mar sot (wtymeD) (canvwany 72 7J*[e [el] e]9 [oj 13] x7] 9] 7]20] 21 WIRE SIDE OF FEMALE TERMINALS Replace the MAP sensor. [MAP SENSOR 3° CONNECTOR Wine SIDE OF FEMALE TERMINALS, Repair open inthe wire between {he ECM (010) and the MAP sen ser ) veo ee wevincoy ©) femcomecronD iam fia) (wr vEL) ; o 12)7JJs|ei7[e]elln 13 ¥7 18/20) 20/22 the ECM (a) and the MAP sensor. (WIRE SIDE OF FEMALE ‘TERMINALS. 11-202K 2K = The Mi has boon reported on. connected, code 5 is indicated Problem verification: 1." Do the ECM Reset Procedure. 2. Start the engine. Hold the engine at 2000 rpm (sien) for | ‘one minute (MIT in neutral, AT in or [Bl postion. sppzeeervweees! Pe is the ML on ana code 5? 4 ves. ‘Check the vacuum line: 1. Turn the ignition smiteh OFF. 2 Disconnect No. 21 hose from the throttle body, connect vacuum pump to the hose {and apply vacuum, ‘= With the SCS short connector | —__| oes it indicate » NO — intermittent ature, system i | ~ Ok'ee this time testorive tray be necessary) — Eheck vacuum hos ips pees Eaesaae ves Check the vacuum line: ] 1. Conneet a T-itting fram & vacuum gauge between the | throttle body base ond No, 2+ hoe 2. Start the engine ee TE en ves input volt 41. Turn the ignition switch OFF. 2. Turn theignition switch ON (i, 3. Measure voltage between ECM connector terminals D8 and no << poos notdvacuum? —_>>-NO (Check the MAP sensor: Connect a vacuum pump to the MAP sensor anc apply vacuum, < Repair vacuum leak in hose rout. in MAP sensor and fold oes it hold vacuum? ves Remove restriction from throttle body. E' ,- Manifold Absolute Pressure (MAP) Sensor (F18A3, F20Z1 engine) ‘The Malfunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (OTC) §: A mechanical problem (vacuum leak} in the Manifold Absolute Pressure (MAP) Sensor system. vacuum pume/ GAUGE '8G1 (GRN/ ECM CONNECTOR D (22) wan) con Tz ele tela [e]s fel — 73 wis | 720] za] 22 no ~ Iter appro 37 {Ronis he AP sansa. Wine SDE OF FEMALE TERMANALS ves (ro page 1122) (cont’a) 11-21PGM-FI System [- Manifold Absolute Pressure (MAP) Sensor (F18A3, F20Z1 engine) (cont'd) — (From page 11.20) Check the ECM input voltage: Stort the engine and allow to | iat Lite << tetnete approx V7 i scr iGRNr ves ECM CONNECTOR D (22P) WHT) Substitute « known-good ECM Mae ae (PeD/aRN ‘300 = - T2y«Jsle[7] 2] 9 [ops 3 17 [we | 7J20| 23/22 WIRE SIDE OF FEMALE TERMINALS 11-22PGM-FI System Re [- Manifold Absolute Pressure (MAP) Sensor (F22Z2 engine) DGS TEE IL The Matfunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 5: A mechanical prob- es- 2 ALSAS em (vacuum leak) in the Manifald Absolute Pressure (MAP) Sensor system, = The MIL has boon reported on. | = With the SCS short connector code 5 ls indicated, Problem verification 1° Do the ECM Reset Procedure. 2. Start the engine, Hold the ‘engine at 2,000 rpm (min) for | ‘one minute (M/T in neutral AT ini or 1B] position) pe mtcpantaoertmar NNO [ — Kent tne, at sougbgrrnesmerwine Be | See time ana eons rbot = Check vacuum connections, es = Make sure all connectors are (Check the MAP sensor 1. Turn the ignition switch OFF, 2 Remove the MAP sensor from throttle body. | 3. Connect a vacuum pump to the MAP sensor and apply vac —— a —— ‘Does it hold vacuum? Replace the MAP sensor. OM CONNECTOR O(2zP1 sar aRw ves we hack th tote body: mar Steconnect the wacvum pump (RED /aRN from the MAP sansor 2. Start the engine. | 3. Pat your finger over the MAP T2174 ]s [6/7 [2] [|x] guyana onthe tote 7 w7hs0/7 [zl arfz2 vo — — a —S2_[ Remove rnin tom tote ee ee facies meno} body. ves a Check the ECM input voto “Turn the ignition switch OFF. 2, Turn hoanton etch ON, 3. Measure voltage betw: ECM connactar torminale DS and 011 No approx. 3 V7 Replace the MAP sensor. sci iGRN es cm connector zap) $61 Check the ECM input vokage: orem [OF 1. Install the MAP senor. (RED/GRN) 2, Start the engine and allow it ! toidle. 1]2)7*]s|6/7 [8 [9 |] — No - << tnttre approx 17 neinetas Pane saneee a {17 [187 20| 24] 22 r WIRE SIDE OF FEMALE TERMINALS ves. known-good ECM tnd recheck (see page 11-9). If Symptom/indication goes away, replace the original ECM, 11-23PGM-FI System p> TDC/CKP/CYP Sensoe tA AANA The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 4: A problem in the Crankshaft Position (CKP) Sensor circuit. ‘Tho Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (OTC) 8: A problem in the Top Dead Center (TDC) Sensor circuit. ‘The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (OTC) 9: A problem in the Cylinder Position (CYP) Sensor circuit, The CKP Sensor determines timing for fuel injection and ignition of each cylinder and also detects engine speed. The TDC Sensor determines ignition timing at start-up (cranking) and when crank angle is abnormal, The CYP Sensor detects the Position of No. 1 cylinder for sequential fuel injection to each cylinder. The TOCICKPICYP Sensor is built into the distribu tor. = The MIL hes been er a Watt Seotettanmcase Seances cous anor sunt - Petter vsti 7 xe sewson === aorae toe sevson SENSOR mice Intermittent failure, system is OK at this time (test-drive may be neo the MIL on and does it indicate NO] sary code 4,8 andior 97 Check for poor connections or Toose wires between the TDC/ ves CYP/CKP sensor and the ECM. al DISTRIBUTOR 6P (Check the sensor resistance: CONNECTOR 1. Turn the ignition switch OFF. 1 2. Discannect the 8P connector from the diatibutor 3. Measure resistance between terminals of the indicated son [a [2[a]- 7 Solan terme. 90807 WE L ————_—- TERMINALS. NO teplace the distributor ignition ieee pisTaBuTOR a ‘CONNECTOR ‘TERMINAL SIDE OF MALE ‘TERMINALS ECM CONNECTOR 8 16P) velels e 2/10 8 “ WIRE SIDE OF FEMALE TERMINALS. ECM CONNECTOR B (16°) TDC P 1GAN) cvP P(veL) DA cKp P ew feels 7 Repair short to body ground in ‘tho indicated sensor wires, a 2/10 13) 4/15/16 WIRE SIDE OF FEMALE TERMINALS ee 11-25PGM-FI System Engine Coolant Temperature (ECT) Sensor ea 3 Engine Coolant Temperature (ECT) Sensor circuit. coolant temperature increases as shown below. [= the mat has been reported on. — with the SCS short connector connected, code Bis indicated, L Problem verification: 1. Do the ECM Reset Procedure. 2._ Turn the ignition switen ON il ‘THERMISTOR ‘The Malfunction Indicator Lamp (ML) indicates Diagnostic Trouble Cade (DTC) 6: A problem in the The ECT sensor is a temperature dependent resistor (thermistor). The resistance of the thermistor decreases as the engine RESISTANCE a) Intermittent fair |e the MIL on and does k indicate \,_NO code 6? ves Too. ENGINE COOLANT TEMPERATURE system is OK at this time (test-drive may be ‘Recessary). Check for poor con: nections or loose wires between ‘the ECT sensor, the ECM and the — ECT SENSOR 2P CONNECTOR 1. Start the engine. Hold the fengina at 3,000 rpm (min) ‘with 'no load (M/T in neuteal AT in (8) oF position! unt the radiator fan comes on, | then let iti 2, Turn the igition switch OFF. 3. Disconnect the 2° connector from the ECT sensor. 4, Measure resistance between the 2 terminals on the ECT sen ot) Re ECT SENSOR 2P CONNECTOR < 2 ves. Replace the ECT sensor. Check the ECM output voltage (ECT fine) 1. Turnthe ignition switch ON (Hh 2. At the engine harness side, ‘measure voltage between the ECT sensor 2° connector ter ‘minal No. 2 end body aroun. ves | tine: ppOXSV? | Measure voltage No als No. and No. 2. ‘Check for an open inthe wire G2 tween the ECT sensor 2P connector term! ECT (neDywan)| 2 ® sesoaoe Es scrensonar concn ® (2 corimeorwnmm 2 / Wine SIDE OF FEMALE TERMINALS. (To page 11.27) ce the original ECM. ‘symptom/indiestion goos away, > ‘open in the wire between the ECM (D22} and ECT sensor. 11-26SE (rom page 11-26) WAT model) re + eres | [check for TCM" circuits | | 4. Turn the ignition switch OFF. | | 2 Disconnect 22P connector i from the i Module (TCM Turn the ignition switch ON «i, i At the engine harness side, i ‘measure voltage betwean the i i i i i I ECT sensor 2P connector ter- ‘minal No.2 and body ground. ves > pron BV? ia No ‘Check for an open in the wire (ECT fine Replace the TCM. ECT SENSOR 2P CONNECTOR ECT (RED/WHT) Cy) To WIRE SIDE OF 9 FEMALE TERMINALS. 4 i i i i i i ECM CONNECTOR D (2P) No ‘Check for 8 short in the wire (ECT Hin: 1"Turn tho ignition switeh OFF 2. Disconnect ECM connector D (22°) from the ECM 3. Check the continuity between |” ECM connector terminal D7 |___ana body grouna No Substitute » known-good ECM and recheck (s 119). symptom/indication goes away, | replace the original ECM. Is there continuity? YES [Reais short inthe wie bot << eereconinainn > >TE] gars FEGM (D7) and ECT sensor. ~ 13 | 20| 21] 22) = ves | Repair ‘WIRE SIDE OF aera > ipsa ves 2 (To page 11-281 n (TP) Sensor oureut VouTace wi | mRoTTie The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 7: A problem in the Throttle Position (TP) Sensor circuit. The TP sensor is @ potentiometer. It is connected to the throttle valve shaft. As the throttle position changes, the throttle position sensor varies the voltage signal to the ECM, ECM CONNECTOR D (22P) ‘TPS (RED/BLK} oe 4[s|6j7]e/ own ; Catal tal Substitute a known-good ECM ee and recheck (see page 11-3). If WIRE SIDE OF FEMALE TERMINALS symptom/indieation gows away ‘place the original ECM. ‘TP SENSOR 3P CONNECTOR WIRE SIDE OF FEMALE TERMINALS ECM CONNECTOR D (22 'vec2 (vELBLU) A ae ve zolat|z2 CGheck for an open in the wit IVES tne TERMINALS Measure voltage between ECM Connector tore! 21 and body round ___ ves S| No | Measure voltage botween ECM connector terminal 08 and body ‘round (Mo page 11-31) heck for an open in the wire {G2 line: Measure voltage between the IAT ‘sensor 2° connector terminal No. Vand No. 2. ‘Check for an open inthe wire WAT one line: Is there apr Yes Substitute » known-good ECM wo sG2 en —\ gS aT (RED/VEL) WIRE SIDE OF FEMALE TERMINALS. Repair open in the wire between ‘the ECM (022) and IAT sensor. ECM CONNECTOR 0 (22) TAT (REDIVEL) — and recheck (seo page 11-9). If Symptom/indieation goes away, replace the original ECM: 2 3 [*]sie|7[s] elon v7 [16/720 21 | 22 ‘WIRE SIDE OF FEMALE TERMIVALS +@— 11-30(rom page 11-30) the wire UAT Hine: 1" Tur the ignition switch OFF, 2. Disconnect ECM connector D (2291 from the ECM. 3 Chack the continuity between ECM connector terminal DB and body ground! Is there continuity? ‘Substitute aknown-go0 recheck (see page 1 Ptom/indica ves. ves ‘the ECM (08) and IAT senco Repair open in the wire between the ECM (D8) and AT sensor ECM CONNECTOR D (22P) var neo vet) a 8] 8 fo[n] [e777 fs [20] 2022] WiRE SIDE OF FEWALE Terwinats T Repair aor in the wir between | } 11-31PGM-FI System Barometric Pressure (BARO) Sensor - “PFFL The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 13: A problem in the “A: -O5: Berometic recoure (BARO) Sensor The BARO Sensor is built nto the ECM = The MIL has boon reported on. = With the StS short connector Connected, code 12 it intent. |” Protiem veriteation: 1 De the CoM Reset Procedure. 2, Turn the ignition site ON Eu ela —\ no [magmaniaaeapennor | tetne tte on ers das tind NO) his time (test-drive may be ves Substitute » known-good ECM | symptom/indication goes away, ace the original ECM, 11-32PGM-FI System — Ignition Output Signal “SC TEPS]L. The Malfunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 15: A problem in the FS SOS pinion Ourpusignal arcu — The MIL has boon reported on, = With the SCS short connector connected, code 15. Is indicated Problem veriiation: 1 Do the ECM Reset Procedure, 2. Start the engine. ‘nections or loose wires between [See See itter one he Ec ECM CONNECTOR A (26P) Check the eM output voltage: Jom (vEL/GRN) “Turn the ignition switch OFF. 2 Tome given sich OW th 5 Measure voltage between ECM connector terminals At? and 1415] 16]/7[10] 19 [20] 722 [23 [7] 25 [26 26 TG (BANTBLK) 2]3]*]5]6|7|6]7w]npale — | ‘Substitute a known-good ECM and ‘WIRE SIDE OF aman ; YES | recheck (ese page 11-3). H symp FEMALE TERMINALS. is there battery voltage? teeta ne page 119) symp. NO the original EC, (Check the CM input voltage: 1. Turn tho ignition switen OFF. DISTRIBUTOR 2P CONNECTOR 2. Disconnect 2° conmactor from the distributor. 16 3. Turn the ignition swith ON th, (eucveL 4 Measure voltage betwoon the 3 ictrbutor 2° connector termi nal No.2 and body grounds No_| Repair open in the wire between pee eDE on Is there battery voltage? the aitibutor and the ignition Pana repeaaa| — Repair open or short in the wire between the ICM sad. the ECM (ATT), NOTE: If the YELIGRN wire was shorted, the ICM may be Samoged, 11-33PGM-FI System — The MIL has been reported on = With the SCS short connector connected, code 17 Is in cated —— Problem verification: 11 Do the ECM Reset Procedur 2. Test-drive with AVT in 2} post tion, MT in 2nd gear, acceler fate to 4,000 rpm (mir), then ‘ecelerste to 1800 roe (rit) with throttle fully lased for at least 8 seconds. Sas Is the MIL on and does itindi- NO cate code 17? eee ves CCheck the ECM input voltage: 1 Tura ‘snitch OFF. 2. Block roar wheels and sot the parking brake. Jack up the front Of the car and support with Safety stands 3. Turmthe ignition switch ON (. 4 Block the right front whoo! and slowly rotate left front wheel fond measure voltage between ECM connector terminal B13 and A26. = Does voltage pul —- approx 5 V7 No ves (Check the circuit (VSS line): 1 Torn the ignition switen OFF. 2. Disconnect ECM connector 8 (18°) from the ECM, 3. Turn the ignition eiich ON th. 48 Block the right front wheel and slowly rotate loft front wheel ‘and measure voltage between ECM connector terminals B13 and A26. a Does voltage pulse approx 5 V? ovena we ves. Substitute a known-good ECM and recheck (see page 11-3) I symp- (- Vehicle Speed Sensor (VSS) ‘The VSS generates a pulsing signal when the front wheels turn Intermittent failure, system is OK ‘at this time. Check for poor con- nections or loose wires between the VSS, the ECM and the TCM. [vse a upfront of cr. wh before A261 ECM CONNECTORS ‘The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 17: A problem in the Vehicle Speed Sensor (VSS) circuit. B07) roe Te le]elel7 e)wlnyele] [2 ]2]«]s[e]7 6 v4] 15 | 16] [18] 19 22|23| 7] 25| 26| [9 [10 [is 14) 15] 16) ‘Substitute @ known good ECM and rocheck (see page 11). If symp- ‘om/indication goes away, replace ‘the orginal ECM, © 4 Tt mm G1 (BRN/BLK) 2 VSS (BLU/WHTY WIRE SIDE OF FEMALE TERMINALS, — Repair short in the wire between the ECM (B13) and the VSS or the TCM. — Repair open in the wire ECM (B13) and the Is OX, test the VSS. cM conwEcTonS acer) ver 1]2]3]«[s[e}7 87 njels] [12] 3] «Js lolz fe v4 15 | 16) | 18] 10,7722 237125 26] [9 [10 1a[ ual 16/16 ver emve00 Tes suum @—_ WIRE SIDE OF FEMALE TERMINALSA/T FI Signal A/B (A/T) cola With the SCS short connector connected, code 30 and/or 31 are indicated, | Probtem voriication: 1°" Do the ECM Reset Procedure. | 2 Test-drive necessary. Orive the car for several miles 20 that the transmission upshifts land downshite several times. Check for a short in the wires IAFSA, AFSB lnos) 1. Turn the ignition switen OFF. 2. Discannect ECM connector B (1891 from the ECM, Disconnect 22P connector from the TCM. Check for continuity between ECM connector terminals 82 andlor 810" and body ground, a EF [ ] “GE The Malfunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (OTC) 30: A problem in the AT TS FI Signal A circuit between Transmission Control Module (TCM) and ECM, The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 31: A problem in the AT TSF Signal B circuit between Transmission Control Module (TCM) and ECM. ECM CONNECTOR 6 16°) APSA (WHT/RED) EE system is OK Cheek for poor connections or loose wires between the TEM and the ECM oes the ML indicate code No 30 andior 31? Yes [ECM CONNECTOR B (16°) s]7is} 14/15/16) AFSB ILT GRNI* WIRE SIDE OF FEMALE TERMINALS. ASA WHT/MED) + code 3 (A/T I sign Tey |s|* pI 2 [rola [a5 [6 arse wT GaN ‘om 22° convEcTOR AFSA (WHT/RED) Is there continuity? | ves (Cheek for an open in (APSA, AFSB lines! ye wires AFSB LT GANT Check for continuity wire «[sle|7]e] ela between ECM connector termi nals 82 andlor 810* and the TCM 7/7419] 20 22P connector terminals No. 7 ‘anajor No. 8 : WIRE SIDE OF FEMALE. TERMINALS Repair open in the ‘the ECM (B2, Repair short in the wire between, ECM (62, B10) end the TCM, place the original ECM, 11-35PGM-FI System — Heated Oxygen Sensor Heater ESIC TEETIC. The Maltunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 41: A problem in the AES. TET rect Oxygen Sensor 02S) Heater circuit ae [= the tt nas been reported on. | = withthe Sc short connector connected, code 41 Is In cated. ‘Problem verification 1.°Do the ECM Reset Procedure. 2X Sta the engine. | income = Intermittent fire, system is OK Is the MIL on and does it indicate. NO at this time. Check for poor con- ECM CONNECTOR A (26P) (foes fectons or loocs wires ote 1 (8UK) — the HO2S and the EC ose, (PS ul aa) ein ‘| semen a]*]s]€ (7/8) elnyepa 1671019722 23/725) 26 3. Mansur sologebatwaon ECM Wine SIDE OF FEMALE Connector terminals 86 and TERMINALS oe no OM CONNECTOR A 26" cyvotegs? > “2 PB> To page 11-90 oasHre - = a = taux vi2laie Check the ECM input voltage: With the voltmeter stil connected 1/15/16 between ECM connector termi als AB and A12, start the engine. WiRE SIDE OF FEMALE Substitute 9 know ———— aw NO and recheck (see p: ECM CONNECTOR A (26P) Bisse os 000 ves L int EG | oaaire -® TT ‘aoe Chest he Mint oor , ; Cait te vel Tae |e sr Taos baton * Fen conctor terminals AB WIRE SIDE OF FEMALE moa Temas 4. Tur the ignition switch ON. | * Monitor ever a 8 minute pe current drops below 0.1 A mmmediatay. ves. S| _ Replace tho HO2S. 11-36Ci (From page 11-36) Vv ‘Check for an open in the wa Tine: 1." Turn the ignition switeh OFF. 2. Disconnect the 4P connector |< fromtne Ho2s, | 3. Tum the ignition ewiteh ON dh 4. Atthe engine wire harness, HO2S connector terminal No, 3 {ormina and bady grounds \cP © Thee boty vatape? >| ves Repair open in the wire between ‘the HO2S and the PGM-FI mai | Check the HO2S resistance: 1 Turn th ignition switen OFF 2, At the HOZS harness, mea Sure resistance between No. 3 {and No. & terminal O25 4° CONNECTOR niet opt (EU UKI ST) f | WIRE SIDE. © oFremate SE Terminats O25 4° CONNECTOR Ea L@ No TERMINAL SIDE OF >" Replace ene HOZ5. TERMINAL SIDE OF MALE = —eV—V— TERMINALS bas ozs 4P CONNECTOR Chek fora shorted HO2S: i Sea tt tan Gk minal No. # and terminals Noy 1 thd No? individu. I ves TERMINAL SIDE OF MALE Ie there continuity? {replace the HO2S. TERMINALS No (Check for an open in ‘the wire gree ra ee lecsennamore ozsure_ -———-@———_po2s ap connecron 1. Disconnect ECM connector A SPLKIWAHTY (266) from tho Ec Tz]2|«]s[e]7/e)]olnpala + [2 | ozsere 2. Check for continuity between ~LteuKrwin ECM connector terminal AS M4] 18] 1617] 18 [19 beryl i2|28} | 3) 4 Pine sive ‘and HO2S connector terminal Wine SIDE OF FEMALE Jor reMate No 4on the angine vara hare | TERIMALS ‘TERMINALS nese de. | : weihew comtnuin? NO_|” Renate open ia the wire between = rainy! ‘tha HO2S and the ECM (A6). ves — . (To page 1-28 (convey 11-37PGM-FI System (- Heated Oxygen Sensor Heater (cont'd) (From page 11-37) | ECM CONNECTOR A (26°) ene © ‘Substitute a known-good ECM and recheck (see page 11-9). If Symptom/indleation goes away, replace the original ECM. Check for a short in the wire JORN/ELC) {Hoss ine Tels]? ee] ape a connector terminal A6 and body 44] 18) 16 wa] t9 71 | 2228 25126 ‘round J WIRE SIDE OF FEMALE L | set famine lee Le 11-38Idle Control System > Idle Air Control (IAC) Valve 3 aS S00: order to maintain the proper idle speed. = The Mit hes been reported on. — With the SCS short connector connected, code 14 is indicated Problem verification: 1." Do the ECM Reeet Procedure, 2. Sant i Is the MIL on and does it indicate code 14? ves ‘The Malfunction Indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 14: A problem in the {dle Air Control (VAC) Valve circuit. ‘The IAC Valve changes the amount of air bypassing the throttle body in response to a current signal from the ECM in cou. ‘Check the IAC valve: Hold the engine at 3,000 rpm (enin-1) with ne toad (M/T in neutral, AT in i or [P post tion! until the radiator fan comes on, then let tide. With the engine running and the accelerator pedal released, disconnect the 2P connector from tho IAC valve. E' ‘ToINTAKE From AIR Intermittent failure, system is OK Check for an open in the wire (IGP tne: 1. Disconnect the 2P connector from the IAC valve, 2, At the engine wire harness ‘measure voltage between the TAC valve 2° connector tormi ‘al No.2 and body ground, ves (Check the cireuit: 1. Turn the ignition switeh OFF tnd reconnect the 2° connec torto the AC valve, 2, Disconnect ECM connector A (26P} from the ECM 3. Tum the ignition switch ON ih. | Momentary connect ECM con nector terminals AB to A1Z overal times. Isthore a reduction in engine rom? No ‘Substitute « known-good IAC at this time (testdrive may be YES | necessary). heck for poor connections or loose wires betwaen the IAC valve and the ECM IAC VALVE 2P CONNECTOR Zz (4 icp |) wveveus tar aad ® WIRE SIDE OF FEMALE TERMINALS ves. Does the 1AC valve click? No Substitute 9 known-good ECM and retest (see page 11-9). If ECM CONNECTOR A (26) (Check for an open or short in the wire betwoen the ECM (AB) and the IAC valve. If wire is OK, replace the AC valve Zymptomvindienion goes away, | cv SUMPERWIRE pat ‘lnc te original ESM ‘eu ee — fox Et Te[sle[sel7 8) wa eya] ves [16 7a 19 [7122 23|/Tas 20] WIRE SIDE OF FEMALE TERMINALS. 11-39Idle Control System [- Air Conditioning Signal -t€ iA $A AAA ‘This signals the ECM when there is a demand for cooling from the air conditioning system: Inspection of Air Conditio wactenst sree | scncomecrons soe a Seeriainen nasi semen a a eee aehpemem | pees esr or Bop emays | Gab Teays biped scram | Race e eee 3, Disconnect the 2° connector {rom the AC pressure switch 4. Turn the ignition switch ON th 5. Moaaure voltage between ECM connector terminals BS and A26 LG? (BRN/BLK \WIRE SIDE OF FEMALE TERMINALS. ECM CONNECTOR B 116°) {RCS tna) L ho. | 1 Turmtne anton wit OFF Treat 2. Disconnect ECM connactor & aporex8v?_ > NO rt 0 (16P) from the ECM 2077 helis le = 3. Chock for continuity between ECM connector terminal 83 | WIRE SIDE OF FEMALE TERMINALS and body ground Check for a short in the wire -— | Aes tern ——|__._ eg [tent ann nam wr trwuen << wemconinany S| So eeata neers AIC pressure switeh, No ; Cheek te AIC compressor Cth “Tuen the fgnition switch OFF 2 haconmedt the AG dode fo the 2? connector. 3. Roconnect the A/C pressure switch 2P connector to the ‘AIC pressure switen 4 Tur the ignition switch ON (th, 5. Momentary connect ECM con: actor terminals AB and AZ6 ECM CONNECTOR A (26) — See the air conditioner inspec- ACC(LTBLU) JUMPER WIRE iu 2] ]*)5]61 718) w nal 615/16] 8 22[ 23/72 [28 WIRE SIDE OF FEMALE ter TERMINALS (BRN/ELK (To page 11-411 11-40Ci (rom page 11-40) | Js there a clicking noise from the AIC compressor cluteh? ves Check A/C operation: | 1, Staretho engine. | 2. Turn the blower switch ON. |_3 Turn the AIC snitch ON, ia er ves Air conditioning signal is OK. —— Check for an open in the wir (ACS tine: Momentariy connect AJC clutch relay 4P connector terminal No, 4 to body ground soveral times No AIC CLUTCH RELAY ‘4° CONNECTOR Giz] acc (raw) Is there a clicking ni < ves Repair open in the wire between ‘the ECM (AB) and the A/C clutch rel ‘Check for an open i NO | {ACS tine: rom ,_NO the AIC compressor clutch? sl WIRE SIDE OF FEMALE TERMINALS ‘Soo air conditioner inspection ECM CONNECTORS ievalican ar ERTS NO_| Repair open in the wire betwe the ECM (B3) and the A/C switeh, ves — ‘Substitute a known-good ECM tnd recheck (soe page 11-9). symptom/indication goes away, replace the original ecw = See the air conditioner inspec: thon Azer) 8.6) OD [ac8 theo yw TPE pe mapee| FD]: ]s]e le ]e aaa sla alata LG (BRN/BLK) WIRE SIDE OF FEMALE TERMINALS 11-41Idle Control System (- Alternator (ALT) FR Signal This signals the ECM when the Alternator (ALT) is charging. ves (Check the ALF FR signal 1." Turn the ignition switch OFF. 2, Reconnect the ALT 4P con rector tothe ALT. Start the engine. Hold the fengine at 3,000 rpm (rnin) ‘with na Toad (WT in neutral [AIT in [Wo [F position) until the radiator fan comes on, then let tte. Measure voltage between ECM ‘connector terminals D5 and 26. —I 3 ‘Doss the voltage decrease when headlights and rear defogger are turned on? No —___| ‘Check for an open in the wi (ALTE tne): 1. Tur the ignition ewiteh OFF. 2. Disconnect the 4 connector from the ALT. ‘Torn the ignition switch ON (W, ‘Measure voltage between the ALT 4P connector terminal [No.2 and body ground, Tes ‘See the ALT inspection 3 4 11-42 NO_[ Repair open in the wir ECM connector terminal O5 | a and body ground. No ‘Substitute a known-good ECM and recheck (see page 11-3). pre Inspection of ALT FR Signa. OM CONNECTORS. A261 ot [ATE wrens a a 1 [a rele] < 2[]n] [nook sve com output voraoe [1213 {eTs[e[7) e[7twfula zTaTs lela [eloiuls {ALTE tn 14/15/16 V2 e3| 725 3 7 [ve 720] 20] 22 Tur the onion switch OFF | 2 Disconnect the 4P connector | ter wrnveK |} from me ALT 2, Tar the nition switch ON WIRE SIDE OF FEMALE TERMINALS 4 Measre voltage betwoon ECM Connector terminals DS and ae scck tor wom ECM CONNECTOR D (22P| Cheek fora short in the wire | -——@ ate wine) ft Turn the ignition switeh OFF. 7 vi No_| 2 Disconnae Eck connector D Vl27yaTs lel a[ fs [rola) ener approx. BV? | (2aprtrom me ecw taal 77 nna z0| 22 heck for contnuty Betweon Lv |se| {2012 WIRE SIDE OF FEMALE TERMINALS ves short in the wire between (05) end the ALT. the EC between ‘the ECM (D5) and the ALT. ALT 4P CONNECTOR ALte (werr/neD) Ly ly FEMALE, ‘TERMINALS,lon of A/T Pos 1" Tur the ignition switeh ON (i, 2. Observe the AUT shit position indicator and select each post [ton seperately > Automatic Transaxle (A/T) Gear Position Signal This signals the ECM when the transmission Is in [Rl or F] position, (Check the A/T shift position indi oes the indicator light prop: xiv? ves. | Check the ECM output voltage (ATP PN tine): 1. Turn the ignition switch OFF, 2. Disconnect the 10P connector from the A/T gear position svrtoh Disconnect the 26P connector {rom the TCM, “Turn the ignition switch ON Measure voltage between ECM connector terminals B& and Az, ves (To page 11-44) No. << sthete approx. 8 v7 1 eM conwecrons A) eave Osteen neorau0 = [2 [3[*[5[6|7 @/7[o)n)2)3] | F[2]3]*]5]6]7 18 1 [35] 16 718 ales 712s|z0| | [fora rele t6 Gt (BRN/BLK) WIRE SIDE OF FEMALE TERMINALS. J (ATP PN tine): 4. Turn the fanition switch OFF. 2 Disconnect ECM connector 8 (18°) trom the ECM, 3, Check for continuity between ECM connector terminals 84 and body ground - ves. Is there continuity? | no Check for a short in the wire | 10 welts hie WIRE SIDE OF FEMALE TERMINALS. Repair short in the wire between the ECM (B4) and the gauge ‘assembly < Substitute a known-good ECM 113). If ‘now aval Able, replace the orginal ECM, (conta 11-43Idle Control System [- Automatic Transaxle (A/T) Gear Position Signal (cont'd) (From page 11-43), ECM CONNECTORS one Azer Bca60) 4. Turn the ignition switeh OFF. 2 Reconnect the 10P connector © ATP PN IRED/BLK) tothe AMT gear position sich, 7 | ‘Check fr an open inthe wire (ATP 3. Reconnect the 38P conmector spears] | Pqeqals sle|7|@ to the TOM. 22| 23/25 [26 1) 5. Measure voltage between G1 (BRN/BLK) | se a Comic we S10¢ OF FEMALE TeMANALs [N] position, is sentation no | _ Begiiv tna, : ret ate Ser ms | kom connecrons — ata sen areenieet [ATP PN (RED/BLK) iircthage ueween Eom Os Sin conemistion in iBl pectin a[2i3{4isiel7[s|/)wln pals Vi2i3iaisiel7is > 14/15/16 | /|18 22| 23 | / | 25 | 26 9 ho V3 [1415 76 ve es7eu0 WIRE SIDE OF FEMALE TERMINALS al ‘900" postion switch, wo [fart om nn we power SO| Sehapentata rin ssa ves ‘Check fr a short in the wire (ATP PN tin Measure voltage between ECM lacraceres eat ‘withthe transmission n gor. ———_—~_no. | ves [AIT gear position signal is OK 11-44[- Starter Switch Signal This signals the ECM when the engine is cranking. Inspection of Starter Switch Sig- al ECM CONNECTORS ae Bier) 1 hash he EO input vor Or use (STS line): hdl Measure voltage betweon ECM 5 . | Connector terminals 8 an AZS TD s[elr te 7polnfela) | ]2ls|«[slel le wramihe ignition ewiren'in the | Salas] 10/7178] hs 6 NOTE: MIT in neutral, AT in il or [Pl postion @ 22|23|/7 25 |26 2 UG? (BRN/BLK) [WIRE SIDE OF FEMALE TERMINALS fusereley box START (il) position | — Repair srt ithe wie Sererevianvinwon | maemo Bed ca ont Seas main relay. — Roplace the No. 12 STARTER ‘SIGNAL (7:5 A) fus ves ‘open in the wire between the ECM (BS) and the No. 12 ‘STARTER SIGNAL (755 Al fu. 11-45Fuel Supply System r- Fuel Lines NOTE: Check fuel system lines, hoses and fue! filter for damage, leaks or deterioration, and replace if necessary. z2Nm (22kgtem, re ibe [38 kgtm, 27 te) Zam (2zkgtm, ‘6 bee) 11-46- Fuel Tube/Quick-Connect Fittings Precautions, EERIE 00 not smoke while working onthe fuel System. Keap open flames away from your work ‘The fuel tube/quick-connect fittings assembly connects the in-tank fuel pump with the fusl feed pipe. For remov- ing or installing the fuel pump and fuel tank, itis neces: sary to disconnect or connect the quick-connect fittings. Pay attention to following} '* The fuel tube/quick-connect fittings assembly is not heat-resistant; be careful not to damage it during ‘welding or other heat-generating procedures, ‘© The fuel tube/quick-connect fittings assembly is not acid-proof; do not touch it with a shop towel which ‘was used for wiping away battery fluid. Replace the fuel tube/quick-connect fittings assembly if it came into contact with battery fluid or similar. ‘* When connecting or disconnecting the fuel tube/ quick-connect fittings assembly, be careful not to ‘bend or twist it excessively. Replace it if damaged. A disconnected quick-connect fittings can be reconnected, but the retainer on the mating pipe cannot be reused fonce it has been removed from the pipe. Replace the retainer when — replacing the fuel pump, — replacing the fual feed pipe. — Ithas been removed from the pipe. — itis damaged. FUEL TUBE RETAINER ‘Quick.-cONNECT TINGS C Disconnection Do not smoke while working on the fuel system. Keep open flames away from your work area. Disconnect the battery negative cable. 2. Remove the fue! fil cap, and relieve fuel pressure in the tank, 3. Relieve fuel pressure. Check the fuel quick-connect fittings for dirt, and clean if necessary. 5. Hold the connector with one hand and press down the retainer tabs with the other hand then pull the connector off Note: ‘© Be careful not to damage the pipe or other parts Do not use tools. If the connector does not move, keep the retai tabs pressed down, and alternately pull and push the connector until it comes off easily, '* Do not remove the retainer from the pipe; once removed, the retainer must be replaced with CONNECTOR S Press down, ~& 6. Check the contact area of the pipe for dirt and dam- age. = Ifthe surface is dirty, clean it — If the surface is rusty or damaged, replace the {uel pump or fuel feed pipe. Be S& CONTACT AREA CONNECTOR wernle “FD (cont’ay 11-47Fuel Supply System 7. To prevent damage and keep out foreign matter, cover the disconnected connector and pipe end with plastic bags, PLASTIC Bags Nore: The retainer cannot be reused once it has been removed from the pipe. Replace the retainer when replacing the fuel pump. replacing the fuel feed pipe. it has been removed from the pipe. itis damaged. r- Fuel Tube/Quick-Connect Fittings (cont'd) Connection Do not smoke while working on the fuel system. Keep open flames away from your work area. 1. Check the pipe contact area for dirt and damage, and clean if necessary. CONTACT AREA PIPE 2. Insert a new retainer into the connector ifthe retainer is damaged, or after — replacing the fuel pump. — replacing the fuel foed pipe. — removing the retainer from the pipe. ‘Now RETAINER (inser into the connector 11-48rz Before connecting a new fuel tube/quick-connect fitting assembly, remove the old retainer from the mating pipe. with the tabs pulled ‘part, pull \\ the retainer Not New FUEL TUBE/ > ‘QUICK.CONNECT FITTING ASSEMBLY 3. Align the quick-connect fittings with the pipe, and align the retainer locking pawls with the connector grooves. Then press the quick-connect fittings onto the pipe until both retainer pawls lock with a click ing sound. NOTE: If it is hard to connect, put a small amount of new engine oil on the pipe end, Connection with new retainer: CONNECTOR 4, Make sure the connection is secure and that the pawls are firmly locked into place. Check visually and by pulling the connector. CONNECTOR RETAINER — ape 5. Reconnect the battery negative cable, and turn the ignition switch ON (ll). The fuel pump will run for about two seconds, and fuel pressure will rise. Repeat two or three times, and check that there is no leakage in the fuel supply system. 11-49Fuel Supply System r- Fuel Injectors Testing NOTE: Check the following items before testing: idle 'sp0e6, ignition timing and idle CO % lf the engine will run 1. With the engine idling, disconnect each fuel injector connector individually and inspect the change in the idle speed ‘© Ifthe idle speed drop is almost the same for each cylinder, the fuel injectors are normal © If the idle speed or quality remains the same when you disconnect a particular fuel injector, replace the fuel injector and retest. 2. Check the clicking sound of each fuel injector by means of a stethoscope when the engine is idling, ‘© I any fuel injector fails to make the typical click: ing sound, check the sound again after replacing the fuel injector. — If clicking sound is still absent, check the follow: ing. + Whether there is any short-circuiting, wire breakage or poor connection in the YEVIELK wire between the PGM-FI main relay and the fu0l injector. + Whether there is any shortcircuiting, wire breakage or poor connection in the wire between the fuel injector and the ECM, Hf all is OK, check the ECM (see page 11-13) and PGM-FI main relay, the engine cannot be started: 1. Remove the connector of the fuel injector, and mea sure the resistance between the 2 terminals of the fuel injector. Resistance should be: 10-131 FUEL INJECTOR © If the resistance is not as specified, {vel injector. place the © If the resistance is as specified, check the fuel pressure. — If the fuel pressure is 8s specified.check the fol lowing + Whether there is any short-circuiting, wire breakage or poor connection in the YEL/BLK. wire between the PGM-FI main relay and the fuel injector. + Whether there is any shortcircuiting, wire breakage or poor connection in the wite be: tween the fuel injactor and the ECM, Ifall is OK, check the ECM (see page 11-13) 11-50r- Fuel Filter Replacement ‘Do not smoke while working on fuel system. Keep ‘open flame away from your work area, ‘¢ While replacing the fuel fitter, be careful to keep a safe distance between battery terminals and any tools. The filter should be replaced: every 2 years or 40,000 km {24,000 miles), whichever comes first or whenever the fuel pressure drops below the specified value (280 ~ 330 kPa, 2.8 ~ 3.3 kglcm®, 40 ~ 48 psi with the fuel pressure regulator vacuum hose disconnected and pinched) after ‘making sure that the fuel pump and the fuel pressure regulator are OK. 1. Disconnect the battery negative cable from the bat- tery negative terminal 2. Place a shop towel under and around the fuel filter. 2. Relieve fuel pressure. 4. Remove the special bolt and the fuel feed pipe from the fuel filter, while supporting it with the another wrench, as shown. 5. Remove the fuel flter clamp and fue! filter. When assembling, use new washers as shown. NOTE: Clean the flared joint of high pressure hoses thoroughly before reconnecting them, SPECIAL BOLT 22m (22 kgtm, ‘ABER WASHER, Replace. Fuel FILTER 98 [ mo aTNm (Lokgtm, — .Bkgtm, 72WeH) 27 ie) 11-51Fuel Supply System — PGM-FI Main Relay —A Troubleshooting — Engine will not start = Inspection of PGM-FI main relay and relay harness. (Check for an open In the wire POM. MAIN RELAY {GND ine! 7 CONNECTOR 4. Turn the ignition switch OFF. een 2. Disconnect the 7P connector refs from the PEM main rely. ‘stel7] | 3. Cheek for continuity between the PGM.FI main relay 7° connector terminal No. 3 and WIRE SIDE OF body ground. FEMALE TERMINALS. No << rsconnane>22-[ uae apn ie ie wen ontinuity? 7 |_ the PGM-FI main relay and G10". ronan nesay ‘Measure the voltage between the 1a Pome it en 7 Snare a ZL ear ety — Repair open oF short in the wire between the PGM-FI WIRE SIDE OF No main relay. and the ECU FEMALE TERMINALS. Is thore battery voltage? (ECM) (10 Al fuse. — Replace the ECU (ECM) (10 A) Yes {use in the under-hood fuse! relay box, (Check for the eirult (1G 1 tne) PGM-FLMAIN RELAY {Turn the ignition sitch ON, ‘7PCONNECTOR 2. Measure the voltage between een yc LB) a ; sere Seat eB | Hii ane anas : — fe i ues rae ves ie ea om (To page 1153) 11-52|From page 11-52 PGM-FLMAIN RELAY 7 CONNECTOR (Check the circuit (ST SW line: 1. Turn the ignition switeh to the START Ul position, Note: _ ST Sw/BLU/RED) “Transmission in (i or (2 post al 2. Mosaure the vokage between eistely) the PGM-FI main rolay 7P connector terminal No.2 and body ground — Repair open or short in the wire between the PGMA main No felay and the No. 12 STARTER } SIGNAL 7S fuse, —<—<—S Roplace the No. 12 STARTER ves. SIGNAL (7.5 A) fuse in the 1 wine sive oF FEMALE TERWINAL © PGMLFI MAIN RELAY — 7P CONNECTOR Check for (FUR tin {Turn the ignition switch OFF fs 2 Disconnect the ECM connec = tora GOP [et7} ECM CONNECTOR A (26) 3. Gheek for continuity between i SIDE OF Fun ion the PGMLFI main clay 7P con aoa cue’ nector torminal No. 1 ond the ECM connector terminal Ad eee open in the wite FUR (GRN/BLKI a[s[e|7[e 0 nye | AACA Wine SIDE OF FEMALE TERMINALS No | Revoir open in the wie between the ECM (Ad) and the PGM-FL —_—— train relay. ves. (Check for an open in the wire {1GP tes JP Reconnect ECM connector A (280 tothe CM 2. Reconnect the BGM main felay 7P connector to the @> eevenes nan [I Pe ‘Tuimane ignition setch ON, 8) bc I eee eo Measure the votage between | feu |] ere the connector terminal Gt o pec : +P [aTsTepe a leV so] )2[3 PY Je [sels le]7 le vali! 16/108 z2|2a\/\25)26} [slo 1a|14)5 [16 ECM CONNECTORS ‘Al2 and ECM connector termi hele BT end A'3 individually = (To page 11-54) (cont'ay 11-53Fuel Supply System (From page 1153) Check the ECM input voltage (FLA tine 1. Turmtho ignition ewiteh OFF. 2. Measure the voltage between ECM connector terminals Ad and A12 whan the ignition Switch is first turned ON) for two seconds. << tetese tov ortess? > [es Check the PGM-FI main ‘= Repair open in the wire between the ECM (A12, 81) andthe PGM-Flmain relay. | — Replace the PGM-FI main ECM CONNECTOR A (26°) FLR(GRN/BLK) - PGM-FI Main Relay (cont’d) AAPA Tro] Jr | 25 [26 WIRE SIDE OF FEMALE TERMINALS known-good ECM id recheck (se page 113) pre- ‘cribed voltage fs now avilable, ‘replace the orginal ECM, 11-54Intake Air System 2%) r- Air Cleaner (ACL) 11-55Intake Air System (- Intake Control System (F22Z2 engine) (Check tor vacuum 1. Hemove the Upp hose from the int Solenoid valve and connect 8 vacuum gauge tothe hose 2. Stan the engine and allow it toidle (Check for vacuum at intake con- trol vacuum tank: Romove the lower vacuum hose ee ___ from the intske control solenotd valve, then check for vaccum, | Esomestuns ves —_! [ves Check for an open in the wire (RESSOL 1. Tur the ignition switeh OFF. 2. Disconnect the intake control solenoid vatve 2° connector. 3. Turn the ignition switch ON i) 44 Moasure voltage between the intake control solenoid valve 2P connector terminale No. 1 and No.2. | ________} | (Fo page 11.57) (To page 1157) 11-56 INTAKE CONTROL SOLENOID, VALVE vacuum pumer > GAUGE | Repair the blockage or vacuum NO_| leak between the intake contral jum tank and the intake mani- fa INTAKE CONTROL SOLENOID VALVE 2P CONNECTOR — RESSOL ea wT iat (BLK YE) (WIRE SIDE OF FEMALE TERMINALS. Ses <_tnttere batery voltage? — is there battery voltage? >=} Replace | no = I ——~ ‘Check for an open inthe wire G1 (ARES ey tne t Mossure voltage between body S 2 Jmarey Ground ana tn intake conta! Ve fclenoid valve 2° connector tern nal No.2 WY << tetorobatery voltage? >NO <_ta there ty votes rid No. 4 ECU (ECM) (10) fuse ves, esi te dv. cee Hise reiay, Bas ‘Check for an open in the wi ECM CONNECTOR A (26°) (Ressott {1 Turn the ignition switch OFF eso. JUMPER WIRE 2 Reconnect the inate solenoid we valve 2? connector. 4. Connact ECM connector tm ‘nals A10 and A25 with a jumper E E {a[s ful fel —— wane si0€ OF 72 (61x) Vv Tera TERMINALS.E' (From page 11-58) Y (Check for vacuum at 4,000 rpm: 1. Raise engine speed to above 44.000 rom. 2. Check for vacuum atthe vac om hoe. No Sheet or ec ane jeeeaneneeeent| co < dows nots vcuum? —>—NO ves Teenie] (From page 1158) ‘Does the solenoid valve cick when S\,_NO the jumper wireis connected? ves Substitute a known-good ECM and recheck (see page 11-9). If pmptom goos away, replace the original ECM, Disconnect the intake contol sole noid valve 2° connector. T Check for a sh (RESSOL liner 1. Turn the ignition switeh OFF 2 Disconnect the ECM connec: tor A320), Check for continuity between ody ground and the intake contrat solenoid valve 2P con: ‘nestor terminal No, 1 ort in the wi 3 Is thore continuity? No Substitute « known-good ECM and recheck (soe page 11-9). I Symptom goes away, replace the original ECM, ‘Check the vacuum line for proper ‘connection or disconnected hove. OK, replace the intake control iaphragm. Repair open in the wire between ECM (A10) and th Intake contrat solenoid valve INTAKE CONTROL SOLENOID ‘VALVE 2° CONNECTOR RESSOL (wet) WIRE SIDE OF FEMALE TERMINALS >= | Repair short in the wire between ECM (A10) and the intake control | solenoid valve, VACUUM PUMP/GAUGE ‘VACUUM HOSE wntaKe CONTROL DIAPHRAGM. 11-57Emission Control System -- Exhaust Gas Recirculation (EGR) System ‘ESL ULIZILTe Malfunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (OFC) 12: A problem in the ZEAL SOE, Ethauet Gas Recirculation €GM) system, — The MIL has been reported on. | = ‘ithe Ses short connector SSnnected, sade 12 tn ron valve irr sensor EGR VALVE 1. Do the ECM Reset Procedure, 2: Connect the SCS short con- | nectar to the service check | 3, Testdrive necessary: Start the | © engine. Hold the engine at 3,000 rpm (min) with no load (MT in neutral, AZT in oF position) nti the raciator fan tomes on, then lt fide, Drive ‘the car on the road for spprox. | 10 minutes. Try to keep the | {engine speed in the 1.700 — 23500 rp rin range, aa Intermittent failuro, system is OK ‘at this time. Check for poor con- Does the ML blink ang NO_| eetions or loose wires between 9s it indicate code 127 the EGR valve lift sensor, the EGR control solenoid valve and ves the ECM, Check the vacuur With the engine at idle, disconnect the #16 hose from the EGR valve and connect # vacuum pump/ gauge tothe hose (Cheek the vacuum: yes | 1. Disconnect the 4P connector ‘rom tha contol box 2, Chack the #18 hose for vacu No tum again (Check for @ short in the wire (E i Check vacuum hose routing of the entire EGR system, If hore routing is OK, replace EGR con- tol solenoid valve. corneal CONTROL 80x 4. Turn the ignltion switch OF. 4° CONNECTOR 2) Disconnect ECM connector A (26P} from tho ECM ESOL (RED) 3. Cheek for continuity between ua the control box 4? connector a4 terminal No.2 and body ‘round "I shor in the wire between the ECM (A16) and the EGR con: ‘ol solenoid valve ves Substitute a known-good ECM ‘and retest (see page 11-9). If ‘Symptom/indieation goes away, replace the original ECM. (To page 11-59) 11-58(From page 1158) — Check the ECM output voltage (vec? tn 1. Turn tho ignition awiteh OFF. 2. Disconnect the 3P connector {rom tho EGR valve lit sensor. 3. Tuem the ignition switch ON Uh 4 At the hamess side, moasure ‘Voltage between the EGR valve Tit sensor 3° connector term! nals No.1 and No. 3 (FIBA3, F202! engine) No.2 and No. 3 (2222 engine) (To page 11-60) reas, F20z1 7/3] 1[2[3 ‘vec (GAN/BLK) (ELELU sc2 Check for an open in the wi ($62 line: Measure voltage between the EGR valve lit sensor 3P connec: tor terminal No. 3 and body ‘round << te ere approx. 5? \ leone No Check for an open in the wit. (Vo02 tine): 1. Turn the ignition switch OFF. 2. Disconnect ECM connector D (22P from the ECM. 3, Check far continuity between ECM connector terminal 021 land the EGR valve ift sensor 3? connector terminal No.3 EGR VALVE LIFT SENSOR ‘3P CONNECTOR F222 ons LL veca (vEL/BLU) N ® saz ‘ST ‘caveun) I Wine SI0€ OF FEMALE TERMINALS F2222 engine veca wetreww) v Repair open in the wire between the EGR valve lift sensor and the ECM (D221, ves. Figs, F2021 engine ‘vec, WELBLU) ne (veLeuwy com ‘CONNECTOR b (22P), we sioeor {1] 21/]«] 5/6 [7 onmte | TERMINALS, 33) A7\% veer No_ [Reps open rth wie baton <__therecontnun? > NO] PRE ete an hereon Evioes" ves Symptom/indication goes away, ‘replace the original ECM. (cont'd) 11-59Emission Control System {From page 11-58) [ ee ‘Check the EGR valve 1. Move the vacuum pume/geuge tothe ean | 2. Startene eng 3 With the engine 2t idle, apply 27 kPa (200 mmHg & in.Hgh of ‘vacuum to the EGR valve r Exhaust Gas Recirculation (EGR) System (cont'd) Does the engine sta or run rough and doos the EGR valve Replace the EGR valve. hole vacuum? ves (Check for an open inthe wire (G1 Tine: 1." Turn the ignition switeh OFF. 2 Disconnect the 4? connector from the contol Box 3. Turm the fgntion switch ON ( 4 Atengine harness side, mea: sure voltage betweon the con: ttol box 4P connector terminal No. 1 and body aroun. No the EGR control solenoid valve {and No. 2 F/PUMP (15.8) fuse in ndor-dash fuse/relay box. lethere ery voltage? ves ‘Check the vacuum line: | 1 "Reconnect the vacuum puma! gauge to the 818 hose, 2. Start the engine and allows it 3. Atthe control box connector, connect the battery positive terminal to torminal No. 1 of the 4? connector. While watch ing the vacuum gauge, con ect the battery negative ter inal to terminal No.2 Check the vacuum hoses: Turn the ignition switch OFF and Inspect the £16 and #24 hoses for leaks, rostrictione, or misrouting. ves v v (To page 11-81) (To page 11-61) Repair open in the wire between = a a < ‘Ave the hoses OK? EL correct an necessary. ‘CONTROL BOX 4P ; 2 ra, rons CONTROL BOX 4P CONNECTOR TERMINAL SIDE OF MALE TERMINALS aaa] 11-60Ei (From page 11-60) (From page 11-60) ‘Check the vacuum lin: 1. Disconnect the lower hose on [EGR control solenoid valve and connect a vacuum gauge tthe hose, Start the engine and allow itto ide eGR CONTROL SOLENOID EGR VACUUM ‘CONTROL VALVE PUMP/GAUGE Check for an op {ESOL line): No Did the engine sta or un rough? bez ‘symptom/indication go: replace the original ECM. ‘Check the ECM input signal (EGR tin 1. Turn the ignition ewiteh OFF. 2. Reconnect the EGR valve lift Sensor 3P connector to the EGR valve it sensor. Reconnect the vacuum pump/ gauge to the EGR valve, ‘Tarn the ignition switch ON (0 Messure votage betweon ECM connector terminals D7 and Isthe voltage approx. 1.2v_—\\ with no vacuum applied and approx. 43.V with 27 KPa (200 img, 8 n.Hg) of vacuurn No \ _spplied tothe EGR valve? Yes yy ‘Does the voltage consistently increaseidecrense aa the vacuum Increasesidecreases?, ves in the wire 1. Reconnect the #16 hose to the EGR valve 2. Start the engine and low it to idle. 3. Connect the ECM connector terminals AY6 ana A12. } Yes Substitute a known-good ECM and recheck (see page 11-9). If Pe (150-260 Hl of vacuuen? Yes, Replace the EGR control solenoid > Replace the EGR vacuum contrat valve ECM D CONNECTOR (22P) =~ Teepe lel [e]efoln 3 AAA 7 0 as 22 cane ‘saz twt7ou0 D— ican Ir open or short in between the EGR vs ‘sensor and the ECM (017) = Mwireis OK. replace the EGR valve, Replace the EGR valve. WIRE SIDE OF FEMALE TERMINALS = lean ee ae ween, (eaeste aa Tmrnpets] | Tenmnais [34/16 [zzl23//2s 25 ee Repair open in the wire between the EGR contro! solenoid valve and tho ECM (A16} 11-61Emission Control System ‘Troubleshooting Inspection of Evaporative Emit co (Check the vacuum when cold 1 Disconnect the vacuum hose from the EVAP purge control canister and connect a vacuum ‘gauge tothe hose, Start the engine and allow it toidle NOTE: Engine coolant tem- erature must be below 75°C herr. Is there vacuum? No (To page 1-63) ,- Evaporative Emission (EVAP) Control ves evap PURGE CONTROL DIAPHRAGM VALVE: evap CONTROL CANISTER: Check the EVAP purge contrat valve 1" Turn the ignition switen OFF 2. Disconnect the 4P connector from the control box. | Star the engine [At the harness sido, messure voltage between the control box 4P connector terminal No. 3and No.4 | on oni Taito cone. neous em to ee cae Tae See [Be as, | ies an aa coeur ar ETERS Ban Tas [09] [os [efardanaar aaa 08 [07 os fonfovdowovford 7a as hao[aalacalce] foo} [oe Lor] ord eu 17] TOM Tern Location 14-5Troubleshooting Procedures ‘When the transmission control module (TCM) senses an abnormality in the input or output system, the (Bj indicator light in the gauge assembly will blink. When the Service Check Connector (located under the dashboard on the passenger's side) in connected with the special tool as shown, the (Oj indicator light will blink the Diagnostic Trouble Code (OTC) when the ignition switch is turned on (il). When the (Bi indicator light has been reported on, connect the Service Check Connector with the special too! Then turn the ignition switch and observe the (Oi indicator light. [RHO is shown; LHD is similar [Bi npicaror UGHT SERVICE CHECK ‘CONNECTOR (2P) GAUGE ASSEMBLY Codes 1 through 9 ere indicated by individual short blinks, codes 10 through 18 are indicated by series of long and short blinks. One long blink equals 10 short blinks. Add the long and short biinks together to determine the code. After deter mining the code, refer to the electrical system Symptom-to:Component Chart on base shop manual (62SN700), section 14. short q M I] M JL sores See DTC 2 4 LAL. eer | shor ‘Some PGM-FI problems will also make the (Bi indicator light come on. After the PGM-FI system, disconnect the BACK UP (RADIO) fuse (7.5 A) in the under-hood fuso/relay box for more than 10 seconds to reset the TCM memory. NOTE: + PGM-FI system ‘The PGIM-FI syste on this model is @ sequential multiport fuel injection system. + The [Bj indicator light may come on, indicating a system problem, when, in fact, there is @ poor or intermittent electrical connection. First, check the electrical connections, clean or repair if necesss + Ifthe electrical readings are not as specified when using the test harness, check the test harness connection before proceeding. + Disconnecting the BACK UP (RADIO) fuse (7.6 A) also cancels the radio pre note of the radio presets before removing the fuse so you can reset them: t stations and the clock setting. Make 14-6Road Test oO; NOTE: Warm up the engine to normal operating temperature (the radiator fan comes ont. 1. Apply parking brake and block the wheels. Start the engine, then move the selector lever to [B) position while depressing the brake pedal. Depress the accelerator pedal and release it suddenly. Engine should not stall 2. Repeat same test in [BJ position. Shift the selector lover to {Bj position and check that the shift points eccur at approximate speeds shown. Also check for abnormal noise and clutch slippage. NOTE: Throttle position sensor voltage represents the throttle opening. = 1. Connect the Test Harness between the TCM and connector (refer to base shop manual (62SN700), section 14) 2, Set the digital multimeter to check voltage between D7 (+) terminal and A25 or A26 terminals for the throttle posi- tion sensor. LHD is shown; RHD is similar, DIGITAL ‘TEST HARNESS MULTIMETER ‘O7LAS - PT30100 o Commercially available or ‘O7LAJ-PTOI0A 7411 - 0020000 Az i Prt 9000000000006] 00005000 d00000] 00080000000 2000000000009] 00000000] 000000] 00000000000 + Az6(-) —@——____| (conta) 14-7Road Test r (cont'd) F18A3, F2021 engines: [Bi Position + Upshift Jst> 2nd 2nd 3rd 3rd Ath—_Lock-up Clutch ON Throttle position sensor voltage: ‘emih 14-16 28-31 43-48 0.788 V (0.6/8 throttle) pre | 8S | Coasting down-hill from a stop mph 8-10 7-18 27-30 feeeeel Throttle position sensor votage: kmh 31-34 2-69 5-91 100-108 2.184 V (3.58 throttle) ‘Acceleration from a stop mph 19-21 39-43 53-57 62-67 Full throw kovh 48-53 | 107-112 | _147- 162 133-141 Acceleration from a stop mph 30-33 66-70 91-94 83-88 + _Downshitt Lockup Clutch OFF 4th-> 3rd ard > and 2nd-> Ist Throttle position sensor voltage: kovh 20-26 2-3 = 0-14 0.788 V (0.6/8 throttle) Coasting or braking to a stop mph 12-16 7-19 6-9 Throitle position sensor voltage an estan 61-67 32-38 10-18 2.184 V (3.5/8 throttle) " When ears slowed by increased grade, | Feo ee eee be wind, ec. _| Fulkthrottle kmh | 126-136 | 131-137] 68-94 2-48 When car is slowed by increased rade, wind, ete ‘mph 80-85 e1-85 55-58 26-30 F2222 engine: [i] Position + Upshift Yet 2nd 2nd 3d ___Srd-> 4th__Lockup Cluteh ON Throttle position sensor voltage: kevh 14-16 | 28-31 43-48 — 0.788 V (0.6/8 throttle) — Coasting down-hill trom @ stop mph 9-10 7-18 27-30 Throttle position sensor voltage: kovh 35-38 o-7 91-97 100-108 2.184 V (3.5/8 throttle) Acceleration from a stop mph 22-24 40-44 57-60 62-67 Fullthrottle kev 4e-5e | 101-106 | 153-158, 137-145 Acceleration from a stop mph 30-34 63-68 95-98 85-90 + Downshitt Lockup Clutch OFF 4th 3rd rd and 2nd tst Throttle position sensor voltage: koh 20-26 aH = 70-14 0.788 V (0.6/8 throttle) Coasting or braking to @ stop mph 12-16 17-19 coed 6-9 Throttle position sensor voltage: = ean ees aoe 10-14 2.184 V (3.578 throttle) When cari stowed by inerosed grade, |, rr — wz | Fullthrowtle kovh | 132-140 | 131-137] 88-94 42-48 When car is slowed by increased grade, wind, ete mph 82-87 1-85 55-58 26-30 14-8eo) Accelerate to about 35 mph (57 kmyh) so the transmission is in 4th, then shift [Bs to (2 position, The car should imme- iately begin slowing down from engine braking CAUTION: Do not shift from (04 or [i] position to [2] or [1] position at speeds ove age the transmission, {62 mph (100 km/h); you may dam- Check for abnormal noise and clutch slippage in the following positions, [H (1st Gear) Position = 1. Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage. =2. Upshifts should not occur with the selector in this position. (2nd Gear) Position = 1. Accelerate from a stop at full throttle. Check that there is no abnormal noise or clutch slippage. ~2. Upshifts and downshifts should not occur with the selector in this position, (Reverse) position Acceletate from a stop at full throttle, and check for abnormal noise and clutch slippage. Test in [P] Parking} Positon Park car on slope (approx. 16°), apply the parking brake, and shift into [P] position. Release the brake; the car should not move. 14-9Fluid Level [- Checking/Changing Checking NOTE: Check the fluid level with the engine at normal ‘operating temperature (the radiator fan comes on). 1. Park the car on level ground. Shut off the angine. 2. Remove the dipstick (yellow loop) from the trans- mission, and wipe it with a clean cloth, 3. Insert the dipstick into the transmission. DIPSTICK (YELLOW LOOP) 4. Remove the dipstick and check the fluid level. It should be between the upper and lower marks. piestick. 5, Ifthe lovel is below the lower mark, add fluid into the filler hole to bring it to the upper mark. Use genuine Honda ATF PREMIUM (Automatic Transmission Fluid: PREMIUM). In an emergency, you may use a quality Dexron® I or Il ATF as a temporary replacement. 6. Insert the dipstick back in the transmission. Changing 1. Bring the transmission up to normal operating tem perature (the radiator fan comes on) by driving the car. Park the cat on level ground, turn the engine off, and then remove the drain plug, 2. Reinstall the drain plug with a new sealing washer; then refill the transmission to the upper mark on the dipstick Automatic Transmission Fluid Capac 2.8 (25 US qt, 2.1 Imp at) at changing 6.0 ¢ (6.3 US at, 6.3 Imp qt) after overhat SEALING WASHER Replace. DRAIN PLUG qaxtsmm 50 Nm (60 kom 98 Bett) 14-101st/2nd Accumulator Body 00) [- Disassembly/inspection/Reassembly NoTE: © Clean all part thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blow out al passages. © Coat all parts with ATF during assembly. CAUTION: Do not use a magnet to remove the check ball; it may magnetize the bal CHECK BALL 18T/2ND ACCUMULATOR ‘BODY O-RING Replace. 1ST ACCUMULATOR, PISTON or O-RING ae on Replace ) a nssumrton meron SNAP RING one ee ese ne is SPRING SPECIFICATIONS mm (in) ‘Standard (New! No. | Spring : | Wire Dia, op. Free Length | No. of Coils @ | istaccumutator spring 8 78007 | 630248) | 705.2776 | 168 @® | Astaccumulator spring A 2.310.091) | 16310642) | 109.6(4.315) | 20.0 @ _| 2nd accumulator spring 35 (0.13 | 22.00.86 | 91013583) | 10.8, 14-11Main Valve Body [ Disassembly/Inspection/Reassembly NOTE: © Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air. Blow out all passages. '® Check all vaives for free movement. If any fal to slide freely, see Valve Body Repair on base shop manual (62SN700). © Repiace the valve body as an assembly if any parts are worn or damaged. © Coat all parts with ATF during assembly. CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls. ‘MODULATOR CONTROL MODULATOR coc vaive SONTE —_ euren ayy FEED PPE VALVE CAP Ineo i tis cneex SiC even nm rowsen & yen Lock ur eves Anw ‘SHIFT i vatve @ sureve ewes LOCK-UP a ¥ 1-2 SHIFT VALVE. CONTROL! ISX Ae cooter neuer Qe vy 2.3 SHIFT VALVE / ¢ “e are reeo s man vate soor ; and damage. . MANUAL VALVE VALVE CAP aa 14-12FILTER MAIN VALVE BODY Sectional View ‘SPRING SPECIFICATIONS DETENT ARM SHAFT Unit: mn tin) ‘Standard (New) No. Spring Wire. oD. Free Length | No. of Coils @ | Lock-up control valve spring 0.7 (0.028) | 6.610.260) | 38.0(1.496) 246 0.7(0.028) | 6.6 (0.260) | 38.5 (1.516) 246 0.7(0.028) | 6.6 (0.260) | 39.0 (1.535) 206 ® | Lock-up shift valve spring | 0.910.035) | 7.640.299) | 73.7 (2.902) 320 ® | Cooler relief valve spring 1.0 (0.039) | 8.410.331) | 46.8 (7.843) 70 @ | Modulator valve spring 1.4 (0.055) | 9.4(0.370) | 33.0(1.299) 105 ® | cPcvaive spring 1.4 (0.055) | 9.410.370) | 33.0(7.299) 105, © | Main orifice control valve spring 1.1 (0.043) | 7.140.280) | 49.11.9383) 221 ® | 1-2shiftvaive spring 0.940.035) | 86(0.338) | 40.4 (1.591) 145, @ | 23 shift vaive spring 0.910.035) | 7.6(0.299) | 57.0 (2.248) 268 14-13Clutch Mustrated Index 18T/2ND CLUTCH ASSEMBLY NOTE: There are two types of pistons, you may find either type in the clutch assembly. SNAP RING CLUTCH END PLATE cuurcH piss ‘Standard thickness: CLUTCH PLATES Standard thickness: 1.94 mm (0.076 in} 2.6 mm (0.10 im) o-niNGs. Replace, (CHECK VALVE DISC SPRING Install in this direction. RETURN SPRING RETURN SPRING SPRING RETAINER ee DISC SPRING SNAP RING: Install in this direction. 2ND CLUTCH DRUM CLUTCH PLATES Standard thickness: 2.0 mm (0.08 in) CLUTCH Discs Standard thickness: 1.944 mm (0.076 In) ‘1ST CLUTCH DRUM cuuTeH END: PLATE ‘SNAP RING: 14.14‘3RD/4TH CLUTCH ASSEMBLY NOTE: There are two types of pistons, you may find either type in the clutch assembly. SNAP RING CLUTCH END PLATE CLUTCH Discs Standard thickness: 1.94 mm (0.076 in) O-RINGS CLUTCH PLATES Replace.. Standard thickness: 2.3 mm (0.09 in) (CHECK VALVE DISC SPRING. Install in this direction, RETURN SPRING ‘SPRING RETAINER: JAN SPRING SNAP RING. eee DISC SPRING Install in this direction. Piston. CLUTCH PLATES Standard thickness: 2.3 men (0.09 in) 4TH CLUTCH ORUM BY elbren ses Muar CLUTCH END: PLATE Standard thickness: 1.94 mm (0.076 in) SRD CLUTCH DRUM SNAP RING 14-15Gearshift Selector NOTE: LHD is shown; RHD is symmetrical. SELECT LEVER KNOB Nm (03 kgm, 2216 ) ‘ply or ardoring ead PusH KNOB. \ ie ; \ ‘SUDER. PUSH KNOB SPRING LEVER COVER AIT GEAR POSITION swiTcH 14-16Steering Special Tools ... sue 17-2 Component Locations Index .. Troubleshooting General Troubleshooting Noise and Vibration Fluid Leaks . Inspection and Adjustment Power Assist Check with Car Parked Pump Belt ... Rack Guide Adjustment Fluid Replacement . Pump Pressure Check ... Power Steering Hoses, Lines Fluid Leakage Inspection Replacement .. Power Steering Pump Removal/Installation ... Steering Gearbox Removal ... Installation .. + The power steering system has been changed to sult the revised power steering geartiox and power steering pump. [ Outline of Model ChangeSpecial Tools Ret. No | Too! Number Description ® ® ® 1 @2 O38 0766 - 0010100 ‘O7MAC - $L00200 O7PAK - ST50110 O7PAK ~ $T50120, (07406 ~ 0010200 (07406 - 0010300 (07408 - 0010400 Belt Tension Gauge Ball Joint Remover, 28mm P/S Joint Adaptor (Pump) PIS Joint Adaptor (Hose) P/S Pressure Gauge Pressure Control Valve Pressure Gauge @2 e ® ® 17-2Component Locations Index NoTE: Before removing the gearbox, remove the driver's airbag assembly and steering wheel After installing the gearbox, check the wheel alignment and adjust if necessary. Do not try to disassemble to steering gearbox and pump. If the gearbox or pump are faulty, replace the whole gearbox: ‘or whole pump as an assembly, LHD type is shown, RHO type is symmetrical. STEERING GEARBOX Rack Guide Adjustment, page 17-14 Removal, page 17-18 Installation, page 17-20 POWER STEERING PUMP Pump Belt inspection, page 17-12 Pump Belt Adjustment, page 17-13. Pump Prossure Check, page 17-16 Removalinetllation, page 17-17 RESERVOIR Flu Level Inspection, page 17-14 Fluié Leakage Inspection, page 17-16 17-3